Tweco WC 1 User Manual
2200 Corporate Drive
Troy, OH 45373
Phone: (937) 440-0100
Fax: (937) 440-0277
WC 1
WC 1
WC 1WC 1
WELD SEQUENCE CONTROLLER
WELD SEQUENCE CONTROLLER
WELD SEQUENCE CONTROLLERWELD SEQUENCE CONTROLLER
Operation / Installation Manual
Manual Part Number: C8M5002
Date: July 9, 2002
Revised: July 24, 2003
July 24, 2003 Manual No. 430429-518
July 24, 2003 Manual No. 430429-518
TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTSTABLE OF CONTENTS
1.0 GENERAL DESCRIPTION............................................................................................ 1
1.1 O
VERVIEW
1.2 C
ONTROL OUTPUTS
1.3 C
ONTROL INPUTS
1.4 C
ONTROL DISPLAY AND STATUS INDICATORS
..........................................................................................................................................................1
...........................................................................................................................................1
...............................................................................................................................................1
.....................................................................................................2
2.0 CONTROL INSTALLATION.......................................................................................... 3
2.1 E
NCLOSURE INSTALLATION
2.2 S
TANDARD ENCLOSURE DIMENSIONS
2.3 R
EMOTE CONTROL RECEPTACLE
.................................................................................................................................3
.................................................................................................................3
.......................................................................................................................4
3.0 WELD SEQUENCE EVENTS........................................................................................5
3.1 W
3.2 P
3.3 W
3.4 S
3.5 A
ELD SEQUENCE PARAMETERS
ULSE WELD MODE PARAMETERS
ELD CYCLE EVENTS
POT WELD MODE
RC ACTIVE TEST
.......................................................................................................................................5
............................................................................................................................................6
..............................................................................................................................................6
........................................................................................................................5
....................................................................................................................5
4.0 USER INTERFACE........................................................................................................ 7
4.1 R
EMOTE CONTROL INTERFACE SPECIFICATION
4.2 R
EMOTE PENDANT INTERFACE
4.3 O
PTIONAL OPERATOR PENDANT
4.4 RS-232 S
4.5 A
UTOMATED USER INTERFACE
4.6 T
YPICAL USER INTERFACE FOR AUTOMATED OPERATION
ERIAL PORT
........................................................................................................................................7
...........................................................................................................................7
.........................................................................................................................7
...........................................................................................................................7
...................................................................................................7
...................................................................................9
5.0 CONTROL SPECIFICATION....................................................................................... 10
5.1 E
NCLOSURE SPECIFICATION
5.2 C
ONTROL CABLES AND CONNECTORS
5.3 C
ONTROLS AND STATUS INDICATORS
5.4 S
YSTEM SPECIFICATIONS
............................................................................................................................ 10
............................................................................................................. 10
.............................................................................................................. 10
................................................................................................................................11
6.0 OPERATIONAL DISPLA Y A ND PROGRAMMING................................................... 12
6.1 S
TATIC WELD DISPLAY SCREENS
6.2 S
TATIC DISPLAY SCREEN ERROR MESSAGES
6.3 M
ODIFYING WELD SCHEDULE AND SYSTEM PARAMETER S
6.4 W
ELD SCHEDULE PARAMETER MENUS
6.5 PAW W
6.6 PAW W
6.7 GMAW O
6.8 S
6.9 S
ELD SCHEDULE MENU SCREENS
ITH COLD WIRE FEED OPTION WELD SCHEDULE MENU SCREENS
PTION WELD SCHEDULE MENU SCREENS
ETUP PARAMETER MENUS
ETUP PARAMETER MENU SCREENS
.................................................................................................................... 12
.................................................................................................. 13
............................................................................... 13
............................................................................................................ 14
........................................................................................................ 14
...................................................... 15
