W16-l2 - welding.com.au · W16-l2 DRAWING NO. W16-11 METHOD OF SPEED RANGE SELECTION DRAWING NO. W17-Cl. CIRCUIT ... R2 when thegun:switch is pressed. When the gun switch is ... The

TABLE OF CONTENTS

INTRODUCTION

C I R C U I T D 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 OF SPEED RANGE SELECTION

DRAWING NO. W 1 7 - C l .

C I R C U I T D E S C R I P T I O N W16-11

DESIGN APPROACH TO SPECIAL

CONTROL FUNCTIONS

SUMMARY

TABLE OF OPTIONS AND GENERAL INFO.

C I R C U I T D E S C R I P T I O N O F OPTIONS

AM126 PRE AND POST GAS

AM127 SOFT START/CRATER FILL

~ ~ 1 2 8 SPOT TIME/CYCLE ARC

AM129 DIGITAL W I R E FEED

AM131 PUSH PULL ADAPTOR

Page 1.

Page 2 - 3

P a g e 4

Page 5 - 6

Page 7

Page 8 - 9

P a g e 10

Page 11

A p p e n d i x 1

A p p e n d i x 2

A p p e n d i x 3

A p p e n d i x 4

A p p e n d i x 5

INTRODUCTION:

The W . I . A . W17 type wire feeder has been designed to feed a range of hard, s o f t and f lux co red w i re s fo r t he Gas-Metal Arc Welding process . 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 motor with integral spur gear box i s coupled t o a two ro l l d r ive assembly forming the bas ic component o f t he wire feeder . The motor i s c o n t r o l l e d by an e l ec t ron ic speed con t ro l which ensures exce l l en t speed r egu la t ion ove r t he fu l l t o rque r ange o f t he mo to r , and inherant compensat ion €or supply vol tage var ia t ions.

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 Wirefeeder are s i tuated under the 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 d p a n e l , a l s o r e f e r r e d t o as "Motherboard", i s mounted on t h e t r a y above the motor by s i x p l a s t i c s u p p o r t s .

The "motherboard" accepts the external cable connect ions and controls the power and braking to the motor , the welding contactor and gas valve func t ions .

The smal le r W16-11 motor speed control panel plugs direct ly into the "mother- boa rd" . Wi thou t t h i s pane l f i t t ed , t he motor w i l l run a t f u l l s p e e d .

In a s tandard W17/W18 wi re feede r t he re a r e twovacan t r ecep tac l e s o f 8 p i n s each . These f ac i l i t a t e t he i nc lus ion o f op t ion boa rds t o a l t e r o r add t o the s tandard wi refeeder func t ions . The p a n e l s f o r W17 and W18 wirefeeders a r e t h e same e x c e p t f o r t h e l i n k s on t h e W16-12 board. These l inks are used t o s e l e c t a d j u s t m e n t r e s i s t o r s f o r t h e wire speed potentiometer depending on the motor used. These differences should be kept in mind when rep lac ing boards . SEE PAGE 6 fo r pane l r ep lacemen t de t a i l s .

The W17 wirefeeder 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 Motor and 25/1 Gearbox and W16-12 Board w i t h l i n k s c u t t o s u i t .

The W18 wirefeeder is f i t t e d w i t h t h e heavy duty 8 ampere Yaskawa Motor and 50/1 Gearbox and 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 connected to 9 & 10 of terminal strip I1S1I1 . These are used to control the contactor in the power source. When K2 is energized the contacts are closed and the power source contactor is 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 effect of holding "H2" on for a short period after the gun switch is released. This is the burnback time and can be adjusted by RV1.

Note : A track goes from the junction of R3 and D13 to the option board pins so that K2 can be controlled by the options when required.

___ "" __-__- "

(5) The gas valve in the base of the wirefeeder is connected to 5 & 6 of terminal strip "Sl" and is controlled by H 3 which i s turned on via D15, R 1 0 & R9 when the gun switch is pressed and via R 1 1 when the purge switch is pressed.

