Sunke SVF1-400 Variable Frequency Weld Control Review

Transcription

1 32711 Glendale Ave. Livonia, Michigan Ph: Fax: Sunke SVF1-400 Variable Frequency Weld Control Review For Sunke Dr. Chyng-Hua Shiou Prepared by Shawn Villaire Josh Whitford RES Testing Facility Reviewed by Donald F. Maatz, Jr. Welding Engineer This report is prepared for Sunke by RoMan Engineering Services, Inc. This report may not be reproduced, except in full, unless written permission is obtained from Sunke and RoMan Engineering Services, Inc. March 16, 2010 Form Test Report K:\REPORTS'10\Intermax\ Timer\RES-5109R2.docx Revision 1 Page 1 of 9 Retention: 3 Years

2 Sunke SVF1-400 Variable Frequency Weld Control Setup Weld control installation o Terminations for incoming bus power, primary output, and grounding are located on the bottom of the unit. The terminals provided sufficient space to allow for use of AWG 2 wire and lugs Primary electrical measurements were collected with a Fluke 196B ScopeMeter Secondary current measurements were collected with a Miyachi 315B Weld Checker, as well as a Unitek Pico secondary current monitor Water requirements for the weld control are 6 liter/min < 30 Celsius Operating temperature range is between 0-50 Celsius All I/O connections are located on one side of the main board o Operating voltage for I/O connections is 24 volts DC o I/O connections matched the schematic provided in the operation manual Job Number: 5109 Page 2 of 9

3 Figure 1 Motherboard I/O Terminations Output of the Sunke VFC weld control was verified to be 500VAC 50HZ given 480V 60 Hz input power Peak output current is 400 amps Output of the weld control (weld time) is adjustable in 1 cycle increments Job Number: 5109 Page 3 of 9

4 Sunke VFC: 51 amps primary current demand per leg, 10,000 amps secondary current 70 KVA Transformer 105:1 Turns Ratio Standard 60Hz AC weld control: 96 amps primary current demand, 10,000 amps secondary current 70 KVA Transformer 105:1 Turns Ratio Job Number: 5109 Page 4 of 9

5 Sunke VFC: 96 amps output to transformer, 10,000 amps secondary current Operation and Testing The weld control is capable of storing 64 weld schedules o Weld schedule selection is accomplished by binary input Programming o Data entry panel has 4 modes: Editor, Test, Welding, and Monitor o The following parameters are user programmable using the data entry panel: o Each programmable function was tested by changing the parameter and validating the output of the control with a Miyachi Weld Checker and or a Fluke 196B ScopeMeter Prohibit start Stepper on/off Number of weld pulses Repeat mode on/off Pulse start Up-slope time Temper mode Secondary current monitoring Pre-squeeze Up-slope current Temper time Current limits Squeeze time Weld time Temper current Pre-heat monitoring on/off Pre-heat mode Weld current Temper time Pre-heat reference value Pre-heat time Down-slope time Hold time Current limit Pre-heat current Down-slope current Off time Alarm notification value Welding mode (PHA/KSR) Cool time Transformer turns ratio Fault notification value Weld monitor on/off Temper monitoring Pressure curve Stepper control selection %I, %C Weld reference value Alarm value Pressure select 1-10 time Stepper increase on/off Weld limits Fault value Pressure select 1-10 value Pressure value Weld fault Job Number: 5109 Page 5 of 9

6 o The following parameters can be monitored using the data entry panel: Number of welds Line voltage Primary weld current Stepper status Maximum welding voltage Secondary weld current Stepper counter Maximum weld current Cooling time Setup utilized to validate the operation of the weld control o Pneumatic weld gun with 480VAC 60HZ transformer 105:1 turns ratio 20% Duty Cycle Test A 20% Duty Cycle test was performed under the following conditions: 480v 3 phase input power from Variac to Control Control output to 200 kva tx (28:2) turns ratio Adjustable water cooled load bank Unitek Pico Secondary Current Meter Model: MG3-W1 Fluke 196 Scope Meter on Primary connection to Control Control Settings: o 200 ms Squeeze o 7 Cycles weld time (117 ms) o 100% PHA o 75 ms hold o 200 ms off Duty Cycle= on Time/ on time + off time o 117 ms/ (200 ms+117 ms+ 75 ms+200 ms) o Duty Cycle=.197 o 5282 Is/ (28:2)= Ip Control was run for approx. 1.5 Hrs. at 20% duty cycle. No sign of any overheating. Current remained stable throughout test showing no signs of internal temperature changes. Job Number: 5109 Page 6 of 9

7 Red waveform: Primary 5282 I (sec) Blue waveform: Primary 5282 I (sec) Red waveform: Primary 5282 I (sec) Blue waveform: Primary 5282 I (sec) Job Number: 5109 Page 7 of 9

8 Red waveform: Primary 5282 I (sec) Blue waveform: Primary 5282 I (sec) Secondary Current Waveform Job Number: 5109 Page 8 of 9

9 Results and Observations The weld control is capable of performing all of the functions stated in the operation manual Each programmable function was verified to perform the stated task All Inputs and Outputs are discrete 24 VDC which may require an external IO interface module when used with other industrial communication protocols (i.e. Ethernet/IP, DeviceNet, ProfiBus) Current and voltage output from the weld control was within stated specifications, and was repeatable Control is capable of performing under full rated load at 20% duty cycle Job Number: 5109 Page 9 of 9