3470 Boul. des Entreprises,
Terrebonne, Quebec, Canada, J6X 4J8
Tel.: (450) 968 8896
Fax: (450) 968 8991
Toll-free: 1-866-968-8896
Web: www.techno-control.com
Email: info@techno-control.com
INSTRUCTION AND PROGRAMMING MANUAL
for the
Alpha Λ Series
Microprocessor-based
RESISTANCE WELDING CONTROLLERS
Version: PGM2: 4.6(WA)/7.5(&7.6)(WAP)/9.5(WAP1)/02.1(03026 & 03026-1) - 2013/11
This document is the property of Techno-Control Cybernetic Inc. It shall not be used, reproduced, copied or transmitted to a third party without
written authorization from Techno-Control Cybernetic Inc
Instruction and Programming Manual for the Alpha Λ Series Resistance Welding Controllers
TABLE OF CONTENTS
1.
INTRODUCTION ............................................................................................................................................... 5
2.
WARNING ......................................................................................................................................................... 7
3.
THE CONTROLLER.......................................................................................................................................... 9
4.
TECHNICAL DESCRIPTION............................................................................................................................. 9
“CONTROLS” indicators ............................................................................................................................................ 11
“POWER” ......................................................................................................................................................... 11
“S.C.R. ON”...................................................................................................................................................... 11
“WELD / NO WELD” ........................................................................................................................................ 11
“SINGLE / REPEAT” ........................................................................................................................................ 11
5.
PROGRAMMING INSTRUCTIONS ................................................................................................................ 13
Programming the welding parameters ....................................................................................................................... 13
Program access ............................................................................................................................................... 13
SQUEEZE ........................................................................................................................................................ 14
WELD TIME ..................................................................................................................................................... 14
PULSE .. .......................................................................................................................................................... 15
COOL .... .......................................................................................................................................................... 15
HOLD .... .......................................................................................................................................................... 15
OFF ....... .......................................................................................................................................................... 16
HEAT%16
Password protection for welding parameters ............................................................................................................. 16
Locking / Unlocking the programming mode.................................................................................................... 16
Changing the password ................................................................................................................................... 17
6.
OPTIONAL FEATURES .................................................................................................................................. 19
Applied pressure confirmation switch (EPD on PS1) ................................................................................................. 19
Two-stages pedals ..................................................................................................................................................... 19
Activation of a second valve ....................................................................................................................................... 19
7.
WIRINGS ......................................................................................................................................................... 21
One one-stage pedal.................................................................................................................................................. 21
One one-stage pedal and an applied pressure confirmation switch (PS1) ................................................................ 21
One two-stages pedal ................................................................................................................................................ 22
One two-stages pedal and an applied pressure confirmation switch (PS1)............................................................... 22
8.
TIMES OF A WELDING SEQUENCE ............................................................................................................. 23
Non repeating welding sequence (“Single”) ............................................................................................................... 23
Repeating welding sequence (REPEAT) ................................................................................................................... 24
9.
MECHANICAL SPECIFICATIONS .................................................................................................................. 27
SPECIFICATION FOR FLAT PANEL MOUNTING VERSION (without enclosure) ................................................... 27
SPECIFICATION FOR EXTERNAL MOUNTING VERSION (with enclosure) .......................................................... 28
SPECIFICATION FOR SCR MOUNT BOARD MOUNTING ..................................................................................... 29
10.
TECHNICAL SPECIFICATIONS ..................................................................................................................... 31
11.
SUGGESTED WIRING (S.C.R. MOUNT) ....................................................................................................... 33
12.
RESPONSIBILITY AND CONDITIONS TO BE APPLIED BY END USER (CSA RULES) ........................... 35
13.
CODES SUMMARY ........................................................................................................................................ 36
14.
PROGRAMS AND PARAMETERS ................................................................................................................. 37
15.
STANDARD TERMS AND CONDITIONS CONTRACT.................................................................................. 39
16.
NOTES............................................................................................................................................................. 40
Page 3
TABLE OF FIGURES
Figure 1: WA-xxxx controllers .................................................................................................................................... 10
Figure 2: WAP-xxxx and WAP1-xxxx controllers ...................................................................................................... 10
Figure 3: ”Controls” display ........................................................................................................................................ 11
Figure 4: ”Program” display........................................................................................................................................ 13
Figure 5: ”Program” button......................................................................................................................................... 13
Figure 6: “Pulse” display ............................................................................................................................................ 15
Figure 7: “Cool” display .............................................................................................................................................. 15
Figure 8: Non repeating welding sequence (SINGLE) ............................................................................................... 23
Figure 9: Repeating welding sequence (REPEAT) .................................................................................................... 24
Figure 10: Repeating welding sequence (REPEAT) with pulse ................................................................................. 24
Figure 11: Minimal cut out hole dimensions ............................................................................................................... 28
Figure 12: Maximal cut out hole dimensions.............................................................................................................. 28
Figure 13: External dimensions of the front interface panel ...................................................................................... 28
Figure 14: Side panel X 2........................................................................................................................................... 29
Figure 15: Back panel ................................................................................................................................................ 29
Figure 16: Mounting dimensions of the SCR Mount board. Drilling positions for fastening screws .......................... 29
Figure 17: ”Controller ready” ...................................................................................................................................... 36
Figure 18: ”Enter Password” ...................................................................................................................................... 36
Figure 19: ”Lock” ........................................................................................................................................................ 36
Figure 20: ”Change password” .................................................................................................................................. 36
Figure 21: ”Enter new password” ............................................................................................................................... 36
Figure 22: ”Password changed” ................................................................................................................................. 36
Figure 23: “Frequency Error”...................................................................................................................................... 36
Figure 24 : « Foot Switch » ........................................................................................................................................ 36
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Instruction and Programming Manual for the Alpha Λ Series Resistance Welding Controllers
1. INTRODUCTION
Congratulations! Your have chosen a high technology welding controller that gives you access to the mechanical
and electronic engineering that built Techno-Control Cybernetic's reputation. If installed and used in accordance to
the instructions contained in this manual, it will offer you years of the same reliable performance all Techno-Control
Cybernetic's products are famous for.
