Mega -MF. ... The millisecond welding-current controller for medium-frequency resistance-welding...

Transcription

1 SER Operating manual Mega -MF... The millisecond welding-current controller for medium-frequency resistance-welding......controlling......monitoring......regulating......documenting... 0 Medium frequency - inverter cycles kva...with Quality - Safeguarding - Function Medium frequencytransformer 000 cycles with rectifier package kva Q S F.

2 V. Mega-MF

3 Notes V V.

4 -007 SER Elektronik & Schweißtechnik GmbH When writing this manual we have tried to be very precise on the text and diagram collection. Nevertheless we cannot completely exclude possible errors. For this reason we will not accept being made liable or juridicial responsible for any error occurring or consequences resulting out of them. Any proposals for improvement or hints on possible errors are welcome. Translated for SER Elektronik&Schweißtechnik GmbH by: Christian G. von Neumann SER Elektronik & Schweißtechnik GmbH Bei den Kämpen D-0 Seevetal-Ramelsloh 0/70 0/7 V. Mega-MF

5 Index Key words... Introduction... Operating elements... 0 Getting started... Wiring... Fuses... Fading out pictures... Parameter / Info. with 7 period controllers... Parameter / Info. with period controllers... Parameter / Functions... Linear stepper... Pressure program P and P... 7 Printer - Port... 7 Parameter / Options... Memory Card... Proportional output... Pneumatic cascade... Current load seam welding... 0 Parameter option QSF... QSF/S current quantity function... QSF/M Multifunction, manual set up... QSF/M Multifunction, intelligent fe-regulation... Installation menu... 7 Installation: picture selection... Installation menu No Installation menu No Installation menu No Installation menu No Installation menu No Installation menu No Installation menu No Installation menu No Installation menu No Special functions... Reset stepper counter... Appendix:... Modifications A... Installation sheet A... Parameter sheet A... Dimensions Mega-MF controller A... LED Mega-MF A... Processing diagram Mega-MF A... Processing diagram Mega-SIN A-... Terminal boards X and X A7... Terminal boards X circuit diagram A... Terminal boards X circuit diagram A... Connector X X, X A0... Connector X X A... Connector X X7 A... Connector X X A... Connector X X0 A... Terminal wiring diagram X and X A... Distance measuring servo cylinder A... Mega-INV wiring diagram A7... Mega-SIN wiring diagram A7-... Connector X X A... Technical data of inverter A... Dimensions Mega-INV inverter A0... Display, LED Mega-INV A... Profibus specification A... Mega-PC wiring diagram A... V. Mega-MF

6 Keywords KEY WORDS V-check... A nd valve I... Ccurrent load seam welding... 0 A adaption current transformer I... adjustable frequency Mega-SIN... A7- air check... A analyse programs I... 7 Appendix... B barcode with profibus... A C calibrate current IK I0..., calibrate current sensor I... calibration cos-phi I... cascade processing with/without start I0... cascade, welding stop I7... circuit diagram X X... A A clear memory I... code of worker with profibus... A connecting boards X X... A7 connector signals X-X0... A connector signals X-X7... A connector signals X-X... A connector signals X-X... A connector X-X X... A0 connector X-X... A0 controller type I controlling current... A controlling time... A, A controlling types I... conversion pressure / force in dan I7 I7... conversion prop. output dan I7... cooling time... cos phi display... cos-phi calibration I... counter stepper I... counter welding spots I... 0 curent upslope... current nominal IK I0... pre-heating... A welding... A current calibrationik I0..., current downslope... current limiting... current sensor calibration I... current time... current time... A current transformer adaption I... current upslope... A D dan for pressure / force I7 I7... dan for prop. output I7... data save I0..., date / time I delete memory I... deviation current halfe waves... device number I dimensions... A dimensions Mega-INV inverter... A0 display welding process... 0 display, led Mega-INV inverter... A distance measurement... A distance measuring I... dutch language I0... E electric cascade... english language I0... EOS (FK) - time (duration) I... 0 EOS (FK) signal after I... 0 EOS (FK) signal for I... 0 EOS (FK) switching point I F Fading out pictures... first picture... 0 force / pressure in dan I7 I7... french language I0... frequency adjustable... A7- frequency inverter I0... frequency mains I... G german language I0... Getting started... H halfe wave... hardware test I... 7 hold time... hold time... A hours operating I... 7 I increase spot count I... 0 increase stepper I7... input measurement selection I... input measuring selectable I... inputs... A Installation picture selection... Installation ID... 7 installation load Mega I Installation menu... 7 Installation menu No Installation menu No Installation menu No Installation menu No Installation menu No Installation menu No Installation menu No Installation menu No Installation menu No installation sheet... A interface printer / PC I0... Introduction... inverter frequency I0... inverter Mega-INV dimensions... A0 inverter Mega-INV display, led... A0 inverter technical data... A inverter type I0... K Key 0/... 0 Key Info... 0 V. Mega-MF

7 Key Installation... 0 Key pad... 0 Key Parameter... 0 Key Quit... 0 Key switch... 0 L language I0... led... A limit current load I... limit flow ( halfe wave I )... A limit flow ( halfe wave U )... A limit relay I... limit relay reset I... Linear stepper... load installation Mega I M mains frequency I... max. programs I0/... max., min. welding time... A measurement input selection I... measuring distance I... measuring input selectable I... measuring of current and voltage I0... measuring part I... Mega- SIN wiring diagram... A7- Mega-INV wiring diagram... A7 Mega-PC wiring diagram... A Mega-SIN processing diagram... A- Memory Card... Memory Card I0... memory delete I... messages I... min., max. welding time... A mode operating I... modification... A modification... A monitoring pressure I7... monitoring with/without current I... N net work address I... network I network interface I network interface I... 7 network interface I0... network interface I... network Mega-PC... A nodeadress profibus I... 7 nominal current IK I0... number of device I O off time... Operating elements... 0 operating hours I... 7 operating mode..., operating mode I... output for controller error I... output for controller ready I... output for distance error I... output for EOS (FK) I... output for I<< error I... output for I>> error I... output for limit error I... output for O/I switch is on I... output for open position I... Key words output for part ok. I... output for pre-stroke position I... output for QSF active I... output for QSF control active I... output for QSF depth active I... output for QSF pressure.error I... output for Quit active I... output for set up mode active I... output for spot counter I... output for start pn.cascade I... output for stepper active I... output for stepper end I... output for stepper warning I... output for U>> << error I... output for V-V valve I... output for VK (locking) I... output standard settings I... outputs... A P Parameter / Functions... Parameter / Info. with period controllers.. Parameter / Info. with 7 period controllers... Parameter / Options... Parameter option QSF... parameter sheet... A part measuring I... pause time... pause time... A PC / printer interface I0... PC interface I PC interface I... 7 PC interface I0... PC interface I... phase angle... picture selection, first picture... 0 Pneumatic cascade... pneumatic cascade I... pneumatic cascade switching time... polish language I0... post heat current downslope... post-heat current uplsope... pre-heat current pre-heat upslope... A pre-heat current... A pre-heat current upslope... pre-heat current upslope... A pre-heat time... A pre-heating time... pre-select program I... pre-select program with rotary switch... pressure / force in dan I7 I7... pressure contact I... 0 pressure monitoring I7... Pressure program P and P... 7 pressure program P I... pressure program P I... pre-stroke I... pre-warning stepper... Printer - Port... 7 printer / PC interface I0... processing diagram Mega-MF... A processing diagram Mega-SIN... A- profibus I... 7 profibus nodeadress I... 7 V. Mega-MF 7

8 Keywords profibus specification... A program pre-select I... program pre-select with rotary switch... program set up... program set up new... program start of, binary I... programs analyse I... 7 programs max. I0/... prop. output dan I7... Proportional output... proportional output I70... Q QSF types I... QSF/M MULTIFUTION, INTELLIGENT FE- REGULATION... QSF/M Multifunction, manual set up... QSF/S current quantity function... R rating valves V- I... 0 regulating voltage... regulation selection I... 7 regulation types I... relay limiter I... reset limit relay I... reset stepper manually... reset stepper with plc... rotary switch program pre-selection... S save data I0..., seam... select no. of transformers I... selection input measurement I... selection regulation I... 7 serial number I servo cylinder distance... A servo cylinder I I7... set time I set up programs... set up welding, LLED... 0 set up welding, no. of I... SPECIAL FUTIONS... spot counter end I spot counter I... 0 squeeze time... squeeze time (begin) I... squeezing time... A standard settings outputs I... start filter I7... start recognition I7... start signal ( duration ) I... status Mega I... 7 status regulator board I... 7 stepper counter... stepper counter I... stepper end... stepper end I... 0 stepper increase I7... stepper reset manually... stepper reset with plc... stepper step -... stepper step -... A switching time pneumatic cascade... T teach weld execute... teach weld for one and more progr.... teach weld function new... technical data inverter... A terminal boards X X... A7 terminals I... test hardware I... 7 text messages I... time... current... A hold... A pre-heating... A time pause... A tool protect (max. Lload)... transformer clearing I... transformer selection I... transformer type I07... transformer, no. of I... type of controller I type of inverter I0... type of transformer I07... V valve nd I... valve rating V- I... 0 VK begin I... 0 W water check... A welding current... welding current... A welding process display... 0 welding spot count end I welding spot count increase I... 0 welding spot counter... welding stop cascadei7... welding time max, min... A Wiring... wiring diagram Mega- SIN... A7- wiring diagram Mega-INV... A7 wiring diagram Mega-PC... A wiring X and X... A worker code with profibus... A X X-X0 signals... A, A X-X X... A0 X-X7 signals... A X X... A7 X X circuit diagram... A A X X wiring... A X, X... A X-X... A X-X signals... A V. Mega-MF

9 introduction INTRODUCTION The Mega-MF welding-current controller, is only one in the series of Mega controllers developed for medium frequency resistance welding techniques. Through universal construction and wide adaptability the following uses are applicable: - single spot welding machines - series spot welding machines - welding robot - electric cascade with up to transformers - pneumatic cascade with up to welding cylinders - parallel-welding with levels of current load - operating mode: single spot welding, series spot welding, seam welding, seam welding with adjustable current loads. While developing the Mega-MF controller, available welding controllers where taken into consideration and only components and operating elements which have been proven in practice have been used. The remarkable features of the Mega-MF welding-current controller are: simple usage, reliability and high flexibility. The following points can only display a fractional variety of the functions: - " cubicle rack - up to periods current processing - up to programs - input connectors, output connectors, potential free and programmable - x0 sign multilingual text display - measuring of primary or secondary current, electrode:- voltage, distance, pressure and force - process monitoring - process controlling - process documentation via printer or PC - networking / operating via PC The technical progression requires the continual development of welding-current controllers. We are grateful for every hint resulting from practical experiences and suggestions so that we can put them into practice. This is also applicable to this operating manual. We hope that an easy getting on in operating and using of Mega-MF welding-current controller is achieved. V. Mega-MF

