S.S.

CONTROLS, PUNE 3WOL-SP20

S.S.Controls
Resistance Spot Welding Controller

Model : 3WOL-SP20

With Built in Thyristor

Manufactured By

S.S.Controls
38, Jaydeo Nagar, Sinhagad Road, Pune-411030, India
Tel : 020-24330689
Email: sscontrols@ymail.com
Website: www.sscontrols.com

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Operation Manual
Microcontroller Based Resistance Spot Welding Controller

Model : 3WOL-SP20

Welding Controller Technical Specification Details:

User inputs
Supply Input: 230V/415 V AC supply selectable
User interface Keys: UP , DOWN and ENTER keys for setting welding parameters etc.
Dimensions: 100mm(W)X192mm(H)X300mm(D)(Standard DIN Enclosure)
Mounting: Option 1 – Side mounting brackets
Option 2 – Panel cutout 92mm X 184mm Standard DIN Mounting.

Display type:
four Seven segment display + 15 LED indications

Features:
1. Compact, user friendly, Microcontroller based circuitry.
2. Non-Volatile Memory(EEPROM) to store twenty weld schedules.
3. Easy to program with the help of UP DOWN and ENTER KEYS.
4. Individual operation within the weld Schedule are indicated by LEDs.
5. Selectors are provided for ‘SET’ and ‘RUN’ mode.
6. Timing set in terms of ‘Half cycles’ (10msec/cycles for 50 Hz supply) of mains supply
frequency, to get better resolution. ‘Full Cycle’ and ‘Multi cycle’ options available.
7. Precise time and energy control ensures consistent weld quality.
8. Built in compensation against fluctuations in the mains supply voltage.
9. Weld / NO WELD Switch, on front panel.
10. Relay contact provided to actuate the solenoid operated pneumatic control valve of
the welding equipment.
11. Foot switch is used to operate welding sequence.
12. Factory setup options of different operation modes are available.
13. Standard Option.
i. W1, W2, W3 welding parameters with cooling parameter C1 and C2.
ii. Dual foot switch.
iii. Single Solenoid valve output.
iv. Single Thyristor output.
v. Half cycle.
vi. Latching and Full pressed foot switch mode.
vii. Hot Key selsction mode

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Switches for selection of particular function on front panel

1. Power ON / OFF Switch
2. Set / Run selectable key lock Switch.
3. Schedule Select / Program Switch
4. Single / Repeat Cycle operation Switch
5. Weld / No Weld Switch.

Different setups for selecting and setting different welding parameters:

 Keep keylock switch in SET mode.

Schedule Select Mode: Assign schedules(01-20) to foot switches F1 and F2. In this we can
select four different schedules to foot switch FS1 and FS2. (for e.g assign sch 01 to F2 and
sch 02 to F1)

Steps for assigning schedule to foot switch FS2 :

Schedule select/ Program Switch in

Schedule select position

Display shows FS2 01

(Schedule No.)

Set schs no. by Keys

Keys
Steps for assigning schedule to foot switch FS1
Schedule select/ Program Switch in
Schedule select position

Press foot switch FS1

Display shows FS1 01

(Schedule No.)

Set schs no. by Keys

Keys

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Program Mode: In this mode we can edit the welding parameters of (01-20) schedules of
different welding types selected through pendent.
For example if we select Spot weld3 type, the procedure for programming schedule is given
below as a flow chart.

Schedule select/ Program Switch in A

Program position
Pq 00, set value by keys

SC 01
Press

Select sch no. through Keys

Squeeze 00, set value by keys

Press Enter Key Press

A
Set the other parameters as
shown in above sequence

Spot-3 Weld parameters:

• PreSqueeze Time 00-99 cycles

• Squeeze Time 00-99 cycles

• Preheat Time (W1) 00-99 cycles

• Heat H1 00-99 % programmable

• Cool (I) Time 00-99 cycles

• Slope for W2 00-9 cycles slope cycle should be less

than W2 cycle.

