Download Weld Control Cabinet 7_6_95.FM5

Bulletin No. 50006-524-01A
March 1996
Raleigh, NC, USA
Instruction Bulletin
Replaces 50006-524-01 dated July 1995
EQ5300
Weld Control Cabinet
Receiving, Installation, and
Specifications
© 1995 Square D All Rights Reserved
EQ5300 Weld Control Cabinet
Receiving, Installation, and Specifications
Bulletin No. 50006-524-01A
March 1996
!!
DANGER
HAZARD OF ELECTRICAL SHOCK, BURN OR EXPLOSION.
•
Read and understand this bulletin in its entirety before installing or
operating EQ5300 weld controls. Installation, adjustment, repair and
maintenance of these weld controls must be performed by qualified
personnel.
•
DO NOT short across capacitors or touch unshielded components or
terminal strip screw connections with voltage present.
•
Install all covers and close door before applying power or operating
the weld control.
•
User is responsible for conforming to all applicable code requirements with respect to grounding all equipment.
•
Many parts in this weld control, including printed wiring boards, operate at line voltage. DO NOT TOUCH. Use only electrically insulated
tools.
•
Power is applied to the weld control for some corrective action procedures. Use extreme caution.
•
Before servicing weld control:
— Disconnect all power.
— Place a “DO NOT TURN ON” label on weld control disconnect.
— Lock disconnect in open position.
Failure to observe these precautions will cause death, personal injury, or electrical
shock.
The EQ5300 Weld Control is manufactured under one or more of the following United States Letters Patents: 4104724,
4251764, 4254466, 4282417, 4289948, 4289951, 4301351, 4388515, 4399511, 4456809, 4459456, 4459457,
4463244, 4516008, 4910659, 4945210, other patents pending.
© 1995 Square D. All rights reserved. This document may not be copied in whole or in part, or transferred to any other
media, without the written permission of Square D.
© 1995 Square D All Rights Reserved
Bulletin No. 50006-524-01A
March 1996
Table of Contents
SCOPE OF MANUAL .......................................................................................................... 2
INSTALLATION .................................................................................................................. 2
Handling & Inspection .................................................................................................. 2
Hoisting......................................................................................................................... 3
Mechanical Installation ................................................................................................ 4
Water Connections ...................................................................................................... 4
Electrical Installation .................................................................................................... 5
Line-side Fuses .................................................................................................... 6
Input Power Connections ...................................................................................... 6
Output Power Connections ................................................................................... 6
Separation of Circuits ........................................................................................... 6
User I/O ................................................................................................................ 7
Weld Control Communications ............................................................................. 7
Operator Interface ................................................................................................. 7
WELD CONTROL COMPONENTS .................................................................................... 8
System Overview ......................................................................................................... 8
Circuit Breaker ............................................................................................................. 8
Isolation Contactor ....................................................................................................... 8
Weld Control Module ................................................................................................... 9
Input and Output Modules ........................................................................................... 9
WRIM Module .............................................................................................................. 9
Control Transformer ..................................................................................................... 9
Firing Board ................................................................................................................. 9
SCR/Power Assembly .................................................................................................. 9
TECHNICAL INFORMATION ........................................................................................... 10
Weld Control Cabinet ................................................................................................. 10
Circuit Breaker ........................................................................................................... 10
Isolation Contactor ..................................................................................................... 10
I/O Modules ............................................................................................................... 11
Input Specifications ............................................................................................ 11
Output Specifications .......................................................................................... 12
WRIM module ............................................................................................................ 13
Introduction ......................................................................................................... 13
Switch Settings ................................................................................................... 14
LED Indicators .................................................................................................... 16
Watchdog Circuitry ............................................................................................. 16
Operation ............................................................................................................ 17
Adjustments ........................................................................................................ 18
User Connections ............................................................................................... 18
Hardware Connections ....................................................................................... 18
Specifications ..................................................................................................... 20
Alarm Detection and Correction ......................................................................... 21
© 1995 Square D All Rights Reserved
1
EQ5300 Weld Control Cabinet
Receiving, Installation, and Specifications
SCOPE OF MANUAL
Bulletin No. 50006-524-01A
March 1996
This manual contains receiving, installation and technical information for the EQ5300 weld
control cabinet. A set of schematics and parts lists containing configuration-specific information is packaged with this manual.
