OPERATION MANUAL

Micro-Computer based Standard Welding Controls

FC-24V/H
 TABLE OF CONTENTS

1.0 OUTLINE AND FEATURES

1.1 OUTLINE ························································································ 4
1.2 FEATURES AND BENEFITS ····························································· 4

2.0 CONSIDERATIONS FOR USE

2.1 PRECAUTIONS ON OPERATING ENVIRONMENT ··························· 4
2.2 PRECAUTIONS FOR INSTALLATION ··············································· 4
2.3 OTHER PRECAUTIONS ····························································· 4

3.0 RATINGS AND SPECIFICATIONS

3.1 RATINGS AND SPECIFICATIONS ··················································· 5

4.0 NAME AND FUNCTION OF EACH SECTION

4.1 FRONT PANEL ·············································································· 6
4.2 REAR PANEL ·············································································· 7
4.3 DIMENSIONS AND PANEL CUTOUT ··············································· 8
4.4 OPENING THE CASE ···································································· 9
4.5 BLOCK DIAGRAM ········································································ 10
4.6 CONNECTIONS ·············································································· 11
4.7 OPERATION SETTING ·································································· 12
4.8 OPERATION TIME CHARTS ···························································· 12

5.0 SCHEDULE DATA TABLE

5.1 SCHEDULE DATA TABLE ······························································· 15
1.0 OUTLINE AND FEATURES

1.1 OUTLINE
1.1.1 The FC-24 is a compact, high performance controller with microcomputer and
can be applied to all resistance welding machines. It is also lightweight and rug-
ged panel mount type.

1.2 FEATURES AND BENEFITS

1.2.1 LED display method allows operator to see all parameters at a glance. It is also
very easy and simple to operate.
1.2.2 With Up/Down Slope function and 2 stage welding current method, it is appli-
cable to all resistance welding.
1.2.3 Vertical type and horizontal type are produced to increase consumer choice.

2.0 CONSIDERATIONS FOR USE

2.1 PRECAUTIONS ON OPERATING ENVIRONMENT

2.1.1 Environment affected by strong vibration or impact
2.1.2 In chemical atmosphere or in areas directly affected by chemicals
2.1.3 Near a high-frequency noise-generating source.
2.1.4 Places with a lot of dust, corrosive gas, or direct sunlight.
2.1.5 The FC-24 is not waterproof or oil resistant. Do not use it in locations subject to
water or oil.

2.2 PRECAUTIONS FOR INSTALLATION

2.2.1 Do not apply a source voltage higher than the rated value.
2.2.2 Ground the machine securely for the safety matters of operators
2.2.3 Do not install input lines in the same duct or conduit as power supply or other
high-voltage lines. Doing so may result in malfunction due to noise. Separate
the input lines from high-voltage lines
2.2.4 Internal elements may be destroyed if a voltage outside the rated voltage is
applied.

2.3 OTHER PRECAUTIONS

2.3.1 Do not wipe the backside of the controller with a water-soaked towel. It may cause
malfunction.
2.3.2 Do not push the touch keys on the front panel with a pointed instrument such as a
screwdriver
2.3.3 Do not disassemble or modify the controller without our written permission. We
are not responsible for any problems caused by disassembly or modification.

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3.0 RATINGS AND SPECIFICATIONS

3.1 RATINGS AND SPECIFICATIONS

ITEM FC-24V, FC-24H
Weld Power 200~240VAC/380~480VAC
Control Power 100~240VAC
Frequency 50/60Hz
Indication 7-Segment LED Display
Operation Mode Spot, Twin Head Spot, Butt, Seam & Brazing
Weld Counter 0 ~ 9999 counts
SCHEDULE 0 ~ 9 schedules
SQUEEZE 0 ~ 99 cycles
UP SLOPE 0 ~ 9 cycles
WELD 1 0 ~ 99 cycles
COOL 0 ~ 9 cycles
Program
WELD 2 0 ~ 99 cycles
Parameters
DOWN SLOPE 0 ~ 9 cycles
HOLD
0 ~ 99 cycles
OFF
CURRENT 1
0.0 ~ 99.9%
CURRENT 2
Control Method Phase Control by Thyristor
Operation Mode Input Mode 1, Mode 2
Start Input Start 1, Start 2
Thermo Input SCR & Transformer Thermo Switch
Hold End Output Relay Contact Output, One Short (0.2 sec)
Valve 1, Valve 2
Pressure Valve Output
Control Voltage Output (100 ~ 240VAC)
Memory Retention More than 10 years after power failure
Ambient Temperature -10 ~ 55℃ (with no icing)
Storage Temperature -25 ~ 85℃ (with no icing)
Ambient Humidity 35% ~ 85% RH (with no condensation)
76mm(W) x 194mm(H) x 208mm(D)
FC-24V
3.0"(W) x 7.6"(H) x 8.2"(D)
Dimensions
194mm(W) x 76mm(H) x 208mm(D)
FC-24H
7.6"(W) x 3.0"(H) x 8.2"(D)