Techno-Control Cybernetic and their distributors are committed not only to provide you with the highest
performance/price ratio made possible by today's technology, but also to offer you unparalleled after-sale service
and fast, competent technical support. Your distributor can answer your questions and offer technical support to
meet most problem situations. Their factory-trained technicians can solve application and maintenance problems
and give you advice for an optimised use of your controller. Should you experience problems or have any question,
your friendly distributor is your first resource.
Should your distributor be unable to meet your requirements, or should you prefer direct factory assistance, our
technical support department will be pleased to assist you for specific applications and/or answer all your questions.
You can reach us:
TECHNO-CONTROL CYBERNETIC Inc.
Sales and technical support
Ph: (450) 968-8896
Fax: (450) 968-8991
Toll-free: 1-866-968-8896
Should our lines be busy, you can leave a message at all times; we will contact you as soon as possible.
NOTE: Before calling, have the following information available:
The model and the serial number of your unit.
The company name of the first owner of the unit (shown on the data sheet, “description of unit”, at the end
of this manual);
The name, address and telephone number (and fax if applicable) of your company;
Your name and title in the company;
The display on the unit: (what message is displayed?)
If you call about a problem, in what circumstances (sequence of events) did the problem appear?
These information will help us find your unit's specific configuration in our data bases, and thus help us diagnose it
and answer your questions.
Page 5
Instruction and Programming Manual for the Alpha Λ Series Resistance Welding Controllers
2. WARNING
Some precautions should be taken in the installation, the operation and the maintenance of your resistance welding
controller. It is highly recommended to:
•
To have the controller installed by a certified electrician;
•
To close the main electrical breaker as well as the air and water supply on your welding controller when it is
not used for a long period, especially when there is no surveillance in the evening or the weekend.
•
To make sure that the SCR is always water cooled when the controller is powered on. Overheating the
SCR can damage it and damage the controller and its components. If your resistance welder is equipped
with a water saving system, make sure that the SCR is still water cooled by placing it outside the water
saving circuit.
•
To keep the cooling water temperature not higher than 40°C (104°F) and not lower than the dew point of
the air temperature to prevent condensation in the resistance welding controller.
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Instruction and Programming Manual for the Alpha Λ Series Resistance Welding Controllers
3. THE CONTROLLER
The resistance welding controller from the ALPHA Λ Series is a welding control unit equipped with a
microprocessor capable of controlling all the welding process with precision and constancy.
The controlled parameters for the WA-xxxx (ALPHA) controllers are: the squeeze time, the welding time, the hold
time, and the welding current. For the WAP-xxxx (ALPHA-P) and WAP1-xxxx (ALPHA-P with optional 16
programs) the following parameters are added: the welding pulses and the cooling time between the pulses.
Furthermore, all input and output signals to and from the controller are insulated against possible interferences by
the use of opto-coupler or uncommitted relay contacts.
Its simple and intuitive human interface, ease of use, quick installation, modular construction, small size and
reliability make this unit a remarkably efficient and productive tool that is easily adaptable to a large spectrum of
welding applications.
4. TECHNICAL DESCRIPTION
For this section, please refer to the figures below. Some of the graphical elements that accompany this manual
were taken from these figures. They are representations of the WA-xxxx (Figure 1) and WAP-xxxx and WAP1xxxx (Figure 2)1 controllers’ interfaces.
1
In this manual, the text elements that are framed by a dashed line and highlighted in grey apply only to controllers
model WAP-xxxx and WAP1-xxxx.
