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USER'S MANUAL 990-301
Revision B, January 2002

WELD SENTRY



RESISTANCE WELDING PROCESS

CONTROL MONITOR

PART NUMBER STOCK

NUMBER

WS2 3-131-XX
WS2/230 3-131-XX-01
WS2/10X 3-131-XX-02
WS2/230/10X 3-131-XX-03

Содержание 3-131-XX

Страница 1: ...ER S MANUAL 990 301 Revision B January 2002 WELD SENTRY 2 RESISTANCE WELDING PROCESS CONTROL MONITOR PART NUMBER STOCK NUMBER WS2 3 131 XX WS2 230 3 131 XX 01 WS2 10X 3 131 XX 02 WS2 230 10X 3 131 XX...

Страница 2: ...ork of UNITEK MIYACHI CORPORATION and may not be reproduced copied exhibited or otherwise used without the written authorization of UNITEK MIYACHI CORPORATION Printed in the United States of America R...

Страница 3: ...one 626 303 5676 FAX 626 358 8048 e mail info unitekmiyachi com The purpose of this manual is to supply operating and maintenance personnel with the information needed to properly and safely operate a...

Страница 4: ...Connections 8 Printer Installation 9 Communications Configuration 11 Control Signals 12 Line Voltage Monitor 13 Set Volume Alarm 13 Set Contrast for Display Screen 13 SECTION 3 OPERATION 14 Operating...

Страница 5: ......

Страница 6: ...asurements include weld current the voltage drop across the electrodes workpiece expansion and deformation the electrode force the size of the electrode face the acoustic energy emitted while the weld...

Страница 7: ...ptions RUN Exits the PROGRAM State without saving the changed schedule The changed schedule will be saved to scratchpad Schedule 0 in memory Exits the MENU state and saves currently displayed selectio...

Страница 8: ...a serial printer or computer Capabilities include two way communications and multiple Sentrys via daisy chain or multiple I O board F RELAY OUTPUT for programmable solid state relays to activate exte...

Страница 9: ...mputer protocol e Print Options select data output options for printer or computer 6 Press RUN to return to the Run State SETUP WELD SENTRY SCHEDULE 7 Select a Weld Sentry Schedule number which will c...

Страница 10: ...Menu Weld Voltage is measured by attaching the clips on the Voltage pickup cable to the welding electrodes CURRENT COIL INSTALLATION 1 Plug the Current Coil Connector into the two pin matching recept...

Страница 11: ...ds to the voltage terminals 6 Select the OUT position for the Coil Shunt Switch on the rear panel 7 Program the Sentry for the appropriate size Shunt select Menu System Menu System Setup CURRENT SHUNT...

Страница 12: ...of voltage caused by induction 5 Figure 5 shows the typical attachments for measuring weld voltage Figure 5 Connecting the Voltage Input cable to electrodes START SIGNAL INSTALLATION The Start signal...

Страница 13: ...ist 2 Refer to the chart below to select the correct wires for the relay s to be used 3 Connect the wires to an appropriate DC device as shown in Figure 6 a The device must have an external power sour...

Страница 14: ...he printer 2 Connect one end to the RS232 Serial Port on the rear of the Weld Sentry 3 QUICK REFERENCE CARD Detailed instructions for printer installation and operation are provided in the printer s U...

Страница 15: ...turning on the printer 9 on the Quick Reference Card The Set Up Parameters will be printed as follows a Press the LF FF button to move the printhead to the right b Move the printhead beneath menu item...

Страница 16: ...entry s line cord from the power line Remove the cover 2 Locate the weld monitor module PCB at the right side of the unit 3 Refer to Section 4 Specification and Drawing 4 32603 Weld Monitor Module 4 D...

Страница 17: ...2 Select Schedules by shorting the appropriate pin s to ground Pin 11 using an external switch closure or logic level The front panel Screen will change to display the selected schedule 3 Maintain th...

Страница 18: ...nto the feed through hole The cable should fit snugly and not push or pull through the hole 7 a Connect the appropriate user supplied power line plug to the opposite end of the cable Plug into power l...

Страница 19: ...enu for installation help and specification information Also displayed across the bottom of all screens are the correct keys to use for the current operation RUN STATE The Run state screen is shown at...

Страница 20: ...ys to move the flashing cursor from field to field to make changes Across the bottom of the screen two lines will display alternately with help messages on which keys to use Press PROG a second time t...

Страница 21: ...ays Set End of Process skip 4 11 and go to 12 4 Make another test weld 5 The screen will display a graph showing the waveform of the weld The example at right shows an AC upslope downslope waveform 6a...

Страница 22: ...area to the right and lengthen the process time This will include the second period in the Sentry monitoring schedule Press the left arrow to move the highlighted area to the left and shorten the proc...

Страница 23: ...ment window is set it can be no longer than the acquisition period Example Weld Schedule longer than 500 ms 30 cycles To measure the first 500ms set start time at 0ms stop time at 500ms and end time p...

Страница 24: ...grams C D and E DISPLAY GRAPH OF LAST WELD Every time a weld is monitored the graphic information is held in memory until another weld is made 1 Press MENU and move the cursor to Display Graph The scr...

Страница 25: ...he programmed measurement unit will be output PRINT GRAPHS Determines if the Graphic data will be output along with the results This selection is not applicable when Print Results For is NONE NO Turns...

