WTC MedWeld 3005 Operator's Manual

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MedWeld 3005

Resistance Weld Control

150 East St. Charles Road

Carol Stream, IL 60188 U.S.A.

Voice: (800) 323-2903

(630) 462-8250

Fax:

(630) 462-8259

Operator's Guide

T93300–20

Revision 01

February, 2002

Part No. M-032025

WELDING TECHNOLOGY CORPORATION

for

24775 Crestview Court

Farmington Hills, MI 48335 U.S.A.

Voice: (248) 477-3900

Fax:

(248) 477-8897

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Summary of Contents for WTC MedWeld 3005

Page 1 Resistance Weld Control Operator’s Guide T93300–20 Revision 01 February, 2002 Part No. M-032025 Copyright © 2001, WTC WELDING TECHNOLOGY CORPORATION 150 East St. Charles Road 24775 Crestview Court Carol Stream, IL 60188 U.S.A. Farmington Hills, MI 48335 U.S.A. Voice: (800) 323-2903...
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Page 9 Also note the sequence of events leading to the problem, and the drawing numbers of the schematics you received with the enclosure. When an immediate response is not critical, contact WTC at the 7’Ã@€hvy) following e-mail addresses: welding-sales@weldtechcorp.com...
Page 10 7UddY^WCdQbdUT Visit our Web site at: PÃ‡urÃXri) www.weldtechcorp.com Contact us by mail at the following addresses: 7’ÃHhvy) WTC Canada 24775 Crestview Court 240 Cordova Road Farmington Hills, MI 48335 P. O. Box 8858 Oshawa, Ontario L1J 1N9 6\PEROV 8VHG LQ 7KLV 0DQXDO...
Page 11 7UddY^WCdQbdUT 5HYLVLRQ +LVWRU\ Revision Release Date Comments 09/04/98 Released as program #T93300-00-16-26-36. 06/07/00 Released as #T93300-00-18-40-64. 06/30/00 Released as #T93300-00-19-42-67. 01/29/02 Released as #T93300-00-20-48-85. 6DIHW\ :DUQLQJ U‚Ã‡urÃPƒr…h‡‚…) Lethal voltages are present when power is applied to the welding control. Refer all Danger! necessary service on this machine ONLY to qualified maintenance personnel.
Page 12 7UddY^WCdQbdUT /LPLWHG :DUUDQW\ WTC warrants that this product is free from defects in design, materials and workmanship for a period of one (1) year from the date of delivery. IN CASE OF SUCH DEFECTS, WTC’S LIABILITY IS STRICTLY LIMITED TO REPAIR OR...
Page 13 7UddY^WCdQbdUT &RS\ULJKW WTC software is copyrighted and all rights are reserved by WTC. The distribution and sale of this 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 14 7UddY^WCdQbdUT :RUNLQJ ZLWK 6WDWLF6HQVLWLYH 'HYLFHV This equipment contains electronic devices which are sensitive to electrostatic discharge. Observe the following warnings AT ALL TIMES, to prevent damage to these devices. Disregarding any of these warnings may cause damage to the equipment. NEVER remove any circuit board WARNINGS! with AC power applied.
Page 15 (2 liters) per minute. The recommended maximum is 1.0 gal (4 l.) per minute. Larger SCRs (2,100 A. or greater) may require a higher flow rate. Consult WTC for more information. This warning applies ONLY to SCRs having cooling- water hosing connected either between tangs, or...
Page 16 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 SLC processor.) 6\VWHP 'HVFULSWLRQ The MedWeld 3005 weld control sits as a combination of modules mounted in the controller chassis for an Allen-Bradley ™ SLC- 500 Programmable Controller. A weld processor sends firing signals to its firing card through a firing cable harness plugged directly into the weld processor card.
Page 18 Compensation (to maintain a desired primary voltage) or Automatic Current Compensation (to maintain constant secondary current). The MedWeld 3005 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 19 (See Figure 2 on page 1-4.) • SLC-500 processor (Figure 3 on page 1-4) • MedWeld 3005 weld processor (Figure 4 on page 1-6) • Communications modules (for RIO, DeviceNet or DIO). The following sections describe these components. =UTGU\T# %?`UbQd_bµc7eYTUD)##...
Page 20 =UTGU\T# %?fUbfYUg A 4-slot chassis mounts the SLC processor, WTC weld processor 8uh††v† and two interface modules. (The latter can be either RIO Network and local modules or the DIO input and output modules.) Figure 2: SLC-500 Module MedWeld 3005...
Page 21 Programming port, the MedLAN port and the WTC firing card interface port. Programming port (top): Use this connector to plug a programming device directly into the WTC weld processor card. • Connect a DEP-100S Data Entry Panel to the Programming port to program the control’s basic operating parameters and...
Page 22 • MedLAN port (middle). Use this connector to link the weld control to other controls and a network monitoring system through the WTC Local Area Network (MedLAN). • Firing Card port (bottom). Use this connector to link the weld processor board to the WTC firing card.
Page 23 =UTGU\T# %?fUbfYUg LED indicators on the weld processor module show control status. These indicators are described below: This LED lights to indicate that the weld processor is receiving power and is functioning normally. F.C. These LEDs light to indicate that the weld processor card has sent the logic level firing signal to the firing card.
Page 24 =UTGU\T# %?fUbfYUg When configured to use RIO integration, the MedWeld 3005 SDPÃD‡rt…h‡v‚ control has two modules in the card rack: The RIO module and the Combination module for local control of critical safety I/O. SDPÃIr‡‚…xÃH‚qˆyrÃ The RIO Network module exchanges serial I/O data between the control and a host located outside of the weld control enclosure.
Page 25 DeviceNet product can behave as Client, Server or both). The network can have up to 64 node addresses. Each node supports an infinite number of I/O. IPU@) For more information on DeviceNet, contact your WTC representative. 9r‰vprIr‡ÃH‚qˆyrÃ The DeviceNet module is shown below: Figure 6: 4UfYSU>Ud]_Te\U...
Page 26 =UTGU\T# %?fUbfYUg HP9VG@ÃG@9ÃT‡h‡ˆ†ÃDqvph‡v‚†Ã The status indicator labeled MODULE uses two colors (green and red) and a flashing state to show the operating status of the DeviceNet module. Color Description Remedy There is no power applied to Apply power. the module. Green The module is in normal None...
Page 27 =UTGU\T# %?fUbfYUg Iˆ€r…vpÃT‡h‡ˆ†Ã8‚qr†Ã The numeric display (below the two bi-color indicators) also provides diagnostic information about the status of the module. The display flashes at 1-second intervals. The table below summarizes the meanings of the numeric codes: Code Description Remedy Network Normal operation.
Page 28 =UTGU\T# %?fUbfYUg Code Description Remedy Slave device is returning error Check accuracy of Scan List table entry. responses when module attempts to Check slave device configuration. communicate with it (node number alternately flashes). Module is initializing the DeviceNet None. This code clears itself once the channel.
Page 29 =_Te\U When configured to use the discrete I/O integration scheme, the 9v†p…r‡rÃDP MedWeld 3005 uses an input module and an output module to H‚qˆyr† replace the RIO Network and Combination modules. These modules can provide either 8 or 16 connections, depending on your application requirements.
Page 30 =UTGU\T# %?fUbfYUg Figure 8: 9^`ed=_Te\U?`dY_^c (8 Inputs) (16 Inputs) 9v†p…r‡rÃPˆ‡ƒˆ‡ÃH‚qˆyr†Ã The output module allows the weld control enclosure to send 8 or 16 signals to a machine, robot or portable gun controller. Again, wire from the output module to the external devices. Refer to the drawing packet provided with your control for a complete list of the outputs used in your application, and the definition of the I/O voltage and voltage source used in your...
