Professional Documents
Culture Documents
Revision 02
Modified: 1/31/06
Part No. M-032170
Welding Technology WTC is committed to quality products, service and support. Our service
Corp. (WTC) department maintains an assistance hotline to assist with application or
troubleshooting during normal business hours.
By Phone or Fax: To arrange for field service, call one of these numbers:
The ITS telephone number offers 24-hour service, seven days a week.
Before calling, make a note of any fault conditions, applicable software
and hardware revision numbers. Record the part number of the
enclosure (on the serial tag on the inside or front door of the enclosure).
Also note the sequence of events leading to the problem, and the
drawing numbers of the schematics you received with the enclosure.For
your convenience, fill out the Problem Report Form on page -xv.
Caution:
This symbol denotes when insufficient or lacking
compliance with the instructions may damage
equipment or files.
NOTE: This convention informs the user about special features, or where to find
more information.
Revision History
Safety Dangers
Caution:
When lifting any weight over 20 kg (~45 lb.),
use either a two-man lift or an assisted lift.
Software Updates
Specifications on The specifications for cooling water are subject to change. For the latest
the Web specifications, go to the WTC Web site:
http://www.weldtechcorp.com/documentation/index.html.
ESD Costs! Electrostatic discharge (ESD) can ignite flammable materials and
damage electronic components. Static electricity can attract
contaminants in clean environments or cause products to stick together.
Other costs of ESD-damaged electronic devices are in their replacement
and production down time. Associated costs of repair and rework,
shipping, labor and overhead can be significant. Reducing losses to ESD
and static electricity is an ABSOLUTE NECESSITY.
Observe the following warnings AT ALL TIMES:
Handling or Moving Handle all circuit boards by their edges ONLY. NEVER touch the traces
ESDS Devices or edge pad connectors.
Transport, store and ship ESDS devices and circuit boards in a static
shielding container. An acceptable container is either a static shielding
bag or a static shielding tote. To be effective, either type of container
MUST be closed.
Workstation If diagnostics are required, move the circuit board to an approved ESD
Requirements workstation. A static-safe workstation must include a grounded ESD
mat, wrist strap and cord. The measured static voltage at a workstation
MUST NOT exceed 50 volts.
Copyright
WTC software and publications are copyrighted and all rights are
reserved by WTC. Distribution and sale of software is intended for the
use of the original purchaser, and only for use on a single machine.
Patents
Phone:
Time:
Part #:
Fault code display. When a fault or error occurs, the Product ### displays
a status code. Indicate each code that is displayed:
For specific comments, fill in the Comments for Feedback form below.
Fax it at (248) 477-8897.
Company Address:
Program/Revision #:
Document Number/Name:
Your comments:
Welding with the The MFDC Inverter replaces the silicon-controlled rectifiers (SCR
MFDC Inverter packs) used to provide the high-voltage welding current to the welding
transformer.
The inverter and timer unit replace both the firing card and the thyristors
used in conventional, single-phase welding. The intelligent timer or
regulator/driver allows the inverter to be driven by firing signals from
Timer Unit The timer unit sends a gating signal to the inverter, as required by the
weld schedule. The timer unit will tell the inverter when to pull in the
main power isolator, allowing the inverter to provide welding current.
The timer unit performs all the weld timing functions required to
execute a weld schedule:
Checks input signals (provided through DeviceNet) and reacts to
them accordingly.
Operates the output signals based on the weld schedule.
Sends the gating signals to the inverter as required by the weld
schedule.
Adjusts the firing signal, based on the controls firing mode, to
provide a constant supply despite changes in the welding
environment.
LEDs on the timer unit module indicate control status. These
indicators are described below:
PWR This LED lights to indicate that power is being supplied to the
timer unit and it is functioning normally.
RUN These LEDs light to indicate that the timer unit card has sent
the logic level gating signal to the inverter. These LEDs are
normally off. They should only turn on when current is
provided by the weld schedule.
SEQ These 2 LEDs light to indicate that communication is
occurring on the MedLAN channel.
NS These LEDs light to indicate that communication is taking
place between the data entry panel (DEP) and the timer unit
card.
EN This LED lights when the control is ready to weld. This means
that the control will provide current under these conditions:
No faults exist
The Control Stop Input is not active (off is active)
The control is in Weld Mode
The WCU is synchronized with the welding bus and
The Inverter is ready to weld (the IRTW signal is high).
If the LEDs do not turn on during the weld schedule, the timer unit may
be faulty, or the control may be sequencing in No Weld mode.
Timer LED Indicators The timer unit in your MedWeld 5000 weld control (shown below) has
indicator lights that show the current status of the weld timer. The
diagrams below show the location of the status lights and what
conditions cause the status lights to turn on.