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4.0 NAME AND FUNCTION OF EACH SECTION

4.1 FRONT PANEL

FC-24H WELDING CONTROL

19 17 18
SQUEEZE UP.S WELD 1 COOL WELD 2 DN.S HOLD OFF COUNT
AUTO WELD
CLEAR
2 3 4 5 6 7 8 9
22 23 21

SCHEDULE CURRENT 1 CURRENT 2 WELD COUNT

25 24 20
1 10 11 12 SCHE PROG
% % DULE OPER

13 14 15 16 OFF/ON
WELD POWER THERMO READY START

1. SCHEDULE : 0~9 schedule 17. AUTO (AUTO/MANUAL) button

2. SQUEEZE : 0~99 cycle Lamp ON = AUTO(Repeart)
3. UP.S (UP SLOPE) : 0~9 cycle Lamp OFF = MANUAL(Single)
4. WELD 1 : 0~99 cycle 18. WELD (WELD/TEST) button
5. COOL : 0~9 cycle Lamp ON = WELD
6. WELD 2 : 0~99 cycle Lamp OFF = TEST
7. DN.S (DOWN SLOPE) : 0~9 cycle 19. WELD COUNT CLEAR button
20. OPERATION/PROGRAM button
8. HOLD : 0~99 cycle
: To select the program and operation mode.
9. OFF : 0~99 cycle
21. ▶ Button : Preset position to right
10. CURRENT 1 : 0.0 ~ 99.9%
22. ◀ Button : Preset position to left
11. CURRENT 2 : 0.0 ~ 99.9%
23. + B utton : Data increment
12. WELD COUNT : 0~9999 count 24. - B utton : Data decrement
13. WELD POWER Lamp Operation : Control power OFF/ON button
: Lights when weld power is supplied. 25. SCHEDULE (WELD SCHEDULE) button
14. THERMO Lamp : Press to increase the schedule No. By 1.
: Lights up when thermo switch is ON.
15. READY Lamp (Weldable conditions)
WELD POWER_ON + THERMO_ON
+ WELD_ON
= READY Lamp is ON.
16. START Lamp
: Lights up when start 1,2 switch is ON.

4.1.1 PARAMETER SETTING SEQUENCE (START Lamp is OFF)

PROG PROG ① The 7-segment display is blinked when press the button.
OPER OPER
② Change the value for setting by using the button.
① ② ③
③ Complete the setting pressing the button.

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4.0 NAME AND FUNCTION OF EACH SECTION

4.1.2 SETTING OF SCHEDULE DATA

START

PROG
: Push button to start the program.
OPER

SCHEDULE : Select schedule number by this button.

: Set Squeeze, Up Slope, Weld1, Cool, Weld2,

Down Slope, Hold, Off, Current1, Current2
by this button.

YES

NO
Input of schedule 0~9 is completed?

YES

PROG
: Finish the programing by this button.
OPER

END

4.2 REAR PANEL

K1 K2 E 02 1 3 5 7 9 11 13 15
G1 G2 03 01 2 4 6 8 10 12 14 16
N.C

N.C
K1
G1
K2
G2

440V
220V
0V
100-240VAC
CONTROL POWER

VALVE COM
VALVE 1
VALVE 2
COM1
START 1
START 2
COM1
MODE1
MODE2

THERMO

OUTPUT
HOLD END

SCR WELD
POWER

The terminal block can be attached and detached.

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4.0 NAME AND FUNCTION OF EACH SECTION

4.3 DIMENSIONS AND PANEL CUTOUT (Unit : mm)

4.3.1 FC-24H (Horizontal type)

FC-24H WELDING CONTROL

SQUEEZE UP.S WELD 1 COOL WELD 2 DN.S HOLD OFF COUNT

AUTO WELD
CLEAR

SCHEDULE CURRENT 1 CURRENT 2 WELD COUNT

SCHE PROG
% % DULE OPER

OFF/ON
WELD POWER THERMO READY START

PANEL CUTOUT

4.3.2 FC-24V (Vertical type)

FC-24V WELD CONTROL

WELD POWER THERMO

READY START

SCHEDULE SQUEEZE UP.S

WELD 1 COOL WELD 2

DN.S HOLD OFF

CURRENT 1
PANEL CUTOUT

CURRENT 2

WELD COUNT

COUNT
AUTO WELD
CLEAR

SCHE PROG
DULE OPER
OFF/ON

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4.0 NAME AND FUNCTION OF EACH SECTION

4.4 OPENING THE CASE

1. Remove the back panel of two

Slide-locks.

