BF Entron WELDSTAR WS2003 User Manual

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Page 1

Introduction to WELDSTAR model WS2003

Spot/Seam control,monitor and machine sequencer for 50/60Hz and MF resistance welding.

For s/w version 1.69

Document revision 0

Page 2

Manufacturers of

advanced welding

BF Entron Ltd. Castle Mill Works, Birmingham new road, Dudley, West Midlands, DY1 4DA England.

Tel: +44 (0)1384 455401 Fax: +44 (0)1384 455551

BF Entron Ltd.

controls

•Welding controls.

•Thyristors and power supplies

•Power Inverters.

•Meters and Monitors.

•Training and Support.

Email: [email protected] Web site: www.bfentron.co.uk

•Consultancy.

WS2003 V1.69

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Table of contents

4. WELDSTAR model WS2003 System

5. Introduction and overview

6. Functions

7. …functions

8. …functions

9. Global parameters

10. Program parameters (x64)

11. Multiweld parameters

12. Mounting

13. Connectors

14. Users connections (discrete)

18. Operation with a fieldbus

19. ...operation with a fieldbus

20. Keypad

21. Menus

22. ..menus

23. Diagnostic screen 1

24. Diagnostic screen 2

25. Status / error codes

29. Configuration menu

30. Edit configuration

33. Edit calibration

36. Edit output map

37. Edit input map

38. Set-up Adapters

39. Backup/Restore

40. Initialise all data

41. System set-up menu

42. Main menu

43. Edit program (AC)

44. Edit program (MF)

46. Edit program (seam)

47. Edit limits

48. Edit Events

49. Electrode menu

50. Stepper status

51. Edit stepper

52. Stepper presets

53. Edit counter

54. ..edit counter(tip-dressing)

55. Sequencer

56. Sequencer Menu

57. Edit sequence

59. Example sequence

60. Weld log

61. View log screen 1

62. View log screen 2

63. Copy program

64. Copy Electrode

65. I/O status

66. Fieldbus input status

67. Analog status

68. Program selection

69. OHMA (Air over oil) system

71. Disabling edits

72. Pop-up current meter

73. Replacing a WS2000 timer

74. Operation: basic spot weld – no weld faults.

75. Operation: basic spot weld – weld fault

76. Operation: repeat spot weld

77. Operation: pulsation spot weld

78. Operation: upslope and downslope

79. Operation: roll-spot welding

80. Operation: seam welding (dual heat)

81. Operation: seam welding (preheat)

82. Operation: EOS signal

83. Operation: Retract

84. Operation: Hi-lift

-----------------------------------------------------------

85. Multiwelding

86. Configuring for multiwelding

87. Electrode/Transformer assignment

88. Assigning a weld program to an electrode

89. Multi-gun operation

90. Multi-gun cascade operation

92. Program selection (multiweld)

-----------------------------------------------------------

93. WS98-2003 PC software

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WELDSTAR model WS2003 System

Ethernet

WSP3

PROGRAMMING

PENDANT

WELDING

CONTROL

WS2003 TIMER

WS2003

EVENT TIMER

WELDSTAR

2000

compatible !

*Optional Plug-in adapter cards for special functions.

*Optional Ethernet adapter required for connection to Ethernet

LOGIC SEQUENCER

WS98-2003

Software for PC

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Introduction and overview

This manual details the features of the WS2003 timer, and shows how

to program the timer using the WSP3 programmer.

The new WELDSTAR model WS2003 is a direct plug-in replacement for the original WS2000. It will fit into existing cabinets, and will work with the existing power supply. Existing connections

are duplicated, including outputs at 110V AC or 24VDC A new programming pendant , type WSP3 is available, and provides a

larger multi-line display, making programming easy. A powerful built-in logic sequencer program provides the timer with a

flexible means of fully controlling small machines or tooling arrangements, without the need for additional hardware.

A plug-in option board provides a 10/100Base-T Ethernet connection. Units may then be networked to a PC running WS98-2003 software for programming and monitoring purposes.

Fieldbus operation (Profibus, Interbus, DeviceNet Modbus etc.) is supported via plug-in option boards.

. MF operation is also supported.

ENTRON

WSP3

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Functions

• Compatible with original Weldstar 2000

• AC 50/60Hz and MFDC (medium frequency) welding all supported.

• Spot / Repeat /Roll-spot / Seam (dual heat) / Seam (pre-heat) welding.

• Single, dual or OHMA (Air over Oil) gun operation.

• Multiwelding with up to 16 SCR/transformers

• Retract/high-lift control.

• Dual weld intervals plus pulsation, upslope and downslope.

• Constant current regulation.

• Up to 64 programmes with internal or external selection.

• Current monitoring with high, low and pre limits. Programmable blocking and weld retry functions.

• Proportional valve controller (0..10V or 4..20mA).

• Programmable outputs (events).

• Machine sequencer logic

• Welding programmes may be linked together to form complex spot schedules.

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…functions

• Contactor timer.

• Head-lock function.

• Analog output of current waveform.

• Electrode management including stepping, counting and tip-dressing functions, with programmable blocking and preset curves.

• Outputs will drive 24V DC or 110V AC loads.

• Primary or Secondary feedback via Toroid.

• Toroid and PV calibration functions.

• Toroid test function.

• Disable edit function.

• External plug-in programming pendant with large backlit 4x20 lcd display, and data backup facility.

• RS232 port, for PC communications.

• Expandable via plug-in option cards

• (Ethernet, Profibus, DeviceNet, Interbus, Modbus TCP/IP, Ethernet/IP etc).

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…functions

In early 2008, a number of new circuits were added to the original design. These are used to provide the following additional features:

• 0..10v or 4..20mA input for pressure monitoring.

• Two general purpose 0..10V inputs can be used by the sequencer. One of these inputs may be used to connect a CT for current measurement.

Note that these features are not available when running this firmware on the original design.

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Global parameters

Configuration

•Sequence (Spot / Roll-spot / Seam(2-heat) / Seam(pre-heat)

•Single gun / Dual gun / OHMA gun / Multi-gun / Multi-gun cascade.

•Discrete/Fieldbus I/O

•Retract (x2): (Simple / Hi-lift+ / Hi-lift- / Maintained / OHMA)

•Program select (Binary / 1-of-4 )

•SCR select (Binary / 1-of-4)

•Frequency (AC 50 Hz / AC 60 Hz / MF 50Hz / MF 60Hz)

•Contactor time (0..200 s)

•Blanking (On/Off)

•Toroid test (On/Off)

•Sensor (Toroid / CT)

•Heat range (Wide/High/Low)

•EOS mode (Cancel/fixed)

•If fault (Head-lock/Stop/Continue/EOS/No EOS)

•Sequencer (On/Off)

•Toroid attenuation factor (1..4)

•Count/Log sync (On/Off)

•Pressure units (kN/lb)

•Analog output (PV/Current).

Calibration (x2)

•Sensor sensitivity(100..60000 mV/kA)

•S/P ratio (1:1..199:1)

•S/P offset (-10kA..+10kA)

•Pressure (2 points, kN/V)

•Inverter (2 points, kA/%heat)

•Analog output scale (0..60kA).

•Analog input gain (0.9..2.5)

•Analog input offset(-9.99…+9.99)

Counter (x2)

• Actual count (0..9999).

• Terminal count(0..9999).

• Stop/continue at end.

• Tip dressing (on/off)

• Dressings (0..9999)

• Dress when new (on/off)

Stepper (x2)

• Stepper on/off.