Timer Status Lights The light color, flicker and location indicate the current status of the
weld timer.
Timer Interface to the The interface between the timer unit and the MFDC inverter allows the
Inverter MedWeld 5000 to specify the amount of current to the work piece, allow
the inverter to alert the timer of fault conditions it detects during the
weld, and provides weld data to the timer, which is then displayed on the
DEP.
The inverter responds to the gating signals from the timer unit. The
timer unit tells the inverter when to pull in the main isolation contactor
and receives the signal from the inverter when the inverter is ready to
weld.
Circuit Breaker The control circuit breaker serves to remove power to the welding
control and all of its internal components. Incoming power enters the
control enclosure through the access plates at the top right of the
cabinet. With the weld control connected to the weld bus and the circuit
breaker in the ON position, supply voltage is applied to the input of the
charging pack as 1L1, 1L2 and 1L3.
The size of the circuit will vary, depending on the size of the inverter
and the application the inverter is to be used in. Cabling into the
inverter should be sized to the current rating of the circuit breaker.
Isolation Contactor The isolation contactor is provided electrically after the inverter. This
contactor removes power from the weld transformer using the
ISOLATION CONTACTOR output at the SLC output module.
Charging Pack The charging pack controls when power will be provided to the
inverter's charging capacitors. The charging pack differs between the
different models of inverters. (Refer to the drawings provided with your
control for more complete information.) Once the charging pack
activated, it remains activated until either an inverter fault is generated,
the charge request signal is deactivated.
If the inverter has discharged just before it is requested to close, the
inverter may delay activating the charging pack for up to 20 seconds.
Control Transformer The control transformer receives the supply voltage (480, 415 or 380
VAC at 50 Hz or 60 Hz) from the circuit breaker. It reduces the supply
voltage to the level required for other devices. It has step-down taps for
120 VAC outputs and
Low-voltage (24 VAC) clean power to the electronics power
input of the inverter regulator board.
MFDC Inverter The MFDC inverter assembly consists of a regulator board, the charging
pack, discharge resistors, capacitors and IGBTs (insulated gate bipolar
transistors). The IGBTs control the time that current is allowed to pass
to the welding transformer.
The regulator board receives the gating signal from the timer unit and
translates the signal into target flux or current (depending on firing
mode). The regulator gates the IGBTs and monitors to obtain the target.
The charging pack is described above. The discharge resistors discharge
the capacitors.
The capacitors smooth the VDC bus and provide energy during the
weld.
The IGBTs are electronic switches that control when power is
supplied to the welding transformer.
Inverters have at least one thermal switch that monitors
temperature. The inverter will stop gating if a thermal switch is
tripped.
The inverter provides the outputs to the welding transformer at H1
and H2.
Timer Unit When the MedWeld 5000 timer unit receives a START WELD
command, the timer unit starts executing the selected weld sequence.
When the DC bus voltage stabilizes, the inverter is ready to weld. The
inverter activates the IRTW signal, and the timer unit is capable of
sending gating signals to the inverter. The inverter performs the power
conversion to provide DC current to the welding transformer.
At the end of the weld sequence, the timer unit drops out the isolation
contactor for the weld transformer.
NOTE: If the weld control 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 timer unit indicates any fault conditions detected at the inverter,
either at the data entry panel, or at another MedLAN device connected
to the timer unit. (This can be the WebVIEW.)
Getting Started
Making the Required To install the MedWeld 5000, follow these steps:
Connections 1. Make certain the circuit breaker handle on the enclosure is in the
OFF (down) position before attempting to open the door.
NOTE: Removable plates may be provided to connect cooling water, weld bus
voltage, the welding transformer and to allow for wiring into the I/O.
4. With the welding bus power off, connect the power cables from the
welding bus to the top of the circuit breaker.
5. Provide the connection to the weld transformer. (Refer to the decal
affixed on the enclosure for assistance in connecting the welding
transformer.)
6. Provide the MedLAN connections through the access plate at the
top of the enclosure (if a MedLAN connection is desired or
required). Provide the I/O connections based on the controls
integration scheme.
I/O would be having different I/O in both the discrete I/O map and the
Fieldbus I/O map. If the operator has programmed matching I/O maps
for discrete and Fieldbus I/O, the Fieldbus I/O takes precedance.
Caution:
DO NOT wire into the network while the network
power supply is turned on. This may short the network
or disrupt communications.
Networking takes place over the MedLAN channel. Use a WTC data
entry device DEP-100, or WebView for network communications or to
program a single weld control.
