HPA150(PSA 2003版)ponteadeira funilaria

8/13/2019 HPA150(PSA 2003 )ponteadeira funilaria

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HPA150 Welding cabinet for P.T.I.Use and maintenance manual

Order code Nr.75543000


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Welding cabinet for PTI

GF WELDING S.p.A.Strada del Portone, 18/24 10137 TORINO (Italia)

Tel.:

Tel.:

Fax:e-mail:

web:

011-3033.278 (Italy Sales dept.)

011-3033.270-279 (Foreign Sales dept.)

011-3033.277 (Italy Service)

011-3033.274 (Foreign Service)

[email protected]


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WARRANTY

The warranty REGULATIONS herein are general and complete those explicitly agreed upon at the time ofsale; they are, in any case, subject to the current local legislation. In particular, the warranty period, un-

less otherwise specified in the sale contract, is for one year as from the date of delivery.

GF WELDING S.p.A. guarantees that the cabin is free of manufacturing defects. If, during the warranty

period malfunctioning should occur due to manufacturing defects the manufacturer reserves the right todecide whether to repair or replace it. GF WELDING S.p.A. will not assume any further responsibility fordamages caused to the customer due to production delays or defects arising from cabinet malfunctioning.

GF WELDING S.p.A. does not give any guarantee, either explicit or implicit, that the programs containedin the welding control fitted in the cabinet are without errors, compatible with any market standard orthat they respond to any special requirement of the manufacturer. In particular,GF WELDING S.p.A. do not assume any responsibility concerning the conformity to the production re-quirements and the functionality of the welding programs and the current self-incrementation made bythe user for a specific task.

The warranty becomes void in the case of tampering on the equipment, failures caused by incorrect con-nections, incorrect use and/or operations carried out by unqualified personnel. Moreover the warrantydoes not cover fuses, cables and connectors or parts subject to wear (e.g. electrodes, seals, etc.)

In particular, the warranty does not cover any circuitry damage caused by electrostatic discharges or byconnection and/or disconnection operations carried out while powered.


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SUMMARY

1. TECHNICAL SPECIFICATIONS:.............................................................................. 5

2. USE....................................................................................................................... 6

3. STRUCTURE.......................................................................................................... 7

3.1 CARRYING STRUCTURE ..............................................................................................73.2 ELECTRICAL CABINET................................................................................................83.3 HYDROPNEUMATIC CIRCUIT ...................................................................................... 11

3.3.1 Pneumatic circuit for gun drive...................................................................... 113.3.2 Cooling system ........................................................................................... 11

4. ELECTRICAL AND HYDROPNEUMATIC CONNECTION........................................... 12

5. STARTING UP ..................................................................................................... 13

6. ELECTRODE DRESSING AND CHANGE MANAGEMENT CARD................................. 14

6.1 MAIN FEATURES ................................................................................................... 146.2 SIGNAL DESCRIPTION FOR ELECTRODE MAINTENANCE......................................................... 14

6.3 DRESSING CYCLE DESCRIPTION.................................................................................. 156.3.1 Electrode force regulation.............................................................................15

6.3.2 Dressing operation ...................................................................................... 156.3.3 Out-of-cycle dressing operation..................................................................... 166.3.4 Electrode changing operation........................................................................ 166.3.5 Emergency spots ........................................................................................166.3.6 Special cases.............................................................................................. 16

7. SAFETY............................................................................................................... 17

7.1 CAUTION NOTES................................................................................................... 177.2 DANGER NOTES ................................................................................................... 177.3 RESIDUAL HAZARDS AND EMERGENCY SITUATIONS ............................................................ 19

8. TROUBLESHOOTING ........................................................................................... 20

9. PREVENTIVE MAINTENANCE............................................................................... 21

10. WELDING CONTROL REPLACEMENT................................................................. 21

11 WARNING PLATES 22


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1. TECHNICAL SPECIFICATIONS:

Nominal voltage power supply 380V +10%-10% 50/60Hz

Equivalent permanent current admitted 250A

Transformer maximum applicable power 150kA 50%FdU

Connection Single-phase

Power supply cables cross section (per phase) 70 mm2(*)

Protection against direct contact differential and ground Hanging system through a trolley with appropriate bracket

Welding control Weld334m PSC

Welding control power supply 27Vac 10% - 100VA max

Weight ~65 kg

Cabinet weight (incl. frame and hydropneumatic part) ~105Kg

Storage temperature (C) 060

Environment temperature (C) 545

Maximum humidity 95%

Pneumatic System

Operation non lubricated air

Pressure 0.30.8 Mpa

Air filter G - Filtration degree 20m

Pressure regulation servovalve G 012 Bar 0-10V

Cooling System

Liquid water Between PH 7.09.0 Hardness G.F.10

Resistivity at 25 Superior to 5K Conductivity at 25 Inferior to 500

Pressure and rate of flow 0.30.6Mpa12 l/m(single-gun)

20 l/m(double-gun)

SCR cooling water consumption 4 l/min.

Water inlet temperature 15 30 C

(*) See Chapter 4


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2. USE

The welding cabinet HPA150 is a machine component, to be assembled by a manufacturer or a user toobtain a complete resistance welding machine.

Its application permits the following:

To take the energy required for the welding from the mains and make it available for atransformer with a specific power.

To automatically adjust the welding current.

To make available the control of monostable electromagnetic valves for pneumatic and/orhydraulic operation, preferably cylinders, to handle the guns.

To command two welding guns (channels A-B) with incorporated transformer; only one gunwelding at a time in all cases.

2 +8 welding programs can be selected for every channel (mono-gun version) and 2 programsgun A + 2 programs gun B (bi-gun version).

The gun connection is carried out through HARTING connectors put on the top of the cabinet.

The welding control outputs to drive the solenoid valves are protected by the Start cycle relayclosing contacts, so that, in the event of an output fault, there is no uncontrolled activation; theStart relay drive is controlled in cycles.


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3. STRUCTURE

The structure of the machine comprises: load-bearing structure electric Cabinet hydropneumatic installation panel

The equipment and component positioning has been made uniform in all PTI cabinets in order to make

the conversion of a mono-gun into a bi-gun version easier by simply adding or removing the plugs.

3.1 Carrying structure

As shown in the picture, the electrical cabinet is secured to the backside of this structure whilethe hydropneumatic panel is secured to its front side. A bracket is mounted on this structure inorder to put the to-the-gun cable and pipe assembly together.


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3.2 Electrical cabinet

Sheet steel electrical cabinet provided with an internal supporting plate. The cabinet can beopened by using a key. On the supporting plate the following components are mounted:

Main switch group QS (see annexes)The welding cabinet circuit breaker can comprise a switching unit provided with a transmissionrod connected mechanically to the control lever of the switch itself. The control rod is mounted

on the lower part of the electric cabin, for easier operation there is a red knob fitted on the endof the rod.

The transmission rod moves the switch to the positions (see drawing):

ON transmission rod in upward position (toward electrical cabinet).

OFF transmission rod in low position (coming out from the electrical cabinet).

Switch in

OFF position

Switch inON position


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VP 0-380-400-415-440-500V VS 0-27V 50Hz single-phase T1 100VA transformer to feed theWeld334m welding control.

VP 0-380-400-415-440-500V VS 0-24V single-phase T2 30VA transformer to feed the

minimum voltage coil necessary to the main switch release.

PGM800/B power compact group max. 160kVA @50% duty cycle

600A 1600V water-cooled SCR

max. SCR inverse peak voltage (1600 V) intermittent load (see separate diagrams)

Requested waterflow rate: 4 l/min

Water inlet max. temperature: 30C

Thermostat (65C).

