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WTC MedWeld 4000, Operator'S Manual

Introducing the WTC MedWeld 4000 Operator's Manual - a comprehensive guide to optimize your welding experience. Easily access and download this invaluable manual for free from manualshive.com. Simplify setup and enhance performance with step-by-step instructions, ensuring seamless operation of your MedWeld 4000 for exceptional results.

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Weld Schedules

4 - 16

Modified: 9/17/08

MedWeld 4000 Operator’s Guide 

M-032116  Programs #T03300, #T02300 and #T02400

93

INITIAL PF LIMIT: HI=nn% LOW=nn%

This function is used to generate a fault condition if the initial 
power factor read during the test fire function (#39) does not fall 
within the high and low limits programmed in this function. 

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. OUT OF 
RANGE fault. 

Summary of Contents for MedWeld 4000

Page 1: ...3302 AC w Ohma Cylinder Support T03310 AC GM WS2 T03311 AC GM WS2 ABB Robot T02300 MFDC Standard T02301 MFDC Type 1 Inverter T02302 MFDC w Ohma Cylinder Pressure Control T02304 MFDC Multi Inverter T02306 MFDC Multi Inverter w Forge Revision 04 Modified 09 17 08 Manual No M 032116 Copyright 2008 WTC ...

Page 2: ...se this Manual 1 xiii Software Updates 1 xiv Cooling Water Requirements 1 xv Specifications on the Web 1 xv Cooling Water Specifications 1 xv Water Flow Rate 1 xv SCRs with Hose Running Between Tangs at 480 VAC 1 xvi Hoses 1 xvi Working with Static Sensitive Devices 1 xvii ESD Costs 1 xvii Personnel Grounding 1 xvii Handling or Moving ESDS Devices 1 xvii Workstation Requirements 1 xvii Contact Inf...

Page 3: ...Bus Daughter Board 1 12 Configuring the FieldBus Daughter Board 1 15 Module Status LEDs 1 15 Network Status LEDs 1 15 Configuration Switches 1 16 Switches Fieldbus Specific Input Register 1 16 Discrete I O Board 1 17 DC Operation 1 19 AC Operation 1 19 Inputs 1 20 Outputs 1 20 Firing Card 1 20 Firing Card Input Signals 1 21 Firing Card Output Signals 1 21 Cascade Firing Board 1 21 SCR Assembly 1 2...

Page 4: ... 2 8 Setting the Weld Processor MedLAN Address 2 10 Programming the Weld Processor 2 12 DEP 100S Programming Device 2 13 How to Program I O Mappings 2 14 Initial Preparation for I O Assignment 2 14 T03300 AC Controls 2 15 T02300 Type 1 Inverter Controls 2 16 Options for Mapping I O 2 17 The I O Options Screen Discrete 2 18 The I O Options Screen FieldBus 2 19 Mapping Inputs 2 20 Mapping Outputs 2 ...

Page 5: ...ions 3 18 Output Abbreviations 3 19 Input Output Mappings T03300 3 20 Input Abbreviations 3 20 Output Abbreviations 3 21 Setting the Word Size 3 21 Chapter 4 Weld Schedules 4 1 What is a Weld Schedule 4 1 Software Capabilities 4 2 List of Functions 4 3 Delay Functions 4 3 Weld Functions and Firing Modes 4 3 AVC Firing Mode I 4 4 Automatic Current Compensation Firing Mode 4 5 Other Functions Contro...

Page 6: ...2300 4 27 Default Weld Schedule Robot 4 27 Default Weld Schedule Machine 4 27 Default Weld Schedule Gun 4 28 Default Weld Schedules in Program T02301 4 29 Default Weld Schedule Robot 4 29 Default Weld Schedule Machine 4 29 Default Weld Schedule Gun 4 30 Default Weld Schedules in Program T02302 4 31 Default Weld Schedule Robot 4 31 Default Weld Schedule Machine 4 31 Default Weld Schedule Gun 4 32 D...

Page 7: ...twares 5 17 Inverter Operating Parameters 5 21 Quick Reference to Setup Parameters T03300 5 22 Quick Reference to Setup Parameters T03302 5 24 Quick Reference to Setup Parameters T03310 5 26 Quick Reference to Setup Parameters T03311 5 28 Quick Reference to Setup Parameters T02300 5 30 Quick Reference to Setup Parameters T02301 5 32 Quick Reference to Setup Parameters T02302 5 34 Quick Reference t...

Page 8: ...old 7 6 Dynamic Squeeze Functions 7 7 SPC Indexing Capabilities 7 8 SPC Functions 7 8 SPC Setup Parameters 7 9 SCR Short Detection 7 10 Retract Features 7 12 Retract Mode 7 12 Cylinder Type 7 13 Air Only Cylinders 7 13 Air Over Oil Cylinders 7 14 Examples 7 17 Example Weld Schedule Air Over Oil Cylinder Operation 7 18 Initiation From Retract 7 21 DEP 100S Programming Restrictions 7 21 Weld No Weld...

Page 9: ...e 10 1 Current Compensation Information for AC Products 10 1 Background Information 10 1 Chapter 11 Application Note Cascade Welding 11 1 Scope 11 1 Cascade Welding Information for AC Products 11 1 Background Information 11 1 Parallel Cascade Method 11 1 Multiple Output Cascade Method 11 2 The Differences Between Method 1 and 2 11 3 Weld Schedules in Cascade Welds 11 3 ...

Page 10: ...he 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 For your convenience fill out the Problem Report Form on page xx By E mail When an immediate response is not critical contact WTC at the following e mail addresses WTC s technical support will r...

Page 11: ...ever failure to observe safety measures may result in death severe bodily injury or serious damage to property WARNING This symbol will be used wherever insufficient or lacking compliance with instructions may result in personal injury Caution and NOTE messages indicate the following Caution This symbol denotes when insufficient or lacking compliance with the instructions may damage equipment or f...

Page 12: ...NJURIES and or DEATH Refer all necessary service on this machine ONLY to qualified maintenance personnel Danger NEVER drill into the control cabinet without properly protecting internal components from metal debris and removing power Failure to observe this requirement may cause a potential EXPLOSION HAZARD Revision Release Date Comments 1 01 0 03 Released as program T03300 01 2 06 05 03 Release o...

Page 13: ... over 20 kg 45 lb use either a two man lift or an assisted lift How to Use this Manual This manual is designed as a reference guide Use it as you would a dictionary See the Table of Contents to locate the instructions or information you require For additional details you are referred to the appropriate sections and page numbers The Table of Contents lists each section and subsection In these secti...

Page 14: ... substitutions or changes as required to the hardware or software described in this manual This manual may be periodically updated to reflect software changes that will affect operation of the equipment described Request copies of the latest updates by completing the Comments for Feedback Form on page xxii or by visiting WTC s Web site www weldtechcorp com ...

Page 15: ... and 8 0 Maximum chloride content 20 parts per million PPM Maximum nitrate content 10 PPM Maximum sulfate content 100 PPM Maximum suspended solids content 100 PPM non abrasive Maximum total suspended and dissolved solids content 250 PPM Maximum calcium carbonate content 250 PPM Resistivity less than 2 000 ohms cm at 25 C 500 μS The hose used must be NO LESS THAN 18 in long across the power voltage...

Page 16: ...ing or destroying the hose 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 If cooling manifolds are used rather than hose leakage current in the...

Page 17: ... ESDS devices or circuit boards put on and wear an Electrostatic Discharge ESD wrist strap Ground this strap through a one megohm 1 MΩ resistor Handling or Moving ESDS Devices 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 ...

Page 18: ...en authorization and payment of royalty fees Patents This product contains intellectual property owned or licensed by WTC excluding but not limited to one or more of the following U S patents Other patents U S or foreign may be issued or pending The software and documentation associated with this product are protected by copyrights owned by WTC Trademarks have been adopted and used on all or part ...

Page 19: ...Getting Started xix Modified 9 17 08 MedWeld 4000 Operator s Guide M 032116 Programs T03300 T02300 and T02400 This page is intentionally left blank ...

Page 20: ...Plant Name and Location Phone Your Name Date Time Program Timer power up message Part Fault code display When a fault or error occurs the Product displays a status code Indicate each code that is displayed Description of the problem Sequence of events leading to the problem Drawing number s of schematic s shipped with the Product ...

Page 21: ...Getting Started xxi Modified 9 17 08 MedWeld 4000 Operator s Guide M 032116 Programs T03300 T02300 and T02400 This page is intentionally left blank ...

Page 22: ...f this manual Our Training and Documentation staff will review your comments and implement the required corrections in future updates For specific comments fill in the Comments for Feedback form below Fax it at 248 477 8897 Comments for Feedback Form Your Name Date Time Company Name Phone Company Address City State ZIP Program Revision of Manuals at your site Document Number Name Your comments ...

Page 23: ...Getting Started xxiii Modified 9 17 08 MedWeld 4000 Operator s Guide M 032116 Programs T03300 T02300 and T02400 This page is intentionally left blank ...

Page 24: ...ed directly into the weld processor In AC weld controls signals from the firing card go to a pair of SCRs silicon controlled rectifiers MFDC weld controls the signals from the timer are passed to the inverter The SCRs or inverter then output high voltage low amperage current to the welding transformer Finally this transformer applies a low voltage at high current to the welding electrodes The modu...

Page 25: ...xibility to the WTC design providing full function and programming capabilities You can program 99 independent weld schedules then assign a weld schedule to one of 99 independent steppers to compensate for lost current density You can program a weld function to use either Automatic Voltage Compensation to maintain a desired primary voltage or Automatic Current Compensation to maintain constant sec...

Page 26: ...0 T02300 and T02400 Physical Description Figure 1 is an internal view of the AC weld control with the door open Figure 1 MedWeld 4000 Weld Control AC NOTE The possible configuration options are too numerous to detail here Contact your WTC sales representative for assistance on configuration options ...

Page 27: ...FDC weld control with the door open The type 1 inverter is the Medar style of inverter If you are unsure of the inverter in your control there will be a label on the inverter that labels it as Medar Figure 2 MedWeld 4000 Weld Control MFDC Type 1 NOTE The possible configuration options are too numerous to detail here Contact your WTC sales representative for assistance on configuration options ...

Page 28: ...S current while operating 578 A RMS mains line current while operating 535 A Power Factor Nominal 81 KVA Input 448 KW Output 363 Duty Cycle Maximum Duty Cycle 20 Peak output 600 A Maximum Weld Time 0 7 seconds Cooling Water Water flow rate 4 liters minute or 1 06 gal min Water temperature 30 C Mean Time Between Failures Mixed Welding and Power on hours 10 duty cycle 1 250 000 hrs 20 duty cycle 500...

Page 29: ...ting 585 A RMS mains line current while operating 578 A Power Factor Nominal 79 KVA Input 418 KW Output 329 Duty Cycle Maximum Duty Cycle 20 Peak output 600 A Maximum Weld Time 0 7 seconds Cooling Water Flow rate 4 liters minute or 1 06 gal min Water temperature 30 C Mean Time Between Failures Mixed Welding and Power on hours 10 duty cycle 1 250 000 hrs 20 duty cycle 500 000 hrs Operating Life 10 ...

Page 30: ...MFDC This following shows an internal view of the Type 2 MFDC weld control with the door open The type 2 inverter is the common inverter Figure 3 MedWeld 4000 Weld Control MFDC Type 2 NOTE The possible configuration options are too numerous to detail here Contact your WTC sales representative for assistance on configuration options ...

Page 31: ... of 250 A or 600 A and higher are optional The supply voltage 380 480 or 600 VAC is connected to the single pack breaker at terminals located at the top of the breaker Refer to Installation Checklist on page 2 27 for more information An operator handle on the outside of the cabinet operates the circuit breaker and visually indicates its condition The handle must be UP to turn ON the breaker The ha...

Page 32: ...te relay based on the status of the CONTROL STOP and WELD NO WELD inputs and a TURN ON function Refer to page 4 8 and TURN ON OFF CONTACTOR SELECT n page 4 23 for more information about these functions Also refer to the drawing packet of schematics provided with your MedWeld 4000 Control Transformer Supply voltage 380 480 or 600 VAC from below the circuit breaker goes to a control transformer It r...