However, for the MedLAN network, you MUST use a DEP-100S
Programming Device to program the MedLAN address for each control
on the network through the programming port.
NOTE: In some configurations, a connector is provided on the door of the
enclosure for convenience in connecting the DEP-100. This port is
internally wired to the timer unit card.
This must be done before you can use MedLAN. If you do not program
a MedLAN address, communication errors may result.
MedLAN and DEP- The network connection requires a WTC Network Power Pack for
100S Connections power to the DEP-100S programming device.
Cable Requirements
WTC recommends using the Belden 9463 cable or equivalent. The
following tables list the cable pinouts.
Caution:
Remove power BEFORE attempting to connect or
disconnect cabling. Exercise care when making the
MedLAN cable connections. If the MedLAN cable
should become connected to the MDP1 and MDP2
power connections, serious damage to communication
components WILL occur.
Cable Routing Wire the MedLAN network ONLY in a daisy-chain method. NEVER
Requirements use stub wiring.
The maximum total length of the MedLAN network cable is 3,000 feet.
Up to 30 weld controls may be connected to a single MedLAN network.
A maximum of one DEP-100S, may be connected to a single MedLAN
network.
Setting the timer The MedWeld 5000 uses MedLAN (WTCs proprietary Local Area
MedLAN Address Network) to create a communications network between devices. After
configuring each control, establishing the MedLAN connection and
powering it up, you must set the MedLAN address for each device
before it can respond to the network.
Caution:
The MedWeld 5000 address is the same as the
DeviceNet node address. If the port address is changed
in the network settings, DeviceNet node address will be
changed to match the port address and vise versa.
Use the WTC DEP-100S to program the MedLAN address for each
individual weld control, through the top (DEP) port of the timer unit.
NOTE: The steps required to set the address are listed below. Refer to the
manual provided with the DEP-100S programming device for more
information on operation.
To set the addresses for each weld control, follow this procedure:
1. Plug the DEP-100S into the DEP port on the timer unit (or the DEP
port on the enclosure door, if provided).
2. Press the key labeled PROGRAM MODE on the DEP-100S.
3. Press F5 on the DEP-100S (for additional functions).
4. Press F4 to select network addressing (NETWORK ADDR).
Press the F1 key to select the port # (MedLAN address).
With the numeric keys, enter an address (port) number (0029).
Press ENTER to tell the DEP-100S you have completed your selection.
Press the F3 (download) to send the new MedLAN address to the
device. (A message that the download was completed will appear
briefly.)
Unplug the DEP-100S and move to the next control. Follow this
procedure for every control in the network.
Caution:
Make certain that each device has a unique address.
Duplicate addresses may cause the network to lock up.
Programming the Each timer unit provides flexible I/O for defining weld schedules. It also
Timer Unit lets you configure the device to meet your application requirements by
programming setup parameters. The control provides programmable
steppers to compensate for lost current density over the life of the
electrodes.
Flexible I/O List for The following is a list of the flexible inputs and outputs available to
Software #F04100 operators. The following I/O can be placed in any order, however, if the
software finds a duplicate in the list, the first duplicate in the list will be
changed to NONE.
- NONE
- BINARY SELECT 1
- BINARY SELECT 2
- BINARY SELECT 4
- BINARY SELECT 8
- BINARY SELECT 16
- BINARY SELECT 32
- WELD INITIATE
- WELD / NO WELD
- ISOLATION CONTACTOR SAVER
- FAULT RESET
- WELD PROCEED
- STEPPER RESET
- STEPPER RESET GROUP 1
- STEPPER RESET GROUP 2
- TIP DRESS
- STEPPER AUX WELD CNTR RESET
- APP ERR ACKNOWLEDGE
- CONTROL STOP
- PRESSURE SWITCH
- AUXILLARY COOLING
- PROGRAM DISPLAY SECURITY
- HEAT DISPLAY SECURITY
- USER INPUT 1
- USER INPUT 2
- USER INPUT 3
- USER INPUT 4
- USER INPUT 5
- USER INPUT 6
Flexible I/O List for The following is a list of the flexible inputs and outputs available to
Software #F04300 operators. The following I/O can be placed in any order, however, if the
software finds a duplicate in the list, the first duplicate in the list will be
changed to NONE.