........................................................................................ 16
............................................................................................................................. 17
............................................................................................................... 17
7.0 WC 1 OFF-LINE RS-232 T ERMINAL PROTOCOL....................................................18
7.1 G
ENERAL DESCRIPTION
7.2 T
ERMINAL PROTOCOL
7.3 T
ERMINAL COMMANDS
...................................................................................................................................18
......................................................................................................................................18
.....................................................................................................................................19
8.0 ENCLOSURE LAYOUTS.............................................................................................22
8.1 WC 1 C
ONTROL ENCLOSURE
- S
TANDARD LAYOUT
P/N: C3A5003............................................................... 22
July 24, 2003 Manual No. 430429-518
8.2 WC 1 C
8.3 O
PERATOR PENDANT
ONTROL ENCLOSURE
P/N: C3A5006 .............................................................................................................24
- C
APSTAN MOTOR DRIVE LAYOUT
P/N: C3A5004.......................................... 23
9.0 ENCLOSURE PARTS LISTS...................................................................................... 25
9.1 WC 1 C
9.2 WC 1 C
9.3 WC 1 P
ONTROL ENCLOSURE
ONTROL ENCLOSURE
ENDANT ENCLOSURE
- S
TANDARD LAYOUT
– C
APSTAN MOTOR DRIVE LAYOUT
P/N: C3A5003............................................................... 25
P/N: C3A5004 ......................................... 27
P/N: C3A5006................................................................................................ 30
July 24, 2003 Manual No. 430429-518
1.0 GENERAL DESCRIPTION
1.1 Overview
The following is a brief description of the WC 1 Thermal Arc Weld Sequence Controller. The WC 1
controller is based on an embedded micro controller. The Controller provides two 0-10 VDC
programmable outputs, one is used to control the Thermal Arc Plasma Power source and the
second, controls a Cold Wire Feed Motor Drive Control. The Controller provides 32 user selectable
weld schedules.
1.2 Control Outputs
The controller has five solid-state isolated relay outputs. One output is configured as an arc start
signal to the Thermal Arc power source. The remaining four has the following default configuration:
• CR1 - Ready – This output is asserted when the Controller is operating normally. It will
reset when the controller is in ESTOP or an Internal/External fault has occurred.
• CR2 - Arc Active – This output is asserted after the arc is established. The signal is
generated from the Thermal Arc power source. The output is cleared if a loss of arc is
detected, internal Program fault, or the cycle start signal is reset.
• CR3 - Cycle Complete – This output is asserted when the programmed weld cycle has
been completed. If a fault or loss of arc has occurred during the cycle the Cycle complete
will not be set.
• CR4 - Cycle Active – This output is active during the complete weld cycle and will be
cleared at the end of all programmed events.
1.3 Control Inputs
The Controller provides nine 24 VDC Optically isolated inputs. Three inputs are dedicated for
ESTOP, Arc Active and Pilot Arc Active. The Arc Active and Pilot Arc Active inputs are connected
to the Thermal Arc power source. The ESTOP input may be internally set to the active state. The
remaining six inputs may be configured for remote schedule or program control. The nine inputs
have the following default configuration:
• ESTOP – This input must be active. If the ESTOP is cleared the control performs an
emergency stop and halts the weld cycle and resets all outputs. When asserted the
controller performs a power up sequence.
• ARC ACTIVE – When asserted the controller will initiate the Start Timer Event. If the weld
is not initiated within 2 seconds of cycle start the control will terminate the weld cycle and
clear the Ready Output. The user must clear the Cycle start input to reset the Ready
output.
• PILOT ARC A C TIVE – This input must be asserted to set the Ready output and to allow
the controller to perform a weld cycle. An external jumper can force this input.
• INP 1 – SCHED 0 – User definable spare input. Under remote schedule mode this input
can be used for weld schedule selection (Bit 0).
• INP 2 – SCHED 1 - User definable spare input. Under remote schedule mode this input
can be used for weld schedule selection (Bit 1).
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• INP 3 – SCHED 2/ PARAMETER SELECT - User definable spare input. Under Remote
Schedule Mode this input can be used for weld schedule selection (Bit 2). Under Remote
Control Mode this input is used to select the parameter to Increase/Decrease. When
Cleared the Current is selected. When Asserted the Wire Feed speed parameter is
selected. This option is only active when the optional wire drive and when the Remote
control mode is enabled.
• INP 4 – SCHED 3/ INCREASE PARAMETER – User definable spare input. Under Remote
Schedule Mode this input can be used for weld schedule selection (Bit 3). Under Remote
Control Mode activating this input will increment the selected parameter as specified by
INP3. The maximum increase level can be user defined for each weld schedule.