Page 33: ...e timer assembly houses these major components Local I O and An optional FieldBus daughter board The following illustrates the connectors on the timer assembly board Figure 4 Timer Assembly Board Connectors Normal Program I O jumper MedLAN port Analog 2 channel Analog 1 channel Power and Local I O connector Connector to Firing Card Connectors to Discrete J2 J4 J5 J8 J6 J7 J9 J10 1 2 900 822x 2 I O...

Page 34: ...icate with up to two Discrete I O boards The weld processor performs the following weld timing functions required to execute a weld schedule Checks input signals provided through the Discrete I O board from the I O modules either FieldBus or Local I O and responds to them accordingly Operates the signals through the Discrete I O board based on the weld schedule Sends firing signals to the firing c...

Page 35: ...fore putting it into service it is necessary to correctly set the baud rate and node address for this board For more details refer to Configuring the FieldBus Daughter Board on page 1 14 NOTE Profibus configuration switches set only the local station address value using binary coded decimal BCD on the dip switches J2 J3 J4 Profibus Connector Configuration DIP Switches RS 485 Serial FieldBus card c...

Page 36: ...us Daughter Board DeviceNet After installing the control and before putting it into service it is necessary to correctly set the baud rate and node address for this board For more details refer to Configuring the FieldBus Daughter Board on page 1 14 J2 J3 J4 DeviceNet Connector Configuration DIP Switches RS 485 Serial LED TXD LED RXD Power Status LED Connector FieldBus card configured FieldBus car...

Page 37: ...rect Device requires commissioning LED2 Red Unrecoverable fault Flashing Red Minor recoverable fault Bit State Function OFF Device not powered not on line LED3 Green Link is OK On line Connected Blinks Green On line but not connected LED4 Red Critical link failure Blinks Red Connection timeout LED3 4 Blinks Green Red A specific communication faulted device The device has detected a Network Access ...

Page 38: ...he two most significant switches 8 and 7 The valid settings are 00 125 kb sec 01 250 kb sec 10 500 kb sec Refer to this diagram for proper switch orientation Switches Fieldbus Specific Input Register Node Address Set the node address for the MedWeld 4000 in the range 0 126 A 7 pole binary switch specifies the address Refer to the following table ON 8 7 6 5 4 3 2 1 MAC ID MSB LSB Baud rate MSB LSB ...

Page 39: ... electromechanical relays rated to switch up to 5 A at 240 VAC This board operates at either 50 or 60 Hz line frequency Figure 7 below shows the connectors and LEDs on the board Figure 7 Discrete I O Board Connectors and LEDs I O from Board p n 900 822x x Program port MedLAN port WTC Firing Card Interface port 10 Outputs dry contacts 8 Inputs 110 VAC 8 Inputs 110 VAC 24 VAC VDC Connector to Timer ...

Page 40: ... voltages Any input voltage less than 140 VAC or 180 VDC will not damage he board A minimum 16 VAC or 15 VDC either polarity is required to activate an input An input will not be activated by any current of less than 2 mA regardless of nominal input voltage Recommended nominal input voltages are 24 VAC 24 VDC or 120 VAC A light emitting diode LED indicates the status of each input If an input is O...

Page 41: ...he entire group It is possible to operate one group of inputs at 120 VAC and the other at 24 VDC When operating at 24 VAC the minimum voltage at which an input is guaranteed to activate is 16 VAC 50 or 60 Hz The maximum voltage guaranteed to NOT activate an input is 5 VAC 50 or 60 Hz At 24 VAC the current draw of the input is 12 mA At voltages between 85 and 140 VAC the minimum voltage at which an...

Page 42: ...puts are SPST normally open only arranged in two groups of four The two SPDT relays are separate Each group of four relays has a single common connection The other two relays have all three poles brought out separately so they can be connected in a normally open or normally closed configuration independent of the other 8 relays The timer s software determines which output is used for which purpose...

Page 43: ...gnals The firing card also outputs a group of logic level signals from the various connections at the welder s primary circuit The weld processor uses these signals to Find the zero degree phase angle point on the supply power as a reference for its phase angle measurements Measure the line voltage current and power factor Adjust the firing phase angle based on the voltage or current depending on ...

Page 44: ... for use with air core current sensing coils which meet the IEC standard of 150 mV output per kA with a sinusoidal 50 Hz current waveform 0 477 μHy mutual inductance On 60 Hz these coils output 180 mV per kA To allow for variance in current sensing coils the welding control has a setup parameter to allow setting the mutual inductance between 0 05 and 0 99 μHy The SCIB secondary current coil input ...

Page 45: ...nsistent welds The primary current I changes as the voltage fluctuates For example if the weld energy E drops the processor firing phase shifts forward to increase I until E stabilizes You program a weld function specifying current in two ways To use either Automatic Voltage Compensation to maintain a desired primary voltage or Automatic Current Compensation to maintain constant secondary current ...

Page 46: ...eld processor receives the ISOLATION CONTACTOR input directly from the isolation contactor This input indicates the status of the contactor pulled in or dropped out The weld processor also receives a Ready to Weld signal from the inverter IRTW This indicates when the inverter is capable of providing weld current The inverter thermal switches indicate that cooling water is present The isolation con...

Page 47: ...verter may delay activating the charging pack for up to 20 seconds The charging pack is external to the Type 1 inverter The Type 2 inverter includes the charging pack internally For Type 1 Medar inverters the charging pack will vary according to the size of inverter Medar MF300 The charging pack for the MF300 inverter is a three phase half wave bridge rectifier The rectifier module is integrated i...

Page 48: ...ack discharge resistors capacitors and insulated gate bipolar transistors IGBTs The IGBTs control the time that current is allowed to pass to the welding transformer The regulator board receives the firing signal from the weld processor and translates the signal into target flux or current depending on firing mode The regulator fires the IGBTs and monitors to obtain the target The charging pack is...

Page 49: ...er NOTE If your configuration provides the weld transformer isolation contactor the inverter remains activated and is de activated only by inverter fault conditions or power down of the weld control Refer to the drawings provided with your system for more information The weld processor requests an upload of weld data and active fault conditions from the inverter It functions as a slave device in t...

Page 50: ...tain the circuit breaker handle on the enclosure is in the OFF DOWN position before attempting to open the door WARNING 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 2 Inspect the inside of the enclosure for any damage caused in shipping Check for any parts which may...

Page 51: ...ottom or side of the cabinet Either pipes or hoses are acceptable 7 Connect the cooling water and test for leaks BEFORE any wiring into the control is performed to reduce the risk of electrical shock 3QedY_ BUVUb d_ QWU hYY V_b dXU bUaeYbU U dc _V S__ Y W gQdUb aeQ Ydi Q T V _g 8 With the welding bus power off and properly locked out connect the power cables from the welding bus to the top of the ...

Page 52: ...rect Refer to Circuit Breaker on page 1 4 14 If using the optional communications daughter board configure the FieldBus DIP switch Refer to Configuring the FieldBus Daughter Board on page 1 10 for further details 15 If using the optional secondary current coil inspect it and verify that its orientation is correct and the 2 pin Phoenix connector is secure 16 Inspect all connections and verify prope...

Page 53: ...eady for welding 3URYLGLQJ 2 RQQHFWLRQV Some inputs outputs require connection and configuration 3URYLGLQJ RFDO 2 As shipped from the factory the MedWeld 4000 has two jumpers installed between J10 pins 10 11 and J10 pins 12 13 on the timer assembly You can set up the CONTROL STOP input to use either an internal or external power source as follows To use the CONTROL STOP input with internal power r...

Page 54: ...communicate with each other NOTE 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 data entry device DEP 100S WebVIEW BANK or WSS for network communications or to program a single weld control However for the ...

Page 55: ...figurations 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...

Page 56: ...inate 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 Designator Pin Function Wire Color BELDEN 9463 MDL2 3 MedLan Line 2 Clear MDLS 2 Line Shield M...

Page 57: ... inside the control WARNING Be certain to cover all components to protect them from metal shavings Metal debris from drilling into the cabinet can cause catastrophic failure The WTC warranty does NOT cover damage caused by metal debris Physically separate the MedLAN cable from wiring greater than 50 volts If the MedLAN cable must cross this wiring it must do so at a 90 angle Figure 7 below illustr...

Page 58: ...dLAN connection and powering it up you must set the MedLAN address for each device before it can respond to the network Use the DEP 100S to program the MedLAN address for each individual weld control through the top DEP port of the weld processor card NOTE The steps required to set the address are listed on the next page Refer to the manual provided with the DEP 100S programming device for more in...

Page 59: ...Press the Program Mode key 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 5 Press the key to select the port MedLAN address 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 1 1 7 94 41D1 144B 41D1 6 6 6 6...

Page 60: ...r 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 DEP 100S programming device into the connector on the e...

Page 61: ...for each weld processor The DEP 100S is shown in Figure 8 on page 2 9 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 Me...

Page 62: ...play mode of the DEP 100S QLWLDO 3UHSDUDWLRQ IRU 2 VVLJQPHQW BEFORE entering any programming changes to I O follow this procedure 1 Turn OFF power to the control 2 Locate the RUN PROGRAM jumper on the timer board 3 Set the RUN PROGRAM jumper to PROGRAM mode 4 Turn ON power to the control 5 Connect the DEP 100S at port J8 on the timer assembly Use the Door Port Interface Kit WTC p n 830 0654 6 Afte...

Page 63: ... the IO Mapping option Proceed to Options for Mapping I O on page 2 16 or Press again to show the Fieldbus Mapping option on the next screen 10 From this screen select to access the option for mapping FieldBus I O Proceed to Options for Mapping I O on page 2 16 88D 3 B 7B1 45 G5 45B DB1 C65B 5DG B 9 94 41D1 144B 1 9 7 6 6 6 6 88D 3 B 7B1 45 695 42EC 1 9 7 6 6 6 6 ...

Page 64: ...and Fieldbus Mapping options 3 From this screen select either 4 to access the options for mapping Discrete I O Proceed to Options for Mapping I O on page 2 16 or 5 to access the options for mapping FieldBus I O Proceed to Options for Mapping I O on page 2 16 88D 3 B 7B1 45 G5 45B DB1 C65B 5DG B 1 1 7 94 41D1 144B 41D1 6 6 6 6 88D 3 B 7B1 45 9 695 42EC 1 9 7 1 9 7 6 6 6 6 ...

Page 65: ... select one of the three menu options presented 1 Discrete IO Options Proceed to The I O Options Screen Discrete on page 2 17 OR this screen appears after selecting the the Fieldbus Mapping option from the IO Mapping screen shown on page 2 15 1 Fieldbus IO Options Proceed to The I O Options Screen FieldBus on page 2 18 88D 3 4YcSbUdU 9 dY_ c Q 4YcSbUdU 9 edc Q 4YcSbUdU ed edc 6 6 6 6 88D 3 6YU TRe...

Page 66: ...n to the ISOLATION CONTACTOR option 4 If your control has the optional isolation contactor use O or U as needed to set this option ENABLED for programming 5 If no isolation contactor is included set the option DISABLED 6 To accept these settings for downloading press A message DOWNLOAD COMPLETE RESTART TIMER appears momentarily D5 If the Normal Program jumper is not in the proper position the DEP ...

Page 67: ...y additional changes 2 Press U to reload from one of the supplied FieldBus I O defaults Selecting OFF performs no action Selecting Default 1 reloads from the supplied Default 1 Selecting Default 2 reloads from the supplied Default 2 3 Press E to scroll down to the FIELDBUS SIZE WORDS option 4 Press U to select the FieldBus word size 0 disables FieldBus communication 1 sets the word size to 16 inpu...

Page 68: ...as needed scroll to the desired input position number For example Input 09 might now have the PRESSURE SWITCH input but you want to assign the STEPPER RESET GROUP 1 input to this input position number The screen would look like this 2 With the cursor at Input 09 press O or U as needed to scroll through the list of available input names This screen appears 88D 3 C D 1 B D 6 9 1 9 ED 29 1BI C5 53D 9...

Page 69: ...OMPLETE RESTART TIMER appears momentarily 5 To exit this screen and return to the IO Mapping screen press D5 For the changes you entered to take effect you must reset the weld processor to RUN mode You may make all programming changes before cycling power to the control 6 Turn OFF power to the control 7 On the timer board set the RUN PROGRAM jumper to RUN mode 8 Turn ON power to the control The se...