Note: The track from the junction of R9 & R 1 0 to the option board pins. This enables the control of the gas valve by the option boards when necessary.

30V

PIN.

L I N K E

L I N K S F ,G

4.

"l__l"__"~-

REFER DRAWING NO. W16-12.

ITEM S1 ............... 12 Terminal Stri .p

Terminals 1-4 Spares not connected 5-G Gas Valve

l

I 1

I 1 7-8 30 Vac. Looping terminal from con t ro l cable t o Off- On swi tch .

9-10 Contactor I 1

I1 11-12 Motor

P 1 . . . . . . . . . . . . . . . . 8 P i n Array . . . . . Loom t o f r o n t p a n e l See Drawing No. W17-0/24

a ) The speed cont ro l po ten t iometer takes P i n s ( 6 , 7 I 8 ) b) Then the re i s 30v which goes t o P i n (5)

c ) The gun s w i t c h t o D12,D101D15, P i n ( 4 ) d) I n c h t o R 1 4 Pin ( 3 ) e ) Purge t o R 1 1 P i n ( 2 ) f ) To t h e L . E . D . on the f / pane l Pin (1)

The Inch/Purye switch Led

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

P 3 . . . . . . . . . . . . . . . 8 P i n Array . . . . . Option board r e c e p t i c a l

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

L I N K S A , B , C , D . 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 Dicjital Option

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 a n a c t u a l s i z e c o m p o n e n t o v e r l a y of t h e W16-12 p a n e l . Note Links A t o D, t h e s e l i n k s c h o o s e t h e s p e e d r a n g e f o r W17 o r W18.

1. W17 Cut Links A & C 2. W18 Cut Links B & D

l

Also Note Link ' E ' c u t o n l y when o p t i o n s r e q u i r e . Now r e f e r to drawings No. W16-11. which i s a double s i z e com- p 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 9 tc

A ! R Q !A P

b I E

~ ~ -~~~ ~

These r e s i s to r s fo rm the t op and bo t t am o f a voltage d i v i d e r w i t h t h e s p e e d c o n t r o l p o t e n t i o m e t e r in t h e c e n t r e .

R16' ,R19' are s e l e c t e d on tes t t o p r o d u c e t h e c o r r e c t start up and f i n a l s p e e d o f t h e m o t o r so t h a t t h e m o t o r s ta r t s just as t h e p o t . i s t u r n e d from zero and when t u r n e d f u l l y clockwise the motor speed i s t h e n r e q u i r e d f o r W17 or VI-8. The Table below shows which 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- f e e d e r

CUT LINKS A , C . CUT LINKS B ,D

W17 W1 8

SELECT FOR MIN. SPEED R 1 8 ' R19 I e. g. POT SET TO M I N . ( 0 RPM) ( 0 R? M)

"""""""___

" "" "- "- SELECT' FOR iW!,X. SPEED. R1G R 1 7 I e .g . POT. SET TO MAX. (126RPM) ( 7 2 RPM)

NOTE: SPEEDS SHOWN ARE OUTPUT SHAFT SPEEDS.

6 .

WL6-11 boards are produced without: R16 ' - R19' and t hese r e s i s t o r s are 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 so t h a t t h e y are s e l e c t e d f o r t h e wirefeeder i n which they 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 board. The new W16-l1 shou ld 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 as t h e o ld board and i n t h e same l o c a t i o n . T h i s can be done by r emov ing t he r e s i s to r s from t h e o l d a n d s o l d e r - i n g them t o t h e new W16-11.. I

A n a l t e r n a t e method i s t o set the speed boa rd up on a n o t h e r wirefeeder, however, t h i s s h o u l d only be done when it i.s n o t p o s s i b l e t o do the previous method as t h i s may n o t be as accur - a te i n a l l cases.

To be comple t e ly accu ra t e use a tachometer and a r e s i s t o r sel- 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 t s p e e d , as done i n t he f a c t o r y .