The following EQ5300 weld control manuals are also available:
INSTALLATION
•
EQ5300 Weld Control Module Functions and Specifications, Instruction Bulletin
No. 50006-524-02
•
EQ5300 Weld Control Module Quick Start Guide, Instruction Bulletin No. 50006524-03
•
EQ5300/SFW WELD Quick Reference Guide, Instruction Bulletin No. 50006524-04
The nameplate on the front of the weld control provides the part number and serial number
of the weld control. This part number is referenced on the drawings and part ordering information that are applicable to your weld control. Use it to locate relevant information in
the schematics package that accompanies this manual.
The weld control module inside the cabinet contains nameplate information for the processor itself.
This weld control is designed to be programmed by the C600 handheld programmer, the
C1600 data entry panel, or a computer with DOS based SFW WELD programming software. The data entry device provides the number and revision level of the software that is
currently in use.
Handling & Inspection
The weld control must be thoroughly inspected before installation:
1.
Do not remove the weld control from the shipping pallet until it is at the final installation site. The pallet protects the weld control and prevents damage to its exterior. Handle carefully to avoid damage to the internal components, frame and
enclosure. When handling the weld control enclosure, balance it carefully to keep
it from tipping.
2.
Remove the weld control from its packaging and visually inspect enclosure for
shipping damage.
3.
Make sure weld control nameplate conforms to the packing slip and corresponding purchase order.
4.
Open weld control door.
5.
Verify that all components are properly seated, securely fastened and undamaged.
6.
Verify that all internal wiring connections are tight and connectors are not damaged.
7.
Close and secure the weld control door.
8.
If any shipping damage is found, notify the carrier and your Square D representative.
!
WARNING
INSTALLATION HAZARD.
Do not operate or install any weld control that appears damaged!
Failure to observe this precaution can cause death, severe personal injury, or
equipment damage.
2
© 1995 Square D All Rights Reserved
Bulletin No. 50006-524-01A
March 1996
EQ5300 Weld Control Cabinet
Receiving, Installation, and Specifications
Hoisting
!
WARNING
HANDLING AND LIFTING HAZARD.
Keep area below and around any equipment being lifted clear of all personnel and
property. Use lifting method shown in Figure 1.
Failure to observe this precaution can cause death, severe personal injury, or
equipment damage.
Eyebolts are provided on the top of the enclosure to facilitate handling with hoisting equipment. Use a spreader bar as illustrated in Figure 1.
Figure 1
© 1995 Square D All Rights Reserved
Hoisting the Weld Control
3
EQ5300 Weld Control Cabinet
Receiving, Installation, and Specifications
Mechanical Installation
Bulletin No. 50006-524-01A
March 1996
Follow these guidelines when installing the weld control:
•
Choose an installation location which is compatible with the weld control’s environmental rating. Refer to Table 1 on page 10 for enclosure environmental ratings.
•
The weld control should be mounted in a location that minimizes the external heat
load on the enclosure from radiative or convective heat sources.
•
Allow sufficient space in front of and clearance around the weld control to allow
for door swing and ventilation. Refer to Figure 2 for door clearance. Refer to the
appropriate cabinet drawing for dimensions.
Figure 2
Door Clearance
•
Mount the weld control vertically on a surface capable of supporting its weight.
Use mounting hardware compatible with the application. Refer to the appropriate
cabinet drawing for mounting information.
•
When selecting the weld control mounting height from the floor, personnel access
to the weld control disconnect handle and flange mounted operator controls
should be considered. Be sure to follow applicable code requirements. For dimensions, refer to the appropriate cabinet drawing.
Water Connections
!
CAUTION
OVERHEATING HAZARD.
• Proper flow of cooling water to the SCR/power assembly must be maintained
during operation of the weld control.
• Keep water hose free of kinks.
Failure to provide the proper flow of cooling water can cause equipment damage.
The SCR/power assembly requires cooling water for proper operation. Refer to the appropriate cabinet drawing for location and size of the water fittings, and for allowable water
inlet temperature, flow rate, and pressure requirements.