Page 31 =UTGU\T# %?fUbfYUg &RPSRQHQW 'HVFULSWLRQV This section is a brief description of the following components provided with the MedWeld 3005 control: • Circuit breaker • Isolation contactor (optional) • Control transformer • Current coil • Firing card • Cascade firing board and •...
Page 32 =UTGU\T# %?fUbfYUg (indicating Weld Mode is selected and the control stop is not selected) before the weld processor will pull in the isolation contactor to provide weld current. When the isolation contactor is closed, 480/600 VAC is supplied to the SCR through 2L1. The 2L2 connector from the isolation contactor provides the interface with the weld transformer.
Page 33 =UTGU\T# %?fUbfYUg Av…vtÃ8h…qÃDƒˆ‡ÃTvthy† The wires connected to the firing card connector J3 (1L1 and 1L2 without an isolation contactor, or 1L1, 1L2 and 2L2 with an isolation contactor) originate across the 380/480/600 VAC supply voltage. These wires carry the zero-crossing logic signal. This signal synchronizes the weld processor with the supply.
Page 34 =UTGU\T# %?fUbfYUg The MedWeld 3005 can switch multiple contactors with one weld 8h†phqrÃAv…vt timer, a firing board and a system of relays. The Cascade Firing 7‚h…q Board (CFB) implements this capability. P‰r…‰vrÃ‚sÃ‡urÃ8A7Ã The CFB controls a system of three relays. They switch the gate lead connections between each firing board and three SCR pairs.
Page 35 The Secondary Current Interface Board (SCIB) is an add-on accessory to WTC’s kernel-based welding controls (i. e., MedWeld 3005, 200, etc.). The SCIB enables the welding control to read secondary current. If the correct software is installed in the weld timer, the SCIB can be used in any welding control which fires the SCRs with 645 firing boards.
Page 36 =UTGU\T# %?fUbfYUg Uur‚…’Ã‚sÃPƒr…h‡v‚Ã The SCIB consists of • An analog integrator, • A voltage-to-frequency (V/F) converter, • A microprocessor and • Switching circuitry. The air-wound (Rowgowski) current-sensing coil induces a signal which represents the first derivative of current. The integrator integrates this signal to determine current. The result then goes to a V/F converter.
Page 37 =UTGU\T# %?fUbfYUg In this way, any drift of component values on the SCIB can be detected and corrected for. Self-calibrate can also detect a damaged or disconnected secondary current-sensing coil. The SCIB contains the necessary connectors to be installed in-line on the cable which normally goes from the weld timer to the firing board.
Page 38 =UTGU\T# %?fUbfYUg Range/Frequency V/F Counts / A per Half-Cycle 0 – 25 kA @ 60 Hz 18 counts / 100 A rectified average per half-cycle 0 – 50 kA @ 60 Hz 9 counts / 100 A “ “ “ “ “ 0 –...
Page 39 =UTGU\T# %?fUbfYUg When commanding the SCIB to secondary AC current mode, the MODE LED will glow green. When commanding to secondary DC current mode, the MODE LED will glow red. If the SCIB is commanded to secondary AC current mode with primary current re-routed to the V input of the weld timer, the MODE LED will blink green at a rate of about once per...
Page 40 Interface Board (SCIB) and secondary current sensing coil must be attached. $YDLODEOH &RQILJXUDWLRQV In addition to multiple integration options, the MedWeld 3005 can be configured in single-pack, tri-pack, six-pack or even 12- pack enclosures. As previously described, the MedWeld 3005 supports RIO integration, DeviceNet, discrete I/O and serial I/O integration.
Page 41 ,QVWDOOLQJ WKH 0HG:HOG To install the MedWeld 3005, you must provide the required connection (for either remote or discrete integration), configure the unit for the MedLAN network, set the network address and program the weld processor to meet your application requirements.
Page 42 See “Remote Integration” on page 2-3, “Discrete Integration” on page 2-15, or “Discrete Integration” on page 2-15. 11. Turn on the cooling water and the main power disconnect. You are now ready to power up the MedWeld 3005 control. "" =UTGU\T# %?`UbQd_bµc7eYTUD)## "...
Page 43 Local Combination module to provide certain critical local and Thsr‡’ÃDP safety I/O signals. These signals are defined in “Local and Safety I/O” on page 3-1. To configure the WTC 3005 for remote integration, you must Tr‡‡vtÃ‡urÃ9DQ correctly set the DIP switches. These switches enable the weld Tv‡pur†...
Page 44 9^cdQ\\Y^WdXU=UTGU\T# Figure 10: 49@CgYdSX<_SQdY_^c Tryrp‡vtÃ‡urÃDPÃB…‚ˆƒÃ The I/O group DIP switches are located in switch block SW1. Switches 7 and 8 determine the I/O group number. DIP Switch I/O Group Valid Rack Number Configuration 3/4, 1/2, 1/4 rack 1/2, 1/4 rack 1/4 rack Tryrp‡vtÃ‡urÃShpxÃTv“rÃ...
Page 45 9^cdQ\\Y^WdXU=UTGU\T# Tr‡‡vtÃ‡urÃShpxÃ6qq…r†† The rack address DIP switches (1 – 6) are on switch block SW1. These switches set the physical address of the whole rack. Valid decimal values are 0 through 31, as shown in the following table. DIP Switch Number Address Dec.
Page 46 9^cdQ\\Y^WdXU=UTGU\T# Tr‡‡vtÃ‡urÃ8G@6SÃPIÃA6VGUÃT‡h‡ˆ†Ã The CLEAR ON FAULT DIP switch is Switch 3 in switch block SW2. When setting this switch to OFF when the RIO network module detects that the PLC has entered Program, Test or Fault Mode, or detects a communications failure, the 3005 RIO module will immediately clear and hold clear all data bits in its Input Image Table.
Page 47 9^cdQ\\Y^WdXU=UTGU\T# You may also wire into the combination module (to provide the local and safety I/O signals). Finally, make the connection to the DeviceNet drop line at the terminal block plug provided on the DeviceNet module. To do this, match the wire insulation wire colors to the colors shown on the terminal block label.
Page 48 9^cdQ\\Y^WdXU=UTGU\T# PƒrvtÃ9@WD8@I@UÃH6I6B@SÃ Follow this procedure: Start up Windows. At the C: prompt, type "WIN". Double-click the DEVICENET MANAGER icon. The computer interface pod has a DeviceNet node address of 62. Nodes initially default to 00. Ensure that only one DeviceNet card to be configured is on line with the computer.
Page 49 NODE 02 Used as the Master to control (REV 02.04 & UP) a WTC Weld Control NODE 30 In a WTC Weld Control, for (REV 02.04 & UP) SCR1 through SCR6 Follow these steps: Under UTILITIES, select NODE COMMISSIONING.
Page 50 NODE 04 Used as the Master to control (REV 02.04 & UP) a WTC Weld Control NODE 29 In a WTC Weld Control, for (REV 02.04 & UP) SCR1 through SCR12 Follow these steps: Under UTILITIES, select NODE COMMISSIONING.
Page 51 9^cdQ\\Y^WdXU=UTGU\T# CURRENT NODE SETTINGS NEW NODE SETTINGS NODE ADDRESS NODE ADDRESS 00 (As on MINI WHO) CURRENT DATA RATE DATA RATE 125kbps 125kbps CURRENT NODE SETTINGS NEW NODE SETTINGS NODE ADDRESS NODE ADDRESS 00 (As on MINI WHO) CURRENT DATA RATE DATA RATE 125kbps 500kbps...
Page 52 9^cdQ\\Y^WdXU=UTGU\T# Select CONFIGURE DEVICE, then SAVE TO SDN, then OK. Note that the DeviceNet card re-boots. Next, choose EDIT SCAN LIST. 10. Within this window, select ALL RECORDS, then SAVE TO SDN, then OK. Select OK again. 11. Close out each window, then exit. On power-up, the DeviceNet card will display "88,"...
Page 53 ROBOT [5 byte transfer] NODE 03 Used as the Master to control (REV 02.04 & UP) a WTC Weld Control NODE 30 In a WTC Weld Control, for (REV 02.04 & UP) SCR1 through SCR3 Follow these steps: Under UTILITIES, select NODE COMMISSIONING.
Page 54 9^cdQ\\Y^WdXU=UTGU\T# CURRENT NODE SETTINGS NEW NODE SETTINGS NODE ADDRESS NODE ADDRESS 00 (As on MINI WHO) CURRENT DATA RATE DATA RATE 125kbps 125kbps CURRENT NODE SETTINGS NEW NODE SETTINGS NODE ADDRESS NODE ADDRESS 00 (As on MINI WHO) CURRENT DATA RATE DATA RATE 125kbps 500kbps...