NOTE: Any W l 6 - l 1 w i l l p r o v i d e s p e e d c o n t r o l i n a 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 h l i n k s are c u t , e n a b l i n g o n e t o s u b s t i t u t e boards t o i s o l a t e f a u l t s .

D u r i n g s e r v i c i n g i f a f a u l t e x i s t s the r emova l -o f Opt ion bo 'a rds re turns 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 L I N K " E " should be remade ( s imply so lde r up 1 when t h e s e o 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 o p t i o n s .

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 wirefeed motor by a d j u s t i n g t h e c o n d u c t i o n a n g l e of S C R I and SCR2, descrilbed on page 2 paragraph l (I) .

W16-11 C I R C U I T D E S C R I P T I O N "

The power supply cons is t s of two 1 2 Volt zener d i o d e s , 21

I C 1 d e r i v e s ZERO C R O S S I N G PULSES f r o m t h e u n f i l t e r e d s u p p l y and 2 2 , w h i c h p r o v i d e s t a b l e 1 2 Volts and 2 4 Volts t o t h e c i r c u i t .

v o l t a g e . I C l ' s o u t p u t d r i v e s a monos tab le , I C 2 , wh ich t r i gge 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 s y n c h r o n i z e d t o mains f requency .

I C 4 compares the motor vo l tage to a v o l t a g e s e t by t h e L7irespeed potent iometer , i t s o u t p u t i s compared t o t h e ramp by IC3. The o u t p u t o f IC3 d r i v e s t r a n s i s t o r H 2 , which bypasses c u r r e n t away f r o m t h e g 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 y c o n t r o l l i n g t h e time €or which t h e SCR's conduct f o r e a c h h a l f c y c l e and t hus t he vo l t age t o t he mo to r i s c o n t r o l l e d .

I C 4 i s s o a r r a n g e d t h a t i t s o u t p u t a c t s t o m a i n t a i n c o n s t a n t BACK EMF from the motor i . e . when motor speed d e c r e a s e s d u e t o app l i ed l oad t he ou tpu t o f I C 4 r e d u c e s a c t i n g t o in t e r sec t t h e 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 conduc t ion ang le of t h e S C R ' s . The re fo re supp ly ing more v o l t a g e t o t h e motor i n o r d e r t o i n c r e a s e i t s speed .

I t s h o u l d b e n o t e d t h a t w i t h o u t H 2 i n c i r c u i t , for example w i t h t h e 5516-11 panel unplugged, the motor w i l l r e c e i v e f u l l v o l t a g e and run a t full speed .

DESIGN APPROACH TO SPECIAL CONTROL FUNCTIONS

The W16-12 motherboard has been designed to meet the requirements of a s t anda rd w i re feede r w i th p rov i s ion fo r f i t t i ng spec ia l i s ed con t ro l funct ions. These opt ional control funct ions can be plugged into the receptac les p rovided i n the motherboard.

There are two such r ecep t i ca l s o f 8 pins each ... PIN 1. Suppl ies power 30v to op t ion boa rds

I

PIN 2 . Provides access to s igna l f rom speed cont ro l po ten t iometer

PIN 3. Provides opportuni ty to send modif ied speed s ignal to speed board i n conjunction with Link E.

PIN 4 . OV common l i n e for a11 boards

J

PIN 5. Provides a means o f con t ro l l i ng t he gas va lue

PIN 6. Provides a means o f con t ro l l i ng t he con tac to r

PIN 7 . Makes gunswi tch s igna l ava i lab le

PIN 8 . Provides a means o f c o n t r o l l i n g t h e motor r e l a y .

AM126 PRE/POST GAS CONTROL

Th i s con t ro l a l l ows sh i e ld ing gas t o f l ow ove r t he weld a r e a f o r a con- t r o l l e d p e r i o d b e f o r e and a f t e r we ld ing t o ensu re t he we ld me ta l i s properly shielded f rom atmospheric gases . When t h e gun switch i s p res sed ,

' gas flows as normal , but the contactor and motor re lay are delayed for an ad jus t ab le time pe r iod . On re leas j -ng the gun s w i t c h , the contac tor and motor re lay are de-energised, but the gas valve remains open for t k - s p rese t "pos t gas" t ime.

