WS4000 Manual

WS4000
Series
Timer Manual
Manual version 1.14

For timer software 1.36
Manual Part Number 91-00-31
Controls covered in this manual:
WS4000
WS4002
WS4004
WS4010
WS4012
WS4014
British Federal Ltd.,

Castle Mill Works,
Birmingham New Road,
Dudley,
West Midlands,
DY1 4DA.
Telephone : 01384 455400
WS4000 Manual
Contents
Contents
INTRODUCTION...................................................................................................1
WS40XX FAMILY MEMBERS ..............................................................................2
CONTROLS WITH FRONT PANEL PROGRAMMERS........................................2
WS4000 .................................................................................................................................... 2
WS4002 .................................................................................................................................... 2
WS4004 .................................................................................................................................... 3
CHASSIS MOUNTED CONTROLS....................................................................................................... 3
WS4010 .................................................................................................................................... 3
WS4012 .................................................................................................................................... 4
WS4014 .................................................................................................................................... 4
SUMMARY OF FEATURES................................................................................................................. 4
TIMER FUNCTIONS .............................................................................................5

WELD SEQUENCES ......................................................................................................................... 5
Standard Spot ........................................................................................................................... 5
Extended Spot .......................................................................................................................... 6
Spot Repeat .............................................................................................................................. 7
STARTING A WELD SEQUENCE ........................................................................................................ 7
Start Signal ............................................................................................................................... 7
Second Stage Start................................................................................................................... 7
WELD CONTROL ............................................................................................................................. 8
Phase Angle Heat Control ........................................................................................................ 8
Constant Current Control.......................................................................................................... 8
Voltage Compensation ............................................................................................................. 8
HEAT STEPPING AND TIP DRESSING ............................................................................................... 8
Stepping.................................................................................................................................... 8
Tip Dressing............................................................................................................................ 10
CURRENT MONITORING ................................................................................................................. 11
High Limit ................................................................................................................................ 12
Pre Limit.................................................................................................................................. 12
Low Limit................................................................................................................................. 12
Conditional Fails ..................................................................................................................... 12
Automatic Retry ...................................................................................................................... 12
Heat Limit................................................................................................................................ 13
Heat Pre-Limit......................................................................................................................... 13
PRESSURE CONTROL.................................................................................................................... 13
END OF SEQUENCE SIGNAL........................................................................................................... 13
End of Sequence Trigger........................................................................................................ 13
End of Sequence Signal Operation ........................................................................................ 14
RETRACT MODES ......................................................................................................................... 15
Standard ................................................................................................................................. 15
Hi-lift +..................................................................................................................................... 15
Hi-lift ..................................................................................................................................... 15
Robot ...................................................................................................................................... 16
OHMA ..................................................................................................................................... 16
GERBI..................................................................................................................................... 16
HEADSET MODE ........................................................................................................................... 17
OHMA SYSTEM ........................................................................................................................... 17
Weld Stroke ............................................................................................................................ 17
WS4000 Manual
Contents
Retract Stroke......................................................................................................................... 19
MEDIUM FREQUENCY WELDING ..................................................................................................... 19
PROGRAMME LOG ........................................................................................................................ 20
HALF CYCLE LOG ......................................................................................................................... 20
PRIMARY CURRENTS LOG ............................................................................................................. 20
BODY CYCLE LOG ........................................................................................................................ 20
TIMER INPUTS AND OUTPUTS ........................................................................22

TIMER INPUTS............................................................................................................................... 22
Start 1 ..................................................................................................................................... 22
Weld on 1................................................................................................................................ 22
Reset Fault 1........................................................................................................................... 22
Reset Electrode 1 ................................................................................................................... 22
Tip Dress Acknowledge 1 ....................................................................................................... 22
2nd Stage Start ....................................................................................................................... 22
Retract 1 ................................................................................................................................. 23
Head Set ................................................................................................................................. 23
Thyristor Temperature ............................................................................................................ 23
Transformer Temperature....................................................................................................... 23
Process Stop........................................................................................................................... 23
Start 2 ..................................................................................................................................... 23
Weld on 2................................................................................................................................ 23
Reset Fault 2........................................................................................................................... 23
Reset Electrode 2 ................................................................................................................... 24
Tip Dress Acknowledge 2 ....................................................................................................... 24
Retract 2 ................................................................................................................................. 24
Programme Select Inputs ....................................................................................................... 24
Toroid Input............................................................................................................................. 24
Primary CT.............................................................................................................................. 24
Voltage Feedback ................................................................................................................... 24
Synchronisation ...................................................................................................................... 24
24v DC .................................................................................................................................... 25
Proportional Valve .................................................................................................................. 25
Fault Bits (MF) ........................................................................................................................ 25
Body Cycle Log....................................................................................................................... 25
Discrete Inputs ........................................................................................................................ 25
Reserved Inputs...................................................................................................................... 25
TIMER OUTPUTS ........................................................................................................................... 25
Weld Air Valve 1 (WAV).......................................................................................................... 25
High Lift Air Valve 1 (HAV) ..................................................................................................... 25
Intensify (OHMA) .................................................................................................................... 26
Blocking (OHMA) .................................................................................................................... 26
Advance (OHMA).................................................................................................................... 26
End of Sequence Output 1 (EOS) .......................................................................................... 26
Fault Output 1 ......................................................................................................................... 26
Ready 1................................................................................................................................... 26
Tip Dress Request 1 ............................................................................................................... 26
End of Stepper 1 ..................................................................................................................... 26
Prewarn 1................................................................................................................................ 27
Gun 1 ...................................................................................................................................... 27
Weld Air Valve 2 (WAV).......................................................................................................... 27
High Lift Air Valve 2 (HAV) ..................................................................................................... 27
End of Sequence Output 2 (EOS) .......................................................................................... 27
Fault Output 2 ......................................................................................................................... 27
Ready 2................................................................................................................................... 27
Tip Dress Request 2 ............................................................................................................... 27
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WS4000 Manual
Contents
End of Stepper 2 ..................................................................................................................... 28

Prewarn 2................................................................................................................................ 28
Gun 2 ...................................................................................................................................... 28
Shunt Trip ............................................................................................................................... 28
Under Voltage Trip.................................................................................................................. 28
Proportional Valve .................................................................................................................. 28
Contactor ................................................................................................................................ 28
Stop......................................................................................................................................... 28
Reset....................................................................................................................................... 29
Discrete Output ....................................................................................................................... 29
Exhaust Valve ......................................................................................................................... 29
Reserved Output..................................................................................................................... 29
TIMER L.E.D.S ...................................................................................................30

SPECIFICATIONS ..............................................................................................31
INSTALLATION ..................................................................................................32
POWER REQUIREMENTS ................................................................................................................ 32
USING WS40XX WITH PROFIBUS FMS .......................................................................................... 32
USING WS40XX WITH CONTROLNET ............................................................................................. 34
USING WS40XX WITH ETHERNET .................................................................................................. 35
USING WS40XX WITH INTERBUS S ................................................................................................ 36
Interbus S Cable Connections ................................................................................................ 36
USING WS40XX WITH DEVICENET ................................................................................................. 38
FIELDBUS I/O ASSIGNMENT .......................................................................................................... 39
PROPORTIONAL VALVE ................................................................................................................. 40
CONNECTIONS .............................................................................................................................. 42
MECHANICAL INSTALLATION ......................................................................................................... 45
PASSCODE FOR KEYPAD AND PENDANT PROGRAMMING........................46

TIMER PASSCODE SYSTEM ........................................................................................................... 46
To Enter Passcode ................................................................................................................. 46
To Set New Passcode ............................................................................................................ 46
To Clear Passcode ................................................................................................................. 46
CONFIGURATION ..............................................................................................47
CONFIGURING THE TIMER USING A PROGRAMMER ........................................................................... 47
Blocking Conditions ................................................................................................................ 51
CONFIGURING THE TIMER USING A P.C. ......................................................................................... 52
CURRENT CALIBRATION .................................................................................53

PRIMARY MONITORING/REGULATION ............................................................................................. 53
SECONDARY MONITORING/REGULATION ........................................................................................ 54
PROPORTIONAL VALVE CALIBRATION.........................................................55

PROGRAMMING ................................................................................................56
PROGRAMMING A WELD USING A PROGRAMMER ............................................................................. 56
PROGRAMMING THE MONITOR USING A PROGRAMMER .................................................................... 60
VIEWING ELECTRODE PARAMETERS USING A PROGRAMMER............................................................ 62
Viewing curve parameters using a programmer..................................................................... 63
Number of Spots Axis (x axis) .............................................................................................. 64
Heat (current or pressure) Axis (y axis)................................................................................ 65
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WS4000 Manual
Contents
Interpretation of Y(KSR) values .............................................................................................. 66

Where values are shown in WS98-4000 ................................................................................ 68
Interpretation of Y(PHA) values .............................................................................................. 68
Where values are shown in WS98-4000 ................................................................................ 70
TO RESET ELECTRODES ............................................................................................................... 70
In Single Gun Mode ................................................................................................................ 70
In Dual Gun Mode................................................................................................................... 71
PROGRAMMING HAMMER AND TIP DRESS PROGRAMMES ............................................................... 71
KEYPAD FUNCTIONS ..................................................................................................................... 72
FURTHER PROGRAMMER FUNCTIONS..........................................................73

RESET FUNCTIONS ....................................................................................................................... 73
Status...................................................................................................................................... 73
Log .......................................................................................................................................... 73
Timer....................................................................................................................................... 73
Electrodes ............................................................................................................................... 73
Timer Data .............................................................................................................................. 73
STATUS FUNCTIONS ..................................................................................................................... 73
Timer Status............................................................................................................................ 73
Electrode Status ..................................................................................................................... 74
I/O Status ................................................................................................................................ 74
TO CHANGE THE DISPLAY CONTRAST .........................................................75

DIAGNOSTICS ...................................................................................................76
Welding and timer information ................................................................................................ 76
Electrode and Tip Dressing Information ................................................................................. 76
Timer I/O Status...................................................................................................................... 76
ERROR MESSAGES ....................................................................................................................... 77
TIMER MEASUREMENTS ................................................................................................................ 85
NETWORKING WITH ETHERNET.....................................................................86

INTRODUCTION ............................................................................................................................. 86
WS40XX TIMER NETWORK PROPERTIES ....................................................................................... 86
PLANNING THE NETWORK ............................................................................................................. 86
INSTALLING THE NETWORK ADAPTER IN PC WITH WINDOWS 95/98 ................................................ 87
Network Adapter Hardware Installation .................................................................................. 87
Software Driver Installation..................................................................................................... 88
Setting up The card Protocols ................................................................................................ 89
Setting up the IP Address ....................................................................................................... 89
CONNECTING THE NETWORK ......................................................................................................... 91
Basic arrangements................................................................................................................ 91
Network using a switch ........................................................................................................... 94
SYSTEM COMPONENTS ................................................................................................................. 95
Adapter ................................................................................................................................... 95
Hub ......................................................................................................................................... 95
Switch ..................................................................................................................................... 95
ASSIGNING ADDRESSES ............................................................................................................... 95
FAULT FINDING............................................................................................................................. 96
Checking a timer is present on a network .............................................................................. 96
To trace the route data takes from a PC to a specific address .............................................. 98
To monitor data and data flow ................................................................................................ 98
MORE INFORMATION ..................................................................................................................... 98
GLOSSARY OF TERMS.....................................................................................99
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WS4000 Manual
Contents
APPENDIX........................................................................................................103
PROGRAMME SELECT CODES ..................................................................................................... 103
WS4000 Manual
vi
Contents
WS4000 Manual
Introduction
Introduction
The WS4000 series are sophisticated welding controls offering many advanced features. These
are summarised below.
Independent control of one or two welding guns.
Number of welding programmes 1x128 (192 using fieldbus) or 2x64.
Advanced, three interval welding sequence.
Constant current or voltage compensation control modes.
Compatible with British Federal Medium Frequency inverter.
Spot and projection welding.
Local programming via P.C. using WS98 software.
Local programming with optional hand held programmer.
Local programming using front panel programmer. (WS4000, WS4002 and

WS4004 only)
Network programming with WS98 via:
Profibus FMS. (Optional)
ControlNet (Optional)
Ethernet (Optional)
Extensive monitoring and diagnostic capability.
Datalog function records measured and target currents for each programme.
Proportional valve control. (Optional)
Hardwired i/o.
High speed serial control using: -
Devicenet (Optional)
Interbus S (Optional)
Flash memory based for easy upgrade of operating software.
WS4000 Manual
WS400xx Family Members

All members of the WS40xx family have an RS232 port and hardwired inputs and outputs.
Differences between family members lie in the type of network used, provision for a proportional
valve and use of a built-in programmer.
Controls with Front Panel Programmers

WS4000, WS4002 and WS4004 all have built-in programmers and are designed to be mounted
through a rectangular aperture in a panel.
WS4000
Standard Features
Front panel programmer
RS232 port
Hardwired inputs and outputs
Factory fitted options
Proportional valve output
Profibus FMS network programming
Plug in Upgrades
Interbus S control network
ControlNet control network
WS4002
Standard Features
RS232 port
WS4000 Manual

Plug in Upgrades
WS4004
Standard Features
RS232 port
DeviceNet control network
Ethernet programming network
Chassis Mounted Controls

WS4010, WS4012 and WS4014 have no built-in programmer and so can be mounted inside a
cabinet with no user access.
WS4010
Standard Features
RS232 port
Profibus FMS network programming
Plug in Upgrades
WS4000 Manual
WS4012
Standard Features
RS232 port
Plug in Upgrades
WS4014
Standard Features
RS232 port
DeviceNet control network
Ethernet programming network
WS4002
WS4004
WS4010
WS4012
WS4014
! Standard feature
O
Optional (during manufacture)
Plug in option/upgrade
P
!
Ethernet
DeviceNet
ControlNet
Interbus S
WS4000
Profibus FMS
Proportional
valve controller
Hard-wired I/O
RS232 port
Front panel
programmer
Summary of Features
P
!
WS4000 Manual
Timer Functions
Timer Functions
Weld Sequences
The process of closing the electrodes onto the components to be welded, applying weld current
and then opening the electrodes, is referred to as a Weld Sequence. The WS40xx is capable of a
number of different weld sequences as shown below.
Standard Spot
Standard Spot is the basic weld sequence, having a Squeeze time, Weld time and a Hold time.
The Squeeze time is the time allowed for the electrodes to close onto the components and build
up full force with which to weld. Welding current is then applied, which produces a slug of
molten material between the components. This must be contained by the force of the electrodes
on the components until it has solidified. This time is the Hold time. After the Hold time the
sequence is complete. The electrodes open, and an End of Sequence signal is given.
Weld air valve

Weld Current
End of Seq.
Squeeze
Weld 2
Start
Hold
End
Standard Spot
The Weld interval may be applied up to 9 times in succession, separated by Cool 2. This
technique is used to weld thick materials, or multiple thicknesses.
Weld air valve

Weld Current
End of Seq.
Squeez Weld 2 Cool 2 Weld 2 Hold

Start
End
Standard Spot with 2 Pulsations
WS4000 Manual
Timer Functions
Extended Spot
The Extended Spot sequence has more parameters to allow finer control of the weld. These
parameters are given below.
Squeeze The Squeeze time is the time allowed for the electrodes to close onto the
components and build up full force with which to weld.
Weld 1. The first of three weld intervals, sometimes call pre-heat. This can be used to burn
through plating on plated materials or surface contamination.
Cool 1 The time between the end of Weld 1 and the beginning of Weld 2.
Weld 2 The second of three weld intervals. This is the application of current that actually
welds the components. Upslope and downslope can be applied to this weld interval.
Cool 2 If pulsations are used (successive applications of Weld 2) the time between
applications of Weld 2 is Cool 2.
Cool 3 Cool 3 is the time between the end of Weld 2 and the beginning of Weld 3.
Weld 3 Weld 3 is the final application of weld current, sometimes called post-heat. This can
be used to prevent the weld cooling too quickly and leading to metallurgical problems.
Pulsations The number of applications of Weld 2.
Hold The time the for which the electrodes contain the molten slug under pressure whilst it
solidifies. After the Hold time the sequence is complete. The electrodes open, and an End of
Sequence signal is given.
Weld air valve