Page 9
WELDING CONTROL
WELDING CONTROL
Λ Alpha Series
Λ Alpha Series
DISPLAY
CONTROLS
DISPLAY
PROGRAM
Power
Squeeze
CONTROLS
PROGRAM
Power
Squeeze
Weld Time
S.C .R. On
Weld Time
S.C .R. On
Hold
Weld / No Weld
Hold
Weld / No Weld
Off
Single / Repeat
Program
Off
Heat %
Up
Down
Weld /
No Weld
Single /
Repeat
Figure 1: WA-xxxx controllers
Page 10
Single / Repeat
Program
Heat %
Up
Down
Weld /
No Weld
Single /
Repeat
Figure 2: WAP-xxxx and WAP1-xxxx controllers
Instruction and Programming Manual for the Alpha Λ Series Resistance Welding Controllers
“CONTROLS” indicators
“POWER”
When power is applied, the "POWER" lamp comes ON and the display shows the
letters "Cr" which indicates that the controller is ready.
“S.C.R. ON”
This lamp comes ON when the SCRs are triggered.
(welding) is occurring at this moment.
It thus confirms that heating
“WELD / NO WELD”
The WELD/NO WELD lamp indicates whether or not there will be heating current
during the weld time. If the lamp is ON, there will be heating. If it is OFF, the weld
time will elapse normally but no current will be applied, thus welding will not occur.
Figure 3:
”Controls” display
The WELD and the NO WELD conditions are selected by pushing the WELD/NO
WELD (▲) button for more than half a second. To make that change, the unit should
not be in the programming mode, i.e. the indicator should show “Cr” (“Controller
ready”).
“SINGLE / REPEAT”
If the SINGLE/REPEAT lamp is ON, the unit will run only ONE welding cycle even if the Start signal is maintained.
You are then in the SINGLE mode. If this lamp is OFF, as soon as a cycle is over and after the OFF time, the unit
will begin another cycle then another as long as the Start signal is maintained. You are then in the REPEAT mode.
If the unit is in the SINGLE mode and the Start signal is still maintained at the end of a cycle, this signal must be
removed then re-applied to initialize a new cycle.
The SINGLE mode and the REPEAT mode are selected by pushing the SINGLE/REPEAT (▼) button for more
than half a second when the unit is not in the programming mode, i.e. the indicator should show “Cr” (“Controller
ready”)..
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Instruction and Programming Manual for the Alpha Λ Series Resistance Welding Controllers
5. PROGRAMMING INSTRUCTIONS
Programming the welding parameters
Depending on the model of controller from the Alpha Series that you are using, the
instructions regarding multiple programs can vary.
If your controller model is WA-xxxx, your controller has one (1) program that can be
configured. The instructions regarding the access to multiple programs do NOT apply to
your controller.
If your controller model is WAP-xxxx, your controller can memorize up to two (2) welding
programs2. All the instructions in this manual apply to your controller.
Program access
To access the programming mode, the unit must not be in alarm status or in a welding
sequence. “Cr” should show in display. Now just press for half a second and release the
PROGRAM button (Figure 5). When the programming mode is accessed, the
PROGRAM lamp (top of Figure 4) comes ON.
Figure 4:
”Program” display
For model WAP-xxxx, which memorize up to two (2) welding programs, you can modify
the program’s parameters by using the ▲ or ▼ arrows. After entering the programming
mode, the controller will show the last accessed program in the display. The two
available programs are numbered “01” and “02”. When you have chosen the program
that you want to modify, press the “PROGRAM” button to access the first parameter of
that program.
Please note that, when executing a welding sequence, the controller will use the
parameters from the last program that was accessed.
Figure 5:
”Program” button
By pressing the PROGRAM button repeatedly, you can access all the parameters that
can be modified. If a parameter is modified, the change is automatically saved when
accessing the next parameter. You can modify the parameters’ values by using the ▲
and ▼ keys.
There are two (2) ways of exiting the programming mode. The first method is to press repeatedly on the
PROGRAM button until you see “Cr” (Controller ready) and confirm all the entered value. The second method,
which is the quickest, is to press on the pedal (or any device that gives a START signal to the controller) to start a
2
The model WAP1-xxxx can memorize up to 16 programs (offered in option only). Since this characteristic is the
only one that differs from the WAP-xxxx, we will not mention this model any more in this manual.
Page 13
welding sequence and confirm the last entered value. By exiting the programming mode in this manner, you can
access the last parameter that was entered before giving a START signal by pressing twice on the PROGRAM
button (remember to press longer the first time to access the programming mode). However, if you give a START
signal after accessing the “Cr” mode, the next time you press twice on the PROGRAM button, you will be brought to
the SQUEEZE parameter.
SQUEEZE
The SQUEEZE time is the time span between the START signal and the beginning of the welding. When the
SQUEEZE cycle has started, the solenoid valve is activated. The SQUEEZE time must be long enough to allow the
electrodes to close on the material to be welded and to stabilize the pressure before beginning to weld. The
available values for the SQUEEZE time are from 0 to 99 cycles3.
Press on the PROGRAM button to go to the next parameter and save the value indicated for the SQUEEZE
parameter.
WELD TIME
The WELD TIME parameter is the TOTAL welding time during which the electrical current is applied.
The available values for the WELD TIME are from 1 to 99 cycles.
Press on the PROGRAM button to go to the next parameter and save the value indicated for the WELD TIME
parameter.
