RFlex Travel Manual

5.1 Information and Signs of Restrictions and Imperatives 

The Manufacturer provides appropriate packaging of the machine for the time of transportation. Packaging type and durability are adapted to the distance and the means of transport, and consequently to the potential risk of damages during transportation. The Manufacturer suggests that every Client uses the means of transport and technical service personnel of the Manufacturer.

Storage of the machine does not involve any particular requirements, apart from appropriate storage environment.

The storage room must ensure sufficient protection against weather factors, it should be as dry as possible and have an acceptable level of humidity (below 70%). It is also necessary to ensure appropriate protection against corrosion, particularly regarding metal components that are not painted for technical reasons.

If the machine is supplied in a box and is wrapped in plastic generating anti-corrosion atmosphere, the machine should stay wrapped and packed for the entire storage period.

For the purposes of protection against humidity, it is recommended that the machine is not stored directly on the floor of the storage room, but rather on pallets.

A component that requires special attention and handling at every stage – including storage – is the generator lamp (triode). The lamp must be stored in its original packaging, in vertical position, with anode directed to the top or bottom, in a dry room. The lamp is a high-vacuum, metal and ceramic component, which is extremely fragile and cannot be hit or dropped even from low height.

Hitting, dropping, shaking or tilting the lamp for a longer time may and usually do result in permanent and irreversible damaging of the lamp. In particular, the filament of the lamp - cathode can be broken, which in most extreme cases can lead to internal short circuits or lamp breaking.

1. MAIN SWITCH - a switch (Fig.3) designed for switching on or off the electricity supplies. 1-ON position means that the switch is switched on whereas the 0-OFF position means that the switch is switched off.
   

   Fig.5. The arrangement of the controls and indicators on the control panel I: 2 – POWER; 3 – TWO-HAND CONTROL OFF/ON; 4 – HF; 5 – HF OFF/ON; 6 – USB; 7 – ETHERNET; 8 – RESTART; 9 – STOP; 10 – JOISTIC; 11 – START; 12 – electrode up; 13 – turn left; 14 – turn right; 14 – electrode down. 

2. POWER – an indicator, which flashes white when the machine is connected to the power supply (Fig.5). 

3. TWO-HAND CONTROL OFF / ON – a key switch (Fig.5) for the activation of the machine control mode for two hands. The switch refers to the push-buttons located on the black handles and the electrode for raising and lowering functions in the joystick. The switch in the ON position - means that in order to activate the push-buttons, both push-buttons for the same function should be pressed whereupon the joystick loses its electrode raising and lowering function. The switch in the OFF position indicates the possibility of controlling by means of a single push-button and that the electrode is raised and lowered by means of the joystick.

     ATTENTION..! Switching off the two-handed control mode makes the work operations easier; however it significantly increases accident risk. Only an authorised and correctly trained, responsible person should have the key for the on/off switch.

4. HF - when the indicator flashes yellow it means that the HF welding process is on (Fig.5). 

5. HF OFF/ON – a switch with the help of which the HF current can be released or put on hold (when it is in OFF position it means that the HF weld cannot be performed)
   As long as the standard welding procedure is concerned the HF OFF/ON switch should be in ON position.When the HF OFF/ON switch is turned to OFF position it means that the duty cycle can be performed without releasing the HF current.
   
   

6.  USB slot – a slot (Fig.5) into which a USB memory card for the storage of welding parameters and the history of messages may be inserted; this also allows the saving of the recipes stored in the HMI panel. 

7. ETHERNET slot – a slot (Fig.5) into which the Ethernet cable is connected when machine diagnosis is required online allowing internet access to the machine. 

8. RESTART – the blue push-button (Fig.5), which should be used to restart the machine control and protection system whenever the alarm message is displayed on the HMI panel. 

9. STOP – the black push-button (Fig.5) is designed for switching off the process of high frequency welding. 

10. JOYSTIC - joystick (Fig.5, Fig. 7) used for the move forward and backwards head of the welding electrode as well as machine driving to the left or to the right with a slow start for easy positioning. With joystick however you can lower or raise the electrode only when the two-hand mode is activated. There are two travel speed:

    • "slow” – (Fig. 6 – A, C, E, G) speed move determined by the parameter located in Service menu panel HMI - Drive speed MANUAL – SLOW.

    • "fast” – (Fig. 6 – B, D) speed move determined by the parameter located Service menu panel HMI - Drive speed MANUAL – FAST. 