4
© 1995 Square D All Rights Reserved
Bulletin No. 50006-524-01A
March 1996
EQ5300 Weld Control Cabinet
Receiving, Installation, and Specifications
Electrical Installation
Incoming
480 VAC
Circuit
Breaker
Isolation
Contactor
SCR
To Weld Transformer
Figure 3
EQ5300 Single Pack User Power Connection
Incoming
480 VAC
Circuit
Breaker
Isolation
Contactor
SCRs
XFMR
A
Figure 4
XFMR
B
XFMR
C
EQ5300 3-Pack User Power Connections
© 1995 Square D All Rights Reserved
5
EQ5300 Weld Control Cabinet
Receiving, Installation, and Specifications
Line-side Fuses
Bulletin No. 50006-524-01A
March 1996
All weld controls must have fuses installed in the line-side power wiring. Proper fuse selection is shown on the safety label reproduced below.
!
DANGER
FAULT PROTECTION HAZARD.
• No internal fault protection. Controller must always have fuses installed
externally on line side of circuit breaker.
• Approved fuses: Bussman FRS-400 Fusetron, Bussman 68400 Welder Limiter,
Gould-Shawmut A4BX400 Type 150 Form 480 Welder Protector Amp-Trap,
Gould-Shawmut ATS-DE-400 Amp-Trap and Gould-Shawmut TRS-400 TRIONIC.
• Do not substitute fuses.
Failure to observe this precaution will cause death, severe personal injury, or equipment
damage.
Input Power
Connections
Route incoming weld bus power cabling through the cutouts on the top of the weld control
enclosure. Connect power cabling to L1 and L2 at the top of the circuit breaker. Use proper
bushing or strain relief.
The current ratings of all branch circuit components and equipment (such as bus taps, disconnect devices, fuses and feeder cables) are based upon the following criteria:
•
Maximum 400 A continuous RMS current
•
Weld control application
•
Expected duty cycle of the application
•
Allowable voltage drop of the feeder system
Generally, the conductor ampacity necessary to limit the voltage drop within acceptable
limits is greater than the required ampacity to prevent conductor overheating.
Torque all power connections to the circuit breaker to 300 in-lbs (25 ft-lbs).
Output Power
Connections
Connect the weld transformer cable to U1 of the SCR/power assembly and to V1 of the circuit breaker or the isolation contactor. Weld transformer cabling exits the enclosure through
cutouts on the bottom of the enclosure. Use proper bushing or strain relief.
Separation of
Circuits
Good wiring practice requires the separation of control, communication and power wiring.
This separation reduces the possibility of coupling electrical transients from one circuit
type to another.
Follow these practices when wiring weld controls:
6
•
Power wiring can be run in metallic conduit or metallic cable trays. Metallic conduit is preferred, although metallic cable trays are acceptable.
•
Do not run power, communications or control wiring in the same conduit or cable
tray.
•
Metallic conduits or metallic cable trays carrying control or communications wiring should be separated by at least 4 inches (10 cm).
•
Metallic conduits or metallic cable trays carrying power should be separated from
control and communications wiring by at least 18 inches (45.5 cm).
•
Whenever power, communications or control wiring cross, the metallic conduits or
trays should cross at right angles.
© 1995 Square D All Rights Reserved
Bulletin No. 50006-524-01A
March 1996
EQ5300 Weld Control Cabinet
Receiving, Installation, and Specifications
•
Do not make ground connection to the bus duct case. The ground connection must
be made to building steel.
The voltage and frequency specifications of the input line must match the weld control configuration. Refer to Table 1 on page 10.
User I/O
Several configurations are available for user I/O wiring. Refer to the appropriate ordering
information for I/O wiring configurations. Refer to the appropriate electrical schematic for
connection and wiring information.
Weld Control
Communications
Refer to the appropriate cabinet drawing for specific wiring information.
An EQ5300 communications network is comprised of a physical network similar to RS485
using a proprietary half duplex (two-wire) communication protocol. Other Square D devices or third party devices are not compatible with this network and should not be used without the expressed written consent of Square D Company.
This network allows many ways to interconnect weld controls to a variety of operator interfaces (C600 Hand Held, C1600 Data Entry Panel, SFW WELD programming software)
as well as plant network gateways. Please refer to the EQ5300 Weld Control Communications document for complete details.
