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WTC MedWeld 3005, Operator'S Manual

The WTC MedWeld 3005 Operator's Manual is a comprehensive guide for operating and maintaining this cutting-edge welding machine. You can easily download the manual for free from our website, ensuring you have all the instructions and specifications at your fingertips. Get the most out of your WTC MedWeld 3005 today!

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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

Dec.

Octal

Weld Control 

Bits (WCU #1)

Weld Control 

Bits (WCU #3)

Weld Control 

Bits 

Weld Control 

Bits (WCU #2)

Weld Control 

Bits (WCU #4)

Weld Control 

Bits (WCU #6)

Weld Control 

Bits (WCU #4)

Weld Control 

Bits (WCU #5)

00

0

I/O ACTIVE

I/O ACTIVE

WCU #1 
CONTROL 
STOP Fault 

EXTEND WELD I/O ACTIVE

I/O ACTIVE

CONTROL 
STOP Fault 

EXTEND WELD

01

1

WELD IN 
PROGRESS

WELD IN 
PROGRESS

WCU #1 
CURRENT 
LIMIT Fault 

HIGH C- 
FACTOR LIMIT 

WELD IN 
PROGRESS

WELD IN 
PROGRESS

CURRENT 
LIMIT Fault 

HIGH C- 
FACTOR LIMIT 

02

2

NO FAULT

NO FAULT

WCU #1 
SCR MISFIRE

LOW C- 
FACTOR LIMIT

NO FAULT

NO FAULT

 SCR MISFIRE

LOW C- 
FACTOR LIMIT

03

3

ALERT ALERT

WCU 

#1 

COMPENSA-
TION Fault 

SYSTEM 
COOLING

ALERT

ALERT

COMPENSA-
TION Fault 

SYSTEM 
COOLING

04

4

END OF 
STEPPER

END OF 
STEPPER

WCU #1 
INSUFFICIENT
LINE VOLT-
AGE

 

Fault

DEP DISPLAY 
Faults

END OF 
STEPPER

END OF 
STEPPER

INSUFFICIENT
LINE VOLT-
AGE

 

Fault

DEP DISPLAY 
Faults

05

5

STEPPER IS 
RESET

STEPPER IS 
RESET

WCU #1 
EXTEND WELD

SPARE STEPPER 

IS 

RESET

STEPPER IS 
RESET

EXTEND WELD SPARE 

06

6

WELD 
COMPLETE

WELD 
COMPLETE

WCU #1 HIGH 
C-FACTOR 
Fault

CONTROL 
STOP Fault 
WCU #3

WELD 
COMPLETE

WELD 
COMPLETE

HIGH C-
FACTOR Fault

CONTROL 
STOP Fault 
WCU #6 

07

7

READY TO 
WELD

READY TO 
WELD

WCU #1 LOW 
C-FACTOR 
Fault

CURRENT 
LIMIT Fault 
WCU #3

READY TO 
WELD

READY TO 
WELD

LOW C-
FACTOR Fault

CURRENT 
LIMIT Fault 
WCU #6 

Summary of Contents for MedWeld 3005

Page 1: ...n 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 Voice 248 477 3900 630 462 8250 Fax 248 477 8897 Fax 630 462 8259 ...

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Page 9: ...numbers Record the part number of the enclosure on the serial tag on the inside or front door of the enclosure Also note the sequence of events leading to the problem and the drawing numbers of the schematics you received with the enclosure PDLO When an immediate response is not critical contact WTC at the following e mail addresses WTC s technical support will respond within 24 hours Monday throu...

Page 10: ...ry or considerable damage to property WARNING This symbol will be used wherever insufficient or lacking compliance with instructions may result in personal injury 3QedY_ DXYc ci R_ gY RU ecUT gXU Y ceVVYSYU d _b QS Y W S_ YQ SU gYdX dXU Y cdbeSdY_ c Qi bUce d Y TQ QWU d_ UaeY U d _b VY Uc D5 This convention informs the user about special features or where to find more information WTC 24775 Crestvi...

Page 11: ...rol Refer all necessary service on this machine ONLY to qualified maintenance personnel Failure to observe basic electrical safety practices may cause serious injury or death 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 ...

Page 12: ...S WITH RESPECT TO GOODS WHICH ARE MANUFACTURED AND CONFORM TO SPECIFICATIONS DESIGNS AND PRINTS SUPPLIED BY THE PURCHASER THIS WARRANTY IS MADE IN LIEU OF ALL OTHER CONDITIONS WARRANTIES REPRESENTATIONS OR GUARANTEES THERE ARE NO OTHER CONDITIONS REPRESENTATIONS WARRANTIES OR GUARANTEES WRITTEN OR ORAL EXPRESS OR IMPLIED STATUTORY OR NON STATUTORY INCLUDING ANY CONDITION WARRANTY REPRESENTATION OR...

Page 13: ...ty fees FNQRZOHGJPHQWV MedLAN is the proprietary local area network used to interconnect products manufactured by WTC The following companies own the marks following their names Allen Bradley SLC Microsoft Windows 3DWHQWV WTC products are covered by one or more of the following patents held by WTC Additional patents are pending 3 736 445 4 001 540 4 104 724 4 251 764 4 254 466 4 282 417 4 289 948 ...

Page 14: ...ne megohm 1 MΩ resistor DQGOLQJ RU 0RYLQJ 6 6 HYLFHV Handle all circuit boards by their edges ONLY NEVER touch the traces or edge pad connectors Transport store and ship ESDS devices and circuit boards in a static shielding container An acceptable container is either a static shielding bag or a static shielding tote To be effective either type of container MUST be closed D5 Use ONLY static shieldi...

Page 15: ...s than 2 000 ohms cm at 25 C 500 µS The hose used must be NO LESS THAN 18 in long across the power voltages D5 Water that is safe for drinking is generally sufficient for cooling water provided it is filtered to eliminate sand and rust particles In addition temperature of the cooling water must NOT fall more than 2 C below the temperature of the surrounding air DWHU ORZ 5DWH In general the SCRs re...

Page 16: ... across the power voltages where SCR tangs are directly cooled OHFWULFDO KDUDFWHULVWLFV The SCR module has three main electrical ratings PIV Peak inverse voltage rating Insulation voltage rating and Nominal current rating The PIV rating represents the maximum voltage allowed across the SCR inverse parallel pair before damage occurs The PIV for the standard SCR module p n 304 0081 is 1 800 V If the...

Page 17: ...Controller A weld processor sends firing signals to its firing card through a firing cable harness plugged directly into the weld processor card This modular design allows use in a number of applications Two forms of integration are possible Discrete interface DIO where the weld control can exchange I O with a machine robot or portable gun controller The control communicates using inputs from the ...

Page 18: ...s to compensate for lost current density The control compensates for changes in the welding environment by monitoring the voltage and increasing the current as required to assure consistent welds The primary current I changes as the voltage fluctuates For example if E drops the processor firing phase shifts forward to increase I until E stabilizes You can program a weld function to use either Auto...

Page 19: ...len Bradley power supply mounted on the left side of the chassis 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 ALLEN BRADLEY PROGRAMMABLE CONTROLLER MEDAR FIRING MODULE ...

Page 20: ...and external programming devices D5 The power supply DOES NOT occupy a slot in the chassis It mounts on the left side with two Phillips head screws located in the top and bottom right corners under the faceplate 6 3URFHVVRU The Allen Bradley SLC 500 processor provides the interface between the MedWeld 3005 processor module and any automation system or welding station Refer to Available Configurati...

Page 21: ...d 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 set its network address PC RUN On steadily The SLC processor is in Run mode CPU FAULT Flashing at power up The processor has not been configured Flashing du...

Page 22: ...ors are shown in Figure 4 below Figure 4 GD3 GU T b_SUcc_b The weld processor performs the following weld timing functions required to execute a weld schedule Checks input signals provided through the SLC processor from the I O modules either remote or discrete and reacts to them accordingly Operates the output signals through the SLC processor based on the weld schedule Sends single phase firing ...

Page 23: ...weld processor card RTW This LED lights when the control is ready to weld It indicates that the control will provide current under the following conditions No faults exist The CONTROL STOP input is not active off is active The control is in Weld Mode The WCU is synchronized with the welding bus The SCR OVER TEMPERATURE input is closed or The TRANSFORMER OVER TEMP input is closed IACK This LED ligh...

Page 24: ...rocedure described in Setting the DIP Switches on page 2 3 The RIO Network module also provides LED indicators to show the status of communications on the network as described next Figure 5 B9 Udg_b 3QbT HYLFH1HW QWHJUDWLRQ When the control provides DeviceNet integration the SLC rack requires two additional modules The DeviceNet module and the combination module for local control of certain critic...

Page 25: ...ce or consume messages and the 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 127 For more information on DeviceNet contact your WTC representative HYLFH1HW 0RGXOH The DeviceNet module is shown below Figure 6 4UfYSU Ud _Te U This module provides two bi color status indicators In addition a numeric code...

Page 26: ...communi cation The channel is disabled for DeviceNet communi cations Power up the module provide network power and verify that the channel is enabled in both the module configuration table and the module command word Green Flashing The 2 digit numeric display shows an error code with more informa tion The channel is enabled but there is no commu nication Configure the Scan List table for the chann...

Page 27: ...t match Scan List table entry node number alternately flashes Enter a matching Scan List device ID 74 Data overrun on port detected Modify your configuration and check for invalid data 75 No network traffic has been detected Verify connections 76 No direct network traffic for module detected None The module hears other network communication 77 Data size returned does not match Scan List s entry no...

Page 28: ... once the module attempts to initialize all slave devices on the channel 85 Data size returned is bigger than expected Check accuracy of Scan List table entry Check slave device configuration 88 Not an error At power up and reset the module displays all 14 segments of these LEDs None 90 User has disabled the communications port Reconfigure your module 91 Bus off condition detected on the communica...

Page 29: ... status of each input or output LVFUHWH QSXW 0RGXOHV The input module allows the weld control enclosure to receive 8 or 16 discrete inputs from a welding machine robot or portable gun controller To access these I O points wire the inputs from the devices into the modules Refer to the drawing packet provided with your control for a complete list of the I O used in your application as well as a defi...

Page 30: ...ler 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 application The complete list of discrete outputs available for the MedWeld 3005 appears on page 3 5 Figure 9 ed ed _Te U dY_ c 8 Inputs 16 Inputs 16 Out...