3
For all the parameters in the Alpha Λ Series resistance welding controller, but the ones referring to the electrical
power, the displayed value is referring to the time measured in cycle of electrical power, in 60th of a second for 60
th
Hz power and in 50 of a second for 50 Hz power. For example, in 60 Hz power, a value of 30 would be 30/60th of
a second, which would be half a second.
Page 14
Instruction and Programming Manual for the Alpha Λ Series Resistance Welding Controllers
PULSE
After pressing the PROGRAM button, the left decimal separator (Figure 6) will start
blinking. This will indicate that you have accessed the PULSE parameter.
The PULSE parameter4 is used for making many welds during the same welding
sequence.
The available values for PULSE are from 1 to 10 pulses.
Figure 6: “Pulse” display
When the selected program has a value which is higher than “01”, the PULSE
indicator blinks when in “Cr” mode to indicate that pulses will occur during the
programmed welding sequence.
Press on the PROGRAM button to go to the next parameter and save the value
indicated for the PULSE parameter.
COOL
After pressing the PROGRAM button, the right decimal separator (Figure 7) will start
blinking. This will indicate that you have accessed the COOL parameter.
The COOL parameter5 is used in conjunction with the PULSE parameter. To access
this parameter, the PULSE value must be higher than “01”. 6
The available values for COOL are from 1 to 10 pulses.
Figure 7: “Cool” display
Press on the PROGRAM button to go to the next parameter and save the value
indicated for the COOL parameter.
HOLD
The HOLD parameter is the number of cycles during which the electrodes are holding the material after the weld.
The main use for this parameter is to hold the material to allow the material to solidify and cool, after being welded,
before releasing the welded material.
The available values for the HOLD parameter are from 0 to 99 cycles.
4
This parameter is only available for models WAP-xxxx and WAP1-xxxx.
This parameter is only available for models WAP-xxxx and WAP1-xxxx.
6 If the value of the PULSE parameter is 1, indicating that there is no pulse, then the programming of the COOL
parameter is ignored and the controller goes directly to the following parameter (HOLD).
5
Page 15
Press on the PROGRAM button to go to the next parameter and save the value indicated for the HOLD parameter.
OFF
The OFF parameter is the pausing time between two (2) welding sequences when in REPEAT mode.
The available values for the OFF parameter are from 0 to 99 cycles.
Press on the PROGRAM button to go to the next parameter and save the value indicated for the OFF parameter.
HEAT%
The HEAT% parameter is the value, in percentage (%), of the maximum power allowed by the welding transformer.
The HEAT% values are from 20% to 99% to take into consideration the influence of the transformer’s inductance
on the SCRs.
Press on the PROGRAM button to end the programming mode and save the value indicated for the HEAT%
parameter. You are then sent to the “Controller ready” mode, indicated by “Cr” on the display.
Password protection for welding parameters
The controllers from the Alpha Series have the ability to lock the programmed welding parameters to prevent
unauthorized personnel from modifying them.
There are two (2) modes to this function: locking/unlocking and Password change.
Please note that the controller’s default password is set to "00" when manufactured.
Locking / Unlocking the programming mode
The next step will explain how to lock/unlock the welding parameters. If the controller is locked, the following
procedure will unlock it or vice versa.
To begin, the controller must be in READY mode, showing “Cr” (Figure 17) on the indicator. Then press the ▲ and
▼ keys simultaneously for half a second before releasing.
You should see “EP” (Figure 18:
”Enter Password”) on the indicator which means “ENTER PASSWORD”. By using the up or down arrows (▲ ▼),
enter the value of the password7. When the value of the password is entered, press the PROGRAM button (Figure
7
Don’t forget, if you haven’t changed the password, it is setup by default to “00”.
Page 16
Instruction and Programming Manual for the Alpha Λ Series Resistance Welding Controllers
5) to confirm the password. You are then sent to the READY mode, seeing “Cr” on the indicator8. Voilà! You have
locked/unlocked the controller.
To verify the state of the lock/unlock function, when in READY mode (“Cr” appears on the indicator), press the
PROGRAM button for half a second then release and press once again the PROGRAM button to access the first
parameter of the last used program. Try to modify the parameter using the up or down arrows (▲ ▼). If you see
“Lo” (Figure 19) on the indicator, then the controller’s parameters are locked. The indicator will come back to “Cr”
after two (2) seconds.
Changing the password
To begin, the controller must be in READY mode, showing “Cr” on the indicator. Then press the ▲ and ▼ keys
simultaneously for half a second before releasing.
You should see “EP” (Figure 18:
”Enter Password”) on the indicator which means “ENTER PASSWORD”. Then press once again the ▲ and ▼
keys simultaneously for half a second before releasing. You should see “CP” (Figure 20: “Change Password”) on
the indicator which means “CHANGE PASSWORD”. After releasing the indicator changes to “EP” to indicate that
you must enter the actual password9. By using the up or down arrows (▲ ▼), enter the value of the old password.
When the value of the password is entered, press the PROGRAM button to confirm the password. Then, if the
password is valid10, you should see “En” on the indicator to request that you “Enter the New Password”. Use the
up or down arrows (▲ ▼) to choose the value of the new password. Press PROGRAM to confirm the new
password. “PC” should appear on the indicator to confirm the “Password Change”. You are then sent to the
READY mode, seeing “Cr” on the indicator. Please keep note of your new password in a safe place for future
reference.
