WTC Technitron T2050 Operating and installation instructions
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
Fax: (630) 462-8259
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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. This means that when
programming your weld in terms of secondary (or primary) A.,
that the programmed current is passed through your work piece,
regardless of dirt, oil, or changes in your secondary circuit.
Weld current is measured either on the primary of the weld
transformer using a CT pickup, or the secondary side of the
transformer using a toroid pickup coil. In addition to this feature,
you can still weld using the traditional percent of available
current mode with AVC (Automatic Voltage Compensation).
AVC programs all currents as a percentage of available current.
The control compensates for changes in your primary voltage to
provide consistent weld quality.
Up to 60 unique weld schedules are stored in nonvolatile
memory. You may "chain" schedules together for a long string of
uninterrupted welding operations, and/or chain in an
interrupted, then re-initiated, "successive" set of welds.
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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
• FS1 – Initiate sequence 1 or Binary Pilot 1
• FS2 – Initiate sequence 2 or Binary Pilot 2
• FS3 – Initiate sequence 3 or Binary Pilot 4
• FS4 – Initiate sequence selected with the Data Entry Panel or
Binary Pilot 8
• ESTOP – Emergency stop
• WELD – External weld/no weld and
• PS/SS – (Second Stage or Pressure Switch) or (Second Stage
or Reset Steppers).
2XWSXWV The outputs are
• VALVE1 – Solenoid Valve 1 or Binary Output 1
• VALVE2 – Solenoid Valve 2 or Binary Output 2
• VALVE3 – Solenoid Valve 3 or Binary Output 4
• VALVE4 – Solenoid Valve 4 or Binary Output 8 or Stepper
end
• WCOMP – Weld Complete
• FAULT– Fault or Fault NOT
All solenoid valve outputs are protected by a pilot safety relay
(K7). K7 prevents possible unexpected gun closure due to failed
output modules. Relay K7 is "latched" in sequence by the output
of one of the valve outputs. Refer to the I/O hookup print at the
back of this manual.
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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:
•TS1 – RS-485 Connections: Terminal strip TS1 has the
positive, negative and ground terminals required for
network communications using the RS-485 standard.
•TS2 –Control Inputs: Terminal strip TS2 is used to attach the
seven defined hardware user input points.
•TS3 –Control Outputs: Terminal strip TS3 includes the six
defined hardware user output points.
•TS4: Terminal strip TS4 has the terminals to accept the CT
(current transformer), toroid and OVERTEMP sensor inputs.
•Data Entry Panel Socket: This socket connects the power and
data transmit/receive signals necessary to operate the Data
Entry Panel (DEP).
•K7: This is the Pilot Safety Relay.
•P1 –KEY SW: This jumper is a substitute for an external key
switch.
•SW1: Switch 1 is eight DIP (dual in-line package) switches
used to configure features of the timer.
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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. A control running firmware version V1.01
will display 77 at power-up. In V1.01, the feature choices of
SW1 are listed in Figure 2 below.
•The second set of switches are DIP (dual in-line package)
switches. These are on the controller PC board at SW1.
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A control running firmware version V1.01A will display 79 at
power-up. Figure 3 on page 3-6 lists in V1.01A the feature choices
of SW1. The difference is switch #3, when closed the PS/SS input
will reset all stepper programs. Therefore, Pressure Switch mode
is not available in V1.01A.
C = ACCESS YELLOW CONFIG
C = BINARY VALVES
C = DISPLAY SCHEDULE
C = HYPERSIL WELD TRANS.
C = RESET FAULT BY PILOT
C = PRESSURE SWITCH
C = BINARY INITIATION
C = CONSTANT CURRENT
0 = ACCESS YELLOW DENIED
0 = DISCRETE VALVES
0 = DISPLAY LAST CURRENT
0 = STACKED IRON WELD TRANS.
0 = FAULT NOT RESET BY PILOT
0 = SECOND STAGE
0 = DISCRETE INITIATION
0 = AVC MODE WELD
8
7
6
5
4
3
2
1
Closed
Open
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Anyone skilled in EPROM reproduction can configure the
features of any T2050 by applying the features of the virtual
switches listed on the next page.
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(DIP switch or Network download control of firmware V1.00
features) (normal)=set in firmware V1.01 displaying 77.
