WS98-4000

Programming
Software Manual

Manual Version 1.06

Part Number 91-00-35
British Federal Ltd.,
Castle Mill Works,
Birmingham New Road,
Dudley,
West Midlands,
DY1 4DA.

Telephone : 01384 455400

Fax: 01384 455554
Fax: 01384 455554
WS98-4000 Manual Contents

Contents
INTRODUCTION 4

INSTALLING WS98-4000 5
Microsoft® Windows NT© 5
UNINSTALLING WS98-4000 5

HELP SYSTEM 6
Back/Forward 6
Hide/Show 6
Print 6
WS98 SETUP 7
COMMUNICATIONS 7
Local Communications 7
Selecting a COM port 7
Network Communications 7
Status Scan Window 8
Electrode Scan Window 8
Line Layout 9
SECURITY 12
Setting up the Security Features 12
LOCK 15
SCAN 16
TRANSFERRING DATA 19
LOADING DATA 19
SAVING DATA 19
CONFIGURING THE TIMER 20
CONFIGURATION PARAMETERS 20
Operating Mode 20
Welding Mode 20
Retract Mode 21
I/O Mode 22
Frequency 22
Language 22
Pressure Monitor 22
Wait for Pressure 22
2nd Stage 22
EOS Trigger 22
EOS Duration 22
Nominal Voltage 22
Contactor Delay 22
Exhaust Time 22
Max Retries 22
Max Weld Time 22
Heat Trim 23
Software version 23
Gun 1 Enabled 23
Gun 1 Monitoring 23
Gun 1 Toroid Test 23
Gun 2 Enabled 23
Gun 2 Monitoring 23
Gun 2 Toroid Test 23
Fieldbus 23

1
WS98-4000 Manual Contents

I.P. 23
Actual Primary Current 23
Block Sequence 23
MF Calibration 24
Printing 24
PROGRAMMING A WELD 25
W ELD PROGRAM 25
Program 25
Gun 25
Electrode 25
Type 25
Mode 25
Inhibited 25
SEQUENCE TIMING 26
Presqueeze 26
Squeeze 26
Weld 1 26
Cool 1 26
Weld 2 26
Cool 2 26
Cool 3 26
Weld 3 26
Pulsations 26
Hold 26
Off 26
1st Delay 27
2nd Delay 27
PRESSURE 27
Demand 27
Force Calibration 27
HEAT/CURRENT 28
Heat 28
Current 28
KSR 28
SLOPE CONTROL 28
Upslope 28
Downslope 28
Start 29
Finish 29
MONITORING 29
PHA Monitoring 29
Auto-Repeat 29
High Limit 29
Pre Limit 29
Low Limit 30
Conditional Fails 30
Heat Pre-limit 30
Heat Limit 30
ELECTRODE 30
Stepping 30
Dressing 30
Force Stepping 30
Spots per Component 30
Prewarning 30
Total Spots 30
Dressing Point 30
Dressings 31
Reset Point 31
Point on the Curve 31

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WS98-4000 Manual Contents

Dress Count 31
Toroid Sensitivity 32
STEPPER 32
Curve 32
Mode 32
Offsets 32
Defining a Curve 32
Import 32
Printing 32
TIP DRESSING PROGRAMMES 34

STATUS 35
Status Message 35
Inputs 35
Outputs 35
Fixed I/O 36
Discrete Inputs 36
Discrete Outputs 36
Mode 36
Electrode Status 36
Datalog 36
Body Cycle Log 36
Half Cycle Log 37
Control Functions 37
OTHER FEATURES 38
CROSS REFERENCE 38
WS98 FILES 38
Log File 38
Action File 38
Audit File 38
Filter File 38
Printing 39
SYSTEM EXPLORER 39
FLASH W IZARD 39
COPYING PROGRAMMES 40
BACKUP W IZARD 41
Auto Archive 42
RESTORE W IZARD 42
EXCHANGING DATA WITH WS98-4000 44
IMPORT W IZARD 44
EXPORT W IZARD 44

3
WS98-4000 Manual Introduction

Introduction
WS98-4000 is a Windows 98® compatible programming system that can be used to examine
and modify data in one or more WS4000 series welding controls.

WS98 uses the Windows Multiple Document Interface (MDI). The “document” refers data
obtained from a disk based file or from a WS4000 Local (RS-232) connection, or a Network
(ControlNet) connection.

The MDI architecture allows a virtually unlimited number of documents to be opened from any
combination of disk or communications port.

The document is the information, but this data is of little use unless we can see it. WS98
provides several 'views' onto the document. The primary view is the Programming View,
which shows all the data for one weld program; this view can be used to access all weld
parameters. Secondary views include a Status View, which shows the condition of the
welding control and there is also a Cross-Reference View which shows all the data in tabular
format.

A certain level of Windows knowledge is assumed in this manual.

Microsoft, Windows 95/98 and Internet Explorer are all registered trademarks, and are
copyright of 1985 – 1998 Microsoft Corporation

4
WS98-4000 Manual Installing WS98-4000

Installing WS98-4000
WS98 is shipped on CD-ROM.

Start Windows and open File Manager or Explorer. Read the folder for the CD drive and
double click on SETUP.EXE. The WS98 installation programme will begin. Follow the
instructions on the screen.

When installation is complete, the Setup programme will have created a British Federal folder,
containing WS98, in the Accessories folder of Program Files. You can make a short-cut to
WS98 by right-clicking on WS98.exe and then clicking “Create shortcut” on the menu
produced. The shortcut icon, thus produced, can then be dragged onto the desktop screen
and renamed.

WS98-4000 contains a number of system DLLs which are replaced if they are older than the
versions on the CD-ROM. These DLLs are:
MFC42.DLL
MSVCRT.DLL
MSVCIRT.DLL
COMCTL32.DLL
DT32.DLL
FMS32.DLL
ISP32.DLL
S7ONLINX.DLL
The DLLs are stored in the WS98 directory.

WS98 is compatible with Windows 95+Internet Explorer 4 or Windows 98. If you have only
Windows 95, you should install Internet Explorer 4 or replace the file COMCTL32.DLL in your
System directory with the one supplied with WS98. You can only do this after rebooting your
machine in MS-DOS mode.

Microsoft® Windows NT©

WS98 is compatible with Microsoft® Windows NT© version 4 Build 1381:Service Pack #4.
This is the minimum NT requirement. You should also install Internet Explorer 4 before
installing WS98.

Uninstalling WS98-4000
To remove WS98-4000 from your computer, click - My Computer
Control Panel
Add/Remove Programs.

