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Amada WELD SENTRY Operation Manual

Resistance welding process control monitor
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RESISTANCE WELDING PROCESS CONTROL MONITOR
WELD SENTRY
OPERATION MANUAL
990-291 REV E

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Summary of Contents for Amada WELD SENTRY

  • Page 1 RESISTANCE WELDING PROCESS CONTROL MONITOR WELD SENTRY OPERATION MANUAL 990-291 REV E...
  • Page 2 Copyright © 1998 - 2021, AMADA WELD TECH INC. The engineering designs, drawings and data contained herein are the proprietary work of AMADA WELD TECH and may not be reproduced, copied, exhibited or otherwise used without the written authorization of AMADA WELD TECH.
  • Page 3 The purpose of this manual is to supply operating and maintenance personnel with the information needed to properly and safely operate and maintain the Weld Sentry Resistance Welding Process Control Monitor. We have made every effort to ensure that the information in this manual is accurate and adequate. The contents of this manual are subject to change without notice.
  • Page 4 SAFETY NOTES This instruction manual describes how to operate, maintain and service the Weld Sentry Resistance Welding Process Control Monitor, and provides instructions relating to its SAFE use. Procedures described in this manual MUST be performed, as detailed, by QUALIFIED and TRAINED personnel.

  • Page 5: Table Of Contents

    Technical Assistance ....................Telephone Service ....................Factory Service Repair ..................APPENDIX A: WELD SENTRY SPECIFICATIONS ............ Weld Sentry Input/Output Cables ................Sentry Voltage Measurement ................Sentry Current Measurement ................Sentry Current Shunt Option ................WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR 990-291...
  • Page 6 Flow Chart for Sentry SPC Menu ................ Current Coil Placed Over a Single Welding Cable ..........Current Shunt Installation ..................Voltage Measurement Clip Attachment ............... Proper Method for Wiring Inputs and Outputs to the Sentry’s Relay ....WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR 990-291...
  • Page 7 1. Applicability. (a) These terms and conditions of sale (these “Terms”) are the only terms which govern the sale of the goods (“Goods”) by Amada Weld Tech Inc. (“Seller”) to the buyer identified in the Sales Quotation and/or Acknowledgment (as each defined below) to which these Terms are attached or incorporated by reference (“Buyer”).
  • Page 8 Agreement. Buyer shall immediately discontinue use of the Software upon any termination of this license or Agreement. This license shall terminate upon any termination of the Agreement. WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR viii...
  • Page 9 (b) IN NO EVENT SHALL SELLER’S AGGREGATE LIABILITY ARISING OUT OF OR RELATED TO THIS AGREEMENT, WHETHER ARISING OUT OF OR RELATED TO BREACH OF CONTRACT, TORT (INCLUDING NEGLIGENCE) OR OTHERWISE, EXCEED THE TOTAL OF THE AMOUNTS PAID TO SELLER FOR THE GOODS SOLD HEREUNDER. WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR 990-291...
  • Page 10 (whether war is declared or not), terrorist threats or acts, riot, or other civil unrest, national emergency, revolution, insurrection, epidemic, lock-outs, strikes or other labor disputes (whether or not relating to either party’s workforce), or restraints or delays affecting carriers or inability or delay in obtaining supplies of WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR 990-291...
  • Page 11 27. Survival. Provisions of these Terms which by their nature should apply beyond their terms will remain in force after any termination or expiration of this Order including, but not limited to, the following provisions: Compliance with Laws, Confidentiality, Governing Law, Dispute Resolution, Survival, and the restrictions on Software in Sections 10(b), (c) and (d). WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR 990-291...
  • Page 12  ...

  • Page 13: Chapter 1: Description

    AMADA WELD TECH’s - Weld Sentry accurately and consistently measures the voltage (AC/DC) and current used during the weld process. This makes it superior to any other precision instrument of its type.
  • Page 14 CHAPTER 1: DESCRIPTION WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR 990-291...

  • Page 15: Chapter 2: Getting Started

    GETTING STARTED Rear Panel Components The Weld Sentry option is an available option for multiple AMADA WELD TECH Power Supplies. The illustration below shows the input and output connections on the rear panel of the obsolete PM7S (Phasemaster 7 with Sentry Option). The I/O Connections will be the same over the different product lines.