Weld Current
Start
Extended weld sequence with 3 pulsations
Hold
Weld 3
Cool 3
Weld 2
Cool 2
Weld 2
Cool 2
Weld 2
Weld 1
Cool 1
Squeeze
End of Seq. Signal
End
WS4000 Manual
Timer Functions
Spot Repeat
The Spot Repeat sequence continuously runs spot sequences for as long as the Start signal is
present. Two extra parameters are required.
Presqueeze The time for the electrodes to close onto the components.
Off The time between sequences
Start
Weld air valve
Weld Current
Start
Hold
Weld 2
Off
Squeeze
Hold
Off
Squeeze
Weld 2
Hold
Weld 2
Squeeze
Presqueeze
End of Seq. Signal
End
Standard Spot Repeat
Starting a Weld Sequence
Start Signal
Weld sequences are initiated by a Start signal. If the timer is configured to operate two guns,
there is a Start signal for each gun. On receipt of the Start signal the timer will read the
programme select inputs and begin a weld sequence for the required programme.
Second Stage Start
If Second Stage Start is enabled in the timer configuration, the timer will read the Second Stage
Start input when it reaches the end of the Squeeze time. If the input is active the sequence will
continue. If it is not the sequence will halt until the input becomes active.
If Second Stage Start is not enabled in the timer configuration, the sequence will proceed
regardless of the Second Stage Start input.
WS4000 Manual
Timer Functions
Weld Control
Phase Angle Heat Control

Phase Angle heat control sets the heat of a weld by specifying a fixed conduction angle. The
minimum and maximum conduction angles are termed 0% and 100% Heat, respectively. This
method of control is open loop. ie. There is no feedback process involved to compensate for
changes in the system.
Constant Current Control
If a weld is under Constant Current control, a current demand is read from the weld programme
and a conduction angle is read from memory. The first cycle of weld (after blanking) is carried out
and the current measured. If the measured current is not the same as the demand current an
adjustment is made to the conduction angle ready for the next cycle of weld. The next cycle is
then done and the process repeated. This continues throughout the weld. At the end of the weld,
the conduction angle is stored in memory, to be used the next time the weld programme is run.
This method of control is closed loop and compensates for changes in the system such as
changes in mains voltage, changes in secondary resistance and inductance.
Voltage Compensation
Only Phase Angle controlled welds can be carried out using Voltage Compensation.
Whilst the timer is idle it continually monitors the mains voltage. When it receives a Start signal it
compares the measured mains voltage with the nominal mains voltage, entered into the timer
configuration, then, if necessary, adjusts the conduction angle of the weld it is about to do, to
compensate for high or low voltage. This method of compensation does not work on a cycle for
cycle basis like constant current but does provide some measure of compensation for external
influences. This method can be used for projection welding.
Heat Stepping and Tip Dressing

The WS40xx has facilities for Heat Stepping and Tip Dressing.
Stepping
Heat Stepping is a system that progressively increases the heat, current or electrode force, over
a number of welds to compensate for electrode wear.
Using new electrodes and correctly set weld parameters, good quality welds will be produced.
WS4000 Manual
Timer Functions
As welding continues over many components, the electrodes will begin to degrade, usually by
mushrooming.
New Electrodes
Worn Electrodes
If the control uses constant current control, the welding current will be the same throughout the
period of welding. However, the surface area of the electrode in contact with the work piece will
have increased. Therefore the current density through the weld will have decreased, thus
reducing the weld quality.
To compensate for this Heat Stepping gradually
progresses.
increases the current, or heat, as welding
The current increases in accordance with a stepper curve. The WS4000 has 10 built in templates
from which curves can be made. The end of the curve is the End of Electrode Lifetime. The
horizontal axis represents the number of welds, and the vertical axis the percentage increase in
heat or current.
If welding continues beyond the End of Electrode Life the current is not increased further. The
curve flattens out.
When the End of Electrode Life is reached the End of Electrode Life output switches on. This
remains on until the Electrode is reset.
Electrodes can be reset by selecting the weld programme that uses the electrode, then applying a
signal to the Stepper Reset input for either Gun 1 or Gun 2, as appropriate. Note that if
programme 0 is selected, all electrodes associated with the gun are reset.
Warning is given of the approach of the End of Electrode Life. When a point is reached, x
components before the End of Life, the Prewarn output switches on. x is the number of prewarn
components before the End of Electrode Life. The WS4000 actually counts welds, not
components, and so it needs to know the number of welds on a component to work in terms of
components.
WS4000 Manual
Timer Functions
Stepping can also be applied to electrode pressure, if a proportional valve is in use.

Tip Dressing
The life of the electrodes can be increased, and the spot diameter kept more consistent by using
Tip Dressing.
A Dressing Point is chosen on the curve, when this point is reached a Tip Dress Request output
is given. At this point the electrodes should be dressed. If not convenient to dress the electrodes
immediately the timer allows welding to continue, still progressing along the curve, until a suitable
time. The electrodes can be dressed before the Tip Dress Request signal is given, if necessary.
When the electrodes have been dressed a Tip Dress Acknowledge signal should be sent to the
timer. This will cancel the Tip Dress Request output and reset the stepper curve to the Reset
Point.
The Reset Point is specified in spots. It is the position on the curve specified by the number of
spots in the Reset Point..
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WS4000 Manual
Timer Functions
The stepper is not normally reset to the foot of the curve because, even though the electrode has
been dressed and its original dimensions restored, the nature of the electrode material will have
been changed by welding.
When the electrodes have been dressed and a Tip Dress Acknowledge sent, the timer will again
continue along the stepper curve until the next Dressing Point where the whole procedure will be
repeated.
The maximum number of dressing is programmed into the timer. Once again a Prewarning output
is given. In this instance it is specified in terms of Dressings.
Current Monitoring
The WS40xx current monitoring facility measures the current produced by welds and compares
the value with an upper and a lower tolerance level. Constant Current welds are always
monitored. Phase Angle controlled welds and Medium Frequency welds are only monitored if
Phase Angle Monitoring is selected.
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WS4000 Manual
Timer Functions
High Limit
High Limit sets the upper limit of acceptable current for the weld pulse, as a percentage of the
desired value. If the measured current is greater than this value a fault output is given and an
error code generated.
Pre Limit
If the currents of a number of consecutive welds lie in the area between the Pre Limit and the
Lower Limit an error code is generated. The number of consecutive welds required to do this is
set by the value entered for Conditional Fails.
High Limit
Required
current
Pre-Limit
Low Limit
Low Limit
Low Limit is the lower tolerance level for the current, as a percentage of the desired value. If the
current is less than this value a fault output is given and an error code generated.
Conditional Fails
The maximum number of consecutive welds permitted, having current in the area between the
Pre-Limit and the Low Limit. The conditional fails counter is only cleared by a weld whose current
is above the Pre-Limit/Low Limit region.
Automatic Retry
By selecting Automatic Retry the weld current will be re-applied if the measured weld current was
below the Low Limit of the monitor.
A counter counts the number of consecutive spots requiring a Retry. If this counter reaches the
value entered for Maximum Retries in the timer configuration, an error message is generated.
The counter is cleared by a weld not requiring a retry.
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WS4000 Manual
Timer Functions
Heat Limit
The timer limits the heat used on welds to the value set for Heat Limit.
Heat Pre-Limit
The timer generates a status message if the heat used in a weld exceeds the value entered for
Heat Pre-Limit.
Pressure Control
WS40xx can control the force the electrodes exert on the components by controlling the air
pressure with a proportional valve. The timer controls the proportional valve by means of a
voltage output (0 to 10 volts DC). In the case of a WS4014 there is the choice of a voltage
controlled valve and a current controlled valve (4 to 20mA). Selection is made by jumper links on
the timer printed circuit board.
There is a calibration procedure for electrode force. When this has been carried out, the required
electrode force can be entered with the other welding parameters.
Stepping and monitoring can be applied to electrode force.
For proportional valves that give a 24v output when the pressure is correct, there is facility in the
timer configuration, to make the weld sequence wait, at the end of the squeeze time, for the
pressure ok signal.
For proportional valves with an analogue monitor output, the timer can be configured to monitor
pressure in the same way that it monitors current.
End of Sequence Signal

When a weld sequence has been completed the timer issues an End of Sequence signal to
inform other equipment that the welding process is complete. The End of Sequence output
switches on, nominally, at the end of the Hold time.
End of Sequence Trigger
In the timer configuration is a setting for End of Sequence Trigger. If set to 0, the End of
Sequence output will switch on at the end of the Hold time. If set to a +ve value the End of
Sequence output will switch on after the end of Hold time, by the programmed number of cycles.
If set to a ve value the output will switch on before the end of the Hold time, by the programmed
number of cycles.
13
WS4000 Manual
Timer Functions
End of Sequence Signal Operation

In Single Spot operation, at the end of the weld sequence the End of Sequence output switches
on. If the Start signal is still present, the End of Sequence signal remains on until the Start signal
is removed.
Start Signal
Weld Sequence
End of Seq. Signal
In Single Spot operation, at the end of the weld sequence the End of Sequence output switches
on. If the Start signal is absent, the End of Sequence signal switches on for a time programmed
as EOS Duration in the timer configuration.
Start Signal
Weld Sequence
End of Seq. Signal
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WS4000 Manual
Timer Functions
In Repeat Spot operation the End of Sequence output switches on for the Off time between
sequences, and for the time entered in the timer configuration as EOS Duration, after the final
sequence.
Start Signal
Weld Sequence
End of Seq. Signal
Retract Modes
Retract is the facility to open the electrodes in two stages. These are a fully open position to
move the electrodes into the work piece and a middle position from which the electrodes can
close onto the work in order to weld.
The WS4000 has four modes of retract operation as outlined below:
Standard
When the Retract Input is switched off the High Lift Air Valve switches off, and the electrodes
close to the mid position. Welding can proceed in this case.
When the Retract Input is switched on, the High Lift Air Valve switches on and the electrodes
open fully. Welding will not proceed in this case.
Hi-lift +
A pulse on the Retract Input causes the High Lift Air Valve to switch on and close the electrodes
to the mid position. Welding can proceed in this case.
Whilst the High Lift Air Valve is on, a pulse on the Retract Input causes the valve to switch off,
and the electrodes go to the fully open position. Welding will not proceed in this case.
Hi-lift
A pulse on the Retract Input causes the High Lift Air Valve to switch off and close the electrodes
to the mid position. Welding can proceed in this case.
Whilst the High Lift Air Valve is off, a pulse on the Retract Input causes the valve to switch on,
and the electrodes go to the fully open position. Welding will not proceed in this case.
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WS4000 Manual
Timer Functions
Robot
When the Retract Input is switched On, the High Lift Air Valve switches on, and the electrodes
close to the mid position. Welding can proceed in this case.
When the Retract Input is switched Off, the High Lift Air Valve switches off and the electrodes
open fully. Welding will not proceed in this case.
STANDARD
H.A.V. O/P
RETRACT I/P
SEQUENCE
Hi LIFT +
H.A.V. O/P
RETRACT I/P
SEQUENCE
Hi LIFT -
H.A.V. O/P
RETRACT I/P
SEQUENCE
H.A.V. O/P
ROBOT
RETRACT I/P
SEQUENCE
OHMA
The OHMA system uses three air valves to control the electrodes. Using this system the actual
mid-position of the electrodes can be controlled by manipulating the timing of the signals
controlling the three air valves. Refer to section on OHMA operation on page 17.
GERBI
The GERBI gun uses an air cylinder and a mechanical latch to achieve three position working.
From the fully open position the gun closes onto the workpiece using the Presqueeze and
Squeeze times. When the weld sequence has finished the gun opens but is restricted by a latch,
so cannot open fully. The all subsequent weld sequences use only the Squeeze time to close the
gun.
When a Retract input is given to the timer, the HAV output switches on to withdrawn the latch,
allowing the gun to open fully. The next weld sequence will use the Presqueeze and Squeeze
times to close the gun.
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WS4000 Manual
Timer Functions
Latch
Presqueeze
Squeeze
Squeeze
Fully open
Closed onto workpiece
Mid position
Headset Mode
Headset mode causes the weld air valve to switch on and close the electrodes for as long as the
Start signal is present, to allow mechanical adjustments to the machine head to be made. No
weld current is given, sequence timings are not used.
The control is put into Headset mode by activating the Headset input. The weld air valve output
then follows the Start input.
A Headset Mode status message is given whilst in this mode.
OHMA System
The OHMA system uses three air valves to control the opening and closing of the electrodes. If
Retract is used, the timing of the valve operations is used to control the gap between the
electrodes in their mid-position.
Weld Stroke
When a Start input is given to the weld control the Blocking valve is switched off and the Advance
valve is switched on. This closes the electrodes onto the workpiece. At the end of the Presqueeze
time the Intensify valve switches on to provide the electrode force required for welding.
The weld sequence proceeds in the usual way until the end of the Hold time when the Advance
and Intensify valves switch off. The electrodes then start to open until the Blocking valve switches
on and prevents further opening. The timing of the Blocking valve turning on (the Gun Open
Time) sets the position to which the electrodes open. The End of Sequence output operates when
the Blocking Valve switches on.
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WS4000 Manual
Timer Functions
START Input
EOS Output
AdvanceOutput
Intensify Output
Blocking Output
Weld Current
Gun close
time
(Presqueeze)
Gun closing
18
Squeeze
time
Hold time
gun open
time
Gun opening
WS4000 Manual
Timer Functions
Retract Stroke
With the electrodes in the fully open position the control will not begin a weld sequence. A Retract
input is required to move the electrodes to their mid-position.
When a Retract input is given (a minimum duration of 300 mS is required) the Blocking valve is
switched off and the Advance valve is switched on. This starts the electrodes moving towards
their mid-position. After the Retract Close time the Advance valve is switched off. The Retract
Close Delay time then begins and when complete, the Blocking valve is switched on, halting the
movement of the electrodes. Hence, these times control the mid position of the electrodes. In this
condition the timer is ready to weld.
When in this ready condition, if a Retract input is detected, the Blocking valve is switched off for
the duration of the Retract Open time. This allows the electrodes to move to the full open position.
300ms
minimum
Retract Input
AdvanceOutput
Intensify Output
Blocking Output
Retract close time
Retract
close
delay
Gun closing to
mid-position
Retract open time
Gun fully
opening from
mid-position
Medium Frequency Welding

WS40xx can be used to drive an inverter for medium frequency welding. The pulse drive,
otherwise used to trigger thyristors, is used to control the inverter.
MF must be selected in the timer configuration.
All welds will be constant current. This is a function of the inverter, not the WS40xx. Current is
controlled by the phase angle heat setting. If the timer is calibrated to the particular inverter and
transformer in use, the timer can be set to constant current. (See section on configuration). In this
mode a demand current is set rather than a demand % heat.
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WS4000 Manual
Timer Functions
Programme Log
A log is kept of the last target current and measured current of each weld programme. This is
most easily accessed via WS98-4000. If this is not available a programmer can be used as
follows.
Press
Select the gun and programme in the usual way.
Values are given as in table below. These are the values for the last weld and are read-only.
Use the
and
Parameter
Notes
Target 1
Current 1
Target 2
Current 2
Target 3
Current 3
Current required for Weld 1

Current measured from Weld 1
keys to move forwards and backwards through the table.
Half Cycle Log

The Half Cycle Log is a record of the values of current measured for each half cycle of current
during the last weld. This is most easily accessed via WS98-4000. If this is not available a
programmer can be used as follows.
MORE
EVENT
Press
Select the gun in the usual way.
The values given are those measured for each half cycle of weld for the last weld, and are readonly.
Use the
and
keys to move forwards and backwards through the results.
Primary Currents Log

A log is kept of the primary currents for the last weld of each gun. This is most easily accessed
via WS98-4000. If this is not available a programmer can be used as follows.
MORE
COUNT
7
Press
Select the gun in the usual way.
The values given are the primary currents measured for Weld 1, Weld 2 and Weld 3, for the last
weld, and are read-only.
9
Use the
and
keys to move forwards and backwards through the readings.
Body Cycle Log