    

    Fig. 6. Positions joystick:

    A – slow move of the head to the left, B – fast move of the head to the left,

    C – slow move of the head to the right,

    D – fast move of the head to the right,

    E – electrode up,

    F – electrode down,

11. START – the green push-button (Fig.5) is used for switching on the process of high frequency welding.

12. up arrow – two push-buttons on the black handles on the operator’s panel (Fig. 5, Fig. 7) used for activating the electrode into upper position. When the two-hand operation mode is activated, both push-buttons should be pressed simultaneously

13. left arrow - two push-buttons on the black handles on the operator’s panel (Fig. 5, Fig. 7) allowing the machine to move left. When the two- hand operation mode is activated, both push-buttons should be pressed simultaneously.

14. right arrow - two push-buttons on the black handles on the operator’s panel (Fig. 5, Fig. 7) required allowing the machine to move right. When the two-hand operation mode is activated, both push-buttons should be pressed simultaneously.

15. down arrow – two push-buttons on the black handles on the operator’s panel (Fig. 5, Fig. 7) used for activating the electrode into lower position. When the two-hand operation mode is activated, both push-button must be presses at the same time.

    

    Fig. 7. The arrangement of the controls and indicators an the control panel:

    12 – electrode up;

    13. turn left; 14. turn right;

    14. electrode down

    15. ANODE CURRENT;

    16. ELECTRODE TEMPERATURE;

    17. EMERGENCY STOP;

16. ANODE CURRENT - the panel ammeter (Fig.5) is supposed to indicate the value of current intensity in La anode circuit and should enable the operator to conduct the vision inspection of the welding process (The Generator Full-load Characteristics).

17. ELECTRODE TEMPERATURE - a thermo-regulator (Fig.6) used for the adjustment of the electrode's temperature. This controls the system which stabilizes the electrode's temperature. A push-button, Temp Regulation in the Main screen window of the touch-panel is used to activate the temperature stabilization feature. The owner’s manual referring to the E5CC temperature can be found in the attachment.

    

    Fig. 8 Control panel;

    18.– EMERGENCY STOP;

    19. - HMI;
18. EMERGENCY STOP - the red mushroom-headed push-button (Fig.5) it is a button that should be pressed only when the functions of the machine need to be halted immediately or when anything regarding the machine’s functions or the operator’s surroundings pose a threat to the production or safety.

    The EMERGENCY STOP button should not be overused, it is supposed to be used only in case of emergency.

     

19. HMI PANEL – the touch-sensitive panel (Fig.5) should be used for changing the machine’s setting parameters and it is supposed to become a reliable source of information about the current state of the welding machine. See chapter 6.6. for more information about performing the servicing procedure applying to the touch-sensitive panel.

    

    Fig.9. THE COMPRESSED AIR PREPARATION SYSTEM.

20. COMPRESSED AIR PREPARATION SYSTEM (Fig.9) – consists of:

    A. The compressed air terminal into which the compressed air hose should be connected. The hose is supposed to provide the system with the compressed air ranging from 0.4 to 0.8 MPa; 

    B. The manually operated compressed air shut-off valve (in order to open the valve - turn it to the left and set to ON position; a turn to the right - the OFF position - the valve is closed);
    C. The compressed air terminal into which the compressed air hose should be connected. The hose is supposed to provide the system with the compressed air ranging from 0.4 to 0.8 MPa; 0.6 M
    

    The level of pressure in the pneumatic system never exceeds the level of pressure propelling the machine.

D. The compressed air filter along with the condensation water release mechanism; 

Fig.10. The signal light column:

A - red color;

B - orange color;

C - green color

21. SIGNAL LIGHT COLUMN (Fig.10):

A. Red color indicates failure and at the same time the alarm message should be displayed on the HMI touch-sensitive panel.

The alarm massages are deleted and the red light on the signal light column stops flashing when the RESTART button is pressed.

In case the efforts were put in vain and the alarm message has not been deleted when the RESTART button had been pushed so it might mean that the cause of failure occurrence had not been removed yet.

See chapter 6.6.2. for further information applying to the alarm massages.

B. Orange color indicates that the high frequency welder starts operating.

C. Green color indicates that the machine is ready for work.

Fig. 11. One of the laser indicators placed on the right side of the welding head.

22. Lasers installed on the welding head (Fig. 11) used for the projection of the welding line on the welded/sealed material. Useful for placing and positioning the material along the welding line. They are switched on directly from the HMI touch-panel.

The laser is to mark the line ON the MATERIAL in the position of the electrode and its holder up. The laser DOES NOT / MUST NOT shine on the front or back edge of the electrode in its position on the material / lower.