• INP 5 – SCHED 4/ DECREASE PARAMETER - User definable spare input. Under
Remote Schedule Mode this input can be used for weld schedule selection (Bit 4). Under
Remote Control Mode asserting this input will decrease the selected parameter as
specified by INP3. The minimum decrease level can be user defined for each schedule.
• INP 6 - CYCLE START – This Input, when asserted, will start a weld cycle and must be
active during the complete weld cycle. If the input is reset the cycle will be terminated. If
the Spot Weld mode is enabled, the weld cycle will be terminated by the user defined weld
time. The Cycle start input must be reset before the next weld cycle can be initiated.
1.4 Control Display and Status Indicators
The controller has a 2-line 16-character Alpha Numeric LCD display which is used to program the
weld schedule data and to configure the control options. Three push button switches are used to
select the desired parameters and to increment or decrement the values. A Program/Run key lock
switch is provided to prevent unauthorized access to the WC 1 weld schedule and system
configuration. Eight Status LEDs are used to indicate the weld sequence events and selected
modes. The Program LED is illuminated when the WC 1 is in weld sequence mode. The Pulse
LED is illuminated when the Pulse Weld function is active. During a weld cycle the status LEDs will
be illuminated to indicate weld event sequence being executed. A RS-232-C serial port is provided
and allows the user to program all of the WC 1 schedules and features off-line.
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2.0 CONTROL IN ST ALLATION
2.1 Enclosure Installation
Install the Enclosure in a c onvenient location that al lows easy operator access to the front control
panel. Allow a minimum clearance of 6” (152mm) fr om the rear of the enc los ure to all o w ac c es s f o r
the external cable connectio ns. To permanently m ount the enclosure rem ove the four r ubber feet
and mount the enclosure using blind-hole fasteners located on the bottom of the enclosure. Connect
the Power cable to a suitable source of AC power. Connect the Po wer supply rem ote cable to the
“POWER SUPPLY CONTROL” rec eptac le. Connect the optional operator pendan t c ontr ol cab le to
the “REMOTE PENDANT” receptacle.
2.2 Standard Enclosure Dimens ions
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2.3 Remote Control Receptacle
The optional remote c ontrol receptacle provides a basic operational control interf ace to the WC 1
controller. The following is the pin-out and control function for the 9 pin receptacle.
PIN DESCRIPTION
1 +24 vdc @ 100 ma. Power Output
2 ESTOP – 24 VDC input
3 CYCLE START – 24 VDC input
4 INC – 24 VDC Input. Increase the current during the weld cycle
5 DEC – 24 VDC Input. Decreases the current during the weld cycle
6 CYCLE ON - 24 VDC Active low sinking (Pull-Down) output
7 CYCLE COMPLETE – 24 VDC Active Low sinking (Pull-Down) output
8 EARTH GROUND
9 READY – 24 vdc Active Low sinking (Pull-Down) output
Table 1 - WC 1 Remote Control Receptacle Pin-Out
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3.0 WELD SEQUENCE EVENTS
3.1 Weld Sequence Pa rameters
The WC 1 Plasma Weld Sequence Controller provides the following user defined parameters:
• START CURRENT – The value of current to be used during the start time event.
• START TI ME – The amount of time to hold the start current before beginning the Ramp Up
Event.
• RAMP UP TI ME – The time required to ramp from the start current to the run current.
• RUN CURRENT – The value of current to be used during the Run time of the weld cycle.
• WELD TIME – The user defined spot weld time when enabled.
• % TAPER CURRENT - The % of Run current used as the end current level for the taper
time and the start of the Ramp Down Event.
• TAP E R TIME – The amount of time required for the Current Taper Event.
• RA MP DO W N TI ME – The amount of time required to ramp from the % Taper current
value to the End current value prior to the End Current Event.
• END CURRENT - The end cycle current level to be used during the End Cycle Time.
• END TIME – The amount of time required for the end weld event.
3.2 Pulse Weld Mode P arameters
If the Pulse mode is enabled the following parameters will be used to define the pulse conditions:
• PULSE ON TIME – Specifies the Pulse On time period when the Pulse mode is enabled.
• PULSE OFF TIME – Specifies the Pulse Off time period when the Pulse mode is enabled.
• % PULSE CURRENT – Specifies the percent of the Run current that will be used during
the Pulse Off time period.
