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BF Entron WELDSTAR WS2003 Manual

Spot/seam control, monitor and machine sequencer for 50/60hz and mf resistance welding
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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

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Summary of Contents for BF Entron WELDSTAR WS2003

  • Page 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...
  • Page 2 Manufacturers of Ltd. advanced welding Entron controls •Welding controls. BF Entron Ltd. Castle Mill Works, Birmingham new road, •Thyristors and power supplies Dudley, West Midlands, •Power Inverters. DY1 4DA England. •Meters and Monitors. Tel: +44 (0)1384 455401 •Training and Support.

  • Page 3: Table Of Contents

    Table of contents WELDSTAR model WS2003 Main menu Operation: basic spot weld – no System Edit program (AC) weld faults. Introduction and overview Edit program (MF) Operation: basic spot weld – weld Functions Edit program (seam) fault …functions Edit limits Operation: repeat spot weld …functions Edit Events...
  • Page 4 WELDSTAR WS2003 System model Ethernet WELDSTAR WS2003 TIMER 2000 compatible ! WSP3 PROGRAMMING PENDANT WS2003 *Optional Plug-in adapter cards for special functions. WELDING *Optional Ethernet adapter CONTROL required for connection to WS98-2003 Ethernet Software for PC LOGIC SEQUENCER EVENT TIMER WS2003 V1.69...

  • Page 5: Introduction And Overview

    Introduction and overview This manual details the features of the WS2003 timer, and shows how This manual details the features of the WS2003 timer, and shows how to program the timer using the WSP3 programmer. to program the timer using the WSP3 programmer. The new WELDSTAR model WS2003 is a direct plug-in replacement for the original WS2000.

  • Page 6: Functions

    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. •...

  • Page 7: Functions

    …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. •...

  • Page 8: Functions

    …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.

  • Page 9: Global Parameters

    Global parameters Configuration Calibration (x2) •Sequence (Spot / Roll-spot / Seam(2-heat) / Seam(pre-heat) •Sensor sensitivity(100..60000 mV/kA) •Single gun / Dual gun / OHMA gun / Multi-gun / Multi-gun cascade. •S/P ratio (1:1..199:1) •Discrete/Fieldbus I/O •S/P offset (-10kA..+10kA) •Retract (x2): (Simple / Hi-lift+ / Hi-lift- / Maintained / OHMA) •Pressure (2 points, kN/V) •Program select (Binary / 1-of-4 ) •Inverter (2 points, kA/%heat)

  • Page 10: Program Parameters (X64)

    Program parameters (x64) Weld program Monitor limits •Pre-squeeze (0..99 cycles) •Current monitor (On/Off) •Squeeze (0..99 cycles) •Current low limit,weld1 (0..99%) •Weld1 (0..99 cycles) •Current high limit,weld1 (0..99%) •Cool1(0..99 cycles) •Current pre-limit,weld1 (0..99%) •Weld2(0..99 cycles) •Current low limit,weld2 (0..99%) •Cool2(0..99 cycles) •Current high limit,weld2 (0..99%) •Pulses(0..99) •Current pre-limit,weld2 (0..99%)

  • Page 11: Multiweld Parameters

    Multiweld parameters When either multi-gun or multi-gun cascade modes are selected, the following additional parameters are available: Transformers •Electrode number (1..16) for each transformer (x16). Calibration (extended to x16) •See ‘Global parameters’ for parameter list. Counter (extended to x16) •See ‘Global parameters’ for parameter list. Stepper (extended to x16) •See ‘Global parameters’...

  • Page 12: Mounting

    Mounting If you have purchased a complete Top bracket system including the WS2003 timer, then the timer will already be mounted in the case. If you have purchased a timer only kit, then you will need to mount the timer to the rest of your equipment.

  • Page 13: Connectors

    Connectors Connectors P1,P2,P3,P4,P7,P13 and P14 are two-part terminals, for use with wires up to 1mm Connectors P5 and P6 are used internally via ribbon cable assemblies, and are not used for 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 routed internally via ribbon...
  • Page 14 Users connections (discrete) WS2003 V1.69...

