WIA W17 Suppliment Owner's manual

TABLE OF CONTENTS

INTRODUCTION

CIRCUIT DESCRIPTION

Wl6-12

WImFEED PANEL

LAYOUT DESCRIPTION

DRAWING

NO.

W16-l2

DRAWING NO.

W16-11

METHOD OF SPEED RANGE SELECTION

DRAWING NO. W17-Cl.

CIRCUIT DESCRIPTION

W16-11

DESIGN APPROACH TO SPECIAL

CONTROL FUNCTIONS

SUMMARY

TABLE

OF

OPTIONS AND GENERAL INFO.

CIRCUIT DESCRIPTION

OF

OPTIONS

AM126 PRE AND POST GAS

AM127 SOFT START/CRATER FILL

~~128

SPOT

TIME/CYCLE

ARC

AM129 DIGITAL

WIRE

FEED

AM131

PUSH PULL ADAPTOR

Page

1.

Page

2

-

3

Page

4

Page

5

-

6

Page

7

Page

8

-

9

Page

10

Page

11

Appendix

1

Appendix

2

Appendix

3

Appendix

4

Appendix

5

INTRODUCTION:

The

W.I.A.

W17

type wire feeder has been designed to feed a range of hard,

soft and flux cored wires for the

Gas-Metal

Arc

Welding process.

A

low

inertia, Printed Circuit type motor with integral spur gear box

is

coupled

to

a

two roll drive assembly forming the basic component of the

wire

feeder.

The motor

is

controlled by an electronic speed control which ensures

excellent speed regulation over the full torque range of the motor, and

inherant compensation €or supply voltage variations.

The electronic controls of the W17/W18 Wirefeeder are situated under the

top lid of the wirefeeder which folds back out of the way for

ease

of

access.

The W16-12

wire

feed panel, also referred to

as

"Motherboard",

is

mounted

on the tray above the motor by six plastic supports.

The "motherboard" accepts the external cable connections and controls the

power and braking to the motor, the welding contactor and gas valve

functions.

The smaller W16-11 motor speed control panel plugs directly into the "mother-

board". Without this panel fitted, the motor

will

run at full speed.

In

a

standard W17/W18 wirefeeder there aretwovacant receptacles of 8 pins

each. These facilitate the inclusion of option boards to

alter

or add to

the standard wirefeeder functions. The panels for

W17

and W18 wirefeeders

are the

same

except for the links on the W16-12 board. These links

are

used to select adjustment resistors for the

wire

speed potentiometer

depending on the motor used. These differences should be kept in mind when

replacing boards.

SEE

PAGE

6 for panel replacement details.

The

W17

wirefeeder

is

fitted with the standard

5

ampere Yaskawa Motor and

25/1

Gearbox and W16-12 Board with links cut to suit.

The W18 wirefeeder

is

fitted with the heavy duty

8

ampere Yaskawa Motor

and

50/1

Gearbox and W16-12 Board with links cut to suit.

3.

1.

(4)

Relay

K2

has normally open contacts connected

to

9

&

10

of

terminal strip

I1S1I1

. These are used to control the

contactor in the power source. When

K2

is energized the

contacts are closed and the power source contactor

is

energized.

"K2"

is energized by

H1,

via D10,

R3,

D13

&

R2 when thegun:switch is pressed. When the gun switch is

released

C2

discharges and has the effect of holding

"H2"

on for a short period after the gun switch is released.

This is the burnback time and can be adjusted by

RV1.

Note

:

A

track goes from the junction of R3 and D13 to the

option board pins

so

that

K2

can be controlled by the options

when required.

___

""

__-__-

"

(5)

The gas valve in the base of the wirefeeder is connected

to

5

&

6

of terminal strip

"Sl"

and is controlled by

H3

which

is

turned on via

D15,

R10

&

R9 when the gun switch is pressed

and via

R11

when the purge switch is pressed.

