Unitek Peco WELD SENTRY 2 User Manual

Resistance welding process control monitor

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USER'S MANUAL 990-301

Revision B, January 2002

RESISTANCE WELDING PROCESS

WELD SENTRY

CONTROL MONITOR

PART NUMBER

WS2

WS2/230

WS2/10X

WS2/230/10X



STOCK NUMBER

3-131-XX

3-131-XX-01

3-131-XX-02

3-131-XX-03

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Page 1 USER'S MANUAL 990-301 Revision B, January 2002  WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR PART NUMBER STOCK NUMBER 3-131-XX WS2/230 3-131-XX-01 WS2/10X 3-131-XX-02 WS2/230/10X 3-131-XX-03...
Page 2: Revision Record
MIYACHI CORPORATION and may not be reproduced, copied, exhibited or otherwise used without the written authorization of UNITEK MIYACHI CORPORATION. Printed in the United States of America. Revision Record Revision Date Basis of Revision 16678 8/96 Correct Calibration Procedure. 19146 1/02 Add Unitek Peco™ Name...
Page 3: Foreword
The purpose of this manual is to supply operating and maintenance personnel with the information  needed to properly and safely operate and maintain the Unitek Peco Weld Sentry We have made every effort to ensure that the information in this manual is accurate and adequate.
Page 4: Table Of Contents
CONTENTS Page Revision Record ............................ii Foreword .............................. iii Declaration of Conformity ................following Table of Contents SECTION 1. WELD SENTRY 2 DESCRIPTION ................1 Weld Monitoring ..........................1 Front Panel ............................2 Rear Panel ............................3 System Overview ..........................4 SECTION 2. INSTALLATION ......................5 Current and Voltage Inputs ........................6...
Page 6: Section 1. Weld Sentry 2 Description
The Unitek Peco Weld Sentry accurately and consistently measures the voltage and current used to make a direct energy (AC), stored energy (DC), constant current (CI), or constant voltage (CV) resistance weld.
Page 7: Front Panel
WELD SENTRY 2 FRONT PANEL DESCRIPTION Figure 1 – Weld Sentry 2 Front Panel Keyboard [KEYPAD] Use the 10 numeric keys to enter numeric values. [.] is used. to enter decimal values and to change Upper and Lower Limits to a negative value.
Page 8: Rear Panel
WELD SENTRY 2 Page 3 REAR PANEL DESCRIPTION Figure 2 - Rear Panel of Weld Sentry 2. A VOLTAGE INPUT - 3 pin receptacle to connect the Voltage pickup cable used to measure weld voltage. B CURRENT INPUT - 2 pin receptacle to connect either a Current Coil cable or a Current Shunt cable to measure weld current.
Page 9: System Overview
Page 4 WELD SENTRY 2 SYSTEM OVERVlEW The following is an overview outline of the tasks required to begin monitoring. Refer to the sections noted for detailed instructions and information. SETUP WELD SENTRY SYSTEM 1. Connect the Voltage and Current Pickup Cables. (Refer to Section 2 - Installation and Section 4 Specifications) 2.
Page 10: Section 2. Installation
WELD SENTRY 2 Page 5 SECTION 2 - INSTALLATION The basic connections required to monitor are the Current and Voltage inputs. The optional connections are the Start Signal, Line Monitor, Control Signals, Relay Output and the RS-232/RS-422/RS-485. Refer to the corresponding sections in Specifications for more detailed information and technical specifications.
Page 11: Current And Voltage Inputs
Page 6 WELD SENTRY 2 CURRENT SHUNT INSTALLATION 1. Select a user-supplied current shunt from Table 1. 2. Disconnect the welding cable coming from one of the terminals on the weld head. 3. Place the Current Shunt between the open connections and then securely re-attach all connections.
Page 12: Start Signal Installation
WELD SENTRY 2 Page 7 VOLTAGE CABLE INSTALLATION 1. Attach each of the voltage pickup leads to the electrodes. Polarity is not critical, the Sentry uses the current signal to detect polarity. Note: The leads should be as close as is practical to the tip end of each electrode.
