Original Instructions: German

Translation of Original Instructions

Operating Panel AWS3 System

OP-AWS3
TP-AWS3

OPERATING INSTRUCTIONS

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Annex:
- Safety Regulations
- General References on Resistance welding
- Contact addresses

Valid for SW version V6.5.0 and higher:

OP-AWS3 TP-AWS3

Version Date Basis of Revision

1.0 2007-06 new

1.1 2010-07 General Information: restricted functions

2.0 2015-02 Completely revised, new: TP-AWS3

2.0a 2015-09 Changes due to new company name

2.1 2016-05 Chap. 4.13: new user ‘engineer’; corrections

Copyright  2016:
AMADA MIYACHI EUROPE GmbH
Lindberghstr. 1, 82178 Puchheim, Germany

Right to make amendments reserved. Deviations may occur. All rights reserved.
The products named in this manual are only used for identification purposes and may be trademarks
or registered trademarks of the respective companies.

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General Notes

Contents

1 General Notes ...................................................................................................... 5

2 Technical Description .......................................................................................... 6
2.1 Technical Data ....................................................................................................................6
2.2 Functional Overview AWS3 Basic - AWS3 Advanced ....................................................7
3 Construction and Mode of Action ...................................................................... 8
3.1 Saving Data.........................................................................................................................8
3.2 Toggle Wheel at OP-AWS3................................................................................................9
3.3 Touch screen at TP-AWS3 ..............................................................................................10
3.4 LED Status Displays ........................................................................................................10
3.5 Screen (Display) ...............................................................................................................11
3.5.1 Display Windows – Quadrants 1 to 4 ...........................................................................................12
3.5.2 Menu Bar......................................................................................................................................... 12
3.5.3 Program Display ............................................................................................................................ 12
3.5.4 Status Bar ....................................................................................................................................... 12
3.5.5 UNDO Function .............................................................................................................................. 12

4 Operation: How to… .......................................................................................... 13

4.1 Perform General Settings................................................................................................13
4.2 Perform System Settings ................................................................................................16
4.2.1 Reset to Default .............................................................................................................................. 16
4.3 Adjust Closed-Loop Control Parameters ......................................................................17
4.4 Configure Display Windows (Quadrants) ......................................................................18
4.5 Set Welding Parameters ..................................................................................................19
4.5.1 Current Profile ................................................................................................................................ 19
4.5.2 Force Profile ................................................................................................................................... 19
4.5.3 Advanced ........................................................................................................................................ 20
4.6 Adjust Displacement Settings ........................................................................................22
4.6.1 Reference Run ................................................................................................................................ 22
4.6.2 Basic Position ................................................................................................................................ 23
4.6.3 Waiting Position ............................................................................................................................. 23
4.6.4 Search Position .............................................................................................................................. 24
4.6.5 Part Detection ................................................................................................................................. 24
4.6.6 Weld to Limit Mode ........................................................................................................................ 25
4.7 Determine Limit Values ...................................................................................................25
4.7.1 Determine Real Time Limit Values................................................................................................ 26
4.8 Generate Reference and Envelope Waveforms ............................................................27
4.8.1 Generate Reference Waveforms ................................................................................................... 28
4.8.2 Generate Envelope Waveforms .................................................................................................... 29
4.8.3 Manage Envelope Waveforms ...................................................................................................... 30
4.8.4 Compare Measuring and Envelope Waveform ............................................................................ 31
4.9 Edit Programs and Parameters ......................................................................................32
4.9.1 Copy Programs and Parameters ..................................................................................................32
4.9.2 Save All Programs and Parameters.............................................................................................. 32
4.9.3 Load All Programs and Parameters .............................................................................................32
4.10 Count Measurements (Weld Counter) ...........................................................................33
4.11 View and Save Measuring Waveforms ..........................................................................34
4.12 Print or Output Measurement Values ............................................................................35

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4.13 Set and Change Passwords ............................................................................................36

4.14 Configure Measured Value Indication (LOGGER) ........................................................38
4.15 Monitor Parameter Overview ..........................................................................................39
4.16 Analyze Accept – Reject Ratio........................................................................................40
4.17 Monitor Statistical Values ...............................................................................................40
4.18 Define Limit Values Statistically .....................................................................................41
4.19 Weld with Action Counter ...............................................................................................42
4.20 Transfer Data to PC/Laptop ............................................................................................43
4.21 Make a Screenshot ..........................................................................................................43
4.22 Update Firmware ..............................................................................................................44
4.23 Adjust Ethernet Settings .................................................................................................45
4.23.1 Configure the Interface .................................................................................................................. 46
4.23.2 Connect to a Shared Folder .......................................................................................................... 46
4.23.3 Create a Shared Folder .................................................................................................................. 48

5 Configure Interfaces .......................................................................................... 49

5.1 Modbus/TCP .....................................................................................................................49
5.1.1 Connection ..................................................................................................................................... 49
5.1.2 Settings ........................................................................................................................................... 49
5.1.3 Controlling the Weld Cycle ........................................................................................................... 50
5.1.4 Parameter Service Channel ........................................................................................................... 54
5.2 Profibus/DP – EtherNet/IP ...............................................................................................54
6 Calibration - Adjusting ...................................................................................... 55
6.1 Force Calibration .............................................................................................................55
6.2 Distance Calibration ........................................................................................................59
7 Configuring Pneumatic Weld Heads ................................................................ 61
7.1 Set the Weld Parameter Pressure ..................................................................................61
8 Problem Solving ................................................................................................ 62
8.1 Trouble Shooting .............................................................................................................62
8.2 Error Messages in Status Bar .........................................................................................63
9 Index ................................................................................................................... 64

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1 General Notes

Information about safety regulations, symbols, copyrights, protection rights,

usage location conditions and notes on resistance welding can be found in the
back section of these operating instructions.
Please read this information carefully before using these operating instructions.

These operating instructions should help you familiarize yourself with the system and
take advantage of its application possibilities when used as directed.
It contains important notes to help operate the unit safely, properly, and economically.
Observing these notes will help avoid risks, decrease repair costs and down times, and
enhance reliability and service life of the unit.

As a general rule: safety first!

Warning

Incorrect or inappropriate configuration, installation, settings, handling or use can cause

mechanical, electrical or thermal hazards, which may result in serious damage or injury.
Ensure the correct execution of these points and follow the respective notes in the
Danger operating instructions.

Do not put the system into operation before you have read the operating instructions!

Danger Persons with cardiac pacemakers and metallic implants are prohibited from
approaching to within a radius of at least 5 m of welding equipment!

Crushing Hazard
There is a risk of crushing during the adjustment movement due to closing electrodes,
stops for limiting adjustment or stroke movement and the stop on the basic pincers unit
Warning for limiting floating movement.

This Class A welding equipment is not supposed to be used in living quarters, where
the power supply is carried out by a public low voltage supply.
There it can be difficult to ensure electromagnetic compatibility because of conducted or
Warning radiated disturbances.

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2 Technical Description
There are two models of control panels available for the AWS3 system:
OP-AWS3 with toggle wheel
TP-AWS3 with touch screen
With the control panel all connected devices are controlled
(e.g. motor control MFP-NC and inverter power source ISQ).
For more information about these devices see the respective operating manuals.
The control panel consists of:
• the display window, which can be divided into 4 free configurable parts (quadrants)
• 8 LED status indicators
• a USB port for a USB stick
• and a toggle wheel (OP-AWS3 only)

display window

LED status
indicators

toggle wheel
(OP-AWS3 only)

USB port

Screenshot

remove USB stick

2.1 Technical Data

Type of device Control panel AWS3
Measuring pause variable
Graphic display VGA, 640 x 480 Pixel
Optical indications 8 front LEDs
Ambient temperature 0 °C to 40 °C
Relative humidity max. 70 %
Dimensions OP-AWS3:
 Housing w 228 x h 144 x d 78 mm
 Housing incl. projection w 228 x h 188 x d 78 mm
TP-AWS3:
 Housing w 292 x h 198 x d 75 mm
 Housing incl. projection w 292 x h 198 x d 100,5 mm
Weight OP-AWS3: approx. 1,7 kg (approx. 3,7 lbs)
TP-AWS3: approx. 3,6 kg (approx. 7,9 lbs)

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2.2 Functional Overview AWS3 Basic - AWS3 Advanced

OP-AWS3 and TP-AWS3 are available in two versions:
 Basic
 Advanced

Functional overview: Basic Advanced

Convenient setting of parameters and limit values for up X X
to 99 programs (Dual 49)
Saving of data on a USB stick (parameter/limit value X X
settings)
Numeric display and static monitoring X X
Digital I/O interface X X
Serial data output (logging of measurement data: numeric X X
parameters and status) via RS232
Screenshot function X X
Various (password protected) user levels adjustable X X
Flexible I/O configuration and monitoring X X
Graphical displays X
SPC (Statistical Process Control) X
Calculation of limit values via SPC evaluation X
Dynamic monitoring (envelope waveforms) X
Logging of measurement data on USB stick X
Advanced analysis functions X
Modbus/TCP interface X
Advanced bus interface optional
(Profibus/DP or EtherNet/IP)
Ethernet interface X X
Firmware update function X X

Not all functions described in this manual are available in the basic version.