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Hardware SW1 Switch is Enabled
Option Flag at EPROM $0206 is Enabled
Host "SW1H" Downloadable Parameter is Disabled
Host "OPTFLGH" Downloadable Parameter is Disabled
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Hardware SW1 Switch is Disabled (SW1 may be removed)
Option Flag at Eprom $0206 is Disabled
Host "SW1H" Downloadable Parameter is Enabled (Host control
of SW1)
Host "OPTFLGH" Downloadable Parameter is Enabled (Host
control of Option)
C = ACCESS YELLOW CONFIG
C = BINARY VALVES
C = DISPLAY SCHEDULE
C = HYPERSIL WELD TRANS.
C = RESET FAULT BY PILOT
C = PS/SS RESETS STEPPER
C = BINARY INITIATION
C = CONSTANT CURRENT
0 = ACCESS YELLOW DENIED
0 = DISCRETE VALVES
0 = DISPLAY LAST CURRENT
0 = STACKED IRON WELD TRANS.
0 = FAULT NOT RESET BY PILOT
0 = SECOND STAGE
0 = DISCRETE INITIATION
0 = AVC MODE WELD
8
7
6
5
4
3
2
1
Closed
Open
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Bit Description
$80 (Reserved for future option)
$40 (Reserved for future option)
$20 (Reserved for future option)
$10 (Reserved for future option)
$08 Invert Fault Output:
(normal)>0 = Fault Output is ON when Fault is present
1 = Fault Output is OFF when Fault is present
$04 Valves:
(normal)>0 = Normal 4-Bit Binary Valves
1 = Use 3-Bit Binary Valves, Valve4=Stepper End
Output
$02 Define SW3 operation:
(normal)>0 = SW3 OPEN = Use PS/SS Input for Second
Stage Input
SW3 CLOSED = USE PS/SS Input for Pressure
Switch
1 = SW3 OPEN = USE PS/SS Input for Second
Stage Input
SW3 CLOSED = USE PS/SS Input to Reset
Steppers
$01 Software Line Clock Filter:
0 = Disable Software Line Clock IIR Filter
(normal)>1 = Enable Software Line Clock IIR Filter
If you change a location listed above from (normal), you MUST
document your changes. At a MINIMUM, mark this manual
wherever necessary. Technitron recommends RoboNet download
control of SW1 and removing the switch from the board. With
SW1 removed, accidental changes cannot be made and the state
of the switches will be stored in the PC. If the features are
unknown and SW1 is removed, they may be uploaded from a
T2050 and thereby recorded in the PC.
SW1 is located on the right side of the upper edge of the T2050
Controller Board #824644 (see Figure 1 on page 2-4 and Figure 2
on page 3-5). Proper switch settings are CRITICAL to satisfactory
operation of the control. Be sure to study and understand these
functions thoroughly.
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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. (This is regardless of the amount of metal in
the throat of the gun or metal stack-up, but provided the welding
transformer can deliver the requested current.) DO NOT use
constant current mode initially. Run AVC mode first.
If open (AVC mode), all welding current is in terms of the percent
of available current. If programming 50% for Weld Cur, the
control will deliver 50% of the maximum current that the welding
transformer and its secondary can deliver. The AVC feature
automatically adjusts the percent of available current so that
weld quality is consistent, regardless of voltage fluctuations on
the welding bus. Refer to Chapter 7, "Faults and Messages",
Compensation Fault before making your first weld, and use AVC
mode first.
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CLOSED = binary schedule initiation
OPEN = discrete schedule initiation.
If DIP 2 is in the closed position, then schedules 1 –15 are
selected by placing a binary combination on inputs FS1 –FS4.
The first four inputs are, in order,
•FS1: Binary Pilot 1
•FS2: Binary Pilot 2
•FS3: Binary Pilot 4
•FS4: Binary Pilot 8
To choose which schedule to run, add up the appropriate binary
pilot numbers to get the desired schedule. For example, to run
schedule 3, energize BINARY PILOT 1 and BINARY PILOT 2 at
the same time. To run schedule 4, energize only BINARY PILOT
4. To run schedule 5, energize BINARY PILOT 1 and BINARY
PILOT 4 at the same time.
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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. Press the DATA W
and Ekeys to change the numeric display value until you reach
the desired schedule number (1 –60).
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CLOSED = Pressure switch
OPEN = Second stage.
If running V1.01 firmware and DIP 3 is in the closed (PRESSURE
SWITCH) 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. After the
sequence is initiated, the pilot may be removed and the sequence
will still run to completion. If the pressure switch is not made
after five seconds, the message P_S will be displayed on the
DEP’s numeric display.
If DIP 3 is 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. If the pressure
switch is not made after five seconds, the message S_S will be
displayed on the data entry panel numeric display.
