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WTC Technitron T2050 Description And Instructions
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WTC Technitron T2050 Description And Instructions

Weld control
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T2050 Weld Control
Description and Instructions
150 East St. Charles Road
Carol Stream, IL 60188 U.S.A.
Voice: (800) 323-2903
(630) 462-8250
Fax:
(630) 462-8259
Technitron
Revision 04
Feburary, 2004
Part No. 710244
M-050004
WELDING TECHNOLOGY CORPORATION
24775 Crestview Court
Farmington Hills, MI 48335 U.S.A.
Voice: (248) 477-3900
Fax:
(248) 477-8897

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  • Page 1 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...
  • Page 2 7DEOH RI &RQWHQWV &KDSWHU  7KH 7HFKQLWURQ 7 &RQWURO           $ERXW WKH 7HFKQLWURQ 7 :HOG &RQWURO            ,QSXWV DQG 2XWSXWV                             ,QSXWV                                            2XWSXWV                                           &KDSWHU  7 &RQWUROOHU %RDUG /D\RXW         ...
  • Page 3 DQR\U_V3_^dU^dc &KDSWHU  +RRNLQJ 8S WKH 7                +RRNXS 3URFHGXUH                            &KDSWHU  7KH 'DWD (QWU\ 3DQHO '(3            2YHUYLHZ RI WKH '(3                           'HWDLOV RI WKH '(3·V )HDWXUHV                    ...
  • Page 4 DQR\U_V3_^dU^dc &KDSWHU  $SSOLFDWLRQ ([DPSOH                 ([DPSOH RI D 6XFFHVVLYH :HOGLQJ $SSOLFDWLRQ       $VVLJQ 6FKHGXOH                             &RQILJXUDWLRQ 3DUDPHWHUV                            $VVLJQ 6FKHGXOH                            ...
  • Page 5 7KH 7HFKQLWURQ 7 &RQWURO $ERXW WKH 7HFKQLWURQ 7 :HOG &RQWURO The Technitron T2050 weld control is a state-of-the-art microprocessor-based, fixed sequence weld control. It provides the ability to upslope, downslope, postheat and apply pulsation. The fast and powerful Motorola MC68HCZ1 (16-bit processor with DSP math capability) enables the T2050 to weld accurately and reliably in constant-current mode.
  • Page 6 DXUDUSX^Ydb_^D" % 3_^db_\ ,QSXWV DQG 2XWSXWV The control has seven inputs and six outputs. The functions assigned to the I/O may be controlled by DIP switches or via downloading from a personal computer through the RS-485 Network port TS1. ,QSXWV The inputs are •...
  • Page 7 7 &RQWUROOHU %RDUG /D\RXW  0DMRU )HDWXUHV RI WKH &RQWUROOHU %RDUG Figure 1 on page 2-4 illustrates the Controller board (p/n 824644) used in the T2050 control. Principal features to note are the following connectors, DIP switches and hardware I/O points: •...
  • Page 8 D" % 3_^db_\\Ub2_QbT<Qi_ed D" % 3_^db_\\Ub2_QbT Figure 1 <Qi_ed =_TYVYUT*(!& ! DUSX^Ydb_^D" % GU\T3_^db_\...
  • Page 9 ',3 6ZLWFKHV )HDWXUH &RQILJXUDWLRQ 6ZLWFKHV The T2050 has two sets of feature configuration switches. They appear in two different forms: • The first form is considered a virtual set of switches and are located in the EPROM U17 at address $0206 and $0208. The setting of the virtual switches may affect the features of the DIP switches SW1.
  • Page 10 49@CgYdSXUc 49@CgYdSXUcF! !1 Figure 3 4Yc`\Qi-') C = ACCESS YELLOW CONFIG 0 = ACCESS YELLOW DENIED C = BINARY VALVES 0 = DISCRETE VALVES C = DISPLAY SCHEDULE 0 = DISPLAY LAST CURRENT C = HYPERSIL WELD TRANS. 0 = STACKED IRON WELD TRANS. C = RESET FAULT BY PILOT 0 = FAULT NOT RESET BY PILOT C = PS/SS RESETS STEPPER...