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Construction and Mode of Action

3 Construction and Mode of Action

3.1 Saving Data
Via the USB port you can save data and parameters on a USB stick.
We recommend using only industrial standard USB sticks (like the one included in the
scope of the delivery).

Avoid performing fast cyclical saving in a row on the USB stick.

This can affect the function and in the long run damage the data medium.
Caution

Loss of Data!
Disable the USB stick before you remove it from the PC in order to use it in the AWS3
control panel.
Caution
Press the disable button on the control panel before you remove the USB stick from the
panel.

Individual operator configurations remain stored even when the device is switched off.
Numerical measured values are buffered in the device. Buffer size is adjustable. If buffer
size is set at a higher number than 0, measured values are exported automatically to the
set external data medium (USB stick or LAN network) when buffer is full.
Buffered numerical measured values remain stored even when device is switched off.
Measured waveforms are not buffered permanently.
It is possible to output selected parameters of each welding to a commercial printer with
a serial connection. To do this, connect the printer to connector X17 (RS232 interface).
Set desired output format and baud rate in screen MENU – GENERAL.
Select with the toggle wheel (see chap. 3.2) resp. via the touch screen (see chap. 3.3).

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3.2 Toggle Wheel at OP-AWS3

The toggle wheel is the central operating element of the OP-AWS3.
All settings are done via the toggle wheel:

• Select menu items by rotating the toggle wheel. The field containing the cursor is
always highlighted in red.
• By pressing the toggle wheel (in the following referred to as ‘clicking’), the selected
element (switch, selected field, quadrant, ...) is chosen resp. activated/deactivated.
• Grayed out option points or parameters are disabled and cannot be selected.

The following elements are input fields:

• Buttons, which trigger a certain action when pressed
• Switches, which have two switching conditions
(black = on / active; gray = off / inactive)
• Selection fields that allow selection from a list of options. By clicking once you can
choose between the options. By clicking again the selected value is stored.
• Entry fields which allow entering numbers.
By clicking once you change to quick edit mode where you can change the whole
number at once. Double-clicking changes to precision edit mode (the single digit is
highlighted in red and can be changed individually). Double-click again to store the
set value and leave precision edit mode.

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3.3 Touch screen at TP-AWS3

The touch screen is operated as usual: touch the respective field/switch with a finger or a
non-metallic blunt object.

Input of numeric values:

Enter numeric values by a fade-in numeric keyboard.

Operation of LED controls:

Select an LED control by tapping on it (LED is highlighted in red). By subsequent tapping
the state of the LED can be toggled (red – blue indication).

Operation of graphic controls:

By tapping on a graphic control an indication line or a graphic cursor will be set
(according to selected function). The graphic cursor can be replaced by tapping on the
graphic waveform or it can be reset by clicking on ‘cursor’.

Operation of teach mode (see chap. 4.6.1):

The teach mode (in MENU – DISTANCE – ADVANCED) can be operated by
continuously pressing the ‘+’ or ‘-’ button. The axis is moving in parametrizable steps
(like a step motor).

Quick acknowledgement of faults and other status messages:

By directly tapping (repeatedly if required) onto the message in the status line.

Shutdown after switching off:

The touch panel initiates a shutdown procedure after switching off the power of the
system. The graphic display of the panel is deactivated immediately. The LED ‘USB /
LAN’ indicates the duration of the shutdown phase, in which the panel must not be
switched on again. If you switch on the system too early, it needs to be switched off
again to initiate a new start.

3.4 LED Status Displays

READY AWS3 ready
TRIGGER1 Measurement activity on axis 1
TRIGGER2 Measurement activity on axis 2
FAULT Device error or sequence fault
ACCEPT Welding within set limits
PREWARN Device or sequence related warning
REJECT Welding outside of set limits
USB/LAN USB stick missing (LED flashing) or access to USB stick (LED
remains lit)

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3.5 Screen (Display)

① ② ③

⑤
⑥
⑦
⑧
⑨
⑭ ⑩
⑪
⑫

⑬
The screen (Display)

1. Display quadrant 1 (Q1) 9. Button for parameter overview

2. Display quadrant 2 (Q2) 10. Button for analysis
3. Menu bar 11. Shows current operation mode
4. Program number selection 12. Status bar for status, help and fault
5. Button „START“ messages
6. Button “STOP” 13. Display quadrant 4 (Q4)
7. Button for logging 14. Display quadrant 3 (Q3)
8. Button for configuration menu

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3.5.1 Display Windows – Quadrants 1 to 4

The measured values can be shown in four fully configurable display windows
(quadrants).
Each quadrant can show the values in one of the following display modes:
• numeric
• graphical
• SPC* chart * SPC: Statistical Process Control
• SPC values
Click on one of the quadrants to see an enlarged and more detailed view of this quadrant
with possible additional settings.
Special feature of the numeric display mode:
After a measurement the measured value can flash in red.
This means, the measured value is outside of the set limits.

3.5.2 Menu Bar

The menu bar includes:
• Display/Setting of the current program number
(1 to 99 at 1 axis mode, 1 to 49 at 2 axes mode)
• Buttons for selecting displays and operation mode
• Display of the current operation mode (SINGLE/AUTO)

3.5.3 Program Display

Shows the number of the welding program currently active:
1 to 99 at 1 axis mode, 1 to 49 at 2 axes mode)
Program selection via toggle wheel or touch screen.

3.5.4 Status Bar

Depending on the control elements selected, the status bar shows:
• Information on the last measurement (axis 1/2) (in black color)
• Help text containing details about the control elements selected (blue)
• General information messages / status messages (purple)
• General error messages (red)
• Error messages concerning device and process faults (dark red)

3.5.5 UNDO Function

The menu bar offers the UNDO button for all screens where parameters can be set or
changed.
With this button you can undo the last (up to 50) settings in this screen one by one.

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Operation: How to…

4 Operation: How to…

4.1 Perform General Settings
After starting-up and initialization the main menu is displayed.
(If main menu is not shown, click on MAIN in the menu bar.)

First perform general settings.

To do this click on MENU in the menu bar.
Screen SETTINGS opens.

Click on GENERAL.
Screen GENERAL opens.

Hereinafter the adjustable basic settings are shown:

LANGUAGE
Choose your language.
UNIT
Choose units of measure:
• for force measurement F: N or lbs
• for pressure measurement p: bar or psi
• for displacement measurement s: µm or th“ (thousandth inch)

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PROGRAM SELECTION
Choose the measuring program selection:
• internal (default) means with the toggle wheel or touch screen or via a connected
bus system
VIEW PROGRAM LIST
Activated: shows a program list with program number and name (can be set via
MENU – COPY – PROGRAM NAME) when you click on the program number
selection field in the menu bar.

• ext./MFP means by external hardware input at connector X112 of MFP-NC

• ext./HFI means by external hardware input at connector X1 of ISQ.
RENEW MAIN VIEW
Refreshing the main view takes time, so if you use external program selection
deactivate this feature in order to speed up the program changeover.
Also deactivate this feature if you configure quadrant windows for SPC. These SPC
quadrant windows have to be configured in the same way for each program;
otherwise the SPC chart will be reset.
Deactivation of this option is therefore advantageous when rapidly switching
programs and using the SPC charts, as the main display has to be configured only
once.
I (Program input) and O (Program output) can be set to binary coded decimal (BCD) or
binary (BIN).
LIST SEPARATOR, DECIMAL SIGN
Data are stored in a CSV (comma separated value) compatible format.
To read this data with e.g. Excel, the sign used for the list separator and the decimal sign
on the AWS3 has to be the same as the one used on your PC.
Choose between semicolon (;) and colon (,) for the list separator and between point (.)
and colon (,) for the decimal sign.
Note:
You can find the signs used on your PC in the regional settings (system settings).

RS232
Set transmission rate and output format of the RS232 interface.
The set transmission rate has to correspond to the transmission rate of the serial
interface of your PC or printer.
Output format:
• off
serial output is switched off.
• AWS3 style
Default (numerical output with parameter denomination)
• AWS3 without header (optional)
numerical output without parameter denomination
• classic style
without header (backwards compatible with older MFP-NC motor controls)
• user style (optional)
specific version with output of minimum and maximum values.

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DATE
Set the current date in the format YY-MM-DD (year-month-day).

TIME
Set the current time in the format HH:MM:SS (hour:minute:second).

GRAPHIC VIEW
Enables graphic viewing (ON/OFF). For continuous fast clock rate disable this function,
to prevent clock rate from slowing down when changing to display with graphic view.