Note: The track from the junction of R9

&

R10

to the option

board pins. This enables the control

of

the gas valve by the

option boards when necessary.

30V

PIN.

LINK

E

LINKS

F

,G

4.

"l__l"__"~-

REFER

DRAWING NO.

W16-12.

ITEM

S1

...............

12

Terminal Stri.p

Terminals

1-4

Spares not connected

5-G

Gas

Valve

l

I1

7-8

30

Vac. Looping terminal

from control

cable

to

Off-

On switch.

9-10

Contactor

I1

11-12

Motor

P1

................

8

Array

.....

Loom

to front panel

See Drawing

No.

W17-0/24

a)

The

speed control potentiometer

takes

Pins

(6,7

I

8)

b)

Then there

is

30v which goes to Pin

(5)

c) The gun switch to D12,D101D15,

(4)

d)

Inch to

R14

(3)

e)

Purge to

R11

(2)

f)

To the

L.E.D.

on the f/panel

(1)

The Inch/Purye switch Led

P2

...............

8

Pin Array

.....

Option

board

receptical

P3

...............

8

Array

.....

Option

board

receptical

P4

&

P5

..........

2

x

8

Pin Arrays

....

Speed

Board recepticals.

LINKS

A,B,C,D.

W17

-

Links

A

and

C

cut,

Links

B

and

D

joined.

W18

-

Links

B

and

D

cut,

Links

A

and

C

joined.

Link

E

cut for certain options

e.g.

X4129

Dicjital Option

AM126

Soft Start/Crater Fill option

Not to

be

cut

5.

REFER

TO

DRAWING

NO.

W16-12.

This

is

an actual size component overlay

of

the

W16-12

panel.

Note

Links

A

to

D,

these links choose the speed range for

W17

or

W18.

1.

W17

Cut

Links

A

&

C

2.

W18

Cut

Links

B

&

D

l

Also

Note

Link

'E'

cut only when options require.

Now

refer

to

drawings

No. W16-11.

which

is

a

double

size

com-

ponent overlay of the

W16-11

speed control panel.

Note

Resistors

R16

to

R19

&

R16'

to

R19.

b

UNKs

h

9

tc

A

!R

Q

!A

P

b

IE

~ ~

-~~~

~

These resistors form the top and bottam of

a

voltage

divider

with

the

speed control potentiometer

in

the centre.

R16'

,R19'

are

selected

on

test

to produce the correct

start

up

and final speed of the motor

so

that the motor

starts

just

as

the pot.

is

turned

from

zero and when turned fully

clockwise

the

motor speed

is

then required

for

W17

or

VI-8.

The

Table

below shows which resistor to adjust for what speed and

wire-

feeder

CUT

LINKS

A,

C.

CUT

LINKS

B

,D

W17

W1

8

SELECT

FOR

MIN.

SPEED

R18

'

R19

I

e.

g.

POT

SET

TO

MIN.

(

0

RPM)

(

0

R?

M)

"""""""___

"

""

"-

SELECT'

FOR

iW!,X.

SPEED.

R1G

R17

I

e.g.

POT.

SET

TO

MAX.

(126RPM)

(

7

2

RPM)

NOTE:

SPEEDS

SHOWN

ARE

OUTPUT

SHAFT

SPEEDS.

6.

WL6-11

boards

are

produced without:

R16

'

-

R19'

and these

resistors

are

inserted on testing

the

wjrefeeder

so

that they

are

selected for the

wirefeeder

in which they

will

work.

In

the event

of

in field failure necessitatiny change

of

1416-11

board. The new

W16-l1

should

be

fitted with resistors

of

the

same

value

as

the

old

board

and

in the

same

location. This

can

be

done by removing the resistors

from

the old and solder-

ing them to the

new

W16-11..

I

An

alternate method

is

to

set

the speed board up on another

wirefeeder,

however, this should

only

be done when

it

i.s

not

possible

to

do

the

previous method

as

this may not

be

as

accur-

ate

in

all

cases.

