Page 1 • #T03311 (AC - GM WS2 / ABB Robot) • #T02300 (MFDC Standard) • #T02301 (MFDC Type 1 Inverter) • #T02302 (MFDC w/Ohma Cylinder & Pressure Control) • #T02304 (MFDC Multi-Inverter) • #T02306 (MFDC Multi-Inverter w/Forge) Revision 04 Modified: 09/17/08 Manual No. M-032116 Copyright © 2008, WTC...
Page 2: Table Of Contents
If You Need Help ....... . 1-x Welding Technology Corp. (WTC) ......1-x By Phone or Fax: .
Page 3 Chapter 1 MedWeld 4000 Overview ....1-1 Control Description ....... 1-1 Physical Description .
Page 4 Chapter 2 Installing the MedWeld 4000 ... . 2-1 Getting Started ........2-1 Before You Begin .
Page 5 Cascade Firing Board Support ......4-23 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 6 Function List T03311 (AC - GM WS2 / ABB Robot) . . . 4-41 Function List T02300 (Standard MFDC Software) ..4-43 Function List T02301 (Medar MFDC Inverter Type 1) . . 4-45 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 7 DEP-100S ......... . . 6-3 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 8 Weld Processor ........9-3 Solving Typical Problems ......9-5 MedWeld 4000 Operator’s Guide viii...
Page 9 The Differences Between Method 1 and 2 ....11-3 Weld Schedules in Cascade Welds ....11-3 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 10: Getting Started
Getting Started If You Need Help . . . Welding Technology WTC is committed to quality products, service and support. Our service department maintains an assistance hotline to assist with application or Corp. (WTC) troubleshooting during normal business hours. By Phone or Fax:...
Page 11: Symbols Used In This Manual
This symbol denotes when insufficient or lacking compliance with the instructions may damage equipment or files. NOTE: This convention informs the user about special features, or where to find more information. Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 12: Revision History
NEVER drill into the control cabinet without properly protecting internal components from metal debris and removing power. Failure to observe this requirement may cause a potential EXPLOSION HAZARD. MedWeld 4000 Operator’s Guide Modified: 9/17/08 M-032116 Programs #T03300, #T02300 and #T02400...
Page 13: How To Use This Manual
Detailed procedures describe the steps required to perform each programming task. Other descriptions explain the procedures for installation, initialization and troubleshooting, along with explanations of the hardware and each weld function. xiii Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 14: Software Updates
Getting Started Software Updates WTC reserves the right to make substitutions or changes as required to the hardware or software described in this manual. This manual may be periodically updated to reflect software changes that will affect operation of the equipment described. Request copies of the latest updates by completing the “Comments for Feedback Form”...
Page 15: Cooling Water Requirements
Getting Started Cooling Water Requirements Specifications on the The specifications for cooling water are subject to change. For the latest specifications, go to the WTC Web site: http://www.weldtechcorp.com/documentation/index.html. Cooling Water The cooling water provided must comply with chemical and physical specifications as stated in the Resistance Welder Manufacturers’...
Page 16: Scrs With Hose Running Between Tangs At 480 Vac
Putting the water into circulation again develops pressure in the cooling circuit, consequently causing the hose to rupture. Therefore, WTC does NOT recommend the use of water savers with these SCRs. When magnetic contactors are used, they remove power from the SCR module and prevent destruction of the hose.
Page 17: Working With Static-Sensitive Devices
The measured static voltage at a workstation MUST NOT exceed 50 volts. Contact Information For detailed information about ESD precautions, contact ESD Association e-mail: eosesd@aol.com Web: www.esda.org Voice: 315–339–6937 e-mail: info@esda.org Fax: 315–339–6793 xvii Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 18: Copyright
Copyright WTC software and publications are copyrighted and all rights are reserved by WTC. Distribution and sale of software is intended for the use of the original purchaser, and only for use on a single machine. Copying, duplicating, selling or otherwise distributing this software is a violation of law.
Page 19 Getting Started This page is intentionally left blank. Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 20: Problem Report Form
Indicate each code that is displayed: Description of the problem: Sequence of events leading to the problem: Drawing number(s) of schematic(s) shipped with the Product ###: MedWeld 4000 Operator’s Guide Modified: 9/17/08 M-032116 Programs #T03300, #T02300 and #T02400...
Page 21 Getting Started This page is intentionally left blank. Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 22: Your Feedback Welcome Here
Comments for Your Name: Date: Time: Feedback Form Company Name: Phone: Company Address: City: State: ZIP: Program/Revision #: # of Manuals at your site: Document Number/Name: Your comments: MedWeld 4000 Operator’s Guide Modified: 9/17/08 xxii M-032116 Programs #T03300, #T02300 and #T02400...
Page 23 Getting Started This page is intentionally left blank. xxiii Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 24: Medweld 4000 Overview
The control communicates with the welding automation: Either machine controllers, factory automation or manually-operated welders. Control Description In the MedWeld 4000, programmed instructions in the software command a timer assembly. The timer assembly controls a weld processor, which issues firing signals to the firing card through a firing cable harness plugged directly into the weld processor.
Page 25 Compensation (to maintain a desired primary voltage) or Automatic Current Compensation (to maintain constant secondary current). The MedWeld 4000 can perform the weld, delay, slope, pulsation or timing functions that your application requires. Other features allow control of outputs, and monitor the status of inputs.
Page 26: Physical Description
MedWeld 4000 Weld Figure 1: Control (AC) NOTE: The possible configuration options are too numerous to detail here. Contact your WTC sales representative for assistance on configuration options. MedWeld 4000 Operator’s Guide Modified: 12/16/08 1 - 3 M-032116 Programs #T03300, #T02300 and #T02400...
Page 27: Type 1 (Medar) Mfdc
MedWeld 4000 Weld Figure 2: Control MFDC Type 1 NOTE: The possible configuration options are too numerous to detail here. Contact your WTC sales representative for assistance on configuration options. 1 - 4 Modified: 12/16/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 28: Type 1 Inverter Specifications
183 A. RMS mains line current 169 A. Cabinet ratings at 20 % duty cycle RMS output current 258 A. RMS mains line current 239 A. MedWeld 4000 Operator’s Guide Modified: 12/16/08 1 - 5 M-032116 Programs #T03300, #T02300 and #T02400...
Page 29: Type 1 (50 Hz) Inverter 600 Amp
183 A. Cabinet ratings at 50 Hz mains, 1000 Hz output, 20 % duty cycle RMS output current 262 A. RMS mains line current 258 A. 1 - 6 Modified: 12/16/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 30: Type 2 (Common) Mfdc
MedWeld 4000 Weld Figure 3: Control MFDC Type 2 NOTE: The possible configuration options are too numerous to detail here. Contact your WTC sales representative for assistance on configuration options. MedWeld 4000 Operator’s Guide Modified: 12/16/08 1 - 7 M-032116 Programs #T03300, #T02300 and #T02400...
Page 31: Component Descriptions
MedWeld 4000 Overview Component Descriptions This section is a brief description of the following components provided with the MedWeld 4000 control (models): • Circuit breaker • Isolation contactor • Control transformer • Current coil • Timer assembly • Discrete I/O board (optional) •...
Page 32: Isolation Contactor
24 VDC that can power discrete inputs and outputs. Current Coils The standard MedWeld 4000 has a coil to measure primary current. An optional coil measures secondary current. The primary current coil is the doughnut-shaped device located near the SCR assembly in the control enclosure.
Page 33: Timer Assembly
MedWeld 4000 Overview Timer Assembly The timer assembly (WTC p/n 900-822x-2) provides a firing signal to the firing card, as required by the weld schedule. The firing card then provides the gate signals to the SCRs. The SCRs send welding voltage to the weld transformer, to apply weld current to the work piece.
Page 34: Fieldbus Daughter Board
Local DEP port J8: Connect a DEP-100S Data Entry Panel to port J8 to program the control’s basic operating parameters and to set its network address. This connector requires using the door/remote I/O interface kit (WTC p/n 830-0654). • MedLAN port J2: Use connector J2 to link the weld control to other controls and a network monitoring system through the Local Area Network (MedLAN).
Page 35 For more details, refer to “Configuring the FieldBus Daughter Board” on page 1-14. NOTE: Profibus configuration switches set only the local station address value using binary coded decimal (BCD) on the dip switches. 1 - 12 Modified: 12/16/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 36 For more details, refer to “Configuring the FieldBus Daughter Board” on page 1-14. MedWeld 4000 Operator’s Guide Modified: 12/16/08 1 - 13 M-032116 Programs #T03300, #T02300 and #T02400...
Page 37: Configuring The Fieldbus Daughter Board
Profibus systems, and for both rocker and slider switches: Slider: Rocker: • ON (closed) sets the bit to a 0. • OFF (open) sets the bit to a 1. 1 - 14 Modified: 12/16/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 38: Configuration Switches
(MSB - LSB) (MSB - LSB) Switches (Fieldbus Specific Input Register) Node Address: Set the node address for the MedWeld 4000, in the range 0 - 126. A 7-pole binary switch specifies the address. Refer to the following table: Switch #7...
Page 39: Discrete I/O Board
MedWeld 4000 Overview Discrete I/O Board The Discrete I/O board (WTC p/n 900-8213-2) serves to add more I/O capability to the welding control. The board’s main features are: • 16 inputs (grouped in 2 banks of 8 inputs per bank. Each bank can operate at a different voltage).
Page 40 (120 V AC/DC nominal), this LED will be OFF. On power-up, the green LED will light (24 V mode) until a high-voltage signal is applied to any input. MedWeld 4000 Operator’s Guide Modified: 12/16/08 1 - 17 M-032116 Programs #T03300, #T02300 and #T02400...