COMMUNICATION SETTINGS
Adjust the settings for communication via Ethernet, Modbus/TCP or bus modules.

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4.2 Perform System Settings

To perform system settings you have to be logged in as Configurator (see chap. 4.13).

Go to screen SYSTEM via MENU – GENERAL - SYSTEM.

Shows general system information, e.g. information about:

• type of power supply (HFI), e.g. ISQ20-3K
• type of motor head (MFP) e.g. MFP400
• control panel (RAM assignment, USB stick memory capacity, software version of
control panel)
DATA LOCATION
Choose data location for programs and parameters
(USB device or LAN network).

After a restart or reset of the control panel data location is set to USB device by default.
Do not use internal, as this is reserved for remote maintenance.

For a function check of the LEDs click LED TEST.

All LEDs on the front panel will light up shortly.
With a double click on LED TEST a pop-up appears that shows the state of the LEDs in
the set language.

4.2.1 Reset to Default

Only use PARAM RESET, if you have no other choice left. Before doing this save all set
parameters on the USB stick.
After using PARAM RESET the system parameters of the AWS3 are no longer valid and
it may not be operated in this state.
Therefore a valid system backup must be loaded after the reset (see chap. Fehler!
Verweisquelle konnte nicht gefunden werden.)!

Loss of data!
If you perform PARAM RESET, all set parameters will be lost!
Caution

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4.3 Adjust Closed-Loop Control Parameters

Go to screen WELD CONTROL via MENU – CONTROL – HFI.
This menu is password protected (see chap. 4.13).
Here you can change the closed-loop control parameters Kp and Ti of the weld control for
Current, Voltage and Power.
The welding curve closed-loop control is a simple P-I controller. The associated
coupling factor Kp (0.0...50.0) and the integration time constant Ti (0.1...100.0ms)
can be set separately for the three different closed-loop controls. Adjust the closed-loop
control in such a way that oscillations in the curve progression are prevented.
These values also depend on the length of the secondary cables and the distance
between them, and the resistance of the welding head and weld material. They can be
optimized by test weldings.

Adjustment:
Set Kp very low, and Ti very high (1).

Now increase Kp until the curve overshoots

at the start (2).

2
Turn back Kp briefly until the curve
smoothens.
Reduce Ti continually until the curve
becomes uneven.
Now turn back lightly until it is smooth (3).

P-4-0

Align the inverter on the basis of the secondary circuit you are using and the intended
purpose by test weldings.
Examples:

For welding operations with a 3 kA inverter and a 6 kA inverter in the lower range:
Type Kp Ti / ms
Current 6 4,0
Voltage 3 2,0
Power 3 2,0

For welding operations with a 6 kA inverter in the upper range:

Type Kp Ti / ms
Current 6 6,0
Voltage 3 5,0
Power 5 3,0

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4.4 Configure Display Windows (Quadrants)

The measured values can be displayed in four configurable display windows
(quadrants).
Each quadrant can be operated in four different display modes.

Go to screen VIEW via MENU - VIEW.

QUADRANT
Select quadrant 1…4 to be configured.
Each quadrant can show only one measured variable.
AXIS
Select the axis to be shown.
VIEW
Select the way the measured variable shall be displayed in this quadrant:
• numeric – numerical display of the value with limits
• graphic – graphical display of values as a curve
(here you can also select the color of the graph)
• SPC*-chart – graphic as statistical run chart
*SPC: Statistical Process Control
• SPC-values – numerical as mean value, standard deviation CP (process suitability)
and CPK (level of production)
Select the measured variable for this quadrant:
PULSE TIME tw (weld time per pulse)
tw~ (weld time in cycles at alternating current)
CURRENT Is Ieff
VOLTAGE Us Ueff
DERIVATES P W R
DISTANCE s1 (part detection) s3 (Displacement value)
MOVEMENT F v
PULSE FOR VIEW (with numerical display)
Select whether values for first (1) or second (2) pulse shall be shown.
Button <-
Switch to next quadrant.
VIEW IN STATUS LINE AXIS 1/2
Select display of the status line.

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4.5 Set Welding Parameters

4.5.1 Current Profile
Go to screen SCHEDULE via MENU – SCHEDULE.
Depending on the set control mode, current, voltage or power is specified as rated value.
The adjustable amplitude ranges differ for the 3 control modes.

The second welding pulse is specified by setting the amplitude of PULSE 2 at a higher
number than zero.
If second welding pulse shall be repeated one or more times, set the desired number of
repetitions (2 to 10) into field 1x. PULSE 2 is then repeated this many times. The
repetition time thus specifies the waiting time between the repetitions.

Only one overall current time of up to 620 ms can be set for each welding pulse.

4.5.2 Force Profile

A force profile is specified to which the current profile is subordinate (only for versions
with servo welding head). The search force has to be set high enough to enable the
head to clearly identify the part and not retract prior to this.

The following should also be specified:

- debounce time (after which part control should occur in the case of search forces)
- welding force 1 (force value for squeeze time and pulse 1)
- welding force 2 (force value for cooling time and pulse 2) and
- holding force (force value for hold time)

Squeeze time and cooling time should be adequately long to allow for the build-up of
welding force and any transient effects!

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4.5.3 Advanced
Click on ADVANCED.

PROGRAMMABLE VALVE
Controls the valve output user-defined (not during dual head operation without MFP-NC).

TOOLS/APC
Is a collection of tools for optimizing welding and active part conditioning.

• Active Part Conditioning (APC)

APC is used for welding contaminated and oxidized surfaces.
It uses the double pulse function of the inverter and parameter monitoring. Thereby
the first pulse prepares (conditions) the surface and checks the conductivity. The
second pulse carries out the real welding.
Settings:
Set first pulse to power [KW] or voltage [V] in screen SCHEDULE. Select amplitude
high enough and time long enough to achieve penetration of the oxide with high
voltage.

The current is monitored. For this set measuring mode to current [A].
Welding current of first pulse starts to flow and increases.
Set a value for the current limit to be monitored which will at most lead to a tacking
weld or adhesion of the components. Each time the first pulse reaches this limit it is
interrupted. As a result a specific current path is created on the components.

In this way varying levels of contamination / oxidation are balanced out and only lead
to pulses of different lengths. If contamination/oxidation is so severe that the desired
current value is not reached within the set 1st pulse time an error signal is emitted in
APC mode.

Components prepared in this way are welded with the second pulse after the rest
time. To do this, select parameters (current and time) which ensure sufficient
welding of the cleared surfaces.

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• Pre-Weld-Check
Checks the conductivity of the future weld. Welding is performed with current [A]
while voltage [V] is monitored.
The following values should be observed:
 Current set to approx. 1/10 of welding current
 Welding time set short, i.e. 5 - 10 ms
The voltage of the first pulse increases if resistance of the weld material is too high.
The first pulse is shut off as soon as the upper voltage limit is reached and an error
message is output. The welding process continues if the measurements remain
within the limit values of the first pulse.

• Weld Limit
Welding is only permitted within the set limits. If these limits are exceeded, an error
signal is output and the welding is interrupted.
Here you can also use the Energy [Ws] setting, i.e. the content of the sector below
the power waveform is added up until it reaches the limit value.

• Weld to Limit
The first and second pulse can be set separately in the welding parameters, the
measuring mode is normally set to Energy. Otherwise a ramp should be set. The
current is switched off when the ramp reaches the upper limit.
Here you can also use the Energy [Ws] setting, i.e. the content of the sector below
the power waveform is added up until the limit value
The pulse is deactivated as soon as the upper limit is reached and the program
switches to next pulse, if parameterized. No error signal is generated!
If no deactivation occurs at the upper limit during the current time, an error signal is
generated.

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4.6 Adjust Displacement Settings

4.6.1 Reference Run

In order to avoid damage to the electrodes and the welding equipment a reference run
should be done:
• prior to the initial welding operation
Caution
• after every change to the electrodes (weight, angle, position, etc.)
• after every change to the welding head

Go to screen DISTANCE (ADVANCED) via MENU – DISTANCE – ADVANCED.

Change to single step mode and activate REFERENCE POSITION.

Click on START in the menu bar and a reference run is performed. Now reference data
is shown in the respective field and REFERENCE POSITION is automatically
deactivated.
Reference data remains saved until a new reference run is performed or the value in the
field right beside REFERENCE POSITION is changed manually.
The validity range of the reference point is determined by selecting global or program.

During a reference run the distances between search- and wait position resp. basic
position can change, so it can happen that due to an unfavorable (high) position of the
lower electrode these positions are limited to the basic position.
If you don’t want this, activate CHECK REFERENCE POSITION and an error message
is generated.

The same procedure has to be carried out after an electrode change!

Afterwards all settings (part control, basic position, waiting position and search position)
are automatically adjusted.