SCR firing card (HCM2123)

Demagnetiser resistance R1 - 1K150W

(About overall dimensions and missing technical features, please see attached technical card)


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A signal and command push-button panel is located on the lower part of the weldingmachine. It consists of:

Green Led WATER FLOW OK (HLFL1)

White Led WELDING POWER ON (HLT1)

Red Led CHANGE ELECTRODES GUN1 (HLCE1)

Red Led CHANGE ELECTRODES GUN2 (HLCE2)

Red Led ALARM 1 (HL1)

Red Led ALARM GUN1 (HLA1) Red Led ALARM GUN2 (HLA2)

Yellow Led DRESSING GUN1 (HLR1)

Yellow Led DRESSING GUN2 (HLR2)

3-position, key selector switch RESET CHANGE ELECTRODES DRESSING GUN1(SACEHR1)

3-position, key selector switch RESET CHANGE ELECTRODES DRESSING GUN2(SACEHR2)

3-position, key selector switch WELD YES, WELD NO, PRESSURE ONLY. (SAS) 2-position, key selector switch GUN1 DRESSING REQUEST (SAR1)

2-position, key selector switch GUN2 DRESSING REQUEST (SAR2)

Red warning lamp "RESET ALARM HARDWARE" (SBLHAH)


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3.3 Hydropneumatic Circuit

The welding cabinet is provided with a hydropneumatic circuit, which drives and cools twopneumatic guns with integrated transformer (PTI), with or without additional opening.

The hydropneumatic components are mounted on a sheet panel put in the cabinet backside.

3.3.1 Pneumatic circuit for gun drive

The pneumatic circuit, which drives the two pneumatic guns, consists of the following

components: Water filter Proportional valve Brass hose fitting 3/8g quick coupling for auxiliary intake

3.3.1.1 Water filter

It is mounted on board of the cabinet. It has the function of removing possible impurities andmoisture present in the pneumatic air and of keeping them in its transparent bucket.

3.3.1.2 Proportional valve (pressure regulation)

It has the function of automatically changing the pressure value during the welding process inorder to exert the correct pressure on the welding electrodes (the pressure value has to be setin the dedicated welding programme).Regulation range 0-12Bar analogical signal 0-10V connections g .

3.3.2 Cooling system

The function of this system is to allow, through brass distributors, water to circulate to cool thefollowing cabinet and gun parts:

transformer SCR Gun upper and lower arm

Brass pipefittings are mounted on the cooling water distributors for flexible pipes, which areprovided with arrows showing the flow direction (material: POLYURETHANE).

This circuit is also composed of the following hydraulic components:

Ball valves g . Flow regulator

3.3.2.1 Flow regulator

On the water outlet, next to the outlet distributor, an adjustable flowmeter has been mounted.


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4. ELECTRICAL AND HYDROPNEUMATIC CONNECTION

These operations are to be carried out by skilled technicians and must conform to the safety standards ofthe country where the machine is installed.

The maximum cross-section of the power supply cables on the main switch is 2x50 mm2.(*)

The cable cross section is calculated according to the welding transformer permanent thermal current

(the cabinet size allows up to 250A) and according to the allowed voltage drop; the definition of thepower supply cable cross section for each machine is to be made by the user according to require-ments.

Check that the factory mains voltage is within the machine power supply tolerance.

The welding cabinet can not be provided with a short-circuit protection on the power feed side, so thisprotection has to be carried out through fuses before the feed itself.

The cabinet is fitted with a differential protection (grouped together with switch QS) against indirect

contacts. It is regulated to 30mA (instantaneous intervention) and a mounting for the ground markedwith a PE plate. This connection is compulsory and is to be made with a conductor having anadequate cross section (see table below);

The ground connection must be checked before starting up the machine.

Minimum cross section of external protection copper conductor to a machine ground

Cross section of Power Supply cablesS (mm2)

Cross section of protection cableSp(mm

2)

S16 S

16


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5. STARTING UP

Connect the welding equipment to the cabinet by means of the relevant power and auxiliary cables,the pneumatic circuit and the hydraulic circuit.

Check the connection for the ground protection.

Link up to the power supply mains.

Close the main switch through the lever command carefully checking that the emergency circuit(minimum voltage coil for switch release) had been closed and connected to the +24Vac.

Feed the cooling and the pneumatic systems.

Regulate the gun pressure and check their correct closure.

At this point the welding cabinet is ready to work.

Before starting up it is advisable to carefully read the Weld334m working description and theprogramming instructions.

A remote programming terminal HHT4300 is used to program Weld334m; they are linked to eachother through a 9-way connector.

Weld334m records the troubleshooting happening during the working session in its alarm storage,which can be consulted through the programming terminal.

The machine is completely turned off (main switch off) by pushing downwards the red-handled rodcommand; to turn it on again, it is necessary to push upwards the same command.

The machine can be turned off also through a release circuit, which is linked to the minimum voltage

coil; in this situation the main switch remains released (its closure is forbidden). Then it is necessaryto turn the machine on again: first of all the main switch has to be restored, then the command rodhas to be pulled downwards to the Off-position (main switch normally open), then this rod has to bepushed upwards (On-position).

The PTI suspended welding machine is provided with a parameter-changing selector, which is put onthe command grip. This selector allows the use of two different programs for every gun. The cabinet ispre-set in order to work both in a mono-gun and in a bi-gun version.

In the mono-gun version:Gun A programme 1 (code 0) programme 2 (code 1) (+8 cam programmes)

In the bi-gun version:Gun A programme 1 (code 0) programme 2 (code 1)Gun B programme 4 (code 2) programma 8 (code 3)

In the mono-gun version, with the help of 4 limit switches, it is possible to use from 1 up to 10ldi Th li it it h li k d t th l t i l bi t th h H ti


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6. ELECTRODE DRESSING AND CHANGE MANAGEMENT CARD

6.1 Main features

The Weld334m control and the F393 card are mainly conceived to be used in manual areas, withthe possibility of commanding 2 welding guns, and integrate all functions necessary to a simplifiedmanagement of the electrode maintenance. The available programmes are 63 and are managedby 6 digital inputs, which the parity control can be added to.

6.2 Signal description for electrode maintenanceThe signals dedicated to the electrode maintenance operations are:

1. A/B Stepper warning (ouput): when it is permanently on, it means that the programmedwelding spot threshold for the electrode change warning has been achieved (HLA1 HLA2).

2. A/B Electrode dressing request (output): when it is permanently on, it means that theprogrammed welding spot number for the dressing operation has been achieved. When it isblinking, it means that an extraordinary dressing operation has been requested by theoperator (HLR1 HLR2).

3. A/B Electrode change request (output): when it is permanently on, it means that the pro-grammed welding spot threshold for the electrode change has been achieved (HLCE1-

HLCE2).

4. A/B Electrode dressing executed (input): when it is active (input level: 24Vdc), it communi-cates to the welding control that the electrode dressing operation has been executed. Thedressing counter is incremented, the Electrode dressing request sgnal is disabled and, ac-cording to the selected Stepper Mode, the executed welding counter is reset (SACEHR1 SACEHR2).

5. A/B Electrode change executed (inlet): when it is active (input level: 24Vdc), itcommunicates to the welding control that the electrode change operation has beenexecuted. Both the dressing and the executed welding counters are reset and theElectrode change request signal is disabled (SACEHR1 SACEHR2).

6. A/B Electrode dressing request (inlet): when it is active (input level: 24Vdc), and theDressing request output is active as well, it communicates to the welding control thatfrom the following welding start, the electrode dressing programme will have to beexecuted. When it is active (input level: 24Vdc) and the Dressing request output is notactive, it communicates to the welding control an extraordinary dressing request;subsequently, from the following welding start, the electrode dressing programme will haveto be executed (in this case the Electrode dressing output blinks) (HLR1-HLR2).

For further information please see the push-button panel description in Chapter 3.2

All signals and commands operate on the selected stepper only inside the relevant weldingchannel (channel A or B).

For more detailed information please see our Weld334m Welding Control technical manual.