Laser regulation procedure:

1. Put the material on the table and lower the holder with the electrode on the table,

2. Use a marker pen to draw a line outlining the front and possibly the rear edge of the electrode (if two lasers are mounted on one side),

3. Lift the electrode up and set the laser / lasers to the drawn lines, possibly with such an offset from these lines as the operator wants to position the foil,

4. Be careful that the material does not move.

Fig. 12 The bumper

23. The side bumpers installed on both sides of the welding head (Fig.9), prevent the machine from colliding with anyone or anything. Any jolt on a bumper will result in the instant disconnection of the machine’s propulsion system; this will be indicated by the message: OPEN GUARD/ EMERGENCY BRAKE.

Fig. 13 Emergency move

23. Emergency move – the switch is used to change the operating mode. In case of an obstacle and stopping on it. The switch deactivates the side bumpers and allows the exit from an obstacle. After switching the switch to position I on the HMI, the "emergency trips" window appears in which the user has the option of using the navigation arrows to pass the welding head left or right at the slow speed. Switching the switch to position 0 activates the side bumpers and restores the correct machine operation mode.

Limit switches for the height of the electrode:

• upper limit switch – when switched on (Fig. 14-A) indicates the upper electrode position. Adjustment of the slider, which activates the switch, must be done when the maximum upper position of the electrode has to be changed. If the limit switch is moved too high, it will not switch on in the upper electrode position – the welding cycle will not be finished and the machine's drive cycle will not be possible. If on the other hand, it is too low – the electrode will not be raised to a sufficient height after the weld cycle and can catch the welded material during its drive, causing damage.
• Lower limit switch – when switched off (Fig. 14-B) indicates the lower electrode position above the work table. Adjustment of the slide on this switch should be carried out each time the electrode has been replaced (when the new electrode is of a height different to the previous one) and when there is a significant change in the thickness of the welded material. The lower limit switch is also an element of the system which protects the operator’s hands from being crushed. If its adjustment is not carried out properly, the anti-crush (ZTG Anti-CRUSH) protection feature will be activated causing the automatic lifting of the electrode into its upper position. The limit switch must be placed at a height that will cause the switch’s rolling wheel to be pressed in by the lower slider of the electrode's height located on the rod from the moment the electrode touches the welded material. (Fig. 14- B).

Fig. 14 Limit switches indicating the electrode's position:

A – upper position;

B – lower position.

Adjustment procedure and determining the correct height of the lower limit switch:

• place the material to be welded on the work table,
• put the electrode into the tool holder and lock it,
• lower the electrode holder with the electrode onto the material, so that the electrode just touches it without any pressure (leave a gap of maximum 5mm / 1/8inch); leave in this position.
• move the lower metal slider on the rod to the position that will disconnect the lower limit switch (the switch roller is directly on the slider (Fig. 14- B),
• if it is not possible to set the metal slider at an appropriate height due to its step adjustment (every 15 mm), loosen the two screws holding the limit switch and move it into a lock-in position with the roller to the lower metal slider of the electrode height (Fig. 14- B), then tighten the screws.
• raise the handle with the electrode into its upper position,
• if it is not possible to set the indicator at an appropriate height due to its step adjustment (every 15 mm), loosen the two screws fixing the switch and move it into such a position that will move its roller to the lower indicator of the electrode height (Fig. 14- B), then tighten the screws. 

ATTENTION! Manipulation with the limit switch indicating the lower position of the electrode excluding the one quoted above is strictly forbidden. Disregarding the manufacturer’s warning may lead to the severe machine failure and as a result to serious body injuries.

In addition, the machine has been equipped with an additional electrode, enabling welding without the use of grounding electrode. After installing this kind of electrode in the holder and starting to lower it, an additional limit switch is activated, which inhibits the movement of the grounding electrode.

6.5 Operating Temperature Controller E5CC

Temperature control unit is used to control the temperature of the electrode. Programming the right temperature of the electrode is required to correct the course of the welding process. The temperature should be selected experimental. Below is a description of the display and control panel temperature control unit (Fig. 15).

Fig. 15. Display and control panel thermoregulatory. 

1. Display with four digit (white) which displayed actual temperature value. In parameter settings mode display present sign of edited parameter.
2. Display with four digit (green) which displayed actual ordered temperature value. In parameter setting mode display present actual value of edited parameter.
3. Control buttons:

move button. Pressing this button cause to edit next digit from edited number.

   - button „DOWN” cause low edited digit by one.

– button „UP” cause increase edited digit by one.