10 Operating elements OPERATING ELEMENTS Display: x0 signs Key 0/: on = process with current flashing or off=process without current (and displaying current flow) Memory Card: save data, copy Key switch: Progr. =all parameters can be set and set up welding Param. =only currentless parameters can be set Auto =automatic operation parameter locked (see bottom) Key pad: Change parameter *=parameter selection #=picture selection (active parameter flashes) Keys +/-: change parameter Arrowed keys left/right: parameter selection (active param. flashes) Arrowed keys forw./backw: picture selection *) see below Key Quit: confirming of commands or messages Parameter, Info, Installation keys: see below (picture selection also by multiple pressing of key) pin female sub D socket: RS/RS interface and simultaneous: first picture of the active key *) *) Key switch: position Progr. Param. Auto Keys: Parameter Info Installation operating mode, welding parameter, faded out pictures, all param. adjustable as under Progr. but current-parameters are not adjustable as under Progr. but parameters are not adjustable data, counter, operat.hrs, ser.-no., cosϕ, faded out pictures, all param. adjustable as under Progr. but current-parameters are not adjustable As under Progr. but parameters are not adjustable Carry out set up welding (teach welding) (LED must flash) processing Memory Card, printer - output, fade out pictures, installation menu with basic picture selection menu display of welding-process 0 V. Mega-MF

11 Getting started GETTING STARTED WIRING The tying up of the terminals and the connecting up in principle can be seen on the wiring diagram attached as appendix. In particular they are: - ready-contact *) +V and 0V, via switch possible - Input - with / without current *) or wire bridged - Input - pressure contact *) or wire bridged - Inputs - start *) start - directly or pre-select start - with separate start - required outputs locking-contact VK, advance-switch contact EOS, valve outputs V- with +V=,, V *) alternatively +V or 0V switched, Power to the inputs can be supplied either by the controller or directly from the PLC ( current admittance: 0mA per input ). For external components +V / A DC is available. All input- and output conditions are displayed via LED s at the back of the controller. Please install the controller only according to your local safety regulations. Also check all connections and screws according to the wiring and set up diagrams. FUSES There are fuses (x0mm / 0V) on the lower terminal board with the plugs X and X. The board is situated at the rear of the controller. - F Valve voltage: AMT at V ; 0,AMT at V - F +V external: AMT The supplied voltage is also displayed by means of LED s at the rear of the controller. Further there are more fuses inside the controller: x0 mm 0V,x mm 00V -F valve voltage like F -F7 free () -F,AMT power supply. Mega int. -F,AT power supply -F,AMT +V external -F,AT power supply -F 0,AMT +V internal Attention: The controller is delivered with the fuses F and F valued at AMT for a valve voltage not exceeding V. With other valve voltage adjust fuse value accordingly! V. Mega-MF

12 Getting started You can switch on the power now. At first the controller will run a self test. Then if all fundamental contact settings like e.g. Ready contact is closed, have been made, either the last picture which was displayed before the controller was switched off is recalled and displayed or the following message is displayed: S. E. R. # 0 M M E G A - M F V. The term V. is an indication to the version number of the controller. This should correspond with your operating manual ( see foot note on this page). The controller is delivered with standard settings. The settings can individually be adjusted to match the machine. (see page installation menu ). The individual pictures are grouped and can be selected with the keys Parameter, Info. and Installation. The next picture in a group is called when - the same key ( e.g. Parameter ) is pressed again - forward key for next picture, or backward key for the previous picture - ( and simultaneously: shows first picture of active key ) - # -call picture via key pad When the Parameter-key is pressed, following picture e.g. is displayed: p r. t r. k A c u r r e n t % In the top row the program number (pr. 0 - according to controller type) is displayed. The program 0 is used to copy the parameters into all programs. Transformer number (Tr. ) is only displayed in controllers for multiple transformers ( - ) in an electric cascade or when welding in parallel-welding mode with power current levels. If feature is available (see current measuring) the current value ka is achieved by measuring the current, otherwise the value is derived from the submittal translation ratio in the controller s installation menu. The bottom row displays the parameter welding current with a minimal value of %. The display flashes the active adjustable parameter which can be adjusted via the - keys + / key pad The next adjustable parameter is selected with the keys - Arrow key left / Arrow key right - * -key on key pad Please note that the parameter selection is dependent on the key position of key switch. V. Mega-MF

13 Fading out pictures FADING OUT PICTURES Pictures/parameters not in continuous use can be faded out and stay active with current settings in the background. When either key; Parameter or Info. is pressed following picture is displayed: Display text no flashes. With either keys + / - or key pad 0 - this parameter can be changed from no to yes and vice versa. By pressing the active key again and again ( parameter or info. ) the faded out pictures with parameters will be displayed one by one. Setting the parameters is possible in usual manner ( please check key position of key switch). To view pictures do: f a d e d p i c t u r e s? n o Selecting the pictures is carried out with installation key and key switch set on param.. Installation key Key switch: Param. Press installation key again and again until following picture is displayed: f a d e o u t a c t i v e p i c t u r e s? n o Display text no flashes. With either keys + / - or key pad 0 - this parameter can be changed from no to yes. When this parameter is changed to yes following picture is displayed: 0 * e v a l u a t. s u m o n * d e v i a t i o n U + 0 parameter / picture Value range Remarks consecutive number and text of parameter / picture *off* = picture will now be displayed in the setting faded pictures (see above) on* on* or off* Through renewed pressing of the installation key the next parameter/picture and their status will be displayed every time the key is pressed. To change this parameter do: Select on* ( on must flash) and set to off* with - key. Pictures that generally are not used can be selected with the installation menu. They are then faded out and deactivated with their minimal values. ( see page 7 ) V. Mega-MF

14 Parameter / Info. with 7 period controllers PARAMETER / INFO. WITH 7 PERIOD CONTROLLERS Parameter key Key switch: Progr.: Param.: all parameters can be set current parameters can not be set Parameter / Picture Value range Remarks pr. (program number) 0- (pr.0 is used to copy) depending on controller type tr. (transformer number) - only with electric cascade operating mode single spot /series spot /seam option level current load seam welding squeeze time 0-00 ms extend. squeeze time for ms series spot welding only welding current -% display also in ka possible current-on time 0- ms upslope 0-0 ms within current time window *) impulses with off time - Impulse., 0-0 ms off downslope 0-0 ms additional after current time hold time 0-00 ms pause time 0-00 ms with series spot only load (current) maximum modulation -%, -- = inactive - 00 µs = -00 % max. load (protect tool ) max. PWM (protect transformer) faded ( out ) pictures, no ( flashing ); Not or rarely needed parameters / pictures can be Change to yes with keys + or 0-, deposited here and remain active with set settings. and then press either keys The picture selection is made by pressing the installation parameter /#. key while the key switch is set to param.. *) When current on time is changed the upslope is re-adjusted if needed. Info key Key switch: Progr. or Param. Parameter / Pictures Value range Remarks pr. (program number) 0- (pr.0 is used to copy) depending on controller type tr. (transformer number) - only with electric cascade welding spots counter operating hrs. / date / time serial number / Network no. MK % RAM PWM (pulse width modulation) 0- display free storage in the measuringcard MK -00 µs pulse width modulation MF faded ( out ) pictures, no ( flashing ); Change to yes with keys + or 0- and then press either keys parameter / #. Not or rarely needed parameters/ pictures can be deposited here and stay active with settings set. The picture selection is made by pressing the installation key while the key switch is set to param.. V. Mega-MF

15 PARAMETER / INFO. WITH PERIOD CONTROLLERS Parameter / Info. with period controllers Parameter key Key switch: Progr.: Param.: all parameters can be set current parameters can not be set Parameter / Picture Value range Remarks pr. (program number) 0- (pr.0 is used to copy) depending on controller type tr. (transformer number) - only with electric cascade operating mode single spot /series spot /seam option level current load seam welding squeeze time 0-00 ms extend. squeeze time for ms with series spot welding only pre-heating current not -% display also in ka possible pre-heating time with 0- ms pre-heating upslope seam 0-0 ms within pre-heating time window *) welding current -% display also in ka possible current on time 0- ms upslope 0-0 ms within current time window *) impulse / interpulse (off time) - Impulse, 0-0 ms off downslope 0-0 ms additional after current time cooling time 0-00 ms post-heating current not -% display also in ka possible post-heating time with 0- ms post-heating upslope seam 0-0 ms within post-heating time window *) post-heat downslope 0-0 ms hold time 0-00 ms pause time 0-00 ms with series spot welding only load ( current ) maximal modulation faded ( out ) pictures, no ( flashing ); Change to yes with keys + or 0-, and then press either keys parameter / # Info key -%, -- = inactive - 00 µs = - 00 % max. load (protect tool) max. PWM (protect transformer) Not or rarely needed parameters/ pictures can be deposited here and remain active with settings set. The picture selection is made by pressing the installation key while the key switch is set to param.. *) see 7 period controller Key switch: Progr. or Param. Parameter / Picture Value range Remarks pr. (program number) 0- (pr.0 is used to copy) depending on controller type tr. (transformer number) - only with electric cascade welding spots counter operating hrs. / device-no. date / time MK % RAM 0- display free storage in the measuring-card MK PWM ( pulse width modulation ) -00 µs pulse width modulation MF faded ( out ) pictures, no ( flashing ); Change to yes with keys + or 0-, and then press either keys parameter or # Not or rarely needed parameters/ pictures can be deposited here and stay active with settings set. The picture selection is made by pressing the installation key while the key switch is set to param.. V. Mega-MF

16 Linear stepper PARAMETER / FUTIONS LINEAR STEPPER Installation menu No.:,,7, With every spot welding the welding current value is adapted, beginning with the set welding current value. Parameter key Key switch: Progr.: Param.: all parameters can be set current parameters can not be set Parameter / Picture Value range Remarks pr. (program number) 0- (pr.0 is used to copy depending on controller type tr. (transformer number) - only with electric cascade pre-warning stepper ( alarm ) 0- welding spots before step end stepper end step, welding spots, current % spots, -% current 0 welding spots = inactive step, welding spots, current % spots, -% current step, welding spots, current % spots, -% current when closing the displayed step, welding spots, current % spots, -% current stepper pictures, the stepper step, welding spots, current % spots, -% current welding spots are automatically step, welding spots, current % spots, -% current resorted in ascending order if step 7, welding spots, current % spots, -% current parameters have been changed. step, welding spots, current % spots, -% current clear all step counters? yes/no set to yes, and press key QUIT Info key Key switch: Progr. or Param. Parameter / Picture Value range Remarks pr. (program number) 0- (pr.0 is used to copy) depending on controller type tr. (transformer number) - only with electric cascade stepper counter x -, alternatively,, or every program, sees installation I (Also see "Reset stepper counter") current % (ka) If the welding current for a welding spot is changed then all following spot welding currents are automatically adapted to the changed current value. pre-warning ( alarm ) : e.g. 00 spots. before stepper end stepper end: e.g. 00 spots Pkt. step step step step step step step 7 step V. Mega-MF

