Introduction to setting of timers

Explaining The setting of Spot welding timers for newcomers & others

By Stuart Dorling

So, you got a spot welder or other type of resistance welder with a timer control system from Westken. We are now looking at an electronic device with its readout screens, lights and buttons, its a bit confusing hey! Read this and it will probably help make things a bit more clear.

You want to know how to set this timer system, well 
”hopefully” you have read the other section concerning spot welding and resistance welding, so now, once again, lets try and explain in a way that is understandable without using to many big words, technical terms or baffling phrases.

Some simple explanations of words and terms can be found on our website. I will give an explanation on terms or words used with timers as we go through this exercise.

A more in depth explanation of the welding processes and equipment will be covered in other sections on the Westken info page

Chapter one

1)   The setup of the Westken Minipak ( wk mps-01) timer as used on the Handispot, Hotspot and 35/50kva foot operated spot welders

2)   The setup of the Westken Minipak ( wk mps-01)  timer as used on the Econospot air operated spot welder

Chapter two

3)   The setup of the Westken Weldpak timer as used on the 50kva Series-90 Pedestal welder,  100kva Powerspot, 100/150kva Stronghold Type pedestal welder and 100/150kva Stronghold type projection welder.

Chapter Three

4)   The setup of the Westken Smartpak timer as used on the 100/150kva Stronghold Type pedestal welder, 100/150kva Stronghold type projection welder and the PA2 and PA3 type large frame pedestal welders

Chapter Four

5) A simple explanation by Westken of clever words used concerning timers.

So you have seen what we want to discuss. All you need to do now is identify what timer system you have, it helps a bit if you know what machine you have, look at the list and away we go.

Chapter one

The setup of the Westken Minipak timer as used on the Handispot, Hotspot and 35/50kva foot operated spot welders

The Westken Minipak timer is equipped with only two buttons which are an Up arrow and Minus sign.

To scroll through the timer menus press the Up arrow. The Westken Minipak timer will sequence through its menu is as follows:

P squeeze

Squeeze

Weld 1

Cool

Weld 2

Hold

Off

To make any changes to the setting of the Westken Minipak you need to press the minus (-) sign button

To increase the time one presses the button repeatedly with about a one second timing.

To decrease the time you press and hold the minus (-) sign

Note *. don’t worry if the time goes up one or two numbers keep holding it and the time will go down.

As a tip.  while setting the Westken Minipak timer goes down quite fast so let it go past the figure that you want and then pulse it back up to the correct number 

Remember that the number is in cycles (50 cycles to a second)

Only the heat is in % meaning that 100% is the full power that the transformer can give out.

Here is some start up settings (just to help you get things going)

Westken Foot pedal machine       Westken Air operated machine

P squeeze     00                                         P squeeze   10

Squeeze       05                                          Squeeze     15

Weld 1        10                                           Weld 1       10

Heat 1         40%                                       Heat 1        40%

Cool            00                                          Cool           00

Weld 2        00                                           Weld 2       00

Heat 2         10%                                       Heat 2        10%

Hold            10                                          Hold           10

Off              00     not used                          off             00 

Please note * Weld 2 is normally only used for problem materials. These materials are things like galvanized and or plated steel and materials that work harden.

Off time. This is a repeat function to allow the machine to stitch or repeat weld. (The Off time function is factory set to only be used and available on air operated machines i.e. the Econospot). What this essentially means is that when the electric foot switch on air machines is kept down the machine will close, weld, open, then  close, weld, open, until the electric foot switch is released.

By making the Off time setting longer the machine will stay “open” for longer.

Upslope.  This is like a soft start or ramp up of the weld power.  The weld will start low and then slope up to the heat % as set. The “ramp or slope” is dependent on the "time" set in upslope.

Pulsations. . This function allows the timer to pulse the weld area with heat. Instead of one large lump of heat going into the weld area the timer uses less heat and sort of machine guns the weld area. This function works well with difficult materials that have coatings on them like zinc or galvanizing. The operator sets this function by having a “time” in the cool time and then the weld will loop around weld1 and cool for the amount of pulsations set and then continue.

Info for Customers purchasing a Westken Minipak timer or replacing a timer.

Looking at the timer from the back or P.C.B side of the timer face, there is, on the right hand side above a resistor a jumper terminal with two positions (a) and (b)

For air operated machines the Jumper terminal is set to pos (a)

For foot pedal machines the Jumper terminal is set to pos (b)

Even though the P.F (power factor) setting is factory set you may in some cases need to use the P.F. adjustment. P.F. adjustment is sometimes necessary on new timers that have been purchased loose and are being fitted by the client.

You set the P.F. as follows;

1) Press the buttons Up and Minus together.

The L.C.D screen will read “Technician only screen”.

P.F. should be set at approx 0.82 during timer setting.

Once settings have been completed then leave timer after setting and it will return to the normal screen after about 30 seconds.

Chapter two

The setup of the Westken Weldpak (WK- MPS-08/10) timer as used on the 50kva Series-90 Pedestal welder,  100kva Powerspot, 100/150kva Stronghold Type pedestal welder and 100/150kva Stronghold type projection welder 

Please note Program select switch on series 90 & “stronghold type” pedestal spot welders

On Series-90 & “Stronghold” type air operated spot welding machines there is an 8 or 10 position program select switch. This switch is normally located  on the left hand side hand control box or

on the “Stronghold”,  fitted directly to the firing control panel just below the timer face.

This select switch is used to call up any of the pre programmed programs in the timer system 1 through to 8 or 1 through to 10 depending on the timer software.

The Westken Weldpak (WK- MPS-08/10) timer is equipped with four buttons. These buttons are, Up / Down arrows and a Plus (+) / (-) Minus sign.