" -

AM127 SOFT START/CRATER FILL CONTROL

Th i s f ac i l i t y p rov ides con t ro l o f t he wire feed speed a t t he s t a r t and f i n i s h o f a weld. I t i s p a r t i c u l a r l y u s e f u l f o r f u l l y a u t o m a t i c and submerged a rc we ld ing app l i ca t ions . The design approach was t o use twc p o t e n t i o m e t e r s , d e s i g n a t e d s o f t s t a r t and c r a t e r f i l l , and switch bet- ween them a t the appropr i a t e times. On c l o s i n g t h e gun swi tch , the motor i s con t ro l l ed by t h e s o f t s t a r t p o t e n t i o m e t e r u n t i l the cur ren t . r e l ay s enses t ha t we ld ing has commenced and t h e a r c e s t a b l i s h e d f o r a preset t ime period. Speed is then con t ro l l ed by t h e normal wire speed po ten t iome te r un t i l t he gun switch i s r e l eased . Welding continues witk t h e w i r e s p e e d c o n t r o l l e d - b y t h e c r a t e r f i l l p o t e n t i o m e t e r f o r a p r e s e t t ime per iod.

AM128 SPOT TIME/CYCLE ARC CONTROL

A toggle switch i s p rov ided t o s e l ec t t he spo t we ld , cyc le a r c o r norxal mode of opera t ion .

In the spot weld ing mode the welding operat ion i s automatical ly s topped a f t e r a prese t opera t ing t ime. A cu r ren t r e l ay i s used t o sense the cu r ren t f l ow and i n i t i a t e a t imer , which i n t u r n de-energises the welding contactor , motor and gas valve a f t e r t h e p r e s e t t i m e has el?.;:se?..

In t he cyc le a r c mode, the welding operat ion i s i n t e r m i t t e n t l y i n t e r - rupted, wi th both on and o f f time pe r iods be ing fu l ly ad jus t ab le ,

3.5. AM129 DIGITAL WIRE FEED PATE METE12 - _ _ _ ~ - ~ " ~ ~

The meter d i s p l a y s t h e wire feed ra te i n metres pe r m i r n l t e , u t i l i s i n g a b r i g h t r e d LED ( l i gh t emi t - t i ng d iode) type read out with l01m high f i g u r e s .

A s the wirefecd motor supply is of a c losed loop voltaye cotnpensatiny des ign , t he mot.or speed i s d i r e c t l y p r o p o r t i o n a l t o t h e o u t p u t volt-age of the speed cont ro l po ten t iometer . This vo l tage is f e d t o a p rec i s ion vol tage divider , and to the digi ta l . panel meter which i s c a l i b r a t e d i n metz:es per m i n u t e .

3 . 7 . M1131 DIJSB i- PtJLL SYSTEM __"___~"" - The m4131 control . converts the s tandard W 1 ' 7 t o a push -t puil wirefeeder s u i t a b l e fcir small diameter and s o f t wi.res. I4 separate power sul>ply i s provided for t h e p ~ n l l gun motor and t h i s i s then cont ro l led by t h e sane speed coatrol si .gni?b as the wi refeeder . The wire speed can he con t ro l l ed by e i t h e r t h e normal specd control- potentiometer on t h e wi refeeder ( w i t h t he t ogg le switch set t o l o c a l ) o r by the po ten t iometer mounted on t h e gun body (with togg1.e switch s e t t o remote) .

The d e t a i l e d c i r c u i t o p e r a t i o n o f each of the above con t ro l Func t ions a r e s e t o u t i r : the following pages and are i n t e n d e d t o assist f a u l t f i nd ing and gene ra l s e rv i ce .

1.

2.

3 .

4.

5.

6 .

7 .

8 .

9 .

10 .