Page 31: ...VAC is connected to the single pack breaker at terminals L1 and L2 For a three phase configuration it enters at terminals L1 L2 and L3 If the optional isolation contactor is used connecting the control to the weld bus and the circuit breaker in the ON position applies supply voltage to the contactor s normally open contacts In single pack configurations the contacts are designated 1L1 and 1L2 for ...

Page 32: ...required by the internally powered safety I O including the isolation contactor Refer to the drawing package provided with your weld control for more information When the control is internally powered the control transformer powers the isolation contactor coil any AC I O the circuit breaker shunt trip and the programmable controller XUUHQW RLO The current coil is the doughnut shaped device located...

Page 33: ...eld processor board uses to measure the welder s current The firing card receives a logic level firing signal through its J2 connector from the weld processor card This signal is optically coupled to a high voltage circuit on the firing card and controls the SCR wired through the firing card connector J1 LULQJ DUG 2XWSXW 6LJQDOV The firing card also outputs a group of logic level signals from the ...

Page 34: ...ng on the firing configuration required HVFULSWLRQ RI DUGZDUH The Cascade Firing Board is the same size as a 645 firing board and uses the same mounting centers The interface consists of Four connectors on the board to receive inputs to the SCR gate leads Three output signal connectors to the SCR gate leads and Three red LEDs Each LED flashes to indicate activation if any of its respective SCR The...

Page 35: ... on the 645 firing board Two connectors accept cables to connect to the weld timer and the firing board The SCIB draws its power from the weld timer No external power source is required The SCIB uses an air wound Rowgowski current sensing coil to measure secondary welding current This sensing coil connects to the SCIB via a 2 pin Phoenix connector The SCIB can measure AC or DC currents up to 100 0...

Page 36: ... at all It will act as if it is not there If commanded by the weld timer the SCIB will disconnect the CCNT input of the weld timer from the firing board and re connect it to the V F converter on the SCIB board In this configuration the weld timer will read the secondary current not the primary current Normally the integrator is controlled by the microprocessor to achieve the most accurate measurem...

Page 37: ...urrent coil input terminals present a 1 000 ohm load to the coil The SCIB has three current ranges which are set with suitcase type jumpers on the circuit board These ranges are 0 25 kA 0 50 kA and 0 100 kA Higher currents up to any desired value can be obtained by using a special jumper setting together with an external resistor network on the current sensing coil Due to the averaging nature of t...

Page 38: ...n the SCIB is a 2 pin pluggable terminal strip of the Phoenix variety This connects the secondary current sensing coil NEVER CONNECT EITHER TERMINAL OF THIS CONNECTOR TO GROUND If the cable for the secondary current sensing coil has a shield disconnect this shield from either of the signal leads Connect the shield to cabinet ground before routing the wires to the SCIB Except when acknowledging a c...

Page 39: ...ration the POWER ERROR LED will glow red and remain red until the SCIB is powered down or a RESET command is issued by the weld timer SSOLFDWLRQ 6RIWZDUH 3DUDPHWHUV Three setup parameters support operation of the SCIB SEC CURR COIL FACTOR X1000 nnnn 0 9999 Use this setup parameter when monitoring secondary current as an adjustment to accommodate for secondary current sensing coils of different sen...

Page 40: ...rent monitoring If selecting secondary current monitoring a Secondary Current 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 ...

Page 41: ...rcuit breaker handle on the enclosure is in the OFF down position before attempting to open the door 51 1 The door is interlocked with the circuit breaker to prevent opening the cabinet door while power is applied DO NOT attempt to force open the door Damage to the cabinet may result NEVER attempt to defeat the interlock 2 Inspect the inside of the enclosure for any damage caused in shipping Check...

Page 42: ...d to reduce the risk of electrical shock 3QedY_ BUVUb d_ QWU hf V_b dXU bUaeYbU U dc _V S__ Y W gQdUb aeQ Ydi Q T V _g 7 With the welding bus power off connect the power cables from the welding bus to the top of the circuit breaker 8 Provide the connection to the weld transformer Refer to the decal affixed on the enclosure for assistance in connecting the welding transformer 9 Provide the MedLAN c...

Page 43: ... the remote integration scheme you must wire into the RIO Local Combination module to provide certain critical local and safety I O signals These signals are defined in Local and Safety I O on page 3 1 6HWWLQJ WKH 3 6ZLWFKHV To configure the WTC 3005 for remote integration you must correctly set the DIP switches These switches enable the weld processor to properly interpret the system addressing a...

Page 44: ...in switch block SW2 These DIP switches 5 and 6 determine the size of the RIO data transfer with valid ranges from 1 4 rack to a full rack For a single WCU or a tri pack system set the rack size to 1 4 rack A six pack configuration requires setting a rack size of 1 2 DIP Switch I O Group Number Valid Rack Configuration 7 8 ON ON 0 ALL ON OFF 2 3 4 1 2 1 4 rack OFF ON 4 1 2 1 4 rack OFF OFF 6 1 4 ra...

Page 45: ...N 02 02 02 ON ON ON ON OFF OFF 03 03 03 ON ON ON OFF ON ON 04 04 04 ON ON ON OFF ON OFF 05 05 05 ON ON ON OFF OFF ON 06 06 06 ON ON ON OFF OFF OFF 07 07 07 ON ON OFF ON ON ON 08 10 08 ON ON OFF ON ON OFF 09 11 09 ON ON OFF ON OFF ON 10 12 0A ON ON OFF ON OFF OFF 11 13 0B ON ON OFF OFF ON ON 12 14 0C ON ON OFF OFF ON OFF 13 15 0D ON ON OFF OFF OFF ON 14 16 0E ON ON OFF OFF OFF OFF 15 17 0F ON OFF O...

Page 46: ...trol of certain critical I O This integration scheme supports a network of DeviceNet devices allowing rapid communications between industrial devices The DeviceNet module communicates with the SLC controller to provide information from the welding environment to the weld processor DeviceNet communications protocol is an open network standard maintained by the Open DeviceNet Vendor Association ODVA...

Page 47: ...tion on the Input and Output image tables used with DeviceNet refer to Discrete Integration on page 3 5 3URJUDPPLQJ WKH HYLFH1HW 0RGXOH Before operation for DeviceNet integration you must configure and program the module Follow these instructions for using the Allen Bradley DNET application Hard Tool procedures and Robot procedures DUG 7RRO 3URFHGXUHV On power up the DeviceNet card will display 88...

Page 48: ...H To go on line follow these steps 1 Select UTILITIES 2 Select SETUP ONLINE CONNECTION 3 Establish communications with the DeviceNet card It is probably using 125 kB sec If this rate does not work try the other menu choices listed below Leave the node setting at 62 for the computer interface D5 If the computer interface pod is faulted the Red LED is ON turn the interface pod switch OFF then ON to ...

Page 49: ...the current node address to the value found using MINI WHO 3 Change the new node address to NODE 30 and a 500 kB sec data rate Do it in two steps as follows 4 After setting these values select APPLY NODE SETTINGS The card re boots WTC NODE ADDRESSING METHOD HARD TOOL 8 byte transfer 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...

Page 50: ...NI WHO to confirm the node addresses They will likely be zero for the DeviceNet card The computer interface is 62 1 5hQ U In this example MINI WHO found node addresses 00 and 62 Configure the DeviceNet card as NODE 29 with the following procedure This is used in any control from seven through 12 pack 1 Close MINI WHO 2 Change the current node address to the value found using MINI WHO 3 Change the ...

Page 51: ...E 352 7 5 722 To set for NODE 30 use this procedure 1 Bring up PROJECT FILE 2 Select A scanner dnet pc1 or a similar line 3 Click on HARD TOOL to highlight it 4 Select UTILITIES 5 Then select SETUP ONLINE CONNECTION Go on line using node 62 and 500 kB sec 6 Select GO ONLINE and then YES Note that the project line now reads HARD TOOL Online 7 On the project window highlight the node 30 line by clic...

Page 52: ...e C prompt type WIN 3 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 D5 A terminating resistor of approximately 121 Ω 1 4 W is recommended at the DeviceNet card RLQJ 2Q LQH To go on line follow these steps 1 Select UTILITIES 2 Select...

Page 53: ...e MINI WHO found node addresses 00 and 62 Configure the DeviceNet Card as NODE 30 with the following procedure This is used in any control from single through six pack 1 Close MINI WHO 2 Change the current node address to the value found using MINI WHO 3 Change the new node address to NODE 30 and a 500 kB sec data rate Do it in two steps as follows Node 62 125 kB Select GO ON LINE then YES GO ON L...

Page 54: ...8 Select GO OFFLINE 352 7 52 27 Follow these steps 1 Bring up PROJECT FILE 2 Select dnet scanner testfix testfix pc1 3 Click on ROBOT to highlight it 4 Select UTILITIES 5 Then select SETUP ONLINE CONNECTION Go on line using node 62 and 500 kB sec 6 Select GO ONLINE and then YES Note that the project line now reads ROBOT Online 7 On the project window highlight the node 30 line by clicking on it CU...

Page 55: ...ications protocol It defines how devices on the network communicate with each other 127 The MedLAN address identifies each weld control s location on the network therefore each weld control s address must be programmed 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 communi...

Page 56: ...rations the MedLAN cable connection is daisy chained to the other controls on the network 0HG 1 LULQJ 6SHFLILFDWLRQV The MedLAN interface is an optically isolated RS 485 connection The interface is a 3 position removable Phoenix connector with a pin 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 tab...

Page 57: ..._ U dc G9 _SSeb 51 1 NEVER connect any of the communication ports to the MDP power wires Damage to the ports or other internal components may result Designator Pin Function Wire Color BELDEN 9463 MDL2 3 MedLan Line 2 Clear MDLS 2 Line Shield MDL1 1 MedLAN Line 1 Blue Designator Function MDL1 MedLAN Line 1 This is the TX RX line of the RS 485 signal Attach it to the blue wire of the cable MDL2 MedL...

Page 58: ...rminate into MTSB Phoenix connectors Terminate the cable with this procedure 1 Strip the cable jacket to 1 inch 2 Remove foil shield strands outside the foil 3 Cover the shield with heat shrink 4 Cover the cable insulation end with one inch of heat shrink tubing 5 Strip 1 4 inch of insulation off each wire 6 Install wires in each connector as shown in Figure 11 below 7 Torque the terminal screws t...

