W16-l2 - Welding

[Pages:23]TACBOOLFNETENTS

INTRODUCTION C I R C U I TD E S C R I P T I O N

Wl6-12 W I m F E E D PANEL LAYOUT DESCRIPTION

DRAWING NO. W16-l2

DRAWING NO. W16-11 METHOD OFSPEED RANGE SELECTION DRAWINNGO. W 1 7 - C l . C I R C U I TD E S C R I P T I O N W16-11 D E S I G NA P P R O A C HT OS P E C I A L

CONTROL FUNCTIONS SUMMARY TABLE OF O P T I O N S AND GENERALINFO. C I R C U I TD E S C R I P T I O N O F O P T I O N S AM126PRE AND P O S T GAS A M 1 2 7S O F TS T A R T / C R A T E RF I L L ~ ~ 1 S2PO8T TIME/CYCLE ARC A M 1 2 9D I G I T A L W I R E FEED AM131 PUSHPULLADAPTOR

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Page 2 - 3

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P a g e 10 Page 11

Appendix 1

Appendix 2 Appendix 3 Appendix 4 Appendix 5

INTRODUCTION:

The W . I . A . W17 t y p ew i r ef e e d e rh a sb e e nd e s i g n e dt of e e d

a r a n g eo fh a r d ,

s o f t and f l u xc o r e dw i r e sf o rt h e

Gas-Metal Arc Welding p r o c e s s . A low

i n e r t i a , P r i n t e d C i r c u i t t y p e motorwithintegralspurgear

box i s coupled

t o a two r o l ld r i v ea s s e m b l yf o r m i n gt h eb a s i c

component o ft h e wire feeder.

The motor i s c o n t r o l l e d byan e l e c t r o n i c s p e e d c o n t r o l whichensures

excellentspeedregulationoverthefulltorquerangeofthemotor,

and

i n h e r a n tc o m p e n s a t i o n o rs u p p l yv o l t a g ev a r i a t i o n s .

The e l e c t r o n i c c o n t r o l s o f t h e W17/W18 W i r e f e e d e ra r es i t u a t e du n d e rt h e t o p l i d o f t h e w i r e f e e d e r which f o l d s back o u t o f t h e way f o r ease of access.

The W16-12 wire f e e dp a n e l ,a l s or e f e r r e dt o

as "Motherboard", i s mounted

on t h e t r a y abovethemotor by s i x p l a s t i c s u p p o r t s .

The " m o t h e r b o a r d "a c c e p t st h ee x t e r n a lc a b l ec o n n e c t i o n sa n dc o n t r o l st h e power a n db r a k i n gt ot h em o t o r ,t h ew e l d i n gc o n t a c t o ra n dg a sv a l v e functions.

The s m a l l e r W16-11 m o t o rs p e e dc o n t r o lp a n e lp l u g sd i r e c t l yi n t ot h e" m o t h e r -

b o a r d " .W i t h o u tt h i sp a n e lf i t t e d ,t h e

motor w i l l run a t f u l l s p e e d .

I n a s t a n d a r d W17/W18 w i r e f e e d e r t h e r e a r e t w o v a c a n t r e c e p t a c l e s o f

8 pins

e a c h .T h e s ef a c i l i t a t et h ei n c l u s i o no fo p t i o nb o a r d st o

a l t e r o r add t o

t h es t a n d a r dw i r e f e e d e rf u n c t i o n s .

The p a n e l sf o r W17 and W18 w i r e f e e d e r s

a r et h e same e x c e p tf o rt h el i n k s

on t h e W16-12 b o a r d .T h e s el i n k s

are

used to select adjustment resistors for the

wire speedpotentiometer

depending on t h em o t o ru s e d .T h e s ed i f f e r e n c e ss h o u l db ek e p ti n

mind when

r e p l a c i n gb o a r d s . SEE PAGE 6 f o rp a n e rl e p l a c e m e n dt e t a i l s .

The W17 w i r e f e e d e r i s f i t t e d w i t h t h e s t a n d a r d 5 ampere Yaskawa Motorand 25/1 Gearboxand W16-12 Board w i t h l i n k s c u t t o s u i t .

The W18 w i r e f e e d e r i s f i t t e d w i t h t h e heavyduty 8 ampere Yaskawa Motor and 50/1 Gearboxand W16-12 Board w i t h l i n k s c u t t o s u i t .

3.

1. (4) Relay K2 has normally open contacts connectedto 9 & 10

of terminal strip I1S1I.1 These are used to control the

contactor in the power source. WheKn2 is energized the contacts are closed and the power source contaicstor energized. "K2" is energized by H 1 , via D10, R 3 , D13 & R2 when thegun:switch is pressed. When the gun switch is released C2 discharges and has the effecotf holding "H2" on for a short period after the gun swiitschreleased. This is the burnback time and can be adjustReVd1. by

Note : A track goes from the junctiofn R3 andD13 to the

option board pinsso that K2 can be controlled by the options

when required.

