Instructions for Use
Welding machine type and start-up method
The ZMF series controller can work in two modes: ordinary spot welding and seam welding. In ordinary spot welding, there are single-point welding and continuous welding modes. The welding start can be initiated through the start pin or the standard pin.
Ordinary spot welding
Single-point welding, pulse start
The controller is in single-point welding, pulse start mode (pulse start:1; continuous/single point:0; standard terminal start:0), when a pulse start signal is given, and the signal length exceeds the start signal filtering time, it enters the welding process. After the welding is completed, it automatically stops, as shown in Figure 61.
Figure81Single-point welding, pulse start timing
Single-point welding, non-pulse start
The controller is in single-point welding, non-pulse start mode (pulse start:0; continuous/single point:0; standard terminal start:0), when a start signal is given, and the signal length exceeds the start signal filtering time, it enters the pre-pressure time, at which time the gas valve opens and outputs. If the start signal is maintained until the end of the pre-pressure time, it enters the welding process, and the gas valve closes and stops outputting after the welding is completed; if the start signal is not maintained until the end of the pre-pressure time, it does not enter the welding process, and the gas valve closes and stops outputting, as shown in Figure 62.
Image82Single-point Welding, Non-Pulse Start Sequence
Continuous Welding, Pulse Start
The controller is in continuous welding, pulse start mode (Pulse Start:1;Continuous/Single-point:1;Standard Terminal Start:0), when a pulse start signal is given, and the signal length exceeds the start signal filtering time, the welding process will begin. After one welding is completed, the welding process will enter the rest period at the end of the maintenance time, and the exhaust valve will close the output. Then, it will automatically enter the second welding, third welding, and N welding processes, until the welding end signal is detected. After receiving the welding end pulse signal, continuous welding will end, and the exhaust valve will close the output, as shown in Figure 63. It should be noted that the pre-pressure time is ignored for the second and subsequent welding processes.
Image83Continuous Welding, Pulse Start Sequence
Continuous welding, non-pulse start
The controller is in continuous welding, non-pulse start mode (pulse start:0; continuous/single point:1; standard terminal start: 0) when a start signal is given. If the signal length exceeds the start signal filtering time, it enters the pre-pressure time, at which point the gas valve opens and outputs. If the start signal is maintained until the end of the pre-pressure time, it enters the welding process. If the start signal is not maintained until the end of the pre-pressure time, it does not enter the welding process, and the gas valve closes the output. At this time, if the start signal is maintained, after one welding is completed, it will enter the rest time at the end of the maintenance time, during which the gas valve will close the output, and then automatically enter the second welding, third welding, N welding process. When the start signal disappears, continuous welding ends, and the gas valve closes the output, as shown in Figure 64 as shown. It should be noted that the pre-pressure time is ignored for the second and subsequent welding processes.
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Figure84 timing diagram of continuous welding, non-pulse start
Single-point welding, standard terminal start
The controller is in single-point welding mode, with the specification terminal start mode (Continuous/Single Point: 1; Terminal Select Specification: 1; Specification Terminal Start: 1;Double Specification DoubleValve: 0) when the specification terminal detects a valid specification number, the signal length exceeds the filtering time, and then enters the welding process. The welding stops automatically after completion, as shown in Figure 65.Attention: In this mode, if the value of the Double Specification DoubleValve is 1, then when specification 1 is started, only valve 1 operates, and when specification 2 is started, valve 2 operates. This function is used for applications where two start signals correspond to two valves.
Figure 85 Single-point welding, specification terminal start
Seam welding
Seam welding pulse start
The controller is in the seam welding mode with pulse start mode (pulse start:1;standard terminal start:0). When a pulse start signal is given, and the signal length exceeds the start signal filtering time, it enters the seam welding pulse cycle for periodic welding until an end signal is received. After receiving the welding end pulse signal, the seam welding pulse cycle ends, and the gas valve closes the output, as shown inFigure 66.
Figure86Seam Welding Pulse Start Timing
Non-pulse seam welding start
The controller is in the seam welding mode with non-pulse start mode (pulse start:0;standard terminal start:0). When the start signal length exceeds the start signal filtering time, it enters the pre-pressure time, at which time the gas valve opens the output. If the start signal is maintained until the end of the pre-pressure time, it enters the welding process. If the start signal is not maintained until the end of the pre-pressure time, it does not enter the welding process, and the gas valve closes the output. At this time, if the start signal is maintained continuously, it enters the seam welding pulse cycle for periodic welding until the start signal ends. After the start signal ends, the seam welding pulse cycle ends, and the gas valve closes the output, as shown inFigure 67.