In the Install/Uninstall screen highlight British Federal WS98-4000 by clicking on it.

Click Add/Remove.

Click OK.

WS98-4000 will be removed from your system.

5
WS98-4000 Manual Help System

Help System
Help with working any part of WS98 can be obtained from the built-in Help System. The Help
System is started by clicking the Help button. This will open a Help screen showing a list of
Help topics.

The opening screen

has Contents and
Index tabs. The
Contents tab gives a
list of topics in the left
hand side of the
window. When clicked,
the help for the topic
appears on the right
hand side of the
window. Underlined
text is a link to another
help topic. To reach the
other topic, click on the
underlined text.

The Index tab gives a

list of keywords. If a
keyword is highlighted,
the help can be
obtained by clicking on
Display, at the bottom
of the window, or
double clicking the
highlighting. A keyword can be highlighted directly by scrolling down the list until it is found,
and then clicking on it, or it can be typed into the keyword box at the top of the window.

Help on the active window can also be obtained by pressing F1.

Back/Forward
Progress through a number of links can be reversed using the Back button. Each time it is
clicked the route through the links is retraced by one stage.

This function can also be reached through the Options menu. Also available through the
Options menu is Forward. This progresses through the links by one stage.

Hide/Show
When Help is started, the left hand side of the window, that provides the route to the
information, is visible. When the help information is being displayed in the right hand part of
the window, the left hand part can be hidden by clicking the Hide button.

If the left hand part of the window is hidden, the Hide button becomes a Show button. If this is
clicked the left hand part of the window re-appears.

These functions can also be reached through the Options menu as Hide Tabs and Show
Tabs.

Print
The help information can be printed by clicking the Print button.

6
WS98-4000 Manual WS98 Setup

WS98 Setup
It is necessary to setup WS98 to operate in the required way. There are three sections to
configure:
• Communications
• Security
• Scanning

Clicking Setup produces a menu with these three options. Alternatively the options are
directly available on the toolbar. This must be done before prior to editing data.

Communications
Local Communications
WS98 can communicate with a single WS4000 via the computer's RS-232 port. This requires
a connecting lead between the WS4000 and the computer. The computer's RS-232 port will
be assigned to a COM port, usually COM1 or COM2. WS98 can be configured to use any
COM port from COM1 to COM4.

In accordance with the RS-232 specification, this link is only recommended for distances of
less than 50m.

Selecting a COM port

• Select Communications from the Setup menu.
• Select the required COM port.
• Check the Local enabled box.
• Click OK or Apply.

All communications are initiated by WS98. If the WS4000 does not respond to the request,
WS98 aborts the communication and issues an error message.

Network Communications
WS98 can use a network link to communicate with several WS4000 timers.

WS98 supports a number of networks:

• ControlNet® Requires a Rockwell/Allen-Bradley 1784KTCX15 B PC card
• Profibus FMS® Requires a Siemens CP5412-A2 PC card
• Ethernet® Requires a Microsoft Windows-compatible PC card

To enable the Network communications, select Communications from the Setup menu and
use the Connections tab.

Enable the required network by checking the box next to it then select OK or Apply.

7
WS98-4000 Manual WS98 Setup

Ethernet requires IP addresses to be set up for each timer on the network. Click the Ethernet
tab to do this. Then highlight the timer to b e addressed , type the address into the IP Address
box and click Apply.

Each network card has its own unique setup which must be completed successfully before
WS98 can use the card. Refer to the card documentation for details on setting up the card.

Status Scan Window

Status Scan is available only to a networked system. If this box is ticked the Status Scan
window opens when WS98 is started and shows information on all the active addresses on
the network

Individual conditions or a selection of conditions can be reset by clicking on them and then
clicking Reset. If all conditions are to be reset, simply click Reset.

Electrode Scan Window

Electrode Scan is available only to a networked system. If this box is ticked the Electrode
Scan window opens when WS98 is started and shows the advancement of all the electrode
programmes.

The electrode advancement is represented by bar graphs. The graphs are colour coded as
below:
Green Stepper in progress
Brown Tip dress request reached
Orange Prewarn reached
Red End of electrode life reached

Electrodes can be reset individually or as a selection, by clicking on them, then clicking Reset.
Electrode areas, if set up, can be reset by clicking Areas, selecting the area in the Areas
screen, then clicking Reset.

The electrodes can be shown in order of address or in order of % complete.

8
WS98-4000 Manual WS98 Setup

Line Layout
If the network is enabled, the Line Layout window allows representation of the working area in
a graphical format. Images can be used and links to addresses and programmes created.

To enter Line Layout

• Click Communications in the Setup menu
• Enable Network communications
• Check the Line Layout box
• Click OK

Line Layout has a hierarchy that allows navigation from a production line view, down to
individual spot welds on components.

Line Layout View

The Line Layout view is the top level view, and contains 10 configurable zones. It can be
customised to graphically represent the line layout.

• Right click on background of Line Layout view.

• Select New Background then use the browser to locate the bitmap image required for the
background.
• Drag the zone icons to appropriate positions on the background image.
• Rename, if necessary, the zone icons by right clicking on them and selecting Rename.

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WS98-4000 Manual WS98 Setup

Zone View
Each zone represents a working area with a number of timer addresses. The zone views
show the working areas for a number of addresses. It is not necessary to use all the zones, if
not required.

• To set up a zone view, double click on it’s icon in the Line Layout view.
• Right click on the background of the zone view.
• Select New background and use the browser to locate the bitmap image to be used for
the background.
• To add timer addresses to zone
• Right click on the zone background and select Add Address.
• Select one or more addresses from the dialogue box and select OK (Addresses
will only appear in the dialogue box if already selected in Active Addresses – see
section on Scan (Stations tab).
• Drag the addresses to the appropriate positions in the zone.
• To change the icons of the addresses
• Right click on the address icon and select Change Icon.
• Select an icon from the menu.
• Weld programmes can be accessed by double clicking on the address icon, then double
clicking the programme.
• Icons can be deleted by right clicking on them and selecting Delete.

The same addresses can appear in a number of zones. When the zone view represents a
working area, component views can be added to the addresses.

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WS98-4000 Manual WS98 Setup

Component View
The Component View shows the physical locations of spot welds on an image of the
component for an address.

• Right click on the address icon.

• Select Component.
• Right click on the background of the Component View.
• Select New Background and use browser to locate component image for background.
• Add some spot welds to the component.
• Right click on the component background and select Add Spot.
• Select one or more weld programmes from the list and select OK.
• Drag the spots to the appropriate positions on the component.
• Data for the spot weld can be accessed by clicking on it.
• A spot weld can be deleted by right clicking on it, then selecting Delete.
• The same spot can appear any number of times on the component.