Operator Interface
A single, 1/4-turn lock connects the cable to the operator interface. This can be either a
C600 Hand Held Programmer, or a C1600 Data Entry Panel. Refer to “Cable Ordering Information” for cable selection.
© 1995 Square D All Rights Reserved
7
EQ5300 Weld Control Cabinet
Receiving, Installation, and Specifications
Bulletin No. 50006-524-01A
March 1996
WELD CONTROL
COMPONENTS
System Overview
The EQ5300 weld control is comprised of several components. Incoming 480 VAC weld
bus power is routed through a circuit breaker, an isolation contactor, and SCR/power assembly before connecting to the weld transformer. Power is supplied to the internal components via a control transformer connected to the 480 VAC bus. If required, a 24 VDC
power supply driven by the control transformer is also utilized.
The weld control module interfaces to the circuit breaker and isolation contactor via I/O
modules. User I/O can be interfaced via discrete I/O modules and/or a welder remote interface module (WRIM). The weld control module interfaces with the SCR/power assembly
via a firing board.
Control Transformer
Inputs
Outputs
Inputs
Outputs
Power Supply
Circuit
Breaker
Weld
Control
Module
Isolation
Contactor
MemPack
Firing Board
SCR Assembly
Figure 5
EQ5300 Weld Control Cabinet
Circuit Breaker
The circuit breaker provides power disconnect and magnetic overload protection for the
weld control power circuit.
Isolation Contactor
The isolation contactor is an electromechanical switch that interrupts weld bus power to the
SCR/power assembly. Optional.
8
© 1995 Square D All Rights Reserved
Bulletin No. 50006-524-01A
March 1996
Weld Control Module
EQ5300 Weld Control Cabinet
Receiving, Installation, and Specifications
The EQ5300 weld control module is comprised of a power supply, microprocessor board,
analog board (interface to firing board) and MemPack. Programming the weld control module allows it to perform weld control functions such as:
•
Fault monitoring
•
Input/output activity
•
SCR firing
See Instruction Bulletin 50006-524-02, EQ5300 Weld Control Module Functions and Specifications, for the complete description of the weld control module.
Note: Do not store the weld control module with the MemPack installed. This will
cause undue draining of the MemPack battery.
Input and Output Modules
The weld control cabinet can contain several configurations of I/O modules: 24 VDC, 110
VAC, relay or solid state outputs, and/or a welder remote interface module (WRIM). Please
refer to the Order Information/Configuration section at the end of this document and the
appropriate configuration schematics for details.
WRIM Module
The welder remote interface module (WRIM) is a Square D manufactured module that provides the translation between the EQ5300 I/O bus and the Allen-Bradley remote I/O network.
Control Transformer
The control transformer steps the 480 VAC weld bus voltage down to 120 VAC. This voltage is for use as an internal power source for power supplies, inputs/outputs and the weld
control module.
Firing Board
The firing board, sometimes referred to as the contactor interface, resides on the SCR power assembly and controls the interface between the weld control module and the SCR.
SCR/Power Assembly
The SCR/power assembly controls the flow of current to the weld transformer and reads
voltage, current, and chill plate temperature. It is comprised of the firing board, a chill plate
mounted SCR (silicon controlled rectifier), snubber assembly, current transformer, and load
resistors.
© 1995 Square D All Rights Reserved
9
EQ5300 Weld Control Cabinet
Receiving, Installation, and Specifications
Bulletin No. 50006-524-01A
March 1996
TECHNICAL
INFORMATION
Weld Control Cabinet
Table 1
Equipment Specifications
Supply Voltage
480 VAC ±20%, 60 HZ
Temperature
Operating Ambient
Storage
0 to 60 °C (32 to 140 °F)
0 to 70 °C (32 to 158 °F)
Humidity
Operating Relative
Operating Absolute
5 to 95% non condensing
1 to 29 g/m3
Circuit Breaker
Refer to Square D Instruction Bulletin 48049-034-02 for installation information.
Isolation Contactor
Refer to Telemecanique Instruction Bulletin W9 135 5817 01 21 for LC1F15 . . . F630 Contactors for complete information.