Page 59: ... If the MedLAN cable must cross this wiring it must do so at a 90 angle Figure 12 illustrates the recommended wiring configuration Note that this diagram shows optional equipment Figure 12 BUS_ U TUT UT 1 GYbY W WSS Network Power Pack WTC Control 1 WTC Control 2 WTC Control 3 WTC Control 4 WTC Control n Belden 9463 cable Control Card1 Control Card2 Control Control Card3 Card4 Enlarged View of Cont...

Page 60: ... 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 127 The steps required to set the address are listed below Refer to the manual provided with the DEP 100S programming device for more information on operation This illu...

Page 61: ...pro vided 2 Press the key labeled B 7B1 45 on the DEP 100S You will see this screen 3 Press on the DEP 100S for additional functions The following screen appears 4 Press to select network addressing NETWORK ADDR This display will appear G5B 3 B 7B1 45 B5F95G B5F95G B5F95G B5 14 C3854E 5 CD5 5B C5DE 456 D 6 6 6 6 G5B 3 B 7B1 45 G5 45B DB1 C65B 5DG B 94 41D1 144B 6 6 6 6 G5B 3 5DG B 144B5CC B 7B1 9 ...

Page 62: ...rocessor provides multiple functions for defining weld schedules It also lets you configure the device to meet your application requirements by programming setup parameters The control also provides a programmable stepper to compensate for lost current density over the life of the electrodes All of these features are programmable from several different programming devices Plug the WTC DEP 100S pro...

Page 63: ...DEP 100S is shown in Figure 13 on page 2 20 Its multi line display and soft function keys allow you to see weld data or to program weld settings As described in the DEP 100S Programming Guide the DEP 100S displays information based on the software revision contained in both the DEP and the weld processor This manual explains how to use displays that are specific to the MedWeld 3005 processor Refer...

Page 64: ...LQJ 6XSSRUW 6 VWHP 66 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 Refer to the XWSS documentation or consult your WTC sales representative for more information 0HG RPPDQ...

Page 65: ...ical modules contained in the PLC chassis These are detailed in Physical Description on page 1 2 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 These outputs are the same f...

Page 66: ...ill 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 It will also de energize the NO FAULT output and trip the circuit breaker THERMAL SWITCH Input This input to the weld processor indicates that the...

Page 67: ...o warn the operator that maintenance is required ISOLATION CONTACTOR Output The ISOLATION CONTACTOR output operates the weld transformer isolation contactor Output 12 on the SLC output module informs the MFDC inverter when it is required to pull in the charging pack The charging pack remains energized It will drop out only when an inverter fault is generated or during an emergency stop condition S...

Page 68: ...ration is provided in RIO Image Tables on page A 1 2UJDQL DWLRQ RI WKH HYLFH1HW 2 Using DeviceNet integration requires the Allen Bradley DeviceNet Module 1747 SDN Scanner Module It is mounted in the SLC 500 programmable controller rack This module establishes a direct link between the control enclosure and the host PLC The module provides the drop to the DeviceNet as well as communication with the...

Page 69: ...ns QSXWV BINARY SELECT Inputs 1 2 4 8 16 These inputs select the schedule to be initiated 1 31 The schedule is selected by a combination of these inputs Each input has a weighted value 1 2 4 8 or 16 The schedule initiated is the one selected by adding the weighted values of the active inputs For example to initiate schedule 4 activate BINARY SELECT Input 4 To initiate schedule 7 activate BINARY SE...

Page 70: ...lls the weld control to cycle without supplying current and without turning on the valves This input affects the weld valves only It does not affect any other outputs CONTROL STOP Input This is a normally HIGH input When this input goes LOW de activated the control aborts the current schedule generates a CONTROL STOP Fault de activates the NO FAULT Output and will not initiate another schedule unt...

Page 71: ...eld schedule contains the function WAIT nnn CY FOR SYSTEM COOLING and this input does not become active within the programmed number of cycles the weld processor completes the weld schedule in No Weld The function CHECK SYSTEM COOLING will complete the sequence in No Weld if the input is not active when checked by the weld schedule If the schedule contains the unconditional wait function WAIT FOR ...

Page 72: ...ts STEPPER RESET Input This input will reset all the steppers to Step 1 and the weld count to 0 TIP DRESS ADVANCE Input This input moves the stepper to the beginning of the second step in the stepper profile PRESSURE SWITCH Input If the weld schedule contains the function WAIT nnn CY FOR PRESSURE SWITCH and this input does not become active in the number of cycles specified the control generates a...

Page 73: ... as described on page 6 12 holds the isolation contactor closed after a weld schedule is completed to prevent it from dropping out between welds If this input is active at the end of a schedule the weld processor will hold the isolation contactor closed for the amount of time programmed If this input is not active the isolation contactor will drop out at the end of the weld schedule However if thi...

Page 74: ...XU gU T Ve SdY_ gYdX Q QSdeQ Y ed _cYdY_ DXQd Yc EcUb 9 ed Yc D 535CC1B9 I QccYW UT d_ Y ed 2XWSXWV WELD VALVE Outputs 1 6 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 pro...

Page 75: ...put to indicate that the control is in No Weld Mode If a valid weld initiate is received while the control is in No Weld Mode the weld schedule will schedule normally but weld current WILL NOT FLOW FAULT Output This output is normally OFF indicating that the control is functioning normally If the control shuts down as the result of a fault condition this output will be turned ON NO FAULT Output Ce...

Page 76: ... has reached its programmed limit WELD IN PROGRESS Output The control turns this output ON and OFF in response to the output control function For more details see Output Control Functions on page 4 9 WELD COMPLETE Output This output turned on and off by the weld control in response to Functions 50 and 51 Refer to Output Control Functions on page 4 9 READY TO WELD Output When active this output ind...

Page 77: ...turns these outputs ON or OFF in a weld schedule using the functions described in Output Control Functions on page 4 9 3QedY_ DXUcU _ed edc QbU QbRYdbQbY i QccYW UT e RUbc Vb_ 4_ D S_ VecU dXYc QRU ed ed V_b UhQ U ecUT Ri dXU gU T Ve SdY_ gYdX Q QSdeQ _ed ed _cYdY_ DXQd Yc EcUb ed ed Yc D 535CC1B9 I QccYW UT d_ _ed ed 3 6 EEUHYLDWLRQV The DEP 100S provides an I O Status display to help troubleshoo...

Page 78: ...nal LOW control stop CSTP ISOLATION CONTACTOR SAVER Input CSVR REMOTE STEPPER RESET Input SR FAULT RESET Input FR PROGRAM MODE SECURITY Input PSEC HEAT DISPLAY SECURITY Input HSEC TIP DRESS ADVANCE Input TIPD PARITY Odd Input BINARY SELECT 64 PTY PRESSURE SWITCH Input PS1 WELD PROCEED Input WPRO STEPPER AUXILIARY COUNTER RESET Input SACR RETRACT PILOT 1 Input RP1 RETRACT PILOT 2 Input RP2 Programm...

Page 79: ...CE Fluid VALVE 1 Output VLV1 VALVE 2 ADVANCE Fluid VALVE 2 Output VLV2 VALVE 3 Output VLV3 VALVE 4 Output VLV4 VALVE 5 Output VLV5 VALVE 6 Output VLV6 RETRACT VALVE 1 RV1 RETRACT VALVE 2 RV2 PRESSURE SELECT 1 Output PV1 PRESSURE SELECT 2 Output PV2 PRESSURE SELECT 3 Output PV3 PRESSURE SELECT 4 Output PV4 INTENSIFICATION Air VALVE Output INTV WELD NO WELD Output LOW for weld WNO ISOLATION CONTACTO...

Page 80: ...FR PROGRAM MODE SECURITY Input PSEC HEAT DISPLAY SECURITY Input HSEC TIP DRESS ADVANCE Input TIPD PARITY Odd BINARY SELECT 64 Input PTY PRESSURE SWITCH Input PS1 WELD PROCEED Input WPRO STEPPER AUXILIARY COUNTER RESET Input SACR RETRACT PILOT 1 Input RP1 RETRACT PILOT 2 Input RP2 Programmable Input 1 PRG1 Programmable Input 2 PRG2 TRANSFORMER OVER TEMPERATURE Input TS2 Programmable Input 4 PRG4 Pr...

Page 81: ... VALVE 1 Output SV2 VALVE 2 ADVANCE Fluid VALVE 2 Output SV3 VALVE 3 Output SV4 VALVE 4 Output SV5 VALVE 5 Output SV6 VALVE 6 Output SV7 RETRACT VALVE 1 Output RV1 RETRACT VALVE 2 Output RV2 PRESSURE SELECT 1 Output PV1 PRESSURE SELECT 2 Output PV2 PRESSURE SELECT 3 Output PV3 PRESSURE SELECT 4 Output PV4 INTENSIFICATION Air VALVE 1 Output INTV WELD NO WELD Output LOW for weld NWO ISOLATION CONTAC...

Page 82: ...E SECURITY Input PSEC HEAT DISPLAY SECURITY Input HSEC TIP DRESS ADVANCE Input TIPD PARITY Odd BINARY SELECT 64 Input PTY ENABLE ISOLATION CONTACTOR Input WCE NO STROKE NO WELD Input NSNW TRANSFORMER OVER TEMP Input TS2 CLOSE BACK UP CYLINDER Input CLBU OPEN BACK UP CYLINDER Input OPBU CLOSE BACK UP VALVE Output Status SV6A OPEN BACK UP VALVE Output Status SV6B SYSTEM COOLING Input SCR THERMAL SWI...

Page 83: ...Output SALT TIP DRESS REQUEST TPDR VALVE 1 ADVANCE Fluid VALVE 1 Output SV2 VALVE 2 ADVANCE Fluid VALVE 2 Output SV3 VALVE 3 Output SV4 VALVE 4 Output SV5 VALVE 5 Output SV6 VALVE 6 Output SV7 INTENSIFICATION Air VALVE INTV WELD NO WELD Output LOW for weld WNO ISOLATION CONTACTOR SSR Relay Output SSR SHUNT TRIP Output PO2 INITIATE ACKNOWLEDGE Output IACK Spare Output 1 FCB1 Spare Output 2 FCB2 Spa...