Page 13: Relay Output Connections
Page 8 WELD SENTRY 2 RELAY OUTPUT CONNECTIONS The Weld Sentry Output Relays can be programmed to close on any combination of Accept/Reject decisions or Line Monitor limits. Refer to Section 3 - Operation and Section 4 - Specifications. Use the Relay Output Wiring Harness provided in the ship kit. Refer to Section 6 - Parts List.
Page 14: Printer Installation
WELD SENTRY 2 Page 9 PRINTER INSTALLATION - Kodak Diconix 180si Printer/Unitek Catalog No. PTR: 1. Use the standard male-to-male RS232 Cable supplied with the printer. 2. Connect one end to the RS232 Serial Port on the rear of the Weld Sentry.
Page 15 Page 10 WELD SENTRY 2 4. PRINTER SET-UP PARAMETERS - The printer should already be configured correctly for use with the Weld Sentry. To printout and review the Printer Set-Up Parameters, hold the ON-Line button down while turning on the printer. (#9 on the Quick Reference Card) The Set-Up Parameters will be printed as follows: a) Press the LF/FF button to move the printhead to the right.
Page 16: Communications Configuration
WELD SENTRY 2 Page 11 a) Move the printhead beneath "Exit". Press "Font" to Enter. The following will be displayed: g) Select YES to save changes. COMMUNICATIONS CONFIGURATION The Weld Sentry's RS232 communication port (transmit, send and busy lines) is configured for use with the Kodak printer and many IBM compatible computers.
Page 17 Page 12 WELD SENTRY 2 The 15-pin "D" sub connector on the rear panel of the Sentry is used for remote schedule selection and to remotely clear error status. 1. Use the mating connector provided in the ship kit of the Sentry.
Page 18: Line Voltage Monitor
WELD SENTRY 2 Page 13 LINE VOLTAGE MONITOR The Weld Sentry can be connected to either a 115,230, 360, or 480 VAC Power Line. Remove the plug covering the Line Monitor Input on the rear panel of the Sentry. Locate the Parts required:...
Page 19: Section 3. Operation
Page 14 WELD SENTRY 2 SECTION 3 - OPERATION OPERATING STATES There are 6 "States" possible for Weld Sentry operation; HELP, MENU, RUN, STANDBY, PROGRAM, and TRIGGER. MENU STATE Press [MENU] to display the Main menu and access the Weld Sentry options and utilities. Unless instructed differently, press [RUN] to exit the Menu state and SAVE changes made to any of the configurations.
Page 20 WELD SENTRY 2 Page 15 TRIGGER STATE When the Sentry detects a trigger signal and begins to monitor the weld, ■ TRIGGER ■ will be displayed during the entire welding sequence. If the Sentry does not detect the same sequence and timing as setup during basic setup, a No weld status will be signaled.
Page 21: Basic Setup
WELD SENTRY 2 BASIC SETUP The Weld Sentry 2 is designed for use with a wide range of resistance welders. Setup for most weld schedules is quick and easy. Additional features are provided to setup custom monitoring schedules for more complex weld schedules. The Weld Sentry automatically determines which type of setup is applicable during Basic Setup.
Page 22 WELD SENTRY 2 Page 17 BASIC SETUP - SET END OF PROCESS When the weld pulses are separated by an "OFF" time they could be part of the same weld process, for example, a quench-temper weld function, or they could be two separate welds spaced close together.
Page 23 Page 18 WELD SENTRY 2 (16b) When the "Test Weld" screen is displayed do not make another weld, instead, press the period on the keypad. The "Period Definition" screen shown below will be displayed. (17b) Press [ 1 ], [ 2 ] or [ 3 ] to highlight and select either the first weld period, the second weld period or the third weld period.
Page 24 WELD SENTRY 2 Page 19 Press [CHNG] to change END to a right arrow and add Program B which is a copy of Program A. Program A will be used to monitor one measurement unit and Program B will be used to monitor another.