- NONE
- BINARY SELECT 1
- BINARY SELECT 2
- BINARY SELECT 4
- BINARY SELECT 8
- BINARY SELECT 16
- BINARY SELECT 32
- WELD INITIATE
- WELD / NO WELD
- ISOLATION CONTACTOR SAVER
- FAULT RESET
- WELD PROCEED
- STEPPER RESET
- STEPPER RESET GROUP 1
- STEPPER RESET GROUP 2
- TIP DRESS
- STEPPER AUX WELD CNTR RESET
- APP ERR ACKNOWLEDGE
- CONTROL STOP
- PRESSURE SWITCH
- AUXILLARY COOLING
- PROGRAM DISPLAY SECURITY
- HEAT DISPLAY SECURITY
- USER INPUT 1
- USER INPUT 2
- USER INPUT 3
- USER INPUT 4
- USER INPUT 5
- USER INPUT 6
When the MedWeld 5000 is part of a network (as with the DeviceNet
integration), the module provides local (discrete) control of certain
critical inputs and outputs.
These outputs are the same for both integration options, with all
connections to safety I/O should be provided. The local and safety I/O
tells the timer unit status of the safety I/O, such as the isolation
contactor, the control stop condition and fault conditions.
This I/O is in addition to the I/O mapping provided for DeviceNet
operation.
Local Inputs This section covers MedWeld 5000 supported inputs/outputs. Your
application may not require all of this I/O. Refer to the drawing packet
provided for your exact I/O availability and designations.
ALERT Output
This output is OFF to indicate that the control is functioning normally.
Alert conditions are usually less serious than faults and are normally
used to warn the operator that maintenance is required.
Organization of the This module establishes a direct link between the control enclosure and
DeviceNet I/O the host PLC. The module provides the drop to the DeviceNet as well as
communication with the PLC.
The local and safety I/O is wired directly into the cabinet. These
connections provide inputs and outputs for local use and safety
interlocks.
The DeviceNet integration scheme uses some of the same signals as
those used in the discrete I/O operation. The major difference is that the
I/O is transmitted over a DeviceNet link from the DeviceNet module (in
the controller chassis).
I/O Definitions
Note: This chapter defines all possible I/O. Your timer unit may not provide all
of this I/O, based on the requirements of your application. Refer to the
drawing packet provided for your exact I/O availability and
designations.
Inputs BINARY SELECT Inputs (#1, #2, #4, #8, #16, & #32)
These inputs select the schedule to be initiated (1 63). The
schedule is selected by a combination of these inputs. Each input
has a weighted value (1, 2, 4, 8, 16, or 32). 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, and #4 (because 1 + 2 + 4 = 7).
NOTE: If your application does not use this input, the control uses a two-cycle
timed delay to determine when all of the inputs are active. (After
receiving a BINARY SELECT or PARITY Inputs, the control delays for
two cycles to assure that all of the desired inputs have become active.)
PARITY Input
The control will recognize only an ODD number of BINARY
SELECT inputs. If the schedule to be operated requires closure of
an even number of BINARY SELECT inputs, the PARITY Input
must also be closed to provide the required odd number of inputs.
This arrangement helps to prevent possible malfunctions if a
required input should fail to close.
Caution:
On power-up, it may be necessary to activate the
RETRACT Input (1 or 2) to energize the output, to
correct the internal state of the retract pilot.
CLOSE BACKUP
OPEN BACKUP
These two inputs control the status of the BACKUP VALVE
outputs, opening and closing as required by the user.
When this input is set to open, the OPEN BACKUP VALVE output
is set. When set to closed, the CLOSE BACKUP VALVE output is
set. (If both inputs are set, the OPEN BACKUP VALVE output is
set.)
Caution:
(If the weld schedule contains Function #77, it
overrides the isolation contactor delay which was
programmed in the setup parameters.
PROGRAM SECURITY
If this input is not jumpered, only data under the Stepper Status
Mode and Heat Display Mode can be changed.
This input is used in conjunction with the HEAT DISPLAY
SECURITY input, only data under the Stepper Display Mode can
be changed.
User Inputs 1 8
These are generic inputs from the SLC. These inputs can be used to
force the timer unit to wait in a weld schedule using the user input
functions.
NOTE: Valves #1 and #2 are shared outputs; they function as the two Advance
(Fluid) valves when enabling Ohma cylinder operation for the processor.
RETRACT 1 VALVE
RETRACT 2 VALVE
These outputs respond to the on/off status of the RETRACT
VALVE 1 and 2 PILOT Inputs, based on the Retract Mode setup
parameter.
FAULT Output
This output is normally OFF, indicating that the control is
functioning normally. If the control shuts down as the result of a
fault condition, this output will be turned ON.
NO FAULT Output
Certain applications use the NO FAULT output (rather than the
FAULT output above). 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 turned OFF.
NO ALERT Output
This output is normally ON. It turns OFF to indicate an alert
condition. Alert conditions are usually less serious than faults and
normally serve to warn the operator that maintenance is required.
ALERT Output
This output is normally OFF and turns on to indicate an alert
condