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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

Содержание WELDSTAR WS2003

Страница 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...

Страница 2: ...DY1 4DA England Tel 44 0 1384 455401 Fax 44 0 1384 455551 Email sales bfentron co uk Web site www bfentron co uk Manufacturers of advanced welding controls Welding controls Thyristors and power suppl...

Страница 3: ...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...

Страница 4: ...ENCER EVENT TIMER Ethernet WS2003 WELDING CONTROL WSP3 PROGRAMMING PENDANT WS2003 TIMER Optional Ethernet adapter required for connection to Ethernet WELDSTAR 2000 compatible Optional Plug in adapter...

Страница 5: ...software for programming and monitoring purposes Fieldbus operation Profibus Interbus DeviceNet Modbus etc is supported via plug in option boards The new WELDSTAR model WS2003 is a direct plug in repl...

Страница 6: ...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 monit...

Страница 7: ...t 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...

Страница 8: ...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 f...

Страница 9: ...ntinue EOS No EOS Sequencer On Off Toroid attenuation factor 1 4 Count Log sync On Off Pressure units kN lb Analog output PV Current Sensor sensitivity 100 60000 mV kA S P ratio 1 1 199 1 S P offset 1...

Страница 10: ...cycles 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...

Страница 11: ...6 Counter extended to x16 Stepper extended to x16 See Global parameters for parameter list See Global parameters for parameter list See Global parameters for parameter list When either multi gun or mu...

Страница 12: ...unt 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...

Страница 13: ...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...

Страница 14: ...WS2003 V1 69 14 Users connections discrete...

Страница 15: ...WS2003 V1 69 15 users connections...

Страница 16: ...WS2003 V1 69 16 users connections...

Страница 17: ...WS2003 V1 69 17 users connections...

Страница 18: ...iagram 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 bit assignment...

Страница 19: ...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 Single gun Multi gun INPUT from bus t...

Страница 20: ...meter 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 sele...

Страница 21: ...hese are organized and accessed LOW CURRENT WELD 2 PROG 0 COUNT1 10 I1 10 5kA I2 12 1kA P 5 00kN STP1 27 EDIT CONFIGURATION EDIT CALIBRATION EDIT OUTPUT MAP CONFIG MENU USE PROGRAM EXT 0 EDIT PROGRAM...

Страница 22: ...ap Setup adapters Backup all data Restore all data Initialise all data Edit system setup ELECTRODE MENU Stepper status Edit stepper Edit counter file SEQUENCER MENU Edit sequence Erase sequence Status...

Страница 23: ...rogram used this is the program number that was last used Measured current the RMS current measured during the last weld Press to reset faults same action as external input The counters will also be r...

Страница 24: ...e counter updates after each weld Stepper complete shows the progress along the stepping curve PV output The output from the PV controller is determined by the pressure parameter in the selected progr...

Страница 25: ...eck 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 Chec...

Страница 26: ...ent Check cables from inverter to welding transformer Check transformer 52 Earth fault Check cables from inverter to welding transformer Check transformer 53 Inverter disabled Check control connection...

Страница 27: ...0 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...

Страница 28: ...des 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...

Страница 29: ...y 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 EDIT CONFIGURATION...

Страница 30: ...ation 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 r...

Страница 31: ...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...

Страница 32: ...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...

Страница 33: ...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 vo...

Страница 34: ...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 Is1 with a m...

Страница 35: ...former 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...

Страница 36: ...or as a FIELDBUS output outputs 1 8 only 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 sequenc...

Страница 37: ...ncer 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 INPUT MAP I01 RESET F...

Страница 38: ...o 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 req...

Страница 39: ...store all of your data in the timer from a backup stored in the WSP3 pendant Note that this operation will overwrite all data which was previously stored in the timer After the restore operation the b...

Страница 40: ...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 conf...

Страница 41: ...les The Edit system set up menu provides a number of functions for examining and selecting these files Caution These functions should only be used by trained and experienced personnel as improper use...

Страница 42: ...ine on the main menu last line hold down the key then press the F key For information only USE PROGRAM EXT 0 EDIT PROGRAM FILE EDIT LIMITS FILE COPY PROGRAM I O STATUS FIELDBUS INPUTS EDIT EVENTS FILE...

Страница 43: ...lation 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...

Страница 44: ...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 cu...

Страница 45: ...set to NORMal or the last program 63 is reached IMPORTANT Set OFF time to 0 for single spot operation If OFF time 0 then repeat operation will occur PROGRAM 0 I1 7 50kA 25 0 PHA PV 5 00kN 50 0 NORM W...

Страница 46: ...CR DOWNSLOPE 0 UPSLOPE 3 HOLD 10 edit program seam 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 If...

Страница 47: ...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 wit...

Страница 48: ...an event set it s output to Note The outputs used must be mapped to EVENT for correct operation see Edit Output Map EVENTS PROG 0 Ev1 1 on SQZ 2 Ev3 6 on W1 5 Visible window Ev2 1 off HLD 5 Ev4 6 off...

Страница 49: ...of heat and current increments related to the number of spots done The curve is defined by a set of 10 points The timer provides interpolation between these points Electrode management is provided vi...

Страница 50: ...ge done of the total number of spots also shown as a bar graph dH of programmed heat being added dI of programmed current being added Select this field and press to reset this stepper same function as...

Страница 51: ...t the preset number see next page and then press to load this stepper with a preset curve If continue at end is selected then at the end of the last step further welding can take place as normal but t...

Страница 52: ...s 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 0 0...

Страница 53: ...e 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...