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6.3 Dressing cycle description

6.3.1 Electrode force regulation

The dressing operation has to be executed with a reduced charge: before dressing, it isnecessary to regulate the electrode force. The pressure change in the pneumatic circuit, whichis transformed into the electrode force by the cylinder, is commanded by a proportional

servovalve with a welding control-managed analogical command.

1. Rotate the GUN DRESSING REQUEST key selector rightwards: when the key selector is in

this position, the welding control automatically selects the welding programme (PRG 62 forGUN A and PRG 63 for GUN B, respectively), changes the execution mode into Withoutcurrent and makes the pneumatic circuit ready for the dressing operations.

2. Insert the force gauge between the electrodes.

3. Press the START push-button (on the welding gun grip) in order to close the gun.

4. Check whether the load on the electrodes is under 150kg (always check pneumaticdressing tool features supplied by the builder), up to a mini. 2 Bar pressure in thepneumatic circuit (minimum working pressure of the welding electrovalve). Change the P1parameter in the welding programme in order to obtain the requested force.

5. Rotate the GUN DRESSING REQUEST key selector rightwards (Off-position).

6.3.2 Dressing operation

1. When the GUN DRESSING signal yellow lamp is switched on, the operator is informedthat it is necessary to start the dressing operations.

2. Rotate the GUN DRESSING REQUEST key selector rightwards.

3. Insert the resistance welding electrode dressing tool (which is manually pneumaticallycommanded) between the electrodes.

4. Press the START push-button (on the welding gun grip) in order to close the electrodeson the dressing tool (NB: the START push-button has to be kept pressed up to the end ofthe dressing cycle). The welding control automatically selects the welding programme (PRG62 for GUN A and PRG 63 for GUN B, respectively) , changes the execution mode intoWithout current and makes the pneumatic circuit ready for the dressing operations.

5. Wait for a second so that possible vibrations caused by the impact of the electrodes againstthe miller are softened.

6. Start the dressing tool pneumatic engine.

7. At the end of the dressing operation, the gun automatically opens: at this point release the

START push-button.8. Rotate the GUN DRESSING REQUEST key selector up to the central position (Off-

position).

9. Rotate the SACEHRx 3-position key selector leftwards up to the GUN DRESSING RESETposition in order to confirm that the dressing operation has been executed. The weldingcontrol automatically resets signals and counters.


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6.3.3 Out-of-cycle dressing operationThe out-of-cycle dressing request (or manual request) is executed by the operator in thecase of an extraordinary electrode maintenance and is commanded as follows:

1. Rotate the GUN DRESSING REQUEST key selector rightwards. When the selector is in thisposition, the dressing programme (PRG 62 for GUN A and PRG 63 for GUN B, respectively)automatically starts at the following cycle-start while the GUN DRESSING signal yellowlamp starts blinks.

2. Execute the same dressing operations as in paragraph 6.3.2.

If the manual request has been made between two dressing cycles, the stepper counter isincremented. On the contrary, if the request has been made between the last dressingcycle and the electrode changing, several dressings can be made without the countermaking allowance for them.

6.3.4 Electrode changing operation

1. When the GUN ELECTRODE CHANGE signal red lamp is switched on, the operator is in-formed that it is necessary to start the electrode changing operations.

2. Change the electrodes.

3. Rotate the SACEHRx 3-position key selector rightwards up to the ELECTRODE CHANGERESET position in order to confirm that the electrode changing operation has been exe-cuted. The welding control automatically resets signals and counters.

The electrode changing operation is over. Now you can carry on with the usual welding op-erations.

6.3.5 Emergency spots

The emergency spots (which are usually the same quantity as the welding spots minus

one) can be programmed for every gun. The emergency spots, which can be set on theSTEPPER - EDIT menu of the hand held terminal (see our welding control programmingmanual) allow the operator to complete the current welding operation although thedressing requestor the electrode change request arise. Therefore, after ending the currentwelding operation, the operator is obliged to execute the dressing or electrode changingoperation, respectively.

6.3.6 Special cases

6.3.6.1 E66 anomaly

The E66 anomaly occurs if the electrode dressing operation is not executed before the pro-grammed emergency spots have expired.This anomaly prevents the execution of a new welding sequence and it is necessary to exe-cute the a.m. electrode maintenance operation in order to resume the usual operations.


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7. SAFETY

In order to ensure maximum working reliability, GF WELDING S.p.A. has made a careful selection ofthe materials and components to be used in the manufacturing of the equipment, submitting it totests before delivery.Welder efficiency over time also depends on the correct use and adequate preventive maintenance inaccordance with the instructions given in this manual.The constructed elements, connection and control parts have been designed and built with a degree ofsafety that can resist abnormal stress and in any case more than that indicated in the manual.Best quality materials have been used and the entry into the company, the storage and use in the

factory is continually checked in order to ensure there is no damage, deterioration or malfunctioning.

7.1 Caution Notes

Before starting up the equipment again after a failure, carefully inspect and check to highlightany damage.

When using a megaohmmeter to check the insulation of electrical equipment, make sure that allthe electronic control equipment has been disconnected to avoid damage to the components.

Always use perfectly dry air for cleaning and with a pressure that does not exceed 0.2 Mpa.

Always use tools in perfect condition and specifically designed for the operation to be carriedout; the use of inadequate or inefficient tools can cause serious damage.

Carry out repair operations in a clean environment, and where possible, without dust. Protect allconnection openings with plastic plugs and carefully cover all machined surfaces of dismantledparts until they are reassembled on the welder.

The running of the welder is to be entrusted to qualified personnel, who have read andunderstood the instructions given in this manual, and who are familiar with the safety devices

installed on the welder.

Before refitting a unit, always spread a film of hydraulic oil on internal parts andcoupling surfaces. Replace all seals and gaskets of hydropneumatic parts with originalspare parts before re-assembling the components.

7.2 Danger Notes

High voltages can cause death upon contact. Always operate with utmost caution and inaccordance with the current accident prevention laws of your country.

Always cut off all equipment supplies, main and auxiliary before starting maintenanceoperations on the said equipment. Place specific warning signboards WELDER BEINGSERVICED - NO NOT POWER ON near the main switches and lock them in OFF position withthe special padlocks.

When running there are parts of the equipment in motion that can cause injuries. Avoid contact

with these parts. Before operating on the equipment ascertain that there is no danger ofaccidental movement caused by connected equipment.


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Never cut off safeties and protection devices installed on the equipment. If this is necessary,indicate this condition by means of warning signboards and operate with utmost caution.

Restore all safeties and protection devices as soon as possible.

Lack of ground connection can cause serious injuries. Always make sure that there are groundconnections and that they comply with the relevant standards.

Do not use inflammable or toxic solvents such ass petrol, benzene, ether or spirit. It isrecommended to use trichloroethylene, taking the necessary precautions.

Before starting up the equipment, always make sure that the maintenance staff is at a safedistance and that no tools or materials have been left near the welder.

Always use protective gloves and goggles when servicing the equipment.

The equipment installation must always abide by the accident prevention regulations. All movingparts and transmission organs are to be protected against accidental contact.

Always make sure that all the protections are installed and correctly closed before starting upthe equipment.

Long overloads or failures can cause overheating of electrical equipment with the development

of harmful fumes; immediately cut off the power for safety, and do not approach the equipmentuntil the fumes have been dispersed by adequate ventilation. Do not inhale the fumes remainingin the equipment while making the repairs.

Never use water jets in the case of fire on the equipment; cut off all power supplies and use CO2extinguishers.

Take every precaution not to mix air and hydraulic oil in the system under pressure to avoid theformation of explosive mixtures.

Always make sure that the systems are not under pressure before starting any maintenanceoperation on the components.

Keep a safe distance from holes and bleed taps when discharging pressure from systems.

Carefully inspect all couplings making sure there is no dust, oil, dirt or defect on the threadsbefore making the connection.

Check that the torque is correct on all couplings and joints before pressurising the systems afterrepairs.

