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Technitron

T2050 Weld Control

Description and Instructions

Revision 04

Feburary, 2004

Part No. 710244

M-050004

WELDING TECHNOLOGY CORPORATION

150 East St. Charles Road

24775 Crestview Court

Carol Stream, IL 60188 U.S.A.

Farmington Hills, MI 48335 U.S.A.

Voice: (800) 323-2903

Voice: (248) 477-3900

(630) 462-8250

Fax:

(248) 477-8897

Fax:

(630) 462-8259

Содержание Technitron T2050

Страница 1: ...on 04 Feburary 2004 Part No 710244 M 050004 WELDING TECHNOLOGY CORPORATION 150 East St Charles Road 24775 Crestview Court Carol Stream IL 60188 U S A Farmington Hills MI 48335 U S A Voice 800 323 2903 Voice 248 477 3900 630 462 8250 Fax 248 477 8897 Fax 630 462 8259 ...

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Страница 5: ... your work piece regardless of dirt oil or changes in your secondary circuit Weld current is measured either on the primary of the weld transformer using a CT pickup or the secondary side of the transformer using a toroid pickup coil In addition to this feature you can still weld using the traditional percent of available current mode with AVC Automatic Voltage Compensation AVC programs all curren...

Страница 6: ... or Binary Pilot 8 ESTOP Emergency stop WELD External weld no weld and PS SS Second Stage or Pressure Switch or Second Stage or Reset Steppers 2XWSXWV The outputs are VALVE1 Solenoid Valve 1 or Binary Output 1 VALVE2 Solenoid Valve 2 or Binary Output 2 VALVE3 Solenoid Valve 3 or Binary Output 4 VALVE4 Solenoid Valve 4 or Binary Output 8 or Stepper end WCOMP Weld Complete FAULT Fault or Fault NOT A...

Страница 7: ... TS2 Control Inputs Terminal strip TS2 is used to attach the seven defined hardware user input points TS3 Control Outputs Terminal strip TS3 includes the six defined hardware user output points TS4 Terminal strip TS4 has the terminals to accept the CT current transformer toroid and OVERTEMP sensor inputs Data Entry Panel Socket This socket connects the power and data transmit receive signals neces...

Страница 8: ...D 3_ db_ Ub 2_QbT Qi_ed _TYVYUT DUSX Ydb_ D GU T 3_ db_ Figure 1D 3_ db_ Ub 2_QbT Qi_ed ...

Страница 9: ...dual in line package switches These are on the controller PC board at SW1 Figure 2 49 CgYdSXUc F 4Yc Qi A control running firmware version V1 01A will display 79 at power up Figure 3 on page 3 6 lists in V1 01A the feature choices of SW1 The difference is switch 3 when closed the PS SS input will reset all stepper programs Therefore Pressure Switch mode is not available in V1 01A C ACCESS YELLOW C...

Страница 10: ...nloadable Parameter is Disabled Host OPTFLGH Downloadable Parameter is Disabled 3520 RFDWLRQ Hardware SW1 Switch is Disabled SW1 may be removed Option Flag at Eprom 0206 is Disabled Host SW1H Downloadable Parameter is Enabled Host control of SW1 Host OPTFLGH Downloadable Parameter is Enabled Host control of Option C ACCESS YELLOW CONFIG C BINARY VALVES C DISPLAY SCHEDULE C HYPERSIL WELD TRANS C RE...

Страница 11: ...o Reset Steppers 01 Software Line Clock Filter 0 Disable Software Line Clock IIR Filter normal 1 Enable Software Line Clock IIR Filter If you change a location listed above from normal you MUST document your changes At a MINIMUM mark this manual wherever necessary Technitron recommends RoboNet download control of SW1 and removing the switch from the board With SW1 removed accidental changes cannot...