8
If you don’t enter the right password, no indication will be given to tell you so. You must follow the verification
procedure to validate the state of locking/unlocking of your controller.
9 Don’t forget, if you haven’t changed the password, it is setup by default to “00”.
10 If the old password that you entered is not valid, the indicator will show “Cr” to indicate that you were sent out of
the password change mode and that you are now in ready mode. The procedure to change the password must be
done once again by using the right password.
Page 17
Instruction and Programming Manual for the Alpha Λ Series Resistance Welding Controllers
6. OPTIONAL FEATURES
The following features are offered as options on your ALPHA Λ Series resistance welding controller. Please take
note that more options can be added and that Techno-Control Cybernetic can modify, add or remove any options at
any time and without notice.
Applied pressure confirmation switch (EPD on PS1)
An applied pressure confirmation switch can be added to allow a precise validation of the applied pressure on the
electrodes.
For connexion instructions, please refer to “Wirings" (section 7, page 21).
Two-stages pedals
A two-stage pedal can be connected to the ALPHA Λ Series resistance welding controller.
For connexion instructions, please refer to “Wirings" (section 7, page 21).
Activation of a second valve
The ALPHA
controller).
Λ Series resistance welding controller is able to activate a second valve (not included with the
For installation instructions of this optional feature, please contact Techno-Control Cybernetic.
Page 19
Instruction and Programming Manual for the Alpha Λ Series Resistance Welding Controllers
7. WIRINGS
One one-stage pedal
One one-stage pedal and an applied pressure confirmation switch (PS1)
Page 21
One two-stages pedal
One two-stages pedal and an applied pressure confirmation switch (PS1)
Pedal
PS1
Stage 1
1FS1
Connect with
wire connector
+15VDC
PS1 /
in AUX
-0VDC
Black
SVA-L
Stage 2
Blue
Brown
SV1-L
SV-N
GND
Page 22
Instruction and Programming Manual for the Alpha Λ Series Resistance Welding Controllers
8. TIMES OF A WELDING SEQUENCE
Non repeating welding sequence (“Single”)
Figure 8: Non repeating welding sequence (SINGLE)
Figure 8 shows the time diagram (sequence of events) of a non repetitive, "single" welding sequence. The
horizontal axis represents time; and the state of each signal is shown vertically. A high line means the signal is
"ON" (applied); a low line means it is "OFF". No matter whether the actual signal is electrically positive, negative or
alternative, these lines show the logical state of the signal, not its electrical values. The vertical dotted lines are
only visual helps to see if different lines change state (rise or fall) simultaneously. For example, see the START
signal: at the beginning (at left), its line is low meaning that this signal is not applied. At time 1, this signal is
applied up to time 2 when it is removed. It is applied again at time 3 up to time 4, then again at time 5 up to time 9,
then again at 10 to slightly before 12. The other lines tell what happens at the same times.
When the START signal is applied at time 1, the controller outputs the SOLENOID VALVE signal to energize the
squeeze solenoid valve, and starts counting the duration of the programmed SQUEEZE time. Assume that you
apply the START signal for a short time, shorter than what is programmed for SQUEEZE (the programmed
SQUEEZE period is shown by the dotted line): as soon as the START signal is removed, the valve is released and
the welding sequence aborted. This is illustrated at time 2. If the START signal is applied (at time 3) for a longer
period than that programmed for SQUEEZE (as illustrated), the solenoid electrovalve is energized for the whole
duration of the START signal. However, as long as the PS1 signal is not received (the PS1 line is low), welding will
not occur. (PS1 is the Valve Pressure Confirmation.) The controller waits for this signal to be received before
welding. Note: if a pressure switch is not used (or if a two-stages pedal is not used), you must put the jumper PS1
(J8) to ON position (see section 11, page 33) so that the controller does not consider the PS1 signal. In the case
illustrated above, since, at time 4, the START signal is removed before the PS1 is received, the welding sequence
is once again aborted. At time 5, we apply the START signal and hold it. Programmed SQUEEZE time is from
time 5 to time 6. Now, at time 7, PS1 is received (its line goes high): this starts the welding current for the
programmed weld WELDTIME and keeps the squeeze valve energized during the WELD and the HOLD times up
to time 8. After the HOLD time, if the START signal is still held ON, the controller will stays at Cr until you release
the START signal. Note that, for a non repetitive ("single") sequence, the OFF time is not used.
From time 10 is illustrated a normal sequence. At time 10, the START signal is applied. This triggers the
SOLENOID VALVE signal to be generated by the controller. This, in turn, causing the SQUEEZE, causes the
pressure switch to output the PS1 signal when the needed pressure is reached. The PS1 signal shows a slight
delay because of the time for the pressure to build up. After the programmed SQUEEZE time (time 11), the
welding current is applied for the programmed WELDTIME, followed by the HOLD time. After the HOLD time (at
time 12), the SOLENOID VALVE signal is removed, causing the PS1 signal to be removed as the pressure switch
Page 23
releases. There is once again a delay caused by the time for the pressure to decrease. At the end of the HOLD
time, the controller is ready to start another welding sequence as soon as the START signal is re-applied.