Always keep at a safe distance from any component that could be set in motion by hydraulic

pressure, when this has not been completely discharged from the systems. Never wear thingsthat could be caught up in the equipment and act as conductors (chains, bracelets, etc.).

Make sure that the tools to be used are in perfect condition and have insulated gripswhere necessary. Check that the insulation of cable and conductors on the testing equipmentshows no signs of breaks or damage.


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7.3 Residual hazards and emergency situationsAfter having carefully considered all possible risks concerning the use of the pendant welder, allthe solutions necessary have been applied to remove the risks and limit hazards for thepersonnel.

However, on the pendant welder the following residual risks remain; these can be removed orreduced taking these precautions:

Risk of circuitry failure on the stop and emergency safety circuits with possible lowering ofsafety level.

CAUTION!

Due to possible failures, the safety circuits for emergency stops may lose part of theirefficiency. Make periodic checks (once a month) on the operating condition of the

safety circuits.

Impact, crushing, shearing risks after starting up of unexpected movements duringmaintenance operations.

CAUTION!

Before starting any maintenance work on the welder, the operator shall disconnectthe main switch and lock it with its relevant padlock.

CAUTION!

With the main switch in the "OFF" position, the input terminal of the main switch islive, and, where present, likewise the terminal of the input transformer on the release

coil of the main switch.

Risks of electrocution, electric shocks when making maintenance operations in the SCR areawith power on.

The welder in the secondary circuit area generates strong alternating magnetic fields. Allmagnetic materials, (iron, steel etc.) in this field are subject to strong mechanical stress.Furthermore the magnetic data recording systems are deleted.

CAUTION!

Persons wearing heart stimulators or pacemakers are not to approach these machines

for any reason whatsoever.

It is also advised not to approach the welder when carrying materials that could becomedamaged:

all types of magnetic cards, such as credit cards, telephone cards, viacard, identity cards, timecards, company permits etc.


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8. TROUBLESHOOTING

The welding control has a diagnostic system that in most cases can trace the cause of any malfunc-tions or incorrect operation.To use the diagnostics correctly it is important to know, through the manual, the significance of thefunctions available on the control to monitor the field (I/O status LEDs, alarms memory, I/O softwaretrace , welding trace, etc).If a diagnostic or machine fault alarm is activated, it is necessary to know the error code. It is

possible, through the manual programming terminal, to display the alarm history and it is alsopossible to consult the paragraph "description of alarms" in the welding control use manual. The listgiven below is only a selection of some of alarms:

Alarm Probable cause

Gun fails to close - Pre-stroke closed input missing

- No Start signal- Pre-stroke not actuated- The gun is blocked for mechanical reasons

- The welding valve / commutation valve is defective- No air pressure

No welding current - Check whether Weld 334 displays alarms- Current sensor is interrupted- Sheet metal parts have not been coupled- The electrode surface shows impurities- Gun is not correctly closed- Pre-approach time too short

The power selector trips - Switch in emergency- Line fuses disconnected

- Thyristor in short-circuit- Weld334 internal fault

The 24 Vdc fuse breaks down- 24V feed in short-circuit- Defective valve coil


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9. PREVENTIVE MAINTENANCE

We recommend to:

Always cut off the power circuit breaker through the release coil, never under load.

Periodically check the differential and magnetic protection are functioning properly using thespecific test button.

Every 10 - 12 weeks check the tightness of the power side connection clamps (circuit breaker,transformer, SCR).

Check the machine ground connection.

Check that no water losses are present; otherwise eliminate them.

Eliminate possible condense present in the air filter bulb

Every 3 monthcheck that fittings and tubes are not corroded; check the manometer; replace the airfilter (before carrying out any maintenance operation to the hydropneumatic system, please

remember to close the 3-globe feeding valves on the panel).

10. WELDING CONTROL REPLACEMENT

This is to be carried out by skilled personnel (qualified electricians or trained and authorised operators)attaining to the relevant accident prevention regulations.

Connect the programming terminal (HHT 4300 or Laptop with SW WMS and interface cable).

Ascertain that circuit breaker QS is deactivated

Open the cabinet door

Cut off the external 24V-fed minimum voltage coil (fuses FU5-FU6)

Disconnect the signal terminals from the Weld334m.

Replace the control and connect the terminals to the new control.

Power on the external 24V-fed minimum voltage coil (fuses FU5-FU6)

Close the cabinet door

Activate the circuit breaker

Load the program following the programming instructions

Disconnect the programming terminal


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11. WARNING PLATES

The cabinet is equipped with all the accident prevention warnings required by current standards.


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WARNING SIGNSFEATURES: TRIANGULAR SHAPE BLACK PICTOGRAM YELLOW BACKGROUND

CAUTION!Electric tensionSTANDARD:Dir. CE 92/58

CAUTION!Mind your handsSTANDARD:Dir. CE 92/58

CAUTION!Intense magneticfieldsSTANDARD:Dir. CE 92/58ISO 3864

CAUTION!

Hot surfacesSTANDARD:Dir. CE 92/58ISO 3864

PROHIBITORY SIGNSFEATURES: ROUND SHAPE BLACK PICTOGRAM-WHITE BACKGROUND RED BORDER AND STRIPE

DO NOT use water to put outfiresSTANDARD:Dir. CE 92/58ISO 3864

NO ENTRY if you wearartificial metal apparatusSTANDARD:Dir. CE 92/58

ISO 3864

NO ENTRY if you wear apacemakerSTANDARD:Dir. CE 92/58

ISO 3864

INSTRUCTION SIGNSFEATURES: ROUND SHAPE WHITE PICTOGRAM BLUE BACKGROUND


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12. REFERENCE STANDARDS AND LEGISLATION

DIRECTIVE/STANDARD

TITLE

98/37/CEE Machines Directive

89/336/CEE Concepts concerning electromagnetic compatibility problems.

UNI EN 292-1 Machinery safety - Fundamental concepts: general engineering principles

Basic methodology terminology.UNI EN 292-2 Machinery safety - Fundamental concepts: general engineering principles.

Specifications and technical principles.

UNI EN 418 Safety of machinery -- Emergency stop devices -- Functional aspects Designprinciples.

UNI EN 470-1 Protective clothing for welding and related procedures. General requirements.

UNI EN 1037 Safety of machinery. Prevention of unexpected start-up.

CEI EN 50063 Safety standards for construction and installation of resistance weldingequipment and related techniques.

CEI EN 60204-1

Machinery safety - Machine electrical equipmentPart 1: general requirements.

CEI EN 60529 Degree of protection for casings (code IP).

ISO 669-1 Specifications for resistance welding materials. International standards.

ISO 5826 Transformers for resistance welding machines.General specifications applicable to all transformers.

UNI 7712 Machine tools. Measurement of noise in working environment.

13. INFORMATION CONCERNING DEMOLITIONThe machine and the systems are composed of metal, plastic and rubber materials, that ifburnt produce gas.

The welding transformer is composed of epoxy resins that if burnt, produce gas.

To proceed correctly with the demolition, carefully separate the electrical cables, flexiblerubber hoses and plastic components from the metal components.

The disposal must be carried out in accordance with the legislation of the country in which

the welding machine is installed.


25/55


14. PRECAUTIONS FOR SAFETY AND CORRECT USE OF THE MACHINE

CAUT I ON :

First and foremost check power-supply voltage corresponds to the voltage indicated on themachine rating plate and that the welding transformer and the auxiliary circuit transformers are

connected properlyR I SK OF DAMAGE TO WELD I NG MACH I NE

I M PORTANT

Before carrying out maintenance on the machine the electricity, pneumatic and cooling watersupplies must be disabled

H I GH R I SK OF ACCI DENT

CAUT I ON :

The cooling system couplings are to be tightened with a maximum torque of 15 Nm.