Page 70: ...eys as needed scroll to the desired output position number For example Output 06 might now have the PRESSURE SELECT 2 output but you want to assign the INTEN SIFICATION VALVE output The screen would look like this 2 With the cursor at Output 06 press O or U as needed to scroll through the list of available outputs This screen appears 88D 3 C D 1 B D 6 9 1 ED ED F1 F5 29 1BI F1 F5 ED ED F1 F5 29 1B...

Page 71: ...ple press the key A message DOWNLOAD COMPLETE RESTART TIMER appears momentarily 5 To exit this screen and return to the IO Mapping screen press D5 For the changes you entered to take effect you must reset the weld processor to RUN mode You may make all programming changes before cycling power to the control 6 Turn OFF power to the control 7 On the timer board set the RUN PROGRAM jumper to RUN mode...

Page 72: ...nnector J2 on the weld processor board 1CPU For support of analog I O either or both connectors J4 and or J5 on the weld processor board 1CPU Type 2 inverter Wire a ferrite bead across each connection If using the transformer over temperature switch wire to terminals 1TB TS1 and 1TB TS2 on terminal block 1TB The CONTROL STOP signal can be internally or externally sourced Refer to the schematics su...

Page 73: ...wing tables when making electrical connections Be sure to observe these specifications exactly 5HTXLUHG 7RUTXH 6 5V Device Suggested Cable Size Captive Nut Assy Copper Lug or Bus Direct to Device Cable Lug Flexibar to Lug or Device Tang 600 A SCR Darrah Q20008 Dynex MP02TT800 3 6 lb ft 5 n m N A N A 1 200 A SCR Darrah Q20001P Powerex ND431825 8 lb ft 11 n m N A N A 1 650 A SCR Eupec T425N18KOF Pow...

Page 74: ...A 22 9 lb ft 31 n m ABB K4TG ABB S6 breaker 13 25 lb ft 18 n m 31 lb ft 42 n m ABB K4TJ N A 22 9 lb ft 31 n m ABB K4TH ABB S7 breaker 13 25 lb ft 18 n m 31 lb ft 42 n m ABB K7TK N A Device Suggested Cable Size Captive Nut Assy Copper Lug or Bus Direct to Device Cable Lug Copper Bus to Lug or Device Tang ABB A110 contactor N A 4 4 lb ft 6 n m captive N A ABB A145 contactor 6 64 lb ft 9 n m N A N A ...

Page 75: ...k drain holes ensure they are open CdU At desired location mount control by ALL 4 mounting tabs CdU Remove access plates to drill for Weld bus cooling water welding transformer and I O CdU Connect cooling water supply to fittings CdU Lock out at welding bus Connect power cables Bus to line side top of circuit breaker CdU Connect weld transformer CdU Connect all I O points CdU Connect external powe...

Page 76: ...s Verify proper crimping and torque Verify NO line to line shorts Refer to page 2 25 Step 16 Verify all I O are present and correctly assigned in software Step 17 Ensure cooling water supply and proper flow rate Step 18 Program required weld schedules settings for setup parameters and stepper profile Step 19 Verify proper hand shaking of I O on power up ...

Page 77: ...9 cdQ Y W dXU UTGU T _TYVYUT UTGU T UbQd_bµc 7eYTU b_WbQ c D D Q T D This page is intentionally left blank ...

Page 78: ...closure This chapter defines the inputs to the MedWeld 4000 and the outputs that it provides The following sections describe each option and the I O provided Local I O When the MedWeld 4000 is part of a network using any communication scheme the timer directly provides for local control of certain critical inputs and outputs These I O are the same for both communication scheme As described in Prov...

Page 79: ...ontrol will generate an ISO CNTR OFF WHEN NEEDED fault condition and trip the circuit breaker Refer to page 5 5 for more information about this fault 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 and trip the circuit breaker THERMAL SWITCH Input TS...

Page 80: ...d this input must be jumpered HIGH If this input is not active when the control receives a schedule initiate a SYSTEM COOLING fault will be generated and the NO FAULT output will be de energized A SYSTEM COOLING fault also occurs if a weld schedule contains Function 79 WAIT nnn CY FOR SYSTEM COOLING and this input does not become active within the number of cycles specified Local Outputs ISOLATION...

Page 81: ... Discrete I O board s Word size in FieldBus is 0 1 or 2 I O bits Word size in discrete is 0 16 or 32 I O bits Here is an example 01 BINARY SELECT 1 Pilot 1 02 BINARY SELECT 2 Pilot 2 03 BINARY SELECT 4 Pilot 3 04 BINARY SELECT 8 Pilot 4 05 WELD INITIATE 06 WELD NO WELD 07 STEPPER RESET 08 FAULT RESET 09 PRESSURE SWITCH 10 NONE 11 RETRACT PILOT 1 12 RETRACT PILOT 2 13 TRANSFORMER OVERTEMP 14 PROGRA...

Page 82: ...dbus and Discrete have the same outputs in common For the listing of supported I O in this program see page 3 18 For descriptions of the I O refer to Input Definitions on page 3 6 and Output Definitions on page 3 10 NOTES The control does not operate when in Program mode Changes to programmed I O are possible only while in this mode For the changes you program to I O to take effect you must cycle ...

Page 83: ...CT 64 Input BS64 These inputs select the schedule to be initiated 1 99 The schedule is selected by a combination of these inputs Each input has a weighted value 1 2 4 8 16 32 or 64 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 SELECT Inputs 1 2 an...

Page 84: ...aults to closed FAULT RESET Input FR This input allows the user to remotely reset all faults TRANSFORMER OVERTEMP TROT This input tells the state of the transformer and external cooling system It is provided as an external welding transformer over temperature switch If not using this input and it is programmed jumper it HIGH If this input is not active when the control receives a schedule initiate...

Page 85: ... 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 PRESSURE SWITCH fault and continues with the schedule The control aborts the weld schedule and generates a PRESSURE SWITCH fault if the weld initiate is removed while the control is waiting in the function WAIT FOR PRESSURE SWITCH WELD PROCEED 1 Inp...

Page 86: ...T input changes the state of the RETRACT VALVE output The first pulse from the input activates the valve output The second pulse from the input de activates the output With NONE selected the control ignores the RETRACT input The Retract Cylinder setup parameter defines the retract cylinder as either AIR NORMAL or AIR INVERTED AIR OIL NORMALLY OPEN or AIR OIL NORMALLY CLOSED AIR NORMAL indicates th...

Page 87: ...ut V4 BINARY VALVE8 VALVE 4 Output V8 BINARY VALVE16 VALVE 5 Output V16 BINARY VALVE32 VALVE 6 Output V32 Turning on the discrete initiate for Valve 1 2 3 4 5 or 6 actuates the binary valve output 1 2 4 8 16 or 32 respectively NO FAULT Output NFLT This output is normally ON to indicate that no fault conditions exist If the control shuts down as the result of a fault condition this output will be t...

Page 88: ...e WELD IN PROGRESS Output WIP 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 END OF HOLD Output EWS This output turns ON after the control completes the number of HOLD CYCLES programmed The output remains active for the number of OFF CYCLES programmed For example setting OFF CYCLES to 08 cycles holds thi...

Page 89: ... GROUP 1 Output ESG1 END OF STEPPER GROUP 2 Output ESG2 Either output is active when the stepper completes the final weld in Step 5 of the stepper profile for Group 1 or 2 The program now issues the END OF STEPPER fault Electrode maintenance is required STEPPER APPROACHING MAX Output SALT This output is turned ON when any assigned active stepper assigned to one of these groups has entered Step 5 S...

Page 90: ...f operation in retract refer to Retract Features on page 7 12 Other I O Program T02300 Program T02300 also includes the following inputs and outputs FieldBus Inputs TIP DRESS Input This input will reset the stepper to step 2 and decrement the Tip Dresses Remaining counter When this input becomes active the control also resets the TIP DRESS REQUEST output DOOR INTERLOCK This input monitors the stat...

Page 91: ... all the steppers auxiliary weld counters The existing STEPPER RESET input also will reset the counters You can view and modify the stepper s auxiliary weld counter It is available on the Stepper Status display of the DEP 100S Hand Held Terminal FieldBus Outputs WELD MODE ON This is an output to confirm that the control is in Weld mode NO ALERT This output is normally ON It turns OFF to indicate a...

Page 92: ...ements When this counter reaches the programmed value for the Aux Counter Max Counts nnnnn setup parameter the STEPPER AUXILIARY COUNTER AT MAXIMUM output will be turned on When programming Aux Counter Max Counts to 00000 the output is disabled Setting the AUX COUNTER RESET input HIGH resets all of the steppers auxiliary weld counters The existing STEPPER RESET input also will reset the counters D...

Page 93: ...the AUX COUNTER AT MAX output will be turned on Setting the STEPPER AUXILIARY COUNTER RESET input HIGH resets all the steppers auxiliary weld counters The existing STEPPER RESET input also will reset the counters You can view and modify the stepper s auxiliary weld counter It is available on the Stepper Status display of the DEP 100S Hand Held Terminal Discrete Outputs WELD MODE ON This output con...

Page 94: ...ding the respective duty cycle generates this fault After this fault occurs the inverter must be de rated AUX WELD COUNTER AT MAX When a stepper increments its Auxiliary Weld Counter also increments When this counter reaches the programmed value for the Aux Counter Max Counts nnnnn setup parameter the STEPPER AUXILIARY COUNTER AT MAXIMUM output will be turned on When programming Aux Counter Max Co...

Page 95: ...WELD WLD ISOLATION CONTACTOR SAVER CSVR FAULT RESET FR NO STROKE NO WELD Input NSNW PROGRAM SECURITY Input PSEC HEAT DISPLAY SECURITY Input HSEC PRESSURE SWITCH Input PS1 WELD PROCEED 1 WP1 WELD PROCEED 2 WP2 STEPPER RESET SR STEPPER RESET GROUP 1 SRG1 STEPPER RESET GROUP 2 SRG2 TIP DRESS TIPD DOOR INTERLOCK DLCK RETRACT PILOT 1 RT1 RETRACT PILOT 2 RT2 USER INPUT 1 UI1 USER INPUT 2 UI2 USER INPUT ...

Page 96: ...TCH Output WM WELD IN PROGRESS WIP NO ALERT Output NALT WELD COMPLETE WCPL READY TO WELD RTW STEPPERS ARE RESET SRST STEPPERS ARE RESET GROUP 1 SRG1 STEPPERS ARE RESET GROUP 2 SRG2 END OF STEPPER EOS END OF STEPPER GROUP 1 ESG1 END OF STEPPER GROUP 2 ESG2 STEPPER APPROACHING MAX SALT STEPPER APPROACHING MAX GROUP 1 SAG1 STEPPER APPROACHING MAX GROUP 2 SAG2 TIP DRESS REQUEST TIPD PRESSURE SELECT 1 ...

Page 97: ...s appear with these abbreviations BINARY SELECT 1 Pilot 1 BS1 BINARY SELECT 2 Pilot 2 BS2 BINARY SELECT 4 Pilot 3 BS4 BINARY SELECT 8 Pilot 4 BS8 BINARY SELECT 16 Pilot 5 BS16 BINARY SELECT 32 Pilot 6 BS32 WELD INITIATE INT WELD NO WELD WLD ISOLATION CONTACTOR SAVER CSVR FAULT RESET FR TRANSFORMER OVERTEMP Input TROT NO STROKE NO WELD Input NSNW PROGRAM SECURITY Input PSEC HEAT DISPLAY SECURITY In...

Page 98: ...S ARE RESET GROUP 1 SRG1 STEPPERS ARE RESET GROUP 2 SRG2 END OF STEPPER EOS END OF STEPPER GROUP 1 ESG1 END OF STEPPER GROUP 2 ESG2 STEPPER APPROACHING MAX SALT STEPPER APPROACHING MAX GROUP 1 SAG1 STEPPER APPROACHING MAX GROUP 2 SAG2 PRESSURE SELECT 1 PS1 PRESSURE SELECT 2 PS2 PRESSURE SELECT 3 PS3 PRESSURE SELECT 4 PS4 INTENSIFICATION VALVE Output INTV INITIATION ACKNOWLEDGE Output IACK RETRACT ...