Line Layout and Status Scan Interaction

The Line Layout interacts with the Status Scan window, if it is enabled. As conditions are
detected by the Status Scan, the icons on the Line Layout view and Zone views are colour
coded to indicate a fault condition.

In the Status Scan window, double click on a message to show the Zone view to which the
address belongs.

In Line Layout view, right click on a zone and select Status, to show the messages for all the
addresses in the zone.

In Zone View, right click on an address and select Status to show the messages for the
address.

11
WS98-4000 Manual WS98 Setup

Security
WS98 provides three levels of security.
• Supervisor
• Superuser
• User

A Supervisor has complete access to all parts of WS98.

A Superuser has complete access to all parts of WS98 except the security settings. An
access timeout applies.
A User has limited access to WS98. The User’s access is defined by a Supervisor. An access
timeout applies.

It must be emphasised that security is applied to the WS98 software and not to the WS4000
Control. Security may be implemented on WS98 controlling a network, but this does not
prevent access to a control using a laptop or a programming pendant.

Setting up the Security Features

To set up the Security features, either click Security in the Configuration menu or click the
Security button on the toolbar. Security starts with the Supervisor screen.

Enable Security by ticking the Security enabled box.

Supervisors
Setup Supervisors by entering a password and a name for each supervisor. The system will
check that each password, as it is entered, is unique. Click Apply

When a Supervisor gains access to WS98 using a password, the name of the Supervisor, but
not the password, appears at the bottom of the WS98 window.

12
WS98-4000 Manual WS98 Setup

Superusers
Set up the Superusers by clicking the Superusers tab on the security screen.

Enter a password and a

name for each supervisor.
The system will check that
each password, as it is
entered, is unique. Enter a
Timeout. Click Apply.

When a Superuser gains

access to WS98 using a
password, the name of the
Superuser, but not the
password, appears at the
bottom of the WS98
window. If a period of
inactivity exceeds the
Timeout time the system
will require the password
to be re-entered. (This is
to help protect the
Superuser against
unauthorised changes
being made during his
absence.)

Users
Set up the Users by clicking the Users tab on the security screen.

This screen allows each User name, password and timeout to be entered. (The timeout is to
help protect the User against unauthorised changes being made during his absence.)

Each User must belong

to a Group. Each Group
has it’s own specifically
defined access.

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WS98-4000 Manual WS98 Setup

Groups
On the Security screen click
the Groups tab.

To define the access each

member of a group will have,
click on the Group to be
programmed in the upper part
of the widow. It will become
highlighted. In the next
window down type the name
you wish to give that Group.
(As you do this it will also
appear in the upper window.)
Define the access by ticking
the Read or Write boxes next
to the categories.
• If R is ticked the section
will appear greyed out and
values can not be edited.
• If W is ticked the section
will appear, and can be
edited.
• If neither box is ticked, the
section does not appear.

Assignments
To assign Users to a Group go to the Security screen and click the Assignments tab.

In the upper part of the

Assignments window
select the Group to which
you want to make
assignments. To add
Users to this group, make
a selection of Users from
the “Available users” list
on the left. Click Add. The
selected Users will be
transferred from the
“Available users” list to the
“Users in group” list.
Users can be removed
from a Group and returned
to the “Available users” list
by selecting them in the
“Users in the group” list
then clicking Remove.

14
WS98-4000 Manual WS98 Setup

Key Disks
A User may have access to WS98 either via password or a Key Disk. A Key Disk removes the
need to memorise a password.

To create a Key Disk for a user, go to the Security screen and click the Key Disks tab. On the
Key Disk window, highlight the User requiring a Key Disk and click Build. A formatted floppy
disk will be required in the a: drive. This will become the Key Disk.

Backup/Restore
A backup file of the security settings can be made for archive purposes or to transfer the
settings from one computer to another.

In the Security screen click Backup/Restore.

To create a backup click “Backup the security settings to:”, then click Browse to select a
destination for the backup file. Type in a name for the backup file and click Save. The Browse
window will close and return to the Backup/Restore window. Click Backup. A backup file will
be created with the specified name and in the specified location.

To restore the security settings from a Backup file, click “Restore security settings from:” Click
Browse and locate the Backup file. Highlight it and click “Open”. The Browse window will
close and the Restore/Backup window will reappear. Click Restore.

Windows will have to be restarted to bring into effect the restored data.

Lock
If Security is enabled and Lock is operated, WS98 will require a password to “unlock” the
system and allow further use.

15
WS98-4000 Manual WS98 Setup

Scan
The Scan window is used to
configure the Status Scan
and Electrode Areas, it is
also used to backup/restore
Electrode Areas and
programme/timer names.
The Status Scan is a
function of WS98 that gets
status information from each
timer on the network. An
Electrode Area is a group of
electrodes, possibly from a
number of timers, that are
used together in the same
area or to produce the same
component, and would
require resetting at the
same time.

Click the Scan icon on the

toolbar, or click Scan in the
Configuration menu.

Filter File
The Scan window will open
with the Filter File. This file
contains every error message that can be produced by a timer. Each error message has
either a tick or a cross next to it If a message has a tick it will be reported by the Status Scan
when that error occurs. If a message has a cross, it will not be reported if that error occurs.
Click on a cross or tick to change it, then click Apply.

A Filter File, called WS98 Filter File.txt, containing a log of the filtered error messages, is kept
in the Windows directory. The name and/or location of this file can be changed using the
browser.

Display
The Display tab sets the way
in which programmes are
displayed by WS98-4000.
This has no effect on the
data in the timer.

16
WS98-4000 Manual WS98 Setup

Stations
The timers to be accessed by
WS98 are identified in the
Stations window.

In the Scan window, click the

Stations tab. A list of all
possible addresses is given.
Addresses to be included in
the scan have tick. Addresses
to be excluded from the scan
have a cross. Click on a tick or
cross to change it, then click
Apply.

The System Explorer part of

the window selects how the
System Explorer displays
programme groups. (See
section on System Explorer.)

Names
Names can be given to timers
and programmes for
identification purposes.

To name a timer click on the

Names tab – the screen to the
right will be shown. Click on
the station to be named
(provided it has been selected
as an active address using the
“Stations” tab). It will become
highlighted. Click on the
highlighted address and when
a box appears around it, type
in the new name, then click the
icon to the left of the box. The
new name will have been
entered.

A timer can only have one

name.