  • Page 15: Users Connections

    …users connections WS2003 V1.69...
  • Page 16 …users connections WS2003 V1.69...
  • Page 17 …users connections WS2003 V1.69...

  • Page 18: Operation With A Fieldbus

    Operation with a fieldbus WS2003 can be operated on a fieldbus, OUTPUTS Pressure instead of through the discrete I/O Fieldbus Error code connections. outputs Timer Output An optional adapter card is required to interface to the required fieldbus. Adapter cards are available for all popular fieldbus Physical Events outputs...
  • Page 19 ...operation with a fieldbus Single gun /Multi-gun Dual gun INPUT from bus to timer OUTPUT from timer to bus INPUT from bus to timer OUTPUT from timer to bus Bit No. Function Bit No. Function Bit No. Function Bit No. Function START 1 Prewarning START 1...

  • Page 20: Keypad

    Keypad Using the keypad •Press the F (function) key to return to the previous WSP3 screen, or to move between menu screens (see ENTRON menus). •The selected function or parameter will flash. •Use the keys to select a different function or parameter. The visible window will scroll when required.

  • Page 21: Menus

    Menus The various functions of the timer are arranged into a set of menus and screens. The diagrams below shows how these are organized and accessed: Diagnostic screen LOW CURRENT WELD 2 PROG=0 COUNT1= 10 STP1= 27% I1=10.5kA I2=12.1kA P->5.00kN <<<...

  • Page 22: Menus

    ..menus << MAIN MENU >> << CONFIG. MENU >> Use program Edit configuration << ELECTRODE MENU >> Edit program file Edit calibration Stepper status Edit limits file Edit output map Edit stepper Edit events file Edit input map *Only if multi-gun or Edit counter file Edit cascade** Edit transformers*...

  • Page 23: Diagnostic Screen 1

    Diagnostic screen 1 Program used Status LOW CURRENT WELD 2 Measured current PROG=0 for weld1 I1=10.5kA I2=12.1kA Measured current for weld2 Note that some elements may not be visible, if that feature is not being used. Status: diagnostic error messages. If more than one exists, these are flashed sequentially. Program used: this is the program number that was last used.

  • Page 24: Diagnostic Screen 2

    Diagnostic screen 2 Note that some elements may not be visible, if that feature is not being used. Status: diagnostic error messages. If more than one exists, these are flashed sequentially. Weld counter: the present value in the counter (updates after each weld) Stepper %complete:shows the progress along the stepping curve.

  • Page 25: Status / Error Codes

    Error codes are sent to Status / error codes the fieldbus (if fitted). The description (abbreviated) appears on the top line of the diagnostic screen. Error code Description Advice No errors Configuration error Edit the configuration file No synchronising signal Check 27V AC sync.
  • Page 26 ..status / error codes Error code Description Advice Transformer hot Check water flow to welding transformer / Reduce duty Inverter hot Check water flow to inverter / Check inverter fans/ Reduce duty Inverter voltage error Check mains supply to inverter Short circuit Check cables from inverter to welding transformer/ Check transformer Inverter no current...
  • Page 27 ..status / error codes Error code Description Advice Stepper 1 end Reset stepper 1 Stepper 2 end Reset stepper 2 Stepper 3 end Reset stepper 3 Stepper 4 end Reset stepper 4 Stepper 5 end Reset stepper 5 Stepper 6 end Reset stepper 6 Stepper 7 end Reset stepper 7...
  • Page 28 ..status / error codes Error code Description Advice Counter 1 end Reset counter 1 Counter 2 end Reset counter 2 Counter 3 end Reset counter 3 Counter 4 end Reset counter 4 Counter 5 end Reset counter 5 Counter 6 end Reset counter 6 Counter 7 end Reset counter 7...

  • Page 29: Configuration Menu

    Configuration menu <<< CONFIG. MENU>>> Visible EDIT CONFIGURATION Note: after changing the window EDIT CALIBRATION configuration, you must restart EDIT OUTPUT MAP the timer before your changes EDIT INPUT MAP will take effect. SET-UP ADAPTERS You can restart the timer by BACKUP ALL DATA cycling the power, or via the RESTORE ALL DATA...