Page 99: ...Communications and I O 3 22 Modified 9 17 08 MedWeld 4000 Operator s Guide M 032116 Programs T03300 T02300 and T02400 This page is intentionally left blank ...

Page 100: ...with each programming device This chapter 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 What is a Weld Schedule A weld schedule is a list of commands that the control is to execute For example to perform a simple spot weld you might us...

Page 101: ...ical 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 You can add functions from this list or delete functions from it You may also change any of the numeric values specified in a function This lets you create a schedule that meets your appli...

Page 102: ...ed amount of weld current 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 ...

Page 103: ...sing 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 Caution The Transformer Turns Ratio setup parameter described on page 5 14 must be accurately programmed for the control to supply the correct amount of secondary current in ACC firing mo...

Page 104: ...PS 32 PREHEAT nn CY nnnn0 AMPS 33 POSTHEAT nn CY nnnn0 AMPS 34 PRE WELD nn CY nnnn0 AMPS 38 WELD nnn IMP nnnn0 AMPS nnnn0 AMPS The stepper is active during this function NOTES ACC faults may occur when the control is firing at or near the 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 co...

Page 105: ...ovide weld current that starts at the first value and increases or decreases linearly to the second value over the number of cycles specified Function 40 uses AVC firing mode Function 45 uses ACC firing Either function will fire for the number of cycles specified For example the function 40 SLOPE 30 CY 45 I TO 65 I tells the control to fire one cycle at 45 of the maximum available current Then ove...

Page 106: ...pulsation weld Pulsation welding provides a specified number of impulses An impulse is a number of heat cycles when weld current flows followed by a number of cycles when current does not flow Consider the following schedule 60 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 re...

Page 107: ...the control to turn outputs on or off within a weld schedule 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 n 1 6 55 TURN OFF VALVE n n 1 6 56 TURN ON 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...

Page 108: ...ction 68 waits in the sequence for up to the specified number of cycles nnn Function 69 waits indefinitely Function 68 continues the sequence in No Weld mode to inhibit weld current from flowing if the Pressure Switch setup parameter is programmed as a FAULT If programming this parameter as an ALERT it continues with the sequence as normal Functions 70 and 71 WELD PROCEED fault Function 70 pauses ...

Page 109: ...put 1 85 WAIT FOR NO INITIATE IF FAULT This function tells the control to check if any faults exist If the output is de energized a fault condition is present the control waits 10 cycles in the weld schedule for the weld initiate to be removed This function should appear after Function 78 PROCESS WELD FAULTS in the weld sequence If the initiate is still present after 10 cycles the control uses the...

Page 110: ... INITIATE NOT PRESENT NOTE An example of using an extend function is shown below in the following schedule of functions Your application requirements may vary from this schedule please use this as an example only START OF SCHEDULE 01 54 TURN ON VALVE 1 01 SQUEEZE 15 CYCLES 30 WELD 08 CY 04000 AMPS 94 EXTEND UNTIL NO INITIATE 78 PROCESS WELD FAULTS 03 HOLD 02 CYCLES 55 TURN OFF VALVE 1 03 HOLD 10 C...

Page 111: ...ES 30 WELD 08 CY 04000 AMPS 94 EXTEND WELD IF LOW CURRENT LIMIT FAULT 78 PROCESS WELD FAULTS 03 HOLD 02 CYCLES 55 TURN OFF VALVE 1 03 HOLD 10 CYCLES END OF SCHEDULE 01 The bold text above for the extend function can be substituted with any extend in your software It is important however that the EXTEND function is immediately after a weld function as shown above if you require the welding control ...

Page 112: ... 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 NOTES This function can advance several steppers simultaneously For example your application may use several different weld schedules to execute a weld on the same tool but those schedules may be assigned to di...

Page 113: ...90 TRANSFORMER TURNS RATIO nnn 1 nnn 1 256 96 POWER FACTOR LIMIT HI nn LOW nn 97 C FACTOR LIMIT HI nnn LO nnn 84 WINDOW HI 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...

Page 114: ...rent it assumes that the electrode tips were touching and generates a TIPS TOUCHING fault Caution If Function 39 appears more than once in a sequence the control uses the data from the most recently executed test fire 92 FAULT IF TIPS NOT TOUCHING This function can generate a fault condition if the control determines that the welding electrodes are NOT touching These conditions MUST be true when u...

Page 115: ...ead during the test fire function 39 does not fall within the high and low limits programmed in this function 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 INITI...

Page 116: ...ART OF SCHEDULE 01 54 TURN ON VALVE 1 01 SQUEEZE 15 CYCLES 39 TEST FIRE 25 CURRENT 98 GOTO SEQ 02 IF CURRENT LESS THAN 02500 98 GOTO SEQ 03 IF CURRENT LESS THAN 03500 30 WELD 08 CY 04000 AMPS 03 HOLD 02 CYCLES 55 TURN OFF VALVE 1 03 HOLD 10 CYCLES END OF SCHEDULE 01 When Function 39 executes if the current detected is less then the value programmed the control will jump to the GOTO schedule number...

Page 117: ...ue 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 schedules in No Weld Refer to Dynamic Squeeze Features on page 7 6 81 SLOW CYLINDER TEST EVERY nn CY nn TIMES This...

Page 118: ...he integrity of the weld data collected This function only processes the weld data It does NOT update the FAULT and ALERT outputs These outputs will be updated when the control executes the function TURN ON WELD COMPLETE OR at the end of the weld schedule This function will be executed only once by the processor If it appears more than once in the schedule it will be executed the first time it app...

Page 119: ...ilities on page 7 8 for a detailed description of the control s SPC capabilities 87 SET SPC OFFSET TO nn This function establishes the 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 anal...

Page 120: ... 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 47 WAIT nn CYCLES FOR PRESSURE ACHIEVED nn 0 99 This function tells the control to pause in a weld sequence until it detects that the valve pressure programmed in Functions 08 13 and 14 has ...

Page 121: ...applying the final pressure before welding This prevents the weld gun from closing too fast and hard on the work pieces n sets the cylinder number Either 1 or 2 Set the pressure mm in the range 0 99 PSI 42 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 r...

Page 122: ...rresponds to CFB 2 firing board A CONTACTOR SELECT 15 corresponds to CFB 5 firing board C This function waits 2 I O scans to make sure the Discrete I O board has updated its outputs and waits 1 cycle so the Cascade Firing Board has time to switch You can select only one contactor at a time If no contactor is selected in the sequence the default firing board A on CFB 1 will be enabled This function...

Page 123: ...LES 00 0 I ACC Firing Mode pg 4 5 30 WELD nn CY IMP nnnn0 AMPS 31 TEMPER nn CY IMP nnnn0 AMPS 32 PREHEAT nn CY IMP nnnn0 AMPS 33 POSTHEAT nn CY IMP nnnn0 AMPS 34 PRE WELD nn CY IMP nnnn0 AMPS 36 WELD nn HALF CYCLES nnnn0 AMPS 38 WELD nnn IMP nnnn0 AMPS nnnn0 AMPS Other Functions Providing Weld Current pg 4 6 40 SLOPE nn CY IMP mm TO mm I 45 SLOPE nn CY nnnn0 AMPS TO nnnn0 AMPS 60 IMPULSE nn HEAT C...

Page 124: ...R LIMITS HI nnnn0 LOW nnnn0 77 ISOLATION CONTACTOR DELAY nn SEC 84 WINDOW HI nn LO nn C FACTOR nnn 90 TRANSFORMER TURNS RATIO nnn 1 nnn 1 256 96 POWER FACTOR LIMIT HI nn LOW nn 97 C FACTOR LIMIT HI nnn LO nnn Test Functions pg 4 14 39 TEST FIRE nn I 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...

Page 125: ...ATE IF FAULT 55 TURN OFF VALVE 1 53 TURN OFF ISOLATION CONTACTOR END OF SEQUENCE Default Weld Sequence Machine START OF SEQUENCE 82 LINEAR STEPPER 00 ASSIGNED 0 OFF 76 SEC CURR LIMITS HI 00000 LO 99990 90 TRANSFORMER TURNS RATIO 100 1 63 TURN ON OUTPUT 0 52 TURN ON ISOLATION CONTACTOR 01 SQUEEZE 30 CYCLES 30 WELD 10 CY 00050 AMPS 78 PROCESS WELD FAULTS 03 HOLD 05 CYCLES 50 TURN ON WELD COMPLETE 64...

Page 126: ...CYCLES 85 WAIT FOR NO INITIATE IF FAULT 55 TURN OFF VALVE 1 53 TURN OFF ISOLATION CONTACTOR END OF SCHEDULE Default Weld Schedule Machine START OF SCHEDULE 82 LINEAR STEPPER 00 ASSIGNED 0 OFF 76 SEC CURR LIMITS HI 00000 LO 99990 90 TRANSFORMER TURNS RATIO 073 1 58 TURN ON WELD IN PROGRESS 52 TURN ON ISOLATION CONTACTOR 01 SQUEEZE 30 CYCLES 10 TURN ON CONTACTOR SELECT 01 30 WELD 10 CY 00050 AMPS 11...

Page 127: ...IGNED 0 OFF 76 SEC CURR LIMITS HI 00000 LOW 99990 90 TRANSFORMER TURNS RATIO 073 1 54 TURN ON VALVE 1 05 INITIAL SQUEEZE 25 CYCLES 62 REPEAT AT NEXT FUNCTION 54 TURN ON VALVE 1 52 TURN ON ISOLATION CONTACTOR 01 SQUEEZE 30 CYCLES 30 WELD 10 CY 00050 AMPS 78 PROCESS WELD FAULTS 03 HOLD 05 CYCLES 55 TURN OFF VALVE 1 53 TURN OFF ISOLATION CONTACTOR 04 OFF 20 CYCLES END OF SCHEDULE ...

Page 128: ...CYCLES 85 WAIT FOR NO INITIATE IF FAULT 55 TURN OFF VALVE 1 53 TURN OFF ISOLATION CONTACTOR END OF SCHEDULE Default Weld Schedule Machine START OF SCHEDULE 82 LINEAR STEPPER 00 ASSIGNED 0 OFF 76 SEC CURR LIMITS HI 00000 LO 99990 90 TRANSFORMER TURNS RATIO 073 1 58 TURN ON WELD IN PROGRESS 52 TURN ON ISOLATION CONTACTOR 01 SQUEEZE 30 CYCLES 80 TURN ON CONTACTOR SELECT 01 30 WELD 10 CY 00050 AMPS 81...

Page 129: ...IGNED 0 OFF 76 SEC CURR LIMITS HI 00000 LOW 99990 90 TRANSFORMER TURNS RATIO 073 1 54 TURN ON VALVE 1 05 INITIAL SQUEEZE 25 CYCLES 62 REPEAT AT NEXT FUNCTION 54 TURN ON VALVE 1 52 TURN ON ISOLATION CONTACTOR 01 SQUEEZE 30 CYCLES 30 WELD 10 CY 00050 AMPS 78 PROCESS WELD FAULTS 03 HOLD 05 CYCLES 55 TURN OFF VALVE 1 53 TURN OFF ISOLATION CONTACTOR 04 OFF 20 CYCLES END OF SCHEDULE ...

Page 130: ...CYCLES 85 WAIT FOR NO INITIATE IF FAULT 55 TURN OFF VALVE 1 53 TURN OFF ISOLATION CONTACTOR END OF SCHEDULE Default Weld Schedule Machine START OF SCHEDULE 82 LINEAR STEPPER 00 ASSIGNED 0 OFF 76 SEC CURR LIMITS HI 00000 LO 99990 90 TRANSFORMER TURNS RATIO 073 1 58 TURN ON WELD IN PROGRESS 52 TURN ON ISOLATION CONTACTOR 01 SQUEEZE 30 CYCLES 10 TURN ON CONTACTOR SELECT 01 30 WELD 10 CY 00050 AMPS 11...

Page 131: ...IGNED 0 OFF 76 SEC CURR LIMITS HI 00000 LOW 99990 90 TRANSFORMER TURNS RATIO 073 1 54 TURN ON VALVE 1 05 INITIAL SQUEEZE 25 CYCLES 62 REPEAT AT NEXT FUNCTION 54 TURN ON VALVE 1 52 TURN ON ISOLATION CONTACTOR 01 SQUEEZE 30 CYCLES 30 WELD 10 CY 00050 AMPS 78 PROCESS WELD FAULTS 03 HOLD 05 CYCLES 55 TURN OFF VALVE 1 53 TURN OFF ISOLATION CONTACTOR 04 OFF 20 CYCLES END OF SCHEDULE ...