17 Pressure program P and P PRESSURE PROGRAM P AND P Installation menu No.:, Two outputs are programmable. The moment for switching on or off can be set for every program within any period of the process ( see remarks ) and is controlled / adjusted automatically. Parameter key Key switch: Progr.: Param.: all parameters can be set current parameters can not be set Parameter / Picture Value range Remarks pr. (program number) 0- (pr.0 is used to copy) depending on controller type pressure P on pressure P off pressure P on pressure P off PRINTER - PORT Installation menu No.: 0,0 squeeze time until hold time SQZ = squeeze time squeeze time until hold time PRE = pre-heating time squeeze time until hold time CUR = current on time squeeze time until hold time COT = cooling time PHT = post-heating time HOL = hold time A printer with a RS/ interface can be used to print the program parameters and the protocols if controller is opted for QSF. The RS/ interface, on the front and at the rear of controller, is standard with the Mega-MF - controller. Installation key Key switch: Param. Please connect the controller with your serial printer. printer-port Parameter / Picture Value range Remarks identification: 0000 protocol off protocol as average value for U / I flow U / I average-value small flow U / I process print card for U / I print with Quit program all programs Installation 0- operator = Month as indicated in date of controller off / on on: every.-0. welding plus 0- weldings or welding errors only yes / no yes / no yes / no yes / no set with +/- or keys 0-, then press key Installation or # 0- depending on controller type press key Quit, data will be printed V. Mega-MF 7

18 Memory Card / Proportional output PARAMETER / OPTIONS MEMORY CARD Installation menu No.: 0 Is used to store data and to copy data to other controllers. Installation key Key switch: Param. Insert Memory Card level into slot (bevel facing down). Parameter / Picture Value range Remarks work on memory card? read all programs all programs or: MEGA Pr. 0- card Pr. 0- other parameter Installation from/to memory card Memory Card start with Quit-key yes/no to yes with + or keys 0-, then press key Installation or # read / write depending on controller type transmit with key Installation or # key Quit, data is processed PROPORTIONAL OUTPUT Installation menu No.: 70,7 Additional board with programmable DC output for every program to control proportional valves. Parameter key Key switch: Progr.: Param.: all parameter can be set current parameters can not be set Parameter / Picture Value range Remarks pr. (program number) 0- (pr.0 is used to copy)) depending on controller type tr. (transformer number) - only with electric cascade proportional output 0-, Volt also in dan adjustable proportional output -, Volt minimum Volt, also in dan V. Mega-MF

19 Pneumatic cascade PNEUMATIC CASCADE Installation menu No.:,, Up to processing cascades can be programmed. With every processing up to 0 programs can be processed one after the other, whereas every program has its own output which can be assigned to any controllable welding cylinder (valve V - V). The start of the cascade processing - is run like the normal program selection (start number equals processing no.). Parameter key Key switch: Progr.: Param.: all parameters can be set current parameters can not be set Parameter / Picture Value range Remarks pneumatic cascade no. - step -0 with pr. (program number) 0-, -- = none depending on controller type same program can be set in several steps switching time - ms stops between steps V. Mega-MF

20 current load seam welding CURRENT LOAD SEAM WELDING Installation menu No.: 0 This seam welding program contains three separate adjustable current settings. It is possible to work with current upslope or downslope when switching to another current load. Parameter key Key switch: Progr.: Param.: all parameters can be set current parameters can not be set Parameter / Picture Value range Remarks pr. (program number) 0- (Pr.0 is used to copy) depending on controller type operating mode seam single spot/series spot/seam squeeze time 0-00 ms current -% display also in ka possible current -% -"- current -% -"- current on time 0- ms impulse/interpulse (off time) - Impulse, 0-0 ms off upslope 0-0 ms downslope 0-0 ms hold time Load ( current )/(limit power) maximum modulation 0-00 ms -%, -- = inactive - 00 µs = - 00 % max. load (protect tool) max. (protect transformer) start - or pre-select + start additional start 7 additional start or start 7+ squeeze time upslope current downslope current upslope current downslope hold time current,, also with impulse (current on time) and off time 0 V. Mega-MF

21 Current load seam welding PARAMETER OPTION QSF QSF/S CURRENT QUANTITY FUTION Installation menu No.:,-,0 The current-function offers the choice to regulate or to monitor the quantity of current needed. The measurement of primary current is executed via a transformer or secondary current is measured either via a measuring belt or measuring coil ( often already included in the transformer). Parameter key Key switch: Progr.: Param.: all parameters can be set current parameters can not be set Parameter / Picture Value range Remarks pr. (program number) 0- (pr.0 is used to copy) depending on controller type tr. (transformer number) - only with electric cascade weld. time max:+7ms min-:7ms ± 0-7 ms 0 = without influencing time only with current + time limiting current + 0% max. 0-%, -- = inactive no function with QSF/S control mode: current yes/no as soon as control mode is set to not yes, current + stepper with yes/no all other control modes are current + time seam yes/no automatically set to no control total time current I yes/no control post welding control current flow I yes/no control of current flow limit total current ( I ) +0% -0% +=off-%, - = off-% Off = no control limit envelope flow I +0% -0% +=off-%, - = off-% Off = no control Info key Key switch: Progr. or Param. Parameter / Picture Value range Remarks pr. (program number) 0- (pr.0 is used to copy) depending on controller type tr. (transformer number) - only with electric cascade evaluation sum: deviation I -%; +% mean current deviation with same current time deviation t ( time deviation ) ms mean current ka eff ka eff current flow ka eff, ms flow in ka eff -0 ms every ms, there after in ms = (milliseconds) ms steps flow deviation % flow in % in ms steps PWM - 00 µs pulse width modulation diodes MF-transformer maximum current 0-00 % 0-00 % primary current welding transf. transformer diode load inverter load (max. current) V. Mega-MF

22 current load seam welding Installation key Key switch: Progr.: Execute set up welding (teach welding); Installation LED must flash. Parameter / Picture Value range Remarks pr. (program number) 0- (pr.0 is used to copy)) depending on controller type tr. (transformer number) - only with electric cascade start teach welding start" seam calibration (with seam only) teach weld (set up welding) U / I mean current ka eff start, valid, new with new all programs as well as single programs can be set up. without QSF 0-0 ka eff if regulating and controlling is deactivated via parameter key. automatic display of switching over measuring range (should be between and ) welding current of set up welding Perform teach weld: The electrodes should be in newer condition. During teach welding the controller works without regulation and supervision. There are only the individual data for current, electrodes voltage, pressure, force, the distance... recorded and stored. The adjustable regulation and monitoring functions are only after leaving the teach welding active (led near the key installation does not flash more). By pressing the key Parameter type in the required parameters: (keyswitch on Progr) squeeze time current time current in % hold time The parameters must be set so that the welds a sufficient strength reach (if possible use weld parameter table). QSF-control set to inactive (key Parameter ) control set to total time yes (key Parameter ) Press key "Installation" x, the "yellow LED"!!! Flashes!!! Now some welds, until at the display "valid" stands for.!!! Valid does not mean: the weld results is in order!!! Press key Info and look for the deviation I Now execute some welds. All welds after mechanical testing must be correct. The current deviation should be smaller than ± %. Major discrepancies suggest a fragile process. Machine as secondary, electrodes, Force, welding parameter must be checked. Press key Parameter and change regulation to aktive. Now start production and at regular intervals check the quality of destructive test control. While look to the deviation in the current. Note: when leaving the setup (light emitting diode Installation will flash no longer) must be the welding and strength tested are! For individual teach welding for one or some program you can use the teach welding function new. Press key "Installation" x, the "yellow LED"!!! Flashes!!! Select program number (one or more) and chnge value valid or start to new... Execute some welds and check the quality. After all new teach weld executed, automatically changed to normal production mode(led is blinking no longer). V. Mega-MF

23 QSF/M Multifunction, manual set up QSF/M MULTIFUTION, MANUAL SET UP Installation menu No.:,-,0 With multifunction feature the controller can be set up for multiple regulating and monitoring (also in combination), depending on the welding project. Conditions are the primary current measuring via the transformer or secondary current measuring via either a measuring belt or measuring coil (often already included in the transformer) as well as the measurement of the electrode voltage at the part to be welded. This measurement should be done with a twisted pair cable, which should be drawn as close as possible to the electrodes. With this construction several types of disturbances can be eliminated by regulation. Parameter key Key switch: Progr.: Param.: all parameters can be set current parameter can not be set Parameter / Picture Value range Remarks pr. (program number) 0- (pr.0 is used to copy) depending on controller type tr. (transformer number) - only with electric cascade weld. time max:+7ms min:-7ms limiting current + 0% max. control mode: current ± 0-7 ms 0 = without influence on only with regulate + time time 0-%, -- = inactive de-activated with regulating current yes/no voltage yes/no as soon as control mode is set current+stepper not yes/no to yes, with yes/no all other control modes are voltage+time seam yes/no automatically set to no current+time yes/no control total U and I yes/no post welding control control flow U and I yes/no control flow U,I limit total U+0% -0% +=off-%, -=off-% off = without control limit total I +0% -0% +=off-%, -=off-% - - limit flow U+0%-0% +=off-%, -=off-% - - limit flow I +0% -0% +=off-%, -=off-% - - V. Mega-MF

24 QSF/M Multifunction, manual set up Info key Key switch: Progr. or Param. Parameter / Picture Value range Remarks pr. (program number) 0- ( is used to copy) depending on controller type tr. (transformer number) - only with electric cascade evaluat. sum: deviation voltage ± % -%; +% mean current / voltage deviation current ± % -%; +% deviation at same current time deviation time ± ms ± ms mean Voltage V eff Volt eff mean voltage over the current time mean current ka eff welding current ka eff ka eff ka eff mean current over the current time post upslope current voltage flow V eff flow in volt eff -0 ms every ms, there after current flow ka eff flow in ka eff in ms steps deviation. voltage flow ± % flow in % in ms steps deviation. current flow ± % flow in % in ms steps diodes MF-transformer 0-00 % transformer diode load maximum current 0-00 % inverter load (max.current) Installation Ikey Key switch: Progr.: Execute set up welding; (teach welding) Installation LED must flash Parameter / Picture Value range Remarks pr. (program number) 0- (pr.0 is used to copy) depending on controller type tr. (transformer number) - only with electric cascade start teach welding start" calibrate seam - welding (seam mode only) (set up welding) U / I mean current ka eff start, valid, new with new all programs as well as single programs can be set up. without QSF if regulating and controlling is deactivated via parameter key 0-0 automatic display of switching over measuring range (should be between and ) ka eff welding current of set up welding V. Mega-MF