10
© 1995 Square D All Rights Reserved
Bulletin No. 50006-524-01A
March 1996
Table 2 provides technical specifications for the input modules.
Table 2
Input Specifications
Unit name
8 Function DC Input Module (Sink type)
Type No.
DN-108
Rated input
24 VDC
Input voltage range
10 V to 30 VDC
No. of inputs
8 points/module (one common connection per 8 points)
Input current
10 mA/point (at 24 VDC)
Input impedance
2.3 k¾
Turn on time
7 msec maximum
Turn off time
11 msec maximum
Must turn on voltage
10 VDC
Must turn off voltage
3 VDC
Must turn on current
4.10 mA at 10 VDC
Must turn off current
0.98 mA at 3 VDC
Input indication
LED indication
Common polarity
Common terminal . . . . . (-)
Internal current draw
20 mA maximum
Isolation mode
Photocoupler (1,500 V RMS / 1 minute)
Circuit configuration
IN7
Internal Circuit
IN0
COM(-)
Contact input
(+)
4
(-)
Contact input
1
2
Transistor output
device
(Open collector)
DC Input (Sink)
5
No-contact input
3
(OUT)
6
7
Terminal screw: M3.5
Unit weight: Approx. 120 g (0.26 lbs)
NC
External wiring example
External power
supply 24 VDC
(+)
(-)
0
Input
Specifications
COM(-)
I/O Modules
EQ5300 Weld Control Cabinet
Receiving, Installation, and Specifications
Note: NC (No Connection) - Do not connect input and other wiring.
© 1995 Square D All Rights Reserved
11
EQ5300 Weld Control Cabinet
Receiving, Installation, and Specifications
Output
Specifications
Bulletin No. 50006-524-01A
March 1996
Table 3 provides technical specifications for the output modules.
Table 3
Output Specifications
Unit name
8 Function Relay Output Module
Type No.
RT-108
No. of outputs
8 points/module
Output signal
Relay output, Independent 1NO. Relay can be replaced.
120 VAC, 4.5 A (240 VAC, 2 A) cos φ = 1
(Each relay unit can be replaced with a transistor or SSR output.)
Output indication
LED indication
Internal current draw
150 mA
Internal Circuit
Circuit configuration
Ry
Ry
External wiring example
Terminal screw: M3.5
Unit weight: Approx. 250 g (.55 lbs.)
Load
power
supply
c
c
a
0 1 2 3 4 5 6 7
Relay Output
a
L
L
12
© 1995 Square D All Rights Reserved
Bulletin No. 50006-524-01A
March 1996
EQ5300 Weld Control Cabinet
Receiving, Installation, and Specifications
WRIM module
Introduction
The welder remote interface module (WRIM) is compatible with the Allen-Bradley 1771
remote I/O link. It allows the EQ5300 weld control module to communicate with various
Allen-Bradley programmable logic controllers.
When using the WRIM with an Allen-Bradley 1771 remote I/O link, only one cable is required. The WRIM maps the weld control module inputs and outputs to the PLC without
racks, I/O modules, or other adapters.
All Allen-Bradley remote I/O standards are supported:
•
1/4, 1/2, 3/4 or full rack simulation
•
Communication at 57.6 KBaud, 115.2 KBaud, and 230.4 KBaud
•
Rack addressing is switch selectable
•
Hold last state
•
Processor restart lockout
•
Green status LED
The WRIM interfaces with the I/O bus of the EQ5300 weld control module and converts it
to an Allen-Bradley remote interface (“blue hose”). To the Allen-Bradley PLC, the WRIM
is functionally identical to two 16-bit output cards and two 16-bit input cards.
Up to three host weld control modules can be supported by a single WRIM. To each of the
host weld control modules, the WRIM is functionally identical to two 8-bit output modules
and two 8-bit input modules.
The WRIM performs three primary functions:
•
Allows an Allen-Bradley PLC to provide logical control signals to each weld control module and to receive logical status information from each weld control module without the use of discrete I/O. The I/O mapping between the two interfaces is
fixed.
•
Provides logical interpretation and support for auxiliary I/O, also known as local
I/O.
•
Sources the cabinet keep-alive strobe signal through the local output module.
The WRIM also supports an RS485 service port, to be used only by Square D authorized
personnel.