Page 41: Dc Operation
120 VAC power source. When operating the inputs with an external power source, nothing should be connected to the +24 VDC power source on the input connector. 1 - 18 Modified: 12/16/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 42: Inputs
SCRs, • Provides gate signals to turn on the SCRs, • Inputs and outputs all of the control’s current monitoring and • Performs high-voltage sensing. MedWeld 4000 Operator’s Guide Modified: 12/16/08 1 - 19 M-032116 Programs #T03300, #T02300 and #T02400...
Page 43: Firing Card Input Signals
All of these signals are transmitted over firing card connector J2 and weld processor card connector J3. Cascade Firing Board The MedWeld 4000 can switch multiple contactors with one weld timer, a firing board and a system of relays. The Cascade Firing Board (CFB) implements this capability.
Page 44: Scr Assembly
(abbreviated to SCIB). The SCIB is an add-on accessory to kernel-based Interface Board welding controls (i. e., MedWeld 4000, 200, etc.). The SCIB enables the welding control to read secondary current. The SCIB installs in-line on the cable which connects between the weld timer and the firing board.
Page 45: Mfdc Control Description
• Automatic Current Compensation (to maintain constant secondary current). The MedWeld 4000 can perform the weld, delay, slope, pulsation or timing functions required by your application. Other functions allow you to control outputs and monitor the status of inputs. Weld Processor...
Page 46: Weld Processor Output
It can only respond to requests for data.) After each weld sequence, the weld processor instructs the inverter to upload the weld summary, including any fault conditions and weld data. MedWeld 4000 Operator’s Guide Modified: 12/16/08 1 - 23...
Page 47: Mfdc Control Component Descriptions
MedWeld 4000 Overview MFDC Control Component Descriptions The MedWeld 4000 MFDC control has the following components: • Circuit breaker (page 1-8) • Isolation contactor (page 1-9) • Charging pack (Type 1 inverter only; see page 1-24) , • Control transformer (page 1-9) •...
Page 48: Control Transformer
The inverter provides the outputs to the welding transformer at H1 and Refer to the MFDC Inverter Technical Reference for specific information for each inverter. MedWeld 4000 Operator’s Guide Modified: 12/16/08 1 - 25 M-032116 Programs #T03300, #T02300 and #T02400...
Page 49: Weld Processor
Faults generated by the MFDC inverter. Inverter faults will de-energize the charging pack. Processor faults will inhibit the firing signal to the inverter (but do not de-energize the charging pack). 1 - 26 Modified: 12/16/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 50 These steps are described in the sections that follow. *HWWLQJ 6WDUWHG 0DNLQJ WKH To aid in installing the MedWeld 4000, tear out or copy the “Installation Checklist” on page 2-26. Use it as a checklist to follow these steps: 5HTXLUHG &RQQHFWLRQV...
Page 51: Providing I/O Connections
9^cdQ\\Y^WdXU=UTGU\T$ 3QedY_^* GXU^\YVdY^WQ^igUYWXdQR_fU" [Wn$%\R ecUUYdXUbQdg_]Q^\YVd_bQ^QccYcdUT\YVd WTC does NOT recommend drilling additional holes in the cabinet for additional brackets. If WA R N I N G! additional holes are required, make certain all components are covered to protect them from metal shavings. Metal debris (from drilling into the cabinet) can cause catastrophic failure.
Page 52 18. Verify that all I/O are present and correctly assigned in the software. Refer to the schematics supplied with the control. 19. Turn on the cooling water and ensure proper flow rate. The MedWeld 4000 control is now ready to power up. =UTGU\T$ ?`UbQd_bµc7eYTU =_TYVYUT*'") #...
Page 53 Some inputs/outputs require connection and configuration. 3URYLGLQJ /RFDO ,2 As shipped from the factory, the MedWeld 4000 has two jumpers installed between J10 pins 10 - 11 and J10 pins 12 - 13 on the timer assembly. You can set up the CONTROL STOP input to use either an internal or external power source, as follows: •...
Page 54 Finally, make the connection to the drop line at the terminal block plug provided on the DeviceNet or Profibus module. 3URYLGLQJ 0HG/$1 &RQQHFWLRQV MedLAN (WTC’s Local Area Network) is a proprietary communications protocol. It defines how devices on the network communicate with each other.
Page 55 6SHFLILFDWLRQV spacing of 5 mm. The baud rate of this connection is 9,600. &DEOH 5HTXLUHPHQWV WTC recommends using the Belden 9463 cable or equivalent. The following tables list the cable pinouts. MedLAN Connector (on the Network Power Pack): Wire Color...
Page 56 9^cdQ\\Y^WdXU=UTGU\T$ MedLAN Connector (on the weld processor card): Wire Color Designator Pin # Function (BELDEN #9463) MDL2 MedLan Line 2 Clear MDLS Line Shield MDL1 MedLAN Line 1 Blue WA R N I N G! NEVER connect any of the communication ports to the MDP- power wires.
Page 57 Be certain to cover all components to protect them from metal shavings. Metal debris (from drilling into the cabinet) can cause catastrophic failure. The WTC warranty does NOT cover damage caused by metal debris. Physically separate the MedLAN cable from wiring greater than 50 volts.
Page 58 Installing the MedWeld 4000 Setting the Weld The MedWeld 4000 uses MedLAN (WTC’s proprietary Local Area Network) to create a communications network between devices. After Processor MedLAN configuring each control, establishing the MedLAN connection and Address powering it up, you must set the MedLAN address for each device before it can respond to the network.
Page 59 9^cdQ\\Y^WdXU=UTGU\T$ To set the address for each weld control, follow this procedure: Plug the DEP-100S into the DEP (top) port on the weld processor card (or the DEP port on the enclosure door, if provided). Press the Program Mode key. You will see this screen: @?G5B?>3?==?>...
Page 60 WTC Network Power Pack. • When connecting the MedWeld 4000 to a network controlled by the WTC Weld Support System (XWSS), programming and data acquisition can be done through WTC’s proprietary programs.
Page 61 9^cdQ\\Y^WdXU=UTGU\T$ '(36 3URJUDPPLQJ 'HYLFH WTC’s DEP-100S Programming Device is a data entry device. Use it to program one, several or up to 30 weld processors on a MedLAN network. • When programming locally, the DEP-100S is plugged directly into the port on the WTC control.
Page 62 9^cdQ\\Y^WdXU=UTGU\T$ +RZ WR 3URJUDP ,2 0DSSLQJV The MedWeld 4000 has a new capability to assign any Discrete or FieldBus I/O point to any I/O function. This section explains how to program I/O mappings for all types of MedWeld 4000 control.
Page 63 9^cdQ\\Y^WdXU=UTGU\T$ 7 $& &RQWUROV Press to pan to these additional options: 88D" 3?==?> @B?7B1==?45 G5<45BDB1>C65B>5DG?B;9? 9441D1144B=1@@9>7 6!6"6#6$ Either • Press from this screen to present the IO Mapping option. Proceed to “Options for Mapping I/O” on page 2-16); or: •...
Page 64 9^cdQ\\Y^WdXU=UTGU\T$ 7 7\SH ,QYHUWHU &RQWUROV Press to pan to these additional options: 88D" 3?==?> @B?7B1==?45 G5<45BDB1>C65B>5DG?B;1>1<?7 9441D1144B41D1 6!6"6#6$ Press again to show the IO Mapping and Fieldbus Mapping options: 88D" 3?==?> @B?7B1==?45 9?695<42EC =1@@9>7=1@@9>7 6!6"6#6$ From this screen, select either:...
Page 65 9^cdQ\\Y^WdXU=UTGU\T$ 2SWLRQV IRU To set the options for mapping Discrete or FieldBus I/O, follow these steps: 0DSSLQJ ,2 Press to select the IO Mapping option. Either this screen will appear: 88D" 3?==?> !4YcSbUdU9??`dY_^c "=Q`4YcSbUdU9^`edc #=Q`4YcSbUdU?ed`edc 6!6"6#6$ In this screen, select one of the three menu options presented: •...
Page 66 9^cdQ\\Y^WdXU=UTGU\T$ 7KH ,2 2SWLRQV 6FUHHQ 'LVFUHWH To set the Discrete I/O options, press the 1 key while in the IO Mapping screen shown above. This screen now appears: 88D" 3?==?> CD1BD?69??@D9?>C B5<?1449?4561E<DC*4561E<D! 9C?<1D9?>3?>D13D?B*49C12<54 5>4?69??@D9?>C gSe T_g^\_QTUhYd 6!6"6#6$ Follow these steps: Use the W or E keys as needed to scroll to the RELOAD DIO DEFAULTS: option.
Page 67 9^cdQ\\Y^WdXU=UTGU\T$ On the timer board, set the RUN/PROGRAM jumper to RUN mode. 10. Turn ON power to the control. The settings you downloaded will now take effect. 7KH ,2 2SWLRQV 6FUHHQ )LHOG%XV To set the FieldBus I/O options, press the 1 key while in the IO Mapping screen on page 2-16.
Page 68 9^cdQ\\Y^WdXU=UTGU\T$ 0DSSLQJ ,QSXWV To change the mapping of input points to input names, press the 2 key while in the IO Mapping screen. This screen appears: 88D" 3?==?> CD1BD?69?=1@ 9>@ED !*29>1BIC5<53D!@9<?D! 9>@ED "*29>1BIC5<53D"@9<?D" gSe T_g^\_QTUhYd 6!6"6#6$ This example is for reference only. What you see will vary, depending on your application and the input mapping currently entered.