___ "" _ _ - _ _ -

"

(5) The gas valve in the baosfe the wirefeederis connected to 5 & 6 of terminal strip "Sl" and is controlled by H 3 which i s turned on viaD15, R 1 0 & R9 when the gun switch is pressed and via R 1 1 when the purge switcihs pressed. Note: The track from the junctionof R9 & R 1 0 to the option board pins. This enables the controlof the gas valve by the option boards when necessary.

30V

PIN.

4.

REFER DRAWING NO. W16-12.

"l__l"__"~-

ITEM S 1 ............... 12 TerminaSltri.p

Terminals 1-4 S p a r e sn o tc o n n e c t e d

l

I1

5-G Gas Valve

I1

7-8 30 Vac. Loopintegrminal

from c o n t r o l cable t o Off-

On s w i t c h .

I1

9-10 Contactor

I1

11-12 Motor

P 1 . . . . . . . . . . . . . . . . 8 P i n Array . . . . . Loom t of r o n tp a n e l

SeeDrawing No. W17-0/24

a ) The s p e e dc o n t r o lp o t e n t i o m e t e r takes

b) Then t h e r e i s 30v whigcohes

Pt oi n

The Inch/Puryeswitch Led

c ) The gun s w i t c ht o D12,D101D15,

d) I n c ht o R 1 4

e) Purge t o R 1 1

f ) To t h e L . E . D . on t h ef / p a n e l

Pins (6,7 I 8)

(5)

Pin (4) Pin (3) Pin (2) P i n (1)

P2 . . . . . . . . . . . . . . . 8 PinArray . . . . . Option board r e c e p t i c a l

P3 ...............

. . . . . 8 P i n Array

Option board receptical

P4 & P5 . . . . . . . . . . 2 x 8 PinArrays . . . . Speed Board r e c e p t i c a l s .

LINKS A,B,C,D. LINK E

L I N K S F ,G

W17 - Links A and C cut, Links B and D joined.

W18 - Links B and D cut, Links A and C joined.

Link E c u t f o r c e r t a i n o p t i o n s e . g . X4129 DicjitalOption

AM126 S o f t S t a r t / C r a t e r F i l l o p t i o n

Not t o be c u t

5. REFER TO DRAWING NO. W16-12.

This i s anactualsizecomponentoverlay

of t h e W16-12 p a n e l .

Note Links A t o D, t h e s el i n k sc h o o s et h es p e e dr a n g ef o r

W17

o r W18.

1. W17 Cut L i n k s A & C

2.

W18 Cut L i n k s B & D

l

Also Note Link ' E ' c u to n l y when o p t i o n sr e q u i r e . Now r e f e r to d r a w i n g s No. W16-11. which i s a d o u b l e s i z e comp o n e n t o v e r l a y o f t h e W16-11 s p e e d c o n t r o l p a n e l . Note R e s i s t o r s R16 t o R19 & R 1 6 ' t o R19.

b

UNKs

h

9t c

A

b

!R

Q

!A

IE P

~ ~ -~~~

~

T h e s er e s i s t o r sf o r mt h et o pa n db o t t a mo f

with t h e s p e e dc o n t r o lp o t e n t i o m e t e r

a voltage d i v i d e r in t h ec e n t r e .

R16' ,R19' a r e s e l e c t e d on t e s t t o p r o d u c et h ec o r r e c t start up

and finalspeedofthemotor

s o t h a t t h e m o t o r s t a r t s just as

t h ep o t . i s t u r n e d from zeroand when t u r n e d f u l l y clockwise

t h e motorspeed i s t h e nr e q u i r e d f o r W17 or VI-8. The Table

belowshowswhich r e s i s t o r t o a d j u s t f o r w h a t s p e e d a n d

wire-

feeder

CUT LINKS A , C .

CUT LINKS B ,D

SELECT FOR MIN. SPEED e . g. POT SET TO M I N .

W17 """"___

R18 '

( 0 RPM)

W1 8

R19 I ( 0 R? M)

" "

"

SELECT' FOR iW!,X.

SPEED.

e . g . POT. SET TO MAX.

"-

R1G (126RPM)

"-

R17 I ( 7 2 RPM)

NOTE: SPEEDS SHOWN ARE OUTPUT SHAFT SPEEDS.

6.