15. RESIDUAL RISKS THAT CANNOT BE ELIMINATED

In order to prevent possible accidents and/or damage to the machine, these are WARNINGS onwhat to DO and NOT DO:

CAUT I ON :Whenever the welding machine does not present the safety characteristics and/or normal

functioning, it must be cut off from the main power supply switch.THE QUAL I F I ED TECHN I CAL PERSONNEL MUST BE I NFORMED OF THE PROBLEM .

I MPORTANT :

the use of the machine by untrained or non-authorized personnel is strictly forbidden.

ACCI DENT HAZARD!

CAUT I ON :

The welding cabinets must not be installed near:- deposits of inflammable and/or explosive materials (paper, solvents, oils, etc.);

- machines, devices, objects sensitive to magnetic fields;R I SK OF VERY SER I OUS DAM AGE

H I GH R I SK OF ACCI DENT

4

6

5

1

2

3


26/55


27/55


16. ANNEXES

Part list RiccabPTI_PSA_DCAC.doc

Assembly layout Drawing n 75543001

Electromechanical layout Drawing n 75543011

Hydropneumatic system Drawing n 75543031

Hydropneumatic system connections Drawing n 75543032

Wiring diagram Drawing n 75543012


28/55


29/55


30/55


31/55


32/55

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24


33/55

Senza autorizzazione scritta della societa' proprietaria il presente disegno non potra' comunque

DIS.

DATA UL.M.

COMM.

ZRY

16.12.05

WELD334mPSC

DENOMINAZIONE

essere utilizzato per la costruzione dell'oggetto rappresentato

CLIENTE

PEUGEOT CINA

MANUAL GUN WITH INTEGRATED TRANSFORMER

ne' venire comunicato a terzi o riprodotto. La societa' proprietaria tutela i propri diritti a rigore di legge.

TECHNICAL DATADATA STAMPA

FG.N.

N.DISEGNOPOS.ARCH

TOTALE FOGLITIPO

16.12.05

23

MOD. CARTGF CAE EPLAN

1

DI FG.

24

2

75543012/03

DESCRIPTION

CUSTOMER

DRAWING N.

YEAR OF MANUFATCURE

WELDING

:

:

:

:


PEUGEOT CINA

75543012/03

2003

POWER

WELDING CONTROL

POWER SUPPLY

:

:

: 380 VAC 50 HZ

WELD334mPSC

150KVA

GF-WELDING SPA

Strada del Portone 18/24

10137 TORINO Italy

Tel.: 39-011 3031111

Fax : 39-011 3139716

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24


34/55


DIS.

DATA UL.M.

COMM.

ZRY

29.07.03

WELD334mPSC

DENOMINAZIONE


CLIENTE

PEUGEOT CINA



POWER SUPPLYDATA STAMPA

FG.N.

N.DISEGNOPOS.ARCH

TOTALE FOGLITIPO

16.12.05

23


2

DI FG.

24

3

75543012/03

(L1)R

(L2)S

10.17/P2201

10.21/P2202

2.5 mmq BLACK HO7-RNF

2AFU5

530

P

S30VA24Vca

TC2

541

1AFUBS

542

380V

1 mmq ORANGE

2AFU6

531

540

U


35/55


DIS.

DATA UL.M.

COMM.

ZRY

29.07.03

WELD334mPSC

DENOMINAZIONE


CLIENTE

PEUGEOT CINA



SCR BLOCK AND FIRING BOARDDATA STAMPA

FG.N.

N.DISEGNOPOS.ARCH

TOTALE FOGLITIPO

16.12.05

23


3

DI FG.

24

4

75543012/03

2.21/501

2.21/502

V

50mm NOIR

HO7RN-F

4.02

502

1000R1

SUPPLY

TRANSFORMER

GUN 1-2

RC1

4.02

503

U

TV1

TV2

TV2

UVR1

FIRING BOARD HCM2123

(ON BOARD HCM2123)TV

J111+

8.04

P3-7

12

8.06

P3-8

K1 G1

1+

11.04

+24TR

G2 K2

7

11.06

P4402

33

+24V

30

COM

2

X1 +24V

16.23

+24V

COM

9

12.04

P4403

TSCR

THSCR

31

X10 A5

THA1

THA2

X10 B5

X20 B5

THB2

THB1

X20 A5

32

OPTIONAL

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

25 mm BLACK (H07-RNF)


36/55


DIS.

DATA UL.M.

COMM.

ZRY

11.07.03

WELD334mPSC

DENOMINAZIONE


CLIENTE

PEUGEOT CINA



POWER SUPPLY TRANSFORMERDATA STAMPA

FG.N.

N.DISEGNOPOS.ARCH

TOTALE FOGLITIPO

16.12.05

23


4

DI FG.

24

6

75543012/03

3.06/502

3.08/503

2.08/PE.4

2.09/PE.5

X10 A1

V

U

C1 A2

ON BOARD

TRANSFORMER

U

TRS1

TA1

V

S

R

WELDING

TRANSFORMER

GUN A

X20 A1 C1 A2

ON BOARD

TRANSFORMER

U

TRS2

TA2

V

S

R

WELDING

TRANSFORMER

GUN B

OPTIONAL

40

P4-1

P4-5

P4-4

/9.04P4-1

/9.08P4-5

/9.06P4-4

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24


37/55


DIS.

DATA UL.M.

COMM.

JAK

29.07.03

WELD334mPSC

DENOMINAZIONE


CLIENTE

PEUGEOT CINA



- WELD 334 CONNECTOR PS -DATA STAMPA

FG.N.

N.DISEGNOPOS.ARCH

TOTALE FOGLITIPO

16.12.05

23


6

DI FG.

24

7

75543012/03

C

O

N

N

E

C

T

O

R

-

P

S

-

W

EL

D

3

3

4

-

P

W

R

2

7

V

c

a

1

2.21

PS-01

-

R

T

N

0

V

2

2.21

PS-02

-

S

I

N

+

3

-

S

I

N

-

4

-

+

2

4

V

I

5

-

+

2

4

V

E

6

-

0

V

7

G

N

D

GND PE PE

2.07

PE

T

O

W

A

R

D

S

M

A

I

N

G

R

O

U

N

D

B

A

R

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24


38/55


DIS.

DATA UL.M.

COMM.

JAK

11.07.03

WELD334mPSC

DENOMINAZIONE


CLIENTE

PEUGEOT CINA



- WELD 334 CONNECTOR P2 -DATA STAMPA

FG.N.

N.DISEGNOPOS.ARCH

TOTALE FOGLITIPO

16.12.05

23


7

DI FG.

24

8

75543012/03

1

5

P

I

N

C

O

N

N

E

C

T

O

R

-

P

2

-

WE

L

D

3

3

4

-

+

2

4

V

8

-

0

V

7

YELLOW

-

E

N

S

E

R

V

15

E1

PE

W

H

I

TE

-

V

S

E

R

V

+

10

6 (CTRL)

B

R

O

W

N

3 (24V) YV5

B

L

U

E

P

I

N

K

1 (GND)

-

V

S

E

R

V

-

3

5 (GND)

2

-

V

S

C

H

11

PARKER SEMPRESS PNEUMATC

EPDN4-1,2-12B-0U10-11-0-VW

COD.3079100

0-10 V

12 bar

G

R

E

Y

-

S

T

S

E

R

V

6

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24


39/55


DIS.

DATA UL.M.

COMM.

JAK

29.07.03

WELD334mPSC

DENOMINAZIONE


CLIENTE

PEUGEOT CINA




FG.N.

N.DISEGNOPOS.ARCH

TOTALE FOGLITIPO

16.12.05

23


8

DI FG.