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Teaching positions (only with servo weld heads)

• Click on ◄►
• By turning the toggle wheel (OP) or by using +/- (TP) you can adjust the electrode in
the desired direction.
• Move the servo weld head to the desired position and again click on ◄►.
• Now select the corresponding position, e.g.
POS_WAIT, POS_SEARCH, PART_MIN or PART_MAX.
• Click the APPLY button and repeat this procedure until all position are programmed.

With INCREMENT+/- you can set the traversing increment for the teach movement. The
traversing increment influences the traversing speed and accuracy.

Motor head traversing by using the toggle wheel and teaching of positions is only
possible in Single Step Mode!

In Teach Mode it is possible to compress the electrodes with the welding head. The
greater the search force, the greater the increase in the squeeze force exerted on the
electrodes.
Caution
This can lead to motor overloading!

4.6.2 Basic Position

Go to screen DISTANCE via MENU – DISTANCE.
Click on HOME.
If previously a reference run on the lower electrode was carried out, the basic position is
within the negative range, as the zero position is on the lower electrode.

Select a basic position in which the welding stroke is not too short! Use the waiting
position for cycle time optimization. This protects the motor and the mechanism of the
system as a lubricating stroke is automatically carried out after every 1000 welding
operations.

4.6.3 Waiting Position

Go to screen DISTANCE via MENU – DISTANCE.
Click on WAIT.
If a reference run was carried out previously it can be corrected here. To move to the
waiting position you must set the assigned input.

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4.6.4 Search Position

Go to screen DISTANCE via MENU – DISTANCE.
Click on SEARCH.
The search position should be selected in a way that ensures that the weld head
switches to search run before it reaches the part or the electrode.

If the search position is too short, the head may collide with the work piece at high
speed, which can cause serious damage to the system and its parts!
Warning

4.6.5 Part Detection

Go to screen DISTANCE via MENU – DISTANCE.

Select PART and enter the lower part detection limit. Select the undermost gray field and
set the upper part detection limit.

If you have defined PART-MIN and PART-MAX in teach mode in the DISTANCE –
ADVANCED menu, you can optimize or overwrite them here.
Rated Value Displacement
Enter the rated value for the displacement (penetration depth) in the WELD TO field. If
this value is reached, the current in the corresponding weld pulse is turned off
immediately.
Displacement Limits
Enter the upper and lower displacement limits in the DISPLACEMENT field.

If you mixed up the values for upper and lower limit, the system automatically swaps out
values.

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4.6.6 Weld to Limit Mode

Go to screen ADVANCED via MENU – DISTANCE – ADVANCED.
Click MODE and choose the mode for measuring the displacement or for specifying the
deactivation distance.

• ABSOLUTE
Displacement is relative to the absolute position at the start of penetration.
• REFERENCE
Displacement is relative to the position defined by the reference run (assumed that a
reference run was carries out before).
• RELATIVE
Penetration depth is specified relative to the position at the start of the welding pulse.

For welding on residual thickness the weld to limit mode must be set to REFERENCE!

PULSE 1/2 SEPARATED

Activate this switch to set or monitor the displacement and the deactivation distance for
pulse 1 and pulse 2 separately.
OFFSET UNTIL WELD FORCE
Set the part recognition offset between search force and weld force.

4.7 Determine Limit Values

Go to screen LIMITS via MENU – LIMITS.

Two indicators to be monitored can be specified for pulse 1 and pulse 2 for each axis.
After each measurement the values of these indicators are evaluated and
• shown by the LEDs on the front side of the unit,
• recorded (logged) and
• made available on the digital outputs on the rear side of the unit.

Determine the upper and lower limits for the desired indicators (Is, Ieff, Us, Ueff, P, W, R,
tw, F)
Limit value monitoring of the corresponding indicator is deactivated if MAXIMUM and
MINIMUM are set to zero.
RESET
Resets the limit values to zero.

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4.7.1 Determine Real Time Limit Values

Go to screen REALTIME via MENU – LIMIT VALUES – REALTIME.

One indicator to be monitored can be specified for pulse 1 and pulse 2 for each axis.
The evaluation during the measurement
• is made available on the designated digital outputs on the rear side of the devices.
After each measurement the evaluation is
• shown by the LEDs on the front side of the unit
• recorded (logged)
Determine the upper and lower limit values for the desired indicator (I, U, P, W).
Limit value monitoring of the corresponding indicator is deactivated if MAXIMUM and
MINIMUM are set to zero.

tbeg / tend
Set the beginning and end point of the monitoring
RESET
A pop-up appears with the following options:
YES reset the limit values to zero
NO terminate the process
DEFAULT reset the limit values for the rated values (of the weld profile) to default
(+/-20%).

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4.8 Generate Reference and Envelope Waveforms

A reference waveform is the mean waveform derived from n trial welding operations. It
can be seen as a reference for an optimal welding operation.

Go to screen MONITORING ENVELOPE WAVEFORMS via

MENU – LIMITS – ENVELOPE.

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4.8.1 Generate Reference Waveforms

Click to REFERENCE WAVEFORM in the screen MONITORING ENVELOPE
WAVEFORM to generate a reference waveform.

PEN
Assigns a color to an indicator.

NUMBER
Indicates the number of measurements (1…99) out of which the arithmetic average
value shall be derived.
RECORD
Activate RECORD.
When a measurement is carried out, it can be used for calculating the average value by
clicking on ACCEPT, the value for NUMBER will then automatically decrease by 1.
Repeat this process until all measurements are made.

Activate the ACCEPT ALL button to use every triggered waveform for the calculation of
the average value, until the value in the NUMBER field is zero.

I_001.ref
File name for the generated reference waveform.
Reference waveforms have the file extension .ref.

After all measurements have been made the reference waveform is automatically saved
on the USB stick.

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4.8.2 Generate Envelope Waveforms

An envelope waveform is based on a reference waveform and is used for additional
monitoring of a weld variable.

Click to ENVELOPE WAVEFORM in the screen MONITORING ENVELOPE

WAVEFORM to generate an envelope waveform.

If a reference waveform was previously generated it will appear in the dialogue field and
you can skip the step SELECT.
SELECT
Opens an existing envelope waveform (*.ENV) for editing or a reference waveform
(*.REF) to determine an envelope waveform by yourself.
INTERVAL
A vertical white line appears on the screen. You can move it by rotating the toggle wheel.
Choose the position at which the monitoring interval or time slot should start and confirm
by clicking.
A second white line appears which you can also move by rotating the toggle wheel.
Click again to define the end of the time slot.

In the first input field next to OFFSET enter the lower limit value of the envelope
waveform and confirm with OK.
In the second input field next to OFFSET enter the upper limit value of the envelope
waveform and confirm with OK.
Now the envelope waveform is fully configured and can be saved or edited again.

DESCRIPTION
Enter a name for the envelope waveform.
SAVE
Saves the envelope waveform on the USB stick.

Screen INPUT WAVEFORM NO. opens. Enter a number for the envelope waveform and
confirm with OK.

Now the envelope waveform is saved with the number on the USB stick.
ARCHIVE
Archives the envelope waveform. This will make the envelope waveform load into the
corresponding control and be accessible for monitoring.

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4.8.3 Manage Envelope Waveforms

Click to LOAD in the screen MONITORING ENVELOPE WAVEFORM to load an
envelope waveform from the USB stick into the control’s archive.
Screen SELECT WAVEFORM opens. Select a waveform and confirm with OK.
The waveform selected will now be loaded.

To save an envelope waveform from the archive onto the USB stick, select a waveform
and click SAVE.

Screen INPUT WAVEFORM NO. opens. Enter a number for the envelope waveform and
confirm with OK.
Now the waveform is saved with the number on the USB stick.
RENAME
You can change the name of the envelope waveform in the archive.
DELETE
The envelope waveform selected in the archive is deleted after repeated confirmation.

If no envelope waveform in the archive is selected, all archived envelope waveforms will
be deleted!
Caution

To use an envelope waveform from the archive for monitoring, select an envelope
waveform and click MONITOR.
Then enter a monitoring number (as waveform 1 or 2). Each program can monitor a
maximum of two envelope waveforms.
After you have confirmed with OK the name of the envelope waveform selected will
appear on the screen beside the corresponding number.
This envelope waveform is now assigned to the current program for monitoring.

ON/OFF
Switch the monitoring on/off.

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4.8.4 Compare Measuring and Envelope Waveform

Click to COMPARE in the screen MONITORING ENVELOPE WAVEFORM to compare
the loaded envelope waveform with the currently measured waveform.
Screen COMPARISON opens.
AUTOSCALE
Sets the image mode.
If the button is activated, scaling is automatically selected which generates the best
image of the current envelope waveform.

If the button is deactivated, the ZOOM enlargement mode is activated, which also
activates the buttons in the lowest line of the screen.

By activating AUTOSCALE the selected indicaator is automatically adapted to suit the

diagram the best possible.

Zoom Menu
YMAX / YMIN
Click YMAX or YMIN to set the upper or lower scale value of the Y-axis for the selected
envelope waveform.