Image87Non-pulse Seam Welding Timing Sequence
Specification Selection Method
The specification selection method includes panel selection specification and terminal selection specification. When selecting the panel specification, the specification number entered in the specification input box on the display screen is the current working specification; when selecting the terminal specification, the value represented by the detected specification terminal is the current working specification. There are two modes for specification terminals, namely 1234 mode and 1248 mode, for detailed information seeTable 6.1 and Table 6.2:
Specification Terminal Input
| Specification Number
|
P18-10 | P11-9 | P11-10 | P11-11 | P11-12 | |
16 | 8 | 4 | 2 | 1 | |
○ | ○ | ○ | ○ | ○ | Invalid
|
○ | ○ | ○ | ○ | ● | 1 |
○ | ○ | ○ | ● | ○ | 2 |
○ | ○ | ○ | ● | ● | 3 |
○ | ○ | ● | ○ | ○ | 4 |
○ | ○ | ● | ○ | ● | 5 |
○ | ○ | ● | ● | ○ | 6 |
○ | ○ | ● | ● | ● | 7 |
○ | ● | ○ | ○ | ○ | 8 |
○ | ● | ○ | ○ | ● | 9 |
○ | ● | ○ | ● | ○ | 10 |
○ | ● | ○ | ● | ● | 11 |
○ | ● | ● | ○ | ○ | 12 |
○ | ● | ● | ○ | ● | 13 |
○ | ● | ● | ● | ○ | 14 |
○ | ● | ● | ● | ● | 15 |
● | ○ | ○ | ○ | ○ | 16 |
● | ○ | ○ | ○ | ● | 17 |
● | ○ | ○ | ● | | 18 |
● | ○ | ○ | ● | ● | 19 |
● | ○ | ● | ○ | ○ | 20 |
● | ○ | ● | ○ | ● | 21 |
● | ○ | ● | ● | ○ | 22 |
● | ○ | ● | ● | ● | 23 |
● | ● | ○ | ○ | ○ | 24 |
● | ● | ○ | ○ | ● | 25 |
● | ● | ○ | ● | ○ | 26 |
● | ● | ○ | ● | ● | 27 |
● | ● | ● | ○ | ○ | 28 |
● | ● | ● | ○ | ● | 29 |
● | ● | ● | ● | ○ | 30 |
● | ● | ● | ● | ● | 31 |
Table 81 Specification Terminal 1248 Mode
Specification Terminal Input
| Specification Number
|
P18-10 | P11-9 | P11-10 | P11-11 | P11-12 | |
○ | ○ | ○ | ○ | ○ | Invalid
|
○ | ○ | ○ | ○ | ● | 1 |
○ | ○ | ○ | ● | ○ | 2 |
○ | ○ | ● | ○ | ○ | 3 |
○ | ● | ○ | ○ | ○ | 4 |
● | ○ | ○ | ○ | ○ | 5 |
Table 82 Specification Terminal 1234 Mode
Note:
● Indicates an effective terminal; ○ Indicates an invalid terminal
This background color indicates that the feature is optional and available on some models
Current Monitoring
The current monitoring function is used to detect the actual current during the welding process and compare the feedback current value with the set reference value and over/under limit values. When the measured current value exceeds the allowable error, the controller will issue an alarm or a warning. If the measured value is below the allowable error range, a counter will be started and compared with it; if it is allowed to re-weld, the controller will re-weld the weld point once. For each welding pulse, the current monitoring function can be set separately. When the measured current value exceeds the current set error, an alarm or warning signal will be generated. For the three welding processes of preheating, welding, and tempering, current reference values, over-limit values, allowable under-limit values, and alarm under-limit values are set separately. As shown in Figure 6.8:
Image8888Illustration of Current Monitoring Threshold
Preheating (welding or tempering) reference values: An actual current reference value can be set, and parameters such as current over-limit and under-limit values are based on this reference value.
Current over-limit value: For current I (current during preheating, welding, or tempering), there is an over-limit range relative to the current reference value. When the actual current exceeds this range, the controller will issue an alarm. At this point, the controller may only issue an alarm without interrupting the welding process, or it may interrupt the welding process. This function can be set through the dip switch S6 on the mainboard.
Current under-limit value: The measured current value has a low limit error relative to the reference current value, which is the alarm under-limit value. When the current measurement value exceeds the allowable alarm range, an alarm will be issued. At this time, it may interrupt the welding or not interrupt the welding and restart the next one.
Current Allowance Deficit Value: An allowable deficit value can be set relative to the current reference value, which is also a percentage. Between the allowable deficit and the alarm deficit, a parameter can be introduced: the consecutive deficit points, which allows for a continuous n points to be located between the allowable deficit and the alarm deficit. If the point count exceeds n, an alarm will sound and the welding process will end.
Consecutive Deficit Points: When the actual current value falls within the range between the current alarm deficit and the current allowable deficit, an additional welding attempt is allowed. If the next attempt still falls within this range and does not exceed the "consecutive deficit points" limit, another welding attempt can be made, until the set value of the consecutive deficit points is reached. If the next point is still deficit, the controller will issue an alarm.