Intermax SVF1-400 Manuel utilisateur
Variable Frequency Welding
Controller
SVF1-400
Instruction Manual
Intermax, Co.
(630) 717-8610
1365 Middleburg Rd.
Naperville Il, 60540
http://www.intermax.com.tw
intermax@dpliv.net
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Ver. 5.5
Table of Contents
I. Introduction 1
II. Variable Frequency Controller 1
1. Variable Frequency vs. Normal Frequency Controller Comparison 2
III. Welding Controller Configuration 3
1. Main features: 4
2. Technical parameters: 4
IV. Operation Description 4
1. Spot Welding 4
2. Repeated Spot Welding 5
3. Seam Welding Mode 5
V. Stepper Function 6
VI. Electric Current Monitoring 8
VII.Programmable Welding Pressure 10
VIII.Programming Console Manual 10
1. Programming Console Screen 10
2. Programming Console 11
3. Modes 12
4. “Programming”, “Test”, and “Weld” Mode Parameter List 12
5. “Monitor” Mode Parameters List 14
IX. DIP Switch Configuration 14
1. S1, S4, S5, S6, S7, S8 14
2. Programmable Pressure Control Combinations (S2, S3) 15
X. Error Messages and Troubleshooting 15
XI. Fig.1 Motherboard Terminal Wiring Diagram 16
XII.Fig. 2 System Wiring Diagram 17
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XIII.Fig. 3 Schedule Selection 17
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I. Introduction
Inverter Welding Controller Advantages
The output for the middle frequency inverter is direct-current waveform. This results
in more straightforward control of the welding process, shorter welding time, and
more consistent welding quality. The welding controller power source frequency is 1
kHz, as opposed to the traditional 50 Hz power source, which allows for much more
precise heat control.
Inverter output voltage Corresponding Output welding current
Compared to traditional welding controllers, the middle frequency inverter has the
following advantages:
1. The welding current is DC, therefore the welding current is less influenced by
inductance from the secondary circuit.
2. Smaller welding transformer is required
3. Increased electrode life cycle
4. Thinner materials, three-layer materials, and materials such as aluminum and
zinc-plated metal can be welded with good results
5. Precision welding
6. Minimized explosions
7. Spot weld quality improves greatly due to better electric current control
II. Variable Frequency Controller
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After the three-phase AC 50/60Hz input goes through the rectifier, the filter turns the
smooth direct current, makes the switch component by IGBT/K1 to have the
alternate voltage output, realizes the hypothesis welding current output through the
adjustment high frequency (5KHz) work's IGBT/K2 clear pulse width.
1. Variable Frequency vs. Normal Frequency Controller Comparison
Compared to common power welding controller shows the variable frequency
welding controller to have higher heating efficiency and lower peak current.
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Variable Frequency at 50Hz, secondary
current: 10.0KA, the transformer ratio: 80
Common power frequency at 50HZ,
secondary current: 10.0KA, the
transformer ratio: 80
Compared to common power frequency controller, the variable frequency conversion
controller has the following advantages:
1. The three-phase AC mains input, more balanced power usage; higher power
factor
2. To the same welding work piece, the weld period reduces, saves electricity;
Welding stability region enlarges; The electrode life grows
3. Can weld with good results: aluminum, the galvanized sheet, high-tensile
steel, stainless steel, magnesium alloy, carbon steel, titanium, etc.
4. Can weld with good results: three-layer materials, and thin materials
5. Less sparking
6. Higher weld spot quality due to faster electric current control response
III. Welding Controller Configuration
The entire control system consists of: the welding controller, the welding
transformer, and the welding gun. The welding controller consists of: the power
supply, the rectifier, the capacitor, IGBT, and the CPU.