XMAX / XMIN
Click XMAX or XMIN to set the upper or lower scale value of the X-axis (time) for all
shown indicators.
Y<-> / X<->
Set a range for enlarged display.
Click Y<-> or X<-> and a white line appears. Move the line by rotating the toggle wheel.
Click to determine the beginning of the display range.

A second white line appears which initially lies on top of the first line. Rotate the toggle
wheel until the second line has reached the end of your desired display range. Enlarge
the diagram by clicking.

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4.9 Edit Programs and Parameters

Go to screen COPY PROGRAMS via MENU – COPY.

4.9.1 Copy Programs and Parameters

SOURCE
Enter number of source program.
DESTINATION
Enter the number of the first and last target program to which the source program and all
parameters shall be copied to.
COPY
Starts the copy process.
COPY AXIS
Copy the settings from axis 1 to axis 2 (1  2) or vica versa (2  1) by clicking the
respective button.

4.9.2 Save All Programs and Parameters

SAVE ALL
A popup INPUT PROGRAM NAME opens.
Enter a file name and start the saving process by clicking OK.
Parameter files have the file extension *.PAR.

To save the welding parameter settings use the PARAMETER backup mode. To back up
your system set the SAVE MODE to Backup. A system backup is only recommended
prior to a firmware update or after the unit has been delivered.

4.9.3 Load All Programs and Parameters

LOAD ALL
Screen SELECT FILE opens. Select a file and click OK to load it.
To load a system backup set the SAVE MODE to Backup.

The backup file must be compatible with the current system settings, otherwise the
backup will be interrupted and an error massage will appear.
If previously a RAM Reset was carried out you may have to log in as CONFIGURATOR
(see chap. 4.13) in order to install the required backup.

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4.10 Count Measurements (Weld Counter)

You can define the method of counting the weldings for axis 1 and 2.
When reaching the set pre-warning value and reaching the final value (counting direction
+) or zero (counting direction -) the corresponding signal will be made available at the
digital output on the rear side of the unit.
Go to screen COUNTER via MENU – COUNTER.

ON/OFF
Enables/disables the counter for the respective axis.

MODE
Select counting direction:
• Plus (+) counts forwards, from zero to the set END VALUE.
• Minus (-) counts backwards, starts at the set START VALUE.

END VALUE
Last plus counter value.
START VALUE
First minus counter value.
PREWARN
Pre-warning value of active counter.
RESET
Resets the counter.

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4.11 View and Save Measuring Waveforms

In the main view, click on the quadrant that is configured for displaying graphics. The
quadrant will open into a full image.

PEN
Select the color and the desired measurement variable in the corresponding field beside.
Select “–“ if you don’t want to display a measurement variable.

The variable entered at last will be the primary measurement variable to which the
scaling of the y-axis will refer to.
The primary measurement variable is displayed in the heading.
AUTOSCALE
Sets the image mode.
If the button is activated it automatically selects scaling that generates the best image of
the current quadrant measurement variable. The primary measurement value is
displayed in the heading.
If it is not activated, the viewing, enlarging and memory submenus are activated.

By activating AUTOSCALE the measurement variable selected is automatically adapted

to suit the diagram the best possible.

▲ and ▼ (arrows)
Click on the downward pointing arrow ▼ to switch to the submenus (SETPOINT
PROFILE, Zoom Menu, CURSOR and SAVE).
Click again for the next submenu and so on.

To get back to the previous menu click on the upward pointing arrow ▲ on the left-hand
side of the screen.
SETPOINT PROFILE
If a setpoint profile already exists choose the value in which it should be displayed
additionally.

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Zoom Menu
Click on ▼ to switch to the Zoom Menu.
YMAX / YMIN
Define the upper/lower y-axis scale value for the primary measurement variable selected
in the PEN field by clicking YMAX and YMIN.
XMAX / XMIN
Define the upper/lower x-axis scale value for all measurement variables displayed by
clicking XMAX and XMIN.
Y<-> / X<->
Define a range for enlarged display.

Click Y<-> or X<-> to make a white line appear. Rotate the toggle wheel to move the
line. Press the wheel to define the beginning of the display range.
A second white line will appear which will initially be lying on top of the first line.
Rotate the toggle wheel until the second line has reached the end of your desired display
range. You can enlarge the diagram by clicking.
CURSOR MENU
Click on ▼ to switch to the CURSOR menu.
Select a measurement variable by clicking on it.
A crosshair (cursor) in the color assigned to the measurement variable appears on the
screen. With the toggle wheel you can move the cursor on the graph. The value pair
belonging to each measurement value will be displayed numerically in the bottom of the
screen.
Click again to exit Cursor mode.

SAVE MENU
Click on ▼ to switch to the SAVE menu.
Save all measurement values of individual or all measuring waveforms on the USB stick.
Select a measurement variable by clicking on it.
Allocate a number to the measurement waveform with which it is saved.
The files are saved on the USB stick in the folder Waveform with the file extension .crv.
The corresponding formula symbol of the measurement variable will be put in front of the
file name.
Click into the view screen to get back to the main view.

4.12 Print or Output Measurement Values

Via the serial interface you can connect a PC with PECO-Software (WinWeld) – for the
evaluation of the data – or a printer.
In the GENERAL screen (see chap. 4.1) you can adjust required settings such as baud
rate and mode by clicking on RS232. In the Classic style mode the serial output has
backwards compatibility with earlier versions of MFP-NC motor control and ISQ.
The data format of the serial output can be found in the description of the respective unit.

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4.13 Set and Change Passwords

Go to screen PASSWORD via MENU – PASSWORD.

LOGIN, LOGOUT
Log in or log out.

For safety reasons we recommend to change all preset passwords after the
commissioning via CHANGE!
Caution

Changes can only be done if you are logged in with the correct password!
If you have forgotten your password please contact our service team.

Incorrect settings/changes can cause faulty operation and serious damage to the
system, for which we assume no liability!
Warning

CHANGE
Each user can change his password.
If you are logged in as SUPERVISOR, you can also change the passwords for
OPERATOR and ENGINEER.
If you are logged in as CONFIGURATOR, you can change all passwords.
Choose the user level in the field next to it and set/change the password in the pop-up
window.

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STATE
Shows the level of your access authority:
• OPERATOR
Authorized to edit the welding amplitude.
Recommended for system operator.
Password on delivery: 0001 (for safety reasons we recommend to change the
password via CHANGE after commissioning).

• ENGINEER
Authorized to edit certain process parameters and characteristics of the display
configuration.
Recommended for advanced system operation.
Password on delivery: 0002 (for safety reasons we recommend to change the
password via CHANGE after commissioning).

• SUPERVISOR
Authorized to set relevant process parameters and characteristics of the display and
unit configuration.
Recommended for system setup.
Password on delivery: 0000 (for safety reasons we recommend to change the
password via CHANGE after commissioning).

• ELECTRODE CHANGE
Authorized to make a reference run and to set the respective parameters.
Password on delivery: 0003 (for safety reasons we recommend to change the
password via CHANGE after commissioning).

• SERVICE
Authorized to update software, calibrate and change selected system parameters.
Recommended for maintenance and system setup.
Password on delivery: 0004 (for safety reasons we recommend to change the
password via CHANGE after commissioning).

• CONFIGURATOR
Authorized to set all process parameters and perform comprehensive display and
unit configuration, including further configuration options.
Recommended e.g. after a firmware update.
Only necessary in exceptional cases, password has to be requested separately.

The password for the CONFIGURATOR cannot be changed, so please be careful with
this password!

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4.14 Configure Measured Value Indication (LOGGER)

Click on LOGGER in the menu bar.

ON, OFF
Enables/disables the taking of measurements (measurement value logging) for the
selected axis AX.

SAVE
Saves all values measured up until now in a log file on the USB stick or the LAN network
(depending on the settings in the SYSTEM screen, see chap 4.2). If there is not enough
memory space on the stick you will be asked to change the stick.
QUERY
Sets the way in which the logged data is displayed:
• All measuring
• Rejected measuring
• Last measuring (detailed)
• Faults indicates occurring faults
• Overloads indicates motor faults that have occurred
AX
Select axis 1, 2 or 1 / 2 (the last is only possible in “last measurement” mode).
P
Select pulse 1, 2, 3 or 1 / 2.
VALUE
Select the measurement variable which is supposed to be displayed.

On the screen the following indicates:

Gray Background = measurement is okay
Red Background = measurement exceeds the limit values
Gray Font = measurement exceeds the measurement range
You can scroll through the logging history by using the arrows ▲ ▼

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Additional information relating to individual measurements is displayed in the detailed

view (last measurement).
It displays:
• which measurement variable has exceeded the limits
• the direction in which the limits were exceeded
• what kind of monitoring led to the error message

The symbols mean:

+ exceeded upwards
- exceeded downwards
± exceeded in both directions
HK the current measurement waveform is partially or completely outside of the
waveform activated for this measurement
RT real time limits

The logger can save a maximum of 1500 measurements per axis in the internal memory.
Afterwards the contents will be saved in a log file and the logging starts anew.