"

10.

l

Wl.6-12 Wire Feed Panel Motor Supply and Braking Con tac to r Con t ro l Gas Valve Control

N16-11 Speed Control Panel . Plugs i n t o W16-12.

w17/w18 same b u t f o r l i n k s a n d a d j u s t r e s i s t o r s .

Some o p t i o n s r e q u i r e l i n k ' E ' t o be c u t . See l i s t of op t ions Paye 11.

K 1 Motor Relay opera ted by H 2 .

K 2 Con tac to r Re lay ope ra t ed by HI.

Gas v a l v e o p e r a t e d by H 3 .

Links A , C c u t f o r P717 Links B,D cut f o r W18 Link E c u t f o r c e r t a i n o p t i o n s ( e . g . PJ.1129)

Speed C o n t r o l P a n e l a d j u s t e d for speed range.

Remove opt ions and make s u r e l i n k ' E ' i s made, to r e t u r n wirefeeder t o s t a n d a r d , for ease of f a u . l t f i n d i n g .

IiIST OF OPTIONS ".-

1. AM126 PIU AND POST GAS.

- """

2 . AM127 SOFT START/ GRATER FILE.

""

3 . AM128 SPOT TIME/ CYCLE ARC,

4. AM129 D I G I T A L WIN? SPEED

""p-

5. AM130 VERNIER D I A L

" """

6. AM131 PUSH/PUI,L OP TI ON

11.

CUT

CUT

YES

"-

YES

YES

YES

"

YES

Y E S

"-

YES

-p

YES

I"

YES

"

YES

"

NO

NO

5 OI? 6

S I CURFtENT CAN RE . , E USED l

"

5

5

NO OTHER O P T I O N S

L 2

l

A P P E N D I X 1

AM126 PRE AND P O S T G A S

AM126 PRE/POST GAS OPTION. - REFER D R A W I N G NO. AM12G/CiL.

Pi.n 1 and p in 4 of t h e o p t i o n p i n s supp1.y 3 0 V and ov r e spec t ive ly . Diode D l d e c o u p l e d t h i s c i r c u i t f r o m o t h e r s . The combination of R1, ZD1 and C1 form a stab1.e 1 2 V supply . .

The c i r c u i t i s i n two p a r t s . One i s IC1 whish ‘5s a timer‘ t r i y - gered by H 1 when the gunswitch goes on. For a perj..od, a f t e r t h e t r i g g e r , se t by RV1 b e , i n g t h e p r e - g a s p e r i o d c o n t a c t o r and motor r e l a y are d i s a b l e d via, H2,D5’ and D6. Leaving the gas va lve oper - a t i n g .

The s e c o n d p a r t c o n s i s t of a timer made from IC2 a n d t h e d i s c h a r g e of C6 when t h e gunswitch i s released. C 6 i s charged q u i c k l y w h i l e t h e gunswitch i s on and d i scharges th rough RV2 and R l l . R11 se ts t h e minimum d i s c h a r g e time. RV2 sets l a r g e r times and i s t h e p o s t - gas time c o n t r o l . IC2 c o n t r o l s H3 which in c o n j u n c t i o n w i t h R 1 4 and D7 h o l d t h e gas valve on f o r a time a f t e r t h e gunswitch i s re Ieased . Note. R 5 sets t h e minimum pre-gas t i m e t o approx. o seconds and Rll sets t h e minimum pos t -gas t i m e to approx. 2 seconds.

APPENDIX 2

AM127 SOFT START/CRATER F I L L

The power supp ly i s d e r i v e d from p i n 1 ( 3 0 V ) and p i n 4 (OV) through D l , R 1 and R2. Zener Diodes Z L and, 2 2 p rov ide 1 2 V and 2 4 V suppl ies smoothed by C l .