Page 132: ...RR LIMITS HI 00000 LOW 99990 81 TRANSFORMER TURNS RATIO 073 1 50 TURN ON VALVE 1 88 TURN ON ISOLATION CONTACTOR 01 SQUEEZE 30 CYCLES 30 WELD 10 CY 00050 AMPS 03 HOLD 05 CYCLES 51 TURN OFF WELD VALVE 1 89 TURN OFF ISOLATION CONTACTOR END OF SCHEDULE Default Weld Schedule Gun START OF SCHEDULE 82 LINEAR STEPPER 01 ASSIGNED 0 OFF 76SEC CURR LIMITS HI 00000 LOW 99990 81 TRANSFORMER TURNS RATIO 073 1 5...

Page 133: ... WAIT FOR STAGE 2 INITIATE 01 SQUEEZE 05 CYCLES 22 PREHEAT 00 CY 20 I 02 COOL 00 CYCLES 20 WELD 08 CY 50 I 03 HOLD 10 CYCLES 74 TURN OFF LOW PRESSURE WELD VALVE 83 TURN ON SEAM DRIVE EOH 07 WAIT 5 CYCLES 84 TURN OFF SEAM DRIVE EOH 86 TURN OFF ISOLATION CONTACTOR END OF SCHEDULE Default Weld Schedule Seam START OF SCHEDULE 19 SEC CURRENT LIMITS HI 00000 LO 99990 44 SET FORGE PRECOMPRESSION FORCE 12...

Page 134: ...UN28 FUN29 FUN30 WELD NN CYC IMP AT NNNN0 AMPS FUN31 TEMPER NN CYC IMP AT NNNN0 AMPS FUN32 PREHEAT NN CYC IMP AT NNNN0 AMPS FUN33 POSTHEAT NN CYC IMP AT NNNN0 AMPS FUN34 PRE WELD NN CYC IMP AT NNNN0 AMPS FUN35 FUN36 WELD NN HALF CYCLES NNNN0 AMPS FUN37 FUN38 WELD NNN IMP NNNN0 AMPS HIGH NNNN0 AMPS LOW FUN39 TEST FIRE NN I FUN40 SLOPE NN I TO NN I FUN41 SET VALVE N TOUCH DOWN PRESSURE NN PSI FUN42 ...

Page 135: ...TIL NO INITIATE FUN76 SEC CURR LIMITS HI NNNN0 LOW NNNN0 FUN77 ISOLATION CONTACTOR DELAY NN SEC FUN78 PROCESS WELD FAULTS FUN79 WAIT NNN CY FOR SYSTEM COOLING FUN80 VERIFY TIPS DOWN EVERY NN CY NN TIMES FUN81 SLOW CYLINDER TEST EVERY NN CY NN TIMES FUN82 LINEAR STEPPER NN ASSIGNED 0 OFF FUN83 SUREWELD STEPPER NN ASSIGNED 0 OFF FUN84 WINDOW HI NN LO NN C FACTOR NNN FUN85 WAIT FOR NO INITIATE IF FAU...

Page 136: ...T NN N I FUN26 WELD NN HALF CYCLES AT NN N I FUN27 FUN28 FUN29 FUN30 WELD NN CYC IMP AT NNNN0 AMPS FUN31 TEMPER NN CYC IMP AT NNNN0 AMPS FUN32 PREHEAT NN CYC IMP AT NNNN0 AMPS FUN33 POSTHEAT NN CYC IMP AT NNNN0 AMPS FUN34 PRE WELD NN CYC IMP AT NNNN0 AMPS FUN35 FUN36 WELD NN HALF CYCLES NNNN0 AMPS FUN37 FUN38 WELD NNN IMP NNNN0 AMPS HIGH NNNN0 AMPS LOW FUN39 TEST FIRE NN I FUN40 SLOPE NN I TO NN I...

Page 137: ...TIL NO INITIATE FUN76 SEC CURR LIMITS HI NNNN0 LOW NNNN0 FUN77 ISOLATION CONTACTOR DELAY NN SEC FUN78 PROCESS WELD FAULTS FUN79 WAIT NNN CY FOR SYSTEM COOLING FUN80 VERIFY TIPS DOWN EVERY NN CY NN TIMES FUN81 SLOW CYLINDER TEST EVERY NN CY NN TIMES FUN82 LINEAR STEPPER NN ASSIGNED 0 OFF FUN83 SUREWELD STEPPER NN ASSIGNED 0 OFF FUN84 WINDOW HI NN LO NN C FACTOR NNN FUN85 WAIT FOR NO INITIATE IF FAU...

Page 138: ...T NN I FUN24 PRE WELD NN CYC IMP AT NN I FUN25 WELD NN CYCLES AT NN N I FUN26 WELD NN HALF CYCLES AT NN N I FUN27 FUN28 FUN29 FUN30 WELD NN CYC IMP AT NNNN0 AMPS FUN31 TEMPER NN CYC IMP AT NNNN0 AMPS FUN32 PREHEAT NN CYC IMP AT NNNN0 AMPS FUN33 POSTHEAT NN CYC IMP AT NNNN0 AMPS FUN34 PRE WELD NN CYC IMP AT NNNN0 AMPS FUN35 FUN36 WELD NN HALF CYCLES NNNN0 AMPS FUN37 FUN38 FUN39 TEST FIRE NN I FUN40...

Page 139: ...D UNTIL NO INITIATE FUN76 SEC CURR LIMITS HI NNNN0 LOW NNNN0 FUN77 ISOLATION CONTACTOR DELAY NN SEC FUN78 PROCESS WELD FAULTS FUN79 WAIT NNN CY FOR SYSTEM COOLING FUN80 VERIFY TIPS DOWN EVERY NN CY NN TIMES FUN81 SLOW CYLINDER TEST EVERY NN CY NN TIMES FUN82 LINEAR STEPPER NN ASSIGNED 0 OFF FUN83 FUN84 WINDOW HI NN LO NN C FACTOR NNN FUN85 WAIT FOR NO INITIATE IF FAULT FUN86 TIP DRESS ADVANCE GROU...

Page 140: ...NN I FUN24 PRE WELD NN CYC IMP AT NN I FUN25 WELD NN CYCLES AT NN N I FUN26 WELD NN HALF CYCLES AT NN N I FUN27 FUN28 FUN29 FUN30 WELD NN CYC IMP AT NNNN0 AMPS FUN31 TEMPER NN CYC IMP AT NNNN0 AMPS FUN32 PREHEAT NN CYC IMP AT NNNN0 AMPS FUN33 POSTHEAT NN CYC IMP AT NNNN0 AMPS FUN34 PRE WELD NN CYC IMP AT NNNN0 AMPS FUN35 FUN36 WELD NN HALF CYCLES NNNN0 AMPS FUN37 FUN38 FUN39 TEST FIRE NN I FUN40 S...

Page 141: ...TE FUN76 SEC CURR LIMITS HI NNNN0 LOW NNNN0 FUN77 ISOLATION CONTACTOR DELAY NN SEC FUN78 PROCESS WELD FAULTS FUN79 WAIT NNN CY FOR SYSTEM COOLING FUN80 VERIFY TIPS DOWN EVERY NN CY NN TIMES FUN81 SLOW CYLINDER TEST EVERY NN CY NN TIMES FUN82 LINEAR STEPPER NN ASSIGNED 0 OFF FUN83 SUREWELD STEPPER NN ASSIGNED 0 OFF FUN84 WINDOW HI NN LO NN C FACTOR NNN FUN85 WAIT FOR NO INITIATE IF FAULT FUN86 TIP ...

Page 142: ...IF ANALOG INPUT N NOT IN WINDOW FUN14 EXTEND UNTIL N IN WINDOW OR NN TIMES FUN15 READ ANALOG N CALIBRATION ZERO POINT FUN16 WAIT FOR ANALOG N FUN17 WAIT FOR ANALOG N IN WINDOW OR NN CY FUN18 SET ANALOG OUTPUT N TO NNNN E N FUN19 READ ANALOG N RELATIVE ZERO POINT FUN20 WELD NN CYC IMP AT NN I FUN21 TEMPER NN CYC IMP AT NN I FUN22 PREHEAT NN CYC IMP AT NN I FUN23 POSTHEAT NN CYC IMP AT NN I FUN24 PR...

Page 143: ... N IS 0 OFF 1 ON FUN68 WAIT NNN CY FOR PRESSURE SWITCH INPUT FUN69 WAIT FOR PRESSURE SWITCH INPUT FUN70 WAIT NNN CY FOR WELD PROCEED INPUT FUN71 WAIT FOR WELD PROCEED INPUT FUN72 OUTPUT 1 ON DELAY FUN73 OUTPUT 1 OFF DELAY FUN74 WELD NNN IMP NN I HIGH NN I LOW FUN75 EXTEND UNTIL NO INITIATE FUN76 SEC CURR LIMITS HI NNNN0 LOW NNNN0 FUN77 ISOLATION CONTACTOR DELAY NN SECONDS FUN78 PROCESS WELD FAULTS...

Page 144: ...T FOR FORCE NNN FUN16 EXTEND NN TIMES UNTIL DISPL NNN FUN17 EXTEND NN TIMES UNTIL DISPL NNN FUN18 WAIT FOR DISPL NNN FUN19 WAIT FOR DISPL NNN FUN20 WELD NN CYC IMP AT NN I FUN21 TEMPER NN CYC IMP AT NN I FUN22 PREHEAT NN CYC IMP AT NN I FUN23 POSTHEAT NN CYC IMP AT NN I FUN24 PRE WELD NN CYC IMP AT NN I FUN25 WELD NN CYC IMP AT NN N I FUN26 WELD NN HALF CYCLES AT NN N I FUN27 FUN28 FUN29 FUN30 WEL...

Page 145: ...CEED INPUT FUN71 WAIT FOR WELD PROCEED INPUT FUN72 OUTPUT N ON DELAY NNNN HALF CYCLES FUN73 OUTPUT N OFF DELAY NNNN HALF CYCLES FUN74 WELD NNN IMP NN I HIGH NN I LOW FUN75 EXTEND UNTIL NO INITIATE FUN76 SEC CURR LIMITS HI NNNN0 LOW NNNN0 FUN77 ISOLATION CONTACTOR DELAY NN SEC FUN78 PROCESS WELD FAULTS FUN79 WAIT NNN CYCLES FOR SYSTEM COOLING FUN80 TURN ON CONTACTOR SELECT N FUN81 TURN OFF CONTACTO...

Page 146: ...N CYC FUN17 TURN ON INTENSIFY VALVE SQZ NN CY FUN18 TURN OFF INTENSIFY ADV VALVE N FUN19 TURN OFF INT ADV VALVE N OPEN NNN HALF CYCLES FUN20 WELD NN CYC IMP NN I FUN21 TEMPER NN CYC IMP NN I FUN22 PREHEAT NN CYC IMP NN I FUN23 POSTHEAT NN CYC IMP NN I FUN24 PRE WELD NN CYC IMP NN I FUN25 WELD NN CYC IMP NN N I FUN26 WELD NN HALF CYCLES NN N I FUN27 FUN28 FUN29 FUN30 WELD NN CYC IMP NNNN0 AMPS FUN3...

Page 147: ...N CY FOR WELD PROCEED INPUT FUN71 WAIT FOR WELD PROCEED INPUT FUN72 OUTPUT N ON DELAY NNNN HALF CYCLES FUN73 OUTPUT N OFF DELAY NNNN HALF CYCLES FUN74 WELD NNN IMP NN I HIGH NN I LOW FUN75 EXTEND UNTIL NO INITIATE FUN76 SEC CURR LIMITS HI NNNN0 LOW NNNN0 FUN77 ISOLATION CONTACTOR DELAY NN SEC FUN78 PROCESS WELD FAULTS FUN79 WAIT NNN CYCLES FOR SYSTEM COOLING FUN80 FUN81 FUN82 LINEAR STEPPER N ASSI...