In the parameter edit window, go to the next parameter

Long press this button (min 3sec.) cause pass to edition mode of leave parameter. If system work in edition mode, pressing button cause return to the main window

CONTROLLER SETTINGS – ORDERED TEMPERATURE VALUE

To change ordered value need to short press button (Fig. 15) or  . It caused pass to parameter edition mode. Available number which will be edit is signalize by quick blinking its. By buttons “UP” or „DOWN” set value of this number, next press „move” button , which move to next position to edition. 

6.6  Programming and Operating the HMI Touch-Sensitive Panel

ATTENTION! Each value of the parameter depicted on the graphics of this manual is taken at random and should be disregarded by the machine’s operator. The values of the parameters should derive from user’s practical experience as they may vary profoundly according to the type of welded material or implemented instrumentation.

In the HMI panel all editable values of the parameters are displayed on a white colour background. In order to display a parameter the user needs to press its value and as a result the on-screen keyboard should be opened. Data can be saved by pressing Enter key.

6.6.1 Connection to Power Source

Shortly after the machine is connected to a power source on the HMI display an alarm window appears along with the following message:

#A001 EMERGENCY STOP 

#K001 PRESS RESTART BUTTON 

According to this situation, the machine needs to be restarted so the blue RESTART key should be pressed. Then we need to wait for 30 seconds till the machine is ready for work and enters a stand-by mode which we know due to the following facts: a light indicator in the light signal column flashes green and the progress bar displayed in the HMI main window flashes green. In case the alarm massage does not disappear from the HMI display see chapter 0.

6.6.2 Alarm Messages

The types of alarm massages:

#A001 EMERGENCY STOP – this kind of message is displayed when:

• the machine is switched on - the machine’s safety circuit must be always checked when the RESTART key is pressed,
• the red mushroom-headed EMERGENCY STOP push-button was pressed and has been jammed. It needs to be unstuck by turning its head to the right.

#A002 TUBE TEMPERATURE – this type of massage means that either the travelling-wave tube cooling does not exist or that the cooling system failure occurs and it is displayed when:

• the fuses that are supposed to protect the power supply circuit of the fan which should cool down the travelling-wave tube are disconnected;
• the contactor that is supposed to trigger the fan that should cool down the tube is either turned off or damaged;
• the tube thermal protection system is put into operation which means that the travelling-wave tube got heated up to too high temperature and as a result the tube band cotter pin that had been connected to the limit switch by a cord got unsoldered.
  
  
  Fig.16. The tube thermal protection system.
  A cotter pin is soldered to a tube band with the help of a solder of melting point much lower than the one at which the tube got overheated (got damaged). If the lamp temperature rises too much the cotter pin will fall out of the band and as a result the limit switch will be triggered, simultaneously the alarm message will be displayed and the power supply for a glow in the tube will be cut off. Then the cause of overheating should be removed.

ATTENTION! The cord should not be fastened to any other parts of the machine but the cotter pin of the band which had been screwed to the tube. Disregarding the quoted warning can result in a limit switch blockage which may lead to the travelling-wave tube overheating and in consequence of such proceeding to its damage.

If the cotter pin gets separated from the band than the band should be taken off from the tube, the pin should be soldered to the band with the standard solder used in electronic engineering (Melting point < 190^oC) so as to the repaired part could be reattached to the tube.

The tube overheating can be caused by:

• the dirt found either in the generator or in the tube radiator;
• the failure of the tube cooling fan or the failure of the fan power supply system;
• the blockage of the machine’s ventilating holes or by the excessive amount of soil collected by the filters installed in the ventilating holes;
• the excessive ambient temperature.

#A003 ANTIFLASH – this type of massage means that the protection system against an arc-over while welding was triggered - due to this message make sure neither the insulating pad, welded material nor the welding electrode had not been damaged.

#A004 ANODE OVERLOAD – this message means that the anode-rise limit was exceeded so the parameters applying to the power released in weld need to be adjusted.

#A005 GRID OVERLOAD – this message means that the grid-rise limit was exceeded so the parameters applying to the power released in weld need to be adjusted.

#A006 LOW AIR PRESSURE – this message means that there is lack of air pressure or the level of air pressure is too low in the pneumatic system. Make sure the hose providing the compressed air is connected to the machine or the level of compressed air is appropriate and then with the help of pressure reducing valve regulator which can be found in the compressed air preparation system adjust the pressure in the machine to the adequate level.

#A008 ELECTRODE IS NOT IN UPPER POSITION –. the message will be displayed if the welding electrode is not in the upper position after switching on the machine. Check the tightness of the pneumatic system and the correct setting of the limit switch indicating the upper position.