Page 69 9^cdQ\\Y^WdXU=UTGU\T$ In the next example, Input 09 is now assigned to the STEPPER RESET GROUP 1 input. Use the O and U keys, repeating as needed to display this desired input: 88D" 3?==?> 9>@ED )*CD5@@5BB5C5D7B?E@! gSe T_g^\_QTUhYd 6!6"6#6$ To assign the input position number to the desired input (Input 09 to the STEPPER RESET GROUP 1 input in this example), press .
Page 70 9^cdQ\\Y^WdXU=UTGU\T$ 0DSSLQJ 2XWSXWV To change the mapping of output points to output names, press the 3 key while in the IO Mapping screen. This screen appears first: 88D" 3?==?> CD1BD?69?=1@ ?ED@ED !*F1<F5!29>1BIF1<F5! ?ED@ED "*F1<F5"29>1BIF1<F5" gSe T_g^\_QTUhYd 6!6"6#6$ This example is for reference only. What you see will vary, depending on your application and the output mapping currently entered.
Page 71 9^cdQ\\Y^WdXU=UTGU\T$ In the next example, Output 06 is now assigned to the INTENSIFICATION VALVE output. Use the O and U keys, repeating as needed to display this screen: 88D" 3?==?> ?ED@ED &*9>D5>C96931D9?>F1<F5 gSe T_g^\_QTUhYd 6!6"6#6$ To assign the output position number to the desired output (Output 06 to the INTENSIFICATION VALVE output in this example), press the key.
Page 72 9^cdQ\\Y^WdXU=UTGU\T$ 5HTXLUHG (OHFWULFDO &RQQHFWLRQV All electrical connections must be mechanically clean and secure. They should have no signs of wear, fretting, damage or chemical corrosion. These requirements are CRITICAL for the high-voltage power connections to, from and within the control. The customer must complete these connections: 3RZHU &RQQHFWLRQV •...
Page 73 9^cdQ\\Y^WdXU=UTGU\T$ 5HTXLUHG 7RUTXH IRU (OHFWULFDO &RQQHFWLRQV All electrical connections must be mechanically clean and secure, without signs of wear, fretting, damage or chemical corrosion. These requirements are CRITICAL for the high-voltage power connections to, from and within the control. This section lists the recommended torque specifications and cable sizes for SCRs, circuit breakers and contactors.
Page 74 9^cdQ\\Y^WdXU=UTGU\T$ 5HTXLUHG 7RUTXH &LUFXLW %UHDNHUV Captive Nut Assy. Copper Bus Suggested Device (Copper Lug or Bus Cable Lug to Lug or Cable Size Direct to Device) Device Tang 10 lb.-ft. (13.5 n-m) ABB S3 breaker 6.64 lb.-ft. (9 n-m) ABB K4TC 10 lb.-ft.
Page 75 9^cdQ\\Y^WdXU=UTGU\T$ ,QVWDOODWLRQ &KHFNOLVW Copy or tear out this checklist, to aid in installing the MedWeld 4000. Be certain to verify and check off each step after performing it. Also, the responsible service technician should sign their initials after completing each step.
Page 76 Installing the MedWeld 4000 Inspect all connections: Verify proper Step 15 crimping and torque. Verify NO line-to-line shorts. Refer to page 2-25. Verify all I/O are present and correctly Step 16 assigned in software. Ensure cooling water supply and proper Step 17 flow rate.
Page 77 9^cdQ\\Y^WdXU=UTGU\T$ This page is intentionally left blank. ""( =_TYVYUT*'") # =UTGU\T$ ?`UbQd_bµc7eYTU = #"!!&@b_WbQ]cD ## D "# Q^TD "$...
Page 78: Communications And I/O
• Discrete I/O. Inputs and outputs are directly wired into the control’s enclosure. This chapter defines the inputs to the MedWeld 4000, and the outputs that it provides. The following sections describe each option and the I/O provided. Local I/O...
Page 79: Local Inputs
The inverter thermal switches indicate that cooling water is present. • The isolation contactor is ready to be pulled in (to provide weld current). • No fault conditions exist at the inverter. 3 - 2 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 80: Local Outputs
Refer to page 5-5 for further information. SHUNT TRIP Output Activating this output trips the circuit breaker in case of a catastrophic failure. MedWeld 4000 Operator’s Guide Modified: 9/17/08 3 - 3 M-032116 Programs #T03300, #T02300 and #T02400...
Page 81: Programmable Inputs/Outputs
Communications and I/O Programmable Inputs/Outputs The MedWeld 4000 provides for programmable input/output assignments, or mappings. An input mapping lists input numbers 01 - 16 and their respective input names. An output mapping lists output numbers 01 - 10 and their respective output names.
Page 82: Supported I/O
If changing the FieldBus word size, you must cycle power to the control OFF, then back ON. The I/O tables configured on power-up are based on the most recently- programmed I/O mappings. MedWeld 4000 Operator’s Guide Modified: 9/17/08 3 - 5 M-032116 Programs #T03300, #T02300 and #T02400...
Page 83: Input Definitions
NO WELD fault is issued. Setting this input to 0 means the input defaults to open. Setting to 1 means the input defaults to closed. 3 - 6 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 84 It does not affect any other outputs. Setting this input to 0 means the input defaults to open. Setting to 1 means the input defaults to closed. MedWeld 4000 Operator’s Guide Modified: 9/17/08 3 - 7 M-032116 Programs #T03300, #T02300 and #T02400...
Page 85 STEPPER RESET GROUP 2 SRG2 This input will reset all the steppers in Group 1 or 2 to Step 1 and the weld count to 0. 3 - 8 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 86 AIR/OIL-NORMALLY CLOSED indicates that the output is turned ON to close the gun. For a detailed explanation of operation in retract, see “Retract Features” on page 7-12. MedWeld 4000 Operator’s Guide Modified: 9/17/08 3 - 9 M-032116 Programs #T03300, #T02300 and #T02400...
Page 87: Output Definitions
Communications and I/O Output Definitions This section describes the output signals that the MedWeld 4000 control provides. At the right of the output names are abbreviations as they appear on the DEP-100S (Data Entry Panel). Valve outputs may be output in two ways: Binary or Discrete. The type is set in I/O map 03 Valve Type.
Page 88 The control is in Weld Mode, • NO faults exist, • The CONTROL STOP input is HIGH, • The WCU is synchronized with the line voltage, MedWeld 4000 Operator’s Guide Modified: 9/17/08 3 - 11 M-032116 Programs #T03300, #T02300 and #T02400...
Page 89 These outputs are activated or de-activated when the MedWeld 4000 executes functions #56 (TURN ON PRESSURE SELECT #n) and #57 (TURN OFF PRESSURE SELECT #n). 3 - 12 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 90: Other I/O: Program T02300
The program sequentially fires 4 CONTACTOR SELECT inputs to the inverter. If a fault is detected in a contactor, a CONTACTOR NOT IN WHEN NEEDED fault will be generated. MedWeld 4000 Operator’s Guide Modified: 9/17/08 3 - 13 M-032116 Programs #T03300, #T02300 and #T02400...
Page 91: Fieldbus Outputs
CONTACTOR SELECT (1 - 4) This output selects which inverter SCR to switch on, when firing multiple SCRs in the inverter. ISOC IS OPEN 3 - 14 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 92: Discrete Inputs
These are generic inputs from the SLC. These inputs can be used to force the weld processor to wait in a weld schedule using the user input functions. CONTACTOR (1 - 4) SHORT Input MedWeld 4000 Operator’s Guide Modified: 9/17/08 3 - 15 M-032116 Programs #T03300, #T02300 and #T02400...
Page 93: Discrete Outputs
This is a status output that shows the status of the isolation contactor. If the isolation contactor is open, this output is activated. DUTY CYCLE LIMIT 3 - 16 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 94 Setting the AUX. COUNTER RESET input HIGH resets all of the steppers’ auxiliary weld counters. The existing STEPPER RESET input also will reset the counters. MedWeld 4000 Operator’s Guide Modified: 9/17/08 3 - 17 M-032116 Programs #T03300, #T02300 and #T02400...
Page 95: Input Abbreviations
Program T02400 (using the Type 1 inverter) has I/O mappings for use with the FieldBus (Profibus) and Discrete I/O communication schemes. Input Abbreviations On the LCD panel of the MedWeld 4000 or DEP-100S, the FieldBus and Discrete inputs appear with these abbreviations: BINARY SELECT 1 / Pilot 1 ........BS1 BINARY SELECT 2 / Pilot 2 ........BS2...
Page 96: Output Abbreviations
Communications and I/O Output Abbreviations On the LCD panel of the MedWeld 4000 or DEP-100S, the FieldBus and Discrete outputs appear with these abbreviations: VALVE1 / BINARY VALVE 1 .........V1 VALVE2 / BINARY VALVE 2 .........V2 VALVE3 / BINARY VALVE 4 .........V4 VALVE4 / BINARY VALVE 8 .........V8...
Page 97: Input/Output Mappings (T03300)
FieldBus (Profibus) and DIO (Discrete I/O) communication systems. Input Abbreviations On the LCD panel of the MedWeld 4000 or DEP-100S, the FieldBus and Discrete inputs appear with these abbreviations: BINARY SELECT 1 / Pilot 1 ........BS1 BINARY SELECT 2 / Pilot 2 ........BS2 BINARY SELECT 4 / Pilot 3 ........BS4...
Page 98: Output Abbreviations
Communications and I/O Output Abbreviations On the LCD panel of the MedWeld 4000 or DEP-100S, the FieldBus and DiscreteDiscrete outputs appear with these abbreviations: VALVE1 / BINARY VALVE 1 .........V1 VALVE2 / BINARY VALVE 2 .........V2 VALVE3 / BINARY VALVE 4 .........V4 VALVE4 / BINARY VALVE 8 .........V8...