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Page 85: ...hapter does not describe how to create or modify a weld schedule These steps will depend on the programming device This chapter only describes all of the weld functions available for use in programming a weld schedule KDW LV D HOG 6FKHGXOH A weld schedule is a list of commands that the control is to execute For example to perform a simple spot weld you might use a weld schedule consisting of the f...

Page 86: ...t range Statistical process control SPC functions Selecting the firing mode to assure consistent voltage or to assure constant secondary current and Pausing in a schedule to wait for certain operating conditions to become true Add or delete functions from this list or change any of the numeric values specified in a function This lets you create a schedule that meets your application requirements T...

Page 87: ... for the number of cycles programmed The function selected also selects the type of firing mode desired The weld function you select also tells the weld processor the type of firing mode to use to control the energy provided to a weld Specify weld current as either A percentage of maximum available current or The amount of secondary current This function tells the control how to compensate for cha...

Page 88: ... NOT include every function that provides weld current Keep this in mind when programming a weld schedule Only the following functions are included in the Weld Data display 9 LULQJ 0RGH 20 WELD nn CY IMP mm I 21 TEMPER nn CY IMP mm I 22 PREHEAT nn CY IMP mm I 23 POSTHEAT nn CY IMP mm I 24 PRE WELD nn CY IMP mm I 25 WELD nn CY IMP mm m I 26 WELD nn HALF CYCLES mm m I The stepper is active during th...

Page 89: ... high and low range of current The current range for each control is unique and depends on factors such as the size of the weld transformer Experiment with the control to determine the upper and lower range of current each control can provide When Function 60 appears before any weld function in a schedule the control displays IMP impulses rather than CY cycles to indicate that the weld control wil...

Page 90: ...ontrol to fire one cycle at 45 of the maximum available current Then over the next 29 cycles gradually increase the heat provided to 65 D5 The processor can fire a range from 20 to 99 I AVC faults may occur when firing at or near these ranges However by defining the slope as an impulse Function 60 appears before this function in the schedule the weld processor gradually increases the energy provid...

Page 91: ...IMPULSE 10 HEAT CY 10 COOL CY 20 WELD 04 IMP 65 I In this example the weld processor will actually fire for 10 cycles at 65 heat then wait for 10 cycles with NO heat and repeat this pattern 4 times 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 74 WELD nnn IMP mm I HIGH mm I LOW nn 1 99...

Page 92: ...PRESSURE SELECT n n 1 4 57 TURN OFF PRESSURE SELECT n n 1 4 58 TURN ON WELD IN PROGRESS 59 TURN OFF WELD IN PROGRESS 63 TURN ON OUTPUT n n 1 8 64 TURN OFF OUTPUT n n 1 8 D5C The function TURN ON WELD COMPLETE will only activate the WELD COMPLETE output under the following conditions There are no active fault conditions AND the BINARY SELECT or WELD INITIATE inputs are still active Function 52 TURN...

Page 93: ...es the appropriate fault condition as listed below The wait functions with no programmable delay will abort the schedule and generate the fault if the initiate is removed while the weld processor is waiting Functions 65 and 66 WELD PROCEED fault Function 65 will wait in the sequence for up to the specified number of cycles nnn for a given input to become either activated or de activated Function 6...

Page 94: ...cient Line 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 Function 79 SYSTEM COOLING fault As a safety measure the control cycles in No Weld to inhibit weld current from flowing 3QedY_ 4 D S_ VecU dXU QRU ecUT Ri dXU gU T Ve SdY_ 9 ed V_b UhQ U gYdX Q QSdeQ Y ed _cYdY_ DXQd Yc EcUb 9 ed Yc D 535CC1B...

Page 95: ...XU QRU ecUT Ri dXU gU T Ve SdY_ 9 ed V_b UhQ U gYdX Q QSdeQ Y ed _cYdY_ DXQd Yc EcUb 9 ed Yc D 535CC1B9 I QccYW UT d_ Y ed 75 EXTEND UNTIL NO INITIATE This function tells the weld processor to monitor the status of the WELD INITIATE input and to extend only the previous function in the weld schedule until it detects that the WELD INITIATE input is inactive 62 REPEAT AT NEXT FUNCTION This function ...

Page 96: ... zero 0 For more details about steppers refer to Chapter 7 Stepper Data 86 TIP DRESS ADVANCE GROUP nn STEP M nn 1 99 m 1 5 This function advances all the steppers assigned to the group number programmed in this function to the step number specified in the function Suppose this function reads TIP DRESS ADVANCE GROUP 02 STEP 05 Every stepper 1 99 assigned to group 02 would advance to Step 5 D5C This...

Page 97: ... nn LO nn C FACTOR nnn This function permits defining a current limit window with high and low limit values The action of this function is based on the firing mode used by the weld function I or Automatic Current Compensation For further details of this feature refer to Dynamic Current Windows on page 5 4 7HVW XQFWLRQV 39 TEST FIRE nn CURRENT nn 20 99 When it executes Function 39 the control will ...

Page 98: ...on can generate a fault condition if the control determines that the welding electrodes are NOT touching These conditions MUST be true when using this function Function 39 TEST FIRE nn CURRENT must appear in the weld sequence Function 92 must appear after the test fire function 39 in the weld sequence Function 91 FAULT IF TIPS TOUCHING cannot appear in the weld sequence When Function 39 executes t...

Page 99: ...dule and This function must appear after the test fire function 39 in the weld schedule D5 Function 98 may appear in a schedule more than once to allow setting up for different welding requirements An example appears in the following schedule of functions This is NOT a recommended weld schedule Your application requirements may vary START OF SCHEDULE O1 54 TURN ON VALVE 1 01 SQUEEZE 15 CYCLES 39 T...

Page 100: ...n page 6 14 If the primary current detected exceeds the value programmed the control proceeds to the next function in the weld schedule If the current is less than the value programmed the control waits for the number of cycles programmed nn CY then repeats the test fire This wait and fire process continues up to the programmed number of tries nn TIMES If the current never reaches the value progra...

Page 101: ...tion 94 but monitors secondary current instead of the LOW CURRENT LIMIT fault If the secondary current provided during the schedule does not reach the minimum value programmed the control restarts the weld schedule and generates the REWELDED fault or alert condition The control will repeat the schedule only once If the desired current is not provided on the re weld the control generates a REWELDED...

Page 102: ...c Y dXU gU T cSXUTe U 89 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 61 ABORT IF NO INITIATE FOR nn CYCLES This function tells the control to verify that the weld initiate has remained active The control wai...

Page 103: ...starting bin number for SPC indexing Bin 99 is the last usable bin If the control reaches bin 99 and is still collecting data data from each weld will be stored in bin 99 until a new offset is assigned As a result data accumulated in this bin is unsuitable for analysis D5 This function does NOT tell the control to collect weld data It only assigns a data storage bin number Refer to the Data Collec...

Page 104: ... 0 Pressure channel 2 corresponds to Analog channel 1 08 SET VALVE n CYLINDER RESSURE TO mm PSI n 1 2 m 0 99 This function sets the final pressure that the cylinder for either weld gun must achieve before welding begins n is the weld gun number either 1 or 2 Set the final pressure mm in the range 0 99 PSI 09 WAIT nn CYCLES FOR PRESSURE ACHIEVED nn 0 99 This function tells the control to pause in a...

Page 105: ...eces n sets the cylinder number Either 1 or 2 Set the pressure mm in the range 0 99 PSI 14 SET VALVE n TIP DRESS RESSURE PSI n 1 2 m 0 99 This function sets a pressure for the specified weld gun that can be different from the welding or touch down pressure settings This is used when running tip dress schedules n sets the cylinder number Either 1 or 2 Set the pressure mm in the range 0 99 PSI 4XLFN...

Page 106: ...QV SJ 50 TURN ON WELD COMPLETE 51 TURN OFF WELD COMPLETE 52 TURN ON ISOLATION CONTACTOR 53 TURN OFF ISOLATION CONTACTOR 54 TURN ON VALVE n 55 TURN OFF VALVE n 56 TURN ON PRESSURE SELECT n 57 TURN OFF PRESSURE SELECT n 58 TURN ON WELD IN PROGRESS 59 TURN OFF WELD IN PROGRESS 63 TURN ON OUTPUT n 64 TURN OFF OUTPUT n QSXW 0RQLWRULQJ XQFWLRQV SJ 65 WAIT nnn CY FOR INP m TO BE p 0 OFF 1 ON m 1 8 p 0 1 ...

Page 107: ...RQV SJ 39 TEST FIRE nn CURRENT mm 20 99 80 VERIFY TIPS DOWN EVERY 00 CY mm TIMES 81 SLOW CYLINDER TEST EVERY 00 CY mm TIMES 91 FAULT IF TIPS TOUCHING 92 FAULT IF TIPS NOT TOUCHING 93 INITIAL PF LIMIT HI nn LOW nn 98 GOTO SEQ mm IF CURRENT LESS THAN nnnn0 mm 1 99 6SHFLDO XQFWLRQV SJ 94 EXTEND WELD IF LOW CURRENT LIMIT FAULT 95 EXTEND WELD IF CURRENT LESS THAN nnnn0 AMPS 99 GOTO SEQ nn 78 PROCESS WE...

Page 108: ...TE 59 TURN OFF WELD IN PROGRESS 75 EXTEND UNTIL NO INITIATE 51 TURN OFF WELD COMPLETE 53 TURN OFF ISOLATION CONTACTOR END OF SEQUENCE nn HIDXOW HOG 6HTXHQFH 5RERW START OF SEQUENCE nn 82 LINEAR STEPPER 0 ASSIGNED 0 OFF 88 TURN ON ISOLATION CONTACTOR 50 TURN ON PRESSURE SELECT 1 52 TURN ON WELD SOLENOID 1 01 SQUEEZE 12 CYCLES 72 WAIT 000 CY FOR LINE 440 VOLTS 24 EXTEND WELD 00 CY 30 02 COOL 00 CYCL...