• Stop /continue at end

• Curve(10 point, interpolated)

Sequencer

•Up to 250 statements

Output Map

• Normal/Event/Sequencer/Fieldbus (x12)

Input Map

• Normal/Sequencer (x14)

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Program parameters (x64)

Weld program

•Pre-squeeze (0..99 cycles)

•Squeeze (0..99 cycles)

•Weld1 (0..99 cycles)

•Cool1(0..99 cycles)

•Weld2(0..99 cycles)

•Cool2(0..99 cycles)

•Pulses(0..99)

•Hold(0..99 cycles)

•Off(0..99 cycles)

•Pressure (0..100%)

•Heat 1(0..99.9%)

•Heat 2(0..99.9%)

•Current 1 (0..60kA)

•Current 2 (0..60kA)

•Balance (seam only)

•Normal/Link program

•Upslope(0..99 cycles)

•Downslope(0..99 cycles)

Additional parameters for OHMA gun

•OHMA gun open (0..99 cycles)

•OHMA gun close (0..99 cycles)

•OHMA retract open (0..99 cycles)

•OHMA retract delay (0..99 cycles)

•OHMA retract close (0..99 cycles)

Monitor limits

•Current monitor (On/Off)

•Current low limit,weld1 (0..99%)

•Current high limit,weld1 (0..99%)

•Current pre-limit,weld1 (0..99%)

•Current low limit,weld2 (0..99%)

•Current high limit,weld2 (0..99%)

•Current pre-limit,weld2 (0..99%)

•Pre-limit count (0..99)

•Retry (On/Off)

•Pressure monitor (On/Off)

•Wait for pressure (On/Off)

•Pressure high limit (0..100%)

•Pressure low limit (0..100%)

Events

•4 x 4 trigger points

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Multiweld parameters

When either multi-gun or multi-gun cascade modes are selected, the following additional parameters are available:

Transformers

•Electrode number (1..16) for each transformer (x16).

Calibration (extended to x16)

•See ‘Global parameters’ for parameter list.

Counter (extended to x16)

•See ‘Global parameters’ for parameter list.

Stepper (extended to x16)

•See ‘Global parameters’ for parameter list.

Weld program (x64)

•Electrode number(1..16).

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Mounting

If you have purchased a complete system including the WS2003 timer, then the timer will already be mounted in the case.

If you have purchased a timer only kit, then you will need to mount the timer to the rest of your equipment.

The timer is supplied complete with two metal mounting brackets. These brackets need to be fixed to a flat surface, as shown in the diagram.

It is recommended that the four holes for the top bracket are made into vertical slots. The position of the bracket may then be adjusted to give the best fit to the timer.

Top bracket

375

4.5 dia.

Bottom bracket

66.5 66.597.0

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Connectors

Connectors P1,P2,P3,P4,P7,P13 and P14 are two-part terminals, for use with wires up to 1mm

Connectors P5 and P6 are used internally via ribbon cable assemblies, and are not used for users connections.

Connector P7 is the preferred connection for the current measurement toroid. If the WS2003 timer is being retrofitted into an older system, there may already be a toroid connected and routed internally via ribbon

P6. In this case, no connection should be made to P7. However, if possible, an existing toroid should be re-routed to P7.

P13 and P14 are not present on units produced before early 2008.

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Users connections (discrete)

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…users connections

WS2003 V1.69

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…users connections

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…users connections

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Operation with a fieldbus

WS2003 can be operated on a fieldbus, instead of through the discrete I/O connections.

An optional adapter card is required to interface to the required fieldbus. Adapter cards are available for all popular fieldbus types: (Profibus-DP, Interbus-S, DeviceNet, Ethernet TCP/IP/MODBUS, etc.)

The diagram opposite shows, schematically, how the I/O is arranged. Selection between Discrete or Fieldbus operation is via the timer configuration.

The tables on the next page show the fieldbus

OUTPUTS

Fieldbus

outputs

Physical

outputs

INPUTS

Fieldbus

inputs

Physical

inputs

F24V, SCR STAT

Mux

Output

Map

Mux

Pressure Error code

Timer

Output

Events

Sequencer

Timer

bit assignments for both single gun/multi-gun and dual-gun operation.

WS2003 I/O routing

Input

Map

Sequencer

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...operation with a fieldbus

Single gun /Multi-gun

INPUT from bus to timer OUTPUT from timer to bus

Bit No.

Function Bit No. Function

0 START 1 0 Prewarning 1 START 2 1 End of stepper 2 START 3 2 Reserved 3 START 4 3 End of count 4 2nd Stage 4 Contactor 5 Weld on* 5 Not ready 6 Reserved 6 Fault 7 Reserved 7 End of sequence (EOS)

8 Reset counter 8 Weld air valve 1 (WAV 1)

9 Reset stepper 9 Low force air valve (LFAV) / Motor 10 Ret r act 1 / Reset All 10 Retract air valve 1 (HAV 1) 11 Reserved 11 Reserved 12 Reserved 12 Discret e input I10 13 Reserved 13 Discret e input I11 14 Reserved 14 Discret e input I12 15 Reset fault 15 Discret e input I13

16 Program bit 1 16 Error c ode bit 1 17 Program bit 2 17 Error c ode bit 2 18 Program bit 4 18 Error c ode bit 4 19 Program bit 8 19 Error c ode bit 8 20 Program bit 16 20 Error c ode bit 16 21 Program bit 32 21 Error c ode bit 32 22 Reserved 22 Error code bit 64 23 Reserved 23 Error code bit 128

24 Discrete output Q01 24 Pressure bit 1 Discrete input I1 25 Discrete output Q02 25 Pressure bit 2 Discrete input I2 26 Discrete output Q03 26 Pressure bit 4 Discrete input I3 27 Discrete output Q04 27 Pressure bit 8 Discrete input I4 28 Discrete output Q05 28 Pressure bit 16 Discrete input I5 29 Discrete output Q06 29 Pressure bit 32 Discrete input I6 30 Discrete output Q07 30 Pressure bit 64 Discrete input I7 31 Discrete output Q08 31 Pressure bit 128 Discrete input I8

*The discrete Weld on input must also be on to enable welding.

Map=1 Map=2

Dual gun

INPUT from bus to timer OUTPUT from timer to bus

Bit No.

Function Bit No. Function

0 START 1 0 End of stepper 2 1 START 2 1 End of stepper 1 2 START 3 2 End of count 2 3 START 4 3 End of count 1 4 2nd Stage 4 Contactor 5 Weld on* 5 Not ready 6 Reserved 6 Fault 7 Reserved 7 End of sequence (EOS)

8 Reset counter 1 8 Weld air valve 1 ( WAV 1)

9 Reset stepper 1 9 Weld air valve 2 ( WAV 2) 10 Ret r act 1 10 Retract air valve 1 (HAV 1) 11 Reset counter 2 11 Retract air val ve 2 (HAV 2) 12 Reset stepper 2 12 Discrete input I10 13 Ret r act 2 13 Discrete input I11 14 Reserved 14 Discret e input I12 15 Reset fault 15 Discret e input I13

Map=1 Map=2

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Keypad

ENTRON

WSP3

Using the keypad

•Press the F (function) key to return to the previous screen, or to move between menu screens (see menus).

•The selected function or parameter will flash.

•Use the keys to select a different function or parameter. The visible window will scroll when required.

•Press the key to access the selected function.

•Press the + or - keys to alter the selected parameter. Press + and – together to set a parameter to 0 or its minimum value.

•On some screens, certain keys can have a special function. These are noted on the page describing that screen.

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Menus

The various functions of the timer are arranged into a set of menus and screens. The diagrams below shows how these are organized and accessed:

Diagnostic screen

LOW CURRENT WELD 2 PROG=0 COUNT1= 10 I1=10.5kA I2=12.1kA

F F F

STP1= 27%

P->5.00kN

Select bottom line in main menu (Version number)

<<< MAIN MENU >>> USE PROGRAM -EXT( 0) EDIT PROGRAM FILE

EDIT LIMITS FILE

<<< CONFIG. MENU>>>

EDIT CONFIGURATION EDIT CALIBRATION EDIT OUTPUT MAP

F+

Press and hold , then type

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..menus

<< ELECTRODE MENU >>

Stepper status Edit stepper Edit counter file

<< WELD LOG >>

View log Clear log

<<SEQUENCER MENU>>

Edit sequence Erase sequence Status: Idle

<< MAIN MENU >>

Use program Edit program file Edit limits file Edit events file Edit cascade** Electrode menu Weld log Sequencer menu Copy program Copy Electrode I/O Status

Fieldbus inputs Analog Inputs WS2003 version

<< CONFIG. MENU >>

Edit configuration Edit calibration Edit output map Edit input map Edit transformers* Setup adapters Backup all data Restore all data Initialise all data Edit system setup

**Only if multi-gun cascade mode is configured.

*Only if multi-gun or multi-gun cascade mode is configured.

<< SYSTEM SETUP >>

Show system files Select active file Restart system

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Diagnostic screen 1

LOW CURRENT WELD 2

Measured current for weld1

PROG=0 I1=10.5kA

StatusProgram used

Measured current for weld2

Note that some elements may not be visible, if that feature is not being used.