24

9

75543012/03

9

P

I

N

C

O

N

N

E

C

T

O

R

-

P

3

-

W

EL

D

3

3

4

FROM TV TRANSFORMER TO CHECK SCR CONDUCTION

OUTSIDE THE WELDING TIME

7

3.11

P3-7

-

V

O

L

T

A

G

E

S

E

N

S

O

R

(

T

V

+

)

8

3.12

P3-8

-

V

O

L

T

A

G

E

S

E

N

S

O

R

(

T

V

-

)

9

-

S

C

H

I

E

L

D

T

V

(

T

V

SC

H

)

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24


40/55


DIS.

DATA UL.M.

COMM.

JAK

29.07.03

WELD334mPSC

DENOMINAZIONE


CLIENTE

PEUGEOT CINA




FG.N.

N.DISEGNOPOS.ARCH

TOTALE FOGLITIPO

16.12.05

23


9

DI FG.

24

10

75543012/03

9

P

I

N

C

O

N

N

E

C

T

O

R

-

P

4

-

W

EL

D

3

3

4

1

4.23

P4-1

CURRENT SENSOR READING

-

S

H

I

E

L

D

T

A

A

(

T

A

A

S

C

H

)

4

4.23

P4-4

-

C

U

R

R

E

N

T

S

E

N

S

O

R

(

T

A

A

+

)

5

4.23

P4-5

-

C

U

R

R

E

N

T

S

E

N

S

O

R

(

T

A

A

-

)

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24


41/55


DIS.

DATA UL.M.

COMM.

JAK

29.07.03

WELD334mPSC

DENOMINAZIONE


CLIENTE

PEUGEOT CINA



- WELD 334

CONNECTOR P20/P22 -

DATA STAMPA

FG.N.

N.DISEGNOPOS.ARCH

TOTALE FOGLITIPO

16.12.05

23


10

DI FG.

24

11

75543012/03

C

O

N

N

E

C

T

O

R

-

P

2

0

-

W

E

L

D

3

3

4

11.10

+24V.11.15

+24V..

1

X1 +24V

12.02

+24V

-

2

4

V

X10 C5

12.08

+24V,

2

-

2

4

V

X20 C5

12.11

+24V,,

HLT1

17.12

+24V:

VOLTAGE

TURNED ON

3

-

0

V

4

X1 0V

13.02

0V

-

0

V

X10 B2

11.12

0V.

X20 B2

11.16

0V..17.12

0V:

C

O

N

N

E

C

T

O

R

-

P

2

2

-

W

E

L

D

3

3

4

1

2.03

P2201

-

S

G

N

C

3

-

S

G

N

O

2

2.03

P2202

-

S

G

C

O

M

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24


42/55


DIS.

DATA UL.M.

COMM.

JAK

11.07.03

WELD334mPSC

DENOMINAZIONE


CLIENTE

PEUGEOT CINA




FG.N.

N.DISEGNOPOS.ARCH

TOTALE FOGLITIPO

16.12.05

23


11

DI FG.

24

12

75543012/03

C

O

N

N

E

C

T

O

R

P

4

4

-I

O

B

-

+

2

4

P

U

L

S

E

T

R

1

3.14

+24TR

-

P

U

L

S

E

T

R

C

O

M

M

A

N

D

2

3.15

P4402

-

S

P

O

U

T

1

9

-

E

V

S

A

W

E

L

D

I

N

G

"

A

"

10

10.01

+24V.

11

P4411

X10 C2

J1/1

YV1

J1/2

10.12

0V.14.11

0V.

-

E

V

S

B

W

E

L

D

I

N

G

"

B

"

12

10.03

+24V..

13

P4413

X20 C2

J2/1

YV2

J2/2

10.13

0V..

OPTIONAL

14.18

0V..

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24


43/55


DIS.

DATA UL.M.

COMM.

JAK

29.07.03

WELD334mPSC

DENOMINAZIONE


CLIENTE

PEUGEOT CINA




FG.N.

N.DISEGNOPOS.ARCH

TOTALE FOGLITIPO

16.12.05

23


12

DI FG.

24

13

75543012/03

P

4

4

-

I

O

B

10.04/+24V

-

T

S

C

R

3

3.17

P4403

-

E

M

E

R

G

E

N

C

Y

4

P4404

FL1

1

3

.

2

3

/

0

V

-

F

L

O

W

S

E

N

S

O

R

O

.

K

.

HLF1

1

3

.

2

3

/

0

V

-

S

T

A

R

T

"

A

"

5

P4405

D1

D1-01

X10 C3

1SC

10.05

+24V,

/

1

6

.

0

9

1

S

P

15.07

1AS

D2

D1-02

X10 A7

2SC

/

1

6

.

0

9

2

S

P

15.08

2AS

-

S

T

A

R

T

"

B

"

6

P4406

V1

D2-01

X20 C3

3SC

10.06

+24V,,

/

1

6

.

1

3

3

S

P

15.11

3AS

V2

D2-02

X20 A7

4SC

/

1

6

.

1

3

4

S

P

15.12

4AS

-

C

O

N

D

U

C

T

I

O

N

+

7

OPTIONAL

-

C

O

N

D

U

C

T

I

O

N

-

8

-

R

E

S

E

R

V

E

D

S

I

G

N

A

L

14

-

W

E

L

D

15

P4415

SAS

-

O

N

L

Y

P

R

E

S

S

U

R

E

16

P4416

SAS12.18

SAS12.18

/15.02+24V

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24


44/55


DIS.

DATA UL.M.

COMM.

JAK

11.07.03

WELD334mPSC

DENOMINAZIONE


CLIENTE

PEUGEOT CINA




FG.N.

N.DISEGNOPOS.ARCH

TOTALE FOGLITIPO

16.12.05

23


13

DI FG.

24

14

75543012/03

10.11/0V

C

O

N

N

E

C

T

O

R

P

4

2

-

I

O

E

-

A

L

A

R

M

A

P

R

E

A

L

A

1

P4201

HLA1

-

A

L

A

R

M

B

P

R

E

A

L

B

2

P4202

HLA2

-

G

U

N

"

A

"

D

R

E

S

S

I

N

G

R

E

Q

U

E

S

T

R

I

C

H

R

A

V

A

3

P4203

HLR1

-

G

U

N

"

B

"

D

R

E

S

S

I

N

G

R

E

Q

U

E

S

T

R

I

C

H

R

A

V

B

4

P4204

HLR2

-

G

U

N

"

A

"

C

H

A

N

G

E

E

L

E

C

T

R

.

R

I

C

H

E

L

A

5

P4205

HLCE1

-

G

U

N

"

B

"

C

H

A

N

G

E

E

L

E

C

T

R

.

R

I

C

H

E

L

B

6

P4206

HLCE2

-

A

L

A

R

M

1

7

P4207

HL1

-

A

L

A

R

M

2

8

P4208

SBLHAH

/12.060V

/12.060V

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24


45/55


DIS.

DATA UL.M.

COMM.

JAK

29.07.03

WELD334mPSC

DENOMINAZIONE


CLIENTE

PEUGEOT CINA




FG.N.

N.DISEGNOPOS.ARCH

TOTALE FOGLITIPO

16.12.05

23


14

DI FG.

24

15

75543012/03

I

O

E

-

W

E

L

D

I

N

G

R

E

Q

U

E

S

T

R

I

C

H

S

A

L

9

-

E

N

D

O

F

W

E

L

D

I

N

G

F

I

N

E

S

A

L

10

-

E

N

D

O

F

S

E

Q

U

E

N

C

E

F

I

N

E

S

E

Q

11

-

R

E

A

D

Y

12

-

O

P

E

N

I

N

G

"

A

"

E

V

A

S

A

1

13

P4213

X10 A3

YV3

11.13

0V.

-

C

L

O

S

I

N

G

"

A

"

E

V

A

S

A

2

14

P4214

X10 B3

-

O

P

E

N

I

N

G

"

B

"

E

V

A

S

B

1

15

P4215

X20 A3

YV4

11.18

0V..

-

C

L

O

S

I

N

G

"

B

"

E

V

A

S

B

2

16

P4216

X20 B3

OPTIONAL

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24


46/55


DIS.