Repeating welding sequence (REPEAT)
START
SQUEEZE
PS1
WELDTIME
COOL
HOLD
OFF
VALVE
CYCLES
TIME
1 2
3
4
5
6
7
8
9
10
Figure 9: Repeating welding sequence (REPEAT)
Figure 10: Repeating welding sequence (REPEAT) with pulse
The repeating sequence (Figure 9), selected by the SINGLE/REPEAT button, is quite similar to the single
sequence except that, if the START signal is held, the sequence will be repeated for as long as it is held. Just as
for the non-repeating (or "single") sequence, we see that, if the START signal is held for less than the programmed
SQUEEZE time (from time 1 to time 2), the sequence is aborted. Between times 3 and 4, the START signal is
applied long enough to start a normal sequence, but since no PS1 signal is provided, there is no welding and the
sequence is aborted as soon as the START signal is released.
From time 5 to time 10 are illustrated three normal repeating sequences. The START signal, applied at time 5,
triggers the squeeze by the SOLENOID VALVE signal, which brings the pressure switch to provide the PS1 signal.
After the programmed SQUEEZE time (time 6), welding current is applied. SOLENOID VALVE is held to the end of
Page 24
Instruction and Programming Manual for the Alpha Λ Series Resistance Welding Controllers
the HOLD time. After the HOLD time, SOLENOID VALVE is turned OFF and the pressure drop causes the
pressure switch to cut the PS1 signal. After the end of HOLD is a delay: the OFF time. During the OFF time,
absolutely nothing occurs. This delay is needed for the squeeze pressure to drop and for the jaws to open, and
sometimes to respect the transformer's or SCR's duty cycle in some applications. This time can be programmed to
your convenience (see page 13). After the OFF time (at time 7), if the START signal is still held, a new sequence is
automatically started. Then, since the START signal is still held at the end of this second sequence, a third one
occurs (from time 8). Since, during this sequence, the START signal is removed (time 9), this will be the last
sequence. The controller is now ready to start again when the START signal is re-applied.
In the repeating welding sequence with PULSE11 (see Figure 10), the sequence occurs in the same manner
excepted for the WELDTIME which is divided in the value set in the PULSE parameter and separated between
each other by the COOL time value. In this example we have 3 PULSES. The WELDTIME begin at time 6 and
finish at time A. At this very moment, the COOL time begins until time B where the WELDTIME start again. This
sequence is repeated until time E for a total of 3 PULSES. Then, this weld sequence ended by the HOLD time
followed by the OFF time at time F. Because we are in REPEAT mode, all the last sequence is repeated and this
until the START signal is maintained.
11
The pulse function is only available for models WAP-xxxx and WAP1-xxxx of the Alpha Series.
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Instruction and Programming Manual for the Alpha Λ Series Resistance Welding Controllers
9. MECHANICAL SPECIFICATIONS12
SPECIFICATION FOR FLAT PANEL MOUNTING VERSION (without enclosure)
12
All dimensions are in inches.
Page 27
Figure 11: Minimal cut out hole dimensions
Figure 12: Maximal cut out hole dimensions
Figure 13: External dimensions of the front interface panel
SPECIFICATION FOR EXTERNAL MOUNTING VERSION (with enclosure)
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Instruction and Programming Manual for the Alpha Λ Series Resistance Welding Controllers
Figure 14: Side panel X 2
Figure 15: Back panel
SPECIFICATION FOR SCR MOUNT BOARD MOUNTING
Ø0. 3125
8.00
Ø0. 3125
7.50
3. 250
0.50
Figure 16: Mounting dimensions of the SCR Mount board. Drilling positions for fastening screws
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Instruction and Programming Manual for the Alpha Λ Series Resistance Welding Controllers
10. TECHNICAL SPECIFICATIONS13
General features
•
•
•
•
•
Synchronized firing
Protection against surge voltage
Completely digital
Controlled by microprocessor
Password protection of the parameters
Programs
•
•
1 program for model WA-xxxx
2 programs for model WAP-xxxx (Alpha-P)
Operating temperature
0°C to 69°C
Parameters
SQUEEZE
0 to 99 cycles, 50/60Hz
Weld Time
1 to 99 cycles, 50/60Hz
PULSE14
1 to 10 pulses
COOL
1 to 10 cycles, 50/60Hz
HOLD
0 to 99 cycles, 50/60Hz
OFF
0 to 99 cycles, 50/60Hz
HEAT
20% to 90%
WELD/NO WELD
ON / OFF
Cycle selector
Single or Repeat
Other characteristics
S.C.R.
90A, 160A, 250A, 500A
START (1FS1) input
Normally opened contact
CONFIRMATION (PS1) input
Normally opened contact (closes when squeeze pressure is reached)
SOLENOID VALVE output
Dry relay contact (already connected to 120vac Max 0.5 amp.)