  • Page 30: Edit Configuration

    Edit configuration Note: after changing the configuration, 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 restart the timer by cycling the power, or via the system set-up menu.
  • Page 31 …edit configuration •Sequence:Spot / Roll-spot / Seam(2-heat) / Seam(pre-heat). •Single gun / Dual gun / OHMA gun / Multi-gun / Multi-gun cascade: the number/type of welding guns to be controlled. •I/O Source:Discrete / Fieldbus(map 1) / Fieldbus(map2). Specifies how the timer obtains input signals ( outputs are always written to both the discrete and fieldbus interfaces).
  • Page 32 ……edit configuration •Heat range (Wide/High/Low): Wide corresponds to a control range of 30-150’. High corresponds to a control range of 30-130’. Low corresponds to a control range of 50-150’. Select the LOW range for machines with a poor power factor, or when exceptionally low currents are required.

  • Page 33: Edit Calibration

    Edit calibration •Toroid: sensitivity of the measuring coil <<< CALIBRATION 1 >>> (toroid), expressed in mV/kA. TOROID: 150 mV/kA Visible •S/P ratio & Offset: See next page for details. S/P RATIO 50:1 window •Pressure: relationship between the PV S/P OFFSET controller output and actual tip force.
  • Page 34 …calibration •If the sensor (Toroid or CT) is measuring the primary current (AC modes only), the timer can display secondary values. It does this by calculation based on the Secondary to Primary ratio (S/P ratio) and offset (S/P offset) parameters. For MF operation set S/P ratio to 1:1, and set S/P offset to 0. •To determine the correct values, do the following: •...
  • Page 35 ……calibration •If you do not have a suitable meter, or you do not wish to do the calculations, you can still use primary feedback by doing the following: Set the S/P ratio = transformer turns ratio in the calibration. Set the S/P offset to 0 in the calibration. •If you do not know the transformer turns ratio, then use a value of 50:1 as many welding transformers will be approximately this figure.

  • Page 36: Edit Output Map

    Edit Output Map Each output may be independently set up as either: • the standard function assigned (see users connections). • as an EVENT output. • as a SEQUENCER output. • 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.

  • Page 37: Edit Input Map

    Edit Input Map <<< INPUT MAP >>> Each input may be independently set Visible I01: RESET FAULT up as window I02: P32 either: I03: P16 • the standard function assigned I04: EDIT DISABLE (see users connections). I05: RESET COUNT I06: RESET STEPPER •...

  • Page 38: Set-Up Adapters

    Set-up Adapters <<< ADAPTERS >>> View of timer with cover removed SLOT 1 Ethernet 1.00 and two adapter cards fitted. SLOT 2 NO ADAPTER The WS2003 timer can be fitted with up to two adapter cards, to provide additional functions. These are fitted into two positions, referred to as slot 1 and slot 2.

  • Page 39: Backup/Restore

    Backup/Restore The Backup and Restore functions provide a convenient means of transferring all of your settings from one timer to another. Backup: Use this function to make a copy of all of your data. The copy is held within the WSP3 pendant.

  • Page 40: Initialise All Data

    Initialise all data The Initialise function provides a convenient means of setting all of the data in the timer to a known initial state. This 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.

  • Page 41: System Set-Up Menu

    System set-up menu <<< SYSTEM SETUP >>> The WELDSTAR model WS2003 is equipped with two SHOW SYSTEM FILES memories, which can be used to store two versions of the SELECT ACTIVE FILE operating firmware files. The Edit system set-up menu RESTART SYSTEM provides a number of functions for examining and selecting these files.

  • Page 42: Main Menu

    Main menu <<< MAIN MENU >>> USE PROGRAM -EXT( 0) EDIT PROGRAM FILE EDIT LIMITS FILE EDIT EVENTS FILE ELECTRODE MENU SEQUENCER MENU WELD LOG For information only COPY PROGRAM I/O STATUS FIELDBUS INPUTS ANALOG STATUS WS2003 VERSION 1.34 Note: To access the Configuration menu, select the ‘version’ line on the main menu (last line), hold down the key, then press the F key.