Status: Program used: Measured current:

•Press to reset faults (same action as external input). The counters will also be reset if they have reached the end of count.

•Press to change to diagnostic screen 2.

diagnostic error messages. If more than one exists, these are flashed sequentially.

this is the program number that was last used.

the RMS current measured during the last weld.

I2=12.1kA

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Diagnostic screen 2

Note that some elements may not be visible, if that feature is not being used.

Status: Weld counter: Stepper %complete PV output:

the selected program.

Measured PV feedback:

•Press to reset faults (same action as external input). The counters will also be reset if they have reached the end of count.

•Press to change to diagnostic screen 2.

diagnostic error messages. If more than one exists, these are flashed sequentially.

the present value in the counter (updates after each weld)

:shows the progress along the stepping curve.

The output from the PV controller is determined by the pressure parameter in

the dynamic value measured from the feedback channel.

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Error codes are sent to

Status / error codes

the fieldbus (if fitted).

The description (abbreviated) appears on the top line of the diagnostic screen.

Error code Description

0 No errors 1 Configuration error Edit the configuration file 2 No synchronising signal Check 27V AC sync. signal source / Check frequency in configuration file 3 4 5 6 Retract not ready Operate retract input 7 Data error Edit program 8 Weld off Close Weld-on switch

9 No current (weld 1) Check secondary circuit / check toroid connection 10 No current (weld 2) Check secondary circuit / check toroid connection 11 Low current (weld 1) Check secondary circuit or adjust parameters 12 Low current (weld 2) Check secondary circuit or adjust parameters 13 Pre-alarm (weld 1) Check secondary circuit or adjust parameters 14 Pre-alarm (weld 2) Check secondary circuit or adjust parameters 15 High current (weld 1) Check secondary circuit or adjust parameters 16 High current (weld 2) Check secondary circuit or adjust parameters 17 Config. Changed Restart the timer (power off/on) 18 No 2nd stage Check the 2nd stage input 19 Toroid overrange Reduce current, or use an external signal attenuator 20 Toroid open circuit Inspect toroid connection 21 Toroid short circuit Inspect toroid connection 22 23 24 25 Sequencer error Edit sequencer program 26 STOP or SCR hot Check external STOP circuit or scr cooling. 27 No 24V supply Check fuse in timer 28 29 30 Headlocked Operate reset fault input 31 No adapter Fit adapter or change configuration 32 Fieldbus inactive Check fieldbus connections / check bus master

dvice

WS2003 V1.69

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..status / error codes

Error code Descrip tion

33 34 35 36 37 38 39 40 41 42 Transformer hot Check water flow to welding transf ormer / Reduce duty 43 44 45 Inverter hot Check water flow to inverter / Check inverter fans/ Reduce duty 46 Inverter voltage error Check mains supply to inverter 47 48 49 50 Short circuit Check cables from invert er to welding transformer/ Check transform er 51 Inverter no current Check cables from inverter to weldi ng transformer/ Check transformer 52 Earth fault Check cables from i nverter to welding transformer/ Check transformer 53 Inverter disabled Check control connecti ons to invert er 54 Max. pulse width Check secondary circuit / Reduce heat/current 55 Max. prim ary current Check secondary circuit / Reduce heat /current 56 57 No Current(Weld off) Cl ose Weld-on switch 58 Low pre ssu re Check air pressure syst e m 59 High pressure Check air pressure system 60 Pressure not ready Check air pressure system 61 Switch off start The START signal is still on after a STOP or power-up condition. 62 63 64

dvice

WS2003 V1.69

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..status / error codes

Error code Descrip tion

65 Stepper 1 end Reset stepper 1 66 Stepper 2 end Reset stepper 2 67 Stepper 3 end Reset stepper 3 68 Stepper 4 end Reset stepper 4 69 Stepper 5 end Reset stepper 5 70 Stepper 6 end Reset stepper 6 71 Stepper 7 end Reset stepper 7 72 Stepper 8 end Reset stepper 8 73 Stepper 9 end Reset stepper 9 74 Stepper 10 end Reset stepper 10 75 Stepper 11 end Reset stepper 11 76 Stepper 12 end Reset stepper 12 77 Stepper 13 end Reset stepper 13 78 Stepper 14 end Reset stepper 14 79 Stepper 15 end Reset stepper 15 80 Stepper 16 end Reset stepper 16 81 Stepper 1 prewarn 82 Stepper 2 prewarn 83 Stepper 3 prewarn 84 Stepper 4 prewarn 85 Stepper 5 prewarn 86 Stepper 6 prewarn 87 Stepper 7 prewarn 88 Stepper 8 prewarn 89 Stepper 9 prewarn 90 Stepper 10 prewarn 91 Stepper 11 prewarn 92 Stepper 1 prewarn 93 Stepper 13 prewarn 94 Stepper 14 prewarn 95 Stepper 15 prewarn 96 Stepper 16 prewarn

dvice

WS2003 V1.69

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..status / error codes

Error code Description

97 Counter 1 end Reset counter 1 98 Counter 2 end Reset counter 2

99 Counter 3 end Reset counter 3 100 Counter 4 end Reset counter 4 101 Counter 5 end Reset counter 5 102 Counter 6 end Reset counter 6 103 Counter 7 end Reset counter 7 104 Counter 8 end Reset counter 8 105 Counter 9 end Reset counter 9 106 Counter 10 end Reset counter 10 107 Counter 11 end Reset counter 11 108 Counter 12 end Reset counter 12 109 Counter 13 end Reset counter 13 110 Counter 14 end Reset counter 14 111 Counter 15 end Reset counter 15 112 Counter 16 end Reset counter 16 113 Tip-dress 1 Dress electrodes then reset counter 1 114 Tip-dress 2 Dress electrodes then reset counter 2 115 Tip-dress 3 Dress electrodes then reset counter 3 116 Tip-dress 4 Dress electrodes then reset counter 4 117 Tip-dress 5 Dress electrodes then reset counter 5 118 Tip-dress 6 Dress electrodes then reset counter 6 119 Tip-dress 7 Dress electrodes then reset counter 7 120 Tip-dress 8 Dress electrodes then reset counter 8 121 Tip-dress 9 Dress electrodes then reset counter 9 122 Tip-dress 10 Dress electrodes then reset counter 10 123 Tip-dress 11 Dress electrodes then reset counter 11 124 Tip-dress 12 Dress electrodes then reset counter 12 125 Tip-dress 13 Dress electrodes then reset counter 13 126 Tip-dress 14 Dress electrodes then reset counter 14 127 Tip-dress 15 Dress electrodes then reset counter 15 128 Tip-dress 16 Dress electrodes then reset counter 16

dvice

WS2003 V1.69

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Configuration menu

<<< CONFIG. MENU>>>

EDIT CONFIGURATION EDIT CALIBRATION EDIT OUTPUT MAP EDIT INPUT MAP

SET-UP ADAPTERS BACKUP ALL DATA RESTORE ALL DATA INITIALISE ALL DATA EDIT SYSTEM SETUP

Visible window

Note: after changing the configuration, you must restart the timer before your changes will take effect.

You can restart the timer by cycling the power, or via the system set-up menu.

Note: To access the Configuration menu, select the ‘version’ line on the main menu (last line), hold down the key, then press the F key.

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Edit configuration

Note: after changing the configuration, you must restart the timer before your changes will take effect.

The diagnostic message ‘CONFIG.CHANGED’ will appear, and further welding will not be permitted until the timer is restarted

You can restart the timer by cycling the power, or via the system set-up menu.

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…edit configuration

•Sequence:Spot / Roll-spot / Seam(2-heat) / Seam(pre-heat).

•Single gun / Dual gun / OHMA gun / Multi-gun / Multi-gun cascade: the number/type of welding guns to be controlled.

•I/O Source:Discrete / Fieldbus(map 1) / Fieldbus(map2). Specifies how the timer obtains input signals ( outputs are always written to both the discrete and fieldbus interfaces).

•Retract:Simple / Hi-lift+ / Hi-lift- / Maintained / OHMA. Set to Simple if not required. One Independent setting for each gun.

•Start:Binary / 1-of-4. Sets the method of program selection.