To name a programme click

!""next to the timer
address/name. The tree of programmes and groups belonging to it will open. Right click the
prog/gun to be named. Select New Name from the menu that opens, and type the name into
the box that appears. Click OK.

The prog/gun will then have a ! to the right of it. Click this and the name or names
associated with that programme will appear.

A programme may have a number of names.

17
WS98-4000 Manual WS98 Setup

To delete a name, click on it and wait for the box to appear around it, as though to change
the name, then press Delete.

To delete all the names associated with a programme, right click the programme name and
select Delete all Names from the menu.

To identify a timer or programme from a name, click the drop-down arrow to the right of
the Locator box. Click on the name you want to locate, and the display beneath the locator
will highlight it’s location in grey.

Electrode Areas
An Electrode Area is
defined in terms of
electrode programmes and
associated timer
addresses.

Select the area to be

created or edited by
clicking on it’s name in the
“Areas” part of the window.
In the “Electrodes” part of
the window click !"next to
the timer address
controlling the electrodes.
This will cause the list of
electrodes for that address
to be presented. Select the
electrodes to be included in
the group and then click
Add. The selection will
move to the “Electrodes in
the area” part of the
window. Continue this
process until all the
required electrodes are added to the area. Electrodes can be removed from the area by
selecting them and then clicking Remove.

When the area is defined, click Apply.

Backup/Restore Areas

A backup file of the Electrode Areas can be made for archive purposes or to transfer the
settings from one computer to another.

In the Scan screen click Backup/Restore Electrode Areas tab.

To create a backup click “Backup the electrode areas settings to:”, then click Browse to select
a destination for the backup file. Type in a name for the backup file and click Save. The
Browse window will close and return to the Backup/Restore window. Click Backup. A backup
file will be created with the specified name and in the specified location.

To restore the settings from a Backup file, click “Restore electrode area settings from:” Click
Browse and locate the Backup file. Highlight it and click “Open”. The Browse window will
close and the Restore/Backup window will reappear. Click Restore.

Backup/Restore Names

A backup file of all user-defined can be created using this feature. The same method is used
as for “Backup/Restore Areas”.

18
WS98-4000 Manual Transferring Data

Transferring Data

Loading Data
Welding programmes can be loaded from a timer, either via a local link or a network, or from
a file.

Creating a New File

To create a new file either click the New File icon on the toolbar or click New in the File menu.

Loading from an existing file

To load an existing file, click Open in the file menu. Select Disk and use the following box to
select the file to be opened. Double click the file or click Open.

Loading from a Local Timer

To load a file from a timer using the RS232 link either click the Local!"icon on the toolbar or
click Open in the File menu and select Local.

Loading from a Network Timer

To load a file from a timer using the network either click the Net!"icon on the toolbar or click
Open in the File menu and select Network.

Saving Data
Data can be saved to a timer, using local RS232 or network communications, or to a file.

Loading Data to a Local Timer

To load data to a timer using the RS232 link either click the !Local"icon on the toolbar or
click Save in the File menu and select Local.

Loading Data to a Network Timer

To load data to a timer using the network either click the !Net icon on the toolbar or click
Save in the File menu and select Network.

Saving Data to a File

To save data to a file Save in the File menu and select Disk. If the data is not updating an
existing file the Save As box will open. A file name and location must then be provided.

19
WS98-4000 Manual Configuring the Timer

Configuring the Timer

The WS4000 may be used in a number of ways, the precise mode of operation is defined by
the configuration file.

To configure the timer:-

• Load data from timer or file.
• Select Configuration from the Windows menu.

The configuration screen will appear as below.

Configuration Parameters
Operating Mode
This selects use of Discrete (traditional hard-wired 24v signals) or Fieldbus (serial
communications) I/O, and one or two gun mode (control of one or two sets of thyristors)

Welding Mode
Selects between:
• Standard (ac) – 50/60 Hz welding using phase angle heat control or constant current.
• Voltage comp. (ac) – 50/60 Hz welding which adjusts the heat of an entire weld to
compensate for high or low mains voltage. This is not a dynamic adjustment as with
constant current. (The nominal mains voltage must be entered for this to work correctly.)
• MF (dc) – Medium frequency (1KHz) welding.

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.

20
WS98-4000 Manual Configuring the Timer

Retract Mode
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 now has four modes of retract operation.

Standard Retract
The electrodes are fully open when the High Lift Air Valve is on.

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 +
The electrodes are fully open when the High Lift Air Valve is off.

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 -
The electrodes are fully open when the High Lift Air Valve is on.

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.

Robot Retract
The electrodes are fully open when the High Lift Air Valve is off.

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.

H.A.V. O/P
STANDARD
RETRACT I/P
SEQUENCE

H.A.V. O/P
Hi LIFT + RETRACT I/P
SEQUENCE

H.A.V. O/P
Hi LIFT - RETRACT I/P
SEQUENCE

H.A.V. O/P
ROBOT RETRACT I/P
SEQUENCE

21
WS98-4000 Manual Configuring the Timer

I/O Mode
(This is only applicable to Fieldbus control of the timer.)
32 Bit Operation uses 32bit Fieldbus words that access all the timer inputs and outputs.
48 Bit Operation uses 48bit Fieldbus words that access all the timer inputs and outputs and
provide an extra 16 inputs and 16 outputs. These extra inputs and outputs are for the purpose
of giving 24v discrete signal access to the Fieldbus to be utilised by other equipment.

Frequency
Use this box to set mains frequency.

Language
Use this box to select the language to be used by WS98-4000.

Pressure Monitor
If this box is ticked pressure is monitored via an analogue signal from the proportional valve.
The tolerances used are those set for current monitoring of Weld 2.

Wait for Pressure

If this box is ticked the weld sequence will wait at the end of squeeze time for the pressure to
reach the required level.

2nd Stage
nd
If this box is checked, the WS4000 will read the 2 stage input when the sequence reaches
the end of the Squeeze Time. If the signal is present, the sequence will proceed. If not, the
nd
WS4000 will wait for the 2 Stage Start signal.

EOS Trigger
The EOS (End of Sequence) Trigger is the point at which the End of Sequence output
switches on. This is usually at the end of the Hold time. A value, either positive or negative,
can be entered to change this point, to make the EOS output switch on x cycles before, or x
cycles after the end of the Hold Time. EOS1 refers to the End of Sequence output for gun 1,
and EOS2 refers to the End of Sequence output for gun 2.

EOS Duration
If the End of Sequence output switches on in the absence of the Start signal, it will stay on for
a fixed period of time. The time is the FK Duration, and is expressed in cycles.

