BF Entron WELDSTAR WS2003 Manuale utente

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

WS2003 V1.69

BF Entron Ltd.

Castle Mill Works,

Birmingham new road,

Dudley,

West Midlands,

DY1 4DA

England.

Tel: +44 (0)1384 455401

Fax: +44 (0)1384 455551

Email: [email protected]

Web site: www.bfentron.co.uk

Manufacturers of

advanced welding

controls

•Welding controls.

•Thyristors and power supplies

•Power Inverters.

•Meters and Monitors.

•Training and Support.

•Consultancy.

BF Entron Ltd.

WS2003 V1.69

Table of contents

4. WELDSTAR model WS2003

System

5. Introduction and overview

6. Functions

7. …functions

8. …functions

9. Global parameters

10. Program parameters (x64)

11. Multiweld parameters

12. Mounting

13. Connectors

14. Users connections

(discrete)

18. Operation with a fieldbus

19. ...operation with a fieldbus

20. Keypad

21. Menus

22. ..menus

23. Diagnostic screen 1

24. Diagnostic screen 2

25. Status / error codes

29. Configuration menu

30. Edit configuration

33. Edit calibration

36. Edit output map

37. Edit input map

38. Set-up Adapters

39. Backup/Restore

40. Initialise all data

41. System set-up menu

42. Main menu

43. Edit program (AC)

44. Edit program (MF)

46. Edit program (seam)

47. Edit limits

48. Edit Events

49. Electrode menu

50. Stepper status

51. Edit stepper

52. Stepper presets

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

65. I/O status

66. Fieldbus input status

67. Analog status

68. Program selection

69. OHMA (Air over oil) system

71. Disabling edits

72. Pop-up current meter

73. Replacing a WS2000 timer

74. Operation: basic spot weld – no

weld faults.

75. Operation: basic spot weld – weld

fault

76. Operation: repeat spot weld

77. Operation: pulsation spot weld

78. Operation: upslope and

downslope

79. Operation: roll-spot welding

80. Operation: seam welding (dual

heat)

81. Operation: seam welding (pre-

heat)

82. Operation: EOS signal

83. Operation: Retract

84. Operation: Hi-lift

-----------------------------------------------------------

85. Multiwelding

86. Configuring for multiwelding

87. Electrode/Transformer assignment

88. Assigning a weld program to an

electrode

89. Multi-gun operation

90. Multi-gun cascade operation

92. Program selection (multiweld)

-----------------------------------------------------------

93. WS98-2003 PC software

WS2003 V1.69

WELDSTAR model WS2003 System

LOGIC SEQUENCER

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

cards for special functions.

WS98-2003

Software for PC

WS2003 V1.69

Introduction and overview

A new programming pendant , type WSP3 is available, and provides a

larger multi-line display, making programming easy.

A powerful built-in logic sequencer program provides the timer with a

flexible means of fully controlling small machines or tooling

arrangements, without the need for additional hardware.

A plug-in option board provides a 10/100Base-T Ethernet connection.

Units may then be networked to a PC running WS98-2003 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 replacement for the original WS2000. It

will fit into existing cabinets, and will work with the existing power supply. Existing connections

are duplicated, including outputs at 110V AC or 24VDC. MF operation is also supported.

This manual details the features of the WS2003 timer, and shows how

to program the timer using the WSP3 programmer.

This manual details the features of the WS2003 timer, and shows how

to program the timer using the WSP3 programmer.

WSP3

ENTRON

WS2003 V1.69

Functions

•Compatible with original Weldstar 2000

• AC 50/60Hz and MFDC (medium frequency) welding all supported.

• Spot / Repeat /Roll-spot / Seam (dual heat) / Seam (pre-heat) welding.

• Single, dual or OHMA (Air over Oil) gun operation.

• Multiwelding with up to 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 monitoring with high, low and pre limits. Programmable blocking and weld

retry functions.

• Proportional valve controller (0..10V or 4..20mA).

• Programmable outputs (events).

• Machine sequencer logic

• Welding programmes may be linked together to form complex spot schedules.

WS2003 V1.69

…functions

• Contactor timer.

• Head-lock function.

• Analog output of current waveform.

• Electrode management including stepping, counting and tip-dressing

functions, with programmable blocking and preset 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 pendant with large backlit 4x20 lcd display,

and data backup facility.

• RS232 port, for PC communications.

• Expandable via plug-in option cards

• (Ethernet, Profibus, DeviceNet, Interbus, Modbus TCP/IP, Ethernet/IP

etc).

WS2003 V1.69

…functions

In early 2008, a number of new circuits were added to the original design.

These are used to 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 for current measurement.

Note that these features are not available when running this firmware on the

original design.

WS2003 V1.69

Global parameters

Configuration

•Sequence (Spot / Roll-spot / Seam(2-heat) / Seam(pre-heat)

•Single gun / Dual gun / OHMA gun / Multi-gun / Multi-gun cascade.

•Discrete/Fieldbus I/O

•Retract (x2): (Simple / Hi-lift+ / Hi-lift- / Maintained / OHMA)

•Program select (Binary / 1-of-4 )

•SCR select (Binary / 1-of-4)

•Frequency (AC 50 Hz / AC 60 Hz / MF 50Hz / MF 60Hz)

•Contactor time (0..200 s)

•Blanking (On/Off)

•Toroid test (On/Off)

•Sensor (Toroid / CT)

•Heat range (Wide/High/Low)

•EOS mode (Cancel/fixed)

•If fault (Head-lock/Stop/Continue/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 (-10kA..+10kA)

•Pressure (2 points, kN/V)

•Inverter (2 points, kA/%heat)

•Analog output scale (0..60kA).

•Analog input gain (0.9..2.5)

•Analog input offset(-9.99…+9.99)

Calibration (x2)

• Actual count (0..9999).

• Terminal count(0..9999).

• Stop/continue at end.

• Tip dressing (on/off)

• Dressings (0..9999)

• Dress when new (on/off)

Counter (x2)

• Stepper on/off.

• Stop /continue at end

• Curve(10 point, interpolated)

Stepper (x2)

Sequencer

•Up to 250 statements

Output Map

•Normal/Event/Sequencer/Fieldbus (x12)

Input Map

• Normal/Sequencer (x14)

WS2003 V1.69

Program parameters (x64)

Weld program

•Pre-squeeze (0..99 cycles)

•Squeeze (0..99 cycles)

•Weld1 (0..99 cycles)

•Cool1(0..99 cycles)

•Weld2(0..99 cycles)

•Cool2(0..99 cycles)

•Pulses(0..99)

•Hold(0..99 cycles)

•Off(0..99 cycles)

•Pressure (0..100%)

•Heat 1(0..99.9%)

•Heat 2(0..99.9%)

•Current 1 (0..60kA)

•Current 2 (0..60kA)

•Balance (seam only)

•Normal/Link program

•Upslope(0..99 cycles)

•Downslope(0..99 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 (0..99%)

•Pre-limit count (0..99)

•Retry (On/Off)

•Pressure monitor (On/Off)

•Wait for pressure (On/Off)

•Pressure high limit (0..100%)

•Pressure low limit (0..100%)

Monitor limits

Events

•4 x 4 trigger points

•OHMA gun open (0..99 cycles)

•OHMA gun close (0..99 cycles)

•OHMA retract open (0..99 cycles)

•OHMA retract delay (0..99 cycles)

•OHMA retract close (0..99 cycles)

Additional parameters for OHMA gun

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