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!1. Main features:
1. Welding frequency: programmable between 25.0Hz ~400.0Hz
2. Up to 64 sets of programmable welding condition
3. Three section of thermal processes: Preheating, welding, tempering;
Each process has its own stepper
4. The programmable pressure control, able to define up to 10 pressure
sections
5. Programmable output: 3 ways of outputs with PLC, robot, etc.
6. Spot weld count function.
!2. Technical parameters:
1. Input voltage: Three-phase 380V, 50Hz/60Hz, power variation +10%, -
20%
2. Output voltage: Single-phase PWM outputs 500V
3. Output current: Peak current 400A
4. Cooling water: Minimum capacity 6L/min, temperature ≤30℃
5. Working condition temperature: 0~50℃
6. Air valve voltage: DC24V
IV.Operation Description
The controller has two welding modes: Spot welding and seam welding.
1. Spot Welding
The welding start signal (X10 -10) will start the solenoid valve, but the
controller will not begin the welding process until the welding enable (X10 - 7) is
switched on. The Weld/No Weld (X10 - 5) is closed, the welding heat will start,
otherwise the welding process will start but with not current. The start signal will
begin the welding process. This welding process includes initial squeeze, squeeze,
heat 1, cool 1, up slope, heat 2, cool 2, down slope, heat 3, cool 3, hold time, off
time. After the welding has finished, the controller sends out a welding end signal.
Each welding schedule has its own “prohibit start” parameter. This parameter permits
or forbids the welding schedule to sequence, When this parameter is ON it will not
allow welding; When OFF, the welding schedule starts.
The spot welding welding sequence time chart is shown below:
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2. Repeated Spot Welding
In repeated spot welding mode, when the controller sends the start signal,
then the output solenoid valve will stay on with the welding clamp closed until the
start signal is switched off. When the start signal is switched off, the controller will
wait until the next start signal to continue to next process.
The repeated spot welding sequence time chart is shown below:
3. Seam Welding Mode
In order to enter Seam Welding Mode, the DIP switch 5 should be switched to
the on position. In this mode, when the start signal is switched on, the solenoid valve
will switch on and the first heat cycle and cool cycle will start. Then heat 2 and cool 2
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will repeat until the start signal is switched off if spare 2 and spare 3 (X11 - 2,3) are
maintained off. But if spare 2 is on, then heat 2 becomes seam 2. If spare 3 (X11 - 2)
is switched on, then heat 2 becomes seam 3. If both are switched on (X11 - 2,3) then
heat 2 becomes seam 4. When the start signal is dropped, then the solenoid valve
will shut off.
The seam welding sequence time chart is shown below:
V. Stepper Function
In order to compensate for the current reduction produced by electrode wear
and tear, our welding control has a function that allows the current to increase in
steps. The user can step-wise increase the electric current a total 10 times according
to the current situation. This function involves a couple parameters: increasing the
electric current, increasing the gap between welds, increasing the electric current in
steps, increasing the weld count in steps, and notifying the point of step increase.
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1. Increasing the electric current: The process of increasing the current
correlates to the electric current settings for the total capacity of the electric
current. Range 0-999.9%.
2. Increasing the gap between welds: Electric Current steadily increases the
weld count for the welding process. Range 0-999.9%.
3. Increasing the electric current in steps: Each increase of each section
correlates to the total electric current capacity percentage increase (current
increase). For example, one step increases the electric current quantity of
Section 1 by 1%, the final result of this increase in Section 1 is (1 + electric
current increase X 1%) X the value of the welding current setting.
4. Increasing the weld count in steps: Each step increases the spot number of
the section each step occupies to increase the spot number percentage
during its process, for example 1% C, each step increases the spot weld
number of Section 1 to occupy the percentage of the total spot count.
Therefore the step increases in the spot number of section 1 = the interval X
1% C.
5. Notifying the point of step increase: Before each step increase process
completes the Nth spot it will inform the user that the process is about to
finish.
6. Electrode early warning: During the last sharpening process, when it is about
to terminate, N spot before the end it will raise a warning beforehand, namely
the electrode warning spot, its value range 0-9999.
7. Number of times electrode sharpened: The user can set the total number of
times to sharpen the electrode according to each actual situation.
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