Nominal Voltage
The nominal line to line mains voltage should be entered for the voltage compensation
system.

Contactor Delay
The time, in seconds, between the end of the Hold time, and switching off the Weld Contactor
output.

Exhaust Time
Used for Retract modes only. This is the time for which the Exhaust Valve output switches on.
(See WS4000 Series Manual)

Max Retries
This sets the maximum number of consecutive welds requiring a retry (regardless of gun). If
this number of retries is reached, the timer registers a fault, the fault could be configured as a
blocking condition. (See section on Blocking conditions.)

Max Weld Time

The value entered for this parameter is the maximum number of weld cycles allowed in a weld
sequence. If total number of weld cycles programmed into a sequence exceeds this value, the

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WS98-4000 Manual Configuring the Timer

sequence will not run and the error message Excess Weld Time Gun 1 or Excess Weld Time
Gun 2 will be given.

Heat Trim
Heat Trim increases or decreases all the heats of phase angle controlled welds on a gun.
eg. If Heat trim is set to –3, a weld programmed as 35% heat will actually weld with 32% heat.

Software version
The timer software version is shown in this box.

Gun 1 Enabled
Ticking this box enables Gun 1 (first thyristor set) operation.

Gun 1 Monitoring
Ticking this box enables Gun 1 (first thyristor set) current monitoring.

Gun 1 Toroid Test

Ticking this box causes a short circuit and open circuit test to be carried out on gun 1 toroid
during the last cycle of the squeeze time. If the a test fails the weld is aborted

Gun 2 Enabled
Ticking this box enables Gun 2 (second thyristor set) operation.

Gun 2 Monitoring
Ticking this box enables Gun 2 (second thyristor set) current monitoring.

Gun 2 Toroid Test

Ticking this box causes a short circuit and open circuit test to be carried out on gun 2 toroid
during the last cycle of the squeeze time. If the a test fails the weld is aborted

Fieldbus
The Fieldbus address is the Profibus FMS address to which the timer will respond.

I.P.
Click in this box to enter the I.P. (Internet Protocol) address for Ethernet control of the timer.

Actual Primary Current

The area concerned with Actual Primary
Current shows the primary currents
recorded during the previous weld. It also
shows the peak current drawn from the
supply, which will be larger than the
average values if Guns 1 and 2 welded
simultaneous.

Maximum primary load is the value set as

the maximum current to be drawn from
the supply. It is rather like setting a fuse rating.

Block Sequence
The area devoted to Block Sequence contains a list of all the different categories of fault
message. If a box is ticked next to a category, that fault message, when it occurs, will block,
or prevent that sequence starting, until the Fault output s reset.

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WS98-4000 Manual Configuring the Timer

MF Calibration
MF calibration is a facility for applying a conversion factor to the % heat used by the medium
frequency inverter, so that values of current can be programmed instead.

Click on Calibrate. The following window opens.

To use this you must first measure the current of a Phase Angle controlled weld using a low
heat. Then measure the current of another Phase Angle controlled weld using a high heat.
Enter the respective values in the MF Calibration window and click Apply. The system will
then calculate a conversion from demand current to the % heat required to produce the
current.

When calibrated, medium frequency welds can be programmed in actual welding current if
KSR is checked.

Printing
The Configuration settings can be printed by selecting Print from the File menu. There is also
a Print Preview facility with this.

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WS98-4000 Manual Programming a Weld

Programming a Weld
Open WS98 and click either Local!"or Net! to load data from the timer, or Open, from File
menu, then Disk, to load data from a file. The data will be shown as below:

All parameters can be changed using standard Windows techniques. If any changes are
made the new values must be sent to the timer by clicking !Local"or !Net.

The individual parameters are explained below.

Weld Program
Program
This selects the programme you are going to edit.

Gun
This selects which gun the programme will use to do the welding. This is only editable if Two
SET THESE FIRST
gun mode is selected in the Timer Configuration.

Electrode
Electrode sets the electrode (and therefore the electrode programme) to be used for the weld.

Type
Type selects either Spot or Repeated Spot welding mode.

Mode
Mode sets the editing for either a Standard or an Extended weld sequence. An Extended weld
sequence uses all the parameters offered by the timer. A Standard weld sequence uses only
basic weld parameters, those parameters not used do not appear on the screen.

Inhibited
If this is ticked the programme will not run. This can be used to prevent accidental operation
of a programme.

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WS98-4000 Manual Programming a Weld

Sequence Timing
All times are in terms of mains cycles.

Presqueeze
Presqueeze is the time allowed for the electrodes to close onto the work piece.
(This parameter is only available in Repeat mode).
Range of values: 0 – 99 cycles.

Squeeze
Squeeze is the time given for the electrode force to reach the required value for welding. In a
Basic sequence this would also incorporate the Presqueeze time.
Range of values: 1 – 99 cycles.

Weld 1
The duration of the pre-heat weld interval.
(This parameter is only available in Extended mode).
Range of values: 0 – 99 cycles.

Cool 1
The time between the pre-heat and main weld intervals.
(This parameter is only available in Extended mode).
Range of values: 0 – 99 cycles.

Weld 2
Duration of main weld interval.
Range of values: 0 – 99 cycles.

Cool 2
The time between successive applications of Weld 2 when Pulsation is in use.
Range of values: 0 – 99 cycles.

Cool 3
The cool time between Weld 3 and Weld 3.
(This parameter is only available in Extended mode).
Range of values: 0 – 99 cycles.

Weld 3
Duration of the post-heat weld interval
(This parameter is only available in Extended mode).
Range of values: 0 – 99 cycles.

Pulsations
The number of applications of Weld 2.
Range of values: 1 – 9 pulses.

Hold
The time allowed, after the application of weld current, for the molten material to solidify,
before the electrodes are opened.
Range of values: 1 – 99 cycles.

Off
The time for which the weld air valve switches off between sequences in Repeat mode.
(This parameter is only available in Repeat mode).
Range of values: 0 – 99 cycles.

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WS98-4000 Manual Programming a Weld

1st Delay
Conduction of the first half cycle of the first weld interval is limited to this value.
Range of values: 40 - 99

2nd Delay
Conduction of the first half cycle of the second weld interval is limited to this value.
Range of values: 40 - 99

Pressure
Demand
Demand sets the force, in Kilo Newtons, exerted by the electrodes on the work piece.

Note: Before programming the electrode force requirements, calibrate the system using the
Force Calibration facility. This changes the programmed values of force to match the actual
electrode force. This is why calibration must be done first.