To

be

completely accurate

use

a

tachometer

and

a

resistor

sel-

ection

box

to

be

able

to

select

the resistor which gives the

correct speed,

as

done in

the

factory.

NOTE:

Any

Wl6-l1

will

provide speed control in any

W17/W18

wirefeeder regardless of whether

it

is

adjusted

or

which links

are

cut, enabling one to substitute

boards

to isolate faults.

During servicing

if

a

fault

exists

the removal-of

Option bo'ards returns

the wirefeeder to standard.'.

.

.Some options

(

AM127

and

AM129

)

require

LINK

''E"

to

be

cut to operate. In this

case

LINK

"E"

should

be

remade

(

simply solder up

1

when these options

are

removed.

Remember

to

recut

LINK

''El'

on reinstallation

of"

these

options.

7.

Wl6-11

SPEED

CONTROL

PANEL

-

mFER

DRAWING

NO.

W1'7-Cl

The

W16-l1

Panel controls the speed

of

the

wirefeed motor

by adjusting the conduction angle

of

SCRI

and SCR2, descrilbed

on

page

2

paragraph

l

(I)

.

W16-11

CIRCUIT

DESCRIPTION

"

The power supply consists

of

two

12

Volt

zener

diodes,

21

IC1

derives

ZERO

CROSSING

PULSES

from the unfiltered supply

and

22,

which provide stable

12

Volts and

24

Volts

to

the

circuit.

voltage.

ICl's

output drives

a

monostable,

IC2,

which triggers

the ramp generator, consisting

of

transistor

H1

and capacitor

Cl.

The results

of

this

is

a

series

of

ramps with a period

of

10mS

synchronized to

mains

frequency.

IC4

compares the motor voltage to a voltage

set

by

the

L7irespeed potentiometer,

its

output

is

compared to the ramp

by

IC3. The output of IC3 drives transistor

H2,

which bypasses

current

away from the gates

of

SCRl

and

SCR2

until

IC3's,

output

goes

low,

thereby controlling the

time

€or

which

the

SCR's

conduct

for each half cycle and thus the voltage to the motor

is

controlled.

IC4

is

so

arranged that

its

output acts to maintain constant

BACK

EMF

from the motor

i.e.

when motor

speed

decreases due

to

applied load the output of

IC4

reduces acting

to

intersect

the

ramp at an earlier point increasing

the

conduction angle

of

the

SCR's.

Therefore supplying more voltage to the

motor

in order

to increase

its

speed.

It

should be noted that without

H2

in circuit,

for

example

with the

5516-11

panel unplugged, the motor

will

receive full

voltage

and

run

at

full

speed.

DESIGN APPROACH

TO

SPECIAL

CONTROL

FUNCTIONS

The W16-12 motherboard has been designed to meet the requirements of

a standard wirefeeder with provision for fitting specialised control

functions. These optional control functions can be plugged into the

receptacles provided

in

the motherboard.

There are two such recepticals of

8

pins each

...

1.

Supplies power 30v to option boards

I

2.

Provides access to signal from speed control potentiometer

3.

Provides opportunity to send modified speed signal to

speed board

in

conjunction with Link

E.

4.

OV

common

line

for a11 boards

J

5.

Provides a means of controlling the gas value

6. Provides a means of controlling the contactor

7.

Makes gunswitch signal available

8.

Provides a means of controlling the motor relay.

AM126

PRE/POST

GAS

CONTROL

This control allows shielding gas to flow over the weld area for a con-

trolled period before and after welding to ensure the weld metal

is

properly shielded from atmospheric gases. When the gun switch

is

pressed,

'

gas flows

as

normal, but the contactor and motor relay are delayed for

an adjustable

time

period. On releasj-ng the gun

switch,

the contactor

and motor relay are de-energised, but the gas valve remains open for

tk-s

preset "post gas" time.