The log file has the file suffix .log and a format compatible with CSV, in which time, date,
counter number, program number, measurement variables and status information on the
measurement are stored in the form of a table.
In the log file the overall status of the measurement is illustrated with the following
symbols:
V positive measurement,
X negative measurement, indicating the measurement variable causing the problem
+ and - indicate the direction in which the limit value was exceeded. () indicates
exceeded pre-warning limits, while {} indicates the exceeding of a limit determined by an
envelope waveform.
BUFFER (is only displayed in last measurement mode)
Set the number of measurements after which the data saved internally shall
automatically be stored in the log file.
If you set the number to 0, automatic saving of the log file to the USB stick is
deactivated. Saving via the SAVE button is still be activated though.

4.15 Monitor Parameter Overview

Click on PARAM in the menu bar.
AXIS 1
Click on AXIS 1 to toggle between axis 1 and 2.

SAVE
Saves the parameters in a text file on the USB stick.
The file will have the file extension .txt.

The text file is saved as a UTF8 text format.

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4.16 Analyze Accept – Reject Ratio

In the menu bar, click on MAIN and then on ANALYSIS.
RESET
Resets all counters for the axis selected.

DETAILS
Specify the accept – reject ratio by activating one of the following buttons:
• ENERGY
Limit value monitoring for configurable power source parameter settings
• s3
Limit value monitoring for displacement
• s1
Limit value monitoring for part detection
• tw
Limit value monitoring for welding time

4.17 Monitor Statistical Values

Requirements for Statistical Process Control (SPC):
• The limit values for the requested measurement variable must be activated. If they
are set to zero, limit value monitoring is deactivated.
• The limit values must be preset appropriately. If there are no exact values, estimate
them generously.
• A display window (quadrant) must be in SPC-chart display mode (for more details
see chap. 4.4)
• Recording of the measurement values starts as soon as one display window is in
SPC-chart mode and ends when the display window is reconfigured.
• In SPC-chart mode, display and calculation are carried out within sequential
measurement intervals (samples).

Configuration
Configure a display window for SPC-chart mode (see chap. 4.4):
Click on the requested display window and the SPC-chart screen will open.

Click on HISTOGRAMM.

SAMPLES
Define the number of measurements of which the statistic is composed to be.
The value must be  1.

The SPC-chart calculates and displays the average value (green) and the standard
deviation (3 Sigma, blue) for the set number of samples.

Colors
The colors in the histogram have the following meanings:
GREEN LINE = average value (Xmw)
RED LINE = limit values
BLUE LINE = standard deviation S (+/- 3 Sigma)

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4.18 Define Limit Values Statistically

Before the limit values can be accepted, limit value monitoring for each respective
quantity must be activated, i.e. the button for monitoring must be ON.
There has to be a great number of measurements already taken with statistical
evaluation activated.

The more measurements are taken and the bigger the number of samples, the more
exact the result of the limit value calculation will be.
In the histogram the average value and the standard deviation are calculated from all
taken measurement values and are then displayed.
In the SPC-chart screen, click on HISTOGRAMM.

DEFINE LIMITS
Calculates and displays the new limit values. After you have confirmed them the newly
calculated limit values are activated.
CALCULATION LIMITS
Select the limit value calculation mode.
You can choose from:
+/-2S / 1S
+/-3S / 2S
+/-4S / 3S
+/-5S / 4S
+/-6S / 5S
99% / 95%
The first value is standard deviation (S) for the limit values; the second value is not used
at the moment.

RESCALE
Adapts image to window.
RESET
Resets statistical calculation history

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4.19 Weld with Action Counter

With the action counter you can set a program run where several programs automatically
run one after another multiple times.
This is especially suitable for manual work stations.
Go to screen ACTION COUNTER via MENU – CONTROL – HFI... – AC…

PROG
Select the desired program.

AXIS
Select the axis which this program is supposed to use for welding.

RUNS
Set the number of program runs after which the action counter switches to the next
program.
0000 designates the end of a cycle and the run begins anew.

A maximum of 40 steps can be programmed. The sequence of program numbers and

the number of runs don’t matter.

ON/OFF
Enables/disables the action counter.
If the action counter is active, the current run will be displayed in red font.

LOOP-MODE / ONE-RUN MODE

ONE-RUN MODE
Tests the action counter’s procedure. After a cycle the Start is locked and the LED
READY switches off.
Click RESET to start again.

LOOP-MODE
The entire action counter procedure is processed cyclically.

CLEAR
Resets all action counter settings to 0.

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4.20 Transfer Data to PC/Laptop

Data loss!
Always click the button to turn out the USB stick in the control panel before removing
the stick and take note of the message on the screen!
Caution
Stop the USB stick’s software related actions before you remove it from the
notebook/PC.
Data structure
The data on the USB stick is stored in four directories.
DATA contains files with these file extensions:
.bmp screenshots
.txt text file of parameters
.par parameter file
.bak parameter backup file

LOGGING contains files with these file extensions:

.log log file

UPDATE contains files with these file extensions:

.gz update file

WAVEFORM contains files with these file extensions:

.env envelope waveform
.ref reference waveform
.crv measuring waveform

Files with the file extension .log, .env, .ref and .crv are saved as a CSV format (Comma
Separated Value format) and can be edited with Excel for instance.
Files with the file extension .par can be read, archived and be written back again.

4.21 Make a Screenshot

You can make a screenshot of every screen in almost every state.

Press (underneath the toggle wheel) if you want to make a screenshot of the
current screen.
The screenshot will be saved on the USB stick (or on the network – depending on your
settings) as a file named SSH_xxx.bmp (xxx is an ongoing number).

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Operation: How to…

4.22 Update Firmware

To update your firmware you have to be logged in as Service or Configurator

(see chap. 4.13).

Plug in the USB stick.

Select MENU – GENERAL – SYSTEM – DATA LOCATION and set the location to
USB-device (if you are updating on-site) or to internal (if you are updating from a remote
place).
Go to screen FIRMWARE UPDATE via MENU – GENERAL – SYSTEM – UPDATE.

Select update file:

gz or SWU file (take account of
the spelling)

Update ISQ
Select update file:
gz file

Update MFP-NC

Update screen

Update all devices

The update files (Aws3Install*.gz, HfiInstall*.gz bzw. MfpInstall*.gz) may not be

changed in the syntax and have to be saved on the USB stick in the respective
folder:
X:/aws3/update (“X” means the according drive in your Windows system).
This folder is created at the first plug-in of the USB stick.

Update:
Choose via the button SELECT the corresponding update file for the respective device
(power supply, motorized head or operating panel).
Start the update by clicking UPDATE

How to update all devices simultaneously:

Choose the update files for each device..
Start the update by clicking UPDATE ALL.
If the update has been carried out successfully reboot the entire system by clicking
RESTART ALL.

DO NOT switch off the AWS3 during the update and the subsequent restart. Switching it
off during these phases can lead to irreparable damage to the devices.
Updating the devices can take up to about 10 minutes.
Caution

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After restarting the system the message “MFP not found” may appear.
The reason for this is that some updates trigger an additional internal update of
Attention subcomponents that takes additional time.
Keep the system turned on in this state for at least 10 minutes.
Then turn it off (turn off the power source) and restart it.
The message may appear again. Wait up to 10 minutes again and then confirm by
clicking “No”.
If the loading of programs takes an unusually long time, turn off the system again and
repeat the restart procedure.
Ensure that the system then stays turned on again for at least 10 minutes.

4.23 Adjust Ethernet Settings

The RJ45 jack in the control panel enables you to create an Ethernet connection to a
shared folder in a local network (LAN) to save logging data and measurement
waveforms.
Adjust the settings as required by selecting MENU – GENERAL – ETHERNET.
When the window opens, first enter the Supervisor’s password.

Password

IP settings

Network connection
settings

Connect / disconnect
the network shared
folder
Afterwards all other settings can be adjusted.

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4.23.1 Configure the Interface

To be able to communicate in the network adjust the settings for your IP address, sub-
network and optional gateway. Most networks use a DHCP server. In this case activate
OBTAIN IP-ADDRESS AUTOMATICALLY and then click on APPLY. The interface
settings will now be applied automatically.

In some networks interface settings have to be adjusted manually. If you are not using a
gateway you have to enter „0.0.0.0“ in the Gateway field.
To activate the new interface settings click APPLY.