J4 - Local I/O
J8 - Service Port
S2 - Switch 2
WRIM
Welder Remote Interface Module
Assembly 52045-042
S1 - Switch 1
LED Indicators
J6 - Weld Control
Module C
S3 - Service Port
Terminator
J7 - User Connections
J5 - Weld Control
Module B
J3 - Weld Control Module A
Figure 6
Switch Settings
Welder Remote Interface Module
Communication Rate
(S2 - #7, #8)
© 1995 Square D All Rights Reserved
The proper settings for the WRIM communication
data rate are determined by the PLC network configuration.
13
EQ5300 Weld Control Cabinet
Receiving, Installation, and Specifications
14
Bulletin No. 50006-524-01A
March 1996
Hold Last State
(S2 - #6)
This is used in conjunction with Processor Restart
Lockout to determine the outputs’ state at the time of
losing communications with the PLC, or when the
WRIM has been disabled by the PLC. To have the outputs hold the last data processed before the loss of
communication, turn Hold Last State ON. To have the
WRIM outputs disabled, turn Hold Last State OFF.
Processor Restart Lockout
(S2 - #5)
This is used with Hold Last State to establish the restart criteria when the PLC stops communicating with
the WRIM, or the WRIM has been disabled by the
PLC. To have the PLC automatically re-establish communications, turn Processor Restart Lockout OFF. To
require the control to be power cycled, turn Processor
Restart Lockout ON.
I/O Rack Size
(S2 - #3, #4)
This determines the size of the rack that is emulated by
the WRIM.
Last Rack
(S2 - #2)
(PLC2 only) Turn ON to indicate the WRIM is the last
rack in the drop.
I/O Rack Number
(S1 - #1 TO #6)
These settings determine the I/O rack number for the
WRIM interface and are dependent on the PLC that is
used.
Service Port Enable
(S2 - #1)
This is used to enable or disable the service port and
should be in the OFF position for normal operation.
Starting Quarter
(S1 - #7, #8)
The proper settings for the starting quarter (S1 - #7,
#8) are determined by the PLC physical installation.
© 1995 Square D All Rights Reserved
Bulletin No. 50006-524-01A
March 1996
EQ5300 Weld Control Cabinet
Receiving, Installation, and Specifications
OFF 7
57.6K
8
ON
OFF 8
OFF 7
OFF 8
ON
8
7
ON
7
ON
115.2K 230.4K
230.4K
Data Rate
Hold
Last State
Don’t Hold
Last State
OFF 6
S2
8
7
6
5
4
3
2
1
OFF 5
ON
OFF 3
ON
4
3
ON
3
Last Rack
2
ON
Normal Operation Service Port
WRIM Switch 2 Settings
OFF 8
OFF 7
0
1st
8
7
6
5
4
3
2
1
ON
8
OFF 7
2
2nd
OFF 8
ON
8
7
ON
7
ON
4
3rd
6
4th
Starting
Quarter
1
2
4
8
16
32
© 1995 Square D All Rights Reserved
Full
OFF 4
ON
OFF 3
OFF 2
Figure 8
5
4
Not
Last Rack
S1
ON
Rack Size
1/2
3/4
1/4
OFF 4
Figure 7
6
Processor
Lockout
Processor
Restart
OFF 1
ON
1 - 6 Binary Select
I/O Rack #
WRIM Switch 1 Settings
15
EQ5300 Weld Control Cabinet
Receiving, Installation, and Specifications
LED Indicators
Bulletin No. 50006-524-01A
March 1996
WRIM Processor Status
GREEN
RI/O Status
OFF - no communication
ON - communications established
Flashing - commands being received in program mode
Indicates the state of the WRIM processor.
RED
Watchdog Circuitry
Indicates the state of the PLC remote I/O communications link.
Off - Normal operating mode
ON - WRIM processor error
Flicker - service port in use
The WRIM controls the isolation contactor and circuit breaker shunt trip through the local
I/O. The WRIM receives power and timing signals from weld control module A (see Figure
8). If weld control module A fails, the WRIM would fail to monitor the state of the isolation
contactor and provide a shunt trip. Because of this, weld control module A provides a keepalive signal by toggling a local I/O point to an Underspeed Control Relay. The weld control
cabinet’s Underspeed Control Relay has a built-in watchdog function, which causes the relay to trip the circuit breaker if the keep-alive signal falls below a certain adjustable frequency. If the relay fails to receive the keep-alive strobe, the relay de-energizes.