"

-

AM127

SOFT

START/CRATER

FILL

CONTROL

This facility provides control of the

wire

feed speed

at

the

start

and

finish of a weld.

It

is

particularly useful for fully automatic and

submerged arc welding applications. The design approach was to use twc

potentiometers, designated soft start and crater fill, and switch bet-

ween them

at

the appropriate

times.

On

closing the gun switch, the

motor

is

controlled by the soft start potentiometer

until

the current.

relay senses that welding has commenced and the arc established

for

a

preset time period. Speed

is

then controlled by the normal wire speed

potentiometer until the gun switch

is

released. Welding continues

witk

the wire speed controlled-by the crater fill potentiometer for

a

preset

time period.

AM128

SPOT

TIME/CYCLE

ARC

CONTROL

A

toggle switch

is

provided to select the spot weld, cycle arc

or

norxal

mode of operation.

In the spot welding mode the welding operation

is

automatically stopped

after

a

preset operating time.

A

current relay

is

used

to

sense the

current flow and initiate a timer, which

in

turn

de-energises the

welding contactor, motor and gas valve after the preset time

has

el?.;:se?..

In the cycle arc mode, the welding operation

is

intermittently inter-

rupted, with both on and off

time

periods being fully adjustable,

3.5.

AM129

DIGITAL

WIRE

FEED

PATE

METE12

-___~-~"~ ~

The

meter

displays the

wire

feed

rate

in

metres

per

mirnlte,

utilising

a

bright red

LED

(light emit-ting

diode)

type read

out

with

l01m

high

figures.

As

the wirefecd motor

supply

is

of

a

closed

loop

voltaye cotnpensatiny

design, the

mot.or

speed

is

directly proportional to the output

volt-age

of

the speed control potentiometer. This voltage

is

fed to

a

precision

voltage divider, and to the digital. panel meter which

is

calibrated in

metz:es

per

minute.

3.7.

M1131

DIJSB

i-

PtJLL

SYSTEM

__"___~""

-

The m4131 control. converts the standard

W1'7

to

a push

-t

puil wirefeeder

suitable

fcir

small

diameter and

soft

wi.res.

I4

separate

power

sul>ply

is

provided

for

the

p~nll gun

motor

and this

is

then controlled

by

the

sane

speed

coatrol

si.gni?b

as

the wirefeeder. The wire

speed

can

he

controlled

by either the normal

specd

control- potentiometer on

the

wirefeeder

(with

the toggle

switch

set

to

local)

or

by

the potentiometer mounted

on

the

gun body (with

togg1.e

switch

set

to

remote).

The detailed circuit operation

of

each

of

the

above control

Functions

are set out

ir:

the following pages and

are

intended to

assist

fault

finding and general service.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

"

10.

l

Wl.6-12

Wire

Feed Panel

Motor

Supply

and Braking

Contactor Control

Gas

Valve Control

N16-11

Speed Control Panel. Plugs

into

W16-12.

w17/w18 same but for

links

and adjust resistors.

Some options require link

'E'

to

be

cut.

See

list

of

options Paye

11.

K1

Motor

Relay operated

by

H2.

K2

Contactor Relay operated

by

HI.

Gas

valve operated

by

H3.

Links

A,

C

cut for

P717

Links

B,D

cut

for

W18

Link

E

cut

for

certain options (e.g.

PJ.1129)

Speed

Control Panel adjusted

for

speed

range.

Remove options and make

sure

link

'E'

is

made,

to

return

wirefeeder

to

standard,

for

ease

of

fau.lt

finding.

IiIST

OF

OPTIONS

".-

1.

AM126

PIU

AND

POST

GAS.

-

"""

2.

AM127

SOFT START/

GRATER

FILE.

""

3.

AM128

SPOT

TIME/

CYCLE

ARC,

4.

AM129

DIGITAL

WIN?

SPEED

""p-

5.

AM130

VERNIER

DIAL

"

"""

6.