This function is for use only with fieldbus control of the timer.
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WS4000 Manual
Timer Functions
The Body Cycle Log is a log of data on each spot weld done since the last time the Start Body
Cycle Log input was active.
The Body Cycle Log is accessed through WS98-4000, and has two parts. A Live part and a
Buffered part. Initially a momentary input is applied to the Start Body Cycle Log input. Then
each weld performed is given a number and its data recorded in the Live part of the log. Each
time a weld is done it is added to the Live log. When another Start Body Cycle Log input is
given, the data is transferred from the Live to the Buffered part of the log. The Live part then
continues to build up again as welding proceeds.
The Live part of the Body Cycle Log can be accessed with a programmer.
MORE
Press
Use the
9
or
then use the
keys to select the weld required

and
keys to move through the data of the weld.
The data given are:-
Parameter
Notes
Spot
Programme
Gun
Target 1
Current 1
Target 2
Current 2
Target 3
Current 3
Heat 1
Heat 2
Heat 3
Number given to spot weld

Weld programme used
Gun used
Heat used in Weld 1
Heat used in Weld 2
Heat used in Weld 3
21
WS4000 Manual
Timer Inputs and Outputs

Timer Inputs
Start 1
This input starts a weld for gun 1. When this input is switched on, gun 1 weld air valve output
switches on and the sequence begins. If the input is removed during the presqueeze or squeeze
time, the weld air valve switches off, and the sequence aborted. If the input is maintained through
the presqueeze and squeeze times, but switched off subsequently, the sequence continues.
Weld on 1
This input enables the weld output for gun 1. A sequence is run without this input, performs
normally, but without producing any current. A status message is given, warning that weld 1 is not
switched on, but no other status messages are produced concerning lack of weld current.
The input needs to be present for the duration of the weld pulses.
Reset Fault 1
This resets the Fault output for gun 1 and clears the status messages. Only momentary
application is required. (Minimum time 40mS.)
Reset Electrode 1
Resets electrodes concerned with gun 1. Select a weld programme that uses the electrode to be
reset, then apply Electrode Reset. Note that selecting programme 0 will cause all electrodes on
Gun 1 to be reset.
Normally used after electrodes have been replaced. Only momentary application is required.
(Minimum time 40mS.)
Tip Dress Acknowledge 1
Signal required after tip dressing on gun 1 to indicate the process is complete and to move to the
Reset point on the stepper curve. Only momentary application is required. (Minimum time
40mS.)
2nd Stage Start
This input is only used if 2nd Stage Start is selected in the timer configuration.
This input is used by both gun 1 and gun 2.
The timer checks that the 2nd Stage Start signal is present when the end of squeeze time is
reached. If the signal is not present the timer waits for the signal before it proceeds. If the Start
signal is removed, the sequence is aborted.
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WS4000 Manual
Retract 1
This input is only used if one of the Retract options is selected in timer configuration.
The input controls the High Lift air valve on gun 1. See Retract Modes in section on Timer
Functions.
Head Set
Whilst this input is maintained in the ON state, the timer is put into Head Set mode. When a Start
signal is given the weld air valve switches on and remains on until the Start signal is removed.
There is no weld current. (See section on Timer Functions.)
Thyristor Temperature
This input is usually connected to a normally closed thermostat attached to the thyristors.
If no input signal is present, an error message is given and the Ready output switched off. The
timer will not respond to a Start.
Transformer Temperature
This input is usually connected to a normally closed thermostat attached to the weld transformer.
Process Stop
Start 2
This input starts a weld for gun 2. When this input is switched on, gun 2 weld air valve output
switches on and the sequence begins. If the input is removed during the presqueeze or squeeze
time, the weld air valve switches off, and the sequence aborted. If the input is maintained through
the presqueeze and squeeze times, but switched off subsequently, the sequence continues.
Weld on 2
This input enables the weld output for gun 2. A sequence is run without this input, performs
normally, but without producing any current. A status message is given, warning that weld 2 is not
switched on, but no other status messages are produced concerning lack of weld current.
The input needs to be present for the duration of the weld pulses.
Reset Fault 2
This resets the Fault output for gun 2 and clears the status messages. Only momentary
application is required. (Minimum time 40mS.)
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WS4000 Manual
Reset Electrode 2
Resets electrodes concerned with gun 2. Select a weld programme that uses the electrode to be
reset, then apply Electrode Reset. Note that selecting programme 0 will cause all electrodes on
Gun 2 to be reset.
Normally used after electrodes have been replaced. Only momentary application is required.
(Minimum time 40mS.)
Tip Dress Acknowledge 2

Signal required after tip dressing on gun 2 to indicate the process is complete and to move to the
Reset point on the stepper curve. Only momentary application is required. (Minimum time
40mS.)
Retract 2
This input is only used if one of the Retract options is selected in timer configuration.
The input controls the High Lift air valve on gun 2. See Retract Modes in section on Timer
Functions.
Programme Select Inputs
Programme selection is made by applying the binary code for the required programme to the
programme select inputs for the appropriate gun. If the timer is configured for 2 guns each gun
can use programmes 0 to 63. If the timer is configured for one gun, programmes 0 to 127 can be
used.
See appendix for list of binary codes.
Toroid Input
The toroid should be positioned on the secondary circuit of the welding transformer. The input
provides secondary current readings for use in constant current control and monitoring. The
toroid should have a sensitivity of 150mV/kA.
Primary CT
This input should be connected to a current transformer on the primary circuit of the welding
transformer. It provides primary current measurements for monitoring purposes.
Voltage Feedback
This input monitors the mains voltage and should be connected, via the correct British Federal
transformer, across the phases of the mains being used by the welding transformer.
Synchronisation
This input requires 27v AC, derived from the same phase that supplies the welding transformer.
The signal is used to synchronise the weld control functions of the timer to the mains.
24
WS4000 Manual
24v DC
This is the power supply for the timer. From this, all the necessary internal supplies are derived.
Proportional Valve
This input accepts an analogue feedback signal from a proportional valve. Used for pressure
control monitoring. Sensitivity 0 to 10v DC, or 4 20 mA on WS4014.
Fault Bits (MF)
For Medium Frequency welding only.
The Fault Bit inputs read the fault codes from the Medium Frequency inverter.
With Fieldbus i/o and Medium Frequency working these inputs are used for medium frequency
fault codes, not as Discrete i/o.
Body Cycle Log
For fieldbus mode only.
When this input is made, data from the Live body Cycle Log is transferred to the Buffered Body
Cycle Log.
Discrete Inputs
Fieldbus mode only.
Inputs that take discrete data and place it on the Fieldbus. These inputs are not used by the
timer, the timer merely act as a discrete/fieldbus converter.
Reserved Inputs
Not presently used.
Timer Outputs
Weld Air Valve 1 (WAV)

Output switches on to close gun 1 electrodes onto the components to be welded.
High Lift Air Valve 1 (HAV)
Used only if timer is configured to use a Retract mode.
This output operates a second air valve on gun 1, controlling whether the gun is fully open and
partly open. It is operated in accordance with the particular made of retract for which the timer is
configured. (See section on Timer Functions.)
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WS4000 Manual
Using Fieldbus i/o there is HAV 1 open and HAV 1 closed. This is for use with a two way valve.
HAV 1 open is the inverse of HAV 1 closed.
Intensify (OHMA)
Used only if timer is configured for OHMA operation.
This output is one of the three required to operate the valves for OHMA operation. See page 17.
Blocking (OHMA)
Advance (OHMA)
End of Sequence Output 1 (EOS)
Output switches on when gun 1 has completed a weld sequence. (See section on Timer
Functions.)
Fault Output 1
Certain types of status message generate a Fault output, for full details see section on
Diagnostics. A Fault output relating to gun 1 causes this output to switch on. The output can be
cleared using the Fault Reset for gun 1, a programmer or by WS98-4000.
Ready 1
This output is active if the timer is ready to weld with gun 1. The output switches off under fault
conditions. See section on Diagnostics for full details.
Tip Dress Request 1
Only used for Tip Dressing.
Output switches on when gun 1 electrode requires dressing, according to the Electrode
Programme. See Heat Stepping and Tip Dressing in section on Timer Functions.
End of Stepper 1
Used for Stepping and Tip Dressing.
Output switches on when gun 1 electrode has reached the end of the electrode curve and
requires changing according to the electrode programme. See Heat Stepping and Tip Dressing
in section on Timer Functions.
26
WS4000 Manual
Prewarn 1
Output switches on when gun 1 electrode is approaching the end of the electrode curve and will
require changing. See Heat Stepping and Tip Dressing in section on Timer Functions.
Gun 1
Switches on when gun 1 is given a Start signal, and remains on until gun 2 is given a Start signal.
Weld Air Valve 2 (WAV)
Output switches on to close gun 2 electrodes onto the components to be welded.
High Lift Air Valve 2 (HAV)
Used only if timer is configured to use a Retract mode.
This output operates a second air valve on gun 2, controlling whether the gun is fully open and
partly open. It is operated in accordance with the particular made of retract for which the timer is
configured. (See section on Timer Functions.)
Using Fieldbus i/o there is HAV 2 open and HAV 2 closed. This is for use with a two way valve.
HAV 2 open is the inverse of HAV 2 closed.
End of Sequence Output 2 (EOS)
Output switches on when gun 2 has completed a weld sequence. (See section on Timer
Functions.)
Fault Output 2
Certain types of status message generate a Fault output, for full details see section on
Diagnostics. A Fault output relating to gun 1 causes this output to switch on. The output can be
cleared using the Fault Reset for gun 2, a programmer or by WS98-4000.
Ready 2
This output is active if the timer is ready to weld with gun 2. The output switches off under fault
conditions. See section on Diagnostics for full details.
Tip Dress Request 2
Only used for Tip Dressing.
Output switches on when gun 2 electrode requires dressing, according to the Electrode
Programme. See Heat Stepping and Tip Dressing in section on Timer Functions.
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WS4000 Manual
End of Stepper 2
Output switches on when gun 2 electrode has reached the end of the electrode curve and
requires changing according to the electrode programme. See Heat Stepping and Tip Dressing
in section on Timer Functions.
Prewarn 2
Output switches on when gun 2 electrode is approaching the end of the electrode curve and will
require changing. See Heat Stepping and Tip Dressing in section on Timer Functions.
Gun 2
Switches on when gun 2 is given a Start signal, and remains on until gun 1 is given a Start signal.
Shunt Trip
This is a voltage free contact acting between P6.03 and P6.04. which closes if the timer detects
current flow through the thyristors at a time when there should be non.
Under Voltage Trip
This is a voltage free contact acting between P6.05 and P6.04. which opens if the timer detects
current flow through the thyristors at a time when there should be non.
Proportional Valve
Analogue output to drive a proportional valve for controlling electrode force. Output range 0 to
10v DC.
Contactor
Single gun use only.
Output to drive coil of contactor connecting weld transformer to thyristors. This switches on at the
same time as the weld air valve and switches off x seconds after the weld air valve switches off. x
is the value programmed as Contactor delay in timer configuration.
If using Fieldbus i/o the Contactor output can be converted to another Discrete output by setting
Contactor = 0 in timer configuration.
Stop
Medium frequency use only.
Output switches on when timer is in Process Stop. Signal is used to disable the medium
frequency inverter.
28
WS4000 Manual
Reset
Medium frequency use only.
Output switches on when a Fault Reset is presented to the timer, either via an input or via
software, that requires it to reset a fault output on the medium frequency inverter.
Discrete Output
Fieldbus mode only.
An outputs that is switched on or off by the Fieldbus. These outputs are not controlled by the
timer, the timer merely act as a fieldbus/discrete converter.
Exhaust Valve
Single gun modes only.
Controls timing of exhaust valve for robot retract mode.
If using Fieldbus i/o the Exhaust output can be converted to another Discrete output by setting
Exhaust = 0 in timer configuration.
Weld air valve
High lift air valve
Exhaust valve
Exhaust time
Reserved Output
Output presently not used.
29
WS4000 Manual
Timer L.E.D.s
Timer L.E.D.s
Weld LED. Illuminates whilst thyristor pulse drive is active.
Weld sequence Active LED. Switches on at the start of a weld

sequence and remains on until the sequence is complete (including
waiting for the End of Sequence signal to terminate.
Timer OK to weld. Same as READY output. LED is on if the Thyristor

and Transformer Thermostat inputs, Process Stop and
Synchronisation inputs are satisfied.
Power LED indicates 24v supply to timer is present.

READY LED. Same as READY output. LED is on if the Thyristor and
Transformer Thermostat inputs, Process Stop and Synchronisation
inputs are satisfied.
ACTIVE LED. Weld sequence Active LED. Switches on at the start of
a weld sequence and remains on until the sequence is complete
(including waiting for the End of Sequence signal to terminate.
WELD LED. Illuminates whilst thyristor pulse drive is active.
30
WS4000 Manual
Specifications
Specifications
Storage temperature
-25 to 70 Celsius
Operating temperature
0 to 60 Celsius
Humidity
Class F to DIN 40040, condensation not permitted
Operating voltage
Nominal 24 V DC to DIN 19240

Maximum 30 V (instantaneous value)
Minimum 19.2 V (instantaneous value)
Synchronisation
Single phase 27 V AC 25%

Frequency 50 Hz 1.0 Hz (60 Hz optional)
Serial communications
RS 232 port for P.C. connection

Profibus FMS (optional)
ControlNet (optional)
Ethernet (optional)
Serial i/o (Fieldbus)
Interbus S (optional)
Devicenet (optional)
Discrete i/o
24 inputs, 16 outputs.
Inputs 24 V DC, 10mA.
Outputs 24 V DC, 500mA.
Signal definition
Input on: +24 V DC 15%

Input off: -1 V DC to +2 V DC, or open circuit.
Proportional valve control
Programmable analogue output 0 - 10 V DC.(optional)
Connections
All i/o connections made with two part plug in terminal blocks.
Dimensions
Basic unit:
39 x 250 x 330mm
Expanded unit: 56 x 250 x 330mm
Weight
Basic unit:
Expanded unit:
3.0 Kg
3.28 Kg
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WS4000 Manual
Installation
Installation
Power requirements
24 Volts +15% 20%
Current consumption is approximately 200mA plus the current required by any load connected to
the input/output connectors
Using WS40xx with Profibus FMS

Profibus FMS can be used to programme WS40xxs. The master computer requires a Profibus
interface card. The master computer must be address 1. Timers must all have different addresses
(entered in the timer configuration). A communication cable from the master computer is daisy
chained to the timers, as shown below.
Master
Computer
WS40xx
WS40xx
WS40xx
1. Strip the cable ends as shown in Figs. I and II.