  • Page 43: Edit Program (Ac)

    Edit program (AC) <<< PROGRAM 0 >>> Visible I1=7.50kA 25.0% PHA window PHA=Phase angle mode. The current and I2=10.0kA 50.0% CCR heat parameters are independently PV=5.00kN@50.0% NORM adjustable. No current regulation takes PSQ= 0 SQZ= 10 place. The current parameter is used for W1 = 0 C1 = 0 monitoring only.

  • Page 44: Edit Program (Mf)

    Edit program (MF) <<< PROGRAM 0 >>> Visible I1=7.50kA 25.0% window UNC=Uncalibrated mode. The current and I2=10.0kA 50.0% heat parameters are independently PV=5.00kN@50.0% NORM adjustable. Actual current is determined by PSQ= 0 SQZ= 10 the inverter. The current parameter is used W1 = 0 for monitoring only.
  • Page 45 ..edit program <<< PROGRAM 0 >>> Visible I1=7.50kA 25.0% PHA window NORM = normal spot weld operation. LINK = I2=10.0kA 50.0% CCR linked spot operation. PV=5.00kN@50.0% NORM PSQ= 0 SQZ= 10 LINKed operation provides a means of W1 = 0 C1 = 0 chaining programmes together so that a W2 = 10...

  • Page 46: Edit Program(Seam)

    ….edit program(seam) <<< PROGRAM 0 >>> Visible I1=7.50kA 25.0% PHA window I2=10.0kA 50.0% CCR BALANCE = 4.5% PV=5.00kN@50.0% PSQ= 0 SQZ= 10 BALANCE : This control is used to W1 = 0 C1 = 0 balance the current when using pulsed W2 = 10 C2 = 0 seam welding.

  • Page 47: Edit Limits

    Edit Limits <<< LIMITS PROG 0 >>> Visible CURRENT: MONITOR On LOW1=15% HIGH1=10% window PRE-LIMIT1= 5% LOW2=10% HIGH2= 8% PRE-LIMIT2= 5% PRE-LIMIT COUNT = 3 RETRY On PRESSURE: MONITOR On WAIT On LOW = 10% HIGH=10% •The PRE-LIMIT COUNT is the number of successive welds which can fail the pre-limit level test, before a warning is generated.

  • Page 48: Edit Events

    Edit Events <<< EVENTS PROG 0 >>> •Each welding program Ev1: 1=on @SQZ + 2 Visible may have up to 4 Ev2: 1=off @HLD + 5 window events defined. Ev3: 6=on @W1 + 5 •Each event can turn Ev4: 6=off @W2 + 3 one output on or off.

  • Page 49: Electrode Menu

    Electrode menu << ELECTRODE MENU >> Electrode management is provided via a combination STEPPER STATUS of stepper and counter functions. EDIT STEPPER The stepper provides a means of gradually increasing EDIT COUNTER FILE the current, to compensate for electrode wear. One stepper is provided per gun.

  • Page 50: Stepper Status

    Stepper status Visible <STATUS ELECTRODE 1> SPOTS DONE= window Select gun (electrode). [RESET] The number of spots made since the dH= 2.5% dI= 5.0% last reset. This may be changed to alter the working position on the curve. The percentage done of the total number Outputs: of spots, also shown as a bar-graph.

  • Page 51: Edit Stepper

    Edit stepper <<< STEPPER 1 on >>> Visible Enable or disable the stepper. CONTINUE AT END window SPOTS +HEAT +AMPS 1.0% 2.5% If continue at end is selected, then at the end of 1.5% 5.0% the last step,further welding can take place as 2: 100 2.0% 7.5%...

  • Page 52: Stepper Presets

    Stepper presets 60.0 When a preset curve is 50.0 loaded, the data is obtained from a table 40.0 which holds the 5 curves Series1 Series2 shown. dH/DI % 30.0 Series3 Series4 The step sizes (spots) are Series5 20.0 all made the same as for step 9, and the +HEAT(dH) 10.0 and +AMPS(dI) parameters...