Страница 54: ...rameter tip dressing to On Note 1 If dress when new is set to On then the tip dress counter output will also be activated after a reset stepper operation This facilitates the dressing of new electrode...

Страница 55: ...e 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...

Страница 56: ...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 wi...

Страница 57: ...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 sta...

Страница 58: ...If the value in Counter n is not zero then continue at STEP xxx If the value in Counter n is zero then continue at the next statement IF Qn ON JUMP xxx n 1 12 x 1 999 If Output Qn is ON then continue...

Страница 59: ...ime JUMP 4 Loop back to create flashing effect Statement Range Function AWAIT ANALOG n mm V n 1 3 0 0 mm 10 0 Waits for Analog input n to be less than mm Volts AWAIT ANALOG n mm V n 1 3 0 0 mm 10 0 Wa...

Страница 60: ...old 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 L...

Страница 61: ...t the log record 1 most recent weld 64 oldest weld Status for this weld Program used for this weld Actual current measured Target current from program Note that if either of I1 or I2 are not shown the...

Страница 62: ...Press the or keys to select the log record 1 most recent weld 64 oldest weld Status for this weld Gun electrode used for this weld PV output Measured PV feedback Value of the counter used for this wel...

Страница 63: ...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 FROM 0 GO TO 1...

Страница 64: ...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 Copy a stepper an...

Страница 65: ...puts 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 I O STATUS I01 RESET FAULT Off I02 P32 GAPSW On I...

Страница 66: ...d to observe the status of the fieldbus inputs Note that this screen is only available if the timer is configured for fieldbus operation BUS INPUTS B00 START1 Off B01 START2 On B02 START3 Off B03 STAR...

Страница 67: ...he result of the 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 Analog Status This screen can be used to observe th...

Страница 68: ...nnected 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 Single Dual Bina...

Страница 69: ...s switched on This closes the electrodes onto the work piece At the end of the Gun close time the 2nd stage input and or wait for pressure function is are checked before the Intensify valve switches o...

Страница 70: ...ion 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 t...

Страница 71: ...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 Typic...

Страница 72: ...ent 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 C...

Страница 73: ...imer 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 progr...

Страница 74: ...WS2003 V1 69 74 Operation basic spot weld no weld faults SQZ W2 HLD W1 0 C1 0 Pulses 1 OFF 0 START input EOS output WAV output FAULT output Current...

Страница 75: ...WS2003 V1 69 75 Operation basic spot weld weld fault SQZ W2 HLD W1 0 C1 0 Pulses 1 OFF 0 START input EOS output WAV output FAULT output Current...

Страница 76: ...WS2003 V1 69 76 Operation repeat spot weld SQZ W2 HLD W1 0 C1 0 C2 0 Pulses 1 START input WAV output Current PSQ HLD W2 SQZ HLD W2 SQZ OFF OFF...

Страница 77: ...WS2003 V1 69 77 Operation pulsation spot weld SQZ W2 HLD W1 0 C1 0 Pulses 3 OFF 0 START input EOS output WAV output FAULT output Current C2 W2 C2 W2 C2...

Страница 78: ...rt of the overall weld time they do not add to the weld time START input WAV output Current Upslope time Downslope time Spot Seam Note that for seam welds the downslope time begins when the initiation...

Страница 79: ...WS2003 V1 69 79 Operation roll spot welding SQZ W2 HLD W1 0 C1 0 C2 0 Pulses 1 START input MOTOR output WAV output Current PSQ HLD W2 SQZ HLD W2 SQZ OFF OFF...

Страница 80: ...WS2003 V1 69 80 Operation seam welding dual heat SQZ W2 START input MOTOR output WAV output Current PSQ W2 W1 W2 W1 W1 HLD W2 W1 W2 W1 C1 0 C2 0...

Страница 81: ...WS2003 V1 69 81 Operation seam welding pre heat SQZ C1 START input MOTOR output WAV output Current PSQ C2 W2 C2 W2 W1 HLD C2 W2 C2 W2...

Страница 82: ...ancel with start mode or after 20 cycles fixed pulse mode This is the recommended method of operation for automatic systems Pulsed mode The start signal goes off before the end of the hold time The EO...

Страница 83: ...HAV output WAV output Retract input The retract operating mode Simple Hi lift Hi lift Maintained is set in the configuration file The retract operating mode Simple Hi lift Hi lift Maintained is set i...

Страница 84: ...ration Hi lift The retract operating mode Simple Hi lift Hi lift Maintained is set in the configuration file The retract operating mode Simple Hi lift Hi lift Maintained is set in the configuration fi...

Страница 85: ...Rs when used with BD16 decoder otherwise up to 4 SCRs Up to 16 pairs of electrodes distributed randomly across the welding transformers Up to 16 4 transformers SCRs can be connected Up to 16 electrode...

Страница 86: ...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 electrod...

Страница 87: ...ctrodes 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 Electro...

Страница 88: ...shown here Weld program 0 is assigned to Electrode 1 Whenever a program is run the control will automatically trigger the correct transformer by referencing the electrode transformer assignment table...

Страница 89: ...program to be triggered independently in the traditional way but allows for selection of a transformer and electrode Multi gun mode allows each welding program to be triggered independently in the tr...

Страница 90: ...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 ele...

Страница 91: ...WS2003 V1 69 91 multi gun cascade operation START input EOS output WAV output Current transformer 1 Cascade Program select inputs Current transformer 2 Current transformer 3 Current transformer 4...

Страница 92: ...r 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 Binary 1of4 Use program External selection START input Program sele...

Страница 93: ...bility 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 networ...

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