Force Calibration
If the force exerted by the electrodes is different to the Demand, a Force Calibration should
be carried out. To do this click the Calibrate button. The calibration screen will appear.

• Click Reset to change any existing scale factor and offset to the default values of 100
and 0 respectively.
• Click OK.
• The Force Calibration screen will close. Set a demand force to a value at the low end of
the working range. Initiate a weld using this programme, with the weld switched off, and
use an electrode force meter to measure the force between the electrodes. Note both the
demand force and the meter reading.
• Set a demand force at the high end of the working range and repeat the above.
• Return settings to low force demand.
• Click Calibrate.

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WS98-4000 Manual Programming a Weld

• Enter the first demand force, multiplied by 100, into the Demand Units box of the
Measurement#1. Enter the corresponding force into the Force box.
• Enter the second demand force, multiplied by 100, into the Demand Units box of the
Measurement#2. Enter the corresponding force into the Force box.
• Click Apply. The scale factor and offset values will be calculated. Calibration is complete.
Click OK.

Heat/Current
Heat
Sets the % heat of the weld for phase angle controlled welds. If Stepping or Tip Dressing is
being used, Heat sets the percentage heat used at the beginning of the curve. The readings
at the side, marked “step” and “act” give the stepped heat and the actual, measured value of
the heat, respectively.

If medium frequency welding is being used the percentage heat sets a demand current for the
inverter. The inverter converts the % heat to a constant current weld, the current regulation
being accomplished in the inverter.

Range of values: 0 – 99.9%

Current
Sets the weld current for constant current welds. If Stepping or Tip Dressing is being used,
Current sets the current used at the beginning of the curve. The readings at the side, marked
“step” and “act” give the stepped current demand and the actual, measured value,
respectively.
Range of values: 2.50 – 80.0 kA.

For phase angle welds, Current is the value the monitor uses.

KSR
If this box is ticked the weld interval is carried out using constant current control. In this the
heat is dynamically updated, in light of the current measurements, to achieve a constant weld
current

In medium frequency welding all welds are constant current. If a medium frequency
calibration has been done (see timer configuration) and KSR is checked, the actual weld
current required can be programmed .

Slope Control
This is only available in Extended mode.

“Slope” is the gradual switch on and switch off of Weld 2. Tick the Slope box to enable the
slope parameters. These are:

Upslope
The number of cycles taken to raise the current from the Start Current/Heat to the welding
Current/Heat.
Range of values: 0 – 9.

Downslope
The number of cycles taken to ramp the current down from welding level to the Finish
Current/Heat.
Range of values: 0 – 9.

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WS98-4000 Manual Programming a Weld

Start
The initial heat or current of Weld 2.
Range of values: 2.50 – 80.0 kA.

Finish
The final heat or current of Weld2.
Range of values: 2.50 – 80.0 kA.

Final heat
Initial heat or current or current
Upslope time Downslope time

Weld 2 time

Monitoring
PHA Monitoring
PHA Monitoring is phase angle monitoring. If this box is ticked the timer will monitor phase
angle controlled welds (non constant current). Constant current welds are always monitored.

Auto-Repeat
If this is ticked, the timer will repeat a weld that has failed due to low current.

High Limit
High Limit sets the highest acceptable value of current for the weld pulse. If the measured
current is greater than this value an error code is generated.
Range of values: 0 – 99%

Pre Limit
Pre-limit is a border line condition in which a number of consecutive occurrences of current
between this level and the low limit are acceptable. The number of acceptable occurrences is
set by Conditional Fail. If this number is exceeded an error code is generated.
Range of values: 0 – 99%

High Limit

Req’d current

Pre-Limit

Low Limit

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WS98-4000 Manual Programming a Weld

Low Limit
Low Limit is the lower tolerance level for the current. If the current is less than this value an
error code is generated.
Range of values: 0 – 99%

Conditional Fails
The maximum number of times a value of current between the Lower Limit and the Pre-Limit
will be accepted without generating an error code. (See Conditional Limit previous).
Range of values: 0 – 9

Heat Pre-limit
Sets a value of heat, which, if exceeded, causes an error message.
Range of values: 0 – 99%

Heat Limit
Heat Limit is a value of heat that cannot be exceeded by this programme.
Range of values: 0 – 99%

Electrode
This section is only required it Stepping or Tip Dressing is in use.

Stepping
Tick this box to enable Stepping.

Dressing
Tick this box to enable Tip Dressing.

Force Stepping
Tick this box to make Stepping/Tip Dressing apply to the electrode force.

Spots per Component

Enter the number of spot welds the electrodes do on a component so that the timer can give
an “End of life Prewarning” whilst stepping. (This parameter is not required for tip dressing,
where the “Prewarn” is specified in terms of the number of tip dresses.)
Range of values: 0 - 9999

Prewarning
The “End of Electrode Life Prewarning” is entered here. For Stepping it is in terms of
components remaining. For Tip Dressing it is in terms oh Tip Dresses remaining.
Range of values: 0 - 99999

Total Spots
This is read only, and shows the number of spot welds done since the last electrode reset.

Dressing Point
(Used only for Tip Dressing) The point on the curve, expressed in number of spots, at which a
Tip Dress Request will be made.
Range of values: 0 - 9999

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WS98-4000 Manual Programming a Weld

Dressings
(Used only for Tip Dressing) The number of Tip Dresses to be carried out during the lifetime
of the electrodes.
Range of values: 0 - 9999

Reset Point
(Used only for Tip Dressing). The point on the curve, expressed in spots, to which the
heat/current/pressure is reset after a Tip Dress.
Range of values: 0 - 9999

Point on the Curve

Gives the position of the stepper on the stepper curve, in terms of spots. (This is also
indicated by a cursor on the graph and by a bar graph.)

Dress Count
Dress Count gives the number of tip dressings done.

Tip Dress Operation

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WS98-4000 Manual Programming a Weld

Toroid Sensitivity
This shows the toroid sensitivity in V/kA.
If this if not the sensitivity of the toroid
actually in use, as would be indicated by
consistently high or low current readings
when compared with a weld current
meter, the value can be changed using
the toroid calibration procedure.

The calibration procedure is to do a weld,

using both the Datalog and a weld
current meter to measure the current.
Then click the Calibrate button to bring
up the calibrate screen. Enter the
measurement from the weld current
meter in the “Meter Current” box and the value recorded in the Datalog into the “Datalog
current” box. Click OK. The toroid sensitivity will be calculated and recorded.

Please note that only values between 2 and 60 can be entered into the Calibration screen.
Also note that only toroids with sensitivities in the range 100 to 200mV/kA can be
accommodated by the timer.