#A011 ELECTRODE TEMPERATURE – this message signals that the set point electrode temperature on the thermoregulator has been exceeded – the machine will be disabled into emergency mode. You should wait until the electrode cools and then check whether the temperature setting on the temperature controller is too high. Another possible option is that the electrode's warm up circuit has broken down. The manufacturer’s service should be contacted in such a case.

#A013 WELDING PARAMETERS NOT REACHED – the machine's control software includes an algorithm which checks whether each partial weld has been properly carried out. If, during the welding, the parameters set out have not been achieved or if welding has been stopped before the task has been completed, the above message will be displayed. The quality of the weld will then be checked and if unsatisfactory, the task must be repeated.

#A019 SENSOR / DRIVE ERROR - ELECTRODE DOWN - the alarm message will be displayed when, after actuating the valve coil, the controller will not receive confirmation from the sensor confirming the achievement of the lower position within 15 seconds. Check whether the sensor has not moved or check that the pneumatic system is close to the actuator.

#A020 SENSOR / DRIVE ERROR - ELECTRODE UP - the alarm message will be displayed when, after actuating the valve coil, the controller will not receive confirmation from the sensor confirming the achievement of the upper position within 15 seconds. Check whether the sensor has not moved or check that the pneumatic system is close to the actuator. 

#A032 START CAPACITOR POSITION NOT ACHIVED – the message will be displayed if the capacitors do not reach the preset position within 15 seconds. Check the capacitor drive.

#A034 EMERGENCY ELECTRODE UP – this message is displayed when the electrode holder which was being lowered upon the work table encountered an obstacle on its way and the protection system against squeezing hazard was put into practice. Make sure there is not anything between the electrode and the work table. If the alarm message does not disappear the adjustment of the switch limit indicating the lower electrode position needs to be conducted. See chapter 6.4. for more information applying to the switch limit adjustment procedure.

#A035 CHECK RESET CIRCUIT IN SAFETY RELAY – means that the safety circuit of the machine has probably been damaged. The manufacturer’s service should be contacted in such a case.

#A046 CURRENT NOT IN TOLERANCE DURING WELDING - this message will be displayed if the current value cannot be reached during operations. The algorithm checks if the anode current has been met. The anode current obtained must be within +/- of the tolerance range of the anode current value for a given percentage of the time for the duration of the welding, specified in the Service Window after choosing Welding process control option.

#A047 DOWN FORCE NOT IN TOLERANCE DURING THE WELDING -this message will be displayed if, during welding, the current downforce falls outside the tolerance range specified in the Service Window after choosing Welding process control option.

#A053 EMERGENCY BRAKE – This message is displayed when the safety switch is pressed. When the mushroom switch is activated in an emergency, the head will suddenly - and violently - brake.

#A054 SAFETY VALVE DAMAGE – This message is displayed when the sensor (marked with the symbol 10B1 on the electric diagram) of confirmation piston valve in the appropriate position is activated. This sensor is located on the safety valve (marked with the symbol 1V3 on the electric diagram). If the piston of safety valve does not reach the correct position, it means that the valve is not working properly.

#A055 SERVO ALARM – this signals an error in the Y-axis drive. Restart the machine and, if the message does not disappear, check the alarm number displayed on the servo and check the description in the servo-drive directory.

#A056 LOW AIR PRESSURE IN SUPPORTING CYLINDERS – means that air pressure in the servomotors supporting the electrode is too low which can result in a rapid lowering of the electrode and it hitting the bench. Adjustment of the compressed air pressure in the circuit of these servomotors should be carried out.

#A057 WELDING POSITION NOT REACHED - the alarm message will be displayed when, after controlling the valve coil, the controller will not receive confirmation from the sensor confirming the achievement of the set position within 8 seconds. Check whether the sensor has not moved or check the tightness of the pneumatic system at the actuator.

#A058 THE ELECTRODE IS NOT LOCATED IN A LOWER POSITION – the alarm message will be displayed if the START button is pressed and the electrode is not in the down position. Lower the welding electrode onto the material.

#A059     TABLE - ERROR OF SET DRIVE POSITION – The alarm message will be displayed if the controller does not receive confirmation from the sensor that the desired position has been reached within 8 seconds of the valve coil having been actuated. Check that the sensor is in position and also check the air tightness of the actuator.

#A060 EMERGENCY REBOUND - AXIS X START/END – The alarm message #A061 X-AXIS BASING ERROR is displayed, together with the alarm, when the end switch, located on the head, is activated. At that moment, the head will deflect and the system will blow.