  • Page 53: Edit Counter

    Edit counter <<< COUNTER 1 >>> Count now is incremented after every weld. When count up to is COUNT NOW = 431 reached, the counter output is COUNT UP TO 500 activated. STOP AT END Set count up to = 0 to disable a TIP DRESSING On counter.

  • Page 54: Edit Counter(Tip-Dressing)

    ..edit counter(tip dressing) <<< COUNTER 1 >>> COUNT NOW = 431 Stepper curve (see edit stepper) COUNT UP TO 500 STOP AT END TIP DRESSING On MAX.DRESSINGS = 10 DRESSINGS DONE = 2 @RESET,STEPPER= 100 DRESS WHEN NEW On The counter can be used to control tip-dressing by setting the parameter ‘tip-dressing’...

  • Page 55: Sequencer

    Sequencer The sequencer provides a means of controlling a small machine, via a series of logic statements. The statements are executed sequentially in the order in which they appear. The START1 input is used to trigger execution of the sequence, and must be maintained. On release of the START1 signal, the sequence is reset.

  • Page 56: Sequencer Menu

    Sequencer Menu << SEQUENCER MENU >> Enter new statements, parameters etc. ,or edit EDIT SEQUENCE the existing sequence (see edit sequence). ERASE SEQUENCE Erase the entire sequence –use with caution! STATUS: IDLE You will be asked to confirm the operation before the erase takes place.

  • Page 57: Edit Sequence

    …edit sequence On the edit sequence screen, the keys have the following functions: At any time: •Press the keys to change the selected line. The entire line will flash. The screen will scroll when required. •Press the key to insert a new (blank) line. The line number will be shown. •Press the F key to return to the sequencer menu screen.
  • Page 58 …..edit sequence The following table lists the available logic statement types: Statement Range Function Line nnn 1..249 Line number within sequencer file ( has no effect) ----- STEP nnn ----- 1..999 Has no effect, but serves as the target for a JUMP or GOSUB statement, or as a logical divider in the program 1..14 Waits for Input nn to be ON AWAIT INPUT Inn ON...

  • Page 59: Example Sequence

    Example sequence Statement Range Function AWAIT ANALOG n<mm V n=1.3, Waits for Analog input n to be less than mm Volts. 0.0<=mm<=10.0 n=1.3, Waits for Analog input n to be greater than mm Volts. AWAIT ANALOG n>mm V 0.0<=mm<=10.0 n=1.3, If Analog input n is less than mm Volts, then continue at STEP xxx, otherwise continue with the next statement.

  • Page 60: Weld Log

    Weld log <<< WELD LOG >>> The timer records the currents from each weld into the weld log. 64 welds in log The log can hold information from VIEW LOG up to 64 welds (after this, the CLEAR LOG oldest record will be discarded). To see the information for each weld, select the VIEW LOG function.

  • Page 61: View Log Screen 1

    View log (screen 1) Press the + or - keys to select the log record Status for this weld ( 1= most recent weld, 64= oldest weld). Program used for this weld Target current from program Actual current measured Note that if either of I1 or I2 are not shown, then that interval was not used. •Press to change to log screen 2.

  • Page 62: View Log Screen 2

    View log (screen 2) Press the + or - keys to select the log record Status for this weld ( 1= most recent weld, 64= oldest weld). Value of the counter used for this weld Gun (electrode) used for this weld Measured PV feedback PV output...

  • Page 63: Copy Program

    Copy program <<< COPY PROGRAM >>> Copy a program (and associated FROM: 0 limit and event files) to any other TO: 1 program, or to all other programmes. •Press the + or - keys to alter the selected parameter. The TO parameter can be set to ALL if required (i.e.

  • Page 64: Copy Electrode

    Copy electrode <<<COPY ELECTRODE>>> Copy a stepper (and associated FROM: 1 counter and calibration files) to TO: 2 any other stepper, or to all other steppers. •Press the + or - keys to alter the selected parameter. The TO parameter can be set to ALL if required (i.e.