•SCR Select: Binary / 1-of-4. Sets the method of SCR selection for multi-gun modes only. Use Binary with an external BD16 decoder, otherwise use 1 of 4.

•Frequency:AC 50 Hz / AC 60Hz / MF 50 Hz / MF 60Hz: Set to the frequency of your mains supply for AC operation. Set to MF 50Hz for MF DC operation with a 50Hz time-base, or set to MF 60Hz for MF DC operation with a 60Hz time-base. (Note that MF operation requires an Ethernet/MF adapter board to be fitted).

•Contactor time (0..200 s): this is the delay (in seconds) after a weld, before the contactor output is turned off. Set to 0 if not required.

•Blanking (On/Off): When set to On, the first 2 cycles of weld current will be excluded from the measurement and limit testing process.

•Sensor (Toroid / CT): The current can be measured via an air-cored toroid on P7, or via an iron-cored CT on P14. Be sure to set the sensitivity correctly in the calibration file.

•Toroid test (On/Off): When set to On, the resistance of the toroid is tested while the timer is idle. The resistance must lie between 10 and 100 Ohms. Values outside this range will prevent the timer from starting.

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……edit configuration

•Heat range (Wide/High/Low): Wide corresponds to a control range of 30-150’. High corresponds to a control range of 30-130’. Low corresponds to a control range of 50-150’. Select the LOW range for machines with a poor power factor, or when exceptionally low currents are required. Select WIDE range for machines that need to produce both very high and very low currents.

• If fault (Continue/Stop/Head-lock/EOS/ No EOS) :If Head-lock is selected, then when a weld fault is detected, the weld air-valve signal is held on and no further welds are permitted, until a fault reset is given. If Stop is selected, then when a weld fault is detected, the weld air-valve opens as normal, but no further welds are permitted, until a fault reset is given. If Continue is selected, then further welds will be permitted, regardless of the status of the previous weld. If EOS is selected, then the EOS signal is always given. If No EOS is selected, then no EOS signal is given when there is a weld fault.

•Sequencer (On/Off): If On is selected, then the sequencer is active, and welds are started via sequencer statements. If Off is selected, then the sequencer is disabled, and welds can be started via the START input.

•Toroid Factor (1..4): the ratio of the external attenuator which is required to measure currents>60kA

•Count/Log sync (On/Off): If set to On, then the log will be cleared when the counter is reset. If set to Off, then the log and counter are independent.

•Units (Metric/Imperial): this selects the system of units (e.g kN/lbf etc.)

•Analog out (PV/Current): this selects the function on the analog output at P2. If PV is selected, then the output follows the setting of the PV parameter in the programmes. If Current is selected, then the output will be the measured current waveform. Scale factors for both functions are set in the calibration file. Note that the output is provided as 0..10V or 4..20mA, depending on the setting of pcb jumper J4/J5.

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Edit calibration

<<< CALIBRATION 1 >>>

TOROID: 150 mV/kA

S/P RATIO 50:1 S/P OFFSET 0 A PRESSURE: Pt1: 10.0kN @ 100%

Pt2: 0.00kN @ 0.0% INVERTER: Pt1: 15.1kA @ 80.0% Pt2: 6.45kN @ 20.0%

ANALOG: 10V = 10kA

AN.IN GAIN x1.000

AN.IN OFFSET +0.00 V

CCR GAIN (SEAM): 5

Note: there are two separate calibration files for each gun in a dual-gun system, and sixteen calibration files in a multi-gun system.

Only if MF mode selected

Visible window

•Toroid: sensitivity of the measuring coil (toroid), expressed in mV/kA.

•S/P ratio & Offset: See next page for details.

•Pressure: relationship between the PV controller output and actual tip force. This is expressed by entering two ‘test’ point values, which then define a straight-line relationship.

•Inverter: relationship between the %heat output and actual current. This is expressed by entering two ‘test’ point values, which then define a straight-line relationship. (Only required for MF mode).

•Analog: the value of current which corresponds to full scale (10V/20mA) from the analog output at P2.

•Analog in gain: value by which the voltage at the analog input (ch 3 only) is multiplied. Use to fine trim the reading, or to match a 5V sensor with the 10V input scale.

•Analog in offset: value of the voltage at the analog input (ch 3 only) for a zero reading. Use in conjunction with the gain parameter to match reading to an external meter.

•CCR gain (Seam): Adjusts the CCR gain for seam welds only. Set to 5 as a starting point.

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…calibration

•If the sensor (Toroid or CT) is measuring the primary current (AC modes only), the timer can display secondary values. It does this by calculation based on the S

econdary to Primary ratio (S/P ratio) and offset (S/P offset)

parameters. For MF operation set S/P ratio to 1:1, and set S/P offset to 0.

•To determine the correct values,

do the following:

• Set the S/P ratio to 1:1 in the calibration.

• Set the S/P offset to 0 in the calibration.

• Do a short circuit weld at a low heat in PHA mode, and measure the secondary current (I

)with a meter. Note the corresponding value (Ip1)

on the timer status screen.

• Do a short circuit weld at a high heat in PHA mode, and measure the secondary current (I

)with a meter. Note the corresponding value (Ip2)

on the timer status screen.

• Calculate and enter S/P ratio = (I

-Is1) / (Ip2-Ip1)

• Calculate and enter S/P offset = Is2-(Ip2x S/P ratio)

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……calibration

•If you do not have a suitable meter, or you do not wish to do the calculations, you can still use primary feedback by doing the following:

1. Set the S/P ratio = transformer turns ratio in the calibration.

2. Set the S/P offset to 0 in the calibration.

•If you do not know the transformer turns ratio, then use a value of 50:1 as

many welding transformers will be approximately this figure.

• The current readings on the timer will be shown in kA, and the timer will

regulate (in CCR mode) to these figures, but they will not tie-up with a meter (i.e. the numbers are not absolute, but in ‘scaled’ Amps).

If you require precise and absolute settings then you must either:

•Do the procedure and calculations (see previous page)

•Use secondary feedback from a toroid, and set the sensitivity correctly.

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Edit Output Map

Each output may be independently set up as

either

or or or

When an output is mapped to ‘event’, it may be programmed to operate at any point in the welding sequence, via an event program. When an output is mapped to ‘sequencer’, it may be programmed to operate under the control of the sequencer program. When an output is mapped to ‘fieldbus’, it will be

• the standard function assigned (see users connections).

• as an EVENT output.

• as a SEQUENCER output.

• as a FIELDBUS output (outputs 1-8 only).

operated under the direct control of the fieldbus inputs.

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Edit Input Map

<<< INPUT MAP >>>

I01: RESET FAULT I02: P32

I03: P16 I04: EDIT DISABLE I05: RESET COUNT I06: RESET STEPPER I07: 2nd STAGE

I08: RETRACT I09: START 1 I10: P8/START 2

I11: P1/START 3 I12: P2/START 4

I13: P4 I14: WELD ON

Visible window

Each input may be independently set up as

either

• the standard function assigned (see users connections).

• as a SEQUENCER input.

When an input is mapped to ‘sequencer’, it may be used as part of the sequencer program, or as a discrete input to the fieldbus. Note that inputs I09 and I14 have special functions, and may only be mapped to standard.

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Set-up Adapters

<<< ADAPTERS >>>

SLOT 1 Ethernet 1.00 SLOT 2 NO ADAPTER

The WS2003 timer can be fitted with up to two adapter cards, to provide additional functions. These are fitted into two positions, referred to as slot 1 and slot 2.

This screen can be used to:

•Show what type of adapter cards are fitted.

•Access any parameters required by that adapter. Note that some adapters do not require any parameters.

View of timer with cover removed and two adapter cards fitted.

Slot 1 Slot 2

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Page 39

Backup/Restore

The Backup and Restore functions provide a convenient means of transferring all of your settings from one timer to another.

Backup: Use this function to make a copy of all of your data. The copy is held within the WSP3 pendant. No data in the timer is changed. Note that only one backup can be stored in the WSP3, and that this is overwritten each time the backup function is used.

Restore:

pendant. Note that this operation will overwrite all data which was previously stored in the timer. After the restore operation, the backup remains in the WSP3.

Before the restore can proceed, a check is made to ensure that the backup data was recorded from the same type of timer (i.e. another WS2003).

