AY-01 (EL2K6VF)

Electroweld Microcontroller
Based Controller
(25 Programmable Schedules)
USER MANUAL
1. The FRONT Panel.

The Front panel contains LEDs, Seven segment displays, User keys, Power on switch
and Program Lock Switch.

Function of LEDs:
The LEDs and 3-digit seven segment displays serve to display output to
operator. The LEDs arc grouped in two sections.
1. Weld parameter section i.e. the top section containing 15 LEDs.
2. Status section i.e. the bottom section containing 4 LEDs.
Weld Parameter Section (15 LED’s):

The Weld Parameter section contains 15-LEDs to display the weld parameter being
programmed in Program Mode and the weld parameter being executed in Run
mode. For example, the squeeze LED is lit when the user is programming the
squeeze cycles in Program Mode. The same led will also light up when the program is
being executed and the squeeze is in process.

These Functions indicated by 15-Weld Parameter LED’s are as follows:

1 SQZ Squeeze,
2 SV2-DLY Forge/Motor Delay
3 W1-CYC W1 Cycles
4 W1-HEAT W1 Heat
5 C1 Cool1
6 W2-SLP W2 Upslope
7 W2-CYC W2 Cycles
8 W2-HEAT W2 Heat
9 C2 Cool2
10 W3-CYC W3 Cycles
11 W3-SLP W3 Down Slope
12 W3-HEAT W3 Heat
13 HLD Hold
 14 OFF Off
15 IMPL Impulses

Status Section (4 LED’s):

The Status Section LEDs indicate the control status. These LEDs are as follows

1 Schedule/Select
2 Program/Run
3 Repeat/Single
4 Weld/No-Weld

Schedule Select: This LED is lit when a user presses the schedule select button.
This LED indicates that user is changing the schedule. The selected schedule
number appears on display. This led turns off when the user presses the 'SET'
'button or presses the 'Schedule Select' button again after setting the desired
schedule.

Run Program: This LED is lit when a user presses the Run/Program button and
enters the program Mode. This LED indicates that the user is modifying the weld
program. During this time, the display shows the parameter value under
modification. After entering all the weld parameters or upon pressing
`Run/Program' button again, this LED turns OFF indicating that control has come
out of program mode.

Single/Repeat: This LED is lit when control is in Repeat Mode, and this LED is off when
control is in Single Mode. To toggle between Single and Repeat press the 'Single/
Repeat' Key.
Weld/No-Weld: This LED is lit when control is in Weld Mode, and this LED is off
when control is in No-weld mode. To toggle between Weld and No Weld press the
'Single/ Repeat' Key.
 Function of the 3-Digit 7 Segment Display:

The Seven Segment Display shows the running program number when it is in Run
Mode. For e.g. 01 means the control is running schedule No. 1

While in Schedule Select Mode, the display shows the selected Schedule Number.
for example it shows S05. When user selects schedule No. 5.

While in Program Mode, the display shows the value of the Weld Parameter. At this
time, the Weld Parameter section LEDs shows the name of parameter being modified.

Function of Front Panel Buttons and Switches :

Power-On Switch: The power on switch is the red colored rocker switch at the
bottom right corner. It is used for turning the control On or Off.

Program Lock: The program lock switch is located at the bottom left corner. It can
be operated only with the provided key. When in lock position the control cannot 9be
 reprogrammed and the running schedule [program] can't be changed. To program a job
or change the schedule it must be kept in the unlock position.

1. `+' Key: The `+' key increase the value of parameter being entered by 1.

2. `-` Key: The `-' key decrease the value of parameter being entered by 1.

3. 'SET' Key: This key has same function as the enter key in a computer. When
pressed the control accepts the parameter being entered and moves to next
parameter. The same key is also used to display value of the JOB COUNTER. (Job
counter functionality is discussed in detail under a separate section).
4. SCHEDULE SELECT: This key is used to change the Weld Schedule/Weld Program. The
control can store and execute up to 25 different weld schedules. To change the schedule,
press this key. At this time, the LED above this key is lit indicating that you are in
Change Schedule mode. The control will display the present schedule for example:
SO1 for schedule 1. Use +, - key to bring desire Schedule Number on display and press
SET.

5. RUN/PROGRAM: To program a schedule press this key. Upon pressing this key,
control enters the Program Mode and the LED above the key is lit, indicating program
mode. At the same time, SQUEEZE LED at the top is also lit indicating that you are
now configuring the squeeze cycles which can be programed using the `+', `-' keys
and pressing SET when done. Upon pressing SET, the Next parameter LED is lit
which is now ready to be programmed. Similarly, the control moves to the next
parameter every time you press SET. You can modify the desired welding parameters
and after entering the last parameter i.e. Impulses, the controller automatically
comes out of the Program Mode and enters the Run Mode. The LED at the top of
the Run/Program Key also Turns Off. If you want to quit in between, you can press
RUN/PROGRAM key once you have modified the parameters you wish to change and
the controller will accept and store parameter you have modified and return to Run
Mode.