Page 109: ...2 CYCLES 53 TURN OFF WELD SOLENOID 2 54 TURN ON EWS OUPUT 14 DELAY 5 CYCLES 55 TURN OFF EWS OUPUT 90 TIP DRESS ADVANCE STPR GROUP 2 STEP 2 END OF SEQUENCE nn HIDXOW HOG 6HTXHQFH 0DQXDO 3RUWDEOH XQ START OF SEQUENCE nn 82 LINEAR STEPPER 01 ASSIGNED 0 OFF 76 SEC CURR LIMITS HI 00000 LO 99990 90 TRANSFORMER TURNS RATIO 100 1 54 TURN ON VALVE 1 05 INITIAL SQUEEZE 25 CYCLES 62 REPEAT AT NEXT FUNCTION 5...

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Page 111: ...vironment 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 The following formula shows this where n transformer turns ratio The C Factor varies with changing conditions in the secondary Decreasing C ...

Page 112: ...nment When shorting or shunting arises less resistance is seen because the full current is not passing through the entire welding circuit This is a concern If the full current is not passing through the weld point a weld below the desired current will occur Depending on the amount of shunting the weld nugget may possibly fail to be formed DPSOH RI QFUHDVLQJ DFWRU In this example a robot uses a kic...

Page 113: ...as either a Fault or an Alert in the setup parameters Low C Factor is a monitoring condition and usually defined as an ALERT High C Factor is a welding quality issue and usually defined as a FAULT RZ DFWRU LPLW The low C factor limit detects cable and connection deterioration HWHUPLQLQJ D RZ LPLW Suppose a weld schedule requires 14 000 A at the end of a stepper program However you do not want to e...

Page 114: ...T and will generate a fault condition if the actual KVAT exceeds the range specified in the weld sequence The High Current KVAT Limit Fault and Low Current KVAT Limit Fault setup parameters define the severity of the fault condition generated by the weld processor when the limits defined in Function 19 are exceeded QDPLF XUUHQW LQGRZV You can define a window of acceptable values for current To def...

Page 115: ...t Calculate the high and low current limits using this equation 9 DPSOH In this mode the target value is determined by the following calculation Target current I in Function 20 Stepper boost x C factor An example of how these calculations are used is shown below Function 20 is WELD 10 CY 50 I Stepper Boost is 2 C Factor is 170 High Current Limit 10 Low Current Limit 20 To determine the target curr...

Page 116: ... example of how these calculations are used is shown below Function 30 is WELD 08 CY 11000 A SEC Stepper Boost is 700 A SEC High Current Limit 10 Low Current Limit 20 To determine the Target Current Target current A in Function 30 stepper boost 11 000 700 11 700 A To determine the High Current limit High Current Limit Target Target x High limit 100 11 700 11 700 x 10 100 11 700 1170 12 870 A To de...

Page 117: ...he current detected when tips are down exceeds the Tips Down Verified Current setup parameter D5C DO NOT confuse the Tips Down Test Fire I setup parameter with Function 39 TEST FIRE nn This setup parameter is used ONLY by the VERIFY TIPS DOWN and SLOW CYLINDER TEST functions Function 39 performs a 1 cycle test fire at the percent heat programmed The test functions described on page 5 7 use the res...

Page 118: ...s less than the value programmed the control waits for the number of cycles programmed nn CY then repeats the test fire This wait and fire process continues up to the programmed number of tries nn TIMES If the current never reaches the value programmed the control generates a TIPS NOT TOUCHING fault and sequences in No Weld 81 SLOW CYLINDER TEST EVERY nn CY nn TIMES This function is nearly identic...

Page 119: ... example Car Type 1 Weld Schedule 20 SET SPC OFFSET TO 01 Weld Schedule 01 15 Welds Made Bins 1 15 Weld Schedule 02 15 Welds Made Bins 16 30 Weld Schedule 03 18 Welds Made Bins 31 48 Car Type 2 Weld Schedule 21 SET SPC OFFSET TO 51 Weld Schedule 04 12 Welds Made Bins 51 62 Weld Schedule 05 12 Welds Made Bins 63 74 Weld Schedule 06 14 Welds Made Bins 75 88 After establishing a bin number the progra...

Page 120: ... V_b c USYQ cYdeQdY_ c ceSX Qc dUQb T_g gXYSX bUaeYbU S_ dY e_ec TQdQ S_ USdY_ 63 VHWXS 3DUDPHWHUV DATA COLLECTION SAMPLE SIZE 05 1 99 DATA COLLECTION SAMPLE FREQUENCY 0100 1 9999 These two parameters set a global command which allows the weld control to sample data for analysis at controlled intervals The sample size is the amount of weld data collected for analysis number of consecutive welds pe...

Page 121: ...is not executing a weld function Sample Frequency WCU Process WIS WSS Process 1 8 Data flagged for retrieval Data uploaded 2 8 Data flagged for retrieval Data uploaded 3 8 Data collected Data ignored 4 8 Data collected Data ignored 5 8 Data collected Data ignored 6 8 Data collected Data ignored 7 8 Data collected Data ignored 8 8 Data collected Data ignored 1 8 Data flagged for retrieval Data uplo...

Page 122: ...a preset amperage the processor checks the SCR Cycle Limit parameter to determine whether the voltage drop was due to a shorted SCR or shunting current The SCR Cycle Limit parameter sets the maximum number of consecutive cycles where a shorted SCR condition without current can occur before the breaker is tripped The control then generates the appropriate fault SHORTED SCR or CURRENT SHUNTING fault...

Page 123: ...ING 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 5HWUDFW 0RGH 6HWXS 3DUDPHWHU The Retract Mode setup parameter determines how the control will react to the presence of an active RETRACT PILOT input This parameter is described in detail on page 6 10 UNLATCHED tel...

Page 124: ... LOW OLQGHU 7 SH This parameter defines the type of gun cylinder being used in the control application This parameter enables defining the retract operation as shown below LU 2QO OLQGHUV With air only cylinders two valves control the weld gun The Weld valve and the Retract valve The Retract valve allows the gun to close to a set gap position Usually a spring or a second return valve returns the gu...

Page 125: ...INDER n IS OUT OF RETRACT will abort the schedule and generate a RETRACT PILOT fault if the cylinder is NOT out of retract D5 Program the RETRACT PILOT fault as an ALERT condition in the setup parameters so the operator can place the valve in the partial retract position and re initiate the weld schedule If this condition is defined as a FAULT the control will require a fault reset before it can c...

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Page 127: ...t or turn ON the FAULT output This indicates that a fault condition was detected Fault conditions normally inhibit initiation of a weld schedule Refer to the INITIATION ON FAULT setup parameter on page 6 10 ALERT tells the control to activate the ALERT output An alert condition generally will not inhibit initiating a weld schedule NONE tells the control to log that the condition was detected but n...

Page 128: ... input when provided was not used to provide the odd number of inputs needed to initiate a schedule It can also indicate that the BINARY SELECT inputs have changed state while the processor is repeating WELD INITIATE NOT PRESENT 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 ...

Page 129: ...d to the weld HIGH CURRENT LIMIT FAULT ALERT LOW CURRENT LIMIT FAULT ALERT These faults indicate that the welding conditions during a weld function exceeded or fell below the range programmed in the setup parameters SCR MISFIRE FAULT ALERT This condition occurs if there is conduction on one half cycle and no conduction on the next half cycle during a weld function This condition may result if arci...

Page 130: ...d setup parameter The control repeats the test fire the number of tries programmed in this function Refer to Dynamic Squeeze Features on page 5 7 INITIAL P F OUT OF RANGE FAULT ALERT This fault is generated when the test fire function 39 appears in a weld schedule before the function INITIAL PF LIMIT HI nn LOW nn If the power factor indicating secondary resistance detected during the test fire is ...

Page 131: ...solation contactor was not pulled in when required by the weld schedule This parameter is NOT programmable This fault is generated when the control detects that the isolation contactor is open when it is trying to execute a weld function The contactor must be closed to provide weld current On detecting this condition the control schedules in No Weld and generates this fault condition If the contro...

Page 132: ... HIGH C FACTOR LIMIT FAULT ALERT LOW C FACTOR LIMIT FAULT ALERT These two conditions indicate that the actual C Factor read during the weld exceeded or fell below the values programmed in the C Factor function C FACTOR LIMIT HI nnn LOW nnn The low limit is helpful to detect cable and connection deterioration The upper limit can detect secondary bridges and shunting paths Refer to C Factor on page ...

Page 133: ...l is initiating a schedule If this occurs the schedule is aborted When the control is idled and not initiated the timeout interval is fixed at 10 sec The SLC processor stopped scanning When the weld processor and PLC processor cannot communicate over the rack backplane If this timeout occurs major system bus faults are suspect If the SLC processor moves out of Run Mode while the control is executi...

Page 134: ...the Shorted SCR Cycle Limit setup parameter ISO CONTACTOR NOT ENABLED FAULT This fault is generated if the isolation contactor is de activated opens while the control is sequencing CONTROL IN NO WELD FAULT ALERT This fault occurs if the control moves from Weld Mode into No Weld Mode while sequencing This fault is also generated if the control receives a weld initiate while in No Weld Mode INITIATI...

Page 135: ...onization If an error occurred during the secondary calibration process due to a missing current range jumper on the SCIB board CURRENT MONITOR MODE PRIMARY SECONDARY Select either primary or secondary current monitoring If selecting secondary current monitoring a Secondary Current Interface Board SCIB and secondary current sensing coil must be attached Refer to Appendix G for a detailed descripti...

Page 136: ...weld initiate when a fault condition is present 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 SHORT DETECTION ENABLED DISABLED This parameter can override the Shorted SCR Cycle Limit and Welder Current Shunting setup parameters Setting to DISABLE means that NO shorted SCR conditions of any ki...

Page 137: ... CYLINDER AIR NORMAL AIR INVERTED This setup parameter defines what type of weld gun cylinder is being used AIR NORMAL Select this type of cylinder when the machine uses an air only cylinder AND the RETRACT output is turned OFF to close the gun 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 WARNING For s...

Page 138: ...7 VALVE 1 INITIAL PRESSURE PSI nn VALVE 2 INITIAL PRESSURE PSI nn This parameter lets you set a base pressure for each pressure valve This sets the initial pressure to be supplied to the valve at power up and at the end of a weld sequence nn sets the pressure in the range 0 99 PSI The default setting is 50 PSI HEAT CYCLE LIMIT 0 SEAM 60 0 99 This parameter defines the maximum number of consecutive...