Stepper
Curve
This selects the curve to be programmed, weld 1, weld 2 weld 3 or pressure. (Welds 1 and 3
will not be available in Standard mode.)

Mode
This selects either a phase angle (PHA) or a constant current (KSR) curve. If the weld is a
phase angle weld, using monitoring, the KSR curve is used by the monitor so that it “tracks”
the increasing heat.

Offsets
An Offset raises or lowers all the heat/current/pressure values in a curve, thus making it
“hotter” or “cooler”. (Because all values are increased or decreased by the same amount, the
graph still looks the same.)

Defining a Curve
A stepper curve is a graph consisting of ten points of heat/current/pressure versus number of
spots. These points can be entered individually in the area shown below, alternatively the
beginning and end points can be entered and a curve imported to fit them.

Import
This feature fits a pre-defined curve to the beginning and end points already defined. There
are ten such curves available.

Printing
The weld, monitor and stepper settings can be printed by selecting Print from the File menu.
There is also a Print Preview facility with this.

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WS98-4000 Manual Programming a Weld

33
WS98-4000 Manual Tip Dressing Programmes

Tip Dressing Programmes

Special programmes exist for electrode maintenance. These programmes consist of:

• an electrode number
• an electrode force
• a time duration for the application of that force

The programmes are 192 to 199 and can not weld. They are only to be used for electrode
maintenance.

Four of the programmes are termed “Hammer”. These are intended to be used to “hammer” in
newly fitted electrodes or caps. The other four programmes are termed “Tip Dress” and are to
be used whilst the tips are being dressed.

To use the Tip Dressing Programmes select Tip Dress Programs from the Window pull down
menu.

Electrode
Sets the electrode being used.

Duration
Sets the length of time electrodes are closed.

Force
Sets the force exerted between the electrodes.

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WS98-4000 Manual Status

Status
The status of the timer is shown on the Status screen. Click Status in the Window menu. An
example is shown below:

Electrode:03Gun:1 (100%)
Electrode:02Gun:1(080%)
Electrode:00Gun:1(050%)
Electrode:05Gun:1(050%)
Electrode:01Gun:1(030%)
Electrode:04Gun1:(030%)

Status Message
This shows any error or warning messages produced by the timer.

Inputs
This section shows which timer inputs are switched on. An active input is indicated by a
yellow box.

Outputs
This section shows which timer outputs are switched on. An active output is indicated by a
yellow box.

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WS98-4000 Manual Status

Fixed I/O
This shows the state of the basic timer I/O. These inputs need to correct in order to get a
“Ready” status. An active input or output is indicated by yellow.

Discrete Inputs
(Only applicable to fieldbus control mode) This section shows the state of hard-wired inputs
which are communicated by the fieldbus system. A description of the input can be typed into
the adjacent box.

Discrete Outputs
(Only applicable to fieldbus control mode) This section shows the state of hard-wired outputs
which are communicated by the fieldbus system. A description of the output can be typed into
the adjacent box.

Mode
Shows if the timer is configured for fieldbus or hard-wired control, and if one or two Gun are
being used.

Electrode Status
This shows, in bar graph form, the level of advancement of the steppers. Each entry is
labelled according to electrode number and gun, and the percentage of the electrode life that
has been used. The bar graphs are colour coded:

Green Stepper in progress

Dark Red Tip dress request reached
Orange Prewarn reached
Red End of electrode life reached

To reset an electrode from this screen, select the electrode or electrodes, then click “Reset
selected electrodes”

Datalog
Each row of the Datalog shows the target currents, and the currents recorded, for the last
weld of each programme. To display the information. tick the box adjacent to the relevant
programme/gun.

To change the list order:

• Click the line to be changed to highlight it.
• Slow click the Prog/Gun number in the highlighted line. The highlighting will disappear
except for the Prog/Gun entry.
• Type in the programme and gun required, separated by a space or comma.
• Click the corresponding box and the data will be transferred to the new line.

39 records are shown in the log. The selection can be changed as above.

Data can be recorded to a file as welding takes place. To do this click Record to Disk. A
browser opens which you must use to name and locate the file into which the data is to be
placed. Having done that, click Save. The browser will close and the Record to disk button will
now be labelled “Recording to filename”. Data will be recorded to the file until the button is
clicked again.

Body Cycle Log

This function is for use only with fieldbus control of the timer.

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.

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WS98-4000 Manual Status

The Body Cycle Log 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 it’s 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. Hence the “Live” log contains the log of the component
presently being welded, and the “Buffered” log contains data on the last component welded.

Half Cycle Log

The Half Cycle Log contains a record of the current measurements for each half cycle of
weld for the last 16 cycles in each Gun.

Control Functions
The Controls Function area allows various combinations of faults and electrodes to be reset.
To reset faults and/or electrodes, tick the required box or boxes and click OK. The datalog is
also reset in this way.

Soft EOS is a facility for forcing the End of Sequence output on for a period of time. Click Soft
EOS, set the required duration and Gun (if applicable) and click OK.

Soft Weld is a facility for starting a weld. Tick Soft Weld and select the programme and gun
required. Tick Weld On then click OK.

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WS98-4000 Manual Other Features

Other features
Cross Reference
The Cross Reference is a table of all programmed parameters for every programme of each
gun. It also shows the positions of steppers etc. and error messages present.

To open, click Cross-Reference on the Window pull-down menu. The Cross Reference can
not be printed directly. If a print is required the file must saved in tab-delimited text format
which is usable by other application that can print, eg. Word or Excel. To do this click on Save
as in the file menu with the Cross Reference window active.

WS98 Files
Log File
To call up the Log File go to WS98 Files in the File menu and click Log File in the selection
box, or click the ▼ symbol next to the Scan button on the toolbar and select Log file.

The Log File is a complete record of all changes and actions carried out using WS98. It also
gives the times the changes were made, and, if Security is in use, the name of the person
who made them. Log-on and log-off times are also recorded as are error messages and other
status information.

The file, WS98 Log File.txt, resides in the Windows directory and is automatically trimmed if
it’s size exceeds 1.44Mb

Action File
To call up the Action File go to WS98 Files in the File menu and click Action File in the
selection box, or click the ▼ symbol next to the Scan button on the toolbar and select Action
file.
.
The Action File is a list of all actions carried out by WS98.The list is in chronological order, the
most recent entry being at the bottom. The file records the actions, the time they were made
and the person who made them (providing Security was implemented).

The file, WS98 Action File.txt, resides in the Windows directory.