DATA UL.M.

COMM.

JAK

29.07.03

WELD334mPSC

DENOMINAZIONE


CLIENTE

PEUGEOT CINA




FG.N.

N.DISEGNOPOS.ARCH

TOTALE FOGLITIPO

16.12.05

23


15

DI FG.

24

16

75543012/03

C

O

N

N

E

C

T

O

R

P

4

3

I

O

E

12.23/+24V

-

R

E

S

E

T

A

L

A

R

M

H

A

R

DW

A

R

E

R

E

S

H

W

F

K

1

P4301

SBLHAH

-

R

E

S

E

T

A

L

A

R

M

H

W

WI

T

H

R

E

P

E

A

T

R

E

S

H

W

R

P

2

-

A

D

D

.

O

P

E

N

I

N

G

C

H

A

NN

E

L

"

A

"

C

O

M

M

A

N

D

C

E

V

A

S

A

3

P4303

X10 A4

1AS

12.08

1AS

2AS

12.09

2AS

A

D

D

I

T

I

O

N

AL

O

P

E

N

I

N

G

F

A

U

L

T

C

O

N

N

E

C

T

WE

I

D

M

U

L

L

E

R

W

S

D

2

,

5

1

0

5

8

6

6

C

A

R

D

-

A

D

D

.

O

P

E

N

I

N

G

C

H

A

NN

E

L

"

B

"

C

O

M

M

A

N

D

C

E

V

A

S

B

4

P4304

X20 A4

3AS

12.12

3AS

OPTIONAL

4AS

12.13

4AS

-

S

E

L

E

C

T

I

O

N

O

F

D

R

ES

S

I

N

G

P

R

O

G

R

A

M

C

H

A

N

N

E

L

"

A"

R

A

V

E

X

T

A

5

P4305

SAR1

-

S

E

L

E

C

T

I

O

N

O

F

D

R

ES

S

I

N

G

P

R

O

G

R

A

M

C

H

A

N

N

E

L

"

B"

R

A

V

E

X

T

B

6

P4306

SAR2

-

P

E

R

F

O

R

M

E

D

D

R

E

S

S

IN

G

C

O

N

F

I

R

M

A

T

I

O

N

C

H

A

N

NE

L

"

A

"

R

A

V

O

K

A

7

P4307

SACEHR116.04

-

P

E

R

F

O

R

M

E

D

D

R

E

S

S

IN

G

C

O

N

F

I

R

M

A

T

I

O

N

C

H

A

N

NE

L

"

B

"

R

A

V

O

K

B

8

P4308

SACEHR216.06

/16.02+24V

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24


47/55


DIS.

DATA UL.M.

COMM.

JAK

11.07.03

WELD334mPSC

DENOMINAZIONE


CLIENTE

PEUGEOT CINA




FG.N.

N.DISEGNOPOS.ARCH

TOTALE FOGLITIPO

16.12.05

23


16

DI FG.

24

17

75543012/03

I

O

E

15.21/+24V

-

G

U

N

"

A

"

R

E

S

E

T

C

H

.

E

L

E

C

.

C

H

G

E

O

K

A

9

P4309

SACEHR1

-

G

U

N

"

B

"

R

E

S

E

T

C

H

.

E

L

E

C

.

C

H

G

E

O

K

B

10

P4310

SACEHR2

-

C

O

D

E

0

11

X10 C4

1SP

12.08

1SP

X10 C8

2SP

12.09

2SP

-

C

O

D

E

1

12

X10 B4

X10 B8

-

C

O

D

E

2

13

P4313

X20 C4

3SP

12.12

3SP

X20 C8

4SP

12.13

4SP

OPTIONAL

OPTIONAL

-

C

O

D

E

3

14

P4314

X20 B4

X20 B8

-

C

O

D

E

4

15

P4315

X20 C9

-

C

O

D

E

5

16

P4316

X20 B9

-

C

O

D

E

P

17

-

E

N

A

B

L

E

W

E

L

D

I

N

G

C

O

N

S

A

L

18

P4318

/3.16+24V

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24


48/55


DIS.

DATA UL.M.

COMM.

JAK

11.07.03

WELD334mPSC

DENOMINAZIONE


CLIENTE

PEUGEOT CINA




FG.N.

N.DISEGNOPOS.ARCH

TOTALE FOGLITIPO

16.12.05

23


17

DI FG.

24

18

75543012/03

I

O

E

17.23/.+24V

-

G

U

N

"

A

"

R

E

S

E

T

C

H

.

E

L

E

C

.

C

H

G

E

O

K

A

9

P4309

SACEHR1

-

G

U

N

"

B

"

R

E

S

E

T

C

H

.

E

L

E

C

.

C

H

G

E

O

K

B

10

P4310

SACEHR2

-

C

O

D

E

0

11

X10 C4

1SP

.1SP

X10 C8

2SP

.2SP

-

C

O

D

E

1

12

X10 B4

X10 B8

10.14/0V:

10.07/+24V:

-

C

O

D

E

2

13

P4313

X20 C4

+24V

FC1

0V

-

C

O

D

E

3

14

P4314

X20 B4

+24V

FC2

0V

-

C

O

D

E

4

15

P4315

X20 C9

+24V

FC3

0V

-

C

O

D

E

5

16

P4316

X20 B9

24V

FC4

0V

-

C

O

D

E

P

17

-

E

N

A

B

L

E

W

E

L

D

I

N

G

C

O

N

S

A

L

18

P4318

/17.02.+24V

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24


49/55


DIS.

DATA UL.M.

COMM.

JAK

29.07.03

WELD334mPSC

DENOMINAZIONE


CLIENTE

PEUGEOT CINA



TABLE OF PROGRAMSDATA STAMPA

FG.N.

N.DISEGNOPOS.ARCH

TOTALE FOGLITIPO

16.12.05

23


18

DI FG.

24

19

75543012/03

PAGE 17 IN THE ELECTRICAL DRAWING SHOWS THE CASE OF TEN PROGRAMS CHOSEN

THROUGH A SELECTOR SWITCH ON GUN 1 GRIP AND THROUGH 4 LIMIT SWITCHES

CASE IN WICH A MANUAL GUN USES FROM 2 UP TO 10 PROGRAMS WITH A LIMIT SWITCH FOR EVERY

PROGRAM CHANGE AND A SELECTOR SWITCH ON THE GUN GRIP TO CHOOSE THE FIRST TWO PROGRAMS.

PAGE 16 IN THE ELECTRICAL DRAWING SHOWS THE CASE OF THE PROGRAMS (PROGRAM 1 AND 2) CHOSEN

THROUGH A SELECTOR SWITCH ON GUN 1 GRIP.

PROGRAM 1

PROGRAM 2

PROGRAM 5

PROGRAM 6

PROGRAM 9

PROGRAM 10

PROGRAM 17

PROGRAM 18

PROGRAM 33

PROGRAM 34

PROGRAM

CODE 0

BIT0 0

*

*

*

*

*

PROGRAM

CODE 1

BIT 1

*

*

*

*

*

PROGRAM

CODE 2

BIT 2

*

*

PROGRAM

CODE 3

BIT 3

*

*

PROGRAM

CODE 4

BIT 4

*

*

PROGRAM

CODE 5

BIT 5

*

*

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24


50/55


DIS.

DATA UL.M.

COMM.

JAK

11.07.03

WELD334mPSC

DENOMINAZIONE


CLIENTE

PEUGEOT CINA




FG.N.

N.DISEGNOPOS.ARCH

TOTALE FOGLITIPO

16.12.05

23


19

DI FG.