  • Page 11 49@CgYdSXUc 2SWLRQ )ODJ (3520 /RFDWLRQ Description  RU (Reserved for future option) 6<63$5237)/*+ (Reserved for future option) (Reserved for future option) (Reserved for future option) Invert Fault Output: (normal)>0 = Fault Output is ON when Fault is present 1 = Fault Output is OFF when Fault is present Valves: (normal)>0 = Normal 4-Bit Binary Valves 1 = Use 3-Bit Binary Valves, Valve4=Stepper End...
  • Page 12 49@CgYdSXUc ',3  &RQVWDQW &XUUHQW RU $9& CLOSED = CC (Constant Current) OPEN = AVC (Automatic Voltage Compensation). When closed (CC mode), all current values are programmed in actual current (A). For example, entering 9.50 as the value for Weld Cur, the control will pass 9,500 A. through the gun during the Weld function.
  • Page 13 49@CgYdSXUc If DIP 2 is open, then energizing FS1 will run schedule 1. FS2 will run schedule 2. FS3 will run schedule 3. FS4 runs the schedule selected on the Data Entry Panel. To select a schedule, press E underneath the Sequence column of the DEP until the center row LED light is next to the Schedule instruction.
  • Page 14 49@CgYdSXUc If DIP 3 is in the 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 instructions.The guns will open and the sequence will stop if the pilot is removed before the PS/SS input is made.
  • Page 15 49@CgYdSXUc ',3  'LVSOD\ 6FKHGXOH RU /DVW &XUUHQW CLOSED = Display schedule OPEN = Display last current. When DIP 6 is in the closed position and a schedule is initiated, the SCHEDULE LED will light and the schedule number running will appear on the numeric display.
  • Page 16 49@CgYdSXUc ',3  2QH 7LPH &RQILJ 212)) CLOSED = access to the one time configuration items on the DEP is enabled. OPEN = access to the one time config items on the DEP is disabled. One-time configuration items are the items on the DEP in the yellow area of the Config column.
  • Page 17 +RRNLQJ 8S WKH 7 +RRNXS 3URFHGXUH Hooking up the T2050 is simple.Follow these steps: Connect cooling water to the hose fittings provided through the bottom of the control enclosure. Ensure that the flow rate of cooling water flow be AT LEAST 1.2 gal/min.
  • Page 18 8__[Y^WE`dXUD" % Check at various percentages, making sure the control does not go over range 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.
  • Page 19 7KH 'DWD (QWU\ 3DQHO '(3 2YHUYLHZ RI WKH '(3 Figure 4 on page 5-16 illustrates the overlay of the Data Entry Panel (DEP). This is WTC p/n 811695 or 811990. As an overview, these are the important features of the DEP: Weld sequence diagram...
  • Page 20 DXU4QdQ5^dbi@Q^U\45@ 45@?fUb\QiGD3 Figure 4 (!!&)%_b(!!))  !& =_TYVYUT*(!% ! DUSX^Ydb_^D" % GU\T3_^db_\...
  • Page 21 DXU4QdQ5^dbi@Q^U\45@ 'HWDLOV RI WKH '(3·V )HDWXUHV Figure 4 on page 5-16 shows the T2050 DEP (Data Entry Panel) overlay. To aid in learning the DEP, all features are numbered and defined below: !GU\T The diagram shows the flow of sequence instructions as they cUaeU^SU execute.
  • Page 22 DXU4QdQ5^dbi@Q^U\45@ !!@b_WbQ] No sequence or config instructions can be changed unless the ]_TURedd_^ control is in 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.