Use this function to restore all of your data in the timer, from a backup stored in the WSP3

Backup

WSP3WS2003

Restore

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Initialise all data

The Initialise function provides a convenient means of setting all of the data in the timer to a known initial state. This can be useful when first setting up a system.

Caution: When you use the Initialise function, you will loose all previously stored data in the timer.

After an initialise operation, you should edit the configuration files (configuration, calibration, mapping etc.), to suit your installation. You will then need to set-up any welding programmes etc. which you wish to use.

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System set-up menu

<<< SYSTEM SETUP >>>

SHOW SYSTEM FILES SELECT ACTIVE FILE

RESTART SYSTEM

Caution: These functions should only be used by trained and experienced personnel, as improper use could render the timer inoperable.

The WELDSTAR model WS2003 is equipped with two memories, which can be used to store two versions of the operating firmware files. The Edit system set-up menu provides a number of functions for examining and selecting these files.

Note: The timer will not operate while this menu is selected.

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Main menu

<<< MAIN MENU >>> USE PROGRAM -EXT( 0) EDIT PROGRAM FILE

EDIT LIMITS FILE

EDIT EVENTS FILE

ELECTRODE MENU SEQUENCER MENU

WELD LOG COPY PROGRAM I/O STATUS FIELDBUS INPUTS

For information only

ANALOG STATUS

WS2003 VERSION 1.34

Note: To access the Configuration menu, select the ‘version’ line on the main menu (last line), hold down the key, then press the F key.

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Edit program (AC)

<<< PROGRAM 0 >>> I1=7.50kA 25.0% PHA I2=10.0kA 50.0% CCR

[email protected]% NORM PSQ= 0 SQZ= 10 W1 = 0 C1 = 0

W2 = 10 C2 = 0 Pulses(W2-C2) = 1 UPSLOPE = 3 DOWNSLOPE = 0

HOLD = 10 OFF = 0 (SINGLE)

Visible window

PHA=Phase angle mode. The current and heat parameters are independently adjustable. No current regulation takes place. The current parameter is used for monitoring only. CCR=Constant current regulation mode. The current parameter is adjustable, but the heat is automatically determined by the timer, as it regulates the current to the set level.

IMPORTANT!

Set OFF time to 0 for single spot operation. If OFF time>0, then r epeat operation will occur.

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Edit program (MF)

<<< PROGRAM 0 >>> I1=7.50kA 25.0% UNC I2=10.0kA 50.0% CAL

[email protected]% NORM PSQ= 0 SQZ= 10 W1 = 0 C1 = 0

W2 = 10 C2 = 0 Pulses(W2-C2) = 1

UPSLOPE = 3 DOWNSLOPE = 0

HOLD = 10 OFF = 0 (SINGLE)

Visible window

UNC=Uncalibrated mode. The current and heat parameters are independently adjustable. Actual current is determined by the inverter. The current parameter is used for monitoring only. CAL=Calibrated mode. The current parameter is adjustable, but the heat is automatically determined by the timer from the calibration data.

IMPORTANT!

Set OFF time to 0 for single spot operation. If OFF time>0, then r epeat operation will occur.

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..edit program

<<< PROGRAM 0 >>> I1=7.50kA 25.0% PHA I2=10.0kA 50.0% CCR

[email protected]% NORM PSQ= 0 SQZ= 10 W1 = 0 C1 = 0

W2 = 10 C2 = 0 Pulses(W2-C2) = 1 UPSLOPE = 3 DOWNSLOPE = 0

HOLD = 10 OFF = 0 (SINGLE)

IMPORTANT!

Set OFF time to 0 for single spot operation. If OFF time>0, then repeat operation will occur.

Visible window

NORM = normal spot weld operation. LINK = linked spot operation.

LINKed operation provides a means of chaining programmes together so that a single start signal generates a sequence of programmes. At the end of a linked program, the next program (numerically ascending) is automatically selected and run, and so on, until either a program set to NORMal, or the last program (63) is reached.

Note: If the low-force option is selected in the configuration, then the presqueeze (PSQ) parameter changes to low-force time (LF). See section ‘low-force approach’. If the OHMA system is selected, additional timing parameters will be shown.

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….edit program(seam)

<<< PROGRAM 0 >>> I1=7.50kA 25.0% PHA I2=10.0kA 50.0% CCR BALANCE = 4.5%

[email protected]% PSQ= 0 SQZ= 10 W1 = 0 C1 = 0 W2 = 10 C2 = 0 UPSLOPE = 3

DOWNSLOPE = 0 HOLD = 10

If the timer is configured for seam welding, then the program screen

Visible window

BALANCE : This control is used to balance the current when using pulsed seam welding. It may be adjusted dynamically (i.e. while the machine is running).

changes as shown above, in order to present only the relevant parameters..

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Edit Limits

<<< LIMITS PROG 0 >>> CURRENT: MONITOR On LOW1=15% HIGH1=10%

PRE-LIMIT1= 5% LOW2=10% HIGH2= 8% PRE-LIMIT2= 5% PRE-LIMIT COUNT = 3

RETRY On

PRESSURE: MONITOR On

WAIT On

LOW = 10% HIGH=10%

Visible window

•The PRE-LIMIT COUNT is the number of successive welds which can fail the pre-limit level test, before a warning is generated.

•If RETRY is On, then in the event of the monitor detecting low or no current, the timer will automatically re-weld, without opening the electrodes.

•Pressure: monitor Pressure is checked to be within limits at the end of the weld.

•Pressure: wait Pressure is checked to be within limits before weld is allowed to start.

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Edit Events

<<< EVENTS PROG 0 >>> Ev1: 1=on @SQZ + 2 Ev2: 1=off @HLD + 5

Ev3: 6=on @W1 + 5 Ev4: 6=off @W2 + 3

e.g. Turn on output 6, 5 cycles into the Weld 1 interval.

All event outputs will be turned off at the end of the weld program.

Visible window

•Each welding program may have up to 4 events defined.

•Each event can turn one output on or off.

•To disable an event, set it’s output to ‘?’.

Note:The outputs used must be mapped to ‘EVENT’ for correct operation. (see Edit Output Map)

An ‘Event’ can only occur during a welding program. For actions required outside the welding program, use the sequencer.

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Electrode menu

<< ELECTRODE MENU >>

STEPPER STATUS

EDIT STEPPER

EDIT COUNTER FILE

A stepper is programmed by means of a curve which will provide values of heat and current increments, related to the number of spots done. The curve is defined by a set of 10 points. The

Electrode management is provided via a combination of stepper and counter functions.

The stepper provides a means of gradually increasing the current, to compensate for electrode wear. One stepper is provided per gun.

Current or Heat

dH9/dI

dH4/dI

dH3/dI

dH2/dI

dH1/dI

dH0/dI

timer provides interpolation between these points.

Step 0 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9

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Spots

Page 50

Stepper status

SPOTS DONE= 45

[RESET] 12%

dH= 2.5% dI= 5.0%

The percentage done of the total number of spots, also shown as a bar-graph.

Select this field and press to reset this stepper (same function as external input).

dH = % of programmed heat being added dI = % of programmed current being added.

Visible window

Select gun (electrode).

The number of spots made since the last reset. This may be changed to alter the working position on the curve.

Outputs:

Output ‘End of stepper’ comes on at the end of the last step.

Output ‘Prewarn’ comes on during the last step.

If tip-dressing is on, then

the outputs behave differently (see edit counter).

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Edit stepper

<<< STEPPER 1 on >>> CONTINUE AT END SPOTS +HEAT +AMPS 0: 10 1.0% 2.5% 1: 50 1.5% 5.0% 2: 100 2.0% 7.5% 3: 100 2.5% 10.0% 4: 100 3.0% 12.5% 5: 100 3.5% 15.0% 6: 100 4.0% 17.5% 7: 100 4.5% 20.0% 8: 150 5.0% 22.5% 9: 200 5.5% 25.0% [PRESET #1]

Visible window

Enable or disable the stepper.

If continue at end is selected, then at the end of the last step,further welding can take place as normal, but the stepper output will remain on. There is no further increase in current. If stop at end is selected, then no further welding may take place until a stepper reset is given.

Quick set-up: Enter values in step 9 only, to define the finishing point, select the PRESET field, edit the preset number(see next page), and then press to load this stepper with a preset curve.