25 QSF/M Multifunction intelligent fe controlling QSF/M Multifunction, intelligent fe-regulation Installation menu No.:,-,0 The intelligent fe-regulation for steel-plates has been adapted to the special materials used. Several types of disturbances can automatically be eliminated by regulation in many ranges, without having them especially adapted by the user. This regulation can also be applied to galvanised or phosphorated plates. An adaptation to other materials is in preparation. Conditions are the primarily current measuring via the transformer or secondary current measuring via either a measuring belt or measuring coil (often already included in the transformer) as well as the measurement of the electrode voltage at the part to be welded. This measurement should be done with a twisted pair cable, which should be drawn as close as possible to the electrodes. With this construction several types of disturbances can be eliminated by regulation. Parameter key Key switch: Progr.: Param.: all parameters can be set current parameters can not be set Parameter / Picture Value range Remarks pr. (program number) 0- (pr.0 is used to copy) depending on controller type tr. (transformer number) - only with electric cascade control yes/no controlling power ±, 0=inactive welding time max:+7ms min:- ± 0-7 ms 7ms 0=without influence on time limit current + 0% maximum 0-%, -- = inactive Info key Key switch: Progr. or Param. Parameter / Picture Value range Remarks pr. (program number) 0- (0 is used to copy) depending on controller type tr. (transformer number) - only with electric cascade evaluat. sum: deviat. voltage ± % -%; +% deviation current ± % -%; +% deviation time ± ms ±7 ms ms = milliseconds mean voltage V eff Volt eff mean current ka eff ka eff voltage flow V eff, ms flow in Volt eff - 0 ms every ms, thereafter ms = ( milliseconds ) in current flow ka eff, ms flow in ka eff ms steps diodes MF-transformer maximum current 0-00 % 0-00 % transformer diodes load inverter load (max. current) V. Mega-MF

26 QSF/M Multifunction intelligent fe controlling Installation key Key switch: Progr.: Execute set up welding; (teach welding) Installation LED must flash. Parameter / Picture Value range Remarks pr. (program number) 0- (pr.0 is used to copy)) depending on controller type tr. (transformer number) - only with electric cascade start teach welding (set up welding) Start, valid, new with new all programs as well as single programs can be set up. without QSF if regulating and controlling is deactivated via parameter key U / I mean current ka eff 0-0 ka eff automatic display of switching over measuring range (should be between and ) welding current of set up welding V. Mega-MF

27 INSTALLATION MENU Installation menu This menu shows the basic installation data and the adaptation of the controller to the machine. These programmable parameters are decisive for the functionality of the controller and the processing of the program. The installation should therefore be executed very carefully and double-checked. Installation key Key switch: Param. Press installation key until following picture shows: I n s t a l l a t i o n C o d e - n o. : The installation-menu is protected by a code, which has been divided into steps of authorisation. The operator code is the number standing for the month. Parameter / Picture Value range Remarks Installation Identification: operator = month number of indicated controller date Following is displayed if data-input was correct and confirmed: with +/- or keys 0-, then press either keys Installation or # I E o u t p u t F K - s i g n a l o n K / F K The authorisation level is displayed at the top left corner of display: I B = operator I E = set up operator I W= factory keys Also here a must: -all programmable parameters flash - selection of the next programmable parameter either with the - left or right or -* -key of key pad -change the parameter with either - keys + or - important: When all settings have been made the key QUIT must be pressed. The controller will restart and all settings are saved. ( please note: Changed parameters are saved immediately ) V. Mega-MF 7

28 Installation: picture selection Installation: picture selection Pictures that are generally not in use, can be selected here. These pictures will be deactivated with their minimum values. Please call the first installation picture as described on the page before. If the key Installation is pressed again, the following picture will be displayed: I n s t a l l a t i o n C h o i c e o f p i c t u r e n o Display text no flashes. With either keys + / - or key pad 0 - this parameter can be changed from no to yes. When this parameter is changed to yes following picture is displayed: 7 * I n s t a l l a t i o n o n * C h o i c e o f p i c t u r e 7 on* Parameter / picture Value range Remarks running number and text of parameter / picture on* or off* *off* = parameter / picture are set to their minimal value and are not displayed By renewed pressing of the Installation key the next parameter/picture with status is displayed. Change: Select on* (on must flash) and set to off* with - key. important: When all settings have been made the key QUIT must be pressed. The controller will restart and all settings are saved. ( please note: Changed parameters are saved immediately ) If data error is displayed, then all set parameters must be checked: -Program parameter -Installation parameter -Machine parameter V. Mega-MF

29 Installation menu no. - Installation menu No. - Inst. Description No. Value range Remarks I E Outputs for: ---- without output contact I W EOS (FK)-signal on K /EOS (FK) continuous switch contact VK-signal on K/VK locking-contact distance error K /SK electrode / part distance error V-signal on K /V valve output V-signal on K0/V valve output or nd valve P signal on K/P pressure program P P signal on K/P pressure program P stepper end on stepper end stepper alarm on warning before end stepper spot counter. on welding spot counter I>> on standard setting, current sum beyond upper limit I<< on any assignable, Current sum below lower limit U>> << on voltage sum beyond upper/lower limit QSF control active ---- = switched off QSF control active (no regulation) limit. error on K/GW limit error /-contact ready on controller is ready for operation open position servo cylinder has reached open pos. pre-stroke position servo cylinder has reached pre-stroke pos. (nothing if installation =, or ) quit quit-switch or ext. quit is active start pneum. cascade from end VHZ. progr. to RZ last progr. QSF depth active QSF-function for depth / distance part OK. part passed pre-control (I!) or if measure during weld part is within tolerance pressure error pressure too high or too low foul: Mega controller fault (not QSF-Error) QSF active QSF-function in controller active with Stepper stepper function active set up to controller set on set up current on O/I-switch is on (int./ext.) all on default standard settings I E current load -LE- program - xxx depending on controller type (not cascade ) assigning current load output LE or transformer or I E pre-stroke valve -0- inactive pre-stroke with servo cylinder toggle static I E second valve -inaktivprogram 0- second valve (output = V) I E pressure prog. P I E pressure pro. P -0- inactive active -0- inactive active -x- standard V. Mega-MF

30 Installation menu no. - Installation menu No. - Inst. Description No. Value range Remarks I E valve rating program 0- with valve V -, -- = without -V- valve V depending on controller type (pr.0 is used to copy) basic settings of all programs I B 0 EOS - function (FK) 0 Inactive cooling time switches after: squeeze time post-heating time pre-heating time -- hold time (Value limit contact welding time lim.val. comes simultaneously when active) I B EOS - time (FK) -0- impulse for approx. 0 ms until start opens I E EOS - signal after -0- cascade end Installation 0 must (FK) every transformer I B EOS-signal for (FK) I E VK-begin I E pressure contact DK I B 0 spot counter end I E increase spot count -0- independent of program dependant of program 0 with start -- with current begin after pressure contact DK with squeeze time with end of squeeze time -0- check with current begin check always the whole current time 0 inactive -- display message at end only stop, free with Quit as, counter zeroed only counters with target count exceeded are zeroed -- --, all counter zeroed 7, counter > limit = 0-0- with every start only start with current I E spot counter -0- together for all programs for every program -- with spot number: transfer to plc: X/ = low Byte X/7= high Byte data start - IN (X/) IN (X/) >ms low byte high byte >0ms >ms >ms >0ms >ms I E stepper end -0- inactive message only weld. stop, free with Quit as, counter zeroed see "reset stepper counter" -x- standard 0 V. Mega-MF

31 Installation menu no. - Installation menu No. - Inst. Description No. Value range Remarks I E stepper counter I E 7 increase stepper I E terminals X I E 0 interface I E network address I E limit current load -0- together for all Programs for every program up to counter counter for multiple programs -0- with every start only start with current -0- standard special for PLC see "Reset stepper counter" special for PLC Step counter zeroed by X/IN switch to set up welding ext. switch with X/7-0- inactive 0 digit printer + RS RS to network (00 baud, stop-bits, bit, no parity) built in printer + RS (00 baud, stop-bits, bit, no parity) PC with RS remote control (00 baud, stop-bits, bit, even parity) -0- inactive - no. corresponds to address -0- can be set is locked I W 0 max. numb. of progr. 0 program(s) depending on controller type I E I B number of programs 0 program(s) can be set by operator until total number of programs is reached see I 0 I E select program. -0- via external inputs as displayed rotary switch select pr. -, process with set start digit switch select pr. -7, process with set start -x- standard V. Mega-MF

32 Installation menu no. - Installation menu No. - Inst. Description No. Value range Remarks I B program select 0 - binary pre-selection with one Start binary with display pre-selection is displayed memory clear!!! memory will be cleared!!! I W program processing I E -0- single program pneumatic cascade with manual start manual start for next program cascade stops at end clear: quit I E start signal 0 until squeeze time if pressure signal is missing, welding will be stopped after,s -- until welding time I E 7 start recognition -0- standard - msec start inputs with filter fast - msec fastest > msec start inputs without filter!! with fast system restart I E process squeeze time -0- after start with servo: start weld after squeeze time after pressure contact with servo: start weld at weld position I E operating mode I B 0 measuring of I B controlling mode I E monitoring -0- can be set is locked with last setting U and I, only U, only I or x I for all programs or single programs x I-measuring can only be done with belt or coil (replace measuring board) ( x I-measuring only for all programs) 0 inactive inactive QSF/S current quantity control QSF/S current quantity control QSF/M manual QSF/M auto intelligent fe-controlling -0- starting with current only with every start I E transformer -active- program 0-xxx depending on controller type tr. - active / inactive -x- standard V. Mega-MF

33 Installation menu no. - Installation menu No. - Inst. Description No. Value range Remarks I E relay limiter 0 drops off if welding OK. draws on during welding draws on if welding OK. drops off during welding as and drops off with KS KS=key sw. set to param or progr. drops off with error -- draws on with error and during seam error - - and with seam error till end I E limit messages I E set up (teach weld) -0- clear with next start clear with Quit key with welding stop during hold time. valve outlet stays put, reset with Quit key or close start contact once. as, key not set to Auto as, key not set to Auto 0 with repeat welding start switch closed and first error: with repeat welding no EOS-signal, weld, EOS-signal (FK) 7 with repeat welding start switch open and first error: EOS-signal (FK), no second weld 0 with EOS-signal (FK) If error, no EOS (FK)!! 0 with seam welding stop 0 with seam welding stop -0- without limit maximum weldings maximum weldings as with welding stop as with welding stop I E 0 nominal current 0,7-00kA calibrate current indicator before set up welding I E current meter sensorcalibration 0 to 0 : translation ratio with primary current measuring and adaptation with belt/coil I E current calibration /U 0 to,0 : calibrating measuring sensor I E cos-phi -0-0, adjustment range of the 0,0 phase shift / i.e. 0,70 The set current percentage is 0,0 re-adjusted 0,0 0,0 0,0 7 0, -x- standard V. Mega-MF