8. SINGLE/REPEAT: This key is used to switch between Single and Repeat weld
modes. Every time you press this key, the control toggles between Single and Repeat.
When in Repeat the LED at the top of this key is lit indicating Repeat mode. When in
single mode this LED remains off.

9. WELD/NO-WELD: This key is used to switch between Weld/ No Weld modes. Every.
time you press this key the control. toggles between Weld and No-Weld. When in
Weld Mode, the led at top of this key is lit indicating Weld Mode. When in No-Weld
mode, this LED remains Off. In No-Weld mode the controller executes the sequence
upon sensing Foot Switch but does not pass any weld current.
 Rear Panel Connection Details:

The Rear End Connections into the Controller consist of the following:
1. Fuse Holder 1. (mains)
2. Fuse Holder 2. (Sv)
3. The Terminal Strip.

Before turning on the control make sure that the necessary connections are made on the
terminal strip.

The terminal strip has following terminals.

0 - 230V - 415V: Power Input should be connected to these terminals. You need to
connect either 0-230 V or 0-415 V, never both. Please make sure that the Controller is
connected to same Supply Phase as the machine.

O/PC - SV1 - SV2: These terminals are meant for connecting the AC solenoid valves.
Either 110V or 230V solenoid valves can be used. Two solenoid valves can be connected,
I one on SV1 and 0/PC and another on SV2 and 0/PC. In case of plain spot welding only
SV1 is used. In some cases, such as seam welding or projection welding forging SV2 is
also used.

SV1 turns on with start of squeeze time and remains on until end of Hold.

SV2 turns ON after the programmed Forge/Motor Delay and remains on until end of hold.
Please note that the Forge/ Motor delay starts along with start of weld or end of
squeeze.

Refer to the following figure for connecting the solenoid valves.

I/PC - FS1 - FS2: These terminals are for connecting potential Free Foot Switches for
initiating the weld sequence. When FS2 is shorted to I/PC no welding takes place,
only the solenoid valve SV1 is turned ON. This is generally used for electrode
alignment. When FS1 is shorted to I/PC -the
3. How to Program a Weld Schedule

Make sure that the Program lock switch is in the 'Unlock Position’.
In-order to program a Weld Schedule, first you need to select the weld schedule you
want to program.
Press 'Schedule Select' Key- The LED on top of this key lights up and the controller
shows the present schedule number. For e.g.: S02 means present schedule no is 2.
You can press `+' and ‘-‘, to bring the desired schedule number
on the display and press 'SET'. Now the schedule is changed and the LED on top of the
schedule select button also turns off.

Now press the 'Program/Run' Key- The LED at the top of this key lights up
indicating you are in program mode. Additionally, the Squeeze LED in the top section
lights up and the controller now displays the ‘Squeeze Time’ display. You can
modify the squeeze time using the`+' and ‘-‘ keys and press 'SET' when done. Upon
pressing `SET', the next led in the top section i.e. FORGE/MOTOR Delay lights up and
the value of this parameter is displayed. You can modify this parameter and press
'SET'. Then the next led is lighted and this goes on and finally after programming
‘Impulses’ the controller 'steps out of the program mode. The LED at the top of
'Program/Run' key also turns off. One can also come out of Program mode by pressing
'Program/Run' key. For example if you wanted to modify only squeeze and don't
want to move to further parameters, you can press the `Run/Program' key to come out of
'Program Mode' and enter 'Run Mode'.

9
The function of various weld parameters is as follows:

1. Squeeze time: This is the time delay between initiation of the solenoid
valve and start of the weld current. At the start of the squeeze, the SV1
(Solenoid Valve1) is initiated.
2. Forge/Motor Delay: In some application a second solenoid valve is used
for Motor or Weld forging. This delay timer starts along with Weld and
when this timer elapses or reaches value 0 the second solenoid valve
SV2 is turned ON- to turn on Motor or Weld Forge.
For e.g. when this parameter is programmed as 3. Then 3 cycles after the
completion of squeeze time and start of weld time, the SV2 will start.
3. Pre-heat: This is the first weld of the three-stage welding process. One
can program
- Welding Up-Slope
- the total number of re-heat cycles
- and weld heat.
If Up-Slope cycles are entered, then the current rises slowly in the
specified number of Cycles. The weld heat can be entered in '%' of
maximum heat or in `kA'.
4. Cool: This is the cool time after preheat. During this time no current
flows.
5. Weld: This is the second weld of the three-stage welding process. One
can program the weld cycles and weld heat. The weld heat can be
entered in '%' of maximum heat or in `kA'.
6. Coo12: This is the cool time after Weld stage during this time no current
flows.
7. Post-heat: This is the third weld of the three-stage welding process.
One can program
-Welding down-slope
- the total number of post-heat cycles
- and weld heat.
If down-slope cycles are entered, then the current reduces down to zero
slowly in the specified number of cycles. The weld heat can be entered in
‘%‘ of maximum heat or in 'kA'.
8. Hold Time: After completion of post-heat, the hold time starts. During this
time, the molten metal solidifies. No current flows during this time. At the
end of the hold time, the SV I and SV2 are turned off.
9. Off Time: Off time is executed only in Repeat mode. During this time, the
control remains idle. Off Time can be used in case of automation for
allowing indexing operations.
10. Impulses: The controller supports pulsation welding. The Weld /Coo12 is
repeated during welding for specified number of impulses. If Impulses is
 programmed as zero, it still means 1 impulse in 'Projection Welding' mode;
where-as in 'Seam Mode' if Impulses is programmed as zero, it represents
manual seaming option and in that case the Weld/Cool2 is repeated as
long as FS1(Foot Switch) is kept pressed. The Projection and Seam
selection is discussed in detail in next section.