Note: PHA mode will make use of both the +HEAT(dH) and +AMPS(dI) parameters. CCR mode uses only the +AMPS(dI) parameter, as the heat is self-adjusting.

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Stepper presets

60.0

50.0

When a preset curve is loaded, the data is

dH/DI %

40.0

30.0

20.0

10.0

0.0 012345678910

step no.

Series1 Series2 Series3 Series4 Series5

obtained from a table which holds the 5 curves shown.

The step sizes (spots) are all made the same as for step 9, and the +HEAT(dH) and +AMPS(dI) parameters are obtained by applying the values in step 9 to the curve as a scaling factor.

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Edit counter

<<< COUNTER 1 >>>

COUNT NOW = 431 COUNT UP TO 500

STOP AT END

TIP DRESSING On MAX.DRESSINGS = 10 DRESSINGS DONE = 2

@RESET,STEPPER= 100 DRESS WHEN NEW On

Note: gun/electrode 1, counter 2 is used

Counter 1 is used by

Count now is incremented after every weld. When count up to is reached, the counter output is activated. Set count up to = 0 to disable a counter. If stop at end is selected, then no further welding may take place until a counter reset is given. If continue at end is selected, then further welding can take place as normal, but the counter output will remain on. Count now is reset to zero by activating the counter reset input.

by gun/electrode 2, etc.

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Page 54

..edit counter(tip dressing)

<<< COUNTER 1 >>>

COUNT NOW = 431 COUNT UP TO 500

STOP AT END

TIP DRESSING On MAX.DRESSINGS = 10 DRESSINGS DONE = 2

@RESET,STEPPER= 100 DRESS WHEN NEW On

The counter can be used to control tip-dressing by setting the parameter ‘tip-dressing’to On.

Note 1

set to On, then the tip-dress (counter) output will also be activated after a reset stepper operation. This facilitates the dressing of new electrodes.

: If ‘dress when new’is

Stepper curve (see edit stepper)

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Sequencer

The sequencer provides a means of controlling a small machine, via a series of logic statements. The statements are executed sequentially in the order in which they appear.

The START1 input is used to trigger execution of the sequence, and must be maintained. On release of the START1 signal, the sequence is reset.

With the sequencer configured (see edit configuration), the START1 signal cannot be used to start a weld. Instead, welds are started via statements within the sequence.

The functions available consist of various input, output, memory, delay, counter and weld operations. It is also possible to program subroutines up to 8 levels deep.

The following resources are available:

Statements(lines) Up to 249 max. Outputs 8 Q1 to Q8 Inputs 16 I01 to I16 Memory 8 M1 to M8 (non-volatile) Counters 8 C1 to C8 (non-volatile)

Analog inputs 3 A1 to A3

Non-volatile values are retained, even if power is lost. Note that the inputs and outputs are shared with the welding controller and event timer (see Input map and Output map).

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Sequencer Menu

<< SEQUENCER MENU >> EDIT SEQUENCE ERASE SEQUENCE

STATUS: IDLE

For information only: Off: the sequencer is turned off (see edit

configuration) Idle:the sequencer is turned on, and waiting for the START input. Line n: the sequence is running and is executing line n.

Enter new statements, parameters etc. ,or edit the existing sequence (see edit sequence).

Erase the entire sequence –use with caution! You will be asked to confirm the operation before the erase takes place. An erased sequence cannot

be restored.

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…edit sequence

On the edit sequence screen, the keys have the following functions: At any time:

•Press the or keys to change the selected line. The entire line will flash. The screen will scroll when required.

•Press the key to insert a new (blank) line. The line number will be shown.

•Press the F key to return to the sequencer menu screen.

When entire line is flashing:

•Press + and – together to delete the selected line

•Press the + or - keys to alter the selected statement type.

•Press the key to momentarily see the selected line number.

•Press the or keys to select a parameter (parameter only will flash).

When parameter only is flashing:

•Press the + or - keys to alter the selected parameter.

•Press + and – together to set 0 or minimum value.

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…..edit sequence

The following table lists the available logic statement types:

Statement Range Function

Line nnn

----- STEP nnn ----AWAIT INPUT In n ON AWAIT INPUT In n OFF OUTPUT Qn ON OUTPUT Qn OFF MEMORY Mn ON MEMORY Mn OFF DELAY nn.n s JUMP nnn GOSUB nnn RETURN COUNTER Cn = xxx DECREMENT COUNTER Cn IF Cn>ZERO, JUMP xxx

IF Qn ON, JUMP xxx

IF Qn OFF, JUMP xxx

IF Mn ON, JUMP xxx

IF Mn OFF, JUMP xxx

IF Inn ON, JUMP xxx

IF Inn OFF, JUMP xxx

WELD (Prog=nn)

1..249 Li ne number within sequencer file ( has no ef fect)

1..999 Has no effect, but serves as the tar get for a JUMP or G OSUB statement, or as a logical divider in the progra m

1..14 Waits for Input nn to be ON

1..14 Waits for Input nn to be OFF

1..12 Turns ON Output n

1..12 Turns OFF Output n

1..8 Sets Memory bit n (non-volatile)

1..8 Clears Memory bit n (non-volatile)

0.1..99. 9 s W aits for specifi ed t ime

1..999 Pro gr am conti nu es at specifi ed S TEP numb er .

1..999 Program continues with the subroutine at the specified STEP number. (Note maximum of 8 nesting levels) Return from subroutine

n=1..8, x=1..999 Load s Counter n with the value xxx (non-volatile)

1..8 The value in Counter n is reduced by 1 (non-volati le)

n=1..8, x=1..999

n=1..12, x=1. .999

n=1..8, x=1..999

n=1..14, x=1. .999

n=0..63,EXT

If the value in Counter n is not If the value in Counter n is If Output Qn is ON If Output Q n i s OFF , t hen conti nue at the nex t statement If Output Qn is OFF If Output Qn is ON, then continue at the next statement If Memory Mn is ON If Memory Mn i s OFF , t hen conti nue at the nex t statement If Memory Mn is OFF If Memory Mn i s ON, then continue at the next statement If Input Inn is ON If Input Inn is OFF, then continue at the ne xt stat ement If Input Inn is OFF If Input Inn is ON, then continue at the next statement Execute weld sequence. The program number is determi ned by t he parameter nn. If nn=EXT, then the program number is read from the external selection inputs. The sequencer will wait untill the weld reaches 'End of sequence', before continuing with the next statem ent.

, then continue at STEP xxx.

then continue at STEP xxx.

zero, then continue at STEP xxx.

zero, then continue at the next statement

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Page 59

Example sequence

Statement Range Function

AWAIT ANALOG n<mm V

AWAIT ANALOG n>mm V

IF ANALOG n<mm V, JUMP xxx

IF ANALOG n>mm V, JUMP xxx

n=1.3,

0.0<=mm<=10.0 n=1.3,

0.0<=mm<=10.0

A short example program:

----- ST EP 1 ----AWAIT INPUT I03 ON

----- ST EP 2 ----OUTPUT Q8 ON DELAY 0. 5

----- ST EP 3 ----WELD (Prog = 01) OUTPUT Q8 OFF

----- ST EP 4 ----OUTPUT Q7 ON DELAY 0. 4 OUTPUT Q7 OFF DELAY 0. 2 JUMP 4

Waits for An alog input n t o be less than mm Volts.

Waits for Analog input n t o be greater than mm Volts.

If Analog input n is less than mm Volts, then continue at STEP xxx, otherwise continue with the next statement.

If Analog input n is greater than mm Volts, then continue at STEP xxx, otherwise continue with the next statement.

Part detector

Clamp ON Pause

W eld operat i on us i ng program number 1 Clamp off

Signal j ob done by flas hi ng out put unt i l S TART released Flash 'On' t i m e

Flash 'Off' tim e Loop back to c reat e flas hi ng effect

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Page 60

Weld log

<<< WELD LOG >>>

64 welds in log VIEW LOG CLEAR LOG

The number of welds presently held in the log.

The timer records the currents from each weld into the weld log. The log can hold information from up to 64 welds (after this, the oldest record will be discarded).

To see the information for each weld, select the VIEW LOG function.

The log can be cleared (emptied) by using the CLEAR LOG function.

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Page 61

View log (screen 1)

Press the + or - keys to select the log record

( 1= most recent weld,

64= oldest weld).