Страница 12: ...ormer and its secondary can deliver The AVC feature automatically adjusts the percent of available current so that weld quality is consistent regardless of voltage fluctuations on the welding bus Refer to Chapter 7 Faults and Messages Compensation Fault before making your first weld and use AVC mode first 3 LQDU QSXWV 21 2 CLOSED binary schedule initiation OPEN discrete schedule initiation If DIP ...

Страница 13: ...tions After the sequence is initiated the pilot may be removed and the sequence will still run to completion If the pressure switch is not made after five seconds the message P_S will be displayed on the DEP s numeric display If DIP 3 is open second stage position the schedule will execute the SQUEEZE DELAY and SQUEEZE instructions then wait until the PS SS input is made before executing any more ...

Страница 14: ...ilot the control will not initiate until all faults except Compensation faults have been cleared at the DEP 3 QWL 6DWXUDWLRQ 21 2 CLOSED 87 degree delayed firing and automatic bleed down enabled OPEN 87 degree delayed firing and automatic bleed down disabled When using Hypersil weld transformers it is essential to use delayed firing and automatic bleed down to avoid saturation Saturation is charac...

Страница 15: ...QDU 9DOYHV 21 2 CLOSED Binary valves on OPEN Binary valves off When DIP 7 is closed the four valves will output a 0 15 binary number If Option flag bit 04 is set 1 then the output will be 0 7 binary number with the fourth output indicating Stepper Program end Use this feature with a binary pressure valve or when more than one output must be turned on at the same time for machine control When using...

Страница 16: ... the weld transformer Turns Ratio AVC set point Program Lockout Network ID Cal Line Voltage and Cal CURRENT of the Data Entry Panel Access to these instructions is restricted because once they are set up they should never be changed Cal Line Voltage and Cal Current values are set at the factory and should NOT be changed If they are changed your control may not operate properly until properly re ca...

Страница 17: ... as required 5 If Emergency Stop Weld and or PS SS are not used jumper the inputs to FSC Review DIP switch settings and voltage tap connections of T1 for your application WARNING NEVER apply 120VAC to FSC as it will destroy the control 6 Make sure the cabinet has a good earth ground according to NEC standards ALWAYS close the enclosure door and latch it tightly before applying power especially on ...

Страница 18: ...nge at high percentages A control in over range will top out displaying a value and then beome unable to display any higher values Record the tap setting turns ratio and good weld current value Then in CC mode SW1 1 closed requesting the same current observed in AVC mode will result in that current maintained constantly ...

Страница 19: ...p n 811695 or 811990 As an overview these are the important features of the DEP 1 Weld sequence diagram 2 Sequence column LED 3 Instruction indicator LED 4 Config column LED 5 Sequence instruction selector button 6 Config instruction selector button 7 Numeric display 8 WELD light 9 DATA W and E buttons 10 NO WELD button 11 PROGRAM MODE button 12 FAULT RESET button ...

Страница 20: ...DXU 4QdQ 5 dbi Q U 45 _TYVYUT DUSX Ydb_ D GU T 3_ db_ Figure 4 45 fUb Qi GD3 _b ...

Страница 21: ...eSdY_ cU USd_b Redd_ When pressed the Sequence column LED 2 will light The instruction indicator LED 3 will move down the column one instruction every time the button is pressed 3_ VYW Y cdbeSdY_ cU USd_b Redd_ When pressed the Config column LED 4 will light The instruction indicator LED 3 will move down the column one instruction every time the button is pressed e UbYS TYc Qi The display shows pr...

Страница 22: ... Program mode In this mode the control will NOT run If you try to change sequence or configuration items when not in Program mode the letters LOC appear in the numeric display 61E D B5C5D Redd_ This button resets the fault currently displayed on the numeric display It may be necessary to press this button more than once to clear multiple faults ...

Страница 23: ...n is called a Configuration instruction A Configuration instruction controls global functions that are common to more than one schedule or weld heat All configuration instructions are located in the right hand column of the DEP To select an instruction to program press the E key directly under the instruction s column on the DEP Figure 4 on page 5 16 Items 5 6 The LED directly above the column wil...