2. Open the housing of the bus connector by slackening the housing screw and raising the
hinged cover.
3. Release the cover of the latching element.
4. The bus connector is supplied with the latching element set to the 30 offset position.
If you want a right-angle cable output:
slacken the screw in the latching element (Figs. III , IV , " ).
raise the latching element slightly and
push the latching element inward.
Re-secure the latching element by refitting the left screw.
5. Connect the green and red cable conductors to the screw terminal block (Fig. V, 1).
Tip: Assembly is easier if you angle the stripped ends of the conductors.
Make sure that the same conductor is always connected to the same terminal
(e.g. green conductor always connected to terminal A , red conductor always
connected to terminal B).
6. Insert the bus cable in the latching element (Fig. V, 2).
32
WS4000 Manual
Installation
7. Tighten the terminal screws to secure the green and red conductors (cable shield must make
metal to metal contact with guide).
8. Close the cover of the latching element and retighten the securing screw.
9. Close the cover of the bus connector housing.
10. Retighten the housing securing screw.
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WS4000 Manual
Installation
Using WS40xx with ControlNet

ControlNet can be used to programme WS40xxs. The master computer requires a ControlNet
interface card. The computer and timers are connected to the network by drop cables. Drop
cables are attached using network taps which contain circuitary to minimise transmission line
reflections. The network cable is 75 co-axial cable, and each end must be terminated with a
resistor.
= Tap
= Termination
Computer
Timer
Timer
Timer
Timer
Drop cables
Timer
Timer
Timer
Timer
Repeater
Segment
Segment
A drop cable must be 1 metre long for correct matching.
segment length (m )
Up to 48 nodes can be connected to a segment length of up to 1kM. There is a trade off between
the number of nodes and segment length, this is shown below.
1000
Max. segment length = 1000m 16.3m (no. of taps 2)
750
500
250
2
16
32
48
number of taps
If more nodes or greater length are required a repeater must be used to create a new segment.
34
WS4000 Manual
Installation
Using WS40xx with Ethernet

Ethernet can be used to programme WS40xxs. The master computer requires an Ethernet
interface card and the system requires a hub or hubs.
Computer
Hub
Timer
Hub
Timer
Timer
Timer
Timer
Timer
Timer
Timer
Example layout
The cable used to connect timers to the hub is known as 'thin ethernet' using an RJ45 connector
at both ends. This cable is suitable for runs up to 100m using star tapology.
With 'thick ethernet' cable runs up to 500m can be implemented, but can only be used between
hubs since it uses a coax type connector. Timers cannot use this type of cable.
Each timer needs to have its own unique IP address.
The design and realisation of an Ethernet network is a highly involved project and should be
undertaken by the system administrator. The example shown above is for illustration only and
should not be taken as a complete design.
35
WS4000 Manual
Installation
Using WS40xx with Interbus S

An Interbus S network can be used to control the inputs and outputs of many timers. The full i/o
capacity of the transmitted data is not used by the timers, this surplus capacity is made available
as discrete i/o for use by other equipment. (See section on inputs and outputs.)
Interbus OUT
Timer
Interbus IN
Timer
Interbus OUT
Interbus OUT
Interbus IN
Timer
Interbus IN
Computer
Interbus S Cable Connections

DO
DO
DI
DI
COM
6
1
7
2
3
5
9
STRAIN
RELIEF
Male 9 Pin
D Connector
Green
Yellow
Pink
Grey
Brown
6
DO
1
DO
7
DI
2
DI
3
COM
STRAIN
RELIEF
Female 9 Pin
D Connector
The link between pins 5 and 9 indicates to the outgoing remote bus, that a cable is connected.
36
WS4000 Manual
Installation
Interbus S Connector Assembly
37
WS4000 Manual
Installation
Using WS40xx with DeviceNet
Computer
Timer
Timer
Timer
vCAN_L
Drain
CAN_H
v+
vCAN_L
Drain
CAN_H
v+
vCAN_L
Drain
CAN_H
v+
0v
+ 24v
Network
power
supply
vCAN_L
Drain
CAN_H
v+
A DeviceNet network can be used to control the inputs and outputs of many timers. The full i/o
capacity of the transmitted data is not used by the timers, this surplus capacity is made available
as discrete i/o for use by other equipment. (See section on inputs and outputs.)
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
Note 121 termination resistor at each end of the line.

The above diagram is a symbolic representation of the interconnection principle involved. For the
actual DeviceNet specifications and standards, refer to the DeviceNet Specifications publication
38
WS4000 Manual
Installation
Fieldbus I/O Assignment

The following table shows Inputs from the fieldbus to the timer
Bit
0
1
2
3
4
5
6
7
Function
Start1
Weld on 1
Reset fault 1
Reset electrode1
Tip dress acknowledge 1
nd
2 Stage
Retract 1
Head set
Bit
24
25
26
27
28
29
30
31
Function
Process stop
Start of body cycle
Reserved for future use
8
9
10
11
12
13
14
15
Start 2
Weld on 2
Reset fault 2
Reset Electrode 2
Tip dress acknowledge 2
Retract 2
Reserved
32
33
34
35
36
37
38
39
Discrete output 1
Discrete output 2
Discrete output 3
Discrete output 4
Discrete output 5
Discrete output 6
Discrete output 7
Discrete output 8
16
17
18
19
20
21
22
23
Programme bit 1
Programme bit 2
Programme bit 4
Programme bit 8
Programme bit 16
Programme bit 32
Programme bit 64
Programme bit 128
40
41
42
43
44
45
46
47

Shaded area only available if 48 bit mode is set in timer configuration
The discrete outputs are outputs on the timer that are under control of the fieldbus. These outputs
are switched by the fieldbus, not the timer. The timer is behaving as an interface for fieldbus to
discrete output.
39
WS4000 Manual
Installation
The following table shows outputs from the timer to the fieldbus.
Bit
0
Function
End of sequence
Bit
24
Weld on 1
25
Weld on 2
26
3
4
5
6
7
Monitor Off Alarm

Exhaust valve on
Transformer thermostat
Thyristor thermostat
Process stop
27
28
29
30
31
Function
Weld air valve 2 /OHMA Intensify 2
High lift air valve 2 open / OHMA
blocking 2
High lift air valve 2 close/ OHMA
advance 2
End of electrode 2
Tip dress request 2
Prewarning 2
Fault 2
Ready 2
32
Discrete input 1
33
Discrete input 2
34
Discrete input 3
35
36
37
38
39
Discrete input 4
Discrete input 5
Discrete input 6
Discrete input 7
Discrete input 8
40
41
42
43
44
45
46
47
Discrete input 9
Discrete input 10
Discrete input 11
Discrete input 12
Discrete input 13
Discrete input 14
Discrete input 15
Discrete input 16
11
12
13
14
15
Weld air valve 1/OHMA

Intensify 1
High lift air valve 1 open/
OHMA Blocking 2
High lift air valve 1 close/
OHMA Advance 2
End of electrode 1
Tip dress request 1
Prewarning 1
Fault 1
Ready 1
16
17
18
19
20
21
22
23
Error code bit 1

Error code bit 2
Error code bit 4
Error code bit 8
Error code bit 16
Error code bit 32
Error code bit 64
Error code bit 128
8
9
10
Shaded area only available if 48 bit mode is set in timer configuration

The discrete inputs are inputs transferred to the fieldbus. These inputs are read by the fieldbus,
not the timer. The timer is behaving as an interface for discrete input to fieldbus.
Proportional Valve
Timer types WS4004 and WS4014
These timers have a built-in proportional valve controller. The input and output can either be 010v DC or 4-20 mA output, depending which links are fitted on the board. The links are located
near connector P6 and are accessed by removing the cover from the timer.
For 0-10v output, fit link J10
For 4-20mA output (current source), fit link J9
For 0-10v input, fit link J8
For 4-20mA input (current sink), fit link J7
It is possible to use a mixture of voltage and current control.
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WS4000 Manual
Installation
Timer types WS4000, WS4010, WS4002, WS4012

These timers require a small additional board (part number 293109 -factory fitted option). This
provides a 0-10v output, and a 0-10v input.
Connect the proportional valve as shown in the following drawings. When installed, the system
will require calibrating to ensure that the programmed electrode force is correctly produced at the
electrodes.
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WS4000 Manual
Installation
Connections
Refer to the following diagram for discrete I/O connections. For connections when using fieldbus,
see over page.
42
WS4000 Manual
Installation
43
WS4000 Manual
44
Installation
WS4000 Manual
Installation
Mechanical Installation
The required aperture and fixing centres for the WS4000 and WS4002 are given below.
Top
Scaled reproduction of fixing details.
45
WS4000 Manual
Passcode for Keypad and Pendant Programming
Passcode for Keypad and Pendant Programming

Timer Passcode System
Unless a passcode has been entered into the timer, all values and options via the keypad or pendant
will be read only, ie. can be viewed, but not changed. If a passcode is entered, values and options
can be changed. The timer will automatically revert to read only" after two minutes if no key has been
pressed. (Each key press re-starts the two minute timeout.)
This passcode operation does not effect use of the timer with WS98-4000. The timer can be
programmed and monitored in the usual way using WS98 without the use of the passcode.
To Enter Passcode
1.
Press
2.
Enter passcode.
3.
Press
To Set New Passcode

A new passcode is set up with a computer connected to the timer via its RS232 port. The British
Federal utility programme passcode.exe is then used to teach the timer a new passcode.
To Clear Passcode
The passcode can be cleared and replaced with the default code of 455400 by using the Clear All
Data function.
MORE
To replace passcode with 455400 press
Important
Changing the passcode in this way also removes all data from the timer.
46
WS4000 Manual
Configuration
Configuration
Configuring the timer using a programmer
1.
Either use the front panel programmer or connect a hand held programmer to the
RS232 connector. Switch on the power.
2.
Check that the front panel display, and, if applicable, the programmer display is
back lit and displaying either:
Ready
or a fault message.
3.
Enter passcode by pressing

press
4.
, followed by the passcode. Then
Enter the Configuration file by pressing keys:
The display will read:

Config
4.
Press:
This will take you to the first function in the System Configuration Table. The
display will read:
Discrete 1 of 128
You can change the display between the options given in the table by pressing
either:
or
5.
Make your selection then press:

or
to scroll to the next parameter. Continue in this
way for the remaining parameters in the table. All your entries are stored when
you scroll to the next function. You may scroll backwards through the file by
pressing:
47
WS4000 Manual
6.
Configuration
Pressing
serves two functions, as follows:

To cancel the last entry made before you press ENTER
At any other time you may use it to go to the end of the Configuration
file
7.
Numeric values can be entered either by pressing:

to increase the displayed value,
to decrease it
or by entering the value from the keypad. If you do this, you must press:
to store the number. (The scroll keys are inactive until ENTER is pressed).
8.
These are the parameters:
Parameter
Possible Values
Notes
I/O
Discrete 1 x 128
Discrete 2 x 64
Fieldbus 1 x 192
Fieldbus 2 x 64
Mode
Normal AC
Hardwired I/O for single gun with 128 progs.

Hardwired I/O for two guns each with 64 progs.
Fieldbus control for single gun with 192 progs.
Fieldbus control for two guns each with 64
progs.
50 or 60 Hz welding using phase angle
(uncompensated open loop)control or
constant current control.
50 or 60 Hz welding using phase angle control
which is adjusted by the control, at the
beginning of the weld period, to compensate
for mains variations. This adjustment is a
single adjustment used for the entire weld
period. It is not dynamic.
Constant current DC welding using a medium
frequency inverter.
Length of fieldbus message.
If ON, enables analogue pressure monitor.
If ON, sequence waits at end of Squeeze time
for correct pressure.
If ON, sequence waits for this signal at end of
Squeeze time.
Sets address for Fieldbus/Network
Sets the switch on point for the End of
Sequence output 1, relative to the end of Hold
time. ie. +10 will cause the End of Sequence
output to switch on10 cycles after the end of
the Hold time.
Duration of the End of Sequence 1 output, in
the absence of the Start signal.
Sets the switch on point for the End of
V. Comp AC
MF DC
I/O
Press. mon.
Press. wait
32/48 bit
on/off
on/off
2nd stage
on/off
LAN address
G1 EOS trig
2 127
-50 to +50
G1 EOS time
0 50
G2 EOS trig
-50 to +50
48
WS4000 Manual
Configuration
G2 EOS time
0 50
Cons. retry
09
Max weld time
10 99
G1 comp.
G2 comp.
MF cal min
-5 to +15
-5 to +15
0 - 99998
MF cal max
0 - 99998
Nom. volts
200 500
Max load
0 2000
G1 Enable
G1 Monitor
G1 Tor. test
on/off
on/off
on/off
G2 Enable
G2 Monitor
G2 Tor. test
on/off
on/off
on/off
Frequency
MF Blanking
50/60 Hz
on/off
Retract
Off
Standard
High Lift +
High Lift -
Sequence output 2, relative to the end of Hold

time. ie. +10 will cause the End of Sequence
output to switch on10 cycles after the end of
the Hold time.
Duration of the End of Sequence 2 output, in
the absence of the Start signal.
The number of consecutive welds, requiring a
Retry, permitted before an error is registered.
Upper limit on the total number of weld cycles
in a weld sequence.
Adjustment made to all welds for gun 1.
Adjustment made to all welds for gun 2.
The welding current produced by the medium
frequency inverter with a heat setting of 0%.
The welding current produced by the medium
frequency inverter with a heat setting of 100%.
Value used by Voltage Compensation mode
for nominal mains voltage
Maximum allowed value of primary current. If a
current in excess of this value is measured a
fault is registered.
Selects operation of gun 1.
Enable monitoring for gun 1.
Tests gun 1 toroid when Start signal is given.
Failure causes a fault output to be given.
Selects operation of gun 2.
Enable monitoring for gun 2.
Tests gun 2 toroid when Start signal is given.
Failure causes a fault output to be given.
Set mains frequency.
If ON causes first two cycles of weld to be
excluded from calculation of RMS current
value of weld. (Applies to Medium Frequency
working only)
Retract not used.
When the Retract Input is switched off the High
Lift Air Valve switches off, and the electrodes
close to the mid position. Welding can proceed
in this case.
When the Retract Input is switched on, the
High Lift Air Valve switches on and the
electrodes open fully. Welding will not proceed
in this case.
A pulse on the Retract Input causes the High
Lift Air Valve to switch on and close the
electrodes to the mid position. Welding can
proceed in this case.
Whilst the High Lift Air Valve is on, a pulse on
the Retract Input causes the valve to switch
off, and the electrodes go to the fully open
position. Welding will not proceed in this case.
A pulse on the Retract Input causes the High
Lift Air Valve to switch off and close the
49
WS4000 Manual
Configuration
electrodes to the mid position. Welding can

proceed in this case.
Robot
OHMA +Retract
OHMA -Retract
GERBI
Contactor
0 240 seconds
(0 = off)
IP address (4)
IP address (3)
IP address (2)
IP address (1)
Subnet mask (4)
Subnet mask (3)
Subnet mask (2)
Subnet mask (1)
Default Gateway(4)
Default Gateway(3)
Default Gateway(2)
Default Gateway(1)
Exhaust
Language
0 250 cycles
English
Deutsch
Francaise
Espanol
Nederlands
Whilst the High Lift Air Valve is off, a pulse on

the Retract Input causes the valve to switch
on, and the electrodes go to the fully open
position. Welding will not proceed in this case.
When the Retract Input is switched On, the
High Lift Air Valve switches on, and the
electrodes close to the mid position. Welding
can proceed in this case.
When the Retract Input is switched Off, the
High Lift Air Valve switches off and the
electrodes open fully. Welding will not proceed
in this case.
Selects OHMA system with Retract. See page
17
Selects OHMA system without Retract. See
page 17
Selects valve operating sequence required by
GERBI gun. See page 16
Enables output for controlling weld transformer
contactor.
First section of Ethernet IP address
Second section of Ethernet IP address
Third section of Ethernet IP address
Fourth section of Ethernet IP address
First section of Subnet mask
Second section of Subnet mask
Third section of Subnet mask
Fourth section of Subnet mask
Not presently used
Not presently used
Not presently used
Not presently used
Controls timing of exhaust valve for robot
retract mode. Single gun only.
Selects English messages.
Selects German messages.
Selects French messages.
Selects Spanish messages.
Selects Dutch messages.
When you reach the end of the Configuration file, the display reads:
Config
9.
50
To exit the Configuration file, press:
WS4000 Manual
Configuration
The display reads:

Ready
or a fault message.
Important Note
When the welding mode has been changed from AC to Medium

Frequency, or vice versa, the timer should be briefly powered down and then powered up
again to make it assume the new mode.
Blocking Conditions
When an error is generated the timer can be prevented from welding until the Fault output is
reset. An error that does this arises from a Blocking Condition. ie. If a fault is designated as a
Blocking Condition, when that fault occurs the timer will do no further welding until the Fault
output is reset.
Blocking Conditions are set as part of the timer configuration.
.
To set the Blocking Conditions press

The display will read
Blocking conditions
Press:
This will take you to the first function in the System Configuration Table. The display will read:
End of stepper :N
You can change the display between the options given in the table by pressing either:
or
or
way for the remaining parameters in the table. All your entries are
stored when you scroll to the next function. You may scroll
backwards through the file by pressing:
Pressing
At any other time you may use it to go to the end of the Configuration file
51
WS4000 Manual
Configuration
The Blocking Conditions are:

End of stepper
WELD OFF
OVERRANGE
TOROID O/C
TOROID S/C
CT OVERRANGE
NO PRI. AMPS
LOW CURRENT 1
LOW CURRENT 2
LOW CURRENT 3
HI CURRENT 1
HI CURRENT 2
HI CURRENT 3
RETRY FAILED
CONSEC. RETRY
NO CURRENT 1
NO CURRENT 2
NO CURRENT 3
PRELIMIT 1
PRELIMIT 2
PRELIMIT 3
PRESS. ERROR
MIN. HEAT 1
MIN. HEAT 2
MIN. HEAT 3
HEAT LIMIT 1
HEAT LIMIT 2
HEAT LIMIT 3
Configuring the timer using a P.C.