Page 148: ...N15 FUN16 FUN17 FUN18 FUN19 FUN20 WELD NN CYC IMP AT NN I FUN21 TEMPER NN CYC IMP AT NN I FUN22 PREHEAT NN CYC IMP AT NN I FUN23 POSTHEAT NN CYC IMP AT NN I FUN24 PRE WELD NN CYC IMP AT NN I FUN25 WELD NN CYC IMP AT NN N I FUN26 FUN27 FUN28 FUN29 FUN30 WELD NN CYC IMP AT NNNN0 AMPS FUN31 TEMPER NN CYC IMP AT NNNN0 AMPS FUN32 PREHEAT NN CYC IMP AT NNNN0 AMPS FUN33 POSTHEAT NN CYC IMP AT NNNN0 AMPS ...

Page 149: ...E N 0 OFF 1 ON FUN67 WAIT FOR INPUT N TO BE N 0 OFF 1 ON FUN68 WAIT NNN CY FOR PRESSURE SWITCH INPUT FUN69 WAIT FOR PRESSURE SWITCH INPUT FUN70 FUN71 FUN72 FUN73 FUN74 FUN75 EXTEND UNTIL NO INITIATE FUN76 SEC CURR LIMITS HI NNNN0 LOW NNNN0 FUN77 EXTEND WHILE INPUT N IS N 0 OFF 1 ON FUN78 FUN79 FUN80 FUN81 TRANSFORMER TURNS RATIO NNN 1 FUN82 LINEAR STEPPER NN ASSIGNED 0 OFF FUN83 FUN84 FUN85 PROCES...

Page 150: ... NN LO NN C FACTOR NNN FUN18 SEC CURR LIMITS HI NNNNN LOW NNNNN FUN19 C FACTOR LIMIT HI NNNN LO NNNN FUN20 WELD NNN CYC IMP AT NN N I FUN21 TEMPER NNN CYC IMP AT NN N I FUN22 PREHEAT NNN CYC IMP AT NN N I FUN23 WELD FIRST SPOT AT NN N I FUN24 WELD NNN IMPULSES AT NN I HIGH NN I LOW FUN25 FUN26 FUN27 FUN28 FUN29 FUN30 WELD NN CYC IMP AT NNNNN AMPS FUN31 TEMPER NN CYC IMP AT NNNNN AMPS FUN32 PREHEAT...

Page 151: ... UNTIL NO INITIATE FUN70 EXTEND WHILE INPUT N IS N 0 OFF 1 ON FUN71 TURN ON WELD VALVE HIGH PRESSURE FUN72 TURN OFF WELD VALVE HIGH PRESSURE FUN73 TURN ON WELD VALVE LOW PRESSURE FUN74 TURN OFF WELD VALVE LOW PRESSURE FUN75 TURN ON FORGE VALVE FUN76 TURN OFF FORGE VALVE FUN77 FORGE DELAY NNNN HALF CYCLES FUN78 FORGE NNN HALF CYCLES FUN79 TURN ON PRECOMPRESSION VALVE FUN80 TURN OFF PRECOMPRESSION V...

Page 152: ...Weld Schedules MedWeld 4000 Operator s Guide Modified 9 17 08 4 53 M 032116 Programs T03300 T02300 and T02400 This page is intentionally left blank ...

Page 153: ...Weld Schedules 4 54 Modified 9 17 08 MedWeld 4000 Operator s Guide M 032116 Programs T03300 T02300 and T02400 ...

Page 154: ...utput 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 5 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 neither output is activat...

Page 155: ...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 4000 expects the INITIATE WELD input to remain active while executing the weld schedule If this input is not active when the weld control executes th...

Page 156: ...ncy cycles when it terminates the weld prematurely due to a HARD OVERCURRENT fault SCR MISFIRE T03300 only 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 arcing occurs during the weld functions TIPS NOT TOUCHING T03300 only FAULT TIPS TOUCHING T03300 only FAULT These two conditi...

Page 157: ...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 not within the range specified in this function this condition is generated POWER FACTOR LIMIT T03300 only FAULT ALERT This condition is generated when the power factor detected while executing ...

Page 158: ...he control schedules in No Weld and generates this fault condition If the control is in No Weld mode it does not generate a fault CURRENT COMPENSATION LIMIT FAULT ALERT T03300 only NONE The secondary current provided to a weld is monitored each cycle during an ACC weld function to provide the desired current to a weld If necessary the control adjusts the current provided based on the current read ...

Page 159: ... COOLING FAULT This fault is generated if the control receives a valid weld initiate and the TRANSFORMER OVER TEMPERATURE SYSTEM COOLING input is not active This fault is also generated if the SCR thermal switch is tripped HEAT CYCLE LIMIT FAULT This fault is generated when the control detects that the number of consecutive weld cycles where conduction occurred exceeded the limit programmed in the...

Page 160: ...urs major system bus faults are suspect If the weld processor moves out of Run Mode while the control is executing a schedule RIO COMM ERROR NOT IN RUN MODE T03300 only FAULT This fault occurs If the host connected to the RIO link moves out of Run Mode or The link encounters a fatal communication error while the control is executing a schedule In either case this fault is flagged regardless of the...

Page 161: ...ol 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 INVERTER SERIAL COMM ERROR T02300 only FAULT ALERT This condition is generated when the weld processor detects a loss of communications with the inverter over the MedLAN cable INITIATION ON POWER UP FAULT This fault is set if initiates are present on...

Page 162: ...nal valve pressure programmed by functions 08 13 or 14 was not achieved within the number of cycles programmed in Function 09 WAIT nn CY FOR PRESSURE ACHIEVED If the sequence contains more than one valve pressure setting the processor will only monitor the last pressure function contained in the sequence This parameter is permanently set to the FAULT condition You CANNOT program it The following t...

Page 163: ...vent damage caused by firing at too great a phase angle on the first cycle of a weld or impulse AC regulates on the current that is actually read DC uses a special algorithm to approximate the current CURRENT LIMIT MODE T03300 Only 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 c...

Page 164: ...or test purposes only Disabling the short detection features can cause catastrophic failure and dangerous operating conditions ALWAYS set this parameter to ENABLED under normal operating conditions RETRACT MODE LATCHED UNLATCHED This parameter tells the control how to react when it receives the RETRACT input UNLATCHED tells the control to let the RETRACT output follow the state of the RETRACT inpu...

Page 165: ...wer factor If the power factor exceeds or falls below these limits a HIGH or LOW POWER FACTOR LIMIT fault is generated 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 NOTE The function POWER FACTOR LIMIT HI NN LOW NN will override the High and Low Power Factor Limit...

Page 166: ...ropping in and out between welds When the ISOLATION CONTACTOR SAVER input is available and set LOW it disables this delay timer NOTE The function ISO CONTACTOR DELAY can be inserted into the weld schedule If written in the weld schedule the function will override this setup parameter but only applies for that particular weld schedule and when in sequence If not programmed into a weld schedule all ...

Page 167: ...s The sample size is the amount of weld data collected for analysis number of consecutive welds per bin The sample frequency is the total number of welds per bin where data is collected the samples are taken from See SPC Indexing Capabilities on page 7 8 for more information TIPS DOWN VERIFIED CURRENT nnnn T03300 0nly 0 9999 This is the value of current that is used as the threshold when the contr...

Page 168: ...meter to establish a reference point for determining the compensation required for line voltage fluctuations when welding in the I firing mode NOMINAL C FACTOR nnn T03300 only 0 999 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 4000 You can program the ...

Page 169: ...rent sensing coils of different sensitivities Setting this parameter to 1000 will result in accurate secondary current readings for coils of 0 477 μHy mutual inductance 150 mV kA 50 Hz or 180 mV kA 60 Hz Setting this parameter above 1 000 will increase the reading Setting below 1 000 will decrease the reading NOTE Sec Curr Coil Factor is only supported when a secondary current interface board SCIB...

Page 170: ...provide sufficient line voltage in the constant primary voltage firing mode The Firing Mode setup parameter is set to PRI VOLTAGE SOFT OVERCURRENT FAULT ALERT The inverter generates this condition when it detects that The current draw was greater than the rated primary current limit programmed in the Maximum Primary Current setup parameter AND At least two but no more than six mid frequency half c...

Page 171: ...rter s maximum safe operating range for two consecutive mid frequency cycles INVERTER BUS FAULT This fault is generated when the inverter detects that the DC bus voltage dropped by more than 40 of the value measured at the start of weld time On detecting this condition the inverter immediately disregards firing signals from the weld processor The inverter then executes the error shut down procedur...

Page 172: ...e chill plate itself exceeded the recommended temperature OUTPUT GROUND FAULT This fault indicates a current imbalance between the two output terminals of the regulator HARD OVERCURRENT FAULT This fault is generated when the inverter detects a current of up to 10 times the rating of at least one IGBT transistor DRIVER LOW VOLTAGE FAULT This inverter generates this condition on detecting a low volt...

Page 173: ...electrode caps must be changed This sets the starting value for the Tip Dresses Remaining counter Each time it receives the TIPS DRESSED input the control decreases the Tips Dresses Remaining counter by one When the maximum number of tip dresses remaining is zero the control activates the CAP CHANGE REQUEST output This indicates that the tips require maintenance Setting this parameter to zero disa...

Page 174: ...the welding control to set the expected facility power when installed at a location This parameter along with the line voltage measurement is used by the welding control to establish a reference point for determining the compensation required for line voltage fluctuations when welding in the I firing mode The value of the nominal line voltage also helps to normalize voltage based calculations for ...

Page 175: ...ACTOR LIMIT ALERT VOLTAGE 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 ...

Page 176: ...ESSURE 50 PSI VALVE 2 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 TI...

Page 177: ...GE ALERT POWER FACTOR LIMIT ALERT VOLTAGE COMPENSATION LIMIT ALERT INSUFFICIENT LINE VOLTAGE ALERT EXTENDED WELD FAULT ISO CNTR OFF WHEN NEEDED FAULT CURRENT REGULATION 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 WELD ...

Page 178: ...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 SEC CURR COIL FACTOR X1000 1000 GUN 1 CLOSE TO PRE BLOCK POS CY 2 000 GUN 1 ADVANCE STOP TIME POS CY 2 000 GUN 1 OPEN FROM BLOCK POS CY 2 000 GUN 1 CLOSE ...

Page 179: ...P F OUT OF RANGE ALERT POWER FACTOR LIMIT ALERT VOLTAGE COMPENSATION LIMIT ALERT INSUFFICIENT LINE VOLTAGE ALERT EXTENDED WELD FAULT ISO CNTR OFF WHEN NEEDED FAULT CURRENT REGULATION 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 FAUL...

Page 180: ...0 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 MAXIMUM TIP DRESSES 50 TIPS DOWN VERIFIED CURRENT 10 AMPS TRANSFORMER TURNS RATIO 100 1 NOMINAL LINE VOLTAGE 468 VOLTS NOMINAL C FACTOR 999 ...

Page 181: ...P F OUT OF RANGE ALERT POWER FACTOR LIMIT ALERT VOLTAGE COMPENSATION LIMIT ALERT INSUFFICIENT LINE VOLTAGE ALERT EXTENDED WELD FAULT ISO CNTR OFF WHEN NEEDED FAULT CURRENT REGULATION 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 FAUL...

Page 182: ...0 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 MAXIMUM TIP DRESSES 50 TIPS DOWN VERIFIED CURRENT 10 AMPS TRANSFORMER TURNS RATIO 100 1 NOMINAL LINE VOLTAGE 468 VOLTS NOMINAL C FACTOR 999 ...

Page 183: ... 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 FAULT WELD PROCEED FAULT PRESSURE SWITCH FAULT RETRACT PILOT FAULT ISO CONTACTOR NOT ENABLED FAULT CONTROL IN NO WELD ALERT INVERTER SERIAL COMM ERROR FAULT INITIATION ON POWER UP FAULT CONTACTOR SHORT FAULT ANALOG NOT WITHI...