Страница 24: ... After SQUEEZE the UPSLOPE TIME is executed UPSLOPE starts at Slope Initial Current value and slopes up to the Weld Current value over the UPSLOPE time in line cycles programmed in the instruction Turn off UPSLOPE by entering a value of 0 4 Next the weld is made using the parameters entered for Weld Cycles and Weld Current To turn off WELD enter 0 for Weld Cyc Weld current but not weld time may al...

Страница 25: ...P output for the number of line cycles specified Note The WCOMP output will not be issued until the valve is off and Off Cyc is programmed 0 i e single mode non repeat or SUCCESSIVE is programmed non zero 11 After the weld process is complete the SUCCESSIVE SCH instruction if programmed non zero will turn off any valve that was previously selected and wait for the pilot to be removed If the pilot ...

Страница 26: ...rovide the desired control pattern Binary valves may be used as many times as necessary in both Use Figure 4 to assign up to 4 functions to the SV outputs The table will help select the proper binary number for each schedule in a chain Choose the valve output pattern necessary and mark the schedule number in the table for that step Fore more information refer to Binary Valve Function Table on page...

Страница 27: ...applied PIL will be displayed If OFF is programmed non zero and the pilot signal is still applied the control will turn off the valve wait the programmed number of cycles then repeat the sequence starting at the Squeeze instruction of the schedule applied In repeat mode the WELD COMPLETE instruction will never be outputted FUNCTION Clamp Electrodes Schedule Valve SV1 SV2 SV3 SV4 Sch 5 0 OFF OFF OF...

Страница 28: ...gure 4 on page 5 16 item 3 the value for that item appears in the numeric display Edit the value by pressing the DATA W and E keys located below the numeric display OHDULQJ 0HPRU Clearing memory requires a special procedure WARNING Performing this operation will ERASE ALL USER PROGRAM AND SETUP DATA All configurable parameters are set to their default values Calibration data is NOT erased To clear...

Страница 29: ... zero the SQUEEZE DELAY time is executed the first time through the schedule All subsequent times the SQUEEZE DELAY is ignored SQUEEZE DELAY is used to accommodate the initial long stroke of a hand held weld gun which then does not open all the way between the repeated weld spots The data range is 0 99 cycles CaeUUjU Squeeze is the amount of time required to close electrodes and achieve full tip p...

Страница 30: ... set to 1 the sequence will not loop back to the WELD instruction resulting in only one pulse of weld cool If set to 2 the control will loop back once for 2 weld cool pulses Impulses are used to weld multi layer or very thick material by controlling the time the heat is applied If Impulses are set to 999 the control will enter Seamer or Roll Spot mode and deliver weld cool pulses until the pilot i...

Страница 31: ... CeSSUccYfU CSX If programmed non zero 1 60 the control will turn off any valve that was previously selected issue a WELD COMPLETE if programmed non zero and wait for the pilot to be removed If the pilot for the same schedule is re applied a branch to the VALVE instruction of the schedule that is programmed in Successive Sch will occur If a different schedule is re applied the active sequence ends...

Страница 32: ...ENT fault is set Low Current Limits are separately programmable in each weld schedule The data range is 0 65 5 kA To turn off Low Current Limit set the value to 0 Low Current Limit defaults to 0 CdU Ub 3_e d Four programmable 2 step stepper programs are available One program is assigned for each of the 4 valves Stepper Count 1 is the Step 1 stepper count for the Valve selected in the Sequence colu...

Страница 33: ...ay the actual welds per part value Normally every weld is counted as a weld per part when the actual welds per part equals the programmed value Part Counter will be incremented In Successive schedules operation welds per part are counted for the same pilot applied and will not advance the Parts Counter until the completion of a full successive operation Aborting or resetting a Successive operation...

Страница 34: ... access Level 3 Full access except for certain restricted Config items Level 2 Full access except for all Config items Level 1 Access ONLY to the WELD function Level 0 No access Udg_b 94 This is the unique address of the weld control on a RS 485 networked system The range is 0 64 where 0 is off line 3Q Y U F_ dQWU Line Voltage calibration allows the user to enter a measured line voltage value The ...