AM131

PUSH/PUI,L

OP

TI

ON

11.

CUT

YES

"-

YES

"

YES

"-

YES

-p

YES

I"

YES

"

YES

"

NO

5

OI?

6

SI

CURFtENT

CAN

RE

.

,

E

USED

l

"

5

NO

OTHER

OPTIONS

L

2

l

APPENDIX

1

AM126

PRE

AND

POST GAS

AM126

PRE/POST

GAS

OPTION.

-

REFER

DRAWING

NO.

AM12G/CiL.

Pi.n

1

and pin

4

of

the option pins supp1.y

30V

and ov respectively.

Diode

Dl

decoupled this circuit from others. The combination

of

R1,

ZD1

and

C1

form

a

stab1.e

12V

supply.

.

The

circuit

is

in two parts.

One

is

IC1

whish

‘5s

a

timer‘

triy-

gered by

H1

when the gunswitch goes on.

For

a

perj..od,

after

the

trigger,

set

by

RV1

be,ing the pre-gas period contactor

and

motor

relay

are

disabled

via,

H2,D5’

and

D6.

Leaving the

gas

valve oper-

ating.

The second part consist

of

a

timer

made from

IC2

and the discharge

of

C6

when

the

gunswitch

is

released.

C6

is

charged

quickly

while

the

gunswitch

is

on

and discharges through

RV2

and

Rll.

R11

sets

the

minimum discharge

time.

RV2

sets

larger

times

and

is

the

post-

gas

time

control.

IC2

controls

H3

which

in

conjunction with

R14

and

D7

hold

the

gas

valve

on

for

a

time

after

the

gunswitch

is

re

Ieased

.

Note.

R5

sets

the minimum pre-gas

time

to

approx.

o

seconds

and

Rll

sets

the

minimum post-gas

time

to

approx.

2

seconds.

APPENDIX

2

AM127

SOFT

START/CRATER

FILL

The power supply

is

derived

from

1

(30V)

and pin

4

(OV)

through

Dl,

R1

and

R2.

Zener Diodes

ZL

and,

22

provide

12V

and

24V

supplies smoothed

by

Cl.

This option switches the speed signal supplied

to

the speed

board

(1016-

I

\

)

from the standard speed .control potentiometer

to two additional potentiometers called "Soft Start

Speed"

and

"Crater

Fill Speed". The switching

is

controlled

by

timers

set

by

the "Soft

Start

Time"

and

"Crater

Fill

Time"

potentio-

meters.

..;

4.

The normal speed signal

is

applied

to

the base

of

Hl.

Softstart

'I

11

It

II

11

II

11

H2.

I'

Crater

fill

'I

II

11

II II

l'

H3.

The

emitters

of

111,H2,H3

are

connected and supply the speed

signal to the speed board. Which speed signal

is

supplied

depends on which transistors

are

switched. H4,H5,H6,1!7 and

H8

control.

the

switching.

The

timers

consist

of

IC1

and

IC2.

IC1

governs the

Soft

Start

duration and

is

current initiated.

IC2

governs the

Crater

Fill

duration and

is

triggered .by

the

Gun-

Switch going off,

it

also

holds the gas

valve

contactor and

motor relay on for

the

Crater

Fill

period,

Via

H14,H15 ,R37

,D12,

D13 and

D14.

APPENDIX

3

m128

SPOT/TTMER/CYCLEARC

Pins

1

and

4

supply

30V

and

ov

respectively to the option board.

Diode

DI

decouples this option from others. The combination,

of

R1,Cl

and

ZD1

form a stable

12V

supply,

.-;

4.

The circuit consists

of'a

timer

IC1.which

is

triqqered

by

the

gunswitch through

H1

.:._.The oatput pin

3

PC1

goes-high hoiding

H2

and

H3

off. Therefore, .contactor,

motor

relay and

qas

valve

operate

as

usual. When

weld

current

flows

through the-current

relay. The

timer

is

enabled

and

after

a

delay

set

by

RV1

(Spot

Time

Control) the output pin

3

of

IC1

goes

low

and contactor and

motor relay

go

off.