Page 184: ...E LIMIT 0 SEAM 60 ISOLATION CONTACTOR DELAY SEC 10 HIGH CURRENT LIMIT WINDOW 20 LOW CURRENT LIMIT WINDOW 20 DATA COLLECTION SAMPLE SIZE 05 DATA COLLECTION SAMPLE FREQUENCY 0100 TRANSFORMER TURNS RATIO 1 073 MAXIMUM TIP DRESSES 000 TRANSFORMER TYPE NONE FIRING MODE PRI CURRENT NOMINAL LINE VOLTAGE 468 SEC SENSOR mV PER 1000A 150 SEC SENSOR FREQUENCY 050 OPERATING HIGH FREQUENCY 1200 MAXIMUM FLUX 02...

Page 185: ...ERT HIGH C FACTOR LIMIT ALERT LOW C FACTOR LIMIT ALERT SYSTEM COOLING FAULT HEAT CYCLE LIMIT FAULT WELD INTERRUPTION FAULT I O FAULT WELD PROCEED FAULT PRESSURE SWITCH FAULT RETRACT PILOT FAULT ISO CONTACTOR NOT ENABLED FAULT CONTROL IN NO WELD ALERT INVERTER SERIAL COMM ERROR FAULT INITIATION ON POWER UP FAULT CONTACTOR SHORT FAULT PRESSURE NOT ACHIEVED FAULT LOW POWER LINE ALERT SOFT OVERCURRENT...

Page 186: ... TIP DRESSES 000 MAXIMUM LINE PRESSURE PSI 100 STATIC ANALOG 1 OUT VALVE PSI 100 STATIC ANALOG 1 OUT VALVE PSI 100 TRANSFORMER TYPE NONE FIRING MODE PRI CURRENT MAXIMUM PRIMARY CURRENT 0400 TYPE 2 NADEX INV W T ON PRIMARY CURRENT ENABLE PULSE WIDTH LIMIT 99 MILLISECOND ON TIME 0 MILLISECOND OFF TIME 0 NOMINAL LINE VOLTAGE 468 SEC SENSOR MV PER 1000A 150 SEC SENSOR FREQUENCY 050 OPERATING HIGH FREQ...

Page 187: ...TTERY ALERT HIGH C FACTOR LIMIT ALERT LOW C FACTOR LIMIT ALERT SYSTEM COOLING FAULT HEAT CYCLE LIMIT FAULT WELD INTERRUPTION FAULT I O FAULT WELD PROCEED FAULT PRESSURE SWITCH FAULT RETRACT PILOT FAULT ISO CONTACTOR NOT ENABLED FAULT CONTROL IN NO WELD ALERT INVERTER SERIAL COMM ERROR FAULT INITIATION ON POWER UP FAULT CONTACTOR SHORT FAULT PRESSURE NOT ACHIEVED FAULT LOW POWER LINE ALERT SOFT OVE...

Page 188: ...ALOG 1 OUT VALVE PSI 100 STATIC ANALOG 1 OUT VALVE PSI 100 GUN 1 CLOSE TO PRE BLOCK POS 20 CY 2 GUN 1 ADVANCE STOP TIME 20 CY 2 GUN 1 OPEN FROM BLOCK POS 20 CY 2 GUN 1 OPEN TO BLOCK POS 20 CY 2 GUN 2 CLOSE TO PRE BLOCK POS 20 CY 2 GUN 2 ADVANCE STOP TIME 20 CY 2 GUN 2 OPEN FROM BLOCK POS 20 CY 2 GUN 2 OPEN TO BLOCK POS 20 CY 2 TRANSFORMER TYPE NONE FIRING MODE PRI CURRENT MAXIMUM PRIMARY CURRENT 0...

Page 189: ...RT HIGH C FACTOR LIMIT ALERT LOW C FACTOR LIMIT ALERT SYSTEM COOLING FAULT HEAT CYCLE LIMIT FAULT WELD INTERRUPTION FAULT I O FAULT ISO CONTACTOR NOT ENABLED FAULT CONTROL IN NO WELD ALERT INVERTER SERIAL COMM ERROR FAULT INITIATION ON POWER UP FAULT PRESSURE SWITCH ALERT LOW POWER LINE ALERT SOFT OVERCURRENT ALERT CURRENT REGULATION ALERT SEC CURRENT SENSOR ALERT WELDING TRANSFORMER FAULT DC BUS ...

Page 190: ...RMER TYPE NONE FIRING MODE PRI CURRENT MAXIMUM PRIMARY CURRENT 0400 TYPE 2 NADEX INV W T ON PRIMARY CURRENT ENABLE PULSE WIDTH LIMIT 99 MILLISECOND ON TIME 0 MILLISECOND OFF TIME 0 NOMINAL LINE VOLTAGE 468 SEC SENSOR MV PER 1000A 150 SEC SENSOR FREQUENCY 050 OPERATING HIGH FREQUENCY 1200 MAXIMUM FLUX 0200 MAXIMUM PRIMARY CURRENT 0300 TYPE 1 MEDAR INV SOFT OVERCURRENT LIMIT 400A TRANSFORMER TURNS R...

Page 191: ...BATTERY ALERT HIGH C FACTOR LIMIT ALERT LOW C FACTOR LIMIT ALERT SYSTEM COOLING FAULT HEAT CYCLE LIMIT FAULT WELD INTERRUPTION FAULT I O FAULT STAGE 2 WELD PROCEED FAULT PRESSURE SWITCH FAULT RETRACT PILOT FAULT ISO CONTACTOR NOT ENABLED FAULT CONTROL IN NO WELD ALERT INVERTER SERIAL COMM ERROR FAULT INITIATION ON POWER UP FAULT CONTACTOR SHORT FAULT ANALOG NOT WITHIN WINDOW FAULT PRESSURE NOT AVA...

Page 192: ...0 MAXIMUM TIP DRESSES 000 MAXIMUM LINE PRESSURE PSI 100 STATIC ANALOG 1 OUT VALVE PSI 100 STATIC ANALOG 1 OUT VALVE PSI 100 TRANSFORMER TYPE NONE FIRING MODE PRI CURRENT NOMINAL LINE VOLTAGE 468 SEC SENSOR MV PER 1000A 150 SEC SENSOR FREQUENCY 050 OPERATING HIGH FREQUENCY 1200 MAXIMUM FLUX 0200 MAXIMUM PRIMARY CURRENT 0400 SOFT OVERCURRENT LIMIT 400A TRANSFORMER TURNS RATIO 1 073 HEAD GRAVITIONAL ...

Page 193: ...Setup Parameters 5 40 Modified 9 17 08 MedWeld 4000 Operator s Guide M 032116 Programs T03300 T02300 and T02400 This page is intentionally left blank ...

Page 194: ...nction 82 It assigns a stepper number to each linear stepper in the weld schedule You can program up to 99 linear steppers The following sections describe linear steppers along with directions on how to program them You can assign a stepper to a group This capability allows for incrementing the stepper when the control executes any weld schedule assigned to that group You can also advance or reset...

Page 195: ...t the stepper for every schedule in the group every time the gun is fired When the control completes the last weld in the last step the electrode tips must be dressed and the stepper reset To use the linear stepper you must include Function 82 as the first function in the weld schedule NOTE The stepper is not active during every weld function it is incremented only when you execute the following f...

Page 196: ...ent step From the Stepper Status display Press to see a different stepper Press to advance 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 When you press you see the stepper reset option at or Press a second time and you will see a display showing th...

Page 197: ...Stepper Data 6 4 Modified 9 17 08 MedWeld 4000 Operator s Guide M 032116 Programs T03300 T02300 and T02400 This page is intentionally left blank ...

Page 198: ...l indicate changes in the welding environment The actual C Factor is calculated by the MedWeld 4000 after every weld The programming device displays this value in the Weld Data display The processor calculates C Factor is by dividing the average secondary current during the weld by the I fired The following formula shows this where n transformer turns ratio The C Factor varies with changing condit...

Page 199: ...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 Example of Increasing C Factor In this example a robot uses...

Page 200: ...er 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 Low C Factor Limit The low C factor limit detects cable and connection deterioration Determining a Low Limit Suppose a weld schedule requires 14 000 A at the end of a stepper program However you do not want to ...

Page 201: ...w nominal C Factor Refer to the discussion of C Factor on page 7 1 The target current is determined by the firing mode used by the weld function I or automatic current compensation This calculation is shown below AVC Target current I programmed in Function 20 stepper boost x C Factor ACC Target current A programmed in Function 30 stepper boost Calculate the high and low current limits using this e...

Page 202: ...Firing Mode In this firing mode the target value is established by the following calculation Target current A in Function 30 Stepper boost An 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 ...

Page 203: ...voltage but high enough so that the current detected when tips are down exceeds the Tips Down Verified Current setup parameter NOTES 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 function...

Page 204: ...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 programmed the control generates a TIPS NOT TOUCHING fault and sequences in No Weld 81 SLOW CYLINDER TEST EVERY nn CY nn TIM...

Page 205: ...number for SPC indexing Here is an 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 es...

Page 206: ...mal production run It is intended for special situations such as tear down which require continuous data collection SPC Setup Parameters 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 a...

Page 207: ...e across the SCRs when the control 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 D...

Page 208: ...he primary current is less than 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 eithe...

Page 209: ... is affected by certain functions and programmable setup parameters which control the operation of Retract Mode Initiate from Retract Cylinder Type WARNING For safety the MedWeld 4000 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 Retract Mode The Retract Mode setup parameter determines how ...

Page 210: ... C Stop condition the CONTROL STOP input is LOW Cylinder Type This parameter defines the type of gun cylinder the control application is using This parameter defines the retract operation as shown below Air Only Cylinders For 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 A spring or a second r...

Page 211: ...ntensify valve adds welding pressure to the gun The Blocking valve can either allow oil to flow or inhibit oil flow Since this valve can be used to inhibit the flow of oil at any point in the gun stroke it allows for a variable gun opening NOTE Selecting AIR ONLY in the Cylinder Type setup parameter disables these valves These outputs control the Advance Intensify and Blocking valves They do NOT t...

Page 212: ...e gun to move from the full retract to the full closed position as shown below This allows the control to fire a weld schedule from the full retract position This setup parameter is added to the time programmed in the function TURN ON ADVANCE VALVE n in the weld sequence Caution This timer controls the gun s position BEFORE the Intensify valve is turned on If this timer is set too low the gun may ...

Page 213: ... length of time If the control does not start from the full open position each time the partial retract opening may vary in size A heavy gun will have difficulty maintaining a constant partial retract position as the gun s orientation changes The heavier the gun the more difficulty in maintaining a constant opening size in vertical versus horizontal orientations BLOCKING VALVE n DELAY CY 2 See pag...

Page 214: ... Initiation From Retract on page 7 21 The Blocking valve is dis engaged based on the Cylinder Type setup parameter Normally Open or Normally Closed The Advance valve will be energized for the length of time specified in the Partial Retract n Delay setup parameter illustrated above Then the Blocking valve is re energized This allows the gun to move from the full retract to the partial retract posit...

Page 215: ...FUNCTION 17 TURN ON ADVANCE VALVE 1 SQZ 20 CY 18 TURN ON INTENSIFY VALVE SQZ 10 CY 20 WELD 10 CYCLES 50 I 78 PROCESS WELD FAULTS 03 HOLD 05 CYCLES 19 TURN OFF INTENSIFY ADV VALVE 1 04 OFF 10 CYCLES 82 LINEAR STEPPER 00 ASSIGNED 0 OFF 80 VERIFY CYLINDER n IS OUT OF RETRACT 62 REPEAT AT NEXT FUNCTION 15 TURN ON ADVANCE VALVE 1 SQX 20 CY 16 TURN ON INTENSIFY VALVE SQZ 10 CY 01 SQUEEZE 00 CYCLES 24 PR...

Page 216: ...ain this function the control lets you execute a sequence with the gun in the full retract position If firing the control from full retract the Extend Sqz From Retract CY 2 setup parameter is added to the time the gun is closed under only hydraulic pressure NOTE These functions are enabled ONLY when setting the Cylinder Type setup parameter to AIR OVER OIL The outputs controlling the Advance Inten...

Page 217: ...t programmed by setup parameter Extend Sqz plus TURN ON ADVANCE VALVE function T2 time control closes gun under air welding pressure Programmed by functions TURN ON INTENSIFY VALVE plus WELD time plus HOLD time t3 time control opens gun If from partial retract Blocking Valve n Delay setup parameter If from full retract Blocking Valve n Delay plus Extend Sqz setup parameters Normally Open NO Blocki...