T h i s o p t i o n s w i t c h e s t h e s p e e d s i g n a l s u p p l i e d t o t h e s p e e d board (1016- I \ ) f r o m t h e s t a n d a r d s p e e d . c o n t r o l p o t e n t i o m e t e r t o two a d d i t i o n a l p o t e n t i o m e t e r s c a l l e d " S o f t S t a r t Speed" and "Crater F i l l Speed". The s w i t c h i n g i s c o n t r o l l e d by timers s e t by t h e " S o f t S t a r t T i m e " and "Crater Fill Time" p o t e n t i o - meters.

..; 4.

The norma l speed s igna l is a p p l i e d t o t h e b a s e of Hl. S o f t s t a r t 'I 11 I t I I 11 I I 11 H 2 .

I ' Crater f i l l 'I II I I II 11 I I I I l' H3. The emitters of 111,H2,H3 are connec ted and supply the speed s i g n a l t o t h e s p e e d b o a r d . Which s p e e d s i g n a l i s s u p p l i e d depends on which t rans is tors are swi t ched . H4,H5,H6,1!7 and H8 control . the swi t ch ing . The timers c o n s i s t of I C 1 and I C 2 . I C 1 gove rns t he S o f t S t a r t d u r a t i o n a n d i s c u r r e n t i n i t i a t e d . I C 2 gove rns t he Crater F i l l d u r a t i o n a n d i s t r i g g e r e d .by t h e Gun- S w i t c h g o i n g o f f , i t also h o l d s t h e g a s valve con tac to r and m o t o r r e l a y on f o r t h e Crater Fill p e r i o d , Via H14,H15 ,R37 ,D12, D13 and D 1 4 .

APPENDIX 3

m 1 2 8 SPOT/TTMER/CYCLEARC

P i n s 1 and 4 supp ly 3 0 V and ov r e s p e c t i v e l y t o t h e o p t i o n b o a r d . Diode DI d e c o u p l e s t h i s o p t i o n f r o m o t h e r s . The combination, of R 1 , C l and ZD1 form a s t a b l e 1 2 V s u p p l y , .-; 4.

The c i r c u i t c o n s i s t s o f ' a t imer IC1.which i s t r i q q e r e d by t h e gunswitch through H 1 .:._.The o a t p u t p i n 3 P C 1 goes -h igh ho id ing H 2 and H 3 o f f . T h e r e f o r e , . c o n t a c t o r , motor r e l a y and qas valve o p e r a t e as u s u a l . When weld c u r r e n t f l o w s t h r o u g h t h e - c u r r e n t r e l a y . The timer i s enab led and a f t e r a d e l a y se t by RV1 (Spo t T i m e C o n t r o l ) t h e o u t p u t p i n 3 of I C 1 goes low and contac tor and m o t o r r e l a y go off. Gas flows as long as the gunswi tch i s h e l d c l o s e d .

I n t h e c y c l e arc mode t h e same p r o c e s s as above takes p l a c e b u t t h e t imer i s connected so t h a t a f t e r a d e l a y ( I n t e r v a l T i m e ) i t resets i t s e l f a n d p r o d u c e s a se r ies of spots sepa red by i n t e rva l s . NOTE: Gas f l o s h 7 i s u n i n t e r r u p t e d . I_-

A P P E N D I X 4

AM129 DIGITAL W I R E FEED

REFER DRAWING NO. AM129/C1 "

AM129 D I G I T A L WIRE SPEED "-

,"

P i n (l) and Pin ( 4 ) provide 30V and.0V respect ively. There are two power s u p p l i e s on t h e AM129 Board, .a 2 4 V supply and a 5 V supply. D l decouples t h i s o p t i o n from o t h e r pane1.s. The. para l le i combina t ion of R 1 2 and R 1 3 d rop vo l t age t o 2 4 V which 'i3 clamped by t h e 1 2 V Zene r Diodes 21 and 22 i n s e r i e s . C2 and C 3 smooth ' t h i s 24V supply.

-4 5

R 1 4 d rops vo l t age t o 5 V , 2 3 clamps t h i s v o l t a g e a t 5 V , C 1 and C4 a r e t h e smoothing capacitors.