34 Installation menu No. - Installation menu No. - Inst. Description No. Value range Remarks I B current transformer -0- coil measuring coil 0A terminal resistor, Ω 00A A A A A belt measuring belt I E current calibration inverter min: - % max: -% characteristic line for current adjustment I B 7 0 proportional output I B 7 conversion prop. output. -0- inactive 0 volt -, volt volt -, volt as, in dan as, in dan 7 0 as, but V during open as, - - as, - - as, - - as as as as as, but for ECO-compression packet as, but dual prop. output V = -000 dan but V during open additionally analog output for: -weldtime: 00msec = 0V -current: 0kA = 0V -depth: mm = 0V fast force (compression)(dan) I W 7 Pressure monitoring -0- inactive I E air pressure I on, so that welding can electrode force be stopped on too high pressure deactivate for machine lock system, no message without pressure contact I E 7 Electrode force conversion V = -000 dan force measuring conversion I E 7 Electrode fast force revaluation V = - dan fast force measuring revaluation I E 0 processing cascade -0- with standing start with start impulse I W numb. of transformers transformer I E transformer Only SU00/0 or Mega-INV I E input measuring MSV -0- as transformer number (only with cascade!!) can be set see inst. (also for distance sensor) -x- standard V. Mega-MF

35 Installation menu no. - Installation menu No. - Inst. Description No. Value range Remarks I E select input measuring MSV -- ext. program 0-xxx with external input - or internal input - depending on controller type (pr.0 is used to copy) I E 7 cascade stop weld with lim. error I E 0 language I W mains frequency I E -0- during cascade process after processing cascade during cascade with EOS (FK) -0- german english dutch polish french other language -0-0 cycles 0 cycles 0 cycles with MHz 0 cycles with MHz I E message texts -0- inactive binary selection of text (not during welding) selection X. (IN ) bit 0 X.7 (IN ) bit X. (IN ) bit X. (S ) bit - with / programs. X. (S ) bit - with programs selection X. (IN ) bit 0 X.0 bit selection X. (IN ) bit 0 -- not used selection X. (IN ) bit 0 X.7 (IN ) bit X. (S ) bit with / programs I E servo cylinder -0- with working position with start to working position without working position without start to working position when welding as + part measurement as, but with part measurement I W 7 servo cylinder -0- inactive I E servo, 00mm cylinder with 00mm cylinder servo, 00mm (*) cylinder with 00mm cylinder /-fold servo, 70mm with 70mm cylinder servo, programmable cylinder parameter can be set servo, 00mm with 00mm cylinder servo, 70mm with 70mm cylinder 7 servo, programmable cylinder parameter can be set I W distance measuring -0- inactive no function running in cascade I E digital pull digital push analogue pull (0mm) with servo cylinder I only 0 or analogue push (0mm) 0mm sensor analogue pull (0mm) 0mm sensor analogue push (0mm) -x- standard V. Mega-MF

36 Installation menu No. -07 Installation menu No. -07 Inst. Description No. Value range Remarks I E measuring part I W 0 Memory Card -0- without pre-control with pre-control output I is adjustable (Attention! No weld stop with errorreading of part measurement! Attention! When measuring part with pre-control the pressure input is taken as trigger input for reading referential value of part control.) with pre-control triggerinput: X/ (IN) no pre-control no distance control with set-up weld -0- inactive active formatting I W 0 inverter frequency cycles 00 cycles cycles 0 cycles frequency selection I E 0 inverter type 0 SU00/0 (0 kva) max. 0 kva SU00/00 (0 kva) max. 00 kva SU00/00 max. 00 kva SU00/0 max. 00 kva (analogue) x SU00/xxx doubled-inverter SU00/000 max. 000 kva (analogue) -0V = -% Mega-INV (00kVA) kva 7 Mega-INV (MVA) kva Mega-INV (00kVA) kva (with interface control) Mega-INV (MVA) kva (with interface control) 0 Mega-SIN (700kVA) I E 07 transformer type -0- T.V ( kva) MF-transformer selection 7 T.V ( kva) T0.V (0 kva) T0.V (0kVA) T0 0.0V (0 kva) T0.0V (0 kva) T0.V (0 kva) MFT0.0 0.V (0kVA) MFT0.0.V (0kVA) MFT0.0.V (0kVA) and tapping of different secondary voltages 0 MFT0.0.V (0kVA) MFT V (00kVA MFT00.0.V (00kVA MFT00.0.V (00kVA MFT00.0.V (00kVA other manufacturer no diodes control -x- standard V. Mega-MF

37 Installation menu No. 0- Installation menu No. 0- Inst. Description No. Value range Remarks I W 0 controller type I E I W 0 network status I W 0 device number 0 --, free 7-periods and cascade -periods seam ( current load seam ) -periods 0 inactive only RS address remote control with data back up with documenting year, month - number I W status: Mega 0 - factory setting optical fibre test with optical fibre test as + quick discharge with quick discharging inverter pc-network network version I W status regulator-board optimised regulation with impulses factory setting I W regulation selection I W operating hours I B 7 date/time I B profibus I B nodeadress profibus -0- no regulation regulation QSF/S regulation QSF/M -0- display installation total time day, month, year, time 0 inactive only E/A-register all function 0- no. corresponds to address I E 0 load installation -0- no no function load set attention! I E analyse programs -0- selectable any program can be selected (key Inf. with QSF) welding program switches to last welding progr. I E hardware test -0- complete standard no low voltage check no low voltage checking I E reserved no function -x- standard V. Mega-MF 7

38 Reset stepper counter SPECIAL FUTIONS Reset stepper counter Installation menu No.: It is possible to clear the stepper counter of one program or of all programs via the external inputs. (up to maximal programs). For this the "terminal X" must be set to (Special function for PLC). This is done in the installation menu with selection I. Clear the stepper counter with following procedure: controller up to programs: -Reset inputs S-S with program no. Set to 0 ; -Set S -select inputs S-S7 of respective program to clear stepper, or leave program no. 0 standing on to clear all stepper counters. check Program start "I" (binary or of ). -set QUIT key to confirm and reset again. The (all) stepper counter(s) is/are now zeroed ( >0ms). -Reset inputs S-S7. -Reset input S. controller with programs: (reset for all counter only) -reset inputs S-S with program no. Set to 0 ; -set input IN (X/) for > 00ms and reset again. ATTENTION: during input IN active, no start possible Reset stepper counter at the controller Manually for every program: -Select picture stepper counter with Info key. -Zero counter for respective program. (Installation menu No. assigns: One stepper counter for all programs, or for every program with own counter) Manually for all programs: -Select picture stepper counter with Parameter key. -Change parameter no to yes and confirm with Quit key. At stepper end automatically zero counter (Installation menu No.: on setting ): -With message Stepper end reached, set key switch to Progr. and confirm with Quit key -The stepper counter was zeroed. ATTENTION: execute ELECTRODE CAP REPLACEMENT V. Mega-MF

39 Appendix APPENDIX: Modifications Installation sheet Parameter sheet Dimensions Mega-MF controller LED Mega-MF Processing diagram Mega-MF A A A A A A Processing diagram Mega-SIN A- Terminal boards X and X Terminal boards X circuit diagram Terminal boards X circuit diagram Connector X X, X Connector X X Connector X X7 Connector X X Connector X X0 Terminal wiring diagram X and X Distance measuring servo cylinder Mega-INV wiring diagram A7 A A A0 A A A A A A A7 Mega-SIN wiring diagram A7- Connector X X Technical data of inverter Dimensions Mega-INV inverter Display, LED Mega-INV Profibus specification Mega-PC wiring diagram A A A0 A A A V. Mega-MF

40 Modification MODIFICATION As from Version.: -Distance measuring and monitoring -Mega-SIN : adjustable frequency from - 0Hz for 0Hz-transformer as from no #: -profibus interface integrated (Installation -) A V. Mega-MF A

41 Date: Controller: Project: Installation sheet 70- I E I W Ausgänge für --=ohne K=FK K=GW K=SK K=VK K=V K=V K7=V K=V K=V K0=V K=P K=P K EOS-signal K VK-signal K distance error K V-signal K V-signal K7 V-signal K V-signal K V-signal K0 V-signal oder. Ventil K pressure P K pressure P stepper end warning stepper spot counter end I >> over limit I << under limit U >> <<out of l. QSF control only K limit error ready position open pos. pre-stroke quit active cascade begin QSF depth act. part i.o. pressure error controller error QSF active stepper active set up weld act. current switch on I E current load output program 0-xxx with current load output transformer or I E pre-stroke function 0 inactive toggle static I E nd valve inactive program 0-xxx I E pressure program P 0 inactive active I E pressure program P 0 inactive active I E valve selction V program 0-xxx with valve V - V I B 0 EOS - output (FK) after 0 inactive squeeze time pre-heat time welding time cooling time post-heat time hold time I B EOS - time (FK) 0 impulse appr. 0 ms until start opens I E EOS - signal cascade 0 cascade end every transformer I E EOS - signal (FK) for 0 all progr. evenly every program I B VK - start 0 with start w. current start w.squeeze time w.squeeze t. end I E pressure contact DK 0 check with current begin check always I B 0 spot counter end 0 inactive message if end stop, clear w.quit, counter = 0 inactive inactive, all counter = 0 7, counter>limit=0 I E Increase spot count 0 with every start if start with current I E spot counter 0 for all programs for every program not used, number -> plc I B stepper end 0 inactive message if end stop, clear w.quit, counter = 0 I E stepper counter 0 for all programs for every program up to counter I E 7 increase stepper 0 with every start start with current only I E connection X 0 standard special for plc special for plc switch to set up we I B 0 interface 0 inactive 0 dig.print+rs built in print+rs PC with RS I B network address 0 inactive address - I B limit current load 0 can be set is locked I W 0 I E max. no. of programs 0 pr. pr. pr. Pr. Pr. Pr. Pr. I B active no. of programs 0 pr. pr. pr. pr. pr. pr. pr. I E program pre-selection 0 ext. Inputs as displayed rotary switch digit switch I E program start 0 inactive binary binary with display memory clear!!! I W I E program processing 0 single program pneumatic casca, next step w.sta, clear with quit I E start signal 0 until squeeze tim until welding time I E 7 start recognition 0 standard -m fast -ms fastest >msec,fast system restar I E process squeeze time 0 after start after pressure contact I E operating mode 0 can be set is locked I B 0 measuring of U and I, only U, only I or x I for all programs or selectable programs I B controlling modes 0 inactive inactive QSF / S QSF / S QSF / M QSF/M auto Fe I B monitoring 0 start with current only with every start I E transformer program 0-xxx, Transformer - active/inactive depending on controller type I E relay limiter 0 switch off at OK. switch on at OK., with key switch switch off w. error switch on w. erro, seam till end I E limit message 0 clear w.new star clear with quit stop in hold time,key switch? Auto, key? Auto 0 + repeat weldin + repeat welding 7 + repeat welding 0, no EOS(FK) 0,seam error sto 0,seam error stop I E set up weld 0 no limit max. weldings max. weldings, with stop, with stop I E 0 nominal current IK 0,7-00kA I E calibrate cur. Sensor 0 bis 0 : I E calibrate cur. sen./u 0 bis,0 : I E cos-phi 0 0, 0,0 0,70 0,0 0,0 0,0 0,0 7 0, I B current converter 0 coil 0A 00A 000A 00A 000A 000A 7 belt I E current calibration min: -% inverter max:-% authorisation hierarchy to alter settings: IW = factory, IE = set up operator, IB = operator A V. Mega-MF A