(max. 10 amps at 120 VAC from external source)
Maximum power available on 110VAC
60 VA available
Maximum power available on 15VDC
7 VA available
Cooling Water temperature of SCR
20ºC (70ºF)
15
minimum, 40ºC (104ºF) maximum
13
Due to the constant effort in the development of its products and to technological improvements, Techno-Control
Cybernetic reserves all rights to modify, in any way possible, the features and the specifications of its products at
any time and without notice.
14 Only the models WAP-xxxx and WAP1-xxxx are equipped with an integrated pulser. The PULSE and COOL
parameters apply only to these models.
Page 31
Cooling Water flow rate of SCR
1.2 G.P.M. minimum
Cooling Water pressure of SCR
90 P.S.I.G. maximum
Options
•
•
•
•
•
16 programs available (Model WAP1-xxxx)
Applied pressure confirmation circuit (EPD)
Two (2) stages pedal
Second valve
Configuration according to your specific needs
NOTE:
a) For all valves or control circuits that you connect on the controllers 110VAC power supply, it is
suggested that you add a filtration unit on the terminals of the switch, like a “SNUBBER” if not
already equipped with this circuit.
b) For “puck” type SCR, water hose should be of non-conductive type and 3/8’’ inside diameter. This
hose must not be shorter than 18 inches in length between the SCR and any connectors.
15
The minimal water temperature depends on the dew point temperature of the surrounding air.
temperature as the dew point of the surrounding air can create condensation.
Page 32
A lower
Instruction and Programming Manual for the Alpha Λ Series Resistance Welding Controllers
11. SUGGESTED WIRING (S.C.R. MOUNT)
Utiliser le schéma SCR MOUNT révision 8 (imprimé en couleur) pour ce manuel.
Page 33
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Instruction and Programming Manual for the Alpha Λ Series Resistance Welding Controllers
12. RESPONSIBILITY AND CONDITIONS TO BE APPLIED BY END USER
(CSA RULES)
•
The supply circuit shall have a disconnect switch or circuit breaker by which each resistance welder and it's
control equipment can be isolated from it's supply circuit by disconnecting all ungrounded conductors in
accordance with CSA C22.1 Rule 42-018 and NEC Section 630-33.
•
The disconnect switch or circuit breaker shall be rated not less than the rating of the supply conductors in
accordance with CSA C22.1 Rule 42-014 and NEC Section 630-31.
•
Overcurrent protection for the resistance welder system shall be provided in accordance with CSA C22.1 Rule
42-016 and NEC Section 630-32.
•
The controller must belong to a system protected with emergency stop buttons and security devices according
to CSA W117.2-96 Section 6.4.3 and ANSI Z49.1: 1999 Section 12.4.5.
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Instruction and Programming Manual for the Alpha Λ Series Resistance Welding Controllers
13. CODES SUMMARY
The controller is in “Ready”mode
and can execute a welding
sequence.
Figure 17:
”Controller ready”
For more details, see section 0.
You have entered the
"Locking / Unlocking"
mode and you must enter
a password.
Figure 18:
”Enter Password”
Means that you must
change the password.
Means that the parameters are
locked.
Figure 19:
”Lock”
For more details, see section 0.
Figure 20:
”Change password”
Figure 23:
“Frequency Error”
For more details, see section 0.
Indicates that the power frequency
is incorrect or unstable. Close the
main power supply and open it
after a moment. If the problem
continues, it could indicate that the
controller is connected to a
frequency that is different than
50hz or 60hz. Otherwise, please
contact Techno-Control
Cybernetic.
For more details, see
section 0
Means that the password
was changed.
Means that you must enter a new
password.
Figure 21:
”Enter new
password”
For more details, see
section 0.
Figure 22:
”Password changed”
Figure 24 :
« Foot Switch »
For more details, see
section 0.
Means that the start
signal is maintained
during more than 3
seconds. Release the
start signal to cancel this
code. This can indicate
that the pedal is still
activated or that the start
signal is sent by another
mean.
Page 36
14. PROGRAMS AND PARAMETERS16
Prog. #
Squeeze
Weld Time
Pulse
Cool
Hold
Off
Heat%
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
16
In the Alpha Series, only the models WAP-xxxx and WAP1-xxxx have multiple programs.
Page 37
15. STANDARD TERMS AND CONDITIONS CONTRACT
WARRANTY: Techno-Control Cybernetic Inc. (TCC in the rest of the text) guarantees each controller built (excluding S.C.R.s) for a period of one year (twelve
months), and each machine (excluding welding transformers) for a period of 90 days, from the date of shipment from the factory, to be free from defective material or
workmanship, when given normal and proper usage on a one shift basis. This warranty is not transferable to another owner.
In the event that the controller is operated on a more than single shift basis, the warranty period will be for approximately 2080 operating hours. If the undersigned
client has a Preventive Maintenance contract with TCC, the conditions of the latter prevails if stated. A change of electronic card or other electronic components
inside the controller under warranty will not affect the initial period of warranty of the controller.