This opt ion provides a v o l t a g e , p r o p o r t i o n a l t o w i r e f e e d r a t e , t o a D . P .M. (Digi ta l Panel Meter) wi th 2V F.S . D . * This p ropor t iona l vo l tage i s der ived from t h e wire speed potentiometer. The s i g n a l from the speed control poten- t iometer i s a v a i l a b l e on Pin ( 2 ) and i s app l i ed t o t he - base of T1 t h r u RI. T l i s arranged as a v o l t a g e f o l l o w e r . ( i . e . t h e v o l t a g e a t t h e emitter " f o l l o w s " t h e v o l t a g e a t t h e b a s e ) . R 2 i s t h e e m i t t e r r e s i s t o r f o r t h i s s t a g e . The emi t t e r vo l t age i s appl ied to the speed board . W16-l1 a s t h e speed s igna l . Hence Link "E" on the wirefeed panel W16-l2 mus t be cu t .

The emitter vol tage of T1 i s a p p l i e d d i r e c t l y t o T2 , a l s o a vol tage fol lower b u t o f t h e o p p o s i t e p o l a r i t y . R3 i n series w i t h R4 c o n s t i t u t e t h e e m i t t e r r e s i s t o r f o r t h i s s t a g e , w i t h RV2 and R 9 i n p a r a l l e l , The s i g n a l i s taken f r o m t h e s l i d e r of RV2 t o a d iv ider cha in compr is ing R 1 8 , R10, RV3 and R1. The s i g n a l from the wiper of RV3 i s s e n t t o t h e D.P.M.

The above i s a desc r ip t ion of t h e s i g n a l p a t h t h r o u g h t h e c i r c u i t . IC1 and T3 and a s soc ia t ed components were not mentioned. However, t h e y a l s o e f f e c t t h e s i g n a l . IC1 i s used here as a compara tor , the inputs a re marked 2 and 3. The vol tage a t i npu t 3 i s s e t by RV1 with R6 and R 5 s e t t i n g t h e limits of adjustment . When t h e v o l t a g e a t i n p u t 2 f a l l s below t h a t s e t a t i npu t 3 t he ou tpu t , 6 , goes high, switching T 3 on and-pu l l ing t he vo l t age a t t h e j u n c t i o n of R 1 8 and R I O down, so t h e D . P . M . r eads ' 0 . 0 ' .

All o f t h e c i r c u i t r y so f a r mentioned i s supplied from the 2 4 V ra i l . T h i s conc ludes the descr ip t ion of the s igna l pa th . There i s , however, more t o t h e AM129, namely IC2 and i t s a s s o c i a t e d components which a re connec ted to t h e 5v supply. The 5v i s a l s o s u p p l y t o t h e D.P.M. v i a 5 .

I C 2 i s a t imer wi th a p e r i o d s e t by R 1 5 , K16 and-C5. The output 3 is normally, approximately 5V b u t s w i t c h e s t o OV €or l second every 1 2 seconds. This low p u l s e i s applied through D2 and 7 t o t h e "HOLD" func t ion of t h e D . P . M . , a l l owing t he D.P.M. t o upda te eve ry 1 2 seconds.

R e f e r t o Drawing No. m129 i n conjunct ion with Drawing No. IlMl29/Cl €or the connection between the AM129 and the D.P.M.

* F.S.D. Ful l Sca le Def lec t ion

AM129 SET UP PROCEDURE .

The accuracy of the Wire feed ra te readout is depen,dant on correct se t t ing of t h e AM129 and W16-11 boards.

For a W17 Wirefeeder The W1G-ll.is adjus ted to p roduce 1 2 7 R P M a t t h e d r i v e r o l l e r s , w i t h wire speed potentiometer se t t o max ( i . e . f u l l y c l o c k w i s e ) . T h i s speed corresponds to a wirefeed ra te of 16.0m/min.

i . e . Wirefeed Rate = revs/min x circumference (metres) (metres/min)

= 1 2 7 x Tf x 40 = 16 m/min - min 1000

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It i s the re fo re necessa ry t o ad jus t t he AM129 i n the Wirefeeder and with -the panels with which it w i l l be used.