Page 25: Programming Menu Features
Page 20 WELD SENTRY 2 PROGRAMMING MENU FEATURES PRINTER and COMPUTER OUTPUT Select PRINT OPTIONS to configure the type of data output which will be transmitted to a printer or computer through the RS232 port. Any data sent to a printer would also be sent to a computer.
Page 26 WELD SENTRY 2 Page 21 PRINT SYSTEM DATA: This is helpful for documentation or troubleshooting. An example printout is shown below with all of the system defaults listed. PRINT CURRENT SCHEDULE & PROGRAMS: Recommended for documentation and troubleshooting. The sample printout shown below is a schedule with 3 programs used to evaluate 3 different measurement units for the same time period.
Page 27: Copying Schedules And Programs
Page 22 WELD SENTRY 2 COPYING SCHEDULES AND PROGRAMS COPY A SCHEDULE - Select this feature from the Main Menu to transfer all of the information from one schedule to another. All associated programs and limits will be copied also. This is recommended for any schedules developed in Schedule 0.
Page 28: Programming The Line Monitor
WELD SENTRY 2 Page 23 PROGRAMMING THE LINE MON'ITOR LINE MONITOR: Select this feature from the Main Menu to setup the Sentry to monitor an external Power Line. Refer to Section 2 - Installation and Section 4 - Specifications. The Line Monitor screen is shown below. If no voltage is sensed at the Line Monitor input on the rear panel, an error message will flash at the bottom.
Page 29: System Menu
Page 24 WELD SENTRY 2 SYSTEM MENU - SETUP SYSTEM CONFIGURATION Press [MENU] and move the cursor to SYSTEM MENU. Press [ENTER] to display the menu shown at the right. Select SYSTEM SETUP to confirm or change the settings listed below. Default settings are listed first.
Page 30 All of the relays are programmed the same, however, only K1 and K2 are provided standard in the Weld Sentry 2. Move the cursor to the desired status conditions and press [CHNG] and change NO to YES to enable the relay to activate on that status.
Page 31 Page 26 WELD SENTRY 2 (7) Select SYSTEM MENU/RESET TO DEFAULTS to reset the Weld Sentry to factory settings. RESET SYSTEM PARAMETERS - will reset all of the Menu selections and Options to the default settings. Schedules and Programs will not be affected.
Page 32: Collecting Weld Data
WELD SENTRY 2 Page 27 COLLECTING WELD DATA The objective in using the Weld Sentry is to obtain a measured value from weld voltage and weld current which will alert the user to a change in the weld process. If the process is stable, or "in control", the weld quality will be consistent and repeatable, with consistent and repeatable measurement results.
Page 33 Page 28 WELD SENTRY 2 Press to view Programs A-E, press [ENTER] to print a summary, press [CHNG] to display the Charts. ◄ ► The range of the graphs is set by calculating the difference between the Average and both the Maximum and Minimum.
Page 34 WELD SENTRY 2 Page 29 X & R CONTROL CHARTS & SUMMARIES - Select this feature from the SPC menu to calculate, and display or print, Statistical Process Control (SPC) information for any program with data in memory. To define the data to be evaluated, the following screen is displayed first: This screen is also used to access the R Control Chart.
Page 35 Page 30 WELD SENTRY 2 R (RANGE) CONTROL CHART - The range, R, of each sub group is calculated and represented by a data point on the R control chart. The range is the difference between the highest and the lowest value in a sub group.
Page 36 WELD SENTRY 2 Page 31 CONTINUOUS - In the screens shown above, CONTINUOUS is the currently selected "Sampling Mode" which has also caused the "Sampling Period" for the Control Chart to be set at "Continuous". "Continuous" is the default sampling mode and enables the Weld Sentry to save all monitored data in SPC History. When a sub group size is entered the sampling period is automatically changed to the same number so that data is continuously saved.