24

20

75543012/03

C

O

N

N

E

C

T

O

R

-

P

1

-

W

E

L

D

3

3

4

SCH

T

X

0

+

-

T

X

0

+

5

P1 5

T

X

0

-

-

T

X

0

-

9

P1 9

R

X

0

+

-

R

X

0

+

4

P1 4

R

X

O

-

-

R

X

O

-

8

P1 8

CONNECTOR REMOTE CONTROL PROGRAMMING WELD 334

D

G

N

D

-

D

G

N

D

1

P1 1

D

G

N

D

-

D

G

N

D

6

P1 6

+

V

N

R

-

+

V

N

R

2

P1 2

+

V

N

R

-

+

V

N

R

7

P1 7

R

E

S

E

R

V

E-

R

E

S

E

R

V

E

3

P1 3

HHT 3400

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24


51/55


DIS.

DATA UL.M.

COMM.

JAK

29.07.03

WELD334mPSC

DENOMINAZIONE


CLIENTE

PEUGEOT CINA



- CONNECTOR GUN ADATA STAMPA

FG.N.

N.DISEGNOPOS.ARCH

TOTALE FOGLITIPO

16.12.05

23


20

DI FG.

24

21

75543012/03

GUN 1ELECTRICMANIFILD

X10

HartingC2

X11Burndy

A

J1Burndy

A

E

V

W

E

L

D

I

N

G

A

A3

B

B

E

V

A

D

D

.

O

P

E

N

I

N

G

A

A5

C

C

T

H

E

R

M

O

S

T

A

T

B5

D

D

C

OM

M

O

N

T

H

E

R

M

O

S

T

A

T

B6

E

E

E

M

E

R

G

E

N

C

Y

C6

F

F

CO

M

M

O

N

E

M

E

R

G

E

N

C

Y

C5

G

G

+

2

4

V

C3

H

H

ST

A

R

T

-

H

A

N

D

L

E

1

B4

K

K

"

C

O

DE

1

"

-

H

A

N

D

L

E

1

C4

J

J

"

C

O

DE

0

"

-

H

A

N

D

L

E

1

A4

L

L

C

E

V

A

S

B3

M

M

E

V

A

D

D

.

C

L

O

S

I

N

G

A

A2

N

N

D

O

N

O

T

U

S

E

A7

P

P

ST

A

R

T

-

H

A

N

D

L

E

2

C8

R

R

"

C

O

DE

0

"

-

H

A

N

D

L

E

2

B8

S

S

"

C

O

DE

1

"

-

H

A

N

D

L

E

2

B2

T

T

0

V

A1

U

U

C

U

R

RE

N

T

S

E

N

S

O

R

T

A

-

C1

V

V

C

U

R

RE

N

T

S

E

N

S

O

R

T

A

+

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24


52/55


DIS.

DATA UL.M.

COMM.

JAK

29.07.03

WELD334mPSC

DENOMINAZIONE


CLIENTE

PEUGEOT CINA



- CONNECTOR GUN BDATA STAMPA

FG.N.

N.DISEGNOPOS.ARCH

TOTALE FOGLITIPO

16.12.05

23


21

DI FG.

24

22

75543012/03

GUN 2ELECTRICMANIFOLD

X20

HartingC2

X21Burndy

A

J2Burndy

A

E

V

W

E

L

D

I

N

G

B

A3

B

B

E

V

A

D

D

.

O

P

E

N

I

N

G

B

A5

C

C

T

H

E

R

M

O

S

T

A

T

B5

D

D

C

O

M

M

O

N

T

H

E

R

M

O

S

T

A

T

B6

E

E

E

M

E

R

G

E

N

C

Y

C6

F

F

C

O

M

M

O

N

E

M

E

R

G

E

N

C

Y

C5

G

G

+

2

4

V

C3

H

H

S

T

A

R

T

-

H

A

N

D

L

E

1

B4

K

K

"

C

O

D

E

3

"

-

H

A

N

D

L

E

1

C4

J

J

"

C

O

D

E

2

"

-

H

A

N

D

L

E

1

A4

L

L

C

E

V

A

S

B3

M

M

E

V

A

D

D

.

C

L

O

S

I

N

G

B

A2

N

N

D

O

N

O

T

U

S

E

A7

P

P

S

T

A

R

T

-

H

A

N

D

L

E

2

C8

R

R

"

C

O

D

E

2

"

-

H

A

N

D

L

E

2

B8

S

S

"

C

O

D

E

3

"

-

H

A

N

D

L

E

2

B2

T

T

0

V

A1

U

U

C

U

R

R

E

N

T

S

E

N

S

O

R

T

A

-

C1

V

V

C

U

R

R

E

N

T

S

E

N

S

O

R

T

A

+

OPTIONAL

C9

"

C

O

D

E

4

"

B9

"

C

O

D

E

5

"

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24


53/55


DIS.

DATA UL.M.

COMM.

JAK

29.07.03

WELD334mPSC

DENOMINAZIONE


CLIENTE

PEUGEOT CINA



CONNECTOR HARTINGDATA STAMPA

FG.N.

N.DISEGNOPOS.ARCH

TOTALE FOGLITIPO

16.12.05

23


22

DI FG.

24

23

75543012/03

0,35MMQ BLUE

X20 A1

JUMPER

CURRENT

SENSOR

TRANSFORMER

C1 A5

JUMPER

THERMOSTAT

TRANSFORMER

HARTING CONNECTOR

SECOND GUN PLUG

B5

0,35MMQ ORANGE

B6

JUMPER

BUTTON

EMERGENCY

C6

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24


54/55


DIS.

DATA UL.M.

COMM.

JAK

29.07.03

WELD334mPSC

DENOMINAZIONE


CLIENTE

PEUGEOT CINA



TERMINAL BLOCKDATA STAMPA

FG.N.

N.DISEGNOPOS.ARCH

TOTALE FOGLITIPO

16.12.05

23


23

DI FG.

24

24

75543012/03

N

U

M

B

E

R

T

E

R

M

I

N

A

L

T

Y

P

E

T

E

R

M

I

N

A

L

T

E

R

M

I

N

A

L

E

W

3

5

+

2

4

V

D

O

U

B

L

E

J

U

M

P

E

R

W

D

K

2

,

5

V

D

O

U

B

L

E

J

U

M

P

E

R

W

D

K

2

,

5

V

+

2

4

V

D

O

U

B

L

E

J

U

M

P

E

R

W

D

K

2

,

5

V

+

2

4

V

D

O

U

B

L

E

J

U

M

P

E

R

W

D

K

2

,

5

V

+

2

4

V

D

O

U

B

L

E

J

U

M

P

E

R

W

D

K

2

,

5

V

0

V

D

O

U

B

L

E

J

U

M

P

E

R

W

D

K

2

,

5

V

0

V

D

O

U

B

L

E

W

D

K

2

,

5

P

4

-

4

P

4

-

5

P

4

-

5

P

4

-

4

D

O

U

B

L

E

W

D

K

2

,

5

4

0

4

0

4

0

4

0

D

O

U

B

L

E

W

D

K

2

,

5

P

4

-

1

P

4

-

1

P

4

-

1

P

4

-

1

D

O

U

B

L

E

W

D

K

2

,

5

P

4

3

0

3

P

4

3

0

3

P

4

3

0

3

P

4

3

0

3

WELDING CABINET TERMINAL BLOCK

D

O

U

B

L

E

W

D

K

2

,

5

P

4

3

0

4

P

4

3

0

4

P

4

3

0

4

P

4

3

0

4

D

O

U

B

L

E

W

D

K

2

,

5

P

4

3

1

8

P

4

3

1

8

D

O

U

B

L

E

W

D

K

2

,

5

P

4

4

0

4

P

4

4

0

4

P

4

4

0

4

P

4

4

0

4

D

O

U

B

L

E

W

D

K

2

,

5

P

4

3

1

3

P

4

3

1

3

P

4

3

1

3

P

4

3

1

3

D

O

U

B

L

E

W

D

K

2

,

5

P

4

3

1

4

HPA150(PSA 2003版)ponteadeira funilaria

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Transcript of HPA150(PSA 2003版)ponteadeira funilaria