The delay between the time that power is applied to the Underspeed Control Relay and the
time that the relay is energized is measured to be 17.15 ms worst-case. An ON-Delay relay
is employed in series with the Underspeed Control Relay to guarantee that weld control
module A is providing the keep-alive signal before energizing.
Figure 9 illustrates the configuration of the cabinet watchdog function.
16
© 1995 Square D All Rights Reserved
Bulletin No. 50006-524-01A
March 1996
EQ5300 Weld Control Cabinet
Receiving, Installation, and Specifications
EQ5300
Weld
Control
Module “A”
WRIM
STROBE
1 2 3 4 5 6 7 8
CLOCK
DATA
INPUTS
DATA
ENABLE
DATA
DATA
12 V
OUTPUTS
12 V RTN
1 2 3 4 5 6 7 8
Underspeed Control Relay
Sense
Input
120 V
Input
+24 VDC
Supply
+
L1
24 V
Input
120 VAC
-
L2
“Cabinet keep alive”
signal
ON-Delay Relay
120 V
Input
Circuit Breaker
SHUNT
TRIP
Figure 9
Operation
Cabinet Watchdog Function
This configuration requires that the following circuitry MUST be fully operational for the
cabinet to remain powered up:
•
IDEC interface of weld control module A
•
12 V supply of weld control module A
•
Local I/O interface of WRIM
•
Processor of WRIM
•
Relay #4 of the local I/O block
If, at any time, any of these functions fail, the Underspeed Control Relay causes the circuit
breaker to be shunt tripped.
If a mechanical relay output block is used, a constant clicking will be heard with a frequency of 1 Hz (one second) from inside the cabinet during normal operation. This noise is the
cycling of relay #4 of the local I/O modules as it is used to toggle the sense input of the
Underspeed Control Relay.
© 1995 Square D All Rights Reserved
17
EQ5300 Weld Control Cabinet
Receiving, Installation, and Specifications
Bulletin No. 50006-524-01A
March 1996
Adjustments
No user adjustments are required. These are all set at the factory.
User Connections
The Allen-Bradley remote I/O connections are made at connector J7 of the WRIM:
J7 Pin
Connection
8
Blue
9
Shield
10
Clear
A termination resistor should be installed on the WRIM if it is the last remote I/O drop on
the physical communications cable. It is connected across pins 6 and 7 of J7. The value of
the resistor should be as follows:
Hardware
Connections
Comm Rate
J7 - 6, 7
Resistor value
57.6 KBaud
150 Ohm
115.2 KBaud
150 Ohm
230.4 KBaud
82 Ohm
Table 4
Pin
Connector J7 - 10-PIN Phoenix (User Connections)
Connection
1
24 V Return
2
+24 VDC
3
Chassis/Earth Ground
4
5
6
Termination Resistor-Allen-Bradley interface
7
Termination Resistor-Allen-Bradley interface
8
“Blue” lead of 1771 interface
9
“Shield” lead of 1771 interface
10
“Clear” lead of 1771 interface
Table 5
Pin
18
Connector J8 - 5-PIN Phoenix (Service Port)
Connection
1
RS422
2
RS422
3
Shield
4
RS422/485
5
RS422/485
© 1995 Square D All Rights Reserved
Bulletin No. 50006-524-01A
March 1996
EQ5300 Weld Control Cabinet
Receiving, Installation, and Specifications
Table 6
Pin
Connector J3 - Weld Control Module A
Connection
1
12 V Return
2
Data Clock from weld control module
3
12 VDC Return
4
Strobe Signal
5
12 VDC Supply
6
Enable Signal
7
12 VDC Supply
8
Data Output
9
Chassis Ground
10
Data Output
Table 7
Pin
Connection
1
Data Output
2
Chassis Ground
3
Data Input
4
12 VDC Supply
5
Enable Signal
6
12 VDC Supply
7
Strobe Signal
8
12 VDC Return
9
Data Clock
10
12 VDC Return
Table 8
Pin
Connector J4 - Local I/O
Connector J5 - Weld Control Module B
Connection
1
12 V Return
2
Data Clock from weld control module
3
12 VDC Return
4
Strobe Signal
5
12 VDC Supply
6
Enable Signal
7
12 VDC Supply
8
Data Output
9