WL6-11 b o a r d s are producedwithout: R16 ' - R19' a n dt h e s e

r e s i s t o r s a r e i n s e r t e d on t e s t i n g the w j r e f e e d e r s o t h a tt h e y

a r e s e l e c t e df o rt h e wirefeeder i n whichthey w i l l work. I n

t h e e v e n t of i n f i e l d f a i l u r e n e c e s s i t a t i n y c h a n g e of 1416-11

b o a r d . The new W16-l1 s h o u l d be f i t t e d w i t h r e s i s t o r s of t h e

same v a l u e a s t h e o l d b o a r d and i n t h e same l o c a t i o n .T h i s

can be donebyremovingtheresistors

from theoldandsolder-

i ntgh ethem t o

new W16-11..

I

A n a l t e r n a t e method i s t o s e t t h es p e e db o a r d upon a n o t h e r wirefeeder, however, t h i ss h o u l d only bedone when i t i.s n o t p o s s i b l e t o d o the previousmethod as t h i s may n o t be as a c c u r ate i n a l l cases.

T o be c o m p l e t e l ya c c u r a t e use a tachometer and a r e s i s t o r s e l e c t i o n box t o be able t o select t h e r e s i s t o r w h i c h g i v e s t h e c o r r e c ts p e e d , as done i n t h e f a c t o r y .

NOTE:

Any W l 6 - l 1 w i l l p r o v i d es p e e dc o n t r o il na n y

W17/W18

w i r e f e e d e r r e g a r d l e s s o f w h e t h e r i t i s a d j u s t e d or

w h i c hl i n k s a r e c u t ,e n a b l i n go n et os u b s t i t u t e

boards

toisolatefaults.

D u r i n gs e r v i c i n g i f a f a u l t e x i s t s t h er e m o v a l - o f

O p t i o nb o ' a r d sr e t u r n s t h e w i r e f e e d e r t o s t a n d a r d . ' .

. .Some o p t i o n s ( AM127 and AM129 ) r e q u i r e L I N K ''E"

to be c u t t o o p e r a t e . I n t h i s

case LINK "E" should

be remade ( s i m p l ys o l d e ru p 1 when t h e s eo p t i o n s

are removed.

R e m e m b e r t o r e c u t L I N K ''El' on r e i n s t a l l a t i o n of"

these options.

7.

Wl6-11 SPEED CONTROL PANEL - mFER DRAWING N O . W1'7-Cl

The W16-l1 P a n e l c o n t r o l s t h e s p e e d

of t h e wirefeedmotor

. by a d j u s t i n gt h ec o n d u c t i o na n g l e

on page 2 paragraph l (I)

of S C R I and SCR2, descrilbed

W16-11 C I R C U I T DESCRIPTION "

The p o w e rs u p p l yc o n s i s t s of two 1 2 Volt zener d i o d e s , 21 and 2 2 , w h i c hp r o v i d es t a b l e 1 2 V o l t sa n d 2 4 V o l t s t o t h e c i r c u i t .

I C 1 d e r i v e s ZERO CROSSING PULSES f r o mt h eu n f i l t e r e ds u p p l y v o l t a g e . I C l ' s o u t p u td r i v e s a m o n o s t a b l e , I C 2 , w h i c ht r i g g e r s t h e ramp g e n e r a t o r ,c o n s i s t i n g of t r a n s i s t o r H 1 and c a p a c i t o r C l . The r e s u l t s of t h i s i s a series of ramps w i t h a p e r i o d of 10mS synchronizedto mains frequency.

I C 4 c o m p a r e st h em o t o rv o l t a g et o

a v o l t a g e s e t by t h e

L 7 i r e s p e e dp o t e n t i o m e t e r , i t s o u t p u t i s compared t o t h e ramp by

IC3T. he

o u t p u to f IC3 d r i v e st r a n s i s t o r H 2 , whichbypasses

c u r r e n t away f r o mt h eg a t e s of S C R l and SCR2 u n t i l IC3's, o u t p u t

goes low, t h e r e b yc o n t r o l l i n gt h e time or which t h e SCR's c o n d u c t

f o re a c hh a l fc y c l e andthusthevoltagetothemotor

is controlled.

IC4 is so arrangedthat its outputactstomaintainconstant

BACK EMF f r o mt h em o t o r i . e . when motor speed d e c r e a s e s d u e t o

a p p l i e dl o a dt h eo u t p u to f

I C 4 reducesacting t o intersect the

ramp a t a n e a r l i e r p o i n t i n c r e a s i n g t h e conductionangle of t h e

S C R ' s . T h e r e f o r es u p p l y i n g more v o l t a g et ot h e motor i no r d e r

toincrease its speed.

It shouldbenotedthatwithout

H 2 i n c i r c u i t , for example

w i t ht h e 5516-11 p a n e lu n p l u g g e d ,t h em o t o r

w i l l receivefull

v o l t a g e and r u n a t full s p e e d .

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