42 Installation sheet - I B 70 proportional output 0 inactive 0 -, Volt -, Volt, in dan, in dan, open: V, open: V 7, open: V, open: V, + output [V] 0, + output [V], + output [V], + output [V] but for ECO compr., but dual prop. Output I B 7 conversion prop. outp. V = -000 dekanewton [dan] I W 7 I E pressure monitoring 0 inactive air pressure electrode force deactivate contact I E 7 elec.force conversion V = -000 dekanewton I E 7 fast force conversion V = - dekanewton I E 0 cascade processing 0 with standing start with start impulse I W I E number of transformers transformer transformer I E measuring input MSV 0 as transformer no. can be set I E select input MSV Programm 0-xxx, internal - or external - I E 7 stop welding 0 in process of cascade after process of cascade 0 with FK (EOS) I W 0 I E language 0 german english dutch polish french... other.. I W I E mains frequency 0 0 Hz 0 Hz ( MHz) 0 Hz ( MHz) 0 Hz ( MHz) I E message text 0 inactive selection selection selection not in use selection I W I E servo cylinder 0 w. work.position w/o work.pos. with part measurement I W 7 I E servo cylinder 0 inactive x00 x00 cyl., -fach x0070mm x00 programm x0000mm x0070mm 7 x00 programm. I W I E distance measuring 0 inactive digital pull digital push servo cylinder analog push analog pull 0 analog push 0 7 analog pull I E I E measuring part 0 w/o pre control with pre control with pre control w/o pre control I W0 memory card 0 inactive active formatting I E 0 inverter frequency Hz 00 Hz Hz 0 Hz I E 0 inverter type 0 SU00/0(0) SU00/00(0) SU00/00 SU00/0 x SU00/xxx SU00/000 Mega-INV 00 7 Mega-INV 00 + HW-Prüfung 7+ HW-Prüfung 0 Mega-SIN 700 I E 07 transformer type 0 T,V kva T,V kva T0,V 0k T0,V 0k T0 0V 0k T0 V 0k T0,V 0k 7 MFT0 0,V MFT0,V MFT0,V 0 MFT0,V MFT00 0,V MFT00,V MFT00,V MFT00,V other manufacturer I W0 I E controller type 0 not in use 7-Zeiten Kaskade -Zeiten Leist. -Zeiten I W0 network status 0 inactive only RS remote control + data backup + document I W0 serial number year, month - number I W status Mega 0 not in use optical fibre test +quick discharge 0, PC-network I W status regulator board 0 not in use optimised regulation with impulses I W regulation selection 0 no regulation regulat. QSF/S regulat. QSF/M I W operation hours 0 display installation total time I B7 date/time day, month, year, time I E profibus 0 inactive only E/A register all functions I E profibus nodeadress 0- no. = adress I E0 load installation 0 no load set I E analyse programs 0 selectable last welding program I E hardwaretest 0 complete no low voltage check I E reserved no function authorisation hierarchy to alter settings: IW = factory, IE = set up operator, IB = operator A V. Mega-MF A

43 Date: Controller: Project: Parameter sheet WELDING PARAMETER CONTROLLING/MONITORING ( Parameter key, change with key set on Prog ) ( Parameter key, change with key set on Prog ) pr. (program number) tr. (transformer number) operating mode: single spot/ seam series spot 7-Periods: current load seam -Periods: squeezing time ms maximum welding time + ms - ms prolong.. squeezing time for ms limit maximum current + % pre-heating current % current pre-heating time ms pre-heating upslope ms control current yes no control voltage yes no welding current current % control current + stepper yes no current time ms current upslope ms control voltage + time yes no impulses with interpulse (off time) control current + time yes no current downslope ms cooling time ms monitor total time U and I yes no monitor flow of U and I yes no pre-heat current current % pre-heating time ms limit total U + % - % pre-heating upslope ms limit total I + % - % pre-heating downslope ms limit flow U + % - % limit flow I + % - % hold time ms pause time ms limit current load % COUNTER READINGS ( INFO KEY) pre-warning stepper end spots. spot counter spots. stepper end spots. stepper counter spots. step spots. % step spots. % step spots. % step spots. % step spots. % step spots. % step 7 spots. % step spots. % pressure P on pressure P off pressure P on pressure P off prop. output A V. Mega-MF A

44 O / I M e m o r y C a r d Progr. P a r a m. Auto P a r a m e t e r In f o In s ta lla tio n Q u it R S / V. dimensions Mega-MF SER Elektronik & Schweißtechnik GmbH dimensions Mega-MF " or ¾-" cubicle rack Mega 7 * 0 # cubicle dimensions: WxHxD= xx70 mm (on ¾= xxmm) cutting out control panel: WxH= x mm ( mm thickness ) ½ " cubicle rack Mega O / I P a r a m e t e r In f o 7 In s ta lla tio n * 0 # P r o g r. P a r a m. Q u it Auto M em ory C ard RS/V. cubicle dimensions: WxHxD= xx70 mm cutting out control panel: WxH=x mm (mm thickness ) \\_bedienungsanleitungen\anhang\amf-dimensions Mega-MF.0.0 A All copy rights concerning these documents or parts there of remain with SER Elektronik & Schweißtechnik GmbH A

45 LED's SER information Elektronik & Schweißtechnik GmbH LED's ( V int. ) electrode electrode transf. transf. transf. transf. transf. transf. DK pressure Q 'Quit' with current ( V ) start binary start + start 7 + start + start + start + start start start E i n g ä n g e / i n p u t s - ( V / READY ) ( V / EXTERNAL ) ( V ) ( -V ) K EOS advance K GW limit K K K K K K K7 K K K0 VK locking SK special P press. P press. V valve V valve V valve V valve V valve V valve - A u s g ä n g e / o u t p u t s - electrode, : display: measurement channel for the electrode voltage (off = electrode ) transformer -: display: transformer cascade switching with MEBL option, max. transformers. \\_bedienungsanleitungen\anhang\a-led A All copy rights concerning these documents or parts there of remain with SER Elektronik & Schweißtechnik GmbH A

46 processing diagram Mega-MF or until start opens 0 msec SER Elektronik & Schweißtechnik GmbH processing diagram value range in milliseconds (0 ms = Per /0Hz) pause time (series spot only) hold time Mega-MF post-heating downslope post-heating time post-heating upslope cooling time current downslope - Impulses (e.g. here ) current upslope: current time (per impulse) interpulse (off time) (with impulses) current time (per impulse) interpulse (off time) (with impulses) current time (per impulse) interpulse (off time) (with impulses) current time (per impulse) pre-heating time ( periods) pre-heating upslope ( periods) squeeze time. prolonged squeeze time (with series spot only) A pre-stroke pressure progr. P, P EOS advance contact VK locking contact valve V-V (assignable) start with pre-selection \\_bedienungsanleitungen\anhang\amf-processing diagram pre-selection binary,,,... (S-S) start to direct (S-S) All copy rights concerning these documents or parts there of remain with SER Elektronik & Schweißtechnik GmbH A

47 processing diagramm Mega-SIN -times seam weld 0 msec SER technische Information Elektronik & Schweißtechnik GmbH processing diagramm Mega-SIN -times seam weld 0-00 hold time value range in milliseconds (0 ms = Per /0Hz) 0-0 current end 0- current time (per impulse) 0-0 off time (with impulses) current time (per impulse) off time (with impulses) current time (per impulse) current upslope current time current upslope current time current upslope 0-00 squeeze time A- EOS advance contact VK locking contact valve V-V (assignable) start with pre-selection pre-selection binary,,,... (S-S) \_bedienungsanleitungen\anhang\a-mf-processing diagram seam Mega-SIN fade out monitoring (0-00) All copy rights concerning these documents or parts there of remain with SER Elektronik & Schweißtechnik GmbH A-

48 terminal board X und X SER Elektronik & Schweißtechnik GmbH terminal board X und X MEG-KX SER 7 A A A A V + (-) 7 0 P R O G R A M M (ext.) current 'QUIT' START pressure ready A A A PE X - V 0V 0V V IN- IN+ inputs with SE +V (V) 0V switching GW limit contact FK advance contact JP JP JP V: total max.a READY(-), Kl. ->0V SE, Kl.0 ->V V->FK, Kl.7 to Mega - X JP jumpered [ READY(-)Kl. on 0V ] JP jumpered [ V- checked by special input SE ] JP free ( ) [ FK Kl.7 with V ] wire bridges: ->, A->A: inputs active at +V (wire bridge -> and A->A if inputs switch at 0V) (optional to Mega X,X0,X) (optional to Mega X) (X0/X) SER 0. MEG-KX SER VK lockung contact B X - A SK 7 special contact B A P 7 B P 0 A X 7- A + + B - - MV V 0MV 0V MV~ MV0V~ V 0V valve voltage V-V 0 rectifier: ~ -> + -> A ~ -> - -> B X 0MV MV - V 0MV MV V 0MV MV all symbols only with Mega-X V X - V V V V: total max.a to Mega X (optional to Mega X) wire bridges: A->, A->, A-> magnetic valves V- can be wirebridged directly all cables with sub D male / female plugs \\_bedienungsanleitungen\anhang\a7-terminal boards X X A7 valve voltage: a) standard: equiped rectifier V (set to V~) b),v~: remove rectifier and bridge A->, B-> c) +V: remove rectifier and bridge A->+, B->-) terminal +: +V external or X terminal terminal -: 0V external or X terminal A terminal number - corresponds to the pin number of sub D plug (X shifted!) terminal board is prepared for mounting on mm support All copy rights concerning these documents or parts there of remain with SER Elektronik & Schweißtechnik GmbH A7