Page 99 Communications and I/O This page is intentionally left blank. 3 - 22 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 100: Weld Schedules
Weld Schedules The MedWeld 4000 control is a full-function device, capable of storing up to 99 unique weld schedules. Each weld schedule can then be assigned to one of 99 independent steppers. Several methods are available to program the weld processor. Refer to “Programming the Weld Processor”...
Page 101: Software Capabilities
Weld Schedules Software Capabilities The MedWeld 4000 provides commands for: • Assigning a schedule to a stepper, • Defining the type of stepper to use (linear or SureWeld), • Turning selected outputs on or off and • Providing weld current.
Page 102: List Of Functions
AC operation: Automatic Current Compensation. ACC monitors the current during each cycle. It compensates for changes detected during the next cycle, to maintain secondary current at the level programmed. MedWeld 4000 Operator’s Guide Modified: 9/17/08 4 - 3 M-032116 Programs #T03300, #T02300 and #T02400...
Page 103: Avc Firing Mode (%I)
For all weld functions, mm = 20 – 99. (The processor can fire a range from 20% to 99% I.) For half-cycle functions, the range is from 20.0% to 4 - 4 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 104: Automatic Current Compensation Firing Mode
IMP (impulses) rather than CY (cycles) to indicate that the weld control will pulsation weld. See Function #60 on page 4-7 for more information. MedWeld 4000 Operator’s Guide Modified: 9/17/08 4 - 5 M-032116 Programs #T03300, #T02300 and #T02400...
Page 105: Other Functions Controlling Weld Current
4 - 6 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 106 This function only affects the next function in a weld schedule. It should appear before every weld or slope function you want to pulsation weld in the schedule. MedWeld 4000 Operator’s Guide Modified: 9/17/08 4 - 7 M-032116 Programs #T03300, #T02300 and #T02400...
Page 107: Output Control Functions
This is designed to improve the process speed, bypassing the delay provided to wait for the isolation contactor to close. 4 - 8 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 108: Input Monitoring Functions
Voltage setup parameter is programmed as a FAULT. If programming this parameter as either an ALERT or NONE, it continues with the sequence as normal. MedWeld 4000 Operator’s Guide Modified: 9/17/08 4 - 9 M-032116 Programs #T03300, #T02300 and #T02400...
Page 109 ZERO CROSSING SYNCHRONIZATION fault to indicate that a fault condition was active. (This is to prevent the control from performing a repeat of the sequence after receiving a FAULT RESET signal.) 4 - 10 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 110: Extend/Repeat Functions
WELD INITIATE input has been removed. NOTE: Functions #62 and #75 are mutually exclusive. They should NOT appear in the same sequence. MedWeld 4000 Operator’s Guide Modified: 9/17/08 4 - 11 M-032116 Programs #T03300, #T02300 and #T02400...
Page 111 When it is in No Weld mode, the control bypasses these Extend Weld functions. (The weld processor will not monitor the amount of current provided, because the control is in No Weld.) 4 - 12 Modified: 9/25/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 112: Stepper Assignment Functions
Function #82 assigns a linear stepper to a weld schedule. Function #83 assigns a SureWeld stepper to a weld schedule. The MedWeld 4000 can have up to 99 independent linear steppers, and up to 99 SureWeld steppers. Linear steppers have 5 programmable levels (called “steps”) to provide additional energy.
Page 113: Functions That Override Setup Parameters
Other functions (described below) also use the data generated by the test fire. 4 - 14 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 114 If less than 10 A. primary current is detected, the control assumes that the electrode tips were NOT touching. It generates a TIPS NOT TOUCHING fault. MedWeld 4000 Operator’s Guide Modified: 9/17/08 4 - 15...
Page 115 If the power factor read during the test fire was not within the range programmed, the control generates an INITIAL P.F. OUT OF RANGE fault. 4 - 16 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 116 This is implemented because the test fire is a single-cycle pulse, and the control is monitoring only changes in resistance (rather than changes in current). MedWeld 4000 Operator’s Guide Modified: 9/17/08 4 - 17 M-032116 Programs #T03300, #T02300 and #T02400...
Page 117 If the current never reaches the setup parameter limit, the control will continue the schedule in Weld mode, but generates a SLOW CYLINDER fault to indicate the condition. 4 - 18 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 118: Special Functions
PROCESS WELD FAULTS This function provides a one-cycle delay in the weld schedule. It asks the MedWeld 4000 to indicate any faults that may have been generated so far in the schedule. The control normally processes all fault conditions at the end of the weld schedule.
Page 119: Spc Indexing Functions
This function overrides the global Data Collection Sample Size and Data Collection Sample Frequency setup parameters described on page 7-9. 4 - 20 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 120: Analog Pressure Control Functions
No Weld mode to inhibit weld current from flowing. If programming this parameter as an ALERT or NONE, it continues with the sequence as normal. MedWeld 4000 Operator’s Guide Modified: 9/17/08 4 - 21 M-032116 Programs #T03300, #T02300 and #T02400...
Page 121 Either #1 or #2. Set the pressure mm in the range 0 – 99 PSI. 4 - 22 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 122: Cascade Firing Board Support
TURN ON CONTACTOR SELECT #nn (nn=1-15) This function selects the contactor number to enable for firing when attached to WTC's Cascade Firing Board in multi-contactor, single- phase applications. Set nn to be in the range 1 – 15. Contactor enabling follows this sequence: #01 corresponds to CFB #1 firing board A;...
Page 123: Delay Functions
TURN ON PRESSURE SELECT #n TURN OFF PRESSURE SELECT #n TURN ON OUTPUT #n TURN OFF OUTPUT #n TURN ON WELD IN PROGRESS TURN OFF WELD IN PROGRESS 4 - 24 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 124: Input Monitoring Functions
(pg. 4-21) SET VALVE n TIP DRESS RESSURE (PSI) CFB Support TURN ON CONTACTOR SELECT #nn (nn=1-15) TURN OFF CONTACTOR SELECT #nn (nn=1-15) Functions (pg. 4-23) MedWeld 4000 Operator’s Guide Modified: 9/17/08 4 - 25 M-032116 Programs #T03300, #T02300 and #T02400...
Page 125: Default Weld Schedules In Program #T03300
TURN ON VALVE #1 SQUEEZE 30 CYCLES WELD 10 CY. 00050 AMPS PROCESS WELD FAULTS HOLD 05 CYCLES TURN OFF VALVE #1 OFF 20 CYCLES END OF SEQUENCE 4 - 26 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 126: Default Weld Schedules In Program #T02300
HOLD 05 CYCLES TURN ON WELD COMPLETE TURN OFF WELD IN PROGRESS EXTEND UNTIL NO INITIATE TURN OFF WELD COMPLETE TURN OFF ISOLATION CONTACTOR END OF SCHEDULE MedWeld 4000 Operator’s Guide Modified: 9/17/08 4 - 27 M-032116 Programs #T03300, #T02300 and #T02400...
Page 127: Default Weld Schedule: Gun
WELD 10 CY. 00050 AMPS PROCESS WELD FAULTS HOLD 05 CYCLES TURN OFF VALVE #1 TURN OFF ISOLATION CONTACTOR OFF 20 CYCLES END OF SCHEDULE 4 - 28 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 128: Default Weld Schedules In Program #T02301
HOLD 05 CYCLES TURN ON WELD COMPLETE TURN OFF WELD IN PROGRESS EXTEND UNTIL NO INITIATE TURN OFF WELD COMPLETE TURN OFF ISOLATION CONTACTOR END OF SCHEDULE MedWeld 4000 Operator’s Guide Modified: 9/17/08 4 - 29 M-032116 Programs #T03300, #T02300 and #T02400...
Page 129: Default Weld Schedule: Gun
WELD 10 CY. 00050 AMPS PROCESS WELD FAULTS HOLD 05 CYCLES TURN OFF VALVE #1 TURN OFF ISOLATION CONTACTOR OFF 20 CYCLES END OF SCHEDULE 4 - 30 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 130: Default Weld Schedules In Program #T02302
HOLD 05 CYCLES TURN ON WELD COMPLETE TURN OFF WELD IN PROGRESS EXTEND UNTIL NO INITIATE TURN OFF WELD COMPLETE TURN OFF ISOLATION CONTACTOR END OF SCHEDULE MedWeld 4000 Operator’s Guide Modified: 9/17/08 4 - 31 M-032116 Programs #T03300, #T02300 and #T02400...
Page 131: Default Weld Schedule: Gun
WELD 10 CY. 00050 AMPS PROCESS WELD FAULTS HOLD 05 CYCLES TURN OFF VALVE #1 TURN OFF ISOLATION CONTACTOR OFF 20 CYCLES END OF SCHEDULE 4 - 32 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 132: Default Weld Schedules In Program #T02304
30WELD 10 CY. 00050 AMPS 85 PROCESS WELD FAULTS 03HOLD 05 CYCLES 51 TURN OFF VALVE #1 89TURN OFF ISOLATION CONTACTOR 04 OFF 20 CYCLES END OF SCHEDULE MedWeld 4000 Operator’s Guide Modified: 9/17/08 4 - 33 M-032116 Programs #T03300, #T02300 and #T02400...
Page 133: Default Weld Schedules In Program #T02306
EXTEND UNTIL NO INITIATE HOLD 10 CYCLES TURN OFF LOW PRESSURE WELD VALVE WAIT 5 CYCLES TURN OFF SEAM DRIVE/EOH TURN OFF ISOLATION CONTACTOR END OF SCHEDULE 4 - 34 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 134: Function List T03300 (Standard Ac)
TURN ON ISOLATION CONTACTOR FUN53 TURN OFF ISOLATION CONTACTOR FUN54 TURN ON VALVE #N FUN55 TURN OFF VALVE #N FUN56 TURN ON PRESSURE SELECT #N MedWeld 4000 Operator’s Guide Modified: 9/17/08 4 - 35 M-032116 Programs #T03300, #T02300 and #T02400...