#A061 AXIS X HOMING ERROR – The message is displayed when the end switch, located on the head, is activated. This may be due to the operator having entered an incorrect, table length value- i.e. one higher than the actual length- in the Movements settings in the service menu . A basing error may also occur in the case of an active endpoint after basing.

#A062 SET PRESSURE HAS NOT BEEN ACHIEVED – The message will be displayed if the specified value of the pressure parameter is lower than the lower tolerance range, specified in the service window in the control parameters of the welding process.

#A063 EMERGENCY REBOUND - AXIS Y START/END - The alarm message #A061 Y-AXIS BASING ERROR is displayed, together with the alarm, when the end switch, located on the head, is activated. At that moment, the head will deflect and the system will blow.

#A064 AXIS Y HOMING ERROR – The message is displayed when the end switch, located on the head, is activated.. This may be due to the operator having entered an incorrect “Axis Y up limit” value- i.e. one higher than the actual value- in the Movements settings in the service menu. A basing error may also occur in the case of an active endpoint after basing.

#A075 DRIVE ERROR – the alarm message will be displayed when an alarm occurs on the inverter. If the alarm can not be delete, check the alarm number displayed on the inverter display and check its explanation in the technical documentation of the manufacturer.

#A076 OPEN GUARD - is displayed when one of the shields was taken off - the shields are equipped with the key- switches that turn themselves on only if the shields are appropriately placed and tightened.

#A077 DRIVE COMMUNICATION ERROR – the alarm will be displayed if there is no communication PLC = Inverter. Check that the cable connectors are not removed.

#A080 INCORRECT LENGTH OF WELDING – an alarm message will be displayed if the weld is impossible to make, because the length of the weld is greater than the length of the table it means if the operator wants to start the cycle in BA drive mode but entered the weld length for AB mode. Check:

• the head is at the beginning of the table, or at the end depending on the choice of the AB-BA drive mode,
• passing parameters have been entered correctly in the HF HEAD DRIVE window,

• the actual table length is correctly entered in the SERVICE MENU window.

#A102 LEFT BUMPER – COLLISION - the message is displayed when the left side bumper is activate. In case of stopping in an obstacle (bumper active), turn the EMERGENCY MOVE switch deactivate the emergency system and use the HMI to move the head exit the obstacle.

#A103 RIGHT BUMPER – COLLISION - the message is displayed when the right side bumper is activate. In case of stopping in an obstacle (bumper active), turn the EMERGENCY MOVE switch deactivate the emergency system and use the HMI to move the head exit the obstacle.

6.6.3 Alarm Screen - Emergency Move

The EMERGENCY MOVE window is displayed when the emergency switch is switched to position I (Fig. 13 Emergency move). In the window, the operator has the option of passing the welding head right or left at slow speed. The movement of the head is done by means of navigation arrows indicating the direction of travel.

Fig. 17 Emergency move

Operation on the machine is only possible when the EMERGENCY MOVE switch is in position 0.

Menu can be found in the upper part of the HMI touch-sensitive display panel with the help of which the User can choose one out of five main virtual windows such as:

• Main screen
• Recipes database
• Power setting
• Work graph
• Service menu

 6.6.5 Main Screen

Fig.12. Main screen.

Recipe - under this name a group of parameters applying to the duty cycle can be found. Once the welding parameters for the particular kind of product deriving from practical experience (the parameters’ values strongly depend on the size of weld, the size of welded material and the electrode’s shape) are established they should be entered in the system and saved under the recipe’s name.

ATTENTION! It is important to remember that in spite of the fact that the above mentioned parameters can be saved under the recipe’s name in the HMI touch-sensitive panel there is also another parameter - ELECTRODE TEMPERATURE that should be adjusted manually.

Additionally, two values next to each parameter’s name can be also found on the HMI display. The first one (on the blue background) is the value of present operating parameter displayed in the actual time, the second one (on the white background) is the set value coming from the production recipe or the operator’s data.

Should the need arise, the operator can always press the digit on the white background and change its value. The value of present operating parameter will be updated at once, though, the change does not affect the executed recipe.

In order to save those changes to a recipe which were made using the Main screen, press the SAVE RECIPE button to copy the parameters from the main screen to the Edit recipe bar in the Recipe database window. The parameters copied may be saved as a new recipe using the Create new button or they can be used to update an existing recipe using the Update button.

