| COMPRO 304 Welding Machine And Resistans Welding Controller Unit Microprocessor based welding machine and resistance welding Control unit developed for Mistas between 1992-1994. Improved version of Compro-303. Used at OYAK RENAULT, TOFAŞ otomotive. Constant current control between 3000-60000 Amper (around 1300 °C, Approx. 50 miliohm).  |  |
Compro304 ComPro304 is a high performance resist welding control unit which is providing fixed seconder current, program and timing functions and it is based Microprocessor (uP). It continuously controls welding results and fixed current regulation resist changes. ComPro304 contains flexible timing parameters and welding control types more than one. These are single/stroke point welding, Seam welding, hanging point welding, Single point multi welding. In all applications depending on its usage it is possible to watch feedback, stepper, down counter, link, pedal/button on ComPro304. And also for ComPro304 there areWMMS (Welding Management and Monitoring System) , local network, welding analysis, quality control and statistics for productivity analysis. It has a developed security system and intervention which is taken from many points. Warnings for quality are not only given from ComPro304 and also given to control outputs and outside. GENERAL CONFIGURATION : Welding Parameters : All welding informations are shown on the 2-lined display to change them easily. The changes are saved until they change. The phases of welding are observed by state leds. 
Şekil 1 - ComPro304 Göstergesi  | Constant current control (% 1 tolerance) between 3000-60000 Amper (around 1300 °C, Approx. 50 miliohm). | | Calculating firing-angle which is taking from signal of toroid. | | Single/Repeat/Link weld programmable. | | Seam Weld. | | Current Stepper Mode. | | Four selenoid valves control. | | 2x24 LCD Display. | | 10 Programs memory. | | Thxr stability before welding. | | Control of over temperature THXR | | Cooling of water control | | Air pressure control | | Punto pressure control | | Weld / No-weld selection | | Emergency relay exit | | Up/Down Counter (Up to 65535 weld) | | Initiating any program by PLC | | 2 Initiating by pedal | | Function leds (Ready,Weld, Error, Initiate) | | Sleep Mode | | Welding Program (0-9) | | Proximity time | | Squeeze time (0-99 cycle) | | Up-Slope (0-99 cycle) | | Up-Slope %Initial Current Value (%15-%98) | | Welding time (0-99 cycle) | | Welding %Current (%15-%99) | | Number of Stroke (0-99 cycle) | | Cooling Time (0-99 cycle) | | Down Slope (0-99 cycle) | | Down Slope | | Hold Time (0-99 cycle) | | Off Time (0-99 cycle) | | Welding Current Tolerance (%Tol, %2-%25) | | Selection of Valve (1,2,B,3,4,No) | | Welded-Unwelded | | Repeated- |
Welding Shapes | Point Welding | | Multi-Welding in a point | | Connected welding | | Seam welding | | Hanging point welding |
Security Precautions : | Pressure-Key Control | | Choosing of from outside | | Controls of Tristors | | Control of Cooling Water | | Extreme temperature Control of Welding transformator kontrolü | | Air-Pressure Control | | Primer-Seconder Leakage control | | Control of triod in feenback welding | | Ignition relay out for emergency (Normally open-ignition) | | Password for unautorized usage |
PLC Communication Outputs-Inputs: | Selection of 4 Binary program from PLC | | Signal output to PLC for end of welding (10 uS open-collector output) |
Specifications of Quality Control : | Connecting to Network (Watching and controlling of 1-128 ComPro304 from single computer) | | Watching welding part with giving a tolerance to Welding current |
Specifications of Display : 24 characters, 2 Line LCD with Backlight, watching all welding parameters State Leds : Welded-Unwelded led It shows state of welding current. It will flow or not. Welded ----> Led indicates Out-Choice led It indicates welding program is selected or not. Out-Choice -----> Led indicates Valve 1, Valve 2, Valve 3, Valve 4 leds During welding it indicates the leds of valves Ready Led It indicates if sysytem is ready to weld. Welding Led It marks moments when welding current is flowing. Welding Parameters on Display : Program (Seq. No) 0-9, (0) Welding Program Aproximitiy Time (Pre. Sqz.) 0-99 cycle, (20) In this moment valve or valves which are marked by program take energy. This phase is used once with squeeze time and repeated welding. Squeeze time 0-99 cycle, (20) During this time valve or valves take energy. Pliers and squeezers are off. Up-Slope %Initial Current Value (Init. Heat) %10-%99, (10) It is initial %Current value for up-slope. It must be %20 of Welding %Current according to NEMA. Up Slope 5-99 cycle, (0) It is the number of weldings from first %Current to end %current. Up-Slope is only used for Stroke Welding and Seam welding. '0' means to cancel Up-Slope. Weld Time 0-99 cycle, (8) It is the number of cycles of welding %Current which will be applied. Welding %Current (%Heat) %15-%99, (50) The percentage of welding current. Polarite (Pol) A,+,-, (+) It determines first alternance for start welding. Option 'A' is started any alternance and next welding is started inverted alternance. Option '+' provides to start upper alternance for each weld-strike. Option '-' provides to start upper alternance for each weld-strike. These selections can make with UpKey when the cursor is on this point. Choosing of Valve seçimi (Valve) 1,2,B,3,4,N, (1) Here, It is choosed welding valve. 1,2,3 and 4 are numbers of valves. 'B' is for 1 and 2 both valves, 'N' is for any valve. The cursor and Upkey are used for choice. Cool Time 0-99 cycle, (0) It is cool Time in stroke welding. Impulse 0-99 cycle, (0) It is the number of Current impulses which will be applied in %Weld currentAkımı.In this mod, Up Slope is only the head of first impuls, and down slope is applied once at the end. Down Slope 0-99 cycle, (0) It is the number of cycles for last value of Down-slope %current from %Welding current. in Down-Slope Impulse Welding it is applied once at the end of last impulse. Down Slope %99-%5, (10) It is the %current value for finishing Down Slope. This value must be %20 of Welding%Current according to NEMA. ‘0’ means cancelling of down-slope. Hold Time 0-99 cycle, (10) After cutting Welding Current, it is the time for valve in energy for cooling. It is replaced between repeated welding. Off Time 0-99 cycle, (10) It is break-time for passing next program. It is replaced between repeated welding and squeeze time. Welding Current Tolrance (%Tol) %2-%25, (0) It expresses the change of %Tol in welding. If there is a +-%Tol welding machine warns. At the same time, in the main connector which belongs to this warning will be activated(/CurrErr). %Tol value will be '0' for destroy tolerance control. Repeated (Rpt) *,R,S, (*) There are three dişfferent situations in this selection.Option '*' for Normal (Singlei) welding, 'R' for Repeated welding, 'S' for seam welding. These selections are done by cursor and Upkey. Link (Lnk) *,L, (*) It is for next selection. With '*' there is no any selection. 'L' for linking. These selections are done by cursor and Upkey. State Leds: They give some information for system's activations. These leds are; Unwelded Led, it indicates all functions will be executed without welding current of ComPro304. Out-Choice Led, It indicates if unit is selected from outside. Valve 1, Valve 2, Valve 3, Valve 4 leds, they indicate active valves with lighting. Ready Led, It indicates if system is ready to run welding program. Welding Led, It indicates welding currents is flowing. Welding Programs for example: in the program below, vertical lines indicate up and down alternances of network. Their lengths are %Heat Value. 
Diagram 2- Example program 
Şekil 5- Örnek Kaynak Programı | 
Endüstriyel Kantar