Page 55 BEFORE communication over the MedLAN channel is possible. Networking takes place over the MedLAN channel. Use a WTC data entry device (DEP-100, MedVIEW, MedLAP or WSS) for network communications or to program a single weld control.
Page 56 5 mm. The baud rate of this connection is 9,600. 8hiyrÃSr„ˆv…r€r‡†Ã WTC recommends using the Belden 9463 cable or equivalent. The following tables list the cable pinouts. MedLAN Connector (on the network power pack):...
Page 57 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 3QedY_^gXU^S_^^USdY^WgYdXdXU 45@! $@b_WbQ]]Y^W4UfYSU* BU]_fU`_gUb256?B5QddU]`dY^Wd_S_^^USd_b TYcS_^^USdSQR\Y^W5hUbSYcUSQbUgXU^]Q[Y^WdXU =UT<1>SQR\US_^^USdY_^c9VdXU=UT<1>SQR\U cX_e\TRUS_]US_^^USdUTd_dXU=4@!Q^T=4@" `_gUbS_^^USdY_^ccUbY_ecTQ]QWUd_ S_]]e^YSQdY_^S_]`_^U^dcG9<<_SSeb NEVER connect any of the communication ports X6SIDIBÄ...
Page 58 9^cdQ\\Y^WdXU=UTGU\T# 8hiyrÃS‚ˆ‡vtÃSr„ˆv…r€r‡†Ã Wire the MedLAN network ONLY in a “daisy-chain” method. NEVER use “stub” wiring. The maximum total length of the MedLAN network cable is 3,000 feet. Up to 30 weld controls may be connected to a single MedLAN network. A maximum of one WSS (Welding Support System) and one Network Power Pack (DEP-100S), OR two Network Power Packs (DEP-100S), OR one computer running MedView or...
Page 59 X6SIDIBÄ 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. If the MedLAN cable must cross this wiring, it must do so at a 90°...
Page 60 MedLAN connection and powering it up, you must set the MedLAN address for each device its before it can respond to the network. Use the WTC DEP-100S to program the MedLAN address for each individual weld control, through the top (DEP) port of the weld processor card.
Page 61 9^cdQ\\Y^WdXU=UTGU\T# To set the addresses 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 pro- vided). @B?7B1==?45 Press the key labeled on the DEP-100S.
Page 62 WTC Network Power Pack. • When connecting the MedWeld 3005 to a network controlled by the WTC Weld Support System (XWSS), programming and data acquisition can be done through WTC’s proprietary programs.
Page 63 DEP and the weld processor. This manual explains how to use displays that are specific to the MedWeld 3005 processor. Refer to “Display at the DEP-100S” on page 7-3 for details on how to use the DEP-100S stepper status and stepper profile programming displays.
Page 64 XryqvtÃTˆƒƒ‚…‡ÃT’†‡r€ÃYXTTÃ The WTC Welding Support System (XWSS) allows you to control a network of WTC controls (including the MedWeld 3005). XWSS runs in the UNIX ™ environment under the X–Windows graphic interface. Programming and data acquisition can also be performed from a single host personal computer.
Page 65 The following sections describe each option and the I/O provided. /RFDO DQG 6DIHW\ ,2 When the MedWeld 3005 is part of a network (as with the Remote I/O or DeviceNet integration), the WTC combination module provides for local (discrete) control of certain critical inputs and outputs.
Page 66 3_]]e^YSQdY_^cQ^T9? This section covers all possible inputs/outputs supported. Your G‚phyÃDƒˆ‡† application may not require all of this I/O. Refer to the drawing packet provided for your exact I/O availability and designations. CONTROL STOP Input When this input is de-activated, the control aborts the present schedule and will not initiate another schedule until the input becomes activated.
Page 67 3_]]e^YSQdY_^cQ^T9? G‚phyÃPˆ‡ƒˆ‡† NO FAULT Output This output is ON to indicate that the control is functioning normally. If the control shuts down as the result of a fault condition, this output will be turned OFF. ALERT Output This output is OFF to indicate that the control is functioning normally.
Page 68 3_]]e^YSQdY_^cQ^T9? 5HPRWH ,2 When remote integration (RIO) is used, the WTC 3005 RIO Network Module must be mounted in the SLC-500’s rack. This module provides a direct link between the control enclosure and the Allen-Bradley RIO network module located in the host PLC.
Page 69 For further information, refer to “Discrete Input Modules” on page 1-13. To make these inputs available to the weld processor, and to allow the MedWeld 3005 to activate the outputs, wire into the discrete I/O modules in the controller rack.
Page 70 3_]]e^YSQdY_^cQ^T9? PARITY Input The control will recognize only an ODD number of BINARY SELECT Inputs. If the schedule to be operated requires closure of an even number of BINARY SELECT Inputs, the PARITY Input must also be closed to provide the required odd number of inputs.
Page 71 3_]]e^YSQdY_^cQ^T9? SCR THERMAL SWITCH Input This input to the weld processor indicates that an SCR has reached an over-temperature condition. It also acts as a ready to weld (RTW) signal from the regulator board to the inverter assembly. If this input is not active when the control receives the signal to initiate a weld schedule, the weld processor generates a SYSTEM COOLING fault and de-energizes the NO FAULT output, to indicate an active fault condition.
Page 72 3_]]e^YSQdY_^cQ^T9? 3QedY_^* ?^`_gUbe`Yd]QiRU^USUccQbid_QSdYfQdUdXU B5DB13D9^`ed!_b"d_U^UbWYjUdXU_ed`edd_ S_bbUSddXUY^dUb^Q\cdQdU_VdXUbUdbQSd`Y\_d CLOSE BACKUP OPEN BACKUP These two inputs control the status of the BACKUP VALVE outputs, opening and closing as required by the user. When this input is set to open, the OPEN BACKUP VALVE output is set. When set to closed, the CLOSE BACKUP VALVE output is set.
Page 73 3_]]e^YSQdY_^cQ^T9? If this contact fails to change states after a valid schedule is initiated, the control will generate a ISO-CNTR OFF WHEN NEEDED fault condition. If this contact fails to return to its original state after the contactor is turned off (including the Isolation Contactor Delay), the control will generate an ISO-CNTR ERR BKR TRIPPED fault condition.
Page 74 WELD VALVE Outputs (1 – 6) Pˆ‡ƒˆ‡† These outputs are activated or de-activated when the MedWeld 3005 executes Function #54 (TURN ON WELD VALVE #n) or Function #55 (TURN OFF WELD VALVE #n). >?D5* Valves #1 and #2 are shared outputs; they function as the two Advance (Fluid) valves when enabling OHMA cylinder operation for the processor.
Page 75 3_]]e^YSQdY_^cQ^T9? ISOLATION CONTACTOR Output This output is activated or de-activated when the MedWeld 3005 executes function #52 (TURN ON ISOLATION CONTACTOR) or function #53 (TURN OFF ISOLATION CONTACTOR). Function #77 (ISOLATION CONTACTOR DELAY nn SEC) also affects this output, as described in the setup parameters on page 6-12.
Page 76 System cooling is provided: • The SCR OVER TEMP input is closed • On DIO/RWC1-P2 controls only: The TRANSFORMER OVER TEMP input is closed. When this output is activated, the RTW LED on the WTC weld processor will light. #!" =UTGU\T# %?`UbQd_bµc7eYTUD)## "...
Page 77 3_]]e^YSQdY_^cQ^T9? STEPPER APPROACHING LAST STEP For linear steppers, this output will activate when the control reaches the start of the last step in the stepper profile. For SureWeld steppers, this output will light when the control reaches the programmed value in the Stepper Approaching Max.
Page 78 3_]]e^YSQdY_^cQ^T9? Note: The processor displays all of the possible I/O on the DEP- Dƒˆ‡ 100S programming device. However, only the Local and Safety 6ii…r‰vh‡v‚† I/O and the I/O in the image table are accessible. (Other I/O can be accessed only through local ladder logic.) For more details, refer to the drawing package provided with your control.
Page 79 3_]]e^YSQdY_^cQ^T9? Pˆ‡ƒˆ‡ WELD IN PROGRESS Output.......WIP WELD FAULT Output (LOW for fault) ....FLT 6ii…r‰vh‡v‚† WELD ALERT Output ..........ALT WELD/NO WELD MISMATCH Output....WM STEPPER IS RESET Output.........SRST WELD COMPLETE Output ........WCMP READY TO WELD Output........RTW HAS WELDED Output ...........HWO END OF STEPPER Output........EOS STEPPER ALERT Output ........SALT TIP DRESS REQUEST .........TPDR STEPPER AUXILIARY COUNTER AT MAXIMUM SACM...
Page 80 3_]]e^YSQdY_^cQ^T9? The following table shows the abbreviations the DEP-100S will 9DPÃ6ii…r‰vh‡v‚† display for each discrete input or output. 9v†p…r‡rÃDƒˆ‡†Ã BINARY SELECT #1 Input ........FS2 BINARY SELECT #2 Input ........FS3 BINARY SELECT #4 Input ........FS4 BINARY SELECT #8 Input ........FS5 BINARY SELECT #16 Input ........FS6 WELD SCHEDULE ENABLE Input ......FSE WELD/NO WELD Input (HIGH for weld) ....NW2 BINARY SELECT #32 Input ........FS7...
Page 81 3_]]e^YSQdY_^cQ^T9? 9v†p…r‡rÃPˆ‡ƒˆ‡†Ã WELD IN PROGRESS Output.......WIP FAULT Output (LOW for fault)........FLT WELD ALERT Output ..........ALT WELDNO WELD MISMATCH Output ....WM STEPPER RESET Output ........SRST WELD COMPLETE Output ........WCMP READY TO WELD Output........RTW HAS WELDED Output ..........HWO END OF STEPPER Output ........EOS STEPPER ALERT Output ........SALT TIP DRESS REQUEST Output ......TPDR STEPPER AUXILIARY COUNTER AT MAXIMUM SACM...
Page 82 3_]]e^YSQdY_^cQ^T9? 9@Q TÃQ!ÃH9T Dƒˆ‡†Ã $$$T‡’yr BINARY SELECT #1 Input ........FS2 6ii…r‰vh‡v‚† BINARY SELECT #2 Input ........FS3 BINARY SELECT #4 Input ........FS4 BINARY SELECT #8 Input ........FS5 BINARY SELECT #16 Input ........FS6 WELD SCHEDULE ENABLE .........FSE WELD/NO WELD Input (HIGH for weld) ....WLD BINARY SELECT #32 Input ........FS7 CONTROL STOP Input (LOW for control stop) ..CS2 ISOLATION CONTACTOR SAVER Input ....2S13...
Page 83 3_]]e^YSQdY_^cQ^T9? Pˆ‡ƒˆ‡† WELD IN PROGRESS Output.......WIP FAULT Output (LOW for fault)........FLT ALERT Output ............ALT WELD/NO WELD MISMATCH Output....WM STEPPER RESET Output ........SRST WELD COMPLETE Output ........WCMP READY TO WELD Output........RTW HAS WELDED Output ...........HWO END OF STEPPER Output........EOS STEPPER APPRO. LAST STEP Output....SALT TIP DRESS REQUEST..........TPDR VALVE #1/ADVANCE (Fluid) VALVE #1 Output ..SV2 VALVE #2/ADVANCE (Fluid) VALVE #2 Output ..SV3...
Page 84 3_]]e^YSQdY_^cQ^T9? #" =UTGU\T# %?`UbQd_bµc7eYTUD)## " #" "%1`bY\" "...
Page 85 :HOG 6FKHGXOHV The MedWeld 3005 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.
Page 86 GU\TCSXUTe\Uc 6RIWZDUH &DSDELOLWLHV The MedWeld 3005 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. Other functions enable •...
Page 87 GU\TCSXUTe\Uc /LVW RI )XQFWLRQV >?D5* Unless otherwise indicated, nn represents any two-digit number from 0 – 99. nnn is a 3-digit number from 0 – 999. Exceptions to this convention will appear next to the function. Delay functions all have the same effect on the weld schedule: 9ryh’ÃAˆp‡v‚†...
Page 88 GU\TCSXUTe\Uc Functions using the AVC firing mode specify weld current as nn%I (representing the percentage of maximum available current). Functions using the ACC firing mode specify a set amount of secondary current, displayed as nnnn0 AMPS. 3QedY_^* DXUDbQ^cV_b]UbDeb^cBQdY_cUde``QbQ]UdUb TUcSbYRUT_^`QWU&!$]ecdRUQSSebQdU\i `b_WbQ]]UTV_bdXUS_^db_\d_ce``\idXUS_bbUSd Q]_e^d_VcUS_^TQbiSebbU^dY^133VYbY^W]_TU The weld data generated by the control (and displayed at the DEP or a >?D5*...
Page 89 GU\TCSXUTe\Uc >?D5* When Function #60 appears before any weld function in a schedule, the control displays IMP (impulses) rather than CY (cycles) to indicate the weld control will pulsation weld. Refer to Function #60 on page 4-7 for more information. 6ˆ‡‚€h‡vpÃ8ˆ……r‡Ã8‚€ƒr†h‡v‚ÃAv…vtÃH‚qrÃ...
Page 90 GU\TCSXUTe\Uc Note: For all weld functions, mm = 20 – 99. The processor can fire P‡ur…ÃAˆp‡v‚† a range from 20% to 99% I. 8‚‡…‚yyvtÃXryq 8ˆ……r‡ SLOPE nn CY mm %I TO mm %I SLOPE nn CY nnnn0 AMPS TO nnnn0 AMPS These functions provide weld current that starts at the first value and increase or decreases linearly to the second value over the number of cycles specified.
Page 91 GU\TCSXUTe\Uc IMPULSE= nn HEAT CY, nn COOL CY (nn=1-99) This function defines the length of a weld impulse. It tells the weld processor that the next function in the schedule should pulsation weld (providing heat cycles followed by cool cycles, rather than just heat cycles). When this function appears before any weld function, the control displays IMP (impulse) rather than CY (cycles) to indicate the weld control will pulsation weld.
Page 92 GU\TCSXUTe\Uc The cool cycles actually fire at a reduced % heat. For example, the following schedule will have the action illustrated here: IMPULSE=10 HEAT CY, 10 COOL CY WELD 004 IMP 75%I HIGH 40%I LOW 10cy 10cy 10cy 10cy 10cy 10cy 10cy 10cy...
Page 93 GU\TCSXUTe\Uc Note: These functions require certain inputs. Before Dƒˆ‡ÃH‚v‡‚…vt programming these functions, check the packet of drawings that Aˆp‡v‚† came with your control for I/O availability. WAIT nnn CY FOR INP #m TO BE #p (0=OFF, 1=ON) (m = 1-8 p = 0-1) WAIT FOR INPUT #m TO BE p (0=OFF 1=ON) (m = 1-8 p = 0-1) WAIT nnn CY FOR PRESSURE SWITCH INPUT...
Page 94 GU\TCSXUTe\Uc • Functions #70 and #71: WELD PROCEED fault. Function #70 pauses and waits for up to the specified number of cycles nnn for the WELD PROCEED input to become active. Function #71 operates the same way, but will wait indefinitely.
Page 95 GU\TCSXUTe\Uc Note: These functions require certain inputs. Before @‘‡rqSrƒrh‡ programming these functions, check the packet of drawings that Aˆp‡v‚† came with your control for I/O availability. EXTEND WHILE INPUT #n IS #m (0 = OFF 1 = ON) (n = 1-8 m = 0-1) This function tells the control to monitor a specific user input (#n), and to extend the previous function in the weld sequence while the input is either off or on.
Page 96 Function #82 assigns a linear stepper to a weld schedule. Function #83 assigns a SureWeld stepper to a weld schedule. The MedWeld 3005 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 97 GU\TCSXUTe\Uc The following functions allow setting programming limits that Aˆp‡v‚†Ã‡uh‡ are unique to a given weld schedule. The new limits override the P‰r……vqrÃTr‡ˆƒ limits programmed in the setup parameters, and apply only to Qh…h€r‡r…† the weld schedule where they appear. They also take priority over any other limits established.
Page 98 GU\TCSXUTe\Uc • Function #39 (TEST FIRE nn% CURRENT) MUST appear in the weld sequence. • Function #91 must appear after the test fire function (#39) in the weld sequence. • Function #92 (FAULT IF TIPS NOT TOUCHING) cannot appear in the weld sequence. When it executes Function #39, the control monitors the actual weld current.
Page 99 GU\TCSXUTe\Uc The following conditions must be true when using this function: • Function #39 must appear in the weld schedule. • This must appear after the test fire function (#39) in the weld schedule. If the power factor read during the test fire was not within the range programmed, the control generates an INITIAL P.F.
Page 100 GU\TCSXUTe\Uc >?D5C* Phase shift during test fire will NOT vary by voltage compensation. The reported current will be extrapolated to what the value of current would have been delivered, using the following calculation: Current Measured x Nominal Voltage Current Reported = Measured Voltage 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...
Page 101 PROCESS WELD FAULTS This function provides a one-cycle delay in the weld schedule. It asks the MedWeld 3005 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 102 GU\TCSXUTe\Uc 3QedY_^c* DXYcVe^SdY_^Q\c_SQecUcdXUS_^db_\d_SQ\Se\QdUdXU f_\dQWUSebbU^dQ^T`_gUbVQSd_bQfUbQWUcQ^TdXU 3VQSd_bV_bdXUgU\T9dQ\c_dUb]Y^QdUcdXUgU\T ce]]QbiTQdQS_\\USdY_^d_QccebUdXUY^dUWbYdi _VdXUgU\TTQdQS_\\USdUT DXYcVe^SdY_^_^\i`b_SUccUcdXUgU\TTQdQ*9dT_Uc >?De`TQdUdXU61E<DQ^T1<5BD_ed`edcDXUcU _ed`edcgY\\RUe`TQdUTgXU^dXUS_^db_\UhUSedUc dXUVe^SdY_^DEB>?>G5<43?=@<5D5?BQd dXUU^T_VdXUgU\TcSXUTe\U DXYcVe^SdY_^gY\\RUUhUSedUT_^\i_^SURidXU `b_SUcc_b9VYdQ``UQbc]_bUdXQ^_^SUY^dXU VYbcd cSXUTe\UYdgY\\RUUhUSedUTdXU dY]UYd Q``UQbcY^dXUgU\TcSXUTe\U VERIFY CYLINDER #n IS OUT OF RETRACT (n = 1-2) This function tells the control to check that the selected cylinder is out of retract. If the cylinder is NOT out of retract, the control will abort the schedule and generate a RETRACT PILOT fault.
Page 103 GU\TCSXUTe\Uc This function can be used to save memory space in the control, by allowing multiple schedules to execute commonly-used functions. The control considers the schedule originally initiated as the last schedule. The stepper assigned to the original schedule is also the only one incremented.
Page 104 GU\TCSXUTe\Uc described on page 5-10. 3QedY_^* DXYcVe^SdY_^Yc^_dTUcYW^UTV_becUY^Q^_b]Q\ `b_TeSdY_^be^9dYcY^dU^TUTV_bc`USYQ\cYdeQdY_^c ceSXQcdUQbT_g^gXYSXbUaeYbUS_^dY^e_ec TQdQS_\\USdY_^ >?D5* There must be a MINIMUM of 5 cycles delay programmed after turning ON any CONTACTOR SELECT prior to any weld current statement. Programs #T-93300-19 and greater will support analog I/O 6hy‚tÃQ…r††ˆ…r through an analog card in the SLC rack.
Page 105 GU\TCSXUTe\Uc parameter is programmed to generate a FAULT, the control continues with the sequence in 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. SET VALVE n TOUCH DOWN RESSURE TO mm PSI (n = 1,2;...
Page 106 GU\TCSXUTe\Uc PRE-WELD nn CY/IMP mm %I WELD nn CY 00.0 %I WELD nn HALF-CYCLES 00.0 %I WELD nn CY/IMP nnnn0 AMPS* 688ÃAv…vtÃH‚qr TEMPER nn CY/IMP nnnn0 AMPS ƒtÃ#$ PREHEAT nn CY/IMP nnnn0 AMPS POSTHEAT nn CY/IMP nnnn0 AMPS PRE-WELD nn CY/IMP nnnn0 AMPS WELD nn HALF-CYCLES nnnn0 AMPS SLOPE nn CY (IMP) mm% TO mm% I P‡ur…ÃAˆp‡v‚†...
Page 107 GU\TCSXUTe\Uc @‘‡rqSrƒrh‡ EXTEND WHILE INPUT #n IS #m (0 = OFF 1 = ON) (n = 1-8 m = 0-1) Aˆp‡v‚†ÃƒtÃ# EXTEND UNTIL NO INITIATE REPEAT (AT NEXT FUNCTION) LINEAR STEPPER #nn ASSIGNED (0 = OFF) T‡rƒƒr…Ã6††vt€r‡ SUREWELD STEPPER #nn ASSIGNED (0 = OFF Aˆp‡v‚†...
Page 108 GU\TCSXUTe\Uc 'HIDXOW :HOG 6FKHGXOH Following is the default sequence for program #T93300-00-1: 9rshˆy‡ÃXryq START OF SEQUENCE #nn LINEAR STEPPER #00 ASSIGNED (0 = OFF) Tr„ˆrpr) SEC CURR LIMITS: HI=0000 LO=9999 Hhpuvr TRANSFORMER TURNS RATIO: 100:1 TURN ON WELD IN PROGRESS TURN ON ISOLATION CONTACTOR SQUEEZE 30 CYCLES WELD 10 CY.
Page 109 GU\TCSXUTe\Uc UvƒÃ9…r††ÃTr„ˆrpr START OF SEQUENCE #nn TURN ON WELD SOLENOID #1 Æ # SQUEEZE 12 CYCLES TURN OFF WELD SOLENOID #1 TURN ON EWS OUPUT DELAY (5 CYCLES) TURN OFF EWS OUPUT TIP DRESS ADVANCE: STPR GROUP 1 – STEP 2 END OF SEQUENCE #nn START OF SEQUENCE #nn UvƒÃ9…r††ÃTr„ˆrpr...
Page 110 GU\TCSXUTe\Uc $"& =UTGU\T# %?`UbQd_bµc7eYTUD)## " #" "%1`bY\" "...
Page 111 • A change in C-Factor will indicate changes in the welding environment. The actual C-Factor is calculated by the MedWeld 3005 after every weld, and is displayed by the programming device in the Weld Data displays. The processor calculates C-Factor is by dividing the average secondary current during the weld by the %I fired.
Page 112 1TfQ^SUTC_VdgQbU6UQdebUc In an application of shunts in a fixture indexing gun, the guns @‘h€ƒyrÃ‚s will pull on the cable. These forces cause strands of wire in the 9rp…rh†vtÃ8 cable to break. As fewer conducting strands remain, the current Ahp‡‚… pathway will decrease, increasing the resistance. This, in turn, will decrease the C-Factor.
Page 113 C-Factor limits that correspond to a current threshold, to meet the needs of the welding process. The MedWeld 3005 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 114 Cycles is number of cycles weld current. The MedWeld 3005 provides a function to define the range of acceptable KVAT values. KVAT LIMIT HIGH=0000 LOW=0000 This defines the range of KVAT that is within acceptance. The...
Page 115 1TfQ^SUTC_VdgQbU6UQdebUc Function #84 defines a current limit window with high and low limit values and a new nominal C-Factor. (Refer to the discussion of C-Factor on page 5-1.) The target current is determined by the firing mode used by the weld function: %I or automatic current compensation.
Page 116 1TfQ^SUTC_VdgQbU6UQdebUc To determine the Low Current Limit: Low Current Limit = Target – (Target x %Low Limit/100) = 8,840 – (8,840 x 20/100) = 8,840 – (1,768) = 7,072 A. In this firing mode, the target value is established by the 688ÃAv…vtÃH‚qr following calculation: Target current = A.
Page 117 1TfQ^SUTC_VdgQbU6UQdebUc '\QDPLF 6TXHH]H )HDWXUHV The MedWeld 3005 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 118 1TfQ^SUTC_VdgQbU6UQdebUc Once you define the dynamic current setup parameters, use the 9’h€vpÃT„ˆrr“r following functions with the test fire function in a weld schedule, Aˆp‡v‚† as described below: VERIFY TIPS DOWN EVERY nn CY nn TIMES This function uses the dynamic squeeze capabilities to verify that the electrode tips are making full contact with the workpiece.
Page 119 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 120 1TfQ^SUTC_VdgQbU6UQdebUc SEND ALL SAMPLES UNTIL NEXT SPC OFFSET This function tells the control to start collecting weld data for all welds. This function should follow the SPC Offset function in the weld schedule because it is still necessary to assign a starting bin number. Weld data collection continues until the control executes another schedule containing this function (without the offset function), to reset the global data collection process.
Page 121 Weld Data Collection is bin dependent. Each bin has its own independent counter and is uploaded to XWSS separately. 6&5 6KRUW 'HWHFWLRQ The MedWeld 3005 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 122 1TfQ^SUTC_VdgQbU6UQdebUc DO NOT disable short detection (by setting this parameter to DISABLE) for normal operating conditions. Danger! When disabling short detection, the control will not shunt trip the circuit breaker in case of an SCR short. The control will not detect situations such as a catastrophic SCR failure.
Page 123 • Initiate from Retract and • Cylinder Type. WARNING! For safety, the MedWeld 3005 ignores any changes to these parameter settings until power is removed from the control. (The control checks the status of these parameters only at power-up.) The Retract Mode setup parameter determines how the control Sr‡…hp‡ÃH‚qrÃTr‡ˆƒ...
Page 124 1TfQ^SUTC_VdgQbU6UQdebUc • LATCHED tells the control to change the state of the output each time it receives a pulse from the RETRACT PILOT input. (The control expects a brief pulse from the input, such as from a push button.) RETRACT PILOT Input RETRACT VALVE Output >?D5* Selecting LATCHED retract may require toggling the state of the...
Page 125 1TfQ^SUTC_VdgQbU6UQdebUc • AIR-INVERTED indicates an air-only cylinder, but the output is turned ON to close the gun. Air-inverted partial retract full retract Retract Output The following sections detail the retract operation under a variety of combinations of parameter settings. (The Retract Mode setup parameter is described on page 6-10.) The processor also provides a function which you can place in a Dv‡vh‡v‚ÃA…‚€...
Page 126 1TfQ^SUTC_VdgQbU6UQdebUc %!& =UTGU\T# %?`UbQd_bµc7eYTUD)## " #" "%1`bY\" "...
Page 127 6HWXS 3DUDPHWHUV The MedWeld 3005 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...
Page 128 (FAULT) (ALERT) If the weld schedule is using the function to TURN ON WELD COMPLETE, the MedWeld 3005 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 129 CUde`@QbQ]UdUbc STEPPER APPROACHING MAX: (FAULT) (ALERT) (NONE) When a weld schedule is assigned to a linear stepper, this fault indicates that the stepper has begun the final step of the assigned stepper. END OF STEPPER: (FAULT) (ALERT) The END OF STEPPER fault indicates that a stepper has completed the last weld in the final step of the assigned stepper.
Page 130 CUde`@QbQ]UdUbc • If the schedule contains the test fire function and the function FAULT IF TIPS NOT TOUCHING, AND the control detects less than 10 A. of primary current during the test fire, the control assumes that the tips were open. It generates the TIPS NOT TOUCHING fault.
Page 131 CUde`@QbQ]UdUbc INSUFFICIENT LINE VOLTAGE: (FAULT) (ALERT) 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). EXTENDED WELD: (FAULT) (ALERT) This fault is generated under one of two conditions, based on which REWELD function appears in the weld schedule: •...
Page 132 CUde`@QbQ]UdUbc ISO CNTR ERR-BRKR TRIPPED: (FAULT) This fault is generated when the MedWeld 3005 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 133 If the control moves into No Weld Mode while sequencing. • If the control powers down while sequencing. • If the SLC processor and the WTC weld processor lose communication while the control is executing a schedule. I/O UPDATE: (FAULT) This fault may occur in one of these conditions: •...
Page 134 CUde`@QbQ]UdUbc PRESSURE SWITCH: (FAULT) (ALERT) This fault is generated if the PRESSURE SWITCH input does not become active within the number of cycles specified in Function #68 (WAIT nnn CY. FOR PRESSURE SWITCH) or if the weld initiate is removed while the control is waiting in Function #69 (WAIT FOR PRESSURE SWITCH).
Page 135 CUde`@QbQ]UdUbc This parameter is permanently set to the FAULT condition. You CANNOT program it. The following two parameters (along with Sec. Curr Coil Multiplier (x1000)) support operation of the Secondary Current Interface Board (SCIB): SECONDARY CURRENT COIL/BOARD: (FAULT) This fault will occur under the following conditions: •...
Page 136 CUde`@QbQ]UdUbc CURRENT LIMIT MODE: (AVERAGE) (PEAK) This parameter specifies which method the control will use during current limit processing. • If this parameter is set to PEAK, the fault is generated if the current limit is exceeded during any one cycle. •...
Page 137 LATCHED tells the control to change the state of the RETRACT output when the input is briefly turned on and then off (pulsed). WARNING! For safety, the MedWeld 3005 ignores any changes made to this parameter until you reset the control (by cycling power). CYLINDER:...
Page 138 CUde`@QbQ]UdUbc The HIGH POWER FACTOR LIMIT fault can help warn of a deteriorating secondary. A LOW POWER FACTOR LIMIT fault can indicate a control malfunction, or an increase in inductive resistance. Function #96 permits overriding the High and Low Power Factor >?D5* Limit setup parameters.
Page 139 These two parameters define a global current range for every weld schedule. The MedWeld 3005 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.
Page 140 The C-factor represents the value of current obtained or expected for each percentage of maximum current deliverable. The programming device displays the actual C- Factor detected by the MedWeld 3005. You can program the acceptable range of C-factor in a weld schedule. &!$ =UTGU\T# %?`UbQd_bµc7eYTUD)##...
Page 141 C-factor value. I/O UPDATE TIMEOUT (MSEC): nnnn (0–9999) This setup parameter programs the maximum length of time in which the WTC weld processor and SLC processor can lose communications while initiating without generating an I/O TIMEOUT fault. The following parameter supports operation of the Secondary Current Interface Board (SCIB): SEC.
Page 142 CUde`@QbQ]UdUbc 4XLFN 5HIHUHQFH WR 6HWXS 3DUDPHWHUV The following list shows the default value for each parameter, as programmed at the factory: INVALID SEQUENCE SELECTED (FAULT) WELD INITIATE NOT PRESENT (ALERT) CONTROL STOP (FAULT) STEPPER APPROACHING MAX (ALERT) END OF STEPPER (FAULT) SUREWELD TREND LIMIT (ALERT)
Page 143 CUde`@QbQ]UdUbc SHORT DETECTION (ENABLED) RETRACT MODE (LATCHED) (AIR-NORMAL) HIGH POWER FACTOR LIMIT (99%) LOW POWER FACTOR LIMIT (10%) TIPS DOWN TEST FIRE %I (20%) VALVE 1 INITIAL PRESSURE (50 PSI) VALVE 2 INITIAL PRESSURE (50 PSI) HEAT CYCLE LIMIT (0=SEAM) (60 CYCLES) ISOLATION CONTACTOR DELAY (5 SEC)
Page 144 CUde`@QbQ]UdUbc &!( =UTGU\T# %?`UbQd_bµc7eYTUD)## " #" "%1`bY\" "...
Page 145 6WHSSHU 'DWD The MedWeld 3005 provides steppers, to help compensate for changes in the welding environment. These stepper settings are programmable, to control how the weld processor will compensate for these variations. :KDW LV D 6WHSSHU" The MedWeld 3005 provides two distinct types of steppers: •...
Page 146 CdU``Ub4QdQ /LQHDU 6WHSSHUV The conventional linear stepper tracks the number of welds completed. It increases the heat provided to the weld at several programmed set points. This serves to compensate for drifts in the welding process. The stepper profile consists of a number of linear steps, and a parameter to allow stepper grouping.
Page 147 CdU``Ub4QdQ As shipped from the factory, the linear steppers use this profile 9rshˆy‡ÃGvrh… by default: T‡rƒƒr…ÃQ…‚svyr START OF STEPPER STEP #1 03 %i 0700 AMPS IN 0060 WELDS STEP #2 03 %i 0700 AMPS IN 0180 WELDS STEP #3 03 %i 0700 AMPS IN 0300 WELDS STEP #4 03 %i 0700 AMPS IN 0600 WELDS STEP #5 03 %i 0700 AMPS IN 0800 WELDS STEP #6 00 %i 0700 AMPS IN 0000 WELDS...
Page 148 CdU``Ub4QdQ • Press to see additional stepper options. The asterisk (*) indicates that additional displays or information are available. When you press , you see the stepper reset option at ; or Ã" • Press a second time, and you’ll see a display showing the status of every linear stepper: @?G5B?>3?==?>...
Page 149 CdU``Ub4QdQ These parameters control the SureWeld steppers: Tˆ…rXryq Qh…h€r‡r…† INC %I/I ON 99 WELDS W/O EXPULSION This parameter programs the “no-expulsion” counter. The control keeps track of the number of welds where expulsion did NOT occur since the stepper last changed the current provided.
Page 150 CdU``Ub4QdQ POSITIVE TREND LIMIT: (99) NEGATIVE TREND LIMIT: (99) These two parameters serve to prevent runaway stepper conditions. These can arise from problems such as improper electrode cooling, incorrect base heat, or arcing secondary current-carrying cables causing problems with the monitoring of power factor drop (PFD).
Page 151 STEPPER APPROACHING MAX. condition. STEPPER APPROACHING MAX.: (99999) When the weld count reaches this limit, the MedWeld 3005 generates the STEPPER APPROACHING MAX. condition, to indicate that the electrodes require maintenance. When selecting the SureWeld stepper status display from the 9v†ƒyh’Ãh‡Ã‡ur...
Page 152 CdU``Ub4QdQ This display shows the status of the values programmed for the SureWeld stepper. These are the amount of boost being added to the weld function, the largest 1-cycle drop detected, the total weld count, the counter of expulsion and no-expulsion welds (Exp and No Exp), and the two trend counters (UT and DT).
Page 153: Table Of Contents
)DXOW &RQGLWLRQV The fault conditions generated by the weld processor may not always identify the source of the problem. However, they do provide a starting point to begin searching. Certain operating conditions are defined as Faults, Alerts, MAJOR, MINOR or NONE conditions in the setup parameters. However, the control’s response to the conditions is standard: When the control detects a fault condition you defined as MAJOR, it may inhibit welding or inhibit initiation of a new...
Page 154 6Qe\d3_^TYdY_^c Fault Page RETRACT PILOT ERROR ......6-8 SCR MISFIRE ....... . 8-5 SLC NOT IN RUN MODE.
Page 155: Control Stop
6Qe\d3_^TYdY_^c Message Explanation Possible Cause Remedy The control detected The CONTROL STOP input Check/repair ladder logic. Note Control Stop that the CONTROL from the robot or PLC pro- if the RIO Control Stop is both STOP input (normally gram was not active when the DIO and Serial I/O.
Page 156 6Qe\d3_^TYdY_^c Message Explanation Possible Cause Remedy The control detected The limit is set too low. Re-program high current limit High Current that the current fired (Function #76) Limit during the weld Welder impedance is lower Check for improper installation schedule exceeded (See p.
Page 157 6Qe\d3_^TYdY_^c Message Explanation Possible Cause Remedy The processor Faulty wiring. (For example, if Check all wiring connections. SCR Misfire detected conduction the gate and cathode wires Verify that they are secure and on one half-cycle are swapped.) correct. (See p. 6-3) without conduction Insufficient squeeze time in Program additional squeeze...
Page 158: Initial Power Factor Out Of Range
6Qe\d3_^TYdY_^c Message Explanation Possible Cause Remedy The control had to Low current limit is set too Re-program the Low Current Extended restart the weld high. Limit setup parameter. Weld schedule due to Unusual condition in the Check for improper part fit-up, insufficient secondary (See p.
Page 159: Insufficient Line Voltage
6Qe\d3_^TYdY_^c Message Explanation Possible Cause Remedy The control could not Check the nominal contactor Try recalculating the nominal Voltage fully compensate for voltage setup parameter. contactor voltage setting. Compensa- a drop or surge in tion Limit Too much load on the line Check line voltage.
Page 160 6Qe\d3_^TYdY_^c Message Explanation Possible Cause Remedy The isolation contac- The instruction to activate the Verify that the schedule Isolation tor was not pulled in isolation contactor (Function contains Function #52. Contactor by the control when #52) was missing from the Off When required by the weld weld schedule.
Page 161: Low Battery
6Qe\d3_^TYdY_^c Message Explanation Possible Cause Remedy The control is unable No incoming voltage to the Verify incoming power to the No Zero- to synchronize with control cabinet. control’s circuit breaker with a Crossing the AC line voltage. volt meter. If no power, check Sync for circuit break shunt trip or other errors.
Page 162 6Qe\d3_^TYdY_^c Message Explanation Possible Cause Remedy TRANSFORMER Defective SCR thermostat. Replace thermostat. System OVER-TEMPERA- Cooling Customer-supplied device Check device. TURE input was not did not activate the TRANS- active when required (See p. 6-6) FORMER OVER-TEMPERA- by the control, or the TURE input when required.
Page 163 6Qe\d3_^TYdY_^c Message Explanation Possible Cause Remedy The SLC processor The SLC processor Clear fault and cycle power. SLC Not in moved into Program experienced a CPU fault. Run Mode Mode while the con- The SLC was physically Switch the SLC processor back trol was executing a moved out of Run mode.
Page 164 6Qe\d3_^TYdY_^c Message Explanation Possible Cause Remedy The control moved Robot or PLC ladder logic Check robot or PLC ladder to Control in from Weld Mode to de-activated the WELD/NO verify that the input is being No Weld No Weld Mode while WELD input.
Page 165 +DUGZDUH 7URXEOHVKRRWLQJ This chapter provides a quick look-up, to let you quickly isolate the cause of a problem, and corrective actions required. 3RZHU 6XSSO\ Symptom Probable Cause Corrective Action Loss of power to the The 16-pin connector on the back of the Remove power from the chassis.
Page 166 8QbTgQbUDb_eR\UcX__dY^W 6/& 3URFHVVRU Symptom Probable Cause Corrective Action Inadequate power or Line power is not con- Verify that line power has been connected loss of power to the nected to the power to the power supply. SLC Processor supply. Check the jumper setting to verify that it matches the input voltage.
Page 167 SLC ladder logic and Verify compatibility; correct as necessary. weld processor firmware If not known, contact your WTC are incompatible. representative for assistance. One or more cards in Verify card position using control con-figu- rack is not properly ration sticker (inside control door).
Page 168 Remove power from the chassis, re- SLC processor is on) seat modules and restore power. Weld processor firmware Verify compatibility; correct as needed. and SLC ladder logic are If not known, consult your WTC incompatible. representative for assistance. )$ =UTGU\T# %?`UbQd_bµc7eYTUD)## "...
Page 169 120VAC is 120 VAC source connected connected. to the power supply. Faulty DEP-100S, WTC Replace as necessary. processor, or network power pack. Incorrect network address Verify the welder ID and network for weld control.
Page 170 8QbTgQbUDb_eR\UcX__dY^W 5,2 1HWZRUN 0RGXOH Symptom Possible Cause Corrective Action Inadequate or no Line power is not connected Verify that line power has been power to the RIO to the power supply. connected to the power supply. module Check jumper settings on the power supply.
Page 171 8QbTgQbUDb_eR\UcX__dY^W Symptom Possible Cause Corrective Action Loss of communica- RIO host’s processor is not Check that the scanner is properly tions between weld connected to scanner. installed in the rack. control and host PLC RIO host’s processor rack Check RIO host’s processor rack (Comm LED is off) inhibited.
Page 172 8QbTgQbUDb_eR\UcX__dY^W Symptom Input State Probable Cause Corrective Action SLC program On, closed, or Input circuit is Check specification and operates as though active. incompatible. sink/source compatibility input is off and/or (if DC input only). the input circuit will Low voltage across Check voltage across not turn on.
Page 173 8QbTgQbUDb_eR\UcX__dY^W Pˆ‡ƒˆ‡ÃH‚qˆyr Symptom Input State Probable Cause Corrective Action SLC program On or Output circuit is Verify proper wiring. Try indicates that the energized. damaged. other circuit; replace output circuit is off, module if necessary. or the output circuit will not turn off. Output device will Off or de- Output device is...
Page 174 8QbTgQbUDb_eR\UcX__dY^W 6ROYLQJ 7\SLFDO 3UREOHPV This table describes some of the typical problems you may see in the field. The recommended procedure to troubleshoot each problem is provided. Problem Possible Cause Possible Solution Circuit breaker SHUNT TRIP output on the I/O is If NO, replace output module.
Page 175 8QbTgQbUDb_eR\UcX__dY^W Problem Possible Cause Possible Solution Control does not Control is not receiving BINARY Check the device supplying the inputs. initiate a weld SELECT inputs. Check the I/O module and check input schedule. supply voltage to the I/O module. Check the I/O Status Display at the DEP.
Page 176 Verify that the data entry device Update software. software is compatible with the weld processor. (Consult your WTC representative for assistance.) Faulty weld processor, faulty DEP- Replace as necessary. 100S or faulty network power pack.
Page 177 8QbTgQbUDb_eR\UcX__dY^W Problem Possible Cause Possible Solution I/O not respond- Problem with the I/O. Check the device supplying the input or ing as expected receiving the output. Incorrect or loose wiring to the input or output module. Faulty input or output module. Isolation con- The weld schedule does not contain Check the weld schedule to confirm that it...
Page 178 8QbTgQbUDb_eR\UcX__dY^W Problem Possible Cause Possible Solution No line voltage Main breaker switch is OFF. Turn on the breaker. reading or no No 480/600 VAC is connected to the Verify that supply voltage (480 or 600 zero-crossing. top of the breaker. VAC) is connected to the top of the breaker.
Page 179 Appendix: I/O Image Tables RIO Image Tables Host PLC Output Image Table (Welder Inputs): Bits Word 0 Word 1 Word 2 Word 3 Word 4 Word 5 Word 6 Word 7 Weld Control Weld Control Weld Control Weld Control Weld Control Weld Control Weld Control Weld Control...
Page 180 Bits Word 0 Word 1 Word 2 Word 3 Word 4 Word 5 Word 6 Word 7 Weld Control Global (Enclo- Weld Control Weld Control Weld Control Dec. Octal Spare Bits Spare Bits Spare Bits Bits (WCU #2) sure) Bits Bits (WCU #5) Bits (WCU #8) Bits (WCU #11)
Page 181 Host PLC Input Image Table (Welder Outputs) Bits Word 0 Word 1 Word 2 Word 3 Word 4 Word 5 Word 6 Word 7 Weld Control Weld Control Weld Control Weld Control Weld Control Weld Control Weld Control Weld Control Dec.
Page 182 Bits Word 0 Word 1 Word 2 Word 3 Word 4 Word 5 Word 6 Word 7 Weld Control Global (En- Weld Control Weld Control Weld Control Dec. Octal Spare Bits Spare Bits Spare Bits Bits (WCU #2) closure) Bits Bits (WCU #5) Bits (WCU #8) Bits (WCU #11)
Page 183 RIO_2 Host PLC Output Image Table (Welder Inputs): Bits Word 0 Word 1 Word 2 Word 3 Word 4 Word 5 Word 6 Word 7 Weld Control Weld Control Weld Control Weld Control Weld Control Weld Control Weld Control Weld Control Dec.
Page 184 Bits Word 0 Word 1 Word 2 Word 3 Word 4 Word 5 Word 6 Word 7 Weld Control Global (En- Weld Control Weld Control Weld Control Dec. Octal Spare Bits Spare Bits Spare Bits Bits (WCU #2) closure) Bits Bits (WCU #5) Bits (WCU #8) Bits (WCU #11)
Page 185 RIO_2 Host PLC Input Image Table (Welder Outputs) Bits Word 0 Word 1 Word 2 Word 3 Word 4 Word 5 Word 6 Word 7 Weld Control Weld Control Weld Control Weld Control Weld Control Weld Control Weld Control Weld Control Dec.
Page 186 Bits Word 0 Word 1 Word 2 Word 3 Word 4 Word 5 Word 6 Word 7 Weld Control Global (En- Weld Control Weld Control Weld Control Dec. Octal Spare Bits Spare Bits Spare Bits Bits (WCU #2) closure) Bits Bits (WCU #5) Bits (WCU #8) Bits (WCU #11)
Page 187 RIO_3 Host PLC Output Image Table (Welder Inputs): Bits Word 0 Word 1 Word 2 Word 3 Word 4 Word 5 Word 6 Word 7 Weld Control Weld Control Weld Control Weld Control Weld Control Weld Control Weld Control Weld Control Dec.
Page 188 Bits Word 0 Word 1 Word 2 Word 3 Word 4 Word 5 Word 6 Word 7 Weld Control Global (En- Weld Control Weld Control Weld Control Dec. Octal Spare Bits Spare Bits Spare Bits Bits (WCU #2) closure) Bits Bits (WCU #5) Bits (WCU #8) Bits (WCU #11)
Page 189 RIO_3 Host PLC Input Image Table (Welder Outputs) Bits Word 0 Word 1 Word 2 Word 3 Word 4 Word 5 Word 6 Word 7 Weld Control Weld Control Weld Control Weld Control Weld Control Weld Control Weld Control Weld Control Dec.
Page 190 Bits Word 0 Word 1 Word 2 Word 3 Word 4 Word 5 Word 6 Word 7 Weld Control Global (En- Weld Control Weld Control Weld Control Dec. Octal Spare Bits Spare Bits Spare Bits Bits (WCU #2) closure) Bits Bits (WCU #5) Bits (WCU #8) Bits (WCU #11)
Page 191 RIO_4 Host PLC Output Image Table (Welder Inputs): Bits Word 0 Word 1 Word 2 Word 3 Word 4 Word 5 Word 6 Word 7 Weld Control Weld Control Weld Control Weld Control Dec. Octal Spare Bits Spare Bits Spare Bits Spare Bits Bits (WCU #1) Bits (WCU #3)
Page 192 Bits Word 0 Word 1 Word 2 Word 3 Word 4 Word 5 Word 6 Word 7 Weld Control Global (En- Weld Control Dec. Octal Spare Bits Spare Bits Spare Bits Spare Bits Spare Bits Bits (WCU #2) closure) Bits Bits (WCU #5) BINARY CONTROL...
Page 193 RIO_4 Host PLC Input Image Table (Welder Outputs) Bits Word 0 Word 1 Word 2 Word 3 Word 4 Word 5 Word 6 Word 7 Weld Control Weld Control Weld Control Weld Control Weld Control Weld Control Weld Control Weld Control Dec.
Page 194 Bits Word 0 Word 1 Word 2 Word 3 Word 4 Word 5 Word 6 Word 7 Weld Control Global (En- Weld Control Weld Control Weld Control Global (En- Weld Control Weld Control Dec. Octal Bits (WCU #2) closure) Bits Bits ( Bits (WCU #3) Bits (WCU #5)
Page 195 RIO_5 Host PLC Output Image Table (Welder Inputs): Bits Word 0 Word 1 Word 2 Word 3 Word 4 Word 5 Word 6 Word 7 Weld Control Weld Control Weld Control Weld Control Weld Control Weld Control Dec. Octal Spare Bits Spare Bits Bits (WCU #1) Bits (WCU #2)
Page 196 Bits Word 0 Word 1 Word 2 Word 3 Word 4 Word 5 Word 6 Word 7 Weld Control Global (En- Weld Control Weld Control Weld Control Weld Control Weld Control Dec. Octal Spare Bits Bits closure) Bits Bits Bits (WCU #3) Bits (WCU #4) Bits (WCU #5) Bits (WCU #6)
Page 197 RIO_5 Host PLC Input Image Table (Welder Outputs) Bits Word 0 Word 1 Word 2 Word 3 Word 4 Word 5 Word 6 Word 7 Weld Control Weld Control Weld Control Weld Control Weld Control Weld Control Dec. Octal Spare Bits Spare Bits Bits (WCU #1) Bits (WCU #2)
Page 198 Bits Word 0 Word 1 Word 2 Word 3 Word 4 Word 5 Word 6 Word 7 Global (En- Weld Control Dec. Octal Spare Bits Spare Bits Spare Bits Spare Bits Spare Bits Spare Bits closure) Bits Bits SPARE CONTACTOR SPARE SPARE SPARE...
Page 199 DeviceNet I/O Tables dnet_map Welder Inputs—Node 30 Host Output Image Table (Node 30) Global SCR#1 SCR#2 SCR#3 SCR#4 SCR#5 SCR#6 Byte 0 Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 ENABLE SCR#1 CONTROL STOP BINARY BINARY BINARY...
Page 200 dnet_map Welder Outputs—Node 30 Host Input Image Table (Node 30) Global SCR#1 SCR#2 SCR#3 SCR#4 SCR#5 SCR#6 Byte 0 Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 ID BIT #0 CONTACTOR IS I/O ACTIVE I/O ACTIVE I/O ACTIVE I/O ACTIVE...
Page 201 dnet_map Welder Inputs—Node 30 Host Output Image Table (Node 30) Global SCR# 7 SCR #8 SCR #9 SCR #10 SCR #11 SCR #12 Byte 0 Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 ENABLE SCR#7 Reserved BINARY BINARY...
Page 202 dnet_map Welder Outputs—Node 30 Host Input Image Table (Node 30) Global SCR#7 SCR#8 SCR#9 SCR#10 SCR#11 SCR#12 Byte 0 Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 ID Bit #0 Reserved I/O ACTIVE I/O ACTIVE I/O ACTIVE I/O ACTIVE I/O ACTIVE...
Page 203 dnet1_map Welder Inputs—Node 30 Host Output Image Table (Node 30) HBit Input Word 0 HBit Input Word 1 HBit Input Word 2 HBit Input Word 3 HBit Input Word 4 MODULE STATUS Enable SCR#1 SCR #1 BINARY PART ID LSW PART ID MSW REGISTER SELECT #1...
Page 204 Host Output Image Table (Node 30) HBit Input Word 0 HBit Input Word 1 HBit Input Word 2 HBit Input Word 3 HBit Input Word MODULE STATUS GLOBAL CONTROL SCR #2 BINARY PART ID LSW PART ID MSW REGISTER STOP SELECT #1 (Bit 08) (Bit 08)
Page 205 dnet1_map Welder Outputs—Node 30 Host Input Image Table (Node 30) HBit Output Word 4 HBit Output Word 0 HBit Output Word 1 HBit Output Word 2 HBit Output Word 3 MODULE STATUS ID BIT #0 SCR #1 I/O ACTIVE ACTIVE PART ID ACTIVE PART ID REGISTER LSW (Bit 00)
Page 206 Host Input Image Table (Node 30) HBit Output Word 0 HBit Output Word 1 HBit Output Word 2 HBit Output Word 3 HBit Output Word 4 MODULE STATUS Global CONTAC- SCR #2 I/O ACTIVE ACTIVE PART ID ACTIVE PART ID REGISTER TOR IS OPEN LSW (Bit 00)

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Summary of Contents for WTC MedWeld 3005

Page 153: Table Of Contents

Page 155: Control Stop

Page 158: Initial Power Factor Out Of Range

Page 159: Insufficient Line Voltage

Page 161: Low Battery