The timer can be configured either locally or remotely using a computer. In both cases the British
Federal programme WS98-4000 must be used.
To configure and programme locally connect the timer to the computer via its RS232 port. Using
this method one computer programmes one timer.
To configure and programme remotely, connect the timer to a network. (Profibus FMS,
ControlNet or Ethernet, as appropriate.) A computer running WS98-4000 must also be connected
to the network, via a suitable interface. Using this method one computer can programme many
timers.
See separate manual for using WS98-4000.
52
WS4000 Manual
Current Calibration
Current Calibration
The timer uses measurement of the weld current for monitoring and control purposes. The current
is measured by a toroid which can be used on, either a primary or secondary cable of the weld
transformer.
Each electrode in the system requires its toroid arrangement calibrating. In the Electrode
Programme select the electrode when setting up as below.
Primary Monitoring/Regulation
1. Set up a single pulse, phase angle controlled weld, using 10% heat.
eg:
Mode
Single
Squeeze 10
Weld 2
5
Cool 2
0
Hold
10
Heat 2
10%
Ensure primary current (as checked in Primary Log) does not exceed 500 amps.
2. In the Electrode programme, select electrode and set F/B to primary. (see page 63)
3. Do a short circuit weld and use a weld current meter to measure the weld current. Make
a note of this current, together with the current in the timer weld log.
4. Increase the heat of the weld to as high a value as possible without exceeding 500
amps primary current, or damaging the electrodes, then repeat step 3.
5. Enter the value for S/P ratio. The value required for S/P ratio in timer configuration is
calculated by dividing the difference in weld current readings by the difference in the
timer log readings and multiplying by 100.
S/P ratio = Difference in weld current readings x 100
Difference in timer log readings
Calculate this to 5 figures.
eg.
Current produced Current produced by
by low heat
high heat
Difference in readings
Weld current meter

reading
13.2
17.9
17.9 13.2 = 4.7
WS1000 log
44.8
59.8
59.8 44.8 = 15
S/P ratio =
4.7
Difference in weld current readings
x 100 =
x 100 = 31.333
Difference in timer log readings
15
53
WS4000 Manual
Current Calibration
6. Enter the value for S/P o/s. The value required for S/P o/s in timer configuration is
calculated as below.
S/P o/s = Weld current meter reading - S/P ratio x corresponding timer log current
100
eg.
17.9 - 31.333 x 59.8 = - 0.837

100
7. In Configuration set F/B to primary.
NB. If the transformer tapping is changed, the above procedure must

be carried out for the new tapping.
Secondary Monitoring/Regulation
1. Set up a single pulse, phase angle controlled weld, using 40% heat.
eg:
Mode
Single
Squeeze 10
Weld 2
5
Cool 2
0
Hold
10
Heat 2
10%
2. In the Electrode Programme, select the electrode and set F/B to secondary. (see page
63)
3. Set Toroid Sensitivity to 150mV/kA.
4. Do a short circuit weld and use a weld current meter to measure the weld current. Make
a note of this current, together with the current in the timer weld log.
5. Calculate the required value for Toroid Sensitivity:
Toroid Sensitivity = 150 x
. Current log reading

. mV
Weld current meter reading
6. Set Toroid Sensitivity to calculated value. (Must be between 100 and 200mV/kA)
eg.
Current log reading
Toroid sensitivity = 150 x

= 131
54
4.9 kA
5.6 kA
. Current log reading

.
mV/kA
= 150
4.9
5.6
WS4000 Manual
Proportional Valve Calibration
Proportional Valve Calibration

The proportional valve and timer require calibrating so that the programmed electrode force is
actually produced at the electrodes
A calibration procedure must be carried out for each electrode programme in use.
Calibration is most easily carried out using WS98-4000. If this is not available, calibration can be
done as follows using the keypad programmer or a pendant.
1. Enter the passcode by pressing
, followed by the passcode, then press
.
ELECTRODE
8 .
2. Enter the Electrode programme by pressing
3. Select the gun and electrode programme required for calibration.
until the display reads
4. Press
PV cal
5. Enter a value of 1.00 then press

6. The display will read PV o/s.
7. Enter a value of 0.0 and press
8. Leave the Electrode programme and programme a simple weld sequence to use the
electrode whose proportional valve you are calibrating. Programme a low electrode force
(PV).
eg. Mode
Single
Squeeze 10
Weld 2
5
Cool 2
0
Hold
10
Heat 2
10%
PV
1.0 volts
9. Switch off the weld, position an electrode force meter between the electrodes and run the
weld programme. Note the reading on the electrode force meter.
10. Re-programme the weld sequence to use a higher electrode force (PV). It is desirable to
have as high a force as the machine will tolerate without damage.
11. Repeat step 9.
12. Calculate Scale Factor
Scale Factor =
High meter reading (kN) Low meter reading (kN)

High value prog. for PV Low value prog. for PV
13. Calculate Offset
Offset = Low meter reading (Scale Factor x Low value prog. for PV) x 10
14. Return to Electrode programme and enter values for Scale Factor and Offset.
55
WS4000 Manual
Programming
Programming
The WS4000 and WS4002 have built in front panel programmers, additionally a hand held
programmer can be used. The WS4010 and WS4012 have no built in programmers, but can be
programmed locally using a hand held programmer. All controls can also be programmed locally
using the RS232 port and a P.C. For this, the British Federal programming software WS98-4000
is required.
WS98 may also be used to programme a number of controls on a network. This requires each
control to be fitted with a network port suitable for the network being used (Profibus FMS,
ControlNet or Ethernet) this must be specified at the time of ordering, the network ports are not
an add-on options. Using this method all the controls may be programmed from a central
computer fitted with a network interface.
Programming a weld using a programmer

1.
2.
Ready
or a fault message.
3.

press
4.
Enter the Programme file by pressing keys:

PROGRAM
4
If the timer has been configured for single gun use, the display will read:
G1
Requiring the programme to be selected. If the timer has been configured for dual
gun use, the display will read:
G1
Requiring first the gun to be selected, and then the programme.
5.
Change the display between the options given in the table by pressing either:
or
56
WS4000 Manual
6.
Programming

or
you move to the next function. You may move backwards through the file by
pressing:
7.
Pressing

At any other time you may use it to go to the end of the file
8.

to decrease it
9.
Parameter
Possible values
Notes
G1 P 0
1 or 2
G1 P 0
0 191 in 1 Gun Fieldbus mode

0 128 in 1 Gun discrete mode
0 63 in either 2 Gun modes.
Standard Spot
Select programmes for Gun 1 or Gun

2.
Select programme to be edited
Welding mode
Repeat Spot
Extended Spot
Extended Repeat
W1
Phase Angle or Con. Current
Weld sequence with no pre-heat or

post-heat.
Standard
spot
sequences
run
continuously, separated by an Off
time, for as long as the Start signal
is maintained.
Weld sequence including pre-heat
and post-heat.
Extended
spot
sequences
run
continuously, separated by an Off
time, for as long as the Start signal
is maintained.
Select Phase Angle (open loop) or
Constant Current (closed loop)
control of Weld 1 interval (pre-heat).
(Only available in Extended modes.)
57
WS4000 Manual
Programming
W2
Slope
Enabled or Disabled
W3
Inhibit
Inhibited or Not Inhibited
Electrode
Gun close
0 to 23 in 1 Gun mode
0 to 7 in 2 Gun mode
0 to 99 cycles
Presqueeze
0 to 99 cycles
Squeeze
1 to 99 cycles
Weld#1
Cool#1
0 to 99 cycles
0 to 99 cycles
Upslope
0 to 99 cycles
Weld#2
0 to 99 cycles
Cool#2
0 to 99 cycles
Downslope
0 to 99 cycles
Cool#3
0 to 99 cycles
Weld#3
0 to 99 cycles
Pulsations
Hold
1 to 9 pulses
1 to 99 cycles
Off
0 to 99 cycles
Gun open
0 to 99 cycles
58

control of Weld 2 interval.
If enabled, allows for programming of
Upslope and Downslope.
control of Weld 3 interval (post-heat).
(Only available in Extended modes.)
If a programme is inhibited it will not
run. Can be used to prevent
programmes being run erroneously.
Selects electrode programme to be
used.
The time required for the electrodes
to close onto the workpiece from their
Ready position. After this time has
elapsed the full force required for
welding is applied. (Only available if
OHMA operation is configured in
Retract options. See page 50.)
Time for electrodes to reach work
piece.
Time for electrodes to reach full force
on work piece.
Duration of first weld pulse (pre-heat).
Time between end of Weld 1 pulse
and the beginning of Weld 2 pulse.
Time for Weld 2 current or heat to
reach programmed value.
Duration of main weld interval,
including upslope and down slope
times.
Time
between
successive
applications of Weld 2, during
Pulsations.
Time for Weld 2 heat or current to
ramp down to minimum.
Time between end of Weld 2 pulse
and the beginning of Weld 3 pulse.
Duration of final weld pulse (postheat).
The number of applications of Weld 2.
Time for which electrodes remain
clamped onto work piece when
welding current has ceased.
Time for which weld air valve
switches off between sequences in
Repeat modes.
to open to the Ready position. (Only
available if OHMA operation is
configured in Retract options. See
page 50.)
WS4000 Manual
Programming
Retract close
0 to 99 cycles
Retract delay
0 to 99 cycles
Retract open
0 to 99 cycles
1st delay
40 to 99 degrees
Next delay
40 to 99 degrees
PHA o/s
-20% to +20%
CCR o/s
-10 to +10kA
Force o/s
-1.00 to +1.00 volts
PV
0 to 9.99 kN (0 to 9.99 volts)
Heat#1
0 to 99.9%
Current#1
0 to 99999 amps
Heat#2
0 to 99.9%
Current#2
0 to 99999 amps
Heat#3
0 to 99.9%
Current#3
0 to 99999 amps
Start Heat
0 to 99.9%
St. Current
0 to 99999 amps
(Only applicable if OHMA +retract is

selected in timer configuration).
to move from fully open to the Ready
position.
The mechanical settling time required
by the valve.
to move from the closed position to
the Ready position.
Conduction angle of initial half cycle
of weld on first weld pulse.
Conduction angle of initial half cycle
of weld on subsequent weld pulses.
Phase Angle Offset increases, or
decreases all heats on the Phase
Angle stepper curve.
Current
Offset
increases,
or
decreases, all the currents on the
Current stepper curve.
Force Offset increases, or decreases,
all the settings on the Force stepper
curve.
Force exerted by electrodes. (The
voltage is the signal to the
proportional valve which is related to
the force by a scale factor, set by the
Force Calibration process.)
Percentage heat for Phase Angle
Control of Weld 1.
If in Constant Current mode this is the
current demand for Weld 1. If in
Phase Angle mode this is the desired
current, as used by the monitor.
Control of Weld 2.
Control of Weld 3.
If in Phase Angle mode this is the
start heat for Weld 2, when using
Upslope.
start current for Weld 2, when using
59
WS4000 Manual
Programming
End Heat
0 to 99.9%
EndCurrent
0 to 99999 amps
Upslope.
If in Phase Angle mode this is the end
heat for Weld 2, when using
Downslope.
end current for Weld 2, when using
Downslope.
Programming the monitor using a programmer

1.
2.
Ready
or a fault message.
3.

press
4.
Enter the Monitor file by pressing keys:

MONITOR
5
G1
Requiring the programme to be selected. If the timer has been configured for dual
gun use, the display will read:
G1
Requiring first the gun to be selected, and then the programme.
5.
Change the display between the options given in the table by pressing either:
or
6.

or
you move to the next function. You may move backwards through the file by
pressing:
60
WS4000 Manual
7.
Programming
Pressing

At any other time you may use it to go to the end of the file
8.

to decrease it
9.
Parameter
Possible Values
Notes
Monitor
On or Off
Enables or disables monitor.
Retry
On or Off
If On the timer re-applies weld current in the

event of a low-current weld.
Low limit1
0 to 100%
Low limit of tolerance for weld 1, as a

percentage of the value entered for
Current#1 in the weld programme.
Hi limit1
0 to 100%
Upper limit of tolerance for weld 1, as a

Pre limit1
0 to 100%
A value between the required current for

Weld 1, and Low Limit1. If the measured
current lies between Pre limit1 and Low
limit1 for a number of consecutive welds, a
Low limit2
0 to 100%

Hi limit2
0 to 100%

Pre limit2
0 to 100%

61
WS4000 Manual
Programming
Low limit3
0 to 100%

Hi limit3
0 to 100%

Pre limit3
0 to 100%

Fail count
0 to 9
The number of consecutive welds with

currents in the Pre limit to Low limit area,
allowed without registering a fault.
Force lim
0 to 100%
If Force Monitoring is in use (must be

selected in Configuration) this is the
tolerance allowed on the programmed force.
Heat limit
0 to 99.9%
The highest permitted value of heat.
Heat warn
0 to 99.9%
A value of heat, which, if exceeded,

registers a fault.
Viewing electrode parameters using a programmer

Electrode and Electrode Curve data should be entered using WS98-4000. The following section
shows how the timer data can be viewed.
1.
Enter the Electrode file by pressing keys:

ELECTRODE
8
G1
Requiring the programme to be selected (as shown by underlining the electrode

programme number). If the timer has been configured for dual gun use, the
display will read:
G1
Requiring first the gun to be selected (as shown by underlining the gun number),
and then the programme.
62
WS4000 Manual
2.
Programming
Move from parameter to parameter using the

or
3.
keys
You can exit this file at any time by pressing:
After selecting the Gun and Electrode Programme, as above, the parameters shown below will be
displayed.
Parameter
Possible Values
Notes
Stepper
On or Off
Counter
Pressure
F/B
On or Off
On or Off
Primary or Secondary
S/P ratio
10:1 to 200:1
S/P o/s
+9.99 to 9.99 kA
Toroid
PV cal
PV o/s cal
100 to 200mV
0 to 99.99kN/V
0 to 9999N
Dressings
Dress at
0 to 9999 dressings
0 to 99999 spots
Reset to
0 to 9999 spots
Dress done
Lifetime
Read only
0 to 99999 spots
Prewarn
0 to 99999 components
Stepper
0 to 99999 dressings tip
dressing
Spots/comp.
Total
Curve pnt.
0 to 9999 spots
Read only
Read only
Enables or disables heat, current or pressure

stepping.
Enables or disables tip dressing.
Enables or disables pressure stepping.
Tells timer if primary or secondary transformer cable
through toroid. (For set up procedure see page 53)
(Only used with primary feedback) Sets turns ratio of
weld transformer. (For set up procedure see page 53)
(Only used with primary feedback) Sets offset value in
relationship between primary and secondary current
values. (For set up procedure see page 53)
Toroid sensitivity (British Federal standard is 150mV).
Scale factor for proportional valve output.
Proportional valve offset. This relates to proportional
valve calibration see page 55.
Number of tip dressings allowed.
The point on the curve (in spots) at which tip dressing
should take place.
The point on the electrode curve (in spots) to which
the stepper returns after a tip dress.
Number of tip dresses already done.
The number of spot welds that a new set of
electrodes can do, without tip dressing.
If stepper only is in use, the Prewarn output switches
on, this number of components before the end of
electrode life.
If tip dressing is in use, the prewarn output switches
on this number of dressings before the end of
electrode life.
The number of stop welds on a component.
Total number of spots done since Electrode reset.
Present position on the electrode curve.
Viewing curve parameters using a programmer

The horizontal axis (X axis) for the Electrode Curve shows the number of spot welds done. The
vertical axis (Y axis) is either the heat, current or pressure axis. The curve is defined by 11
points on the spots axis and their corresponding current, heat or pressure values. The points on
the spots axis are 0, End of Electrode Life and 9 intermediate points labelled X1 to X9. The
corresponding values on the vertical (heat, current or pressure) axis are, initial value (entered in
Weld Parameters), End Heat (or current or pressure) and 9 intermediate points labelled Y1 to Y9.
63
WS4000 Manual
Programming
End Heat
Y9
X9,Y9
Y8
X8,Y8
Y - axi
Y7
X7,Y7
Y6
X6,Y6
Y5
X5,Y5
Y4
X4,Y4
Y3
X3,Y3
Y2
X2,Y2
Y1
X1,Y1
X1
X2
X3
X4
X5
X6
X -axis
X7
X8
X9
End of
Electrode Life
Prog. Heat
Number of Spots Axis (x axis)

1.
Enter the Curve file by pressing keys:

COUNT
7
G1

display will read:
G1
2.

or
64
keys
WS4000 Manual
3.
Programming
A table of values is then presented, line by line, for the number of spots represented by points X1,
X2, X3 etc. up to X9. The values shown are actual number of spot welds.
Heat (current or pressure) Axis (y axis)

1.
Enter the Curve file by pressing keys:

MORE
PROGRAM
G1

display will read:
G1
2.

or
3.
keys
After selecting the Gun and Electrode Programme, as above, the parameters shown below will be
displayed.
Parameter
Possible Values
Notes
End force
End I1
0 to 9.99 kN
0 to 40000 amps
End I2
0 to 40000 amps
End I3
0 to 40000amps
Electrode force at end of electrode curve.