Страница 35: ...lve is energized to prevent the tips from closing energized It is also checked during normal sequence operation The display will flash C_F for Contactor Fault The voltage is monitored by op amps U5 U22 and U6 F5B D5 6Qe d This fault indicates that the over temperature switch on the SCR is open The display will flash O_F for Over temperature Fault The over temperature switch is monitored with 40 VD...

Страница 36: ... 1 is satisfied Then make sure the control can read current to your satisfaction Know what the transformer turns ratio is and enter it correctly If everything is correct when SW1 6 is open the display should match the reading on a secondary current meter Return the control to Constant Current mode G 3EBB5 D 6Qe d This denotes that the Low Current Limit has been exceeded When this fault occurs the ...

Страница 37: ... error will occur the first time new firmware and or PC board is booted up It may be caused by switching relay or valve noise applied to the microprocessor Always apply snubbers across all relay and valve coils Keep relays physically and electrically away from the microprocessor and its power source T1 0RWRUROD 5HVHW 6WDWXV 5HJLVWHU E01 Test Module reset momentarily displayed E02 System Reset mome...

Страница 38: ...9 LO Compensation under 20 2WKHU 6WDWXV 0HVVDJHV PIL The pilot is not clear at off single Remove the pilot or press RESET anti repeat ES Stepper reset acknowledged momentarily displayed Accept calibration value change If yes press FAULT RESET LOC Locked out or not in program mode S_S Second Stage Open close to latch in sequence P_S Pressure Switch Open close to continue sequence CLr Memory has bee...

Страница 39: ...be but normally is not necessary if the firmware is changed U7 PROM or if the current transformer CT or toroid coil is replaced 3ULPDU XUUHQW RQWURO Primary current control is turned on by programming a transformer Turns Ratio of 1 or higher You must have a current transformer CT with a 0 2 ohm burden resistor across its terminals connected to TS4 Technitron normally installs the CT The primary cu...

Страница 40: ...erical current readout and Constant Current control is relative to the perception of the user The control does not care what that value is or what it means The T2050 delivers if it can in constant current the value request based on the RMS current of the last weld and the value you told the control it was The greatest concern is that the current NOT exceed the maximum level permitted by the W jump...

Страница 41: ...alues reside in two memory locations one for primary and one for secondary The control does not know or remember where the range jumpers are located 3ULPDU XUUHQW DOLEUDWLRQ 3URFHGXUH To calibrate primary current follow this procedure 1 Choose a primary current range W1 W4 that cannot be exceeded at a 99 available current weld 2 Turn off power and set SW1 1 to be OPEN AVC Mode 3 Program a simple w...

Страница 42: ...nt mode will be used or you want to see secondary current displayed program the Turns Ratio used in Step 5 To correct slight offsets between the current displayed and your secondary meter change the Turns Ratio tenths value 8Y d If your transformer has taps now is the time to determine what the transformer turns ratio is for each tap If you change taps you MUST program the new value DO NOT RE CALI...

Страница 43: ...value 7 Press the CONFIG E key will be displayed Press the FAULT RESET key 8 Re weld at different currents to confirm that the secondary current readings now match your secondary meter Explore and record the range of current the system is able to deliver without incurring HI or LO compensation faults 9ROWDJH DOLEUDWLRQ 3URFHGXUH To calibrate voltage follow this procedure 1 Measure and record the l...

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Страница 45: ...stripper ejects the part into a box Each box holds 25 parts The clamp is assigned to SV1 gun valve to SV2 and the part stripper to WCOMP SW2 7 must be closed for binary valve operation Refer to Binary Valve Function Table on page 9 47 The procedure for programming this example follows VVLJQ 6FKHGXOH 4 Assign Schedule 1 to clamp and align the parts before making the first spot weld SCHEDULE 1 VALVE...