Page 135 POWER FACTOR LIMIT: HI= NN% LOW= NN%* FUN97 C-FACTOR LIMIT: HI= NNN LO= NNN FUN98 GOTO SEQ #NN IF CURRENT LESS THAN NNNN0 FUN99 GOTO SEQ #NN FUN100 4 - 36 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 136: Function List T03302 (Ac W/Ohma Cylinder Support)
TURN ON ISOLATION CONTACTOR* FUN53 TURN OFF ISOLATION CONTACTOR* FUN54 TURN ON VALVE #,1,$,0,MAXOUTS FUN55 TURN OFF VALVE #,1,$,0,MAXOUTS FUN56 TURN ON PRESSURE SELECT #,1,$,0,PSELOUTM MedWeld 4000 Operator’s Guide Modified: 9/17/08 4 - 37 M-032116 Programs #T03300, #T02300 and #T02400...
Page 137 POWER FACTOR LIMIT: HI= NN% LOW= NN%* FUN97 C-FACTOR LIMIT: HI= NNN LO= NNN FUN98 GOTO SEQ #NN IF CURRENT LESS THAN NNNN0 FUN99 GOTO SEQ #NN FUN100 4 - 38 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 138: Function List T03310 (Ac - Gm Ws2 Specification)
FUN52 TURN ON ISOLATION CONTACTOR FUN53 TURN OFF ISOLATION CONTACTOR FUN54 TURN ON VALVE #N FUN55 TURN OFF VALVE #N FUN56 SET PRESSURE = N MedWeld 4000 Operator’s Guide Modified: 9/17/08 4 - 39 M-032116 Programs #T03300, #T02300 and #T02400...
Page 139 POWER FACTOR LIMIT: HI= NN% LOW= NN%* FUN97 C-FACTOR LIMIT: HI= NNN LO= NNN FUN98 GOTO SEQ #NN IF CURRENT LESS THAN NNNN0 FUN99 GOTO SEQ #NN FUN100 4 - 40 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 140: Function List T03311 (Ac - Gm Ws2 / Abb Robot)
FUN52 TURN ON ISOLATION CONTACTOR FUN53 TURN OFF ISOLATION CONTACTOR FUN54 TURN ON VALVE #N FUN55 TURN OFF VALVE #N FUN56 SET PRESSURE = N MedWeld 4000 Operator’s Guide Modified: 9/17/08 4 - 41 M-032116 Programs #T03300, #T02300 and #T02400...
Page 141 POWER FACTOR LIMIT: HI= NN% LOW= NN% FUN97 C-FACTOR LIMIT: HI= NNN LO= NNN FUN98 GOTO SEQ #NN IF CURRENT LESS THAN NNNN0 FUN99 GOTO SEQ #NN FUN100 4 - 42 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 142: Function List T02300 (Standard Mfdc Software)
Weld Schedules Function List T02300 (Standard MFDC Software) This is the list of funcations for the T02300 MFDC MedWeld 4000 software. NOTE: A * in the function list will indicate there is currently no function in that position. Functions that contain a * may be reserved for future use.
Page 143 EXTEND WELD IF LOW CURRENT LIMIT FAULT FUN95 EXTEND WELD IF CURRENT LESS THAN NNNN AMPS FUN96 FUN97 C-FACTOR LIMIT: HI=NNNN LO=NNNN FUN98 FUN99 GOTO SEQ#NN FUN100 4 - 44 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 144: Function List T02301 (Medar Mfdc Inverter Type 1)
SLOPE NNNN0 AMPS TO NNNN0 AMPS FUN46 SLOPE NN HALF CYCLES NNNN0 AMPS TO NNNN0 AMPS FUN47 FUN48 FUN49 WELD NNN IMP. NNNN AMP HI, NNNN AMP LO MedWeld 4000 Operator’s Guide Modified: 9/17/08 4 - 45 M-032116 Programs #T03300, #T02300 and #T02400...
Page 145 EXTEND WELD IF LOW CURRENT LIMIT FAULT FUN95 EXTEND WELD IF CURRENT LESS THAN NNNN FUN96 FUN97 C-FACTOR LIMIT: HI=NNNN LO=NNNN FUN98 RESET STEPPER NN FUN99 GOTO SEQ#NN FUN100 4 - 46 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 146: Function List T02302 (Mfdc W/Pressure Control And Ohma Cylinder)
FUN50 TURN ON WELD COMPLETE FUN51 TURN OFF WELD COMPLETE FUN52 TURN ON ISOLATION CONTACTOR FUN53 TURN OFF ISOLATION CONTACTOR FUN54 TURN ON VALVE #N MedWeld 4000 Operator’s Guide Modified: 9/17/08 4 - 47 M-032116 Programs #T03300, #T02300 and #T02400...
Page 147 EXTEND WELD IF LOW CURRENT LIMIT FAULT FUN95 EXTEND WELD IF CURRENT LESS THAN NNNN FUN96 FUN97 C-FACTOR LIMIT: HI=NNNN LO=NNNN FUN98 FUN99 GOTO SEQ#NN FUN100 4 - 48 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 148: Function List T02304 (Mfdc For Multi-Inverter Systems)
TURN ON VALVE #N FUN51 TURN OFF VALVE #N FUN52 TURN ON OUTPUT #N FUN53 TURN OFF OUTPUT #N FUN54 TURN ON PRESSURE SELECT #N MedWeld 4000 Operator’s Guide Modified: 9/17/08 4 - 49 M-032116 Programs #T03300, #T02300 and #T02400...
Page 149 SET SPC OFFSET TO NN FUN92 SEND ALL SAMPLES UNTIL NEXT SPC OFFSET FUN92 C-FACTOR LIMIT: HI=NNNN LO=NNNN FUN93 FUN94 FUN95 FUN96 FUN97 FUN98 FUN99 GOTO SEQ #NN FUN100 4 - 50 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 150: Function List T02306 (Mfdc For Multi-Inverter Systems With Forge Valve)
FUN51 NEG ANALOG WINDOW=.NNNN +/- .NNNN E+N FUN52 ABORT IF ANALOG INPUT #N NOT IN WINDOW FUN53 FAULT IF ANALOG INPUT #N NOT IN WINDOW MedWeld 4000 Operator’s Guide Modified: 9/17/08 4 - 51 M-032116 Programs #T03300, #T02300 and #T02400...
Page 151 FUN96 VERIFY CYLINDER #N IS OUT OF RETRACT FUN97 EXTEND IF LOW CURRENT LIMIT FAULT FUN98 GOTO REPEAT NNN TIMES FUN99 GOTO SEQ #NN FUN100 4 - 52 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 152 Weld Schedules This page is intentionally left blank. MedWeld 4000 Operator’s Guide Modified: 9/17/08 4 - 53 M-032116 Programs #T03300, #T02300 and #T02400...
Page 153 Weld Schedules 4 - 54 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 154: Setup Parameters
Setup Parameters The MedWeld 4000 provides a number of programmable setup parameters. They allow for customizing the control to meet your application requirements. These parameters “inform” the control about its operating environment. They also define the hardware (such as the type of transformer used and its turns ratio), and describe acceptable limits on the ranges of weld parameters (such as secondary current, power factor and C-factor).
Page 155: Parameter Descriptions
(FAULT) (ALERT) If the weld schedule is using the function to TURN ON WELD COMPLETE, the MedWeld 4000 expects the INITIATE WELD input to remain active while executing the weld schedule. If this input is not active when the weld control executes the function TURN ON WELD COMPLETE, the control generates this condition.
Page 156 10 A. of primary current during the test fire, the control assumes that the tips were open. It generates the TIPS NOT TOUCHING fault. MedWeld 4000 Operator’s Guide Modified: 9/17/08 5 - 3 M-032116 Programs #T03300, #T02300 and #T02400...
Page 157 This fault indicates that the weld initiate was removed or time expired while the control waited for the programmed line voltage (in Function #72 or #73). 5 - 4 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 158 20%I. ISO CNTR ERR-BRKR TRIPPED: (FAULT) This fault is generated when the MedWeld 4000 signals to open the isolation contactor (to cut off weld current) but the isolation contactor did NOT open. It can also occur if the isolation contactor is pulled in when a weld initiate is not present.
Page 159 If the control moves into No Weld Mode while sequencing. • If the control powers down while sequencing. • If the WTC weld processor loses communication while the control is executing a schedule. I/O: (T02300 only) (FAULT) This fault is issued when there has been a loss of communication over a set amount of time and no I/O is being received at the weld processor.
Page 160 The processor entered Program Mode while the control was executing a weld sequence. • The WTC weld processor loses communications for more than the time specified in the I/O Update Timeout (mSEC): nnn setup parameter. The fault may be set at any time, including when the control is initiating a schedule.
Page 161 (approximately 10 percent of the maximum available on- time at 1,200 Hz operating mid-frequency). 5 - 8 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 162 (no zero-crossing synchronization). • If an error occurred during the secondary calibration process due to a missing current range jumper on the SCIB board. MedWeld 4000 Operator’s Guide Modified: 9/17/08 5 - 9 M-032116 Programs #T03300, #T02300 and #T02400...
Page 163 INHIBIT tells the control to ignore the initiate and generate this fault. • ALLOW tells the control to ignore the fault condition and initiate the schedule. 5 - 10 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 164 LATCHED tells the control to change the state of the RETRACT output when the input is briefly turned on and then off (pulsed). For safety, the MedWeld 4000 ignores any WARNING! changes made to this parameter until you reset the control (by cycling power).