SLIDE LOCK FOR

PANEL MOUNTING

2. Pull out the two case locking bars.

CASE LOCKING BAR

3. Gently separate the two halves of

the case.

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4.0 NAME AND FUNCTION OF EACH SECTION

4.5 BLOCK DIAGRAM

Weld Transformer

220/440VAC SCR

Pulse
Generation

Angle
Command
Micro Computer
Phase RAM ROM
Detection

Control
Power
I/O

Pressure
Panel Controller
Output

Panel Switch Display

100VAC SOL Valve Input/Output of Various Signals

(2 systems)
240VAC

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4.0 NAME AND FUNCTION OF EACH SECTION

4.6 CONNECTIONS

SCR

Inside of FC-24
G1
Weld Transformer
K1

G2

K2

E Non Connection

0V
01
Weld Power
200~240VAC
02
380~480VAC
03

1 Control Power
2 100~240VAC

3 Non Connection

4 VALVE COM
5 VALVE 1

6 VALVE 2

7 COM1

8 START 1

9 START 2
COM1
10 COM1
VCC
11 MODE 1
0V
VCC1 12 MODE 2
13
THERMO
14

15
HOLD END
16

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4.0 NAME AND FUNCTION OF EACH SECTION

4.7 OPERATION SETTING

MODE SWITCH
OPERATION
SCHEDULE REMARKS
MODE
MODE 1 MODE 2

SPOT OFF OFF 0~9

1 START 1
TWIN HEAD SPOT ON OFF
2 START 2

SEAM DN.S = 0
OFF ON 0~9
BRAZING DN.S(1~9) is Pulsation

BUTT ON ON 0~9

Note : Aftetr changing the mode switch, power OFF/ON the controller.

4.8 OPERATION TIME CHARTS

4.8.1 SPOT WELDING

VALVE 1

VALVE 2

HOLD END

CU1 CU2 CU1

SCHEDULE

SQ UP.S W1 CO W2 DN.S HO OF SQ S1 W1

START 1

START 2

START1, 2

SQ : SQUEEZE UP.S : UP SLOPE W1 : WELD 1 CO : COOL W2 : WELD 2

DN.S : DOWN SLOPE HO : HOLD OF : OFF CU1 : CURRENT 1 CU2 : CURRENT 2

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4.0 NAME AND FUNCTION OF EACH SECTION

4.8.2 TWIN HEAD SPOT WELDING

VALVE 1

VALVE 2

HOLD END

SCHEDULE 1 SCHEDULE 2
CU1 CU2 CU1 CU2

SCHEDULE

SQ UP.S W1 CO W2 DN.S HO OF SQ UP.S W1 CO W2 DN.S

DON'T CARE
START 1

DON'T CARE
START 2

4.8.3 BUTT WELDING

VALVE 1

VALVE 2

HOLD END

CU1 CU2

SCHEDULE

SQ UP.S W1 CO W2 DN.S HO OF

START 1

START 2

START1, 2

SQ : SQUEEZE UP.S : UP SLOPE W1 : WELD 1 CO : COOL W2 : WELD 2

DN.S : DOWN SLOPE HO : HOLD OF : OFF CU1 : CURRENT 1 CU2 : CURRENT 2

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4.0 NAME AND FUNCTION OF EACH SECTION

4.8.4 SEAM WELDING

VALVE 1

MOTOR
VALVE 2

HOLD END
REPEAT(DN.S=0)

CU1 CU2 CU2 CU2

SCHEDULE

SQ UP.S W1 CO W2 HO W2 HO W2 HO OF

START 1

START 2

START1, 2

4.8.5 BRAZING WELDING

VALVE 1

VALVE 2

HOLD END
PULSATION(DN.S=1~9)

CU1 CU2 CU2 CU2

SCHEDULE

SQ UP.S W1 CO W2 HO W2 HO W2 HO OF

START 1

START 2

START1, 2

SQ : SQUEEZE UP.S : UP SLOPE W1 : WELD 1 CO : COOL W2 : WELD 2

DN.S : DOWN SLOPE HO : HOLD OF : OFF CU1 : CURRENT 1 CU2 : CURRENT 2

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5.0 SCHEDULE DATA TABLE

5.1 SCHEDULE DATA TABLE

SCHEDULE 0 1 2 3 4 5 6 7 8 9

SQUEEZE

UP.S

WELD 1

COOL

WELD 2

DN.S

HOLD

OFF

CURRENT 1

CURRENT 2

Page 15
 FORWEL
34-10, Sinseon-ro 329 beon-gil,
Nam-gu, Busan, Korea
Postcode/Zip Code : 48548
Tel: +82 51 6119345
Fax: +82 050 6272580
Website: www.forwel.com
Email: [email protected]

Note: Specifications subject to change without notice. Cat. No. 190228