BF Entron WELDSTAR WS2003 User manual

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
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BF Entron Ltd.
Castle Mill Works,
Birmingham new road,
Dudley,
West Midlands,
DY1 4DA
England.
Tel: [phone]
Fax: [phone]
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.

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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

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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

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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.
F
WSP3
BF
ENTRON

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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.

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…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).

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…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.

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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)

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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