Page 37 Page 32 WELD SENTRY 2 weld counts from SPC Program History. Enter a Schedule number to display the summary screen. Press [ENTER] to print the Reject Report. Press to display Reject Reports for any other Programs A-E. ◄ ► Note: The SPC weld count is different than the system Weld Counters or Weld Count on the Run screen.
Page 38: Section 4. Specifications
WELD SENTRY 2 Page 33 SECTION 4 - SPECIFICATIONS VOLTAGE INPUTS The Weld Voltage measurement range is 0.10 to 40 volts peak. The pickup cable (4-32409-01) is a 7 foot (2.1 m) shielded cable assembly with a 3-pin plug (520-110) on one end which mates with a 3-pin receptacle (550-070) mounted on the rear panel of the Sentry.
Page 39 Page 34 WELD SENTRY 2 SAMPLING RATE One voltage and current measurement is "sampled" every 40 microseconds during the programmed acquisition period. This corresponds to a sampling rate of 25,000 samples per second, or 25KHz. The sample data is used as calculations for measurement units.
Page 40 Therefore, the weld current changes very little during the welding sequence. The Sentry uses a Unitek Peco patented solution in which both the Weld Voltage and Weld Current are amplified to the same level and then the Current is mathematically subtracted from the Voltage.
Page 41 Page 36 WELD SENTRY 2 COMMUNICATIONS INTERFACE RS232 communications interface is used to transmit weld monitor process data and line voltage conditions to a user supplied serial data logging device, such as a serial printer or personal computer, at speeds up to 9,600 Baud.
Page 42 WELD SENTRY 2 Page 37 FORMAT OF DATA OUTPUT Data can be Prints or transmits summary data for each measurement. When the Graph Mode prints Graphs for any one or all of the Basic Measurement Parameters. In the Raw Data Mode, prints, or transmits voltage and current data for each data point in either ASCII or Binary Format.
Page 43 Page 38 WELD SENTRY 2 SENTRY RELAY OUTPUTS The Sentry is supplied with 2 DC solid state relays, K1 and K2, rated 3 to 60 volts, 1 amp (P/N 4-33049- 01). Two additional sockets, K3 and K4, are provided for user-supplied relays to be added. Either AC or DC solid state relays can be used.
Page 44: Section 5. Calibration
WELD SENTRY 2 Page 39 SECTION 5 - 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 45 Page 40 WELD SENTRY 2 VOLTAGE MEASUREMENT CHECK If desired, the following procedure can be used to check the accuracy of the voltage measurement result. Required Equipment 1. Stable DC Voltage Source (calibrated) 2. Precision Shunt (.01 to 10 milliohm resistance) Setup Welder 1.
Page 46 WELD SENTRY 2 Page 41 CURRENT COIL CALIBRATION The Weld Sentry has a built-in calibration procedure for the Current Coil measurement circuit. If changing current pickup type, Coil or Shunt, it may be necessary to calibrate the coil input circuit. Coil Calibration requires the use of a precision shunt of known resistance.
Page 47: Section 6. Parts List
Page 42 WELD SENTRY 2 SECTION 6 - PARTS LIST WELD SENTRY 2 SHIP KIT 990-333 Weld Sentry 2 Users Manual 4-32878-01 3-1/2" Data Acquisition Software disk 10-309-01* Current Pickup Coil, lx, 150- 100,000 Amps 10-310-01** Current Pickup Coil, 10x, 15 - 10,000 Amps...
Page 48: Appendix A. Spc Formulas
WELD SENTRY 2 Page 43 APPENDIX A - SPC FORMULAS SPC MEMORY - When a Weld Schedule is set for Weld Sentry ON, monitoring results for each related program are automatically saved in memory. The Weld Sentry SPC memory is capable of saving up to 20,000 individual results for all programs combined.
Page 49 Page 44 WELD SENTRY 2 TABLE 2 - Factors for calculating Control Limits Subgroup Size 1.880 3.267 1.023 2.574 0.729 2.282 0.577 2.114 0.483 2.004 0.419 0.076 1.924 0.373 0.136 1.864 0.337 0.184 1.816 0.308 0.223 1.777 0.285 0.256 1.744 0.266...

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