Audit File
To call up the Audit File go to WS98 Files in the File menu and click Audit File in the selection
box, or click the ▼ symbol next to the Scan button on the toolbar and select Audit file.

The Audit file is a record of all changes made to the programmable parameters. It shows the
parameter changed, the old value and what it was changed to, and the time the change was
made. If Security was implemented it also shows who made the change.

The file, WS98 Audit File.txt, resides in the Windows directory.

Filter File
To call up the Filter File go to WS98 Files in the File menu and click Filter File in the selection
box, or click the ▼ symbol next to the Scan button on the toolbar and select Filter file..

The Filter File records all the errors, with a time/date stamp, that occur. The errors are
recorded in accordance with the Filter in Status Scan.

The file, WS98 Filter File.txt, resides in the Windows directory.

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WS98-4000 Manual Other Features

Printing
The WS98 Files can be printed by selecting Print from the File menu. There is also a Print
Preview facility with this.

System Explorer
System Explorer is started by clicking System Explorer in the View menu.

The System Explorer shows local and network connections as

a Windows tree control, similar to Windows Explorer. The
nodes can be expanded to reveal several sub-items. Each
sub-item is a reference to the program that can be requested
from the local connection. A programme, when selected, can
be double-clicked to load it’s data to the screen.

The display mode can be changed by right-clicking on the

tree and selecting the required setting from the menu.

Flash Wizard
The Flash Wizard is started from the File menu.

The Flash Wizard allows reprogramming of the WS4000 operating system.

The operations of the WS4000 are contained within a re-programmable flash memory device,
which can be updated with new or revised functions, as they become available.

Only experienced users should attempt to re-programme the WS4000.

Start the Flash Wizard, read the opening screen and click Next.

Use the browser to locate the new timer software file (this will have the extension .mhx)

Click Finish.

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WS98-4000 Manual Other Features

The Flash Programmer will:

• Show the timer software file and the path to it.

• Detect and display the type of flash memory device in the WS4000.
• Erase the old programme.
• Re-programme the WS4000.

A bar graph indicates the overall progress of these functions.

Copying Programmes
WS98-4000 has a facility for copying Weld, Monitor and Electrode programmes.

Click Copy in the Edit menu, or press Control and C. The copy window will appear.

In the Program section, select the type, or types, of programme you wish to copy.

In the Program range section, select the programme or programmes you wish to copy, then
select the programme, or programmes, you want to receive the data.

eg.1 If you want to copy programme 3 to programme 5, set:-

Source: from 3 to 3

Destination: from 5 to 5

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WS98-4000 Manual Other Features

eg.2 If you want to copy programme 3 to programmes 5,6,7 and 8 set:-

Source: from 3 to 3

Destination: from 5 to 8

eg.3 If you want to copy programmes 3,4 and 5 to programme 6,7and 8 set:-

Source: from 3 to 5

Destination: from 6 to 8

When the source and destination programmes have been entered, click Copy. A confirmation
screen will appear. If you click Yes, the programmes will be copied.

Backup Wizard
This function can only be used with networked timers.

The Backup Wizard is started from the File menu.

The Backup Wizard makes copies of the data in the WS9000is connected to the network. A
backup can be made of one or more timers, and the resulting file stored to disk. The backup
file can be used to restore data to the timers(s) or to compare data with the timer(s).

Select the timer, or timers, to be backed up. Then use the browser to select a location for the
backup file.

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WS98-4000 Manual Other Features

Auto Archive
WS98 has the facility for automatically archiving any changes made to any timer on the
network.

Initially Auto archive should be checked in the Backup Wizard to create the Auto Archive file.
After that, the file will be updated whenever the network is used to make a change to any
timer. (Note that if change is made to a timer programme, by means other than the network,
these changes will not be included in the automatic archive.)

Restore Wizard
This function can only be used with networked timers.

The Restore Wizard is started from the File menu.

The Restore Wizard transfers data from a Backup file to a timer, or a number timers, on the
network. Data can be backed up to original, or alternative locations.

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WS98-4000 Manual Other Features

The timer, or timers, can be restored, either from data in the automatic archive by checking
the “Restore from Auto-Archive” box, or from a backup file. The backup file can be located
and selected using the browser.

When the data source has been established a list of addresses appears. Highlight the one to
be restored and check the appropriate destination box.

Original Location
Sends data to address from which it came.

Alternative location and change the address parameter.

Sends data to different address and changes the address in the data to match new location.

Alternative location but don’t change the address parameter.

Sends data to different address and causes that address to become the address from which
the backup was created.

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WS98-4000 Manual Exchanging Data with WS98-4000

Exchanging Data with WS98-4000

Import Wizard
WS98-4000 can read an Excel file that contains weld parameters as well as other information.
You can select the columns that contain weld data. The following parameters can be
imported:
• Programme number
• Programme name
• Station number
• Station name
• Gun
• Squeeze
• Weld 2
• Current 2
• Cool 2
• Hold
• Pulses
• Force

To import an Excel file:

• Ensure that you have an Excel ODBC driver installed. You can check by selecting the
ODBC applet from Control Panel.
• Give a name to the Excel worksheet. You can do this in Excel by selecting
Insert->Name->Define. Make sure the named range includes the cells that you want to
import.

To start the Import Wizard click Import Wizard in the File Menu. Click Next in the window that
opens.

Use the Source browser to select the xxx.xls file to be imported.

Use the Destination browser to name and locate the xxx.WS98 file to be created.

Click Next.

In the upper box of the window that opens, enter the name of the section in your Excel
worksheet that contains the weld parameters, then click Read Worksheet.

When the worksheet has been read it appears in the lower box. Right click on the headers, in
turn, and select, from the list that appears, the type of parameter to which the column refers.

Click Next.

Select the action to be taken after the conversion, then click Finish.

Export Wizard
The File Export Wizard converts files in WS98 format to Microsoft Excel format.

WS98 files that have been created from a WS4000 contain all the programmable parameters.
These parameters can be converted into Microsoft Excel (.xls) format.

The worksheet contains a number of rows and columns. The columns correspond to the
parameters and the rows correspond to the programmes.

When the data has been exported it can be read and manipulated by Microsoft Excel.

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The Export Wizard is started from the File menu.

When the wizard starts click Next.

Use the Source browser to select the file to be exported. (If you want to export the data in the
timer you must first save it to a xxx.WS98 file (use Save As from the file menu) then export
that file.)

Use the Destination browser to name and locate the xxx.xls file to be created.

Click Next.

Select whether or not you wish to view the created file. If you choose “Yes”, Microsoft Excel
is started and loaded with the finished file.

Click Finish.

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