The red sign on the HMI panel in the main window Fig. 19 indicates that the machine is not ready for operation. The buttons on the HMI panel and on the operator panel are inactive until the operator reboots the machine with the blue RESTART button on the operator panel. Selecting the RESTART button has the same effect as attaching the safety circuit and starting the sub-up process of the generation lamp for 30 seconds. During this time, the progress bar gradually turns green (Fig. 20), and the buttons allow the head to pass on the X and Y axes while the buttons allowing the head to drop over the workbench are active; however, it is not possible to switch to high frequency. Once the progress bar is completely green, a READY sign will appear on the progress bar and from that point, all buttons, including the high frequency, activation buttons, will be active.

Fig. 19 Information NOT READY displayed on HMI panel

Fig. 20 Progress bar gradually filling in green after selecting RESTART button on the control panel

Name: - the recipe’s name executed for production purposes.

Initial power – this parameter indicates the position (capacity) of the output capacitor found in the generator; the anode current intensity in the initial phase of high frequency weld strongly depends on the value of this parameter. (Parameter expressed in percentage values, where 0% indicates the lowest level of capacity - the lowest level of anode current intensity and 100% indicates the highest level of capacity - the highest level of anode current intensity.)

The parameter’s value of Initial power and the value of anode current (power released in material) are not linearly dependent as a result the appropriate precautionary measures should be taken when adjusting values of this parameter. 

The current value of Initial power parameter and the value of set parameter are equal to each other only in the initial phase of the welding procedure. When the procedure is initiated, the output capacitor’s position is automatically adjusted in order to achieve Operating power.

Operating power [A] – this parameter indicates Ia anode current used for welding. (Parameter expressed in ampere values ranging from 0 to 4 A.)

Values in green color on the Anode current meter’s scale indicate the acceptable values of the Ia anode current. 

When the welding procedure is initiated the output capacitor (Initial power) is automatically adjusted so as to achieve the Operating power.

Delay time [s] – this parameter indicates time during which the electrode had adhered to the welded material before the weld was initiated. (Parameter expressed in second values ranging from 0 to 99 s.)

Welding time [s] – this parameter means time the machine takes to process the high frequency weld. (Parameter expressed in second values ranging from 0 to 99 s.)

Cooling time [s] – this parameter indicates time in which the electrode was being pressed against the welded material after the weld had come to an end - material cools down being pressed against the table. (Parameter expressed in second values ranging from 0 to 99 s .).

Power level [0-6] – is the main setting of the machine's power; adjustment is carried out by changing the anode voltage Ua in the range from 1 to 6 where 1 is low power and 6 is maximum power:

0 - the anode transformer is disconnected;

1 – Ua = 3,4kV;

2 – Ua = 3,95kV;

3 – Ua = 4,75kV;

4 – Ua = 5,87kV;

5 – Ua = 6,85kV;

6 – Ua = 8,2kV;

Pressure [bar] – the parameter indicates compressed air pressure in the pneumatic system of the electrode clamping as expressed in bars; the parameter determines the electrode down-force in relation to the material during welding.

Work mode [0/1] – The parameter defining the welding work mode. 0 value indicates that the machine is working in ‘Time’ welding mode. 1 value indicates that the machine is working in ‘Current’ welding mode. A detailed description of the “Time” and “Current” operating modes is provided on pages 71-72 of the documentation.

Regulation mode [0/1] – The parameter defining the range of automatic adjustment mode of the output capacitor. Typing 1 value (MAX mode) switches it into full automatic adjustment mode of the output capacitor. 0 value (MIN mode) means that during welding, the output capacitor is adjusted only when the anode current exceeds the value inserted in the Power max parameter. A detailed description of the MAX and MIN operating modes is provided on page 72 of the documentation.

Options:

Work mode standby / work

- green button means that the machine is turned on and ready to work, work during normal operations.

 - orange button means that the machine is in standby mode. This mode is used to swathing the machine to mode sleep, which gives the possibility to the heating of the electrode before the work shift.

A reference situation:

A working shift lasts from 7:00 am - 3:00 pm.

The Operator ending the shift at 3 p.m. must NOT turn the machine off at the MAIN SWITCH and must NOT press the EMERGENCY STOP button; he/she should only put the machine into STANDBY mode. The STANDBY MODE window then opens (Fig. 21). The operator sets the electrode heating, switch- on time in this window, in the table ‘ELECTRODE FOR HEATING SETTINGS FOR STANDBY MODE’; in our case, heating is to be active from 6:40 to 7:00.

The operator then leaves the machine. This setting will cause the machine’s electrode to engage at 7 each day, as indicated, in order to allow efficient operation from the beginning of the shift and thereby facilitating welding of repeatable qualitny. The above situation is shown in the following graph.

