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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7DEOHRI&RQWHQWV

&KDSWHU 7KH7HFKQLWURQ7&RQWURO 

$ERXWW H7HF QLWURQ7:HOG&RQWURO  

,QSXWVDQG2XWSXWV  

,QSXWV 

2XWSXWV 

&KDSWHU 7&RQWUROOHU%RDUG/D\RXW 

0DMRU)HDWXUHVRIW H&RQWUROOHU%RDUG  

&KDSWHU ',36ZLWFKHV  

)HDWXUH&RQILJXUDWLRQ6ZLWF HV  

79DQG96ZLWF 

2SWLRQVDW(3520/RFDWLRQ 

(3520/RFDWLRQ 1RUPDO 

(3520/RFDWLRQ   

2SWLRQ)ODJ 

(3520/RFDWLRQRU6<63$5237)/*+ 

',3&RQVWDQW&XUUHQWRU$9& 

',3%LQDU\,QSXWV212))  

',33UHVVXUH6ZLWF RU6HFRQG6WDJHZLW 9  

',33UHVVXUHVZLWF RU6HFRQG6WDJHZLW 9$

2SWLRQIODJVHW   

',35HVHW)DXOWE\3LORW<(612  

',3$QWL6DWXUDWLRQ212)) 

',3'LVSOD\6F HGXOHRU/DVW&XUUHQW 

',3%LQDU\9DOYHV212)) 

',32QH7LPH&RQILJ212))  



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+RRNXS3URFHGXUH 

&KDSWHU 7KH'DWD(QWU\3DQHO'(3  

2YHUYLHZRIW H'(3  

'HWDLOVRIW H'(3·V)HDWXUHV  

&KDSWHU 3URJUDPPLQJWKH7  

)L[HG6HTXHQFH3URJUDPPLQJ  

:HOG6F HGXOH2YHUYLHZ 

%LQDU\9DOYH)XQFWLRQ7DEOH  

& DQJLQJ3URJUDPPHG9DOXHV  

&OHDULQJ0HPRU\ 

6HTXHQFH,QVWUXFWLRQ'HILQLWLRQV  

&RQILJXUDWLRQ,WHP'HILQLWLRQV 

&KDSWHU )DXOWVDQG0HVVDJHV 

)DXOW/('VRQW H'DWD(QWU\3DQHO 

/LVWRI1XPHULF'LVSOD\0HVVDJHV  

3RZHUXS6WDWXV

0RWRUROD+&5HVHW6WDWXV5HJLVWHU

&RQWURO)DXOWV 

2W HU6WDWXV0HVVDJHV

&KDSWHU 5HFDOLEUDWLQJWKH7 

)DFWRU\&DOLEUDWLRQ  

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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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,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

• 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.

Figure 249@CgYdSXUcF! !

4Yc`\Qi-''

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

Closed

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Figure 349@CgYdSXUcF! !1

4Yc`\Qi-')

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.

79DQG96ZLWF 

2SWLRQVDW(3520/RFDWLRQ

(DIP switch or Network download control of firmware V1.00

features) (normal)=set in firmware V1.01 displaying 77.

(3520/RFDWLRQ 1RUPDO

Hardware SW1 Switch is Enabled

Option Flag at EPROM $0206 is Enabled

Host "SW1H" Downloadable Parameter is Disabled

Host "OPTFLGH" Downloadable Parameter is Disabled

(3520/RFDWLRQ 

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

Closed

Open

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