Program used for this weld

Status for this weld

Actual current measured

Note that if either of I1 or I2 are not shown, then that interval was not used.

•Press to change to log screen 2.

Target current from program

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Page 62

View log (screen 2)

Press the + or - keys to select the log record

( 1= most recent weld,

Status for this weld

64= oldest weld).

Gun (electrode) used for this weld

PV output

•Press to change to log screen 1.

Measured PV feedback

Value of the counter used for this weld

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Page 63

Copy program

<<< COPY PROGRAM >>>

FROM: 0

Copy a program (and associated limit and event files) to any other program, or to all other

TO: 1

programmes.

•Press the + or - keys to alter the selected parameter. The TO parameter can be set to ALL if required (i.e. copy 1 program to all others).

•Select the last line ( GO ), then press the key to execute the copy function. This line will briefly show COPY DONE, when the function is complete.

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Page 64

Copy electrode

<<<COPY ELECTRODE>>>

FROM: 1

Copy a stepper (and associated counter and calibration files) to any other stepper, or to all other

TO: 2

steppers.

•Press the + or - keys to alter the selected parameter. The TO parameter can be set to ALL if required (i.e. copy 1 stepper to all others).

•Select the last line ( GO ), then press the key to execute the copy function. This line will briefly show COPY DONE, when the function is complete.

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Page 65

I/O Status

<<< I/O STATUS >>> I01:RESET FAULT Off

I02:P32/GAPSW. On I03:SEQUENCER On I04:EVENT Off I05:RESET COUNT Off I06:RESET STEPPER Off

....

etc.

Visible window

This screen can be used to observe the status of the discrete inputs and outputs. Each input or output is labeled to show how it is mapped. i.e. standard function / event / sequencer. (see edit input map and edit output map)

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Page 66

Fieldbus input status

<<< BUS INPUTS >>> B00:START1 Off

B01:START2 On B02:START3 Off B03:START4 Off B04:2nd STAGE Off B05:WELD ON Off

....

etc.

Visible window

This screen can be used to observe the status of the fieldbus inputs. Note that this screen is only available if the timer is configured for fieldbus operation.

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Page 67

Analog Status

<<< ANALOG STATUS >>>

Channel 1 = 0.00 V Channel 2 = 2.34 V Channel 3 = 9.55 V

TOROID R = 20

•Analog input channels voltage at each of the analog inputs.

•Toroid resistance toroid test, in Ohms. If a measurement>750 Ohms is obtained then the (infinity) symbol is shown. If the toroid test is off, then ??? is shown

: the result of the

: the dynamic

This screen can be used to observe the status of the analog inputs.

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Page 68

Program selection

Single/

Ext

START

Programmes can be selected in a variety of different ways, depending on the settings used.

Note: If 2-input binary is selected, then the inputs START 1 and 2nd STAGE must be activated within 0.3 s of each other.

Set these parameters in the configuration file.

X = don’t care, or not connected

Note that if a program number exceeds the maximum (63), then the number will wrap around through 0. e.g. If N=62, then N+3=65. Applying wrap-around, N=N-64, giving a final value of N=1.

Dual

Single

Dual

Binary

1of4

Binary

1of4

nary/

1of4

Set this parameter from the main menu

program

N = 0..63 X 1 N 1 EXT P=0..63 1 P 1

N = 0..15

EXT

N = 0..31

EXT

N = 0..15

EXT

ernal

selection

=0..7

rogram

input

1N 1 3N+16 1 2N+32 1 4N+48 1 10 1 316 1 232 1 448 1 1N 1 2N+32 2

1 2

1N 1 3N+16 1 2N+32 2 4N+48 2 10 1 316 1 232 2 448 2

selected Gun

P2+32

1 2

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Page 69

OHMA (Air over Oil) system

The OHMA system uses three valves to control the opening and closing of the electrodes. If Retract is used, the timing of the valve operations is used to control the gap between the electrodes in their mid-position. To enable the OHMA system, you must make appropriate settings in the configuration file.

Weld Stroke

When a Start input is given to the weld control the Blocking valve is switched off and the Advance valve is switched on. This closes the electrodes onto the work-piece. At the end of the ‘Gun close’ time, the 2ndstage input and/or ‘wait for pressure’ function is/are checked, before the Intensify valve switches on to provide the electrode force required for welding.

The weld sequence proceeds in the usual way until the end of the Hold time when the Advance and Intensify valves switch off. The electrodes then start to open until the Blocking valve switches on and prevents further opening. The timing of the Blocking valve turning on (the Gun Open Time) sets the position to which the electrodes open. The End of Sequence output operates when the Blocking Valve switches on.

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…OHMA system

Retract Stroke

With the electrodes in the fully open position the control will not begin a weld sequence. A Retract input is required to move the electrodes to their mid-position.

When a Retract input is given, the Blocking valve is switched off and the Advance valve is switched on. This starts the electrodes moving towards their mid-position. After the Retract Close time the Advance valve is switched off. The Retract Close Delay time then begins and when complete, the Blocking valve is switched on, halting the movement of the electrodes. Hence, these times control the mid position of the electrodes. In this condition the timer is ready to weld.

When in this “ready” condition, if a Retract input is detected, the Blocking valve is switched off for the duration of the Retract Open time. This allows the electrodes to move to the full open position.

RETRACT input

ADVANCE output

INTENSIFY output

BLOCKING output

Retract close

time

Gun closing to mid-position

Retract delay

time

Retract open time

Gun fully opening from

mid-position

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Page 71

Disabling edits

Normally, a user can access the parameters via the keypad on the WSP3 programming pendant, and make any changes, as required. Under some circumstances, it may be desirable to prevent such general access.

The timer provides an input called ‘EDIT DISABLE’, which can be used to block all parameter edits. With this input on, it will still be possible to view parameters, but no changes are permitted via the keypad.

If edits are attempted, the display will briefly show

It is suggested that this input is controlled via a key-switch, such that only the key-holder is able to open the switch, and thus be able to edit parameters.

Typical connections to Timer

** EDITS DISABLED **

and the edit will be blocked.

If this feature is not required, simply leave this input unconnected.

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Pop-up current meter

The timer will measure the current on both the weld1 and weld 2 intervals, and this is displayed on the diagnostic screen. Often, when programming the timer, you will need to refer to these current measurements. In order to avoid having to switch between screens, there is a convenient pop-up current meter window, which allows you to view the measured currents without leaving the screen you are on. The pop-up meter is activated by pressing the key. To close the pop-up window, press the key again.

<<< CALIBRATION >>> TOROID: 150 mV/kA

TOROID FACTOR x1 S/P RATIO 50:1

Note that the window may not show both weld1 and weld2, if either interval was not used. Some screens use the key for another purpose (such as selecting an item from a list). In this case, the pop-up meter is not available from that screen.

I1=6.06kA I2=8.45kA

Pop-up window

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Replacing a WS2000 timer

If you have an existing installation with a WS2000 timer and a primary toroid, and you are replacing that timer with a WS2003, then use the following procedure:

1. Note the existing settings (weld program), measure the welding current with a meter, and note the current measured by the WS2000.

2. Fit the new timer (WS2003).

3. Adjust the primary toroid calibration trimmer to fully anti-clockwise.

4. Initialise the data in the WS2003.

5. Set the toroid sensitivity to 1400mV/kA

6. Set up the appropriate welding program, using the settings recorded in step 1, but using PHA mode.

7. Weld – measure the current (x) with a meter, and (y) on the timer.

8. Calculate x/y and enter this as the S/P ratio.

9. Weld – the current (z) on the timer should agree with the meter.

10. Enter z (the current value) into the current parameter in the timer program.

11. Weld.

12. Select CCR if required.

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Operation: basic spot weld – no weld faults

Current

START input

EOS output

FAULT output

WAV output

SQZ

W1=0, C1=0, Pulses=1, OFF=0

HLD

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Operation: basic spot weld – weld fault

Current

START input

EOS output

FAULT output

WAV output

SQZ

W1=0, C1=0, Pulses=1, OFF=0

HLD

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Operation: repeat spot weld

Current

START input

WAV output

PSQ

SQZ

HLD

W1=0, C1=0, C2=0, Pulses=1

OFF

SQZ

HLD

OFF

SQZ

HLD

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Operation: pulsation spot weld

Current

START input

EOS output

FAULT output

WAV output

SQZ

W1=0, C1=0, Pulses=3, OFF=0

HLD

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Operation: Upslope and Downslope

Current

START input

Spot

WAV output

The upslope and downslope times are part of the overall weld time – they do not add to the weld time.