49 A A \\_bedienungsanleitungen\anhang\a-terminal board X circuit diagram All copy rights concerning these documents or parts there of remain with SER Elektronik & Schweißtechnik GmbH wire bridge for V verification SE +V READY+ READY- INPUT 0V COM. INPUT +V JP JP V/0V wire bridge READY(-) -> 0V internal +V +V EOS.S EOS.M 7 EOS.O GW.S GW.M 0 GW.O BEREIT+ BEREIT- EINGGEM 0V X to Mega X (required: cable with sub D pin male / female plugs) 0 A A A SE READY selective plugging terminal number ("terminal customer") special input standard: V verification with JP +V not switched *) (READY + =+V with external power supply) (READY(-)=0V with external power supply) inputs +V switching inputs 0V switching wire bridges with delivery,a= +V ( +V switched ) *),A= 0V *) *) max. A total load S S S S S S 7 S7 S +V START JP 0 SE 0/ wire bridge when using EOS Q DK as valvel V with V-: connect valve to terminal (EOS.S) and terminal A(0V) 0/ DK Q S S S S S S S7 S START EOS.O EOS.M EOS.S GW.O GW.M GW.S A A A 7 A / ( current ) DK ( pressure contact ) Q ( 'QUIT' ) S ( start / pre-select ) S (start / pre select ) S (start / pre select ) S (start / pre select ) S (start / pre select ) S (start / pre select ) S7 (start 7 / pre select ) S (start / pre select ) pre select START EOS ( advance contact ) programmable with Mega installation no. e.g. valve V=EOS, locking contact VK=GW GW ( limit contact ) max. contact load: 0V-/0W customer terminal terminal board X SER Elektronik & Schweißtechnik GmbH terminal board X

50 A \\_bedienungsanleitungen\anhang\a-terminal boards X circuit diagram to Mega X terminals - according "customer terminals" ( cable pin male / female plugs ) X X 7 0 -outputs -/MV~ ( cable with pin male / female plugs ) X :prop., pressure, force, distance X0:measuring channel: eclectrode voltage X:distance measureing 0 to Mega X terminals 7- X X -electrodes U,U,U -current A + + B - - VK SK valve voltage for V-V: +V*) 0V*) locking contact special contact P pressure program MV~ (/) V-*) P pressure program (e.g. of terminal board X, terminal ) MV0V~(/) 0V-*) (e.g. of terminal board X, terminal ) B A B A 7 B A 0 PE wire bridge wire bridge wire bridge 7 0 MV+ V MV- 0V MV- MV+ MV- MV+ 7 MV- MV+ 0 PE customer terminal V valve V valve V valve V valve V valve V valve terminal board X SER Elektronik & Schweißtechnik GmbH A All copy rights concerning these documents or parts there of remain with SER Elektronik & Schweißtechnik GmbH -'Quit' input -external inputs to Mega X terminals - ( cable pin male / female plugs ) to Mega X,X0,X terminals - ( cable pin male / female plugs ) *)max. A total load when using the V of Mega - X terminal board X

51 A0 A0 \\_bedienungsanleitungen\anhang\a0-connector X-X X All copy rights considering these documents or parts there of remain with SER Elektronik & Schweißtechnik GmbH -all inputs- -READY +/- +V/+V 0V -EOS advance contact- -GW limit contactinputs EOS and VK- output (functions programmable) outputs / MV voltage ~ X required: sub D pin male plug X required: sub D pin male plug -VK locking contact -SK special contact -P/P contacts for pressure progr. V-V valvel contacts /V~ valve voltage EOS advance contact m FK e F valve voltage AMT bei V~ 0,AMT bei V~ fuses on the power unit: x 0 m m / 0 V x0mm/0 V: F: valve voltage as F F:,AMT Mega internal power supply F:, AMT +V external F: 0, AMT +V internal F AMT for V external x0mm/00 V: F7:,AT recognition of rotating direction F:,AT power supply F:,AT power supply SK m e special contact since 00 jumper for FK, GW und SK: m= mechanical (relais output -pin contact) e = electronically (+V / 0mA max. output, 0V = X, Pin ) (relais also with -pin contact) GW limit contact m LED indicators for inputs and outputs SER GW e DK pressure contact Q Quit 0/ current V (SE special input) [start] with progr. pre-selection [] S start [] S7 start 7 [] [] [] S S S start start start [] S start [] S start [] S start free V/READY V/external +V -V EOS advance contact GW limit contact VK locking contact SK special contact P pressure prog. cont. P pressure prog. cont. V valve V valve V valve V valve V valve V valve 0. SER X required: sub D pin female plug to power unit X (required: sub D pin male plug) X ---optional--- required: Coax male plug for ARCNETnetwork X ---optional--- required sub D pin male plug -Proportionaloutput + -pressure-,- force-, -measuring input- -distance measurement- to power unit ARCNET proport. / distance connector X-X,X SER Elektronik & Schweißtechnik GmbH connector X-X,X

52 connector X-X SER Elektronik & Schweißtechnik GmbH connector X-X X0 required: sub D pin female plug input: current measurement electrode voltage main load LE RS + printer RS network input required sub D pin male plug RS output ( network ) RS network output current measure/. electrode voltage LE X current measure/. electrode LE,LE,LE required sub D pin male plug measurement chanel switching for electrode voltage required sub D pin male plug -pol. Stift proportional outputs + pressure-, force-, distance measurement SER required: sub D pin female plug input: current measurement electrode voltage LE, LE, LE X required sub D pin female plug -Quit- input external inputs - X JP JP U-LE electrode voltage current load LE MEASURE MEASURE MEASURE MEASURE MEASURE MEASURE relay relay JP and JP: required: sub D pin male plug RS (printer) RS input (network) X7 V/INTERN free ( ) U-LE electrode voltage current load LE measurement chanel switching display for multiple cylinders ( binary coded ) X X Quit ( limit value ) external inputs measuring chanel switching proportional output pressure- / force- / distance measurement \\_bedienungsanleitungen\anhang\a-connector X-X A All copy rights concerning these documents or parts there of remain with SER Elektronik & Schweißtechnik GmbH A

53 connector signals X-X7 SER Elektronik & Schweißtechnik GmbH connector signals X-X7 X power supply -> Mega-INV X sub D male socket required: sub D pin female plug 7 0 LE//+ SP ~ th-out SP ~ th-out measurement measurement 0V-extern 0V-extern SP ~ SP ~ MV ~ 7 0 power - SP ~ SP ~ power - th-in direction of rotation earth power - MV0V ~ X ARC-NET B-Stecker inner contact outer contact required: B female plug X inputs / outputs sub D pin female socket required: sub D pin male plug 7 0 S single start S " S " S " S " S " S7 " S " start SE special input 0/ with current Q Quit DK pressure contact 7 0 case V V not switched K/EOS normally open contact K/EOS center pole of pole switch K/EOS normally closed contact K/GW normally open contact K/GW center pole of pole switch K/GW normally closed contact readyt ready selection 0V shield X input / output sub D pin female socket required: sub D pin male plug 7 0 K/VK normally open contact K/VK center pole of pole switch K/VK normally closed contact K/SK normally open contact K/SK center pole of pole switch K/SK normally closed contact K/P K/P K/P K/P MV~ MV0V~ 7 0 case K/V K/V K/V K/V K7/V K7/V K/V K/V K/V K/V K0/V K0/V shield X RS / RS in sub D pin female socket required: sub D pin male plug 7 TXD + RXDA TXDA RXD + GND TXD - +V CTSA RXD - X RS out sub D pin female socket required: sub D pin male plug TXD + RXD + TXD - 7 RXD - case shield X7 current sub D -pin male socket required: sub D pin female plug 7 case GND + U - U measurement I - measurement I + shield with connection of transformer / coil to the SER power unit X7 socket must be wire bridged: pin to 7 and Pin to \\_bedienungsanleitungen\anhang\a-connector signals X-X A All copy rights concerning these documents or any part there of remain with SER Elektronik & Schweißtechnik GmbH A

54 plug allocation X-X SER Elektronik & Schweißtechnik GmbH plug allocation X-X X voltage sub D pin male socket required: sub Dr pin female plug 7 case GND + U - U + U U=main power - U + U I - - U I + shield X proportional, pressure, force, distance sub D pin female socket required: sub D pin male plug 7 0 case SIGNAL O PROPORTIONAL SIGNAL U / I SEAM RESET relay: pressure switching +V relay: pressure switching 0V - V + V PROPORTIONAL PRESSURE AGND (proportional) AGND (pressure) PRESSURE GND + V shield X0 switching measurement channels sub D pin female socket required: sub D pin male plug 7 0 case I + U + UM UM UM GND + V I - U - UM UM UM GND + V shield X quit /external inputs - sub D pin male socket required: sub D pin female plug 7 0 case RESET IN (with servo cylinder S) IN (with digit switch: bit0 third decade) IN (with digit switch: bit third decade) V-extern. V-extern. V-extern. V-extern. 0V-extern. shield X distance measurement sub D pin female socket required: sub D pin male plug 7 0 case GND GND V 0O - 0O + BO + BO - AO + AO - 0U - 0U + BU + BU - AU + AU - shield X power supply / ->Mega-MF X sub D female socket required: sub D pin male plug 7 0 LE//+ SP ~ th-out SP ~ th-out measurement measurement 0V-extern 0V-extern SP ~ SP ~ MV ~ power - SP ~ SP ~ 7 power - 0 th-in direction of rotation earth power - MV0V ~ case shield \\_bedienungsanleitungen\anhang\a-connector signals X-X A All copy rights concerning these documents or parts there of remain with SER Elektronik & Schweiß GmbH A

55 plug allocation X-X0 SER Elektronik & Schweißtechnik GmbH plug allocation X-X0 X controller signals from inverter sub D pin female socket required: sub D pin male plug 7 0 +V in " " " " " " " " " " " 7 0 transverter on standby / operation reserve phase error intermediate circuit under voltage intermediate circuit over voltage inverter error temperatur error general error ready reserve reserve X Lichtleiter Inverter -pol. (within cableset M-ASL-MFSET-xx) X7 interface servo assist sub D -pin male socket required: sub D pin female plug 7 TxD RxD GND RTS CTS X distance sensor - sub D -pin female socket required: sub D pin male plug U (+VCC) signal sensor U (-VCC) U (+VCC) signal sensor U (-VCC) 7 U (+VCC) signal sensor U (-VCC) case shield X.0 distance sensor sub D -pin female socket required: sub D pin male plug 7 case U (+VCC) signal sensor U (-VCC) shield X0.0 U (+VCC) signal sensor U (-VCC) -br -ge -bl distance sensor -pin. male required: -pin. female X. distance sensor sub D -pin female socket required: sub D pin male plug 7 case U (+VCC) signal sensor U (-VCC) shield X0. U (+VCC) signal sensor U (-VCC) -br -ge -bl distance sensor -pin. male required: -pin. female X. distance sensor sub D -pin female socket required: sub D pin male plug U (+VCC) signal sensor U (-VCC) 7 case shield X0. U (+VCC) signal sensor U (-VCC) sensor selection within installation menu Mega-controller: - I: =sensor input adjustable - I: select sensor <-> program: ext. = sensor ext. = sensor ext. = sensor -br -ge -bl distance sensor -pin. male required: -pin. female X \\_bedienungsanleitungen\anhang\amf-plug allocation X-X A power supply MF controller pin male socket distance between pins = 7,mm required: pin female plug, WAGO-Nr.: -70/ L L thermo contact thermo contact PE All copy rights of these documents or parts there of remain with SER Elektronik & Schweißtechnik GmbH A