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CLOSED = Reset Steppers
OPEN = Second stage.
If running V1.01A and DIP 3 is closed (Reset Steppers position)
and the control is in program mode, when input PS/SS it true, the
stepper programs will be reset. The display will read RES,
indicating the stepper programs are all reset.
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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. If the pressure
switch is not made after five seconds, the message S_S will be
displayed on the DEP’s numeric display.
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CLOSED = Reset faults by pilot
OPEN = Do not reset fault by pilot.
If DIP 4 is closed (reset faults by pilot), all faults will be cleared
when a new pilot is applied. If the stepper has ended and not
been reset, the STEPPER END fault will re-appear with the next
weld. If DIP 4 is open (do not clear faults with pilot) the control
will not initiate until all faults (except Compensation faults) have
been cleared at the DEP.
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CLOSED = 87-degree delayed firing and automatic bleed
down enabled.
OPEN = 87-degree delayed firing and automatic bleed down
disabled.
When using Hypersil weld transformers, it is essential to use
delayed firing and automatic bleed-down to avoid saturation.
Saturation is characterized by a "grunting" noise coming from the
transformer. This noise is the sound of the transformer
magnetically tearing itself apart, which will eventually destroy it.
When a transformer saturates, less total current passes through
the part. This results in bad welds.
By contrast, stacked-iron transformers are very forgiving and
difficult to saturate. If full welding power is needed without
delay (as in a 1- or 2-cycle weld), then turn delayed firing (anti-
saturation) OFF. When seam welding, Hypersil transformers are
typically not used, and anti-saturation and automatic bleed down
are disabled.
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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.
If DIP 6 is open, the last average half-cycle RMS Weld current or
the average half-cycle sum of Weld + Cool + Impulses
programmed, will appear on the numeric display.
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CLOSED = Binary valves on
OPEN = Binary valves off.
When DIP 7 is closed, the four valves will output a 0 –15 binary
number. If Option flag bit $04 is set = 1, then the output will be
0 –7 binary number with the fourth output indicating Stepper
Program end. Use this feature with a binary pressure valve, or
when more than one output must be turned on at the same time
for machine control. When using binary valves, only one stepper
program is available. This assumes that you are using one gun
with different pressures.
If DIP 7 is open, the valves function sequentially. Programming a
number 1 –4 (or 3 if flag bit $04 is set = 1) will turn on a valve
output 1 –4 (or 3).
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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. These items are the weld
transformer Turns Ratio, AVC set point, Program Lockout,
Network ID, Cal Line Voltage and Cal CURRENT of the Data
Entry Panel. Access to these instructions is restricted because
once they are set up, they should never be changed. Cal Line
Voltage and Cal Current values are set at the factory and should
NOT be changed. If they are changed, your control may not
operate properly until properly re-calibrated. A special keystroke
sequence is needed to change calibration values so they are not
changed accidentally.
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Hooking up the T2050 is simple.Follow these steps:
1. Connect cooling water to the hose fittings provided through
the bottom of the control enclosure.
2. Ensure that the flow rate of cooling water flow be AT LEAST
1.2 gal/min.
3. Connect the L1, L2 line power cables and the H1, H2 weld
transformer cables to the labeled copper bars provided in the
enclosure.
4. Referring to the I/O hookup schematic located at the back of
this manual, connect the inputs and outputs as required.
5. If Emergency Stop, Weld and/or PS/SS are not used, jumper
the inputs to FSC. Review DIP switch settings and voltage
tap connections of T1 for your application.
WARNING! NEVER apply 120VAC to FSC, as it will
destroy the control.
6. Make sure the cabinet has a good earth ground according to
NEC standards. ALWAYS close the enclosure door and latch
it tightly before applying power, especially on the initial
application of power.
8Y^dc* Begin the initial start-up in AVC mode (SW1-1 set open). Set the
tap on the weld transformer so good welds are made at the
midrange of the percent of available current (40 –80%). Enter the
proper transformer Turns Ratio. Before going to Constant
Current mode, check the measurement of current (SW1-6 open).
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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. Then in CC mode (SW1-1 closed), requesting
the same current observed in AVC mode will result in that
current maintained constantly.
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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:
1. Weld sequence diagram
2. Sequence column LED
3. Instruction indicator LED
4. Config column LED
5. Sequence instruction selector button
6. Config instruction selector button
7. Numeric display
8. WELD light
9. DATA Wand Ebuttons
10. NO WELD button
11. PROGRAM MODE button
12. FAULT RESET button
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