Current

Upslope time Downslope time

Weld time

Downslope time

Seam

START input

Upslope time

WAV output

Note that for seam welds, the downslope time begins when the initiation input turns off.

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Operation: roll-spot welding

Current

START input

MOTOR output

WAV output

PSQ

SQZ

W1=0, C1=0, C2=0, Pulses=1

HLD

OFF

SQZ

HLD

OFF

SQZ

HLD

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Operation: seam welding (dual heat)

Current

START input

MOTOR output

WAV output

PSQ

SQZ

C1=0, C2=0

HLD

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Operation: seam welding (pre-heat)

Current

START input

MOTOR output

WAV output

PSQ

SQZ

HLD

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Operation: EOS signal

Handshake mode: The start signal

Current

START input

EOS output

20~

WAV output

Current

START input

EOS output

20~

WAV output

remains on until EOS is given. When start is removed, EOS goes off immediately (cancel with start mode) or after 20 cycles (fixed pulse mode). This is the recommended method of operation for automatic systems.

Pulsed mode

off before the end of the hold time. The EOS signal is a fixed pulse of 20 cycles.

If a new start signal is given during the EOS pulse, a new sequence will start immediately. Then EOS will go off immediately (cancel with start mode) or at the end of the 20 cycle pulse (fixed pulse mode).

: The start signal goes

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Operation: Retract

The retract operating mode

(Simple/Hi-lift+/Hi-lift-

/Maintained) is set in the

configuration file.

No/ Simple

Maintained

Retract input

HAV output

START input

WAV output

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Operation: Hi-lift

The retract operating mode

(Simple/Hi-lift+/Hi-lift-

/Maintained) is set in the

configuration file.

Hi-lift+

Hi-lift-

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Multiwelding

SCR

Welding transformer

Up to 16 pairs of electrodes, distributed randomly across the welding transformers.

WS2003 configured for single gun use.

Only one transformer/SCR is connected. Electrodes must be closed one pair at a time.

WS2003 configured for multi-gun use.

Up to 16 welding transformers/SCRs when used with BD16 decoder, otherwise up to 4 SCRs.

Up to 16/4 transformers/SCRs can be connected. Up to 16 electrode pairs can be closed at a time. Control can ripplefire through up to 16 spots, or each spot can be individually triggered. Transformers/SCRs can be different sizes.

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Configuring WS2003 for multiwelding

There are two modes available for multiwelding: ‘MULTI-GUN’ and ‘MULTI-GUN CASCAD E’.

Multi-gun mode allows each welding program to be triggered independently, in the traditional way, but allows for selection of a transformer and electrode.

In multi-gun cascade mode, up to sixteen welding programmes can be grouped together, and triggered from a single start command. The programmes then ripple through with minimal time between them, selecting transformers and electrodes on the fly. The group of programmes is referred to as a cascade.

Selection of these modes is made by selecting ‘EDIT CONFIGURATION’ from the config. Menu:

Operating mode selection: Press the + or – keys until either multi-gun or multi-gun cascade is shown.

SCR select: use BINARY if the SCRs are equiped with a decoder (such as a BD16), otherwise select 1 of 4.

Binary: up to 16 SCRs. 1 of 4: up to 4 SCRs

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Electrode/Transformer assignment

The physical arrangement of the electrodes and welding transformers must be

entered into the control.

1. From the config. menu, select ‘EDIT TRANSFORMERS’.

<<< CONFIG. MENU>>>

EDIT CONFIGURATION EDIT CALIBRATION EDIT OUTPUT MAP EDIT INPUT MAP

EDIT TRANSFORMERS SET-UP ADAPTERS BACKUP ALL DATA RESTORE ALL DATA INITIALISE ALL DATA EDIT SYSTEM SETUP

3. Each transformer has a separate calibration file. Perform the calibration procedure (see main manual) for each transformer connected.

Visible window

In the example shown here: Electrodes 1 and 2 are attached to Transformer 1.

Electrodes 3 and 4 are attached to Transformer 2. Electrodes 5 and 6 are attached to Transformer 3. Electrodes 7 and 8 are attached to Transformer 4. Electrodes 9..16 are not used.

2. Assign each electrode to a transformer.

<<<TRANSFORMERS>>> E1 -> T1 E2 -> T1

E3 -> T2 E4 -> T2 E5 -> T3 E6 -> T3 E7 -> T4 E8 -> T4 E9 -> T9 E10 -> T10 E11 -> T11 E12 -> T12 E13 -> T13 E14 -> T14 E15 -> T15 E16 -> T16

Visible window

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Assigning a weld program to an electrode

Each weld program should be assigned to a particular electrode. This is done on the

‘EDIT PROGRAM’ screen, accessed from the main menu.

<<< PROGRAM 0 >>> I1=7.50kA 25.0% PHA I2=10.0kA 50.0% CCR

[email protected]% NORM PSQ= 0 SQZ= 10 W1 = 0 C1 = 0 W2 = 10 C2 = 0

Pulses(W2-C2) = 1 UPSLOPE = 3 DOWNSLOPE = 0

Visible window

In the example shown here:

HOLD = 10 OFF = 0 (SINGLE) ELECTRODE = 1

Whenever a program is run, the control will automatically trigger the correct transformer, by referencing the electrode/transformer assignment table, as shown on the previous page. In addition, the electrode number is also used to access the appropriate stepper, counter and calibration information.

Weld program 0 is assigned to Electrode 1.

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Multi-gun operation

Multi-gun mode allows each welding program to be triggered independently,

in the traditional way, but allows for selection of a transformer and electrode.

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Multi-gun cascade operation

In multi-gun cascade mode, up to sixteen welding programmes can be grouped

together, and triggered from a single start command. The programmes then ripple

through with minimal time between them, selecting transformers and electrodes on the

fly. The group of programmes is referred to as a cascade. Up to 16 cascades may be

programmed.

To set up a cascade, select ‘EDIT CASCADE’ from the main menu.

<<< CASCADE 0 >>> STEPS = 5 S01:P00->E01->T01 ON

S02:P02->E02->T02 ON S03:P10->E03->T03 ON

S04:P11->E04->T04 ON S05:P12->E05->T05 ON

Note that in multi-gun cascade mode, the program selection inputs refer to a cascade, and not directly to a weld program.

Visible window

Individual steps can be turned ON or OFF to assist setting up.

In the example shown here: The cascade consists of 5 steps, using programmes 0,2,10,11 and 12. Note that the electrode and transformer numbers are automatically assigned, by reference to the electrode number in the selected weld program.

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…multi-gun cascade operation

Curren t (transformer 1)

Curren t (transformer 2)

Curren t (transformer 3)

Curren t (transformer 4)

START input

Program select inputs

Cascade #

EOS output

WAV output

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Program selection (multiweld)

Programmes can be selected in a variety of different ways, depending on the settings used.

Set these parameters in the configuration file.

X = don’t care, or not connected

Note that if a program number exceeds the maximum (63 or 15), then the number will wrap around through 0. e.g. If N=62, then N+3=65. Applying wrap-around, N=N-64, giving a final value of N=1.

Mode

Multi-gun

Mode

Multi-gun cascade

Binary/

1of4

Binary

1of4

Binary/

1of4

Binary

1of4

Set this parameter from the main menu

Use

program

N = 0..63 X 1 N EXT P=0..63 1 P

N = 0..15

EXT

Use

cascade

N = 0..15 X EXT P=0..15

N = 0..3

EXT

External

selection

External

selection

START

input

1N 3N+16 2N+32 4N+48 10 316 232 448

START

input

1N 1P 1N 3N+4 2N+8 4N+12 10 34 28 412

Program selected

Cascade selected

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WS98-2003 PC software

WS98-2003 PC software is available for use with the WS2003 timer. This offers the user the ability to program and monitor the welding control, and to back-up all of the programmed data on a PC.

Timers may be connected to the PC via RS232 (1 timer only) or via Ethernet (multiple timers on a network).

WS98-2003 is available on CDROM, and works with all versions of Microsoft Windows™ (98 onwards). Contact BF Entron for more details.

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