Page 165 AIR-INVERTED—Select this type of gun cylinder when the machine uses an air-only cylinder, AND the RETRACT output is turned ON to close the gun. For safety, the MedWeld 4000 ignores any WARNING! changes made to this parameter, until you reset the control (by cycling power).
Page 166 These two parameters define a global current range for every weld schedule. The MedWeld 4000 calculates the high current window as a percentage boost over the current expected. The low current window is a percentage decrease from the expected current. (The expected current is the base current—programmed in the weld...
Page 167 This parameter tells the control the turns ratio of the welding transformer used. This lets the control determine secondary current during a weld. (Secondary current equals the primary current multiplied by the turns ratio.) 5 - 14 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 168 The programming device displays the actual C-Factor detected by the MedWeld 4000. You can program the acceptable range of C-factor in a weld schedule. To determine the nominal C-Factor, first perform a series of welds.
Page 169 Sec. Curr Coil Factor is only supported when a secondary current interface board (SCIB) is installed to measure the secondary current from the weld transformer. 5 - 16 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 170: Inverter Fault Status (Mfdc - T023Xx Softwares)
In the PRIMARY I and SECONDARY I firing modes, the Maximum on or Flux Limit is reached on 4 or more consecutive high-frequency half-cycles. MedWeld 4000 Operator’s Guide Modified: 9/17/08 5 - 17 M-032116 Programs #T03300, #T02300 and #T02400...
Page 171 The inverter generates this fault on detecting that the application is attempting to operate the isolation contactors at a rate higher than allowed by the de-rating of the discharge resistors. 5 - 18 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 172 (FAULT) If no diode peak is detected in the primary current for three consecutive pulses of the same high-frequency half-cycle phase, a fault is set. MedWeld 4000 Operator’s Guide Modified: 9/17/08 5 - 19 M-032116 Programs #T03300, #T02300 and #T02400...
Page 173 CAP CHANGE REQUEST output. This indicates that the tips require maintenance. Setting this parameter to zero disables the tip dress operation. 5 - 20 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 174: Inverter Operating Parameters
These parameters set the range of acceptable values used by the MFDC Inverter to determine the amount of weld current to provide, based on the selected firing mode. MedWeld 4000 Operator’s Guide Modified: 9/17/08 5 - 21 M-032116 Programs #T03300, #T02300 and #T02400...
Page 175: Quick Reference To Setup Parameters (T03300)
PRESSURE NOT ACHIEVED (FAULT) SECONDARY CURRENT COIL/BOARD (FAULT) CURRENT MONITOR MODE (PRIMARY) TRANSFORMER (AC WOUND) CURRENT LIMIT MODE (AVERAGE) INITIATION ON FAULT (INHIBIT SHORT DETECTION (ENABLED) 5 - 22 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 176 (10 AMPS) TRANSFORMER TURNS RATIO (100:1) NOMINAL LINE VOLTAGE (468 VOLTS) NOMINAL C FACTOR (999) I/O UPDATE TIMEOUT (250 mSEC) SEC. CURR COIL FACTOR (X1000) (1000) MedWeld 4000 Operator’s Guide Modified: 9/17/08 5 - 23 M-032116 Programs #T03300, #T02300 and #T02400...
Page 177: Quick Reference To Setup Parameters (T03302)
PRESSURE NOT ACHIEVED (FAULT) SECONDARY CURRENT COIL/BOARD (FAULT) CURRENT MONITOR MODE (PRIMARY) TRANSFORMER (AC WOUND) CURRENT LIMIT MODE (AVERAGE) SHORT DETECTION (ENABLED) RETRACT MODE (LATCHED) (AIR-NORMAL) 5 - 24 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 178 GUN 2 CLOSE TO PRE-BLOCK POS (CY/2) (000) GUN 2 ADVANCE STOP TIME POS (CY/2) (000) GUN 2 OPEN FROM BLOCK POS (CY/2) (000) GUN 2 CLOSE TO PRE-BLOCK POS (CY/2) (000) MedWeld 4000 Operator’s Guide Modified: 9/17/08 5 - 25 M-032116 Programs #T03300, #T02300 and #T02400...
Page 179: Quick Reference To Setup Parameters (T03310)
SHORT DETECTION (ENABLED) RETRACT MODE (LATCHED) (AIR-NORMAL) ANALOG OUTPUT (VOLTAGE) HIGH POWER FACTOR LIMIT (99%) LOW POWER FACTOR LIMIT (10%) TIPS DOWN TEST FIRE %I (20%) 5 - 26 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 180 DATA COLLECTION SAMPLE FREQUENCY (100) MAXIMUM TIP DRESSES (50) TIPS DOWN VERIFIED CURRENT (10 AMPS) TRANSFORMER TURNS RATIO (100:1) NOMINAL LINE VOLTAGE (468 VOLTS) NOMINAL C FACTOR (999) MedWeld 4000 Operator’s Guide Modified: 9/17/08 5 - 27 M-032116 Programs #T03300, #T02300 and #T02400...
Page 181: Quick Reference To Setup Parameters (T03311)
SHORT DETECTION (ENABLED) RETRACT MODE (LATCHED) (AIR-NORMAL) ANALOG OUTPUT (VOLTAGE) HIGH POWER FACTOR LIMIT (99%) LOW POWER FACTOR LIMIT (10%) TIPS DOWN TEST FIRE %I (20%) 5 - 28 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 182 DATA COLLECTION SAMPLE FREQUENCY (100) MAXIMUM TIP DRESSES (50) TIPS DOWN VERIFIED CURRENT (10 AMPS) TRANSFORMER TURNS RATIO (100:1) NOMINAL LINE VOLTAGE (468 VOLTS) NOMINAL C FACTOR (999) MedWeld 4000 Operator’s Guide Modified: 9/17/08 5 - 29 M-032116 Programs #T03300, #T02300 and #T02400...
Page 183: Quick Reference To Setup Parameters (T02300)
CAPACITOR DISCHARGE (FAULT) CAPACITOR CHARGING (FAULT) CHARGE/DISCHARGE DUTY CYCLE (FAULT) INVERTER ISO CONTACTOR OFF (FAULT) INVERTER OVER TEMP (FAULT) OUTPUT GROUND (FAULT) HARD OVERCURRENT (FAULT) 5 - 30 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 184 SEC SENSOR mV PER 1000A. (150) SEC SENSOR FREQUENCY (050) OPERATING HIGH FREQUENCY (1200) MAXIMUM FLUX (0200) MAXIMUM PRIMARY CURRENT (0300) MAXIMUM SECONDARY CURRENT (20000) MedWeld 4000 Operator’s Guide Modified: 9/17/08 5 - 31 M-032116 Programs #T03300, #T02300 and #T02400...
Page 185: Quick Reference To Setup Parameters (T02301)
INVERTER SYSTEM FAILURE(FAULT) *NON-RESETTABLE ILLEAGAL POWER FREQ. (FAULT) *NON-RESETTALBE MAIN FUSE OPEN (FAULT) *NON-RESETTALBE SEC. CURRENT SENSOR (NONE) INCOMPATIBLE HARDWARE (FAULT) INITIATION ON FAULT (INHIBIT 5 - 32 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 186 OPERATING HIGH FREQUENCY (1200) MAXIMUM FLUX (0200) MAXIMUM PRIMARY CURRENT (0300) [TYPE 1 MEDAR INV] SOFT OVERCURRENT LIMIT (400A) TRANSFORMER TURNS RATIO (1:073) MAXIMUM SECONDARY CURRENT (20000) MedWeld 4000 Operator’s Guide Modified: 9/17/08 5 - 33 M-032116 Programs #T03300, #T02300 and #T02400...
Page 187: Quick Reference To Setup Parameters (T02302)
CHARGE / DISCHARGE DUTY CYCLE (FAULT) OUTPUT GROUND (FAULT) HARD OVERCURRENT(FAULT) LOW VOLTAGE (FAULT) TFMR SEC DIODE FAILURE (FAULT) TRANSFORMER DUTY CYCLE (FAULT) INVERTER SYSTEM FAILURE(FAULT) *NON-RESETTABLE 5 - 34 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 188 OPERATING HIGH FREQUENCY (1200) MAXIMUM FLUX (0200) MAXIMUM PRIMARY CURRENT (0300) [TYPE 1 MEDAR INV] SOFT OVERCURRENT LIMIT (400A) TRANSFORMER TURNS RATIO (1:073) MAXIMUM SECONDARY CURRENT (20000) MedWeld 4000 Operator’s Guide Modified: 9/17/08 5 - 35 M-032116 Programs #T03300, #T02300 and #T02400...
Page 189: Quick Reference To Setup Parameters (T02304)
TFMR DUTY CYCLE(FAULT) TFMR SEC DIODE FAILURE (FAULT) INITIATION ON FAULT (INHIBIT HEAT CYCLE LIMIT (0=SEAM) (60) ISOLATION CONTACTOR DELAY (SEC)(10) HIGH CURRENT LIMIT WINDOW (20%) 5 - 36 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 190 OPERATING HIGH FREQUENCY (1200) MAXIMUM FLUX (0200) MAXIMUM PRIMARY CURRENT (0300) [TYPE 1 MEDAR INV] SOFT OVERCURRENT LIMIT (400A) TRANSFORMER TURNS RATIO (1:073) MAXIMUM SECONDARY CURRENT (20000) MedWeld 4000 Operator’s Guide Modified: 9/17/08 5 - 37 M-032116 Programs #T03300, #T02300 and #T02400...