Current for Weld 1 at the end of electrode
curve.
curve.
65
WS4000 Manual
Programming
End heat 1
0 to 100%
End heat 2
0 to 100%
End heat 3
0 to 100%
Y1 (KSR)
0 to 100%
to
Y9 (KSR)
Y1 (PHA)
0 to 100%
to
Y9 (PHA)
curve.
Heat for Weld 1 at the end of electrode
curve.
curve.
curve.
Percentage
of
current
increase
corresponding to X1, X2 etc. on spots axis.
See following notes.
NB. In the case of a phase angle controlled
weld, these current values are used by the
current monitor.
Percentage of heat increase corresponding
to X1, X2 etc. on spots axis.
See following notes.
NB. In the case of a constant current
controlled weld, these values are not used.
Interpretation of Y(KSR) values

The Y(KSR) values show:
Demand current for constant current controlled welds
Monitor current for phase angle controlled welds.
Start of curve
X value = 0 spots
Y value = 0% - representing the current value entered for weld 1, weld 2 or weld 3 (depending on
curve being programmed) entered in the Weld programme.
End of curve
X value = Lifetime (entered in Electrode programme)
Y value = 100% - representing End I1, End I2 or End I3 depending on curve being programmed.
Intermediate points
The intermediate values of Y are shown as a percentage of the difference between the current at
the start of the curve and the current at the end of the curve. These values of Y correspond to the
values for X1, X2 and X3 etc.
66
WS4000 Manual
Programming
7000
6900
6800
Y - axis
6700
6600
6500
6400
6300
6200
6100
6000
% Change
Amps
Example
An electrode has a lifetime of 500 welds. The current increases from 6000 amps to 7000 amps
over this lifetime, according to the curve below.
Electrode Curve
100
90
80
70
60
50
40
30
20
10
0
X9,Y9
X8,Y8
X7,Y7
X6,Y6
X5,Y5
X4,Y4
X3,Y3
X2,Y2
X1,Y1
50
100
150
200
250
300
350
400
450
500
Spots
X - axis
WS98 shows
actual currents
Programmer
shows % change
Point X1,Y1
Values shown by programmer X1 = 50 spots
Y1 = 10% increase
Actual values (as shown in WS98-4000)
X1 = 50 spots
10
(7000 6000 ) = 6100amps
100
Y1 = 6000 +
Point X2,Y2
Y2 = 20% increase
X2 = 100 spots
20
(7000 6000 ) = 6200amps
100
Y2 = 6000 +
The values shown by WS98-4000 are the actual currents used, not the percentage increase.
67
WS4000 Manual
Programming
Where values are shown in WS98-4000

Start current
Which curve
Type of curve
X values
Y values
End Current
Lifetime
Interpretation of Y(PHA) values

Start of curve
X value = 0 spots
Y value = 0% - representing the Heat value entered for weld 1, weld 2 or weld 3 (depending on
curve being programmed) entered in the Weld programme.
End of curve
X value = Lifetime (entered in Electrode programme)
Y value = 100% - representing End heat1, End heat2 or End heat3 depending on curve being
programmed.
Intermediate points
The intermediate values of Y are shown as a percentage of the difference between the heat at
the start of the curve and the heat at the end of the curve. These values of Y correspond to the
values for X1, X2 and X3 etc.
68
WS4000 Manual
Programming
80
75
70
Y - axis
65
60
55
50
45
40
35
30
% Change
Heat
Example
An electrode has a lifetime of 500 welds. The heat increases from 40% to 80% over this lifetime,
according to the curve below.
Electrode Curve
100
90
80
70
60
50
40
30
20
10
0
X9,Y9
X8,Y8
X7,Y7
X6,Y6
X5,Y5
X4,Y4
X3,Y3
X2,Y2
X1,Y1
50
100
150
200
250
300
350
400
450
500
Spots
X - axis
WS98 shows
actual Heats
Programmer
shows % change
Point X1,Y1
Y1 = 10% increase
X1 = 50 spots
Point X2,Y2
Y2 = 20% increase
10
(80 30 ) = 35%heat
100
Y1 = 30 +
X2 = 100 spots
20
(80 30 ) = 40%heat
100
Y2 = 30 +
The values shown by WS98-4000 are the heats used, not the percentage increase.
69
WS4000 Manual
Programming
Where values are shown in WS98-4000

Start heat
Which curve
Type of curve
X values
Y values
End heat
Lifetime
To Reset Electrodes
In Single Gun Mode

To reset a specific electrode select a weld programme that uses the electrode to be reset, then
apply a Stepper Reset signal. (Connector P2, pin 3 if using discrete I/O, see page 42. Input bit 3 if
using Fieldbus, see page 39 ).
To reset all electrodes, select weld programme 0 and apply a Stepper Reset signal.
Electrodes can also be reset using WS98, see WS98-4000 Manual, or by using the Pendant, see
page 73.
70
WS4000 Manual
Programming
In Dual Gun Mode

To reset a specific electrode, select a weld programme that uses the electrode to be reset. Apply
a Stepper Reset signal for the gun using the electrode. (In discrete mode, Gun 1 Stepper Reset is
connector P3 pin 3 and Gun 2 Stepper Reset is P4 pin 3, see page 43. In Fieldbus mode Gun 1
Stepper Reset is input bit 3 and Gun 2 Stepper Reset is input bit 11, see page 39.)
eg. To reset Electrode 3, Gun 2. Select a weld programme on gun 2 that uses Electrode 3, then
apply Stepper Reset Gun 2.
To reset all electrodes on a gun, select weld programme 0 on the gun, then apply a Stepper
Reset for that gun.
Electrodes can also be reset using WS98, see WS98-4000 Manual, or by using the Pendant, see
page 73.
Programming Hammer and Tip Dress Programmes

Press
Use
or
MORE
ELECTRODE
8
to select either:- Hammer 1 (prog 192)
Tipdress 1 (prog 193)
Hammer 2 (prog 194)
Hammer 3 (prog 196)
Hammer 4 (prog 198)
The parameters associated with the Hammer and Tip Dress programmes are given below.
Parameter
Possible Values
Notes
PV
0 to 9.99 v (0 to 9.99 kN)
Time
Electrode
0 to 9.9 seconds
0 to 23
Force to hammer in electrode, or force

exerted on tip dresser
Duration of tip closure.
Electrode being hammered or dressed.
71
WS4000 Manual
Programming
Keypad Functions
F 0 (configure)
1 (status)
2 (log)
3 (reset)
4 (program)
5 (monitor)
6 (event)
7 (count)
8 (electrode)
9 (more)
Configuration parameters
Status
Log (program)
Reset
Program parameters
Monitor parameters
Bus I/O status
Curve X (spots)
Electrode parameters
More
st
1 key
nd
key
rd
3 key
(when reqd)
72
eg. F 3 2 = Clear Logs
1 (status)
2 (log)
3 (reset)
8 (electrode)
0 (configure)
1 (status)
2 (log)
3 (reset)
4 (program)
5 (monitor)
6 (event)
7 (count)
8 (electrode)
9 (more)
Y (load)
Reset status
Clear logs
Reboot Timer
Reset electrode
Inhibit flags
Electrode status
Log (body cycle)
Clear all data
Curve Y (currents)
Measurements
1/2 cycle log
Log (primary currents)
Tip dress programmes
Debug (for service use)
Download request
CT input
PV feedback
Toroid Resistance
Voltage
Last program used
WS4000 Manual
Further Programmer Functions

Reset Functions
Note that the passcode must be entered before these functions can be accessed.
Status
To reset Status messages press

Log
To clear the Data Log press

Timer
To reboot the timer press
Electrodes
To reset the electrodes

Timer Data
MORE
To clear all user entered data, eg. weld parameters, press
Status Functions
Timer Status
STATUS
1
Press
The timer, or programmer display will show all the timer status messages in succession,
excluding electrode status messages. The meanings and possible causes of these messages can
be found in the Diagnostics section.
73
WS4000 Manual
Electrode Status
MORE
STATUS
1
Press
The timer, or programmer display will show all electrode status messages in succession. The
meanings and possible causes of these messages can be found in the Diagnostics section.
I/O Status
EVENT
Press
The display will read Bus I/O Status. Use the

and
keys to move forwards and
backwards through the readings. Each reading is an 8 bit binary word, either input or output,
showing the state of each bit.
eg. a display of In 2 00000000, means that all the bits in input word 2 are zero.
The i/o bit allocations are given in the section on Timer Inputs and Outputs.
74
WS4000 Manual
To Change the Display Contrast
To Change the Display Contrast

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Switch off supply to cabinet.

Unplug the green connectors P1, P2, P3, P4, P5 and P6
Remove timer back cover.
Plug in connector P6.
Switch on timer.
Adjust multiturn trimmer VR1 on timer printed circuit board to achieve required display
contrast.
Switch off cabinet.
Remove connector P6.
Replace timer back cover.
Replace all connectors.
VR1
Adjust trimmer VR1
75
WS4000 Manual
Diagnostics
Diagnostics
Welding and timer information
When a timer or welding fault occurs, an error message will appear on the display of the timer or
programming pendant. If there are several faults they will be displayed sequentially. If the display
is showing other information, the faults can be reached by accessing Timer Status.
Electrode and Tip Dressing Information
Information on electrodes is provided by Electrode Status (see previous section). Information is
given on: Expired electrodes
Electrode prewarning
Tip dress requests
Timer I/O Status

The states of all inputs and outputs of the timer are given by I/O Status (see previous section).
The I/O shown is regardless of whether the I/O is hardwired or fieldbus.
Some additional hardwired I/O is also used. If this does not satisfy the timer requirements, error
messages are given in Timer Status, and the timer will not weld.
For the WS40xx to weld the following conditions are necessary.
Stop i/p
Transformer i/p
Thyristor i/p
Sync. I/p
PV #1 i/p
Trip o/p
76
!
!
!
!
(If selected)
WS4000 Manual
Diagnostics
Error Messages
1
2
3
0
0
0
Blocking file error
Process stop
No i/o card
5
6
0
0
No synchronisation
Max. mains load exceeded
Head set mode

Max. weld time exceeded
Gun 1
11
12
1
0
0
1
0
0
Max. weld time exceeded

Gun 2
13
Fieldbus inactive
Fieldbus RAM error
14
15
1
0
0
0
0
1
Program inhibit Gun 1
16
Program inhibit Gun 2
17
Invalid data Gun 1

Invalid data Gun 2
Waiting for pressure
19
20
24
0
0
1
1
0
0
Blocking condition Gun 1
25
Blocking condition Gun 2
26
DS processor ram error
28
DS processor error
29
Network processor ram

error
Network processor error
30
31
EOS
Transformer temperature
Thyristor temperature
Config file error
Fault
Ready
Possible Cause
Code
Error
Transformer thermostat open circuit too hot

Thyristor thermostat open circuit too hot
Data corruption in timer configuration file. Reenter data.
Data corruption in blocking file. Re-enter
data.
Process Stop switch open circuit
A card required by the timer for its present
configuration is missing. Fit card.
24 V AC missing from P6.11 and P6.12
Check mains supply. Check circuit breaker.
Current drawn from mains exceeded
Maximum Primary Load value in timer
configuration.
Number of weld cycles for Gun 1 exceeded
value programmed for Max. weld time in
timer configuration.
Number of weld cycles for Gun 2 exceeded
value programmed for Max. weld time in
timer configuration.
Fieldbus is disconnected or not running.
Internal timer fault. If persists return to British
Federal.
Attempted to run inhibited programme on
Gun 1.
Attempted to run inhibited programme on
Gun 2.
Corrupt data for Gun 1.
Corrupt data for Gun 2.
Timer waiting for pressure correct signal
from proportional valve. (If this is not required
deselect Wait for pressure in timer
configuration.)
Error for Gun 1 is programmed as a blocking
condition in Timer Configuration.
Error for Gun 2 is programmed as a blocking
condition in Timer Configuration.
Federal.
Federal.
Federal.
Federal.
77
WS4000 Manual
Diagnostics
Ready
Fault
EOS
Possible Cause
Code
Error
Gun 1 disabled in
Configuration
Weld off Gun 1
Over range Gun 1
32
33
34
1
1
0
0
1
1
Toroid open circuit Gun 1
35
Toroid short circuit Gun 1
36
Error in curve Gun 1
37
Ct over range Gun 1

No pri current Gun 1
38
39
1
1
0
0
1
0
Low current weld 1 Gun 1
40
41
42
High current weld 1 Gun 1
43
44
45
Retry failed Gun 1
46
Too many consecutive

retries Gun 1
47
No current weld 1 Gun 1
48
49
78
Start signal given for Gun 1, but Gun 1 not

enabled in Timer Configuration.
Gun 1 weld switched off.
Gun 1 weld current exceeds maximum
capability of WS4000. Check toroid
sensitivity is correct.
Gun 1 toroid open circuit. Check toroid
wiring. Check for damage to toroid.
Gun 1 toroid short circuit. Check toroid
Invalid parameter(s) programmed for Gun 1
stepper curve.
Primary current too large for WS4000.
No primary current measured for Gun 1
during weld interval. Electrodes missing or
not closed onto component, possible cable or
connection problems.
Gun 1, weld 1 current below lower limit of
monitor. Poor component fit, leads wearing,
surface contamination, current demand not
realisable, tolerance too tight.
Gun 1, weld 1 current above upper limit of
monitor. Component missing, current
demand not realisable, tolerance too tight.
Gun 1 weld current was too low and the weld
was retried. The retried weld also failed.
The number of consecutive welds requiring a
retry exceeded the number programmed for
Max retries in timer configuration.
No weld current measured for Gun 1 weld 1.
Electrodes missing or not closed onto
component, possible cable or connection
problems.
Electrodes missing or not closed onto component,
possible cable or connection problems.
WS4000 Manual
Diagnostics
Ready
Fault
EOS
Possible Cause
Code
Error
50
Current pre limit weld 1

Gun 1
51

Gun 1
52

Gun 1
53
Proportional valve error

Gun 1
Retract not ready Gun 1
54
55
Min heat weld 1 Gun 1
56
57
58
Heat prelimit weld 1 Gun 1
59
60
61
Max heat Gun1
62
No second stage Gun 1
63

problems.
Current measured for Gun 1 weld 1, fell in
the band between the monitors low limit and
pre limit for a number of successive welds in
excess of the value programmed for Fail
Count (termed Conditional fails in WS984000). Cables wearing.
Correct air pressure not achieved. - Air line
pressure too low.
Gun 1 is configured for Retract operation and
received a Start signal whilst the Retract
output was in the wrong state.
Gun 1 weld 1 used minimum heat.
Transformer tapping changed, too low a
current programmed for transformer being
used.
used.
used.
Heat used by Weld 1 Gun 1 reached or
exceeded the value set for Heat prelimit.
Gun 1 used maximum heat allowed by the
programmed value of Heat limit. Poor
component fit, low mains, leads worn.
Second stage Start signal missing.
79
WS4000 Manual
Diagnostics
Ready
Fault
EOS
Possible Cause
Code
Error
Gun 2 disabled in
Configuration
Weld off Gun 2
Over range Gun 2
64
65
66
1
1
0
0
1
1
Toroid open circuit Gun 2
67
Toroid short circuit Gun 2
68
Error in curve Gun 2
69
Ct over range Gun 2