Page 218: ...n the control will allow you to execute a sequence with the gun in the full retract position When the control is fired from full retract the Extend Sqz From Retract CY 2 setup parameter is added to the time the gun is closed under only hydraulic pressure DEP 100S Programming Restrictions Software version T 96300 13 or greater has features that modify operation of the DEP 100S Data Entry Panel Thes...

Page 219: ...ent being delivered during the first MFDC half cycle It is during this half cycle that the inductance of the transformer is overcome If setting the FIRING MODE to PRI CURRENT or FIRING MODE to PRI VOLTAGE in the setup parameters the secondary current shown will be the primary current multiplied by the turns ratio set in the XFMR Turns Ratio setup parameter If setting the FIRING MODE to SEC CURRENT...

Page 220: ...alue to determine if the inverter can deliver more voltage or current if necessary If the on time is less than 406 μsec the inverter can deliver more voltage or current If the on time is 406 μsec and more voltage or current is required the application must be modified to use a transformer with a higher turns ratio or a larger inverter I The percent current provided during the last weld This value ...

Page 221: ...ip Dress functionality However this version of the software also inhibits the ability to turn the stepper on or off However you can advance or reset the stepper Refer to Displays at the DEP 100S on page 7 3 NOTE The SureWeld stepper is not available in controls equipped with the MFDC inverter sch nn The last schedule initiated by the selected WCU schedule nn WCU nn The selected weld control addres...

Page 222: ...e more 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 NOTES on MFDC Faults The MFDC inverter provides fault detection and generates additional fault conditions The inverter uploads fault conditions to the weld processor after each weld sequence Refer to the MFDC Technical Reference Man...

Page 223: ...NCE SELECTED 8 3 INVERTER MAIN IC OFF WHEN NEEDED 8 7 INVERTER SERIAL COMM ERROR 8 9 ISO CONTACTOR OFF WHEN NEEDED 8 12 ISOLATION CONTACTOR NOT ENABLED 8 14 I O UPDATE 8 13 LOW BATTERY 8 12 LOW C FACTOR 8 13 LOW CURRENT LIMIT 8 6 NO ZERO CROSSING SYNC 8 8 POWER FACTOR LIMIT 8 10 PRESSURE SWITCH ERROR 8 14 RETRACT PILOT ERROR 8 14 SCR MISFIRE 8 9 SLOW CYLINDER 8 10 STEPPER APPROACHING MAX 8 4 SURE ...

Page 224: ...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 Incorrect or loose wiring at the input module Check the wiring diagram for proper I O designations Verify that all wiring connections are secure We...

Page 225: ...heck the wiring to verify that 24 VDC or 120 VAC is being provided to the CONTROL STOP input The operator or ladder logic removed the CONTROL STOP input Check and correct the cause Stepper Approaching Maximum See p 5 2 The linear stepper assigned to the schedule initiated has started the first weld in the last step The electrodes will soon need maintenance Dress or replace the electrodes to avoid ...

Page 226: ...nsate and possibly generate a HIGH CURRENT LIMIT fault With a pressure gauge verify that constant pressure is being maintained Check for things affecting pressure such as hoses binding in the weld gun tooling faulty or sticky solenoid valves or slow moving cylin ders Incorrect measurement of the primary current Since both the weld processor and the firing card are involved in cur rent measurement ...

Page 227: ...as necessary Control Failed to Fire The MFDC inverter assembly failed to fire for a half cycle Faulty firing cable The inverter did not receive the fir ing signal Check the firing cable connec tor Verify that it is secure Inverter fault occurred during the weld preventing it from firing for the half cycle Review the inverter fault condi tion and act accordingly Extend Weld See p 5 5 The control ha...

Page 228: ...he 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 and replace as necessary The solid state relay is faulty Replace relay The instruction to activate the isolation contactor was exe cuted but the control was un...

Page 229: ...g weld bus Re distribute the weld bus load Brown out of power source Correct power delivery problem System Cooling See p 5 6 TRANSFORMER OVER TEMPERA TURE input was not active when required by the control or the SCR thermal switch was tripped Defective SCR thermostat Replace thermostat Customer supplied device did not activate the TRANS FORMER OVER TEMPERA TURE input when required Check device Loo...

Page 230: ...ver the MedLAN cable Faulty MedLAN cable and or connectors Check the MedLAN cable to verify communications SCR Misfire See p 5 3 The processor detected conduction on one half cycle without conduction on the next half cycle Faulty wiring For example if the gate and cathode wires are swapped Check all wiring connections Verify that they are secure and correct Insufficient squeeze time in the weld sc...

Page 231: ...ule timing and 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 assemb...

Page 232: ... too high or low current for the 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 cur rent boost over the thresh old Adjust the stepper boost Insufficient Line Voltage See p 5 4 The weld initiate was removed or time expired while the control was waiting for the programmed line v...

Page 233: ...powered controls an internal control transformer fuse is blown Check fuses Replace as necessary The solid state relay is faulty Replace solid state relay The instruction to activate the isolation contactor was exe cuted but the control was unable to pull in the contactor due to incorrect or loose wir ing to the output module Check the wiring diagram that came with your control for proper I O desig...

Page 234: ...cuting a weld schedule Robot or ladder logic de activated the WELD NO WELD Input Check robot or 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 Incorrect or loose wiring to the input module Check for proper I O designa tions Verify that all wiring connections are secure Faulty input module Replace ...

Page 235: ... 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 input module Faulty weld processor card Replace weld processor Weld Current Shunting See p 5 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 configura...

Page 236: ...fault generated Inverter processor failure Replace inverter DEP 100S displays NO ZERO CROSS ING Fault Check line voltage on the WELD DATA screen on the DEP 100S display will likely be 0 VDC Fuse blown in bus plug Replace fuse Fuse blown in control Replace fuse Mains voltage loses cycles Use Line Ana lyzer to check bus Insure that all bus connections are tight Insure that bus plugs are connected ti...

Page 237: ...RING Does not light Weld control is in No Weld mode Place weld control in Weld mode Check DEP 100S and switch settings Weld function is not in weld sequence Add weld function to sequence Weld function has 0 cycles programmed Program the number of cycles the weld needs to fire Inverter did not fire Verify weld Check DEP 100S for additional faults MEDLAN COMM LEDs do not blink Bad connection between...

Page 238: ... being generated from the secondary current coil Verify that cable from coil to inverter is not broken Inverter input may be damaged Replace inverter WORKAROUND Set the weld control in primary current control mode Adjust weld current as required generally slightly higher magnetizing current required for primary winding DEP 100S displays SOFT OVERCUR RENT Fault alert Inverter is firing current at t...

Page 239: ...ach the target cur rent DEP 100S on time is always at maximum Tar get heat is too high Increase mains voltage up to 480 VAC Reduce secondary impedance Possibilities Run shunts to gun installed closely together Install shorter shunts if possible Install larger shunts Increase weld transformer secondary voltage Target current reached as inverter begins weld cycle DEP 100S shows average current that ...

Page 240: ...he transformer Transformer hot Water flow rate is too low Transformer hot Water tempera ture is too high Transformer hot Transformer duty cycle current requested is too high Thermal switch failure Replace transformer Inverter processor failure Replace inverter as necessary LINE BUS Fault DEP 100S displays LOW POWER LINE FAULT Inverter could not provide sufficient voltage in Primary Voltage firing ...

Page 241: ... for Primary Cable troubleshooting flowchart Replace cable as necessary Weld transformer is defective See Inverter Technical Reference manual M 034045 for Check Trans former troubleshooting flowchart Primary shorted to ground Replace transformer Primary shorted to secondary Replace transformer The two coils used to check for ground fault are located on inverter out puts H1 and H2 Check the two cab...

Page 242: ...undamaged cable or contact WTC Technical support for connection information NOTE This field repair could slightly affect the inverter s calibration and make the primary current displayed by the control inaccu rate Preferably re calibrate the unit after repair Defective sensors on inverter Replace inverter Defective inverter processor Replace inverter Vdc BUS Fault DEP 100S displays DC BUS OVER VOL...

Page 243: ...ry cable Replace cable Open weld transformer primary cable Replace cable Missing mains line phase Replace blown fuse in bus plug Shorted inverter transistor Replace inverter Transistor driver failure Replace inverter Failure of inverter snubber circuit Replace inverter Bridge rectifier diode SCR failure Replace inverter DEP 100S displays LOW VOLTAGE fault Inverter processor failure Replace inverte...

Page 244: ...and 3 Verify that fuse is not blown Verify that control transformer power supply is operational Charging relay voltage is not present Check pin 4 with oscilloscope Output relay on inverter proces sor failure Replace inverter Broken loose wiring to charging relay coil or Voltage on charging relay coil Replace wiring or tighten connections Charging relay coil failure Replace relay Relay contacts are...

Page 245: ...HARGE fault Failure of inverter discharge resistor circuit Replace inverter as necessary MF600 Failure of inverter processor Replace inverter as necessary MF600 Discharge relay N O contacts are welded closed Replace discharge relay MF600 Solid state relay for mains contactor shorted failure Replace solid state relay LED On Inverter Symptom Probable Cause Corrective Action ...

Page 246: ...0 VAC power at the control transformer Check the control circuit breaker Verify 480 600 VAC is present in incoming lines Verify that operator handle is UP to turn ON the breaker No 24 VDC VAC at the timer assembly Check the fuse on the control transformer s secondary to see if it is blown Replace if necessary Timer assembly is defective Verify that line power is connected to the power supply and t...

Page 247: ...efective power supply Monitor the line power to chassis power for possible transient or shorting Replace power supply Processor not in Run Mode All processor LEDs are functioning normally 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 voltag...

Page 248: ...ne power is not con nected to the power supply Verify that line power is connected to the power supply Improper voltage jumper setting Check the jumper setting to verify that 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 sho...

Page 249: ... you have a network power supply and that external 120 VAC 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 Tw...

Page 250: ...r cables grounded SCR breaking over at low potential or shorted Firing card is faulty Replace firing card Inverter is faulty Replace inverter assembly 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 tr...

Page 251: ...I O module and the input supply voltage to the I O module Check the I O Status Display at the DEP Control is in retract and the setup parameter specifies that initiation is INHIBITED from retract Check the setup parameters Either take the control out of retract before initiating or re program the Initiation from Retract setup parameter After changing the state of the retract setup parameters you m...

Page 252: ...place as necessary 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 e...

Page 253: ...tactor Use the I O Status display on the DEP 100S to verify that the inputs are HIGH 1 The solid state relay is faulty Replace solid state relay If the control 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 wiri...

Page 254: ...uit 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 On the 1 200 A inverter the zero crossing signal comes through the gate board on the SCR pack Tighten loose connect...

Page 255: ...Hardware Troubleshooting 9 10 Modified 9 17 08 MedWeld 4000 Operator s Guide M 032116 Programs T03300 T02300 and T02400 ...

Page 256: ...he learned information might cause incorrect welding current for one or two welds after the change is made Changes to the welding machine that could cause momentary incorrect weld current values are 1 Replacement or redressing of welding electrodes 2 Replacement of secondary cables or flexible shunts 3 Changing the welding transformer tap setting 4 Maintenance or parts replacement on the welding g...

Page 257: ...Application Note Current Compensation 2 ML 010041 Application Note Current Compensation ...

Page 258: ... at a time in succession This is called cascade welding This application note gives some guidelines on setting up and using cascade welding systems with a single phase AC welding control Parallel Cascade Method There are two possible ways to do cascade welding The first and simplest method is to hook up L2 to three welding transformers each attached to a welding gun Then connect the output H of a ...

Page 259: ...on is likely to cause intermittent circuit breaker trips and or poor weld quality 4 Poly pulse or pulsation welding should not be used Failure to follow these guidelines will result in diminished weld quality sticking electrodes increased downtime caused by intermittent circuit breaker trips and may void your warranty Multiple Output Cascade Method Another example of cascade welding is to use a si...

Page 260: ...ld Schedules in Cascade Welds When programming weld schedules for cascade welding it is best to use a separate weld schedule for each weld Separate weld schedules provide a greater degree of control and monitoring on each weld and generally make it easier to achieve good weld quality Production line conditions may not allow time for a separate weld schedule for each weld It may become necessary to...

Page 261: ...Application Note Cascade Welding 4 ML 010041 Application Note Cascade Firing ...

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