  • Page 65: I/O Status

    I/O Status <<< I/O STATUS >>> I01:RESET FAULT Visible window I02:P32/GAPSW. I03:SEQUENCER I04:EVENT I05:RESET COUNT Off I06:RESET STEPPER Off ..etc. This screen can be used to observe the status of the discrete inputs and outputs. Each input or output is labeled to show how it is mapped.

  • Page 66: Fieldbus Input Status

    Fieldbus input status <<< BUS INPUTS >>> B00:START1 Visible window B01:START2 B02:START3 B03:START4 B04:2nd STAGE B05:WELD ON ..etc. This screen can be used to observe the status of the fieldbus inputs. Note that this screen is only available if the timer is configured for fieldbus operation.

  • Page 67: Analog Status

    Analog Status <<< ANALOG STATUS >>> This screen can be Channel 1 = 0.00 V used to observe the Channel 2 = 2.34 V status of the analog Channel 3 = 9.55 V inputs. TOROID R = 20 •Analog input channels: the dynamic voltage at each of the analog inputs.

  • Page 68: Program Selection

    Program selection Programmes can be selected in a variety of Set this parameter different ways, depending on the settings from the main menu used. Note: If 2-input binary is selected, then the Single/ Binary/ External START Program Dual 1of4 program selection input selected...

  • Page 69: Ohma (Air Over Oil) System

    OHMA (Air over Oil) system The OHMA system uses three valves to control the opening and closing of the electrodes. If Retract is used, the timing of the valve operations is used to control the gap between the electrodes in their mid-position. To enable the OHMA system, you must make appropriate settings in the configuration file.
  • Page 70 …OHMA system Retract Stroke With the electrodes in the fully open position the control will not begin a weld sequence. A Retract input is required to move the electrodes to their mid-position. When a Retract input is given, the RETRACT Blocking valve is switched off and the input Advance valve is switched on.

  • Page 71: Disabling Edits

    Disabling edits Normally, a user can access the It is suggested that this input is parameters via the keypad on the controlled via a key-switch, such WSP3 programming pendant, and that only the key-holder is able to make any changes, as required. open the switch, and thus be able Under some circumstances, it may be to edit parameters.

  • Page 72: Pop-Up Current Meter

    Pop-up current meter The timer will measure the current on both the weld1 and weld 2 intervals, and this is displayed on the diagnostic screen. Often, when programming the timer, you will need to refer to these current measurements. In order to avoid having to switch between screens, there is a convenient pop-up current meter window, which allows you to view the measured currents without leaving the screen you are on.

  • Page 73: Replacing A Ws2000 Timer

    Replacing a WS2000 timer If you have an existing installation with a WS2000 timer and a primary toroid, and you are replacing that timer with a WS2003, then use the following procedure: Note the existing settings (weld program), measure the welding current with a meter, and note the current measured by the WS2000.
  • Page 74 Operation: basic spot weld – no weld faults Current START input EOS output FAULT output WAV output W1=0, C1=0, Pulses=1, OFF=0 WS2003 V1.69...
  • Page 75 Operation: basic spot weld – weld fault Current START input EOS output FAULT output WAV output W1=0, C1=0, Pulses=1, OFF=0 WS2003 V1.69...

  • Page 76: Operation: Repeat Spot Weld

    Operation: repeat spot weld Current START input WAV output W1=0, C1=0, C2=0, Pulses=1 WS2003 V1.69...

  • Page 77: Operation: Pulsation Spot Weld

    Operation: pulsation spot weld Current START input EOS output FAULT output WAV output W1=0, C1=0, Pulses=3, OFF=0 WS2003 V1.69...

  • Page 78: Operation: Upslope And

    Operation: Upslope and Downslope Current Spot START input Upslope time Downslope time WAV output Weld time The upslope and downslope times are part of the overall weld time – they do not add to the weld time. Current Downslope time START input Seam Upslope time...
  • Page 79 Operation: roll-spot welding Current START input MOTOR output WAV output W1=0, C1=0, C2=0, Pulses=1 WS2003 V1.69...
  • Page 80 Operation: seam welding (dual heat) Current START input MOTOR output WAV output C1=0, C2=0 WS2003 V1.69...
  • Page 81 Operation: seam welding (pre-heat) Current START input MOTOR output WAV output WS2003 V1.69...