Page 191: Quick Reference To Setup Parameters (T02306)
CAPACITOR CHARGING (FAULT) CHARGE/DISCHARGE DUTY CYCLE (FAULT) INVERTER ISO CONTACTOR OFF (FAULT) INVERTER OVER TEMP (FAULT) OUTPUT GROUND (FAULT) HARD OVERCURRENT(FAULT) LOW VOLTAGE (FAULT) TFMR DUTY CYCLE(FAULT) 5 - 38 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 192 LOW PRESSURE CLY CAP AREA (28.27*100) LOW PRESSURE CLY ROD AREA (26.5*100) HIGH PRESSURE CLY CAP AREA (63.61*100) HIGH PRESSURE CLY ROD AREA (56.54*100) MAXIMUM SECONDARY CURRENT (20000) MedWeld 4000 Operator’s Guide Modified: 9/17/08 5 - 39 M-032116 Programs #T03300, #T02300 and #T02400...
Page 193 Setup Parameters This page is intentionally left blank. 5 - 40 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 194: Stepper Data
What is a Stepper? The MedWeld 4000 provides a linear stepper. It adds heat according to a stepper profile that you can program. You program steppers using the WTC programming device. Tell the weld processor which linear stepper you want to control the weld schedule, by using the stepper assignment function #82.
Page 195: Default Linear Stepper Profile
END OF STEPPER Use one of the programming methods (DEP-100S, WSS or WebVIEW) to change the stepper profile to the values required by your application. 6 - 2 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 196: Dep-100S
CdU``Ub4QdQ 'LVSOD\ DW WKH When you select the Linear Stepper Status display from the DEP-100S, use this display to view the stepper status: '(36 @?G5B?>3?==?> <9>51BCD5@@5BCD1DEC* 2__cd* D_dQ\GU\Tc- CdU` !CdU`3_e^d- cd`b !QTfQ^SUgSe 6!6"6#6$ This screen shows the amount of energy being added to each weld function ( Boost ), the current step ( Step ) and the selected stepper ( stpr ), as well as the total weld count and the step count (the number of welds completed during the current step).
Page 197 Stepper Data This page is intentionally left blank. 6 - 4 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 198: Advanced Software Features
• A change in C-Factor will indicate changes in the welding environment. The actual C-Factor is calculated by the MedWeld 4000 after every weld. The programming device displays this value in the Weld Data display. The processor calculates C-Factor is by dividing the average secondary current during the weld by the %I fired.
Page 199: Example Of Decreasing C-Factor
After the shorting condition occurs, the control may see 14,300 A. • Initial C-Factor = 12,450 A. / 65% = 192. • Final C-Factor = 14,300 A. / 65% = 220. 7 - 2 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 200: Low C-Factor Limit
Factor limits that correspond to a current threshold, to meet the needs of the welding process. The MedWeld 4000 also provides Function #97 (C-FACTOR LIMIT: HI=000 LO=000) to define the high and low C-Factor limits for a weld schedule. Use to determine when the welding conditions indicate the need for maintenance.
Page 201: Dynamic Current Windows
Stepper Boost is 2% • C-Factor is 170 • High Current Limit = 10% • Low Current Limit = 20%. To determine the target current: 7 - 4 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 202: Acc Firing Mode
To determine the Low Current Limit: Low Current Limit = Target – (Target x %Low limit/100) = 11,700 – (11,700 x 20/100) = 11,700 – 2,340 = 9,360 A. MedWeld 4000 Operator’s Guide Modified: 9/17/08 7 - 5 M-032116 Programs #T03300, #T02300 and #T02400...
Page 203: Dynamic Squeeze Features
Advanced Software Features Dynamic Squeeze Features The MedWeld 4000 provides a test fire function. Use it to determine the initial secondary resistance of a test fire, and whether the electrode tips were touching, (based on current draw). The data generated by the test fire can be used by the control in several ways.
Page 204: Dynamic Squeeze Functions
Weld Mode, but generates a SLOW CYLINDER fault to indicate the condition. MedWeld 4000 Operator’s Guide Modified: 9/17/08 7 - 7 M-032116 Programs #T03300, #T02300 and #T02400...
Page 205: Spc Indexing Capabilities
Analyzing the collected weld data can help recognize certain welding trends such as changes in resistance of the work piece, primary current and line voltage. You can then use the WTC XWSS (Weld Support System) to retrieve and analyze the stored data.
Page 206: Spc Setup Parameters
XWSS to retrieve the data. It will then collect data for 6 more cycles (without flagging XWSS) before starting the process again. The example table on the next page is for Bin #1 ONLY. MedWeld 4000 Operator’s Guide Modified: 9/17/08 7 - 9 M-032116 Programs #T03300, #T02300 and #T02400...
Page 207: Scr Short Detection
Weld Data Collection is bin dependent. Each bin has its own independent counter and is uploaded to XWSS separately. SCR Short Detection The MedWeld 4000 provides two parameters to aid in detecting either shunting current or a shorted SCR. By setting the Short Detection setup parameter to ENABLE, the processor continuously monitors the primary voltage across the SCRs when the control is not executing a weld function.
Page 208 This fault conditions indicates that shunting was detected for more than 3 cycles but less than the number of cycles programmed in the Shorted SCR Cycle Limit setup parameter. MedWeld 4000 Operator’s Guide Modified: 9/17/08 7 - 11...
Page 209: Retract Features
Retract Mode • Initiate from Retract • Cylinder Type For safety, the MedWeld 4000 ignores any WARNING! changes to these parameter settings until power is removed from the control. The control checks the status of these parameters only at power-up.
Page 210: Cylinder Type
AIR-NORMAL informs the control that the gun is an air-only cylinder using “normal” retract. The output is turned OFF to close the gun. Air-Normal RETRACT Partial retract Full retract Output MedWeld 4000 Operator’s Guide Modified: 9/17/08 7 - 13 M-032116 Programs #T03300, #T02300 and #T02400...
Page 211: Air Over Oil Cylinders
• AIR/OIL–NC signifies that the cylinder is air-over-oil with a normally-closed (NC) blocking valve. The BLOCKING VALVE output is de-energized (LOW) to inhibit oil flow. 7 - 14 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 212 TURN ON ADVANCE VALVE function. This will decrease any gap opening that is used further down the line. MedWeld 4000 Operator’s Guide Modified: 9/17/08 7 - 15 M-032116 Programs #T03300, #T02300 and #T02400...
Page 213 This parameter sets the length of time to allow for the gun to move from the fully-closed position to the partial retract position, as shown below: Blocking Valve Delay Timer: Fully closed Partial retract 7 - 16 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 214: Examples
This action is initiated by the retract input (as described in “Initiation From Retract” on page 7-21). MedWeld 4000 Operator’s Guide Modified: 9/17/08 7 - 17 M-032116 Programs #T03300, #T02300 and #T02400...
Page 215: Example Weld Schedule: Air Over Oil Cylinder Operation
SQUEEZE 00 CYCLES PREWELD 00 CY 30%I COOL 10 CYCLES WELD 10 CYCLES 50%I HOLD 05 CYCLES TURN OFF INTENSIFY/ADV VALVE #1 OFF 10 CYCLES 7 - 18 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 216 Extend Sqz From Retract (CY/2) value is added to the value of Blocking Valve #n Delay. This allows the gun to return to the prior position. MedWeld 4000 Operator’s Guide Modified: 9/17/08 7 - 19 M-032116 Programs #T03300, #T02300 and #T02400...
Page 217 = time control opens gun If from partial retract: Blocking Valve #n Delay setup parameter If from full retract: Blocking Valve #n Delay plus Extend Sqz setup parameters 7 - 20 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 218: Initiation From Retract
(Refer to Chapter 3 of the DEP-100S Programming Guide.) It allows changing the software setting at the weld processor from Weld to NoWeld. This feature is NOT supported by this version of the MedWeld 4000 software. The Display Mode does not provide the W/NW STATUS option on its display.
Page 219 1TfQ^SUTC_VdgQbU6UQdebUc 9LHZLQJ :HOG 'DWD Software supporting the MFDC displays data on the Weld Data screen on the DEP-100S (Hand-Held Terminal) differently from that for AC welding controls. This section describes the differences in the Weld Data screen: @?G5B?>3?==?> RecFcUS9`bY9XVS SV ]Qh _^dY]UTSf...
Page 220 This value is used to alert the maintenance staff of a welder's deteriorating secondary or shunting conditions. The DC buss voltage at the WCU. This is updated each time the DEP-100S polls the WCU. MedWeld 4000 Operator’s Guide Modified: 9/17/08 7 - 23 M-032116 Programs #T03300, #T02300 and #T02400...
Page 221: Stepper Function
(However, you can advance or reset the stepper. Refer to “Displays at the DEP-100S” on page 7-3.) NOTE: The SureWeld stepper is not available in controls equipped with the MFDC inverter. 7 - 24 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 222: Fault Conditions
An inverter fault will activate the NO FAULT output at the weld processor, and the INVERTER READY TO WELD (IRTW) output. IRTW will inhibit the weld processor from sending a firing signal to the inverter. MedWeld 4000 Operator’s Guide Modified: 9/17/08 8 - 1 M-032116 Programs #T03300, #T02300 and #T02400...
Page 223: Ac Control Faults
HIGH CURRENT Fault ......8-17 8 - 2 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Proograms #T03300, #T02300 and #T02400...
Page 224 The robot or ladder logic is Repair robot or ladder logic not holding the INITIATE program. input high for the amount of time required by the applica- tion. MedWeld 4000 Operator’s Guide Modified: 9/17/08 8 - 3 M-032116 Programs #T03300, #T02300 and #T02400...
Page 225 A linear stepper in the group # assigned to the sched- Dress or replace the electrode End of ule initiated completed the last step in the profile. tips. Reset the stepper. Stepper (See p. 5-3) 8 - 4 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Proograms #T03300, #T02300 and #T02400...