No primary current Gun 2
70
71
1
1
0
0
1
0
72
73
74
75
76
77
Retry failed Gun 2
78
Too many consecutive

retries Gun 2
79
80
80
Start signal given for Gun 2, but Gun 2 not

enabled in Timer Configuration.
Gun 2 weld switched off.
Gun 2 weld current exceeds maximum
capability of WS4000. Check toroid
sensitivity is correct.
Gun 2 toroid open circuit. Check toroid
Gun 2 toroid short circuit. Check toroid
Invalid parameter(s) programmed for Gun 2
stepper curve.
Primary current too large for WS4000.
No primary current measured for Gun 2
during weld interval. Electrodes missing or
not closed onto component, possible cable or
connection problems.
Gun 2 weld current was too low and the weld
was retried. The retried weld also failed.
The number of consecutive welds requiring a
retry exceeded the number programmed for
Max retries in timer configuration.
problems.
WS4000 Manual
Diagnostics
Ready
Fault
EOS
Possible Cause
Code
Error
81
82

Gun 2
83

Gun 2
84

Gun 2
85
Proportional valve error

Gun 2
Retract not ready Gun 2
86
87
88
89
90
Heat pre limit weld 1 Gun 2
91
92
93

problems.
problems.
Correct air pressure not achieved. - Air line
pressure too low.
Gun 2 is configured for Retract operation and
received a Start signal whilst the Retract
output was in the wrong state.
used.
used.
used.
81
WS4000 Manual
Diagnostics
Ready
Fault
EOS
Possible Cause
Code
Error
Max heat Gun 2
94
No second stage Gun 2
95
Gun 2 used maximum heat allowed by the

programmed value of Heat limit. Poor
component fit, low mains, leads worn.
Second stage Start signal missing.
End of stepper 0
End of stepper 1
End of stepper 2
End of stepper 3
End of stepper 4
End of stepper 5
End of stepper 6
End of stepper 7
End of stepper 8
End of stepper 9
End of stepper 10
End of stepper 11
End of stepper 12
End of stepper 13
128
129
130
131
132
133
134
135
136
137
138
139
140
141
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
End of stepper 0 curve reached.

End of stepper 8 curve reached
End of stepper 14
End of stepper 15
End of stepper 16
End of stepper 17
End of stepper 18
End of stepper 19
End of stepper 20
End of stepper 21
End of stepper 22
End of stepper 23
142
143
144
145
146
147
148
149
150
151
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1

End of stepper 0 Gun 2

136
137
138
139
140
141
142
143
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
End of Gun 2 stepper curve 0 reached

Prewarning
Prewarning
Prewarning
Prewarning
Prewarning
Prewarning
Prewarning
Prewarning
Prewarning
160
161
162
163
164
165
166
167
168
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
End of stepper curve 0 approaching

82
0
1
2
3
4
5
6
7
8
WS4000 Manual
Diagnostics
Ready
Fault
EOS
Possible Cause
Code
Error
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

Prewarning 0 Gun 2
Prewarning 1 Gun 2
Prewarning 2 Gun 2
Prewarning 3 Gun 2
Prewarning 4 Gun 2
Prewarning 5 Gun 2
Prewarning 6 Gun 2
Prewarning 7 Gun 2
168
169
170
171
172
173
174
175
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
End of Gun 2 stepper curve 0 approaching

Tip dress request

Tip dress request
Tip dress request
Tip dress request
Tip dress request
Tip dress request
Tip dress request
Tip dress request
Tip dress request
Tip dress request
Tip dress request
Tip dress request
Tip dress request
Tip dress request
Tip dress request
Tip dress request
Tip dress request
Tip dress request
Tip dress request
Tip dress request
Tip dress request
Tip dress request
Tip dress request
Tip dress request
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Electrode 0 requires dressing.

168
Electrode 0 Gun 2 requires dressing.
Prewarning
Prewarning
Prewarning
Prewarning
Prewarning
Prewarning
Prewarning
Prewarning
Prewarning
Prewarning
Prewarning
Prewarning
Prewarning
Prewarning
Prewarning
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Tip dress request 0 Gun 2
83
WS4000 Manual
Diagnostics
Ready
Fault
EOS
Possible Cause
Code
Error

DC transformer hot
Inverter diode monitor
169
170
171
172
173
174
175
225
226
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
Inverter driver error
227
Inverter too hot

Inverter voltage error
228
229
0
0
Inverter P.S.U. fault
230
Inverter over current

Inverter toroid error
Inverter short circuit
231
232
233
0
0
0
Inverter no current
Inverter earth fault
234
235
0
0
Inverter disabled
236
Thyristor fail
241

Medium Freq. transformer overheated.
Medium Freq. secondary rectifier diodes
overheated.
Medium Freq. inverter fault. Return to British
Federal.
Medium Freq. inverter overheated.
Federal.
Federal.
Medium Freq. welding current too high.
Medium Freq. toroid fault.
Connections to primary of Medium Freq.
transformer are short circuit.
No current produced by Medium Freq. inverter.
One of the Medium Freq. inverter outputs to the
transformer is short circuit to earth.
Medium Freq. inverter output stage disabled on
control board. Move Link 1 from 1-2 to 2-3
Thyristor passing current when switched off.
NB:
If the thyristor fails the mains contactor will trip. When power is restored to the timer it will
show the Thyristor Fail message, until cleared.
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WS4000 Manual
Diagnostics
Timer Measurements
Press
MORE
MONITOR
The display will read Measurements. Use the

and
keys to move forwards
and backwards through the measurements. The measurements given are shown below:
Measurement
Expected Value
Note
CT =
20 2000 amps
PV input
0 100%
Toroid 1
Toroid 2
Voltage
1:03 2:01
20 50R
20 50R
200 500 volts
---
Version
---
Measurement of primary current obtained from the

current transformer.
Analogue feedback voltage from proportional
valve.
Resistance of Gun 1 toroid.
Resistance of Gun 2 toroid.
Mains voltage
Last programme used on each gun (in this
example prog. 3 was last programme to be used
on Gun 1, and prog. 1 was last programme to be
used on Gun 2).
Timer software version number.
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WS4000 Manual
Networking with Ethernet

Introduction
There are many benefits associated with implementing networking in an engineering
environment.
Reductions in point to point wiring and associated costs.
Allows many types of equipment to share common network architecture.
Remote administration
Centralised monitoring.
Centralised backup of plant critical data.
WS40xx Timer Network Properties

Speed
10Mb/s
Connection:
UTP RJ45
I/P Address:
w.x.y.z (Class C)
Subnet Mask:
255.255.255.0 (fixed Class C)
Max. recommended ping: 1000 bytes
Port used:
502
Fixed MAC ID. (Registered) 00-B0-E7 (next three octets administered by British Federal)
Planning the Network

When planning your timer network you must consider a number of things:
The weld timers should be on an independent network to avoid data from other sources
compromising the network bandwidth.
Maximum number of timers on a controlling computer is 30. If this is exceeded problems of

manageability arise.
How many timer addresses do you require both now and in the future?
This will determine if you need a router and what class of network is required.
These addresses will need to be reserved and unique on your network.
Is the network administered by someone else?

If so you will need to ask for an IP address for each timer. You will also need the subnet mask
for these addresses. - Class C only.
If you have control of a network connected to the Internet or other networks:

The timers should be on an isolated (switched) segment to prevent other users
affecting any data on the timer network.
Ensure that the timer IP addresses are unique.
If you have control of a network not connected to the Internet or other networks:
Ensure that the timer IP addresses are unique.
Keep a written record of all IP addresses for your network.
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WS4000 Manual
Are you using DHCP? If so you will need to reserve network addresses based on the MAC
address of the timer. The timers only support fixed IP addresses.
Installing the Network Adapter in PC with Windows 95/98
Network Adapter Hardware Installation

This section depends to a great extent of the card manufacturer please follow the
manufacturers guidelines.
1.
2.
3.
4.
5.
Shut down the computer and remove the mains plug.

Ensure you have an Anti-Static wrist band.
Find a suitable slot in the computer and install the card (usually PCI or ISA)
Remove the blanking plate at the rear of the slot.
Firmly insert the card into the slot taking care not to damage any surrounding components or
wires.
6. Secure the card at the rear using the screw from the blanking plate.
7. Replace the cover.
Open computer and remove

blanking plate.
Take Network Adapter card.
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WS4000 Manual
Insert Network Adapter card.
Connect network cable to computer.
Secure Network Adapter card,

then close computer.
Connect network cable to hub.
Software Driver Installation

This section depends to a great extent on the card manufacturer please follow the
manufacturers guidelines.
1. If you are using plug and play hardware and operating system, this process should run
without much user intervention. If not please consult the manufacturers guidelines.
2. After powering up the operating system should recognise that new hardware has been
installed, if the hardware is recognised a driver will automatically be installed.
If not windows will ask for the driver disk.
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WS4000 Manual
3. At this point the PC will ask to be restarted.
Setting up The card Protocols

If you have a network administrator consult them for the appropriate set up for the system.
1. Go to the control panel and click on network.
2. Ensure that TCP IP is installed as a protocol, if not use ADD - PROTOCOL MICROSOFT
TCPIP
3. Remove all other protocols that are not required, usually NetBuei and
IPX.
Setting up the IP Address

1. Obtain the network address for the P.C. from your list of available addresses or from the
information provided by the network administrator.
2. If you are using DHCP. From the start menu run winipcfg.exe and write down the adaptor
address. The administrator will need this.
From the network control panel double click on TCPIP and go to the IP address TAB and
check "obtain IP address automatically" is set. Check with the administrator that the assigned
IP address is in the same subnet as the timers.
Remember to reserve any timer addresses.
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WS4000 Manual
3. If you are configuring the PC manually.

Set the ip address to the address required e.g 192.168.0.1
Timer address range is (192 to 223).(0 to 255).(0 to 255).(1 to 254)
Set the subnet mask to 255.255.255.0 (Class C)
4. Click ok and ok again to close the network control panel.
5. The PC will now restart.
6. After the PC has started perform the following ping tests: (See section on Ping)
ping 127.0.0.1 and ensure there is a response. This tests the installation of the Network
Adapter in the PC.
ping the PC address e.g. 192.168.0.1 and ensure there is a response. If using DHCP use
winipcfg to obtain the ip address.
ping another device on the network e.g. 192.168.0.2 This checks cabling between
devices.
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WS4000 Manual
Connecting the Network
Basic arrangements
The diagram shown below shows a network arrangement where a number of timers are
connected to a PC using a single hub.
PC fitted with
network adapter
card
Cable type: Category 5 with
screened connectors (cables
with braided copper screen, no
foil screen).
Hub
If using STP cable to connect

from hub to timer, ensure that
ground connection is made at
hub connection ONLY
Maximum length for any
cable: 100 metres.
Timer
Timer Timer Timer Timer
Timer
Timer
Maximum recommended
number of timers per
controlling PC: 30
Timer Timer Timer
UP-LINK
NORMAL
Illustration of hub to timer connections
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WS4000 Manual
It should be noted that some hubs and switches are dual speed. If this is the case, the timer
connections need to run at 10Mb/s, whilst other connections can run at a higher speed.The
diagram shown below shows a network arrangement where a network hub is connected directly
to some timers, and to other timers via additional hubs.
PC fitted with
network adapter
card
Maximum
recommended
number of timers per
controlling PC: 30
Hub
Hub
Hub
Timer
Timer
Cable type: RJ 45 UTP

Timer Timer
Timer
Timer
Timer Timer
Crossover cable or
Uplink port see note
below
Timer Timer
It should be noted that to make a connection from one hub to another either:
Use a Crossover cable and connect from one standard port to another standard port.
Use standard non-crossover cable but connect from the Uplink port on one hub to standard
port on the other.
In both cases this will perform the required crossover.
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WS4000 Manual
UP-LINK
NORMAL
Non crossover cable

Switch in Uplink
position
UP-LINK
NORMAL
Illustration of hub to hub connection using Uplink port
UP-LINK
NORMAL
Crossover
cable
UP-LINK
NORMAL
Illustration of hub to hub connection using crossover cable

It is advisable to use a different colour for crossover cables to that used for non-crossover cables,
for purposes of easy identification.
It should also be noted that some hubs and switches are dual speed. If this is the case, the timer
connections need to run at 10Mb/s, whilst other connections can run at a higher speed.
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WS4000 Manual
Network using a switch

The network shown below shows timers in two cells. The timer data for the two cells is kept
separate by the use of the switch. The advantage of separating areas in this way reduces overall
network traffic and keeps different types of data separate, thus removing possible problems of
one set of data monopolising the network at an inappropriate time.
PC fitted with
network adapter
card
Switch
CELL
CELL
Hub
Hub
Timer Timer
Timer Timer
Timer
Timer
Timer
Timer
British Federal independent network

For connections between hub and switch, see switch manufacturers information.
The timer uses TCP/IP (Transmission Control Protocol/Internet Protocol), so all other network
elements concerned with timer data must also use this protocol.
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WS4000 Manual
System Components
Adapter
Any user PC that you wish to connect to the network will require a network adapter. This device
provides the necessary connection for the network cabling to fit to your user PC. In addition it is
responsible for the transfer of information between the network and the user PCs memory. A
network adapter is simply an add-in board, which physically plugs onto the motherboard of your
user PC, network server or mobile user PC (mobile versions usually connect via a slot).
Hub
In its simplest form a hub is a central location for the attachment of cabling from a number of
network users. An advantage of using a hub on a network is that it provides fault tolerance
(protection from total network failure if you lose one connection). By giving each individual user a
single cable connection to their individual hub port, only that user is affected if the connection or
cable is broken.
Switch
A switch is a network hardware device. It will receive network information through a single
connection, store it temporarily then send it out to another specific destination on your network
based on the network address (an ID given to each user PC on the network) included on the
information package. Switches will allow you to break down your network into smaller sections
which will remain in contact from inside the switch, this would effectively give you two separate
networks in one. If it is possible to place user PCs which are in regular contact together in the
same sections then this would reduce the information traffic by half on each section of network.
Unlike hubs, which share the communication channel on the network for all your connections, a
switch provides a dedicated communication channel on each connection at full cable speed.
Switches are most commonly found on larger networks providing dedicated communication
channels to multiple hubs or power user PCs.
Assigning Addresses
To assign an address to a timer you will need to provide a unique Class C network address for
each timer.
The Class C address system allows for a maximum of 254 IP addresses per network as follows:
Address 192.168.0.1. gives a network address of 192.168.0 and a host (timer) address
of 1.
It is recommended that a maximum of 30 timers are connected to a subnet managed by WS98. If
more timers are used the amount of data from the timers may cause problems with the network
loading and management of the data.
If you have a network administrator it is important that you get a range of addresses from them as
addresses will be centrally managed and if your network uses DHCP the addresses must be
reserved for the timers to prevent other devices from acquiring an address.
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WS4000 Manual
Example 1
If you have a network administrator, request a Class C address for each timer and any PC that is
to be used with the welding data (WS98). These addresses must be on the same subnet.
If the network uses DHCP you must ensure that the DHCP server does not issue addresses that
are in use by the timers or controlling computers.
It is strongly recommended that the timer network is protected from any other network traffic with
the use of a switch.
Example 2
If you have full control of your network and it is not connected to any other networks, including the
Internet, you can assign any Class C address. In order to maintain a standard it is recommend
that you use :
192.168.0.1 through to 192.168.0.254
N.B. addresses 192.168.0.0. and 192.168.0.255 are reserved for system use.
If you plan to expand your network to include more that 255 timers you will need to use another
subnet and ensure that the controlling PC is on the same subnet.
It is strongly recommended that the timer network is protected from any other network traffic with
the use of a switch.
Fault Finding
Checking a timer is present on a network

To check a timer is on a network and responding correctly a programme called ping can be
used. This sends data across the network to a specific IP address and checks for a response
from that address.
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WS4000 Manual
The ping options available are:
C:\WINDOWS>ping
Usage: ping [-t] [-a] [-n count] [-l size] [-f] [-i TTL] [-v TOS]
[-r count] [-s count] [[-j host-list] | [-k host-list]]
[-w timeout] destination-list
Options:
-t
Ping the specifed host until stopped.