To scroll through the Weldpak timer menus press the Up arrow. The Westken Weldpak timer will sequence through its menu is as follows.

(0)              P squeeze

(0)              Squeeze

(0)              Weld 1

(0)              Cool

(0)              Weld 2

(0)             Hold

(0)             Off

(0)              Upslope

(0)              Pulsations

(0)            The number shown in brackets is the program number.

To make any changes to the setting of the Westken Weldpak you need to press the Plus (+) button to increase or the minus (-) button to decrease the “time”. This “time” is the cycle time for the shown function.

You can also go up or down the sequence by pressing the Up or Down arrows.

Once the correct setting/change is made you can use the machine immediately. There is no need to save what you have done or exit from the menu.

Remember that the number is in cycles (50 cycles to a second)

Only the heat is in % meaning that 100% is the full output welding current that the transformer

can give out and 10% is only 10% of the full welding current output of the transformer.

Here are some suggested start up settings for

The Westken Weldpak timer system to help you get going.

On a Westken Air operated spot welding machine

          P squeeze       10

          Squeeze          15

          Weld 1           10

          Heat 1            40%

          Cool               00

          Weld 2            00

          Heat 2            10%

          Hold               10

          Off                  00 

          Upslope          00

          Pulsations         1

Please note * Weld 2 is normally only used for problematic materials that can be difficult to weld. These are materials like galvanized and or plated steel and materials that work harden like spring steel.

Info for Customers purchasing a Westken Weldpak timer or replacing a timer.

You set the P.F. (power factor) as follows;

1) Press the Up and down arrow buttons together.

The L.C.D screen will read

“Technician only screen”.

P.F. should be set at approx 0.82

Please Note *  You will also find ½ cycle on/off and the high lift latch select. On/off

Further adjustments made in the “technicians’ only screens” are

1)   ½ cycle on/off switch. This allows for setting of the timer system in a ½ cycle mode. This mode allows for finer weld settings than the full cycle mode.

2)   Hi lift on/off switch. This function is used when a second solenoid valve and high lifting cylinder is used on the spot welder. The high lift option on a spot welder allows for better part access of parts to be welded into the spot welding tip area.

Once settings have been completed on the Westken Weldpak timer system then leave timer after setting. The timer will return to the normal screen after about 30 seconds.

Chapter three

 

Chapter Four

A simple explanation of clever words by Westken used concerning welding and timers.

There are lots of words that are used to explain functions and facilities used on a resistance welding timer control and/or spot welders and their timers so let have a look at some of them. Please note this is a generalization of words and terms supplied by Westken and not an in depth study of what each word or term means. These explanations and descriptions are for guide line purposes only. Words highlighted and in italics have descriptions in the section “intro to words & terms”.

PLEASE NOTE: It is important to note that all calculations for time or “time periods” used on our timers is based on the fact that electrical supply in South Africa is 50hz/sec therefore a time setting of 50cycles will be equivalent to 1 second, 100cycle is 2 seconds and 25cycles is a half second. This is standard with the majority of timers systems through the world.Westken manufactures to this specification.

Pre-squeeze time. This is a delay time before the Squeeze time which can be used to extend the squeeze time when the machine is initially started. Most often used when the machine is in repeat mode to allow the machine to start a motor or use a highlights function on the first weld after which the pre-squeeze is bypassed and only the squeeze is used thereby shortening the up & down movement of the welding head.

Squeeze Time.  This is the delay time between the starting of the machine sequence by the foot or hand switch and the start of current passage through the weld area.  This period allows the air cylinder on the welding head to operate “close” and achieve the required welding electrode pressure at the welding tips before welding current flows.

Weld Time.  This is the actual time duration that the current is allowed to pass through the weld area.

Weld heat / Weld current or Phase Heat or Percentage % heat.  It is the amount of weld current allowed to pass through the weld area.  It is normally expressed as a percentage of the total available output of the machine.

Hold Time.  It is the period during which the weld is allowed to cool and solidify before the spot welder jaws are allowed to open.

Off Time.  It is the time when the machine is not operating between welding sequences when the machine is being used in the repeat mode. 

Repeat Time.  See off time

Cool Time.  It is the tine between individual weld pulses when more than one weld pulse is required during a welding operation.

Upslope. Is the ability of the timer to ramp up (slowly increase) the heat for the first few cycles to allow as a pre heat of the weld area to stop weld spatter/sparks etc during the start of the weld. This function also helps clean the weld area just prior to welding taking place.

Pulsation. This function allows the timer to pulse the weld area with heat. Instead of one large lump of heat going into the weld area the timer uses less heat and sort of machine guns the weld area. This function works well with difficult materials that have coatings on them like zinc or galvanizing.

P.F (Power Factor). This is the relationship or balance between the timer and transformer which helps ensure that the timer fires the transformer as efficiently as possible. The timer looks at the sine wave that is being fed to the timer by its power supply and it is matched the sine wave that is being fed to the transformer. 

Analogue Settings.  The settings based upon control by an analogue timer.

Digital settings.  The settings based upon control by a digital timer that uses the zero crossing of the input power sine wave as a reference point.

Weld on/off switch. Most timer systems have a means to switch the weld off and still operate the machine during tip dressing and/or tip replacement. 

FRL (filter, regulator, lubricator) this is a device that is attached to the machine to control the air pressure that is sent through to the cylinder. The pressure in the cylinder ends up at the tip face. This device also filters the air for impurities and lubricates the air that is passed to the cylinder.

Thyristor. This is the device that controls electrical supply to the transformer.

Introduction to Setting Timers

Explaining The setting of Spot welding timers for newcomers & others By Stuart Dorling

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