4.23.2 Connect to a Shared Folder

To create a permanent connection to a folder shared within the network, the
administrator first has to create a user account in this network which has the required
access rights (usually full access rights) for the shared folder. In the ETHERNET screen,
enter the user name as well as the password underneath the NETWORK CONNECTION
field.
Please pay attention to the correct spelling.
Then enter the network domain (DOMAIN) the PC’s name which the shared folder is
located on (SERVER) and the name of the shared folder.
Take note that if you adjust the interface settings manually you have to enter the IP
address of the PC which the shared folder is located on in the SERVER field.
You can enter a subdirectory and separate it from the main directory by using double
slash ‘//’.

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Click CONNECT to create a connection.

If you have been connected successfully the connection string will appear in the bottom
left.
If the PC fails to connect an error message is shown.

Click DISCONNECT to permanently break off an existing connection.

To save data in the shared folder change the data location in screen
MENU – GENERAL – SYSTEM to NETWORK.

The connection string is saved and the device will automatically try to connect again
after you have turned it off/ on.
If the connection fails, the data location will be reset to USB-device (default setting).
If the network connection is disconnected during operation, attempting to save data on
the network will cause an error and the data location will be reset to USB-device.
An error message appears: “data volume more than 95% full: please change.”
As a consequence of this error the unit can be non-operable for some seconds.

The connection with the share folder should only be used in networks which
guarantee a safe physical connection! The connection to wireless networks can
lead to problems during operation of the unit!
Attention

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Due to the fact that the AMADA MIYACHI EUROPE has no influence on the structure,
management and assignment of rights in the connected network, functionality related
to Ethernet connections is excluded from the product warranty.

Depending on the network, connecting the unit to a shared folder can extend the booting
and shutdown times of the unit.
Connection to a shared folder is only possible in local Windows networks which support
the CIFS protocol.
The system does not support other/proprietary structures such as ActiveDirectory etc.

4.23.3 Create a Shared Folder

To create a shared folder on a Windows PC, proceed as follows:
1. Open Windows Explorer.
2. Create a folder.
3. Right-click on the folder and click on Properties/Release or Advanced.
4. Click to ‘Share this folder’.
5. Name the shared folder.
6. Select a a user for sharing.
7. Allow Full Access, Read and Change for this user.
8. Apply the settings.
The procedure can vary depending on the Windows version you are using.

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Configure Interfaces

5 Configure Interfaces
5.1 Modbus/TCP
5.1.1 Connection
Ethernet CAT5 or CAT7 cable: X10 (RJ45 connector on control panel)
Maximum baud rate: 100 Mbit

5.1.2 Settings
Adjust the settings for the Ethernet interface in the ETHERNET screen by selecting
MENU – GENERAL – ETHERNET. Enter the Supervisor’s password.
Specific setup for Modbus/TCP can be adjusted in the MODBUS screen (via MENU –
GENERAL – MODBUS).

Activate the communication (ON/OFF).

After activation the status of the communication as well as the IP addresses of the
connected clients (Modbus Master) are shown.
A maximum of 3 clients can be connected at the same time.

STATUS
LISTENING No client is connected and server (Modbus slave) is waiting for
incoming requests.
CONNECTED Server is connected to one or more clients.
Cyclic polling or acyclic communication is completely performed by
the client.
For cyclic polling there should be a time interval of at least 20 ms to
avoid overloading the network.

Don’t use cyclic polling in large or slow networks or in networks with high data traffic.

BUS (I/O)
Shows the binary input/output bits via the bus.

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Configure Interfaces

Configuring Pneumatic Weld Heads (HFI only):

When configuring a pneumatic weld head (HFI only) observe the following things for
performing the start signal :

• Wire jumper from pin 1 to pin 11 in plug X12 on rear side ISQ (plus pin 2 to pin 12 in
dual head operation)
• Configuration of A64 as A_START_EXT_1 in MENU – GENERAL – SYSTEM – I/O
STATUS HFI (plus A65 as A_START_EXT_2 in dual head operation)

5.1.3 Controlling the Weld Cycle

Controlling the weld cycle via Modbus/TCP differs in several points from the standard
scheme of binary I/O.
The following diagram illustrates the subdivision of the weld cycle into 3 phases:

MFP Ready
& HFI Ready

Start

Ok / Reject

Measurement
Toggle Bit

End Of Cycle

Search Force

Start Evaluation Select new

welding (Ok / Reject) Program or
cycle and Read Read / Write
Measuring Parameters
Values

Welding phase (yellow):

Is initiated by Start signal. Status signals and End Of Cycle are cleared. The start signal
may only be set if the signals MFP Ready and HFI Ready are active.
Note: setting the Start signal via the bus is only available for application configurations
including MFP-NC-AWS3.
Evaluation phase (green):
Is initiated by status change of Measurement Toggle Bits. Afterwards the status signals
(Ok / Reject) and the current measurement values can be read.
Configuration phase (blue):
Is initiated by Ready signal. Now a new program can be selected or parameters can be
changed. The next Start signal may only be set after completing all configurations.

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Standard Cycle at Configuration for Servo Weld Head (MFP-NC and HFI)

Start from PLC

(save Toggle Bit prior)

Toggle Bit changed?

Yes Reset Start

Wait one PLC cylce
(to ensure data consistency)

Read PLC status (Ok / Reject)

Read Measuring Values

MFP Ready AND HFI Ready? Home Position OR Wait Position?

Yes Yes

Remove part

Wait for next part (≥ 100 msec)

Standard Cycle at Configuration for Pneumatic Weld Head (HFI)

Start extern from PLC

(Save Toggle Bit prior)

Toggle Bit changed?

Yes Reset Start

Wait one PLC cycle
(to ensure data consistency)

Read PLC status (Ok / Reject)

Read Measuring Values

HFI Ready? Weld Head up AND HFI Ready?

Yes Yes

Removal of component

Wait for next part (≥ 100 msec)

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Optimized Cycle at Configuration for Servo Weld Head (MFP-NC and HFI)

Start from PLC Start

(Save Toggle Bit prior)

Trigger Bit active?

Yes

Reset Start

Toggle Bit changed?

Yes

Wait one PLC Cycle

(tp ensure data consistency)

Read PLC status (Ok / Reject)

Read Measuring values

Start active?

Yes

Reset Start AND wait ≥ 100 ms No

Trigger Bit off AND MFP Ready AND HFI Ready?

Yes Home Position OR Wait Position?

Yes

Remove part

Wait for next part

Important:
When a device fault occurs (Fault HFI or Fault MFP) the cycle must be cancelled and the
state before the cycle must be re-established after acknowledge of the fault.

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Optimized Cycle at Configuration for Pneumatic Weld Head (HFI only)

Start Exter from PLC

(Save Toggle Bit prior)

Trigger Bit active?

Yes

Reset Start Extern

Toggle Bit changed?

Yes

Wait one PLC Cycle

(to ensure data consistency)

Read PLC status (Ok / Reject)

Read Measuring Values

Start Extern active?

Yes

Reset Start Extern AND wait ≥ 100 ms

No

Trigger Bit off AND HFI Ready?

Yes Weld Head up AND HFI Ready?

Yes

Remove part

Wait for next part

Important:
When a device fault occurs (Fault HFI) the cycle must be cancelled and the state before
the cycle must be re-established after acknowledge of the fault.

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5.1.4 Parameter Service Channel

Read Parameters:

Write Parameter ID to ParamIdRead

Read Parameter ID from ParamIdRead

No

ParamIdRead = Parameter ID ?

Yes

Read ParamRead

Write Parameters:

Write ParamWrite

Write Parameter ID to ParamIdWrite

Read Parameter ID from ParamIdWrite

No

ParamIdWrite = Parameter ID ?

Yes

Increment ParamCmdWrite

Read ParamAckWrite

No (t <= 15s)

ParamAckWrite = ParamCmdWrite ?

Important:
Writing parameters as well as changing the program number may only be done if the
MFP / HFI Ready bits are set.
If the timeout of 15 sec. of response time limit is exceeded, the value is obtained as not
written. Then you either have to set an error status or try writing again.

5.2 Profibus/DP – EtherNet/IP

Settings for Profibus/DP and Ethernet/IP can be found on separate documentations
(available on request).

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Calibration - Adjusting

6 Calibration - Adjusting
The AWS3 system is already calibrated when delivered.
We recommend calibrating the system annually.

Switch off the welding current before you start the calibration!
Caution

6.1 Force Calibration

To be able to calibrate the system, you have to be registered as „CONFIGURATOR“ or

“SERVICE” at the control panel (see chap. 4.13).

Go to screen MOTOR CONTROL via MENU – CONTROL – ADVANCED.

Deactivate FORCE INTERPOLATION TABLE ON/OFF.

SET VALUE shows 5 values in ascending sequence. Start with the highest value.

The highest REAL VALUE must equal the highest SET VALUE.
I.e. this real value may not be changed; calibration must be done as described below,
via GEAR RATIO FORCE.

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Set highest SET VALUE (60 in this example) as SEARCH force in the SCHEDULE
screen.

Switch to single step mode by clicking on STEP in the menu bar.