To see statistics and continue - type Control-Break;
To stop - type Control-C.
-a
Resolve addresses to hostnames.
-n count
Number of echo requests to send.
-l size
Send buffer size.
-f
Set Don't Fragment flag in packet.
-i TTL
Time To Live.
-v TOS
Type Of Service.
-r count
Record route for count hops.
-s count
Timestamp for count hops.
-j host-list Loose source route along host-list.
-k host-list Strict source route along host-list.
-w timeout Timeout in milliseconds to wait for each reply.
C:\WINDOWS>
To ping a timer from the network computer, start MS-DOS Prompt, then type ping followed by
a space, followed by the IP address of the timer being investigated.
eg. ping 192.168.0.200
The PC will send data to the IP address and check for a response. A report will then be given on
the screen.
eg.
Microsoft(R) Windows 98
(C)Copyright Microsoft Corp 1981-1998.
C:\WINDOWS>ping 192.168.0.10
Pinging 192.168.0.10 with 32 bytes of data:
Reply from 192.168.0.200: bytes=32 time=1ms TTL=32
Reply from 192.168.0.200: bytes=32 time<10ms TTL=32
Ping statistics for 192.168.0.200:
Packets: Sent = 4, Received = 4, Lost = 0 (0% loss),
Approximate round trip times in milli-seconds:
Minimum = 0ms, Maximum = 1ms, Average = 0ms
To ping continuously
To make the PC continually ping a timer use the t switch.
eg. ping 192.168.0.200 -t
97
WS4000 Manual
To stop the ping programme type
!".
To set ping data size
The maximum data size that should be used to ping a timer is

1000 bytes
To set data size use the l switch, followed by a space followed by the data size.
eg. ping 192.168.0.200 l 1000
To trace the route data takes from a PC to a specific address

It may be advantageous to determine the actual route used from a PC to a specific IP address.
To do this a programme called tracert can be used.
To run tracert from the network computer, start MS-DOS Prompt, then type tracert followed by
a space, followed by the IP address of the timer being investigated.
eg. tracert 192.168.0.200
A report of the route taken by the data , in terms of routing points (hops), is put on the screen.
To monitor data and data flow
A programme called Sniffer can be used to determine data flow, examine data and perform
various diagnostic functions on network data.
Sniffer is application available from NIA (www.sniffer.com).
A download is available called "NetXRay" for evaluation purposes.
This programme
problems.
has
proved
to
be
extremely
useful
in
diagnosing
network
More Information
If you require more information on TCP/IP or networking there are a number of good resources
and books on the subject which are listed below:
Exam Cram TCP/IP Gary Novosel, Kurt Hudson, James Michael Stuart ISBN 1-57610-677-2
published by Coriolis.
Microsoft Windows NT Server 4.0 Administrators Pocket Consultant William R. Stanek ISBN 07356-0574-2 published by Microsoft.
http://t2.technion.ac.il/~s2845543/tcpip_rl.html TCPIP resources list
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WS4000 Manual
Glossary of Terms
Glossary of Terms
AVC
CCR
Const I
Constant current
ControlNet
Cool
Cool 1
Cool 2
Cool 3
Cool time
CT
Current transformer
DeviceNet
Downslope
Downslope time
End of sequence
EOS
Ethernet
Fieldbus control
Gerbi
Heat
Heat 1
Heat 2
Heat 3
Heat stepping
Hold
Automatic Voltage Compensation

Constant current regulation. See Constant Current
Constant current
Closed loop control of weld current resulting in weld current being
regulated to a programmed value. The current achieved by this
method of control is independent of external influences.
A network for controlling a number devices (a device could be a
weld timer).
The time interval, in a weld sequence, between applications of
current.
The time period, within a weld sequence, between the end of Weld 1
pulse and the start of Weld 2 pulse.
The time period, within a weld sequence, between successive
applications of the Weld 2 pulse (pulsations).
The time period, within a weld sequence, between the end of Weld 2
pulse and the start of Weld 3 pulse.
A period of time, in a weld sequence, between applications of
current. Expressed in mains cycles.
Current transformer
A coil of wire wound on a circular core. This is used to measure the
current in a wire passing through the circular core. The weld timer
uses this to measure primary current.

A network for controlling a number stations (a station could be a
weld timer).
A linear decrease in current from the welding value to a final value,
applied to the main weld pulse (Weld 2).
Time taken for current to decrease from the welding value to a final
value. Expressed in mains cycles.
An output that switches on as the electrodes open on completion of
a weld. The output indicates completion of the weld sequence.
End of sequence.
A network for programming a number devices (a device could be a
weld timer).
General term for control of timers over a network.
A type of weld gun that uses a mechanical latch to provide 3
electrode positions.
A measure of power put into a phase angle controlled (non- constant
current) weld. The Heat relates directly to the firing angle in
electrical degrees, on the mains voltage waveform. Expressed as
a percentage.
% Heat set for weld interval 1 (Weld interval 1 is sometimes referred
to as preheat).
% Heat set for weld interval 2. Weld interval 2 is usually
programmed to provide the actual weld, unlike weld 1 preheat, and
weld 2 post heat.
% Heat set for weld interval 3 (Weld interval 3 is sometimes referred
to as post heat).
See Stepping.
The time, in a weld sequence, between the last application of
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WS4000 Manual
Hold time
Hub
I.P. address
IGBT
Initiation signal
Interbus S
Inverter
kA
KSR
kVA
LED
mA
Medium Frequency
Inverter
Medium frequency
welding
MF
mV
Network adapter
Off time
OHMA
PC
PHA
Phase angle control
Ping
Post heat
Pre heat
Presqueeze
Presqueeze time
Primary current
Profibus DP
100
Glossary of Terms
current and the electrodes opening. This time allows the molten
material created by the weld process, to solidify.
The time period following the last weld pulse, prior to the electrodes
opening. This period allows the molten material to solidify.
Expressed in mains cycles.
A component used with the Ethernet network for connecting a
number of devices such that all data appears on all parts of the
network.
Internet Protocol Address. A unique address used by devices on an
Ethernet network.
Insulated Gate Bipolar Transistor. A type of power transistor used in
inverters.
The signal that starts the weld sequence.
A network for controlling a number stations (a station could be a
weld timer).
See Medium Frequency Inverter
Kilo amp. 1000 amps
German initials for constant current.
Unit of power. 1000 volt amps
(Light Emitting Diode) An indicator that gives light when energised.
There are different coloured types and some types can change
colour.
Milli-amp 1/1000 amp
A piece of equipment for powering a Medium Frequency welding
transformer.
System of welding using 1000 Hz or 1200 Hz instead of mains
frequency.
Medium frequency (welding)
Milli-volt 1/1000 volt
An interface card for a computer giving it access to an Ethernet
connection.
In a Repeated weld sequence, this is the time between sequences.
Expressed in mains cycles.
A type of air valve system.
Personal computer
Phase angle control.
Open loop control of weld current using Heat setting. This method
does not use Constant Current and the current achieved can be
influenced by external parameters such as mains voltage, cable
lengths, etc..
A diagnostic programme that tests if a station on an Ethernet
network is responding.
The application of current to prevent the weld (carried out by Weld
2) cooling too quickly. Sometimes called Weld 3.
The application of current, in preparation for the actual weld current.
This application of current is intended to burn through the plating or
surface contamination of the work piece. Sometimes call Weld 1.
The time interval in a weld sequence for the electrodes to close onto
the work piece.
The time allowed for the welding electrodes to close onto the
components to be welded. Expressed in mains cycles.
The current in the primary winding of the weld transformer. The
current drawn from the mains whilst welding.
A network for controlling a number devices (a device could be a
weld timer).
WS4000 Manual
Profibus FMS
Prog Sel
Programme Select I/P
Proportional valve
Pulsations
Pulse Drive O/P
Retract
Retract air valve
RS232
Second Stage
Initiation
Second Stage Start

Secondary current
Squeeze
Squeeze time
Start 1
Start 2
Start signal
Stepper
Stepping
Subnet mask
Switch
Synchronisation
Thermostat
Thyristor
Tip dress
acknowledge
Tip dress request
Glossary of Terms
A network for programming a number devices (a device could be a

weld timer).
See Programme Select i/p
An input, usually one of several, giving a binary number to select the
weld programme to be used.
A device for regulating air-line pressure. Controlled by 0 10 v DC
or 4 20 mA analogue signal.
The number of times the main weld interval (Weld 2) is applied.
Successive applications of Weld 2 are separated by a Cool time.
Timer output for driving thyristor firing circuit.
A system whereby the electrodes have two open positions: - Fully
open to move the weld gun to and from the work piece, and an
intermediate working position, for normal welding.
For use on a gun where the electrodes can be opened and closed in
two stages. This is an electrically controlled valve for admitting air to
the air cylinder responsible for first stage of closing of the
electrodes.
Serial communication system suitable only for short cables. This is
the type of connection made via a COM socket on a computer.
A signal required to allow the weld sequence to proceed from the
end of the Squeeze time to the beginning of the Weld interval. If the
timer requires this signal, and it is absent, the sequence is halted
until the signal is given. This input may be used to check electrode
force has reached the correct value, or to make the sequence wait
until another machine has finished its weld.
See Second Stage Initiation
The current in the secondary winding of the weld transformer. The
weld current.
The time interval in a weld sequence for the electrodes to exert full
welding force on the work piece.
The time allowed for the welding electrodes to build up full pressure
on the components to be welded. Expressed in mains cycles.
The signal that starts the weld sequence on Gun 1.
The signal that starts the weld sequence on Gun 2.
The signal that starts the weld sequence.
A programme of parameters required for stepping.
A technique of progressively increasing the weld current over the
course of a large number of welds in order to compensate for the
effects of electrode wear.
Ethernet term. A mask used to determine what subnet an IP address
belongs to. An IP address has two components, the network
address and the host address. Subnetting enables the network
administrator to further divide the host part of the address into two or
more subnets.
An Ethernet device for connecting other Ethernet devices together
having the ability to direct packets of data to a specific destinations
rather than the whole network.
The actions of the weld timer are synchronised to the zero voltage
crossing points of the mains.
A switch device that operates at a certain temperature.
High power switch used for switching the mains supply to the weld
transformer. Thyristors are controlled by a pulse drive.
An input to a weld timer acknowledging that the electrodes have
been dressed.
An output given by a weld timer to indicate that the electrodes
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WS4000 Manual
Tip dressing
Toroid
Upslope
Upslope time
VA
WAV
Weld 1
Weld 2
Weld 3
Weld air valve
Weld current
Weld Transformer
102
Glossary of Terms
require dressing.
Filing or machining worn electrodes to restore their original shape
and dimensions.
An adaptation of a Stepper to facilitate automatic dressing of
electrodes.
A device used for sensing current in a cable. The current carrying
cable must pass through the toroid.
A linear increase in current from an initial value to the welding value,
applied to the main weld pulse (Weld 2).
Time taken for current to increase from an initial value to the welding
value. Expressed in mains cycles.
Volt amp
Weld air valve.
A weld pulse intended to burn through surface coatings in
preparation for the next weld pulse which will actually weld the
components. Sometimes called Pre Heat. Expressed in mains
cycles.
The weld pulse that welds the components together. Expressed in
mains cycles.
A weld pulse following the pulse that welded the components
together, included to slow the rate of cooling of the weld, sometimes
called Post Heat. Expressed in mains cycles.
Electrically controlled valve for admitting air to the air cylinder
responsible for forcing the weld electrodes together.
High current passed from one electrode to the other, through the
components being welded. The current must be large enough to
generate sufficient heat to melt the metal and produce a weld.
Electrical component for converting mains voltage input to low
voltage, welding current output.
WS4000 Manual
Appendix
Appendix
Programme Select Codes
Prog. No.
Select 64
Select 32
Select 16
Select 8
Select 4
Select 2
Select 1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
0
0
0
0
0
1
1
1
0
0
0
0
0
1
1
1
0
0
0
0
0
1
1
1
0
0
0
0
0
1
1
1
0
0
0
0
0
1
1
1
0
0
0
0
0
1
1
0
0
1
1
1
0
0
1
0
0
1
1
1
0
0
1
0
0
1
1
1
0
0
1
0
0
1
1
1
0
0
1
0
0
1
1
1
0
0
1
0
0
1
1
1
0
0
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
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48
49
50
0
0
0
0
1
1
1
1
0
1
1
1
1
0
0
0
1
0
0
0
1
0
0
1
1
0
1
0
Prog. No.
Select 64
Select 32
Select 16
Select 8
Select 4
Select 2
Select 1
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
1
1
1
0
0
0
0
0
1
1
1
0
0
0
0
0
1
1
1
0
0
0
0
0
1
1
1
0
0
0
0
0
1
1
1
0
0
0
0
0
1
1
1
0
0
0
0
1
1
0
0
1
0
0
1
1
1
0
0
1
0
0
1
1
1
0
0
1
0
0
1
1
1
0
0
1
0
0
1
1
1
0
0
1
0
0
1
1
1
0
0
1
0
0
1
1
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
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101
102
103
104
105
106
107
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
0
1
1
1
0
0
0
0
1
0
0
1
0
0
1
1
0
1
0
1
0
1
0
1
Prog. No.
Select 64
Select 32
Select 16
Select 8
Select 4
Select 2
Select 1
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
1
1
1
0
0
0
0
0
1
1
1
0
0
0
0
0
1
1
1
1
0
0
1
0
0
1
1
1
0
0
1
0
0
1
1
1
0
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
105
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Appendix

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WS4000

Manual version 1.14

British Federal Ltd.,

TIMER FUNCTIONS .............................................................................................5

TIMER INPUTS AND OUTPUTS ........................................................................22

End of Stepper 2 ..................................................................................................................... 28

TIMER L.E.D.S ...................................................................................................30

PASSCODE FOR KEYPAD AND PENDANT PROGRAMMING........................46

CURRENT CALIBRATION .................................................................................53

PROPORTIONAL VALVE CALIBRATION.........................................................55

Interpretation of Y(KSR) values .............................................................................................. 66

FURTHER PROGRAMMER FUNCTIONS..........................................................73

TO CHANGE THE DISPLAY CONTRAST .........................................................75

NETWORKING WITH ETHERNET.....................................................................86

Independent control of one or two welding guns.

Number of welding programmes 1x128 (192 using fieldbus) or 2x64.

Advanced, three interval welding sequence.

Constant current or voltage compensation control modes.

Compatible with British Federal Medium Frequency inverter.

Spot and projection welding.

Local programming via P.C. using WS98 software.

Local programming with optional hand held programmer.

Local programming using front panel programmer. (WS4000, WS4002 and

Network programming with WS98 via:

Profibus FMS. (Optional)

Extensive monitoring and diagnostic capability.

Proportional valve control. (Optional)

High speed serial control using: -

Flash memory based for easy upgrade of operating software.

WS400xx Family Members

WS40xx Family Members

Controls with Front Panel Programmers

WS400xx Family Members

Interbus S control network

Chassis Mounted Controls

WS400xx Family Members

ControlNet control network

Optional (during manufacture)

Weld air valve

Weld air valve

Squeez Weld 2 Cool 2 Weld 2 Hold

Weld air valve

End of Seq. Signal

End of Seq. Signal

Starting a Weld Sequence

Phase Angle Heat Control

Heat Stepping and Tip Dressing

increases the current, or heat, as welding

Stepping can also be applied to electrode pressure, if a proportional valve is in use.

End of Sequence Signal

End of Sequence Signal Operation

End of Seq. Signal

End of Seq. Signal

End of Seq. Signal

Closed onto workpiece

Retract close time

Retract open time

Medium Frequency Welding

Current required for Weld 1

keys to move forwards and backwards through the table.

Half Cycle Log

keys to move forwards and backwards through the results.

Primary Currents Log

keys to move forwards and backwards through the readings.