56 A. \\_bedienungsanleitungen\anhang\a--terminal wiring X X since o l d v e r s i o n - required: sub D pin male plug 0 0 view of soldering side connecting point customer +V. X F AM (+V) *) F ready +V. V~=.0 AMT V~=0.AMT 0V~=0.AMT 0V X *) *) S X S S S S S single start start binary with pre-selection alternate +V or 0V switching, power consumption: 0mA *)+V/0,A for proportional valves etc. Mega-MF S7 7 7 S Mega-MF start 0/I with DK pressure current contact start Q quit SE special input special input SE must be wired for V verification K/EOS advance contact K/GW limit contact (error / warning, etc.) - o l d v e r s i o n - terminal wiring X, X old SER Elektronik & Schweißtechnik GmbH information A. All copy rights concerning these documents or parts there of remain with SER Elektronik & Schweißtechnik GmbH - o l d v e r s i o n - X connecting point customer MV~ MV0V~ magnetic valve voltage K/VK locking contact 7 K/SK special contact contact stress: K/P pressure 0V-/0W K/P pressure 0 7 K/V valve K/V valve K7/V valve 0 K/V valve K/V valve K0/V valve - o l d v e r s i o n - terminal wiring X, X old

57 A \\_bedienungsanleitungen\anhang\a-terminal wiring X X required: sub D pin male plug 0 0 view of soldering side connecting point customer +V. X F AM (+V) *) F ready +V. V~=.0 AMT V~=0.AMT 0V X X *) *) S +V. () S S S S S single start start binary with pre-selection alternate +V or 0V switching, power consumption: 0mA *)+V/0,A for proportional valves etc. 0R SK m e Mega-MF S7 7 7 S (*) Mega-MF start 0/I with DK pressure current contact start Q quit 0 SE special input +V. () K/EOS advance contact 0R FK m e 0R GW m e 7 0 K/GW limit contact (error / warning, etc.) special input SE must be wired for V verification or cooling. If X.0 open: check air/water or V ext. will be displayed caution: ground is 0V (X.) since printed circuit board (00) switches for FK (EOS), GW, SK: m= relay e= transistor V/0mA 0V (X.) must be wired. terminal wiring X, X SER Elektronik & Schweißtechnik GmbH information A All copy rights concerning these documents or parts there of remain with SER Elektronik & Schweißtechnik GmbH X connecting point customer MV~ MV0V~ magnetic valve voltage K/VK locking contact K/SK special contact contact stress: 7 K/P pressure 0V-/0W K/P pressure 0 7 K/V valve K/V valve K7/V valve (*) special function at servo cylinder: open: cylinder in up position closed. cylinder in pre-stroke position 0 K/V valve K/V valve K0/V valve terminal wiring X, X

58 distance measurement servo-cylinder SER Elektronik technische Information & Schweißtechnik GmbH distance measurement servo-cylinder sensor measuring range system zero: machine zero: distance between sides : - new set up needed if cutting or change electrode: set up without current (O/I LED off), key switch "Progr.", change display upper right side to "zero", button "Installation" twice until LED flash, start sequence - new set up needed if cutting or change component: set up without current (O/I LED off), key switch "Progr.", change display upper right side to "part new", button "Installation" twice until LED flash, start sequence working- or pre-stroke position : open position electrode : - ( position values relate to "system zero" (absolutely)) \\_bedienungsanleitungen\anhang\a-distance measurement.0.0 A All copy rights concerning these documents or parts there of remain with SER Elektronik & Schweißtechnik GmbH A

59 A7 \_bedienungsanleitungen\anhang\a7mf-wiring diagram Mega-INV L L L PE L L L PE Mega-INV Phoenix -pol. RM.0 standby / operate X D-Sub. -pol. status X RS Phoenix -pol. RM.0 U V PE X temperatur contact HP -pol. D-Sub. -pol. light cable powersupply X X U V PE mf-transformer C C PE + - wiring diagram Mega-MF / Mega-INV SER Elektronik All copy rights concerning these documents or parts there of remain with SER Elektronik & Schweißtechnik GmbH A7 X X inputs, start, FK EOS advance contact GW limit contact D-Sub. -pol. optional: terminal boards X voltage valve outputs VK, SK P, P, valve - X D-Sub. -pol. Mega-MF PE RS status X7 D-Sub. -pol. light cable X HP -pol. powersupply X D-Sub. -pol. 7 I- I+ current X7 D-Sub. -pol. U+ U- voltage X D-Sub. -pol. U+ signal U- distance X D-Sub. -pol. Prop AGND 0 Druck prop.-output / pressure X D-Sub. -pol. technische Information wiring diagram & Schweißtechnik GmbH Mega-MF / Mega-INV

60 A7- \_bedienungsanleitungen\anhang\a7-mfs-wiring diagram Mega-SIN L L L PE + frequency selection (- 0V = - 0 Hz) - L L L PE Phoenix -pol. RM.0 X Mega-SIN Phoenix -pol. RM.0 standby / operate X status X RS U V PE X Phoenix -pol. temperatur RM.0 contact D-Sub. -pol. HP -pol. D-Sub. -pol. light cable X powersupply X U V PE 0Hz-transformer C C PE wiring diagram Mega-MF / Mega-SIN SER Elektronik All copy rights concerning these documents or parts there of remain with SER Elektronik & Schweißtechnik GmbH A7- X inputs, start, FK EOS advance contact GW limit contact X D-Sub. -pol. optional: terminal boards X voltage valve outputs VK, SK P, P, valve - X D-Sub. -pol. Mega-MF PE RS status X7 D-Sub. -pol. light cable X HP -pol. powersupply X D-Sub. -pol. 7 I- I+ current X7 D-Sub. -pol. U+ U- voltage X D-Sub. -pol. U+ signal U- distance X D-Sub. -pol. Prop AGND 0 Druck prop.-output / pressure X D-Sub. -pol. technische Information wiring diagram & Schweißtechnik GmbH Mega-MF / Mega-SIN

61 connection, fuses, plugs X0-X Mega-INV SER Elektronik technische Information & Schweißtechnik GmbH connection, fuses, plugs X0-X Mega-INV (M0x0) (M0x0) (M0x0) (M0x0) PE L L L O S M remote control power supply -> Mega-MF X status -> Mega-MF X7 light cable -> Mega-MF X error X. X. F,AT INV charging x F.,AMT INV V x X PE electr.(out) electr.(+) electr.(out) electr.(+) O S M standby/operate standby/operate (0V) 0V +V PE Quit (0V) Quit current (0V) -0 Hz: Mega-SIN current (0V) 0V weld. time weld. time (+) current L current L ( temper. IGBT ) ( temper. IGBT ) current prim. current prim. PE F.,AMT INV V, V x0 current sec. current sec. ready error temperatur tr. temperatur tr. F,AT Mega 00V~ x F0 0,AMT INV ventilator x0 X. X. X. X. X. X. F.,0AMT INV V extern x0 X X X M F,AT Mega 00V~ x F. 0,AMT INV -V x0 (transport) F,0AMT Mega valve-voltage x0 F.,AT INV 00V~ x F,AMT Mega V extern x0 F,AMT Mega V, V x0 F.,AT INV 00V~ x F 0,AMT Mega -V x0 \\_bedienungsanleitungen\anhang\amf-connector signals X0-X.skf A All copy rights concerning these documents or parts there of remain with SER Elektronik & Schweißtechnik GmbH A

62 technical data Mega-INV SER user information Elektronik & Schweißtechnik GmbH Bei den Kämpen D-0 Seevetal-Ramelsloh technical data Mega-INV technical data medium frequency inverter Mega-INV Mega-INV-0 Mega-INV-00 Mega-INV-00 Mega-INV-000 Mega-INV- 00P mains voltage 00 V~ phases 00 V~ phases 00 V~ phases 00 V~ phases 00 V~ phases main fuses typical A slowly typical 00 A slowly Typical A slowly typical 00 A slowly Typical A slowly cable profile main typical mm² up to 0 m typical mm² up to 0m (00A main fuse) typical 0 mm² up to 0m (A main fuse) typical 0 mm² up to 0m (00A main fuse) typical 0 mm² up to 0m (A main fuse) cable profile output typical mm² up to 0 m typical mm² up to 0 m typical 0 mm² up to 0 m typical 0 mm² up to 0 m typical 0 mm² up to 0 m working frequency 000 Hz 000 Hz 000 Hz 000 Hz 000 Hz mains frequency 0-0 Hz 0-0 Hz 0-0 Hz 0-0 Hz 0-0 Hz output current 00 A max 00 A max 00 A max 00 A max 00 A max output voltage 0 V 0 V 0 V 0 V 0 V output power max. 0 kva 00 kva 00 kva 00 kva 00 kva discharge time regulation controller Dimensions (height x width x length) 00 V after s 0 V after s current regulation with ext. controller ext. w. MegaMF, option: inverter integrated x 7 x mm 00 V after s 0 V after s current regulation with ext. controller ext. w. MegaMF, option: inverter integrated x 7 x mm 00 V after s 0V after s current regulation with ext. controller ext. w. MegaMF, option: inverter integrated x 7 x mm 00 V after s 0 V after 0 s current regulation with ext. controller ext. w. MegaMF, option: inverter integrated 7 x 7 x mm 00 V after s 0V after s ext. w. MegaMF, option: inverter integrated x 7 x mm Weight kg kg kg kg kg ambient temperature ºC max ºC max ºC max ºC max ºC max rel. humidity 0 % max, no condensation 0 % max, no condensation 0 % max, no condensation 0 % max, no condensation cooling water 0 ºC max - l/min 0 ºC max - l/min 0 ºC max l/min ºC max 0 l/min water pressure bar max bar max bar max bar max \_bedienungsanleitungen\anhang\amf-mega-inv technical data A A

63 dimensions Mega-INV SER user information Elektronik & Schweißtechnik GmbH Bei den Kämpen D-0 Seevetal-Ramelsloh + (0)-70-7 dimensions Mega-INV Mega-INV 0,00,700 (in mm) Mega-INV 000 (in mm) \_bedienungsanleitungen\anhang\a0mf-mega-inv dimensions.0.00 A0 A0