Fig. 21 Standby mode window 

Electrode open / closed

- an open padlock on the red background indicates that the welding electrode was not closed in its holder, when you press the grey closed padlock the holder will be closed.

  - a closed padlock on the green background indicates that the welding electrode is closed in its holder, when you press on the grey open padlock the holder will be open.

Temp Regulation off / on

  - push-button signals that the electrode temperature stabiliser is switched on, pressing the push-button turns off temperature stabilization.

- push-button signals that the electrode temperature stabilizer is switched on, pressing the push-button turns off temperature stabilization.

Turning on temperature stabilisation results in the maintaining of a stable temperature level and a repeatable weld quality.

Light off/on

  - a lamp which does not glow on the red background indicates that the work table lighting in the welding zone is switched off, when you press the grey glowing lamp, the lighting will be switched on.

- a glowing lamp on the green background indicates that the work table lighting in the welding zone is switched on, when you press the grey lamp, the lighting will be switched off.

Laser 1 off / on

  - push-button  signals that the laser indicator 1 is switched off, pressing the push-button  turns on the  laser indicator 1.  

- push-button signals that the laser indicator 1 is switched on, pressing the push-button turns off the laser indicator 1.

Laser 2 off / on

  - push-button  signals that the laser indicator 2 is switched off, pressing the push-button  turns on the laser  indicator 2.  

- push-button  signals that the laser indicator 2 is switched on, pressing the push-button  turns off the laser indicator 2.

In the standard, the laser indicator denoted as Laser 1 is located on the left side of the welding head and Laser 2 on its right side, looking from the front of the machine, that is, from the control panel side / operator's side.

Work Mode

Current / Time

- the electric circuit on the green background indicates that the machine is working in ‘Current’ welding mode; pressing the grey clock indicates that the machine will enter the ‘Time’ welding mode. ‘Current’ welding mode indicates that the machine’s counter has started counting high frequency weld time, which was entered in the Welding time parameter, as soon as the machine recognizes the appropriate value of the la anode current which should either exceed or be equal to the value entered in the Work current parameter. To put it differently, in Current welding mode, the welding time equals the sum of both the value of the time the machine takes to produce the anode current- that is, the value entered in the Operating power parameter- and the value of time entered in the Welding time parameter.

If the machine does not manage to produce Operating power within 25 seconds, the duty cycle will be discontinued.

- the clock on the green background indicates that the machine is working in ‘Time’ welding mode; pressing the grey, electric circuit indicates that the machine will enter ‘Current’ welding mode. The ‘Time’ welding mode indicates that high frequency weld time is equal to the value entered in the recipe’s parameter under the name Welding time.

It is worth noticing that in ‘Time’, welding mode, the duty cycle can be executed even if the machine has not managed to produce Operating power. The result of this will be that the weld achieved may be of irregular strength.

Regulation Mode min / max

  - push-button  signals that the machine is working in limited automatic adjustment mode of the output capacitor; pressing the  push-button switches it into full automatic adjustment mode of the output capacitor. The min mode means that during welding, the output capacitor is adjusted only when the anode current exceeds the value inserted in the Power max parameter.

  - push-button  that the machine is working in full automatic adjustment mode of the output capacitor; pressing the  push- button switches it into limited automatic adjustment mode of the capacitor. The max mode means that during welding, the output capacitor is adjusted automatically so that the anode current is at the level set in the Operating power parameter.

Drive Mode – the welding head can work in five passage modes:

  - operation at the site mode – the machine works stationary (welds in the same place without moving). None of the passage parameters are active.

  - working mode from left to right without return – the machine makes a weld at the length set moving to the right and remains at the place of the last weld when the task is completed.

  - working mode from right to left without return – the machine makes a weld at the length set moving to the left and remains at the place of the last weld when the task is completed.

  - working mode from left to right with return – the machine performs welds along the length set moving to the right and returns automatically to the place of the first weld when the task is finished.

  - working mode from right to left with return – the machine performs welds along the length set moving to the left and returns automatically to the place of the first weld when the task is finished.

set to base axis X - the button starts the process of homing the X axis - determining the zero point for the travel of the head. To start, hold down the button. The homing process is indicated by the button blinking. When the button turns green and stop blinking, the process is finished. During the proces homing, the welding head moves to the left until the limit switch operates and bounces off the limit switch by the length set in the program.

set to base axis Y - the button starts the process of homing the Y axis - determining the zero point for the travel of the head. To start, hold down the button. The homing process is indicated by the button blinking. When the button turns green and stop blinking, the process is finished. During the proces homing, the welding head moves to the front until the limit switch operates and goes to the base position ( about the middle of axis).