Place the probe of the calibrated measuring instrument between the electrodes. Ensure
the probe is horizontal aligned.
Place the small ball into the probe’s cut-out.
To be able to repeat this procedure, manually set the traversing distance to 10 mm.

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In the MOVEMENT screen, set the speed for the single STEP to 10.0 mm/s.

Switch on the measuring instrument.

Click START in the screen SCHEDULE.
A single run is carried out and the measurement values taken are shown on the display
of the measuring instrument.
After the measuring click STOP.
We recommend to measure 2 more times and use the average value of the 3
measurements taken as the result.

If the measured value differs from the SET VALUE more than the given tolerance, adjust
the value for GEAR RATIO FORCE in the MOTOR CONTROL screen.

Here applies:
if the force value taken during the single run is too low, the value for GEAR RATIO
FORCE must be decreased, if the value taken is too high, the value must be increased.
Based on experience the value should be changed in increments of 0.01.
To check the adjustment, you can take another measurement as described above.

Now take the next (second highest) SET VALUE (in this example 35), set it as SEARCH
force in the SCHEDULE screen and start again.
Note down the measured value and repeat the measuring procedure 2 times. Then
calculate an average from the three values taken and enter this average value as REAL
VALUE below the corresponding SET VALUE in the MOTOR CONTROL screen.
Now perform the measuring in the same way with the rest of the SET VALUES until all of
the REAL VALUES are adjusted.

Please note that the REAL VALUES must be ascending.

That means that every value must have a higher value on the right-hand side and a
decrease value on the left-hand side.

After the measuring has been finished all REAL VALUES are set.

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To check the calibrated values, activate FORCE INTERPOLATION TABLE and set the
requested SET VALUE as search force in the SCHEDULE screen.
Now start the single run, the measured value should now be within the tolerance range.
Then set the next SET VALUE as search force and measure again.
This way all 5 SET VALUES can be checked.

If one of the first four SET VALUES should still be outside of the tolerance range even
after calibration, increase or decrease the corresponding REAL VALUE by 1 in the
MOTOR CONTROL – ADVANCED screen and measure again.

When doing this, leave FORCE INTERPOLATION TABLE activated.

Please note: the highest REAL VALUE may not be changed.

If adjustment is necessary, it must be done as described above via GEAR RATIO
FORCE.

If all values are within the tolerance range, the force calibration is finished.

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Calibration - Adjusting

6.2 Distance Calibration

First perform a reference run using the same force you will use for the later
measurement (see chap. 4.6.1).
We recommend to use half of the highest force set value (in this example highest force
set value is 250, so you should set 125 as force value for the reference run).

Go to screen MOVEMENT and adjust the AUTO values as shown below:

• VELOCITY: 200.0
• ACCELERATION: 1000
• SEARCH VELOCITY: 10.0

We recommend to use the following end-gauges for the distance calibration:

• MFP25, MFP60: 1, 1,5 and 2 mm
• MFP1, MFP2, MFP400, MFP800: 1, 3 and 5 mm

Search position has to be at least 1.5 mm larger than the largest end-gauge.

Hold the smallest end-gauge between the electrodes as horizontally as possible and
start calibration by clicking on START.
The measured distance is displayed in the bottom left (in this example an end-gauge of 1
mm was used, the measured value is -1001 µm. That is a deviation of 0.1% and is
therefore within the tolerance range).

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Calibration - Adjusting

Repeat the above procedure with the other two end-gauges. If one of the measured
values should be outside of the tolerance range, calibrate as follows:

Go to screen MOTOR CONTROL and change the PRE-SETTINGS.for

GEAR RATIO FORCE.

Here applies:
If the measured value was too high, decrease the value for GEAR RATIO FORCE.
If the measured value was too low, increase the value for GEAR RATIO FORCE.

Based on experience the value should be changed in increments of 0.001.

To check the calibration, perform another measurement as described above.

If the value is then within the tolerance range, the distance calibration is finished.

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Configuring Pneumatic Weld Heads

7 Configuring Pneumatic Weld Heads

7.1 Set the Weld Parameter Pressure
When selecting the air control mode the pressure for the proportional valves can be pre-
set (applies only to units featuring a welding pressure cylinder, e.g. FPxxx).
During the closing time the head is closed with the lower closing pressure.
Average closing time: approx. 500 ms.
Additionally, the squeeze time has to be long enough to enable the welding pressure to
build up and the system to cool down (average squeeze time: approx. 500 ms).
The welding pressure remains until the end of the weld cycle.

The following applies to units featuring adjustment cylinders (e.g. F120):

Adjustment time = closing time + squeeze time.
These units use a proportional valve that harnesses a welding pressure spring together
with the force cylinder. This creates the welding pressure.
The hold time starts after the on-time has ended. During the hold time the electrodes
stay closed. This way the welding joint cools faster through the electrodes, which usually
leads to a stronger connection.

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Problem Solving

8 Problem Solving
8.1 Trouble Shooting
Bluescreen:
When the control panel shows a ‚Bluescreen‘ (blue display with icons), please initiate a
shutdown by pressing both buttons simultaneously for max. 10 sec.

For a shutdown press both buttons

simultaneously for max. 10 seconds

Alternatively you can shut down the control panel as follows:

• Plug in a USB keyboard.
• Switch to the “Other” icon by using the arrow keys ← and → and press ENTER.
• Then switch to the “Terminal“ icon and press ENTER.
• Now enter “shutdown –h” and press ENTER (to enter the “-“ symbol please use the
“-“ key on the number pad of the keyboard).

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Problem Solving

8.2 Error Messages in Status Bar

No. Error Cause
4002 Open file USB stick or file damaged
4003 Save File USB stick or file damaged
4004 Wrong file type or file faulty xxx is wrong or faulty file header
4005 Refresh chart
4006 Access to BAT RAM Battery low
4007 Load file USB stick or file damaged
4008 File already existing and write- An attempt was made to overwrite a
protected protected file
4010 Cursor cannot be displayed
outside of display detail
4011 Installation of data cache failed Installation of data cache failed
4020 CAN: Time-out read data Data transfer overloaded, possible
causes:
• connectivity problem at control panel
• firmware incompatibility of control
panel and MFP-NC/ISQ
• possible hardware fault
4021 CAN: Time-out write data Data transfer overloaded, possible
causes:
• connectivity problem at control panel
• firmware incompatibility of control
panel and MFP-NC/ISQ
• possible hardware fault
4022 CAN: Time-out receive request
4023 CAN: Time-out send request
4024 CAN: Overload of order buffer Bottleneck executing several tasks,
possible causes:
• connectivity problem at control panel
• firmware incompatibility of control
panel and MFP-NC/ISQ
• possible hardware fault
4030 ETHERNET: IP address in
reserved area

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Index

9 Index
Adjust Closed-Loop Control Parameters 17 Modbus/TCP Einstellungen 49
Adjusting 55 Monitor Parameter Overview 39
Advanced 7, 20 Monitor Statistical Values 40
Analyze Accept – Reject Ratio 40 Operating 9
Basic 7 Operation 13
Basic position 23 Parameter Service Channel 54
Bluescreen 62 Part detection 24
Calibration 55 Pneumatic Weld Heads 50
Compare Measuring and Envelope Waveform 31 Print or Output Measurement Values 35
Configure the Interface 46 Profibus/DP 54
Configuring Pneumatic Weld Heads 61 Program Display 12
Connect to a Shared Folder 46 Reference Run 22
Construction and Mode of Action 8 Reset to default 16
Controlling the Weld Cycle 50 Save All Programs and Parameters 32
Copy Programs and Parameters 32 Saving Data 8
Count Measurements 33 Screen 11
Current Profile 19 Screenshot 43
Define Limit Values Statistically 41 Search position 24
Determine Real Time Limit Values 26 Set and Change Passwords 36
Displacement Settings 22 Set Weld Parameter Pressure 61
Display 11 Shared Folder 48
Display Windows – Quadrants 1 to 4 12 Status Bar 12
Display Windows (Quadrants) 18 System Settings 16
Edit Programs and Parameters 32 Technical Data 6
Error Messages 63 Technical Description 6
EtherNet/IP 54 Toggle Wheel 9
Firmware-Update 44 Tools/APC 20
Force Calibration 55 Touch screen 10
Force Profile 19 Transfer Data to PC/Laptop 43
General Notes 5 Trouble Shooting 62
General Settings 13 UNDO Function 12
Generate Envelope Waveforms 29 USB port 8
Generate Reference and Envelope Waveforms 27 View and Save Measuring Waveforms 34
Interface configuration 49 Waiting position 23
LED Status Displays 10 Wegkalibrierung 59
Load All Programs and Parameters 32 Weld Counter 33
LOGGER Configuration 38 Weld to Limit Mode 25
Manage Envelope Waveforms 30 Weld with Action Counter 42
Menu Bar 12 Welding Parameters 19
Modbus/TCP 49

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