WELD SENTRY 2
Page 25
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Select RELAY OUTPUT from the System Menu to program Relays K1 to K4 to activate on any
combination of accept/reject decisions. Refer to Section 2 - Installation, and Section 4 -
Specifications
RELAY KI, K2, K.3 and K4 - select the relay to be programmed to display the screen shown at
right. All of the relays are programmed the same,
however, only K1 and K2 are provided standard in
the Weld Sentry 2.
Move the cursor to the desired status conditions and
press [CHNG] and change NO to YES to enable the
relay to activate on that status.
RELAY STATUS CONDITIONS - Definitions for each Output Relay Status are listed below. An
Upper Limit and a Lower Limit can be programmed for each individual Weld Sentry Program. A Weld
Sentry Schedule can have up to 5 Programs, A thru E. The relay will be activated when any one of the
status conditions is met for any one of the Programs.
REJECT HI:
The measurement result is or greater than the Upper Limit.
REJECT LO:
The measurement result is less than the Lower Limit.
ACCEPT:
The measurement result is within limits; equal to or less than the Upper Limit and
equal to or greater than the Lower Limit.
NO WELD:
The Sentry did not received the expected 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 exceeded the measurement scale.
The full scale measurement is determined by the Gain Setting displayed on the
second program screen. An overload error can occur due to a voltage or current
spike. A spike could affect the quality of the weld but may not cause an out of limit
condition.
LINE STOP:
The Line Voltage has exceeded the limits setup through the Line Monitor feature.
Refer to Section 2 - Installation and Section 3 - Line Voltage Monitor.
MARGINAL:
The measurement result is within either the
upper or the lower “marginal” zone shown at
right. The upper marginal line is at 2/3 of the
distance between the center line and the upper
limit. The lower marginal line is at 2/3 of the
distance between the center line and the lower
limit. Several consecutive welds in the
marginal zone may indicate a trend in the
process such as dirty electrodes or increased
resistance due to heat. When SPC Control
Limits are used for the programmed Upper
and Lower Limits, the marginal zone is defined to be consistent with the Western
Electric rule used in Statistical Process Control. The accepted theory is that 2 out of 3
consecutive welds b2
ợ
and +3
ợ
or between -2
ợ
and -3
ợ
indicate a process
out of control.
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