Page 139: ...99 This parameter sets the maximum number of consecutive cycles where a shorted SCR condition without current can occur before the breaker is tripped WARNING If the control detects a shorted SCR condition with current for four out of seven half cycles the control will trip the breaker regardless of the programmed value of this setup parameter Refer to the description of these features in SCR Short...

Page 140: ...DXU S_ db_ ecUc dXYc fQ eU d_ TUdUb Y U dXU cUS_ TQbi SebbU d b_fYTUT 2U SUbdQY d_ S_bbUSd i b_WbQ dXYc QbQ UdUb V_b dXU _ UbQdY W U fYb_ U d 256 B5 QddU dY W d_ ecU dXU gU T Ve SdY_ c ecY W 1ed_ QdYS 3ebbU d 3_ U cQdY_ 133 _dU DXU DEB C B1D9 Ve SdY_ Q _gc _fUbbYTY W dXYc QbQ UdUb cUddY W GXU b_WbQ Y W dXU S_ db_ V_b 133 6YbY W 6e SdY_ c YV i_e SXQ WU dXU deb c bQdY_ dXU S_ db_ gY bUaeYbU dXU VYbc...

Page 141: ... while initiating without generating an I O TIMEOUT fault The following parameter supports operation of the Secondary Current Interface Board SCIB SEC CURR COIL MULTIPLIER X1000 nnnn 0 9999 Use this setup parameter when monitoring secondary current as an adjustment to accommodate for secondary current sensing coils of different sensitivities Setting this parameter to 1000 will result in accurate s...

Page 142: ...LTAGE COMPENSATION LIMIT ALERT INSUFFICIENT LINE VOLTAGE ALERT EXTENDED WELD FAULT ISO CNTR OFF WHEN NEEDED FAULT CURRENT COMPENSATION LIMIT ALERT ISO CNTR ERR BRKR TRIPPED FAULT NO ZERO CROSSING SYNC FAULT LOW BATTERY ALERT HIGH C FACTOR LIMIT ALERT LOW C FACTOR LIMIT ALERT SYSTEM COOLING FAULT HEAT CYCLE LIMIT FAULT WELD INTERRUPTION FAULT I O UPDATE FAULT RIO COMM ERROR NOT IN RUN MODE FAULT WE...

Page 143: ...INITIAL PRESSURE 50 PSI HEAT CYCLE LIMIT 0 SEAM 60 CYCLES ISOLATION CONTACTOR DELAY 5 SEC HIGH CURRENT LIMIT WINDOW 20 LOW CURRENT LIMIT WINDOW 20 SHORTED SCR CYCLE LIMIT 60 CYCLES DATA COLLECTION SAMPLE SIZE 5 DATA COLLECTION SAMPLE FREQUENCY 100 TIPS DOWN VERIFIED CURRENT 10 AMPS TRANSFORMER TURNS RATIO 100 1 NOMINAL LINE VOLTAGE 468 VOLTS NOMINAL C FACTOR 999 I O UPDATE TIMEOUT 250 mSEC SEC CUR...

Page 144: ...CUde QbQ UdUbc UTGU T UbQd_bµc 7eYTU D 1 bY ...

Page 145: ...lsion based on a list of parameters you program You program steppers using the WTC programming device Tell the weld processor which type of stepper you want to control the weld schedule by using the stepper assignment functions 82 or 83 These assign both a stepper number and the type of stepper linear or SureWeld to the weld schedule You can program up to 99 linear steppers and 99 SureWeld stepper...

Page 146: ...control will verify the stepper that was activated to see which group it belongs to The control then bumps up the weld count on all steppers that are associated to the group Use the DEP 100S or other programming device to assign steppers to a group For example if one gun tips was used to several different schedules using different steppers grouping allows you to automatically increment the stepper...

Page 147: ... one of the programming methods DEP 100S XWSS MedVIEW MedVIEW lite or MedCommander to change the stepper profile to the values required by your application LVSOD DW WKH 3 6 When you select the linear stepper status display from the DEP 100S use this display to view the stepper status This display shows the amount of energy being added to each weld function Boost the current step and the selected s...

Page 148: ...itude of weld expulsion The SureWeld stepper compensates for tip wear by identifying the current level where expulsion occurs then backing off the current to a point just below the level of expulsion The SureWeld stepper automatically adjusts the current as required To assign a SureWeld stepper to a weld schedule you MUST include Function 83 as the first function in the weld schedule D5 The steppe...

Page 149: ...ese events as expulsion A good starting value for this parameter is 1 3 to 1 2 the number of programmed weld cycles 1 CYCLE EXPULSION DETECTION LEVEL 00 75 This is a drop in power factor that exceeds this programmable set point assumed to be due to expulsion This value is programmable in increments of 0 01 A good method to determine this value is to determine the power factor drop for welds where ...

Page 150: ...hen using the I firing mode MAXIMUM ADD L CURRENT 00000 AMPS This parameter sets the limit on how far to decrement the total heat supplied during a weld function when the SCR firing mode is ACC Total heat is the base I in A defined in the last weld function in the schedule minus the I in A added by the stepper MAXIMUM I 99 This parameter sets the maximum amount of total heat to supply during a wel...

Page 151: ...e point where the SCR alerts you when the stepper is approaching the maximum current while the SCR firing mode is ACC D5 When the control detects that the heat or secondary current has reached the alert point programmed it generates the STEPPER APPROACHING MAX condition STEPPER APPROACHING MAX 99999 When the weld count reaches this limit the MedWeld 3005 generates the STEPPER APPROACHING MAX condi...

Page 152: ... From this display Press to see a different stepper Stpr Press to reset the stepper Press to see the stepper settings for a different weld processor wcu Press to see additional stepper options The asterisk indicates that additional displays or information are available Pressing displays a screen showing the status of every SureWeld stepper Press a second time to return to the initial stepper displ...

Page 153: ...ore as a warning of a potential problem or that maintenance may be required If set to NONE the control logs the fact that the condition occurred but takes no action The following table lists each fault described in this chapter in alphabetical order with the page where the description appears Fault Page CONTROL IN NO WELD 8 12 CONTROL STOP 8 3 END OF STEPPER 8 3 HEAT CYCLE LIMIT 8 10 HIGH C FACTOR...

Page 154: ...n odd number of inputs Check the number of BINARY SELECT inputs used to select the schedule number If this is an even number activate the PARITY input Incorrect or loose wiring at the input module Check the wiring diagram for proper I O designations Verify that all wiring connections are secure Bad connectors improper seating or faulty SLC proces sor input module or weld processor module Remove po...

Page 155: ...tenance Dress or replace the electrodes to avoid the END OF STEPPER fault condition The stepper profile is programmed incorrectly Check the stepper profile End of Stepper See p 6 3 A linear stepper in the group assigned to the sched ule initiated completed the last step in the profile Dress or replace the electrode tips Reset the stepper Sure Weld Trend Limit See p 6 3 The stepper reached a progra...

Page 156: ...he firing card Secure the cable that runs between the firing card and the processor Check for bad con nector Replace as necessary Expulsion caused reduction in the weld resistance This may cause the current to exceed the calculated maximum Adjust the schedule to reduce expulsion while maintaining suf ficient current to provide a good weld Low Current Limit See p 6 3 The current fired fell below th...

Page 157: ... increasing weld pressure Isolation contactor is dropping out early or coming in late Correct isolation contactor program or relay logic circuit Faulty firing card Replace firing card Tips Not Touching or Tips Touching See p 6 3 The electrode tips were detected as not being closed or not being open when expected Tips closing or opening too slowly due to dirty or poorly lubricated cylinder or stuck...

Page 158: ...part fitup Verify that the correct valve is programmed in the weld schedule The inductance of the welding circuit was changed Check for any changes in the secondary loop Incorrect measurement of power factor Make sure the current wires and voltage sense leads are secure with the correct termi nals of the firing card Current coil resistor on firing card or load resistor on SCR assembly is not conne...

Page 159: ... control to compensate for line voltage variations Avoid programming values of 20 I or secondary current that is too low Steppers are pushing the total current programmed current boost over the threshold Adjust the stepper boost Insufficient Line Voltage See p 6 5 The weld initiate was removed or time expired while the control was waiting for the programmed line voltage in Function 72 or 73 Overlo...

Page 160: ... to allow the weld processor to open or close the isolation contactor Use the I O Status display on the DEP 100S to verify that the inputs are high 1 when required Verify that the Ready to Weld signal was high 1 when required For externally powered controls an internal control transformer fuse is blown Check fuses replace as necessary The solid state relay is faulty Replace relay The instruction t...

Page 161: ...stribute the weld bus load Brown out of power source Correct power delivery problem Low Battery See p 6 6 The battery on the back of the processor card is low or discharged Replace battery processor card The battery is soldered in place Only qualified personnel should attempt to replace the battery in an ESD safe environment High C Factor See p 6 6 The C factor read during the weld part of the sch...

Page 162: ...6 7 The control entered No Weld mode while executing a weld schedule Robot or PLC ladder logic de activated the WELD NO WELD Input Check robot or PLC ladder to verify that the input is being held HIGH throughout the weld schedule Use the DEP s I O Status display to monitor the status of this input Also check the DEP I O status Incorrect or loose wiring to the input module Check for proper I O desi...

Page 163: ...he input module Check for proper I O designa tions Check to make sure all wiring connections are secure Faulty input module Replace input module Retract Pilot Error See p 6 8 The retract cylinder was not out of retract when checked by the control Operator error The input was not activated when required by the operator Either the Retract Mode or the Cylinder Type setup parameters were changed and t...

Page 164: ...No Weld mode Verify that the data entry device is in Weld Mode Loose or incorrect wiring to the input module Check for proper I O designa tions Check to make sure all wiring connections are secure Faulty input module Replace module Weld Current Shunting See p 6 8 Back feeding EMF is causing a voltage drop across the transformer but no measurable current is flowing in the primary In a multi gun con...

Page 165: ...ts mate Remove power from the chassis Re seat the power supply Power to the rack was cycled too fast causing a large current inrush and resulting in a thermal overload Remove power to the rack for a MINIMUM of two minutes Then restore power Blown fuse on the power supply Check the fuse to see if it is blown Replace if necessary Line power is not connected to the power supply Verify that line power...

Page 166: ...CPU Fault LED is on Improper voltage jumper setting Check the jumper setting on the power supply Verify that it matches the input voltage SLC Processor not in Run Mode All SLC LEDs are off Improper mode selected Verify the processor mode selected If in Program or Test mode return to Run Mode Line power out of range Check the jumper setting on the power supply Verify that it matches the input volta...

Page 167: ...tly If upgrading the processor ladder verify that the logic chip is properly seated SLC ladder logic and weld processor firmware are incompatible Verify compatibility correct as necessary If not known contact your WTC representative for assistance One or more cards in rack is not properly seated or positioned Verify card position using control con figu ration sticker inside control door Remove pow...

Page 168: ...hat line power is connected to the power supply Improper voltage jumper setting Check the jumper setting to verify it matches the input voltage Loss of RAM memory Batt LED is on The battery on the weld processor card is low or dead Replace the battery on the weld processor card The battery is soldered in place Only qualified personnel should attempt battery replacement in an ESD safe environment W...

Page 169: ...network power supply and that external 120VAC is connected Faulty DEP 100S WTC processor or network power pack Replace as necessary Incorrect network address for weld control Verify the welder ID and network address of the device Communication over the MedLAN channel is inoperable MedLAN LEDs may be off or blinking Improper or loose MedLAN wiring Check for secure and correct wiring Two or more con...

Page 170: ... and or RIO module in the chassis Remove power Inspect the power supply and RIO module connections Remove power from the chassis Re seat modules Loss of communica tions between weld control and host PLC Fault LED is on Internal fault Cycle power to the I O chassis Replace the RIO module if the LED remains lit after power up Loss of communica tions between weld control and host PLC Fault LED is bli...

Page 171: ...roper installation Symptom Possible Cause Corrective Action LED Symptom Input State Probable Cause Corrective Action ON Input device will not turn off On closed or active Device is shorted or damaged Verify device operation Replace if necessary ON SLC program oper ates as though input is off On closed or active Input circuit is damaged Verify proper wiring Try other input circuits replace if neces...

Page 172: ...r open circuit Check wiring and common connections Input signal turn on time too fast for input circuit Check timing specifications Input circuit is damaged Verify wiring and try other input circuit Replace module OFF Input device will not turn on Off open or inactive Input device is shorted or damaged Verify operation and replace if necessary OFF SLC program operates as though it is on Off open o...

Page 173: ...lace module if necessary Low or no voltage across the load Measure the source voltage and check specifications ON Output device will not turn off and the SLC program indicates that it is off On or energized Output device is incompatible Check specifications Incorrect wiring Check wiring disconnect from the SLC and verify device operation Output device is damaged Verify device operation Replace dev...

Page 174: ...unded SCR breaking over at low potential or shorted Firing card is faulty Replace firing card Circuit breaker is faulty Replace circuit breaker Circuit breaker trips while welding The magnetic trip on the circuit breaker is set too low This causes the control to trip during the weld time of a schedule Adjust the circuit breaker s magnetic trip threshold The SCR is breaking over at low potential or...

Page 175: ...age to the I O module Check the I O Status Display at the DEP Control is in retract and the setup parameters specify that initiation is INHIBITED from retract Check the setup parameters Either take the control out of retract before initiating or change the Initiation from Retract setup parameter You must also cycle power after changing the state of the retract setup parameters Control has detected...

Page 176: ...sary Control sequences without firing SCR The control is in No Weld Check the status of the WELD NO WELD input Verify that the control and all data entry devices are in Weld mode A fault occurred causing the control to complete the weld schedule in No Weld Check the data entry device to determine any fault conditions Clear the fault s correct the problem and re initiate Programming error Check the...

Page 177: ...trol is externally powered one of the internal control transformer fuses may be blown Check fuses Replace as necessary The control was unable to pull in the isolation contactor due to incorrect or loose wiring to the output module Check the wiring diagram that came with your control for proper I O designations Make sure all connections are secure Isolation contactor is not being held in between we...

Page 178: ...L2 Faulty circuit breaker Supply voltage IS connected to the breaker Verify that power is available on the load side of the circuit breaker Faulty cable between firing and processor card Replace cable If No Zero Crossing Sync occurs during a weld there may be a loose connection or weak welding bus Tighten loose connections Install weld bus capacitors Re distribute loads on the weld bus Install a s...

Page 179: ...Y SELECT 2 BINARY SELECT 2 BINARY SELECT 2 02 2 BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 03 3 BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 04 4 BINARY SELECT 16 BINARY SELECT 16 BINARY SELECT 16 BINARY SELECT 16 BINARY SELECT 16 B...

Page 180: ...ELECT 8 Spare BINARY SELECT 8 Spare 12 14 BINARY SELECT 16 Reserved b BINARY SELECT 16 Spare BINARY SELECT 16 Spare BINARY SELECT 16 Spare 13 15 INITIATE WELD Reserved INITIATE WELD Spare INITIATE WELD Spare INITIATE WELD Spare 14 16 WELD INPUT Reserved WELD INPUT Spare WELD INPUT Spare WELD INPUT Spare 15 17 STEPPER RESET Reserved STEPPER RESET Spare STEPPER RESET Spare STEPPER RESET Spare a To u...

Page 181: ...VE I O ACTIVE I O ACTIVE I O ACTIVE I O ACTIVE I O ACTIVE 01 1 WELD IN PROGRESS WELD IN PROGRESS WELD IN PROGRESS WELD IN PROGRESS WELD IN PROGRESS WELD IN PROGRESS WELD IN PROGRESS WELD IN PROGRESS 02 2 NO FAULT NO FAULT NO FAULT NO FAULT NO FAULT NO FAULT NO FAULT NO FAULT 03 3 ALERT ALERT ALERT ALERT ALERT ALERT ALERT ALERT 04 4 END OF STEPPER END OF STEPPER END OF STEPPER END OF STEPPER END OF...

Page 182: ...o use the tri pack enclosure as a dual pack refer to Local and Safety I O for a description of the WCU 3 NOT PRESENT input page 3 2 When this input is held HIGH WCU 3 is disabled and the weld processor card can be removed from the chassis b Reserved for RIO communication status c Weld PLC Processor not in Run Mode d Communications error between 3005 RIO Network Module and Host PLC e Reserved for R...

Page 183: ...RY SELECT 2 BINARY SELECT 2 02 2 BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 03 3 BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 04 4 BINARY SELECT 16 BINARY SELECT 16 BINARY SELECT 16 BINARY SELECT 16 BINARY SELECT 16 BINARY SELECT 16...

Page 184: ...ARE 10 12 BINARY SELECT 4 GLOBAL STEPPER RESET BINARY SELECT 4 SPARE BINARY SELECT 4 SPARE BINARY SELECT 4 SPARE 11 13 BINARY SELECT 8 GLOBAL FAULT RESET BINARY SELECT 8 SPARE BINARY SELECT 8 SPARE BINARY SELECT 8 SPARE 12 14 BINARY SELECT 16 Reserved a a Reserved for RIO communication status and Host PLC status BINARY SELECT 16 SPARE BINARY SELECT 16 SPARE BINARY SELECT 16 SPARE 13 15 INITIATE WE...

Page 185: ...PROGRESS WELD IN PROGRESS WELD IN PROGRESS WELD IN PROGRESS 02 2 NO FAULT NO FAULT NO FAULT NO FAULT NO FAULT NO FAULT NO FAULT NO FAULT 03 3 ALERT ALERT ALERT ALERT ALERT ALERT ALERT ALERT 04 4 END OF STEPPER END OF STEPPER END OF STEPPER END OF STEPPER END OF STEPPER END OF STEPPER END OF STEPPER END OF STEPPER 05 5 STEPPER IS RESET STEPPER IS RESET STEPPER IS RESET STEPPER IS RESET STEPPER IS R...

Page 186: ...NO FAULT SPARE NO FAULT SPARE 11 13 ALERT SPARE ALERT SPARE ALERT SPARE ALERT SPARE 12 14 END OF STEPPER Reserved a a Reserved for RIO communication status END OF STEPPER SPARE END OF STEPPER SPARE END OF STEPPER SPARE 13 15 STEPPER IS RESET NOT IN RUN MODE b b Weld PLC Processor not in Run Mode STEPPER IS RESET SPARE STEPPER IS RESET SPARE STEPPER IS RESET SPARE 14 16 WELD COMPLETE COMMUNICA TION...

Page 187: ...ELECT 2 02 2 BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 03 3 BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 04 4 PROGRAM MODE SECURITY PROGRAM MODE SECURITY PROGRAM MODE SECURITY PROGRAM MODE SECURITY PROGRAM MODE SECURITY PROGRAM MOD...

Page 188: ...BINARY SELECT 4 GLOBAL STEPPER RESET BINARY SELECT 4 SPARE BINARY SELECT 4 SPARE BINARY SELECT 4 SPARE 11 13 BINARY SELECT 8 GLOBAL FAULT RESET BINARY SELECT 8 SPARE BINARY SELECT 8 SPARE BINARY SELECT 8 SPARE 12 14 PROGRAM MODE SECURITY Reserved a a Reserved for RIO communication status and Host PLC status PROGRAM MODE SECURITY SPARE PROGRAM MODE SECURITY SPARE PROGRAM MODE SECURITY SPARE 13 15 I...

Page 189: ...PROGRESS WELD IN PROGRESS WELD IN PROGRESS WELD IN PROGRESS 02 2 NO FAULT NO FAULT NO FAULT NO FAULT NO FAULT NO FAULT NO FAULT NO FAULT 03 3 ALERT ALERT ALERT ALERT ALERT ALERT ALERT ALERT 04 4 END OF STEPPER END OF STEPPER END OF STEPPER END OF STEPPER END OF STEPPER END OF STEPPER END OF STEPPER END OF STEPPER 05 5 STEPPER IS RESET STEPPER IS RESET STEPPER IS RESET STEPPER IS RESET STEPPER IS R...

Page 190: ...NO FAULT SPARE NO FAULT SPARE 11 13 ALERT SPARE ALERT SPARE ALERT SPARE ALERT SPARE 12 14 END OF STEPPER Reserved a a Reserved for RIO communication status END OF STEPPER SPARE END OF STEPPER SPARE END OF STEPPER SPARE 13 15 STEPPER IS RESET NOT IN RUN MODE b b Weld PLC Processor not in Run Mode STEPPER IS RESET SPARE STEPPER IS RESET SPARE STEPPER IS RESET SPARE 14 16 WELD COMPLETE COMMUNICA TION...