  • Page 16: Screen Format

    SENTRY PROGRAM SCREEN, SENTRY PROGRAM GRAPH and PM7S RUN STATE. where “S” indicates the Sentry Status Line which shows: Sentry Program (A-E), Measurement Unit (results of last weld), Upper/Lower Limits; and Sentry Status (ON/OFF). WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR 990-291...
  • Page 17 CURRENT: AMP SECONDS LOWER UPPER SENTRY 299.1µ 270.0µ 310.0µ READY □ □ ▲ ▼ ◄ ► SELECT MODIFY , CHNG, SAVE ▲▼ Select Schedule (e) SENTRY PROGRAM GRAPH (f) PM7S RUN STATE WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR 990-291...
  • Page 18 CHAPTER 2: GETTING STARTED WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR 990-291...

  • Page 19: Chapter 3: Installation

    Snap the coil completely closed. Plug the Current Coil Connector into the matching receptacle on the Sentry rear panel. Depress the COIL/SHUNT Switch to select COIL. Figure 3-1. Current Coil Placed Over a Single Welding Cable WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR 990-291...

  • Page 20: Current Shunt Installation - User Supplied

    To install the Current Shunt, disconnect the welding cable coming from one of the terminals on the weld head as shown in figure 3-2. Place the Current Shunt betweed the open connections and then securely re-attach all connections. Figure 3-2. Current Shunt Installation WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR 990-291...

  • Page 21: Weld Voltage Cable Installation

    There are 5 Shunt positions (E1 – E5) on the Sentry’s Control Board which are used to configure communications protocol for the RS-232 Serial Port. Programming for communications is accessed through the Main Menu/Weld Sentry/Communications. WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR 990-291...
  • Page 22 Locate the Sentry Board at the right side of power supply. Change Shunt positions as desired. g Replace the cover. h Replace and tighten screws. Re-connect the power supply to the power source. WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR 990-291...

  • Page 23: Chapter 4: Operating Instructions

    Select the Weld Schedule which you want to monitor. Note: In order to monitor using the Weld Sentry, you must have first develop a Weld Schedule. b Select Weld Sentry/Basic Setup from the Main Menu. Basic Setup is used to create a Sentry Program(s) specifically for the related Weld Schedule.

  • Page 24: Modify An Existing Sentry Program

    Move the cursor and move to the desired field to change; Measurement Unit, Lower or Upper Limits, Sentry ON/OFF, or change Program Line to display A-E. Converting Multipliers – Weld Sentry results are expressed using multiplier abbreviations. Lower and Upper Limits must be entered using corresponding multipliers. The Multipliers are:...
  • Page 25 ▼ ◄ ► SELECT MODIFY , CHNG, SAVE Use [ ◄ ► ] to modify the Measurement and Delay Times. g Press [SAVE] to save the changes and replace the current Program(s). WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR 990-291...
  • Page 26  ...

  • Page 27: Chapter 5: Service

    Section I: Calibration Calibration Check The Weld Sentry has a built-in Calibration Check which can be used as an easy way to check the accuracy of the Voltage and Current measurement circuits. It is good Quality Assurance practice to establish a regular Calibration Check.

  • Page 28: Current And Voltage Input Adjustments

    2 Disconnect Voltage and Current Input cables from the rear of the Sentry. 3 Remove the cover and locate the Weld Sentry board at the right side of the unit. 4 Refer to drawing 4-32603-01, Assembly PCB, Weld Monitor Module.

  • Page 29: Setup Pm7S Or 250Dps

    6 Select [WELD] for the Weld/No Weld switch on the PM7S/250DPS. 7 Use the manual firing switch to fire the power supply. 8 The Weld Sentry measurement should equal 90 millivolt*Seconds ± 2%. 9 If the voltage measurement is not correct, refer to Current and Voltage Input Adjustments, above, and adjust the voltage input.

  • Page 30: Technical Assistance

    CHAPTER 5: SERVICE Technical Assistance If you need further technical assistance, please contact either your authorized service agent or AMADA WELD TECH at the postal or e-mail address or telephone or FAX number shown in the Foreword of this manual.
  • Page 31 TEL. +1-626-303-5676 FAX, +1-626-358-8048 http://www.amadaweldtech.com AMADA WELD TECH CO., LTD. 200, Ishida, Isehara-shi, Kanagawa 259-1196, Japan AMADA WELD TECH KOREA CO., LTD. 28, Dongtanhana 1-gil, Hwaseong-si, Gyeonggi-do, 18423, Korea TEL. +82-31-8015-6810 FAX. +82-31-8003-5995 AMADA WELD TECH SHANGHAI CO., LTD. Unit 401, A206(C8), No. 77, Hongcao Road, Xuhui District, Shanghai, China TEL.
  • Page 32 AMADA WELD TECH INC. 1820 South Myrtle Ave., Monrovia, CA 91016, U.S.A. TEL. +1-626-303-5676 FAX. +1-626-358-8048...

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