3.3 Weld Cycle Events
The Weld cycle is initiated by asserting the Cycle Start Input. The controller will monitor the Arc
Active input and will assert the Active output when active. The controller will set the Thermal Arc
Power source to the value specified by the Start Current Parameter. After the Start time has expired
the Current output would be ramped to the Run current value over the Ramp Up time specified. At
the end of the Ramp Time the Run current value will be active. If the Pulse mode is enabled the
Pulse On time will be used to specify the time at Peak Current. The Pulse Off Time and Percent
Current will be used to define the background pulse condition. If the Spot Time is Disabled the
controller will continue to operate in the Run Event. When the Cycle Start is reset the controller will
begin the Taper Time and ramp the Run current to the level specified by the Percent Taper
parameter. If the Pulse mode is enabled the pulsing will start during the Ramp Up event and will
continue through the ramp down event. At the end of the ramp down time the controller will set the
End Current value and will hold this value for the time specified by the End Time parameter. The
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Cycle Complete will be asserted at the end of the weld cycle when the Arc Active Signal has been
cleared by the power source. The Cycle complete will remain set until the next Cycle start is
asserted. To disable any weld event set the associated time to zero.
3.4 Spot Weld Mode
If the Spot Time mode is enabled the Taper Event will be started at the end of the Spot Weld Time.
Then the normal end events will be executed. In this mode the Cycle Start must be active until the
end of the weld cycle. The Controller will not reset the weld event until the Cycle input has been
cleared. The Cycle complete will be asserted when the Arc Active Signal is cleared. The Cycle
Complete Output will be cleared when the Cycle start is cleared.
3.5 Arc Active Test
If the Arc Active input from the power source is not active within the user specified start time after
the cycle start has been asserted, the controller will clear the weld event and reset the Ready
Output. The Cycle Start input must be cycled off before the Ready Output can be asserted. If the
Cycle start input is cleared prior to the weld event the controller will terminate the arc and will not set
the Cycle Complete output.
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4.0 USER INTERFACE
4.1 Remote Control Interface Specification
The WC 1 Controller provides a remote control interface that allows the user to connect an external
PLC or robotic control to the WC 1. The interface provides remote schedule select, cycle start and
operational status indication. The WC 1 inputs are configured to operate from a 24 VDC power
source. The inputs can be configured for Pull-Up (Sourcing) or Pull Down (Sinking). A 24 VDC @
200MA isolated power supply (TB5) is provided to allow dry contact closures to activate the WC 1
inputs. All Relay Outputs are opto-isolated solid-state relays and will switch AC/DC loads up to 120
VAC at 1 amp.
4.2 Remote Pendant Interface
A 9 pin CPC circular connector is provided to allow the use of a manual operator control pendant.
The Optional Operator Pendant is designed to connect to this Operator Control connector and will
perform the following Control functions:
• ESTOP – Palm button provides emergency stop input to the weld control.
• CYCLE ON – Toggle switch to start and stop a weld cycle.
• INC CURRENT – Pushbutton switch used to increase the Run current during a weld cycle.
The control will provide user defined limits for current change.
• DEC CURRENT – Pushbutton switch used to Decrease the Run current during a weld
cycle. The control will provide user defined limits for current change.
• READY – Green LED Indicator.
• CYCLE ON – Red LED Indicator.
• CYCLE COMPLETE – Green LED Indicator.
4.3 Optional Operator Pendant
The Operator Control Pendant is a NEMA 1 rated clamshell enclosure with a 15 ft control cable and
Remote I/O plug. If the WC 1 controller is to be used in a robotic or PLC based application the
remote pendant option is disabled and the inputs must be reconfigured for the desired remote
PLC/Robotic control functions.
4.4 RS-232 Serial Port
All weld schedule programming can be performed off-line via a RS-232 serial port or using the
internal display and program buttons. The Internal display allows the user to program all of the WC 1
Plasma Weld sequence parameters and to configure the controller operational modes. It can also
be used to Save and Load internal weld schedules.
4.5 Automated User Interface
The WC 1 controller allows full remote control capabilities for use with PLC or robotic controllers.
The control provides a 24-vdc interface that allows the users to select weld schedules and to
start/Stop the welding sequence. The controller provides a simple hand shaking output that allows
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