Af te r ensur ing the cor rec t ou tput speed the AMI29 can be adjusted by the follow- ing procedure . . .

(1) Set RV1 fu l ly an t i c lockwise

( 2 ) S e t RV2 fu l ly an t i c lockwise

Hold in ac tua l bu t ton fo r con t inuous r eadou t i n fo l l . owing s t eps ..

( 3 ) Set Wirespeed po t . to maximum and a d j u s t RV3 t o o b t a i n a readout of 16.0 m/min.

RV3 i s a mul t i t u rn trim pot . , c lockwise adjustment ra ises readout value.

Se t wi respeed po t . to minimum and a d j u s t RV1 clockwise u n t i l r e a d o u t j u s t t u r n s t o 0 . 0 m/min. Check tha t r eadou t starts as p o t . is turned of f min. and motor s tar ts .

Adjust wirespeed pot . to produce 40 R P M and check the readout i s 5.0 m/min. if readout is low a d j u s t RV3 so r ead iou t i s 5.0m/min.

Check s t e p s ( 3 ) and ( 4 ) .

The o p t i o n c o n s i s t s of two p r i n t e d c i r c u i t boards.,,,AML31-1 AM131-2, mounted on a h e a t s i n k . . The whole assembly plugs into the mother -board , P 1 and P2. The standard loom i s removed from PI. of motherboard and plugged into P i of AMP31-2.

A P . C . mount r e l a y on MI131-2 i s ' e n e r g i z e d by t h e l o c a l / r e m o t e s w i t c h on t h e f r o n t p a n e l when e n e r g i z e d t h e n o r m a l s p e e d c o n t r o l p o t e n t i o m e t e r on t h e f r o n t p a n e l i s o p e r a t i v e . When de-energized t h e s p e e d c o n t r o l o n t h e gun i s o p e r a t i v e . The AE4131-1 p r o v i d e s s u p p l y v o l t a g e t o t h e p u l l m o t o r p i n 1- and p i n 4 supply 30V and ov r e spec t ive ly . Th i s i s smoothed by C 1 and s u p p l i e s t h e p u l l m o t o r v i a T5. The base of T5 i s c o n t r o l l e d by T3 and enable by T 4 . The gunswi tch and inch swi tch cont ro l T 2 and T 4 , t o e n a b l e T5. The c o n t r o l of T 5 i s done v i a I C 1 and T3. The s p e e d s i g n a l i s p icked up on p i n 3 o r p1 a n d s u p p l i e d t o T l . R V 1 a l lows a v o l t a g e t o be added t o t h i s s i g n a l t o g i v e a "Lead.". T h i s v o l t a g e i s t h e n f e d i n t o p i n 2 of IC1 which compares it t o t h e v o l t a g e of pin3 which i s h a l f t h e p u l l m o t o r v o l t a g e . The re fo re , I C I . c o n t r o l s T 5 v i a T3 t o m a i n t i a n t h e v o l t a g e a c r o s s t h e p u l l m o t o r a t twice t h e v o l t a g e a t p in2 . Th i s i s because t he p u l l m o t o r r e q u i r e twice t h e v o l t a g e of t h e push motor t o a c h i e v e t h e same Wire Speed. The "Leadv ment ioned previously refers t o mak ing t he pu l l mo to r p u l l more wire than the push motor so t h a t t e n s i o n i s main ta ined i n t h e l e a d . I n s e t t i n g u p t h i s "Lead" t h e n o r m a l s p e e d p o t . i s set t o min . where the push motor i s s topped and R V 1 i s ad jus ted . s o t h e p u l l m o t o r J u s t s ta r t s .

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I I I I I I I I I I I I 1 I I I I I

S A I U H T t

4- Puru OVM I

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8 8

1 I - WELDING INDUSTRIES

I 1 1 l im CIRCUIT DIAGRAM FOR