Chassis Ground
10
Data Input
© 1995 Square D All Rights Reserved
19
EQ5300 Weld Control Cabinet
Receiving, Installation, and Specifications
Bulletin No. 50006-524-01A
March 1996
Table 9
Pin
Connector J6 - Weld Control Module C
Connection
1
12 V Return
2
Data Clock from weld control module
3
12 VDC Return
4
Strobe Signal
5
12 VDC Supply
6
Enable Signal
7
12 VDC Supply
8
Data Output
9
Chassis Ground
10
Data Input
Specifications
Table 10
Parameter
Specifications
Spec
Min
Typ
Notes
Max
Units
Deg. C
Size
4.1" x 8.54"
Operating Temp
0
60
32
140
Deg. F
Storage Temp
-40
80
Deg. C
-40
20
176
Deg. F
Input Voltage
19
24
30
VDC
Input Current
50
150
1000
mA
© 1995 Square D All Rights Reserved
Depending on accessory board and
peripherals used
Bulletin No. 50006-524-01A
March 1996
Alarm Detection and
Correction
EQ5300 Weld Control Cabinet
Receiving, Installation, and Specifications
If problems arise while using the WRIM, one of the following errors may have occurred.
Follow the steps outlined on the following pages to isolate and solve the problem.
Problem: No RI/O communications
Symptoms: Green LED always OFF
1.
Probable Cause: Reversed connection on connector J7 of the WRIM.
Recommended Solution: Make sure the cable is connected with the blue lead on
pin 8, the shield on pin 9, and clear lead on pin 10.
2.
Probable Cause: Incorrect Data Rate setting.
Recommended Solution: Make sure that the settings of S2 - 7, 8 match the Data
Rate setting on the PLC.
3.
Probable Cause: Incorrect First I/O Group setting.
Recommended Solution: Make sure that S2 - 7, 8 are set properly as determined
by the PLC configuration.
4.
Probable Cause: Incorrect I/O Rack Number setting.
Recommended Solution: Make sure that S1- 1 to 6 are set properly.
5.
Probable Cause: Incorrect setting of the switches for Last Rack and Rack Size.
Recommended Solution: Check the settings of S2 - 2, 3, 4.
Problem: Synchronization difficulty.
Symptom: Green LED intermittently ON.
1.
Probable Cause: Missing termination resistor.
Recommended Solution: Check J7 for the presence of the termination resistor.
Make sure it is in the correct position.
2.
Probable Cause: Incorrect termination resistor value.
Recommended Solution: Make sure that the termination resistor being used
matches the requirements.
© 1995 Square D All Rights Reserved
21
EQ5300 Weld Control Cabinet
Receiving, Installation, and Specifications
Bulletin No. 50006-524-01A
March 1996
Problem: Unintelligible transmit data.
Symptom: Green LED flashing.
1.
Probable Cause: PLC is in program mode.
Recommended Solution: Check the PLC to make sure it is in the correct operating
mode.
2.
Probable Cause: Reversed connection on connector J7 of the WRIM.
Recommended Solution: Make sure that the cable is connected with the blue lead
on pin 8, the shield on pin 9, and clear lead on pin 10.
Problem: WRIM Error.
Symptom: Red LED ON.
1.
Probable Cause: WRIM is in test or service mode.
Recommended Solution: Ensure that S2-1 is in the OFF position, then cycle power
to the EQ5300 cabinet.
22
© 1995 Square D All Rights Reserved
Bulletin No. 50006-524-01A
March 1996
EQ5300 Weld Control Cabinet
Receiving, Installation, and Specifications
© 1995 Square D All Rights Reserved
23
EQ5300 Weld Control Cabinet
Receiving, Installation, and Specifications
Bulletin No. 50006-524-01A
March 1996
Electrical equipment should be serviced only by qualified electrical maintenance personnel. No responsibility is assumed by Square D for any consequences arising out of the use of this material.
© 1995 Square D All Rights Reserved