  • Page 23 3URJUDPPLQJ WKH 7 )L[HG6HTXHQFH 3URJUDPPLQJ The T2050 is a fixed-sequence control. This means that it executes all program instructions in order, and it executes all instructions. If you do not wish to use a function or instruction (such as steppers), you must program it to a value of 0. Two types of instructions can be entered with the Data Entry Panel (DEP).
  • Page 24 @b_WbQ]]Y^WdXUD" % :HOG 6FKHGXOH 2YHUYLHZ When a schedule is initiated, the instruction indicator LEDs on the DEP (Figure 4 on page 5-16, item 3) will cycle down the list of instructions. This shows which item is currently being executed. The first instruction to execute is SQUEEZE DELAY. SQUEEZE DELAY will turn on the valve programmed for that schedule, and then pause for the number of line cycles programmed.
  • Page 25 @b_WbQ]]Y^WdXUD" % When all impulses are complete, DOWNSLOPE TIME is executed. Downsope starts at the Welds Current value and slopes down to the Slope End current value over the Downslope time in line cycles. Turn off Downslope Time by entering a value of 0. Next, TEMPER (a post-heating) may be applied to the weld nugget by using the parameters entered for Temper Cycles and Temper Current.
  • Page 26 @b_WbQ]]Y^WdXUD" % c. Press and release the NO WELD key. d. Release the FAULT RESET key. e. "SCH" will be displayed for 2 seconds and the successive schedules will be aborted. If Successive schedules was programmed 0, then the CHAIN SCHED instruction (if programmed non-zero) will cause a "branch"...
  • Page 27 @b_WbQ]]Y^WdXUD" % %LQDU\ 9DOYH)XQFWLRQ 7DEOH FUNCTION Clamp Electrodes Schedule & Valve # Sch. # 5 Sch. # 1 & 3 Sch. # Sch. # 2 & 4 Sch. # Sch. # Sch. # Sch. # Sch. # Sch. # Sch. # # 10 Sch.
  • Page 28 @b_WbQ]]Y^WdXUD" % &KDQJLQJ 3URJUDPPHG 9DOXHV You can only edit values (except for the SCHEDULE instruction) when the control is in Program Mode. If you purchased the optional keyswitch, the control CANNOT be placed in Program Mode unless the switch is turned to the "Unlock" position. To place the control in Program Mode, press the PROGRAM MODE button on the DEP.
  • Page 29 @b_WbQ]]Y^WdXUD" % The display will show "CLr" for 2 seconds and all programmable data will be set to the default values. Restore the setting of switch SW1–8 to OFF. 6HTXHQFH ,QVWUXFWLRQ 'HILQLWLRQV CSXUTe\U Schedule selects which weld schedule is being programmed when in Program Mode.
  • Page 30 @b_WbQ]]Y^WdXUD" % E`c\_`U3iS\Uc The upslope current will range from the Initial Current up to the Weld Current over the Upslope Time. The timing range is 0 – 99 cycles. For example, if your Weld Cur is set to 60% of available current, and Upslope Time is set to 5 cycles, then upslope weld will start at the Initial Current value (or 60% if programmed higher) and ramp up to 60% of available current over the 5 cycles...
  • Page 31 @b_WbQ]]Y^WdXUD" % DU]`Ub3iS This is tge duration of the temper current in line cycles. The range is 0 – 99 cycles. Temper serves to control the cooling of the nugget, thereby preventing cracking and brittle weld spots. DU]`Ub3eb The amount of current passed during Temper time. Program this current in primary or secondary A.
  • Page 32 @b_WbQ]]Y^WdXUD" % ?VV3iS If Off time is 0, the SV VALVE outputs are turned off and the sequence ends. After the valves are off, the WCOMP output is energized for the time programmed in WELD COMPLETE. If the OFF Time is greater than 0, the control is in Repeat mode. In Repeat mode, OFF Time turns off all VALVE outputs and pauses for the number of line cycles entered.