Страница 26: ...for the same time period Limits have not been set yet PRINT ALL SCHEDULES PROGRAMS Select this feature to transmit data for all of the Schedules and Programs saved in memory This is helpful for docum...

Страница 27: ...rresponds to Weld Count which is displayed on the Run state screen To reset enter 0 or any number up to 9999999 It may be desired to enter an existing weld count to coordinate the Sentry with the weld...

Страница 28: ...larm to sound and Line Voltage is Outside of Limits will be displayed at the bottom of the screen The alarm condition will clear immediately when the line returns within limits If the out of limits ti...

Страница 29: ...Y MARKS ON will display the polarity marks on graphics of weld pulses BASIC SETUP SAMPLE WELD TIME 1 second 2 seconds 4 seconds Sets the maximum time allowed for a sample weld including all off times...

Страница 30: ...ected weld current Either the current signal was too low or the process was terminated too soon Process time is defined in Basic Setup OVERLOAD The amplitude of the current or voltage signal has excee...

Страница 31: ...STATUS is changed by entering a Security Code on the bottom line of the screen UNPROTECTED System security is OFF This is the default condition PROTECTED System security in ON No schedule or program...

Страница 32: ...elating a range of Sentry results with a range of good welds After an acceptable range is established identify the variables which cause problems in your process Simulate the specific conditions which...

Страница 33: ...liable the statistics will be Always use at least 100 welds Press ENTER to print the graph Press CHNG to display the Run Chart RUN CHART The Run Chart shows a data point for each weld in sequence by w...

Страница 34: ...ove the cursor to Sub Group Sample Size SUBGROUPS It is typical in SPC to evaluate sample data in groups to calculate an average and a range for each group This produces more statistically reliable re...

Страница 35: ...nt representing 30 is shown on the X bar control chart for that sub group The line in the center of the chart is the average value of all the data points and is called X bar bar CONTROL LIMITS Upper a...

Страница 36: ...ds equal to the Sub Group Sample Size and then will not save any more welds until the number of welds equal to the Sampling Period have been monitored Note All welds will always be monitored Periodic...

Страница 37: ...ludes only the welds counted in SPC History for an individual program When collecting data it may be helpful to both reset the system weld counters and erase SPC history to coordinate the system and p...

Страница 38: ...e Sentry using the voltage measurement and the resistance value of the shunt I V R Theoretically up to 400 00A could be measured however due to power losses this would not be practical A current shunt...

Страница 39: ...rement Window is defined by a delay time and a measurement time beginning at the start of an acquisition period The measurement window must be equal to or smaller than the acquisition period MONITORIN...

Страница 40: ...1250 A 125 A 4 2 5V 2500 A 250 A 2 5V 5000 A 500 A 1 10V 10000 A 1000 A 0 8 12500 A 1250 A 0 4 25000 A 2500 A 0 2 50000 A 5000 A 0 l 100000 A 100000 A 1 5 20V 0 25 40V CURRENT VOLTAGE DIFFERENCE MEAS...

Страница 41: ...onnector Pins 1 Circuit Ground 2 Receive Input to Sentry 3 Transmit Output from Sentry 4 Request To Send 5 Clear To Send 6 Data Set Ready 7 Circuit Ground 20 Data Terminal Ready Busy Data sent when hi...

Страница 42: ...ng protocol 9600 Baud Half Duplex 10 bit message 8 ASCII Coded Data Bits 1 Start and 1 Stop Bit In order to communicate with another device such as a printer or a computer the Sentry s Receive Line mu...

Страница 43: ...lay Outputs connector P N 250 187 using the wiring harness 4 31982 01 which is provided with the Sentry The following table lists the specifications for wiring the relay harness RELAY SIGNAL TIMING Th...

Страница 44: ...PUT ADJUSTMENTS In addition to the built in calibration check there are 4 precision voltage references which can be measured on the Sentry Control Board If the built in calibration check shows either...

Страница 45: ...ram screen and enter Voltage Gain 1 Current Gain 4 Delay Time 0 000ms Measurement Time 10 ms 4 Press SAVE to save the schedule and program in memory Test Procedure 1 Use weld cables to connect each en...

Страница 46: ...he current coil input circuit should be adjusted as follows a Remove the cover and locate the PCB at right side of the unit b Refer to Drawing 4 32603 Assembly PCB Weld Monitor Module c Adjust each tr...

Страница 47: ...ing 15 pin connector plug Control Signals 15 pin connector hood shipped with Sentry P N 3 131 01 shipped with Sentry P N 3 131 01 02 OPTIONAL ACCESSORIES 10 312 01 10 310 01 10 308 01 4 33049 01 555 0...

Страница 48: ...program used The oldest block is defined by the chronology of the last weld saved to that block If only one Sentry Program is ON it is possible to save results for 20 000 welds for a single program Th...

Страница 49: ...76 1 924 8 0 373 0 136 1 864 9 0 337 0 184 1 816 10 0 308 0 223 1 777 11 0 285 0 256 1 744 12 0 266 0 283 1 717 13 0 249 0 307 1 693 14 0 235 0 328 1 672 15 0 223 0 347 1 653 16 0 212 0 363 1 637 17 0...

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