Page 226 The weld sequence was Inhibit initiated with a fault present, Initiation on but the weld schedule would Fault not sequence due to a fault condition. MedWeld 4000 Operator’s Guide Modified: 9/17/08 8 - 5 M-032116 Programs #T03300, #T02300 and #T02400...
Page 227 A failure on processor. Check for bad con- one of these cards may cause nector. Replace as necessary. this fault to occur.) 8 - 6 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Proograms #T03300, #T02300 and #T02400...
Page 228 IC Off When Needed Pico fuse on the input module Replace Pico fuse. is defective or has blown. MedWeld 4000 Operator’s Guide Modified: 9/17/08 8 - 7 M-032116 Programs #T03300, #T02300 and #T02400...
Page 229 Incorrect or loose wiring to Check for proper I/O designa- the input module. tions. Verify that all wiring connections are secure. Faulty input module. Replace input module. 8 - 8 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Proograms #T03300, #T02300 and #T02400...
Page 230 Isolation contactor is dropping Correct isolation contactor out early or coming in late. program or relay logic circuit. Faulty firing card. Replace firing card. MedWeld 4000 Operator’s Guide Modified: 9/17/08 8 - 9 M-032116 Programs #T03300, #T02300 and #T02400...
Page 231 Also check for poor part fitup, arcing and problems with fac- Power factor values are Check the power factor tors such as the gun programmed incorrectly. settings. timing. 8 - 10 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Proograms #T03300, #T02300 and #T02400...
Page 232 Weld Data Function #72 or #73. display of the DEP.) MedWeld 4000 Operator’s Guide Modified: 9/17/08 8 - 11 M-032116 Programs #T03300, #T02300 and #T02400...
Page 233 The High C-factor limit was Raise the high C-factor limit. exceeded the value (See p. 5-6) programmed too low. programmed in Function #97. 8 - 12 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Proograms #T03300, #T02300 and #T02400...
Page 234 Check to make sure all was removed while wiring connections are secure. the control was exe- cuting a schedule. Faulty input module. Replace input module. MedWeld 4000 Operator’s Guide Modified: 9/17/08 8 - 13 M-032116 Programs #T03300, #T02300 and #T02400...
Page 235 Loose or incorrect wiring to Check for proper I/O designa- the input module. tions. Check to make sure all wiring connections are secure. Faulty input module. Replace module. 8 - 14 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Proograms #T03300, #T02300 and #T02400...
Page 236: Mfdc Fault Status Leds
MF1200: Verify that the 15- conductor cable between bridge rectifier and inverter SCR Firing Interface Connector on inverter are properly seated. Inverter processor failure. Replace inverter. MedWeld 4000 Operator’s Guide Modified: 9/17/08 8 - 15 M-032116 Programs #T03300, #T02300 and #T02400...
Page 237 Verify that Belden cable is wired with the Blue wire on pin 1 at both ends of cable. Replace DEP-100S cable from CI board to WTC Processor. Replace CI board. Replace WTC timer. Replace inverter. 8 - 16 Modified: 9/17/08 MedWeld 4000 Operator’s Guide...
Page 238 Remove one shunt cable to weld gun and verify that the weld gun is not shorted. MedWeld 4000 Operator’s Guide Modified: 9/17/08 8 - 17 M-032116 Programs #T03300, #T02300 and #T02400...
Page 239 Current does not decrease from higher to lower weld current because DC sec- ondary current does not decay quickly enough. 8 - 18 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Proograms #T03300, #T02300 and #T02400...
Page 240 Mains voltage drops Correct mains voltage. INVERTER BUS significantly during weld. FAULT. Inverter processor failure. Replace inverter. (The DC voltage dropped 40% during a weld.) MedWeld 4000 Operator’s Guide Modified: 9/17/08 8 - 19 M-032116 Programs #T03300, #T02300 and #T02400...
Page 241 Wires between coil and WTC recommends replacing the processor board are inverter. broken (usually during weld transformer primary cable installation to inverter. (Ground fault on every weld.) 8 - 20 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Proograms #T03300, #T02300 and #T02400...
Page 242 BUS Fault DC BUS OVER mains. Defective substation transformer. VOLTAGE FAULT. Combination of ground Find and correct ground faults. faults. Defective inverter Replace inverter. processor MedWeld 4000 Operator’s Guide Modified: 9/17/08 8 - 21 M-032116 Programs #T03300, #T02300 and #T02400...
Page 243 Replace inverter. Failure of inverter snubber Replace inverter. circuit. Bridge rectifier diode/ Replace inverter. SCR failure. DEP-100S displays Inverter processor failure. Replace inverter. LOW VOLTAGE fault. 8 - 22 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Proograms #T03300, #T02300 and #T02400...
Page 244 Replace SCR firing card. rectifier is not firing all SCRs. (DEP-100S DC Voltage display is LOW.) Bridge rectifier has a Replace bridge rectifier. shorted phase. MedWeld 4000 Operator’s Guide Modified: 9/17/08 8 - 23 M-032116 Programs #T03300, #T02300 and #T02400...
Page 245 MF600: Discharge relay Replace discharge relay. N.O. contacts are welded closed. MF600: Solid state relay Replace solid state relay. for mains contactor (shorted) failure. 8 - 24 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Proograms #T03300, #T02300 and #T02400...
Page 246: Hardware Troubleshooting
Check the fuse to see if it is blown. Replace if necessary. I/O point is shorted. Inspect all I/O points for correct and secure connections. Correct and/or tighten any suspect connection(s). MedWeld 4000 Operator’s Guide Modified: 9/17/08 9 - 1 M-032116 Programs #T03300, #T02300 and #T02400...
Page 247: Processor
Controller is inoper- Defective I/O devices or Test inputs and outputs, according to the able, but no major I/O wiring. I/O Troubleshooting section. CPU faults are detected 9 - 2 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 248: Weld Processor
Remove power from the chassis, re- processor is on) seat modules and restore power. Weld processor firmware Verify compatibility; correct as needed. and ladder logic are If not known, consult your WTC incompatible. representative for assistance. MedWeld 4000 Operator’s Guide Modified: 9/17/08 9 - 3...
Page 249 Each control must have a be off or blinking) number. UNIQUE address. Faulty WTC processor, Replace as necessary. faulty DEP-100S or faulty Network Power Pack. 9 - 4 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 250: Solving Typical Problems
Faulty firing card or I/O module. Replace module is active when the SCR is not as necessary. shorted. Faulty firing card. Replace firing card. Intermittent ground. Replace circuit breaker. MedWeld 4000 Operator’s Guide Modified: 9/17/08 9 - 5 M-032116 Programs #T03300, #T02300 and #T02400...
Page 251 Also check input supply voltage to the I/O module. Faulty I/O module or weld processor. Replace as necessary. 9 - 6 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 252 Check each control’s address. Verify that MedLAN address. each has a UNIQUE address. Verify that the DEP-100S software is Update software. compatible with the weld processor. (Consult your WTC representative for assistance.) Faulty weld processor, DEP-100S or Replace as necessary. faulty Network Power Pack. Control The control is in No Weld.
Page 253 Bad connection between current coil Check for proper and secure wiring and firing card. connections between firing card and current coil. Faulty firing card. Replace firing card. 9 - 8 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 254 (On the 1,200-A. inverter, the zero- crossing signal comes through the gate board on the SCR pack.) Faulty firing card. Replace firing card. Faulty weld processor. Replace weld processor. MedWeld 4000 Operator’s Guide Modified: 9/17/08 9 - 9 M-032116 Programs #T03300, #T02300 and #T02400...
Page 255 Hardware Troubleshooting 9 - 10 Modified: 9/17/08 MedWeld 4000 Operator’s Guide M-032116 Programs #T03300, #T02300 and #T02400...
Page 256: Chapter 10 Application Note: Current Compensation
Application Note: Current Compensation Scope This application note is intended for customers using single-phase, AC welding controls only. The door of your welding control will be labeled "AC" or "MFDC". This not does NOT apply to MFDC welding controls. Current Compensation Information for AC Products Background In order to more accurately control the welding current, the MedWeld 4000 AC welding controls “learn”...
Page 257 Application Note: Current Compensation ML-010041 Application Note: Current Compensation...
Page 258: Background Information
Application Note: Cascade Welding Scope This application note is intended for customers using a single AC weld control to fire multiple weld guns. The door of your welding control will be labeled "AC" or "MFDC". This not does NOT apply to MFDC welding controls.
Page 259: Multiple Output Cascade Method
Application Note: Cascade Welding • To weld on gun #3: gun 3 must be closed and guns 1 and 2 must be left open. When multiple welding transformers are connected in parallel to one welding control as shown in Figure 1, some additional rules should be followed: No more than three weld transformers should be used.
Page 260: Weld Schedules In Cascade Welds
Application Note: Cascade Welding The Differences The cascade system in Figure 1 is the least expensive but it cannot make welds as quickly as the system in Figure 2 due to the extra time needed Between Method 1 to allow each welding gun to open and close. The cascade system of and 2 Figure 1 is also limited, for practical reasons, to three welding guns or less.
Page 261 Application Note: Cascade Welding ML-010041 Application Note: Cascade Firing...

WTC MedWeld 4000 Operator's Manual

Chapter 1 Medweld 4000 Overview

Chapter 3 Communications and I/O

Chapter 4 Weld Schedules

Chapter 5 Setup Parameters

Chapter 6 Stepper Data

Chapter 7 Advanced Software Features

Chapter 8 Fault Conditions

Chapter 9 Hardware Troubleshooting

Chapter 10 Application Note: Current Compensation

Chapter 11 Application Note: Cascade Welding

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