  • Page 33 @b_WbQ]]Y^WdXUD" % CdU``Ub3_e^d" This is the Step 2 stepper count for the valve selected in the Sequence column. Program 0 in Stepper Count 1 and Stepper Count 2 to disable the steppers. 9^SbUQcU" Increase 2 is the percentage that the current will increase over the course of Stepper Count 2.
  • Page 34 @b_WbQ]]Y^WdXUD" % Small offsets between the calibrated value and the delivered value in constant current may be nullified by adjusting the tenths digit of Turns Ratio. 1F3CUd`_Y^d AVC Setpoint is the voltage value that the Automatic Voltage Control algorithm pivots on. If set to 0, the AVC system is turned off.
  • Page 35 )DXOWV DQG 0HVVDJHV )DXOW /('V RQ WKH 'DWD (QWU\ 3DQHO When a fault listed on the DEP occurs, the LED next to the fault will blink on and off. This distinguishes the fault condition from a sequence instruction in the other column. One fault is displayed at a time, so that the proper message can be shown on the numeric display.
  • Page 36 6Qe\dcQ^T=UccQWUc Things to check are • Is the tap on the weld transformer set to deliver a requested AVC current and make good welds, at mid range of the percent of available current (40 – 80%)? The control must have room to make corrections. The closer the control is programmed to the limits, the more likely the faults will occur.
  • Page 37 6Qe\dcQ^T=UccQWUc /LVW RI 1XPHULF 'LVSOD\ 0HVVDJHV The following is a list of numeric display messages. 3RZHUXS 6WDWXV X.XX Software version number on power-up, momentarily displayed. EPROM check sum, momentarily displayed after software version. Memory Fault. A data check sum error occurred in Sequence, or Config or both.
  • Page 38 6Qe\dcQ^T=UccQWUc &RQWURO )DXOWV Stepper 1 program ended Stepper 2 program ended Stepper 3 program ended Stepper 4 program ended Emergency Stop Contactor Fault SCR Overtemp Half Cycling Fault Data out of range – Error High Data out of range – Error Low System Error Line clock missing Compensation over 99%...
  • Page 39 5HFDOLEUDWLQJ WKH 7 )DFWRU\ &DOLEUDWLRQ Before shipment, your T2050 control was tested and calibrated by Technitron. It was calibrated on a 480 V line, welding at values near 140 primary and 13,000 secondary A. Voltage and currents were calibrated to the values at the time of the final test. Primary current was calibrated on 1 kA.
  • Page 40 BUSQ\YRbQdY^WdXUD" % 6HFRQGDU\ &XUUHQW &RQWURO Secondary current read out and control are "turned on" by programming a Turns Ratio of 0. You must have a toroid coil connected to TS4. The toroid coil is considered optional and is not normally installed. The secondary current range is controlled by a combination of "W"...
  • Page 41 BUSQ\YRbQdY^WdXUD" % 3QedY_^* >5F5BQddU]`dd_SQ\YRbQdU`bY]Qbi_bcUS_^TQbi SebbU^dY^3_^cdQ^d3ebbU^d]_TU1\gQicSXUS[V_b dXU`b_`UbSebbU^dbQ^WUVYbcdRiTU\YfUbY^WQd)) Y^1F3]_TUQ^T]UQcebY^WdXUSebbU^d>5F5B cgYdSXd_3_^cdQ^d3ebbU^d]_TUgYdX_edVYbcd SXUS[Y^WdXUS_^db_\µcQRY\Ydid_QSSebQdU\ibU`_bd SebbU^dQd" % Q^T))1F3SebbU^d Remember: If any range jumper is changed the control is NOT calibrated in the new range. If the jumper is returned to the original calibrated position, the control is still NOT calibrated. Calibrated current values reside in two memory locations, one for primary and one for secondary.
  • Page 42 BUSQ\YRbQdY^WdXUD" % Divide the secondary current reading by the Turns Ratio of the weld transformer. The result is the primary current value. Are you sure you have the proper ratio? Does your transformer have taps? The control must be in Program mode and the CONFIG and CAL CURRENT LEDs lit.