• Weld Time (W2) 00-99 cycles

• Heat H2 00-99 % programmable

• Cool (2) Time 00-99 cycles

• Anneal Time (W3) 00-99 cycles

• Energy Level (W3) 00-99 % programmable

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• Hold Time 00-99 cycles

• Off Time 00-99 cycles

 If Slope cycle S2 is more than zero, W2 automatically set greater than slope cycle,
e.g if S2 =03, then W>03 and if decremented less than 03 it will roll back to 99
cycles.

Supervisor Setup
Hot key mode: In this mode we can disable or enable online editing of selected Weld cycle
or weld energy parameter in run mode.
Set the front panel switches in a position as described below:
 SET/ RUN keylock Switch in SET position.
 Schedule select / Program Switch in Program position.
 One Cycle /Repeat Switch is in One Cycle position.
 Weld / No Weld Switch is in No Weld position.
 Press the foot switch FS2 for 10 sec the display shows Ht-E. and dsbL for disable
and EnbL for enable.

Ht-E

Press

dsbL EnbL

Pressr Key Pressr Key

Disable Hot keys and

returns back to main menu

Select any one, W1, W2,W3,

H1,H2,H3

Pressr Key

Enables the access of selected

parameter in RUN mode

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Minimum Firing Angle (FA) setting:

Set the minimum firing angle from a range 300 to 900
Set the front panel switches in a position as described below:
 SET/ RUN keylock Switch in SET position.
 Schedule select / Program Switch in Program position.
 One Cycle /Repeat Switch is in Repeat position.
 Weld / No Weld Switch is in Weld position.
 Press the foot switch FS2 for 10 sec the display shows FA 51.

Shows previous set angle

FA 51

Set the firing angle by Keys

Press Key

RUN MODE:
 Change key lock switch to RUN mode. Display shows schedule no. and hot key
parameter(if it is enabled in set mode)
 Keep One cycle/ Repeat switch on One cycle.
 Weld / No weld switch on No weld.
 Press the foot switch to check electrode alignment and the job position.
 Switch Weld / No weld to Weld position, press the footswitch. Now the actual welding
will take place. Check whether the parameter setting for particular job is proper.
 If not satisfied, change key lock switch to SET mode and try with some different
parameter combination.
 To run the welding sequence in repeat mode change One cycle / Repeat switch on
Repeat position.

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 Standard Connection Diagram :

For Model with In – Built Thyristors.

COM
TO TRIGGER
FS2
FS1
SOLENOID VALVE L
SOLENOID
N/O
SUPPLY
N
P
P
S
R E
LINE1
I C
230/415V50Hz O TO WELDING HEAD
IN OUT M N
IN OUT
LINE2 A
D
/N A
R R
Y
Y

Spotpic 0603
WELDING
CONTROLLER TRANSFORMER

Back Panel Connections -

• COM, FS2
& FS1 : Connect the footswitches across these terminals as shown
above.
Use Normally Open (N/O) contact of the foot switches. Contact
closer will start the sequence.
 P, N/O : These are the POLE, Normally Open contacts of the inter-locking
relay inside the controller. This relay is switched ON at start of
SQZ and is used to operate external solenoid valve to operate
the pneumatic cylinder of the welding head.
 IN : Connect 230V Or 415V A.C. Mains lines as indicated near the IN
terminal on back side of the instrument. (Use 4.0 sq mm wire).
(Caution: Connecting wrong supply may damage the equipment)

• OUT : Connect primary of transformer of the welding transformer directly

Across this terminals. The necessary thyristor are built in.

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Other Factory Setup option:

1. Four foot switch operation.
2. Dual Solenoid Valve.
3. Dual Thyristor.
4. Full cycle and Multi cycle option.
5. Spot welding mode options are:
 Three Weld.
 Single Weld.
 Impulse cycle(max 9).
 Chained foot switch.
 Forge Delay.
6. Seam Welding mode option.
 Seam continuous.
 Seam Intermittent.
7. Non Latching / Latching footswitch option.
8. Full press / Half pressed foot switch option.
9. Weld counter and Job counter.

S.S.Controls
38, Jaydeo Nagar, Sinhagad Road, Pune-411030, India
Tel/Fax: 020-24330689
Email: sscontrols@ymail.com
Website: www.sscontrols.com