  • Page 82: Operation: Eos Signal

    Operation: EOS signal Handshake mode: The start signal remains on until EOS is given. When Current start is removed, EOS goes off immediately (cancel with start mode) START input or after 20 cycles (fixed pulse mode). This is the recommended method of EOS output operation for automatic systems.
  • Page 83 Operation: Retract The retract operating mode The retract operating mode (Simple/Hi-lift+/Hi-lift- (Simple/Hi-lift+/Hi-lift- /Maintained) is set in the /Maintained) is set in the configuration file. configuration file. No/ Simple Retract input HAV output Maintained START input WAV output WS2003 V1.69...
  • Page 84 Operation: Hi-lift The retract operating mode The retract operating mode (Simple/Hi-lift+/Hi-lift- (Simple/Hi-lift+/Hi-lift- /Maintained) is set in the /Maintained) is set in the configuration file. configuration file. Hi-lift+ Hi-lift- WS2003 V1.69...

  • Page 85: Multiwelding

    Multiwelding Up to 16 pairs of electrodes, distributed Welding randomly across the transformer welding transformers. WS2003 WS2003 configured for configured for single gun use. multi-gun use. Up to 16 welding transformers/SCRs when used with BD16 decoder, otherwise up to 4 SCRs. Only one transformer/SCR is Up to 16/4 transformers/SCRs can be connected.

  • Page 86: Configuring For Multiwelding

    Configuring WS2003 for multiwelding There are two modes available for multiwelding: ‘MULTI-GUN’ and ‘MULTI-GUN CASCADE’. There are two modes available for multiwelding: ‘MULTI-GUN’ and ‘MULTI-GUN CASCADE’. Multi-gun mode allows each welding program to be triggered independently, in the traditional way, but allows for selection of a transformer and electrode.

  • Page 87: Electrode/Transformer Assignment

    Electrode/Transformer assignment The physical arrangement of the electrodes and welding transformers must be The physical arrangement of the electrodes and welding transformers must be entered into the control. entered into the control. In the example shown here: 1. From the config. menu, select Electrodes 1 and 2 are attached to Transformer 1.

  • Page 88: Assigning A Weld Program To An

    Assigning a weld program to an electrode Each weld program should be assigned to a particular electrode. This is done on the Each weld program should be assigned to a particular electrode. This is done on the ‘EDIT PROGRAM’ screen, accessed from the main menu. ‘EDIT PROGRAM’...

  • Page 89: Multi-Gun Operation

    Multi-gun operation Multi-gun mode allows each welding program to be triggered independently, Multi-gun mode allows each welding program to be triggered independently, in the traditional way, but allows for selection of a transformer and electrode. in the traditional way, but allows for selection of a transformer and electrode. WS2003 V1.69...

  • Page 90: Multi-Gun Cascade Operation

    Multi-gun cascade operation In multi-gun cascade mode, up to sixteen welding programmes can be grouped In multi-gun cascade mode, up to sixteen welding programmes can be grouped together, and triggered from a single start command. The programmes then ripple together, and triggered from a single start command. The programmes then ripple through with minimal time between them, selecting transformers and electrodes on the through with minimal time between them, selecting transformers and electrodes on the fly.
  • Page 91 …multi-gun cascade operation Current (transformer 1) Current (transformer 2) Current (transformer 3) Current (transformer 4) START input Program Cascade # select inputs EOS output WAV output WS2003 V1.69...

  • Page 92: Program Selection (Multiweld)

    Program selection (multiweld) Set this parameter Programmes can be selected from the main menu in a variety of different ways, depending on the settings Binary/ External START Program Mode 1of4 program selection input selected used. N = 0..63 Binary P=0..63 Set these parameters in the N+16 N = 0..15...

  • Page 93: Ws98-2003 Pc Software

    Timers may be connected to the PC via RS232 (1 timer only) or via Ethernet (multiple timers on a network). WS98-2003 is available on CDROM, and works with all versions of Microsoft Windows™ (98 onwards). Contact BF Entron for more details. WS2003 V1.69...

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