  • Page 43 BUSQ\YRbQdY^WdXUD" % Make a weld, with or without work. Measure the secondary current with a secondary current meter such as Technitron’s WS10, blanking the first 3 cycles in the measurement on the WS10. (First = 4, last = 15 on the WS10 or WS25.) The control must be in Program mode and the CONFIG and CAL CURRENT LEDs lit.
  • Page 44 BUSQ\YRbQdY^WdXUD" % This page is intentionally left blank. =_TYVYUT*'!! ! DUSX^Ydb_^D" % GU\T3_^db_\...
  • Page 45 $SSOLFDWLRQ ([DPSOH ([DPSOH RI D 6XFFHVVLYH :HOGLQJ $SSOLFDWLRQ A part has two different spot welds made successively. The first weld is made, the part is rotated and pieces are added to the part for the second weld. Before each weld, a clamp is used to gauge and hold the part precisely before the electrodes are engaged.
  • Page 46 1``\YSQdY_^5hQ]`\U 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=2 ;The part is now clamped go to Schedule #2 and make the first weld OFF CYC=0 ;N/A the sequence jumped to Schedule #2. &RQILJXUDWLRQ LOW CURRENT = Your values.
  • Page 47 1``\YSQdY_^5hQ]`\U $VVLJQ 6FKHGXOH Assign Schedule #2 to make the first spot weld: SCHEDULE=2 VALVE=3 ;The clamp is still on (SV1) add SV2, and energize the gun valve (SV1+SV2=3). SQUEEZE DELAY=0 ;N/A SQUEEZE=40 ;Give the electrodes time to close and build pressure, the clamp is still energized.
  • Page 48 1``\YSQdY_^5hQ]`\U $VVLJQ 6FKHGXOH Assign Schedule #3 to re-clamp the parts with SV1 before the second spot weld is made: SCHEDULE=3 VALVE=1 ;Energize the gauging clamp SV1. SQUEEZE DELAY=0 ;N/A SQUEEZE=40 ;Give the clamp time to clamp and align the parts. UPSLOPE=0 ;N/A WELD CYC=0...
  • Page 49 1``\YSQdY_^5hQ]`\U $VVLJQ 6FKHGXOH Assign Schedule #4 to make the second weld: SCHEDULE=4 VALVE=3 ;The clamp is still on (SV1). Add SV2 and energize the gun valve (SV1+SV2=3). SQUEEZE DELAY=0 ;N/A SQUEEZE=40 ;Give the electrodes time to close and build pressure. The clamp is still energized.
  • Page 50 1``\YSQdY_^5hQ]`\U $VVLJQ 6FKHGXOH Assign Schedule #5 to release and eject the part: SCHEDULE=5 VALVE=0 ;Turn off the clamp and gun before the clamp is energized. SQUEEZE DELAY=0 ;N/A SQUEEZE=40 ;Give the clamp and electrodes time to open before ejection. UPSLOPE=0 ;N/A WELD CYC=0 ;N/A...
  • Page 51 1``\YSQdY_^5hQ]`\U %LQDU\ 9DOYH)XQFWLRQ 7DEOH FUNCTION Clamp Electrodes Schedule & Valve # Sch. # 5 Sch. # 1 & 3 Sch. # Sch. # 2 & 4 Sch. # Sch. # Sch. # Sch. # Sch. # Sch. # Sch. # # 10 Sch.
  • Page 52 1``\YSQdY_^5hQ]`\U This page is intentionally left blank. =_TYVYUT*(!% ! DUSX^Ydb_^D" % GU\T3_^db_\...
  • Page 53 $SSHQGL[ $ 6FKHPDWLFV This section contains the required T2050 weld control schematics. As listed by drawing number, they are I/O Hookup for T2050 503-5-2050-01 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]...
  • Page 54 This page is intentionally left blank. =_TYVYUT*(!& ! DUSX^Ydb_^D" % GU\T3_^db_\...