4. How to Run a Weld Schedule

The controller when ready for initiation, displays the present schedule number or
weld-current of the last weld. Make sure that the schedule you want to run is
selected.

In order to select a schedule, press 'Schedule Select' key and then use `+' and ‘-‘
keys to set the desired schedule number. When done press the ‘SET’ key.

Press the Foot Switch FS1 for initiating the welding sequence.

If it is desired to only bring-the electrode down but not to initiate weld

sequence press FS2.

In order to execute the sequence, without passing weld-current put the controller in
‘No Weld’ mode by pressing the 'Weld/NoWeld' button. Please note that the LED at
the top of this button is off when the control is in 'No Weld' mode.

5. JOB COUNTER

The controller has job counter which increments every time a weld is made. The
value of weld counter can be seen by pressing 'SET' button in Run Mode. The 3-
digit counter scrolls.

In order to clear the Job counter, press `+' and `-`simultaneously while counter is
being displayed. The counter is cleared after the display. blinks.
6. OEM SETTINGS

Please note that the settings in this section are meant only for machine
manufacturers or Advanced users. Incorrect setting of these parameters can lead to
welding problems.
In order to enter the OEM settings, turn the controller OFF using the Red toggle
switch. Now keep the '+' & ‘-‘ button pressed and power on the controller. The various
settings are listed in sequence as they appear in the controller.

1. P00/P01: This setting is used to switch between '%' and 'KA' mode. You can change the
setting by pressing '+' and ‘-‘key and press 'SET' when done.
P01 represents the '%' mode and P00 represents the ‘KA’ mode.

2. S00/S01: This setting is used to switch between 'Projection' and 'Seam' modes. You can
change this setting by pressing the '+' and ‘-‘ key and press 'SET' when done.
S00 represents the ‘Projection’ mode and S01 represents ‘Seam’ mode.

3. F00/F01: This setting is used to switch between 'Voltage Feedback' and 'No Voltage
Feedback' modes. You can change this setting by pressing the '+' and ‘-‘ key and press
'SET' when done.
F00 represents the ‘No Voltage Feedback’ mode and F01 represents ‘Voltage
Feedback’ mode.

.Difference in 'Projection' & 'Seam' Mode:

1. In ‘Projection’ mode. the SV2/Forge output remains ON until end of HOLD: In
‘Seam’ mode. the SV2/Motor output turns off at start of hold.
2: In ‘Projection’ mode when 'Impulses' are zero, it is treated as one weld impulse. In
‘Seam’ mode when 'Impulses' are zero it is treated as manual seaming and Weld/Cool
is repeated, as long as the foot switch is pressed.

4. L XX [LIMIT FIRING ANGLE]:

This setting is used to set the maximum thyristor firing angle limit. The controller
is factory set at 51 degrees firing angle limit. The firing angle limit can be
programmed as any value between30 and 99 degrees. Machine manufacturers
need to program the fifing angle limit by pressing no load supply current of
transformer at maximum tap with maximum fire setting in weld schedule eg. 90%
with 99 cycles. Change the fire limit and measure the No Load current. Generally
increasing the firing angle limit causes reduction in No Load losses and vice versa.
Set the firing angle to give acceptable and stable No Load supply current .
5. VOLTAGE: The controller displays the present supply voltage. This setting is only for
information. No action is required here.
6. ERROR CODES: The controller displays an error code. For example, E01 whenever it
encounters a problem.
E01: Program Incomplete:
The controller displays this error code if the selected weld schedule isn’t programmed
correctly. Make sure that the squeeze and hold cycles are not zero in programmed
weld schedule.

DEFAULT PARAMETRS:
SS0
FF0
LN0
HC0
L50
F01

Following Videos show the Electroweld AY-01 Welding

Controller Programming in action:

https://www.youtube.com/watch?v=q8FQm2ckt7M

(AY-01 Controller Programming video)

https://www.youtube.com/watch?v=UO0wyJRKJj4
(AY-01 Controller Programming Segment starts at 5:30 on the above video)