Page 191: ...E SPARE SPARE SPARE 01 1 BINARY SELECT 2 BINARY SELECT 2 SPARE SPARE SPARE SPARE SPARE SPARE 02 2 BINARY SELECT 4 BINARY SELECT 4 SPARE SPARE SPARE SPARE SPARE SPARE 03 3 BINARY SELECT 8 BINARY SELECT 8 SPARE SPARE SPARE SPARE SPARE SPARE 04 4 BINARY SELECT 16 BINARY SELECT 16 SPARE SPARE SPARE SPARE SPARE SPARE 05 5 INITIATE WELD INITIATE WELD SPARE SPARE SPARE SPARE SPARE SPARE 06 6 WELD INPUT W...

Page 192: ...R SAVER SPARE SPARE SPARE SPARE SPARE SPARE 10 12 BINARY SELECT 4 STEPPER RESET SPARE SPARE SPARE SPARE SPARE SPARE 11 13 BINARY SELECT 8 FAULT RESET SPARE SPARE SPARE SPARE SPARE SPARE 12 14 BINARY SELECT 16 Reserved a a Reserved for RIO communication status and Host PLC status SPARE SPARE SPARE SPARE SPARE SPARE 13 15 INITIATE WELD Reserved SPARE SPARE SPARE SPARE SPARE SPARE 14 16 WELD INPUT Re...

Page 193: ...FAULT WCU 1 SCR MISFIRE LOW C FACTOR LIMIT NO FAULT NO FAULT SCR MISFIRE LOW C FACTOR LIMIT 03 3 ALERT ALERT WCU 1 COMPENSA TION Fault SYSTEM COOLING ALERT ALERT COMPENSA TION Fault SYSTEM COOLING 04 4 END OF STEPPER END OF STEPPER WCU 1 INSUFFICIENT LINE VOLT AGE Fault DEP DISPLAY Faults END OF STEPPER END OF STEPPER INSUFFICIENT LINE VOLT AGE Fault DEP DISPLAY Faults 05 5 STEPPER IS RESET STEPPE...

Page 194: ...FICIENT LINE VOLT AGE Fault 11 13 ALERT WCU 3 STEPPER APPROACH ING MAXIMUM WCU 2 CONTROL STOP Fault EXTEND WELD ALERT WCU 6 STEPPER APPROACH ING MAXIMUM WCU 5 CONTROL STOP Fault EXTEND WELD 12 14 END OF STEPPER Reserved a WCU 2 CURRENT LIMIT Fault HIGH C FACTOR Fault END OF STEPPER Reserved b WCU 5 CURRENT LIMIT Fault HIGH C FACTOR Fault 13 15 STEPPER IS RESET NOT IN RUN MODE c WCU 2 SCR MISFIRE L...

Page 195: ...T 2 SPARE BINARY SELECT 2 BINARY SELECT 2 02 2 BINARY SELECT 4 SPARE BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 SPARE BINARY SELECT 4 BINARY SELECT 4 03 3 BINARY SELECT 8 SPARE BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 SPARE BINARY SELECT 8 BINARY SELECT 8 04 4 BINARY SELECT 16 SPARE BINARY SELECT 16 BINARY SELECT 16 BINARY SELECT 16 SPARE BINARY SELECT 16 BINARY SELECT 16 05 5 INITIATE...

Page 196: ... 09 11 WCU 1 BINARY SELECT 64 ENABLE CONTACTOR SAVER WCU 2 BINARY SELECT 64 BINARY SELECT 64 BINARY SELECT 64 SPARE BINARY SELECT 64 BINARY SELECT 64 10 12 SPARE GLOBAL STEP PER RESET SPARE SPARE SPARE SPARE SPARE SPARE 11 13 SPARE GLOBAL FAULT RESET SPARE SPARE SPARE SPARE SPARE SPARE 12 14 SPARE Reserved a a Reserved for RIO communication status and Host PLC status SPARE SPARE SPARE SPARE SPARE ...

Page 197: ...IN PROGRESS WELD IN PROGRESS SPARE WELD IN PROGRESS WELD IN PROGRESS 02 2 NO FAULT SPARE NO FAULT NO FAULT NO FAULT SPARE NO FAULT NO FAULT 03 3 ALERT SPARE ALERT ALERT ALERT SPARE ALERT ALERT 04 4 END OF STEPPER SPARE END OF STEPPER END OF STEPPER END OF STEPPER SPARE END OF STEPPER END OF STEPPER 05 5 STEPPER IS RESET SPARE STEPPER IS RESET STEPPER IS RESET STEPPER IS RESET SPARE STEPPER IS RESE...

Page 198: ... 10 12 SPARE SPARE SPARE SPARE SPARE SPARE SPARE SPARE 11 13 SPARE SPARE SPARE SPARE SPARE SPARE SPARE SPARE 12 14 SPARE Reserved a a Reserved for RIO communication status SPARE SPARE SPARE SPARE SPARE SPARE 13 15 SPARE NOT IN RUN MODE b b Weld PLC Processor not in Run Mode SPARE SPARE SPARE SPARE SPARE SPARE 14 16 SPARE COMMUNICA TIONS ERROR c c Communications error between 3005 RIO Network Modul...

Page 199: ...RY SELECT 2 BINARY SELECT 2 02 ENABLE SCR 3 GLOBAL STEPPER RESET BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 03 ENABLE SCR 4 GLOBAL FAULT RESET BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 04 ENABLE SCR 5 SCR 1 TIPS DRESSED BINARY SELECT 16 BINARY SELECT 16 BINARY SELECT 16 BINARY SELECT 16 BINAR...

Page 200: ...2 b Byte 3 b Byte 4 b Byte 5 b Byte 6 b Byte 7b 00 ID BIT 0 CONTACTOR IS OPEN I O ACTIVE I O ACTIVE I O ACTIVE I O ACTIVE I O ACTIVE I O ACTIVE 01 ID BIT 1 STEPPER APPROACHING LAST STEP WELD IN PROGRESS WELD IN PROGRESS WELD IN PROGRESS WELD IN PROGRESS WELD IN PROGRESS WELD IN PROGRESS 02 ID BIT 2 END OF STEPPER END OF CAP LIFE NO FAULT NO FAULT NO FAULT NO FAULT NO FAULT NO FAULT 03 SIZE BIT 0 S...

Page 201: ...NARY SELECT 2 BINARY SELECT 2 BINARY SELECT 2 BINARY SELECT 2 02 ENABLE SCR 9 Reserved BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 BINARY SELECT 4 03 ENABLE SCR 10 Reserved BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 BINARY SELECT 8 04 ENABLE SCR 11 Reserved BINARY SELECT 16 BINARY SELECT 16 BINARY SELECT 16 BINARY SELECT 16 B...

Page 202: ...GRESS WELD IN PROGRESS WELD IN PROGRESS WELD IN PROGRESS WELD IN PROGRESS WELD IN PROGRESS 02 ID Bit 2 Reserved NO FAULT NO FAULT NO FAULT NO FAULT NO FAULT NO FAULT 03 SIZE BIT 0 Reserved ALERT ALERT ALERT ALERT ALERT ALERT 04 SIZE BIT 1 Reserved END OF STEPPER END OF CAP LIFE END OF STEPPER END OF CAP LIFE END OF STEPPER END OF CAP LIFE END OF STEPPER END OF CAP LIFE END OF STEPPER END OF CAP LI...

Page 203: ...1 02 MODULE STATUS REGISTER 18 Unused 34 SCR 1 BINARY SELECT 4 50 PART ID LSW Bit 02 66 PART ID MSW Bit 02 03 MODULE STATUS REGISTER 19 Unused 35 SCR 1 BINARY SELECT 8 51 PART ID LSW Bit 03 67 PART ID MSW Bit 03 04 MODULE STATUS REGISTER 20 Unused 36 SCR 1 BINARY SELECT 16 52 PART ID LSW Bit 04 68 PART ID MSW Bit 04 05 MODULE STATUS REGISTER 21 Unused 37 SCR 1 INITIATE WELD 53 PART ID LSW Bit 05 6...

Page 204: ...ARY SELECT 4 58 PART ID LSW Bit 10 74 PART ID MSW Bit 10 11 MODULE STATUS REGISTER 27 GLOBAL FAULT RESET 43 SCR 2 BINARY SELECT 8 59 PART ID LSW Bit 11 75 PART ID MSW Bit 11 12 MODULE STATUS REGISTER 28 SCR 1 TIP DRESSED 44 SCR 2 BINARY SELECT 16 60 PART ID LSW Bit 12 76 PART ID MSW Bit 12 13 MODULE STATUS REGISTER 29 SCR 2 TIP DRESSED 45 SCR 2 INITIATE WELD 61 PART ID LSW Bit 13 77 PART ID MSW Bi...

Page 205: ...D BIT 1 33 SCR 1 WELD IN PROGRESS 49 ACTIVE PART ID LSW Bit 01 65 ACTIVE PART ID MSW Bit 01 02 MODULE STATUS REGISTER 18 ID BIT 2 34 SCR 1 NO FAULT 50 ACTIVE PART ID LSW Bit 02 66 ACTIVE PART ID MSW Bit 02 03 MODULE STATUS REGISTER 19 SIZE BIT 0 35 SCR 1 ALERT 51 ACTIVE PART ID LSW Bit 03 67 ACTIVE PART ID MSW Bit 03 04 MODULE STATUS REGISTER 20 SIZE BIT 1 36 SCR 1 END OF STEPPER 52 ACTIVE PART ID...

Page 206: ...IN PROGRESS 49 ACTIVE PART ID LSW Bit 01 73 ACTIVE PART ID MSW Bit 01 10 MODULE STATUS REGISTER 26 Global END OF STEPPER 42 SCR 2 NO FAULT 50 ACTIVE PART ID LSW Bit 02 74 ACTIVE PART ID MSW Bit 02 11 MODULE STATUS REGISTER 27 Global ERROR IN PART DOWN LOAD 43 SCR 2 ALERT 51 ACTIVE PART ID LSW Bit 03 75 ACTIVE PART ID MSW Bit 03 12 MODULE STATUS REGISTER 28 SCR 1 TIP DRESS REQUEST 44 SCR 2 END OF S...

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