Gas

flows

as

long

as

the gunswitch

is

held

closed.

In the cycle

arc

mode the

same

process

as

above

takes

place but

the

timer

is

connected

so

that

after

a

delay (Interval

Time)

it

resets

itself and produces a

series

of

spots

separed

by

intervals.

NOTE:

Gas

f

losh7

is

uninterrupted.

I_-

APPENDIX

4

AM129

DIGITAL

WIRE

FEED

REFER

DRAWING

NO.

AM129/C1

"

AM129

DIGITAL

WIRE

SPEED

"-

,"

(l)

and Pin

(4)

provide

30V

and.0V respectively. There

are

two power

supplies on the

AM129

Board, .a

24V

supply and

a

5V

supply.

Dl

decouples

this option from other pane1.s. The. parallei combination

of

R12

and

R13

drop voltage to

24V

which

'i3

clamped

by

the

12V

Zener

Diodes

21

and

22

in

series.

C2

and

C3

smooth 'this

24V

supply.

-4

5

R14

drops voltage to

5V,

23

clamps this voltage

at

5V,

C1

and

C4

are

the

smoothing capacitors.

This option provides a voltage, proportional to wirefeed rate, to a

D.P

.M.

(Digital Panel Meter) with

2V

F.S

.D.

*

This proportional voltage

is

derived

from the

wire

speed potentiometer. The signal from the speed control poten-

tiometer

is

available on Pin

(2)

and

is

applied to the- base

of

T1

thru

RI.

Tl

is

arranged

as

a

voltage follower. (i.e. the voltage at the

emitter

"follows" the voltage at the base).

R2

is

the emitter resistor for this

stage. The emitter voltage

is

applied to the speed board. W16-l1 as

the

speed signal. Hence Link

"E"

on the wirefeed panel

W16-l2

must

be cut.

The

emitter

voltage

of

T1

is

applied directly to

T2,

also

a

voltage follower

but of the opposite polarity.

R3

in

series

with

R4

constitute the emitter

resistor for this stage, with

RV2

and

R9

in parallel, The signal

is

taken

from the slider

of

RV2

to

a

divider chain comprising

R18,

R10,

RV3

and

R1.

The signal from the wiper of

RV3

is

sent to the D.P.M.

The above

is

a description

of

the signal path through the circuit.

IC1

and

T3

and associated components were not mentioned. However, they also

effect the signal.

IC1

is

used here

as

a

comparator, the inputs are marked

2

and

3.

The voltage

at

input

3

is

set by

RV1

with

R6

and

R5

setting the

limits

of

adjustment. When the voltage at input

2

falls below that set

at

input

3

the output,

6,

goes high, switching

T3

on and-pulling the voltage

at the junction

of

R18

and

RIO

down,

so

the

D.P.M.

reads

'0.0'.

All

of the circuitry

so

far mentioned

is

supplied from the

24V

rail.

This

concludes the description

of

the signal path. There

is,

however, more to

the

AM129,

namely

IC2

and

its

associated components which are connected to

the 5v supply. The 5v

is

also supply to the

D.P.M.

via

5.

IC2

is

a

timer with

a

period set by

R15,

K16

and-C5. The output

3

is

normally,

approximately

5V

but switches to

OV

€or

l

second every

12

seconds. This

low pulse

is

applied through

D2

and

7

to the

"HOLD"

function

of

the

D.P.M.,

allowing the

D.P.M.

to update every

12

seconds.

Refer to Drawing

No.

m129

in

conjunction with Drawing

No.

IlMl29/Cl €or

the connection between the AM129 and the

D.P.M.

*

F.S.D.

Full Scale Deflection

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WIA W17 Suppliment Owner's manual

WIA W17 Suppliment Owner's manual

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