During the warranty period, TCC will replace, or repair, at their option, any part, or parts, of their manufacture found defective by TCC inspection. Upon notification by
the client, TCC will either ask that parts be returned F.O.B. to the TCC plant, or the manufacturer's plant, for inspection, or may elect to make inspection at the
purchaser's premises. In either event, parts found defective by TCC inspection will be replaced F.O.B. the TCC factory, Terrebonne, Québec, or that of the
manufacturer, depending upon the terms allowed by this latter. All labour supplied by TCC, in connection with such warranty work, shall be charged.
No allowance will be made for any expense incurred by purchaser in repairing defective, or supplying missing parts, except on our written consent. We do not,
moreover, undertake liability for indirect or consequential damage of any nature, or due to any cause. Any articles not of TCC manufacture included in this proposal
are sold under such warranty only as the makers give us, and we are enabled to enforce, but such articles are not guaranteed by us in any way.
All TCC parts & products are thoroughly checked & tested as required in our quality assurance program. TCC shall not be liable and does not accept any
responsibility whatsoever for any loss of production or loss of profits that are caused, directly or indirectly by either malfunction of machinery or equipment, whether
new or used, or lack of expected performance thereof. TCC hereby specifically excludes any and all liability and responsibility for latent defects in the machinery or
equipment as well as for any and all damages, direct or indirect, caused thereby, including but without restricting the generality of the foregoing, loss of profits. The
warranty of TCC for defects is strictly limited to what is provided for in this clause.
TERMS OF PAYMENT: NET--within thirty (30) days from date of shipment, subject to credit approval by our head office, unless otherwise specified in our quote.
TITLE AND LIEN RIGHTS: The equipment shall remain the property of TCC, regardless of how affixed to any realty or structure, title hereto shall remain in the
company (TCC) until the purchase price (including any notes therefore) has been fully paid in cash. The company (TCC) shall, in event of client’s default to fully pay,
have all rights of repossession and any other rights available to a conditional seller under the laws applicable thereto.
HARDSHIP: TCC shall not be liable for failure to deliver, or delays in delivery, occasioned by strikes, lockouts, fires, inability to obtain materials or shipping space,
breakdowns, delays of carriers or suppliers, and other causes beyond their reasonable control. Under no circumstance can TCC be held responsible of loss of
production or loss of profits.
PRICE: All prices quoted are subject to change without notice at any time prior to written acceptance of the order or otherwise stated by the quote. These prices are
also subject to any additional charge necessitated by any tax which TCC may be required to collect or pay upon sale of said equipment. We reserve the right to
invoice for said tax with original invoice or at any date subsequent to such original invoices. We reserve the right to charge any price difference that may occur in
currency exchange between the time a price is quoted and the time when it invoiced to the client. All quotes are to be considered Free Carrier TCC (FCA Incoterms
2000) unless otherwise stated.
STORAGE FEE: If, 10 working days after the notification that the equipment is ready to be shipped to the client, the equipment is still in TCC’s facility, a storage fee of
0,50$ per day per square foot of storage will be charged to the client.
CSA CERTIFICATION: Controllers manufactured by TCC are certified CSA and CSAus. For equipments that are not CSA certified (or by another competent
authority), it is the responsibility of the client to get the proper certification. TCC can offer this certification at the client’s expense at his request. If modifications are
required after the inspection, they will be charged to the client.
CANCELLATION OR RETURN OF MERCHANDISE: Orders for special equipment or for machines incorporating special features, or non-stock items, cannot be
cancelled or returned, except on such terms as specified by TCC, at its option. Our general policy regarding return of merchandise is published at www.technocontrol.com and can be transmitted on request.
ORDER OF PRECEDENCE: There is no understanding or agreement outside of this written proposal. All previous communications between the parties hereto,
either oral or written, with reference to the subject matter of this proposal are hereby superseded. An order based upon this proposal, when duly accepted and
approved at our head office at Terrebonne, Québec, shall constitute the agreement between the parties hereto and no modification thereof shall be binding upon the
parties, or either of them, unless such modifications shall be in writing duly accepted by the client and approved by an executive officer or authorized representative of
this Company.
DISPUTE RESOLUTION AND APPLICABLE LAW: The parties acknowledge and agree that it is preferable to resolve all disputes between them confidentially,
individually, and in an expeditious and inexpensive manner. The parties accordingly acknowledge and agree that private dispute resolution is preferable to court
actions. Before commencing any legal action, the parties shall first attempt to resolve any dispute or differences between them by way of good faith negotiation.
Neither party shall commence any legal proceedings unless and until the good faith negotiation fails. In case of any litigation arising in connection with any
transaction, and after the failure of the good faith negotiation stated above, it is agreed that the place of trial be held in Quebec and governed by the laws of the
Province of Quebec.
Techno-Control Cybernetic Inc.
3470 Entreprises Boul.
Terrebonne, Quebec, Canada, J6X 4J8
Tel.: (450) 968 8896 Fax: (450) 968 8991
Toll-free: 1-866-968-8896
Page 39
16. NOTES
Page 40