Страница 46: ...eld STEPPER COUNT1 Your choice There is only one stepper in binary valve mode INCREASE 1 Your choice There is only one stepper in binary valve mode STEPPER COUNT2 Your choice There is only one stepper in binary valve mode INCREASE 2 Your choice There is only one stepper in binary valve mode PARTS COUNTER 25 After 25 parts are made initiation will be blocked The operator replaces the box WELDS PER ...

Страница 47: ...es time to close and build pressure the clamp is still energized UPSLOPE 0 N A WELD CYC 8 Weld time WELD CUR 65 Pass 65 available current COOL 0 N A IMPULSES 1 N A DOWNSLOPE CYC 0 N A SLOPE END CUR 20 N A QUENCH CYC 0 N A TEMPER CYC 0 N A TEMPER CUR 0 N A HOLD CYC 10 N A WELD COMPLETE 0 N A SUCCESSIVE SCH 3 Turn both valves off and wait for another initiation On re initiation go to Schedule 3 CHAI...

Страница 48: ...LAY 0 N A SQUEEZE 40 Give the clamp time to clamp and align the parts UPSLOPE 0 N A WELD CYC 0 N A WELD CUR 20 N A COOL 0 N A IMPULSES 1 N A DOWNSLOPE CYC 0 N A SLOPE END CUR 20 N A QUENCH CYC 0 N A TEMPER CYC 0 N A TEMPER CUR 0 N A HOLD CYC 10 N A WELD COMPLETE 0 N A SUCCESSIVE SCH 0 N A CHAIN SCH 4 The part is now clamped Go to Schedule 4 Make the second weld OFF CYC 0 N A The sequence jumped to...

Страница 49: ... N A WELD CYC 5 Weld for 5 cycles WELD CUR 65 Pass 65 of available current COOL 2 65 current for 10 cycles is too much for this application Cool it IMPULSES 2 Three layers of metal need plenty of heat applied slowly Go back and WELD again DOWNSLOPE CYC 5 Try cooling the spot slowly to prevent cracking SLOPE END CUR 20 N A QUENCH CYC 0 N A TEMPER CYC 0 N A TEMPER CUR 0 N A HOLD CYC 10 N A WELD COMP...

Страница 50: ...lamp and electrodes time to open before ejection UPSLOPE 0 N A WELD CYC 0 N A WELD CUR 65 N A COOL 0 N A IMPULSES 1 N A DOWNSLOPE CYC 0 N A SLOPE END CUR 20 N A QUENCH CYC 0 N A TEMPER CYC 0 N A TEMPER CUR 0 N A HOLD CYC 10 N A WELD COMPLETE 30 Energize the ejector for a half second to eject the part Use the WCOMP output SUCCESSIVE SCH 0 N A CHAIN SCH 0 NA OFF CYC 0 Off Single turns off all valves...

Страница 51: ...4 Sch 5 0 OFF OFF OFF OFF Sch 1 3 1 ON OFF OFF OFF Sch 2 OFF ON OFF OFF Sch 2 4 3 ON ON OFF OFF Sch 4 OFF OFF ON OFF Sch 5 ON OFF ON OFF Sch 6 OFF ON ON OFF Sch 7 ON ON ON OFF Sch 8 OFF OFF OFF ON Sch 9 ON OFF OFF ON Sch 10 OFF ON OFF ON Sch 11 ON ON OFF ON Sch 12 OFF OFF ON ON Sch 13 ON OFF ON ON Sch 14 OFF ON ON ON Sch 15 ON ON ON ON ...

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Страница 53: ...ed T2050 weld control schematics As listed by drawing number they are 503 5 2050 01 I O Hookup for T2050 824644 1 of 2 Series 2050 Weld Control 824644 2 of 2 Series 2050 Weld Control 473 0 0426 01 Model 2050 Data Entry Panel Sheet 1 of 2 473 0 0426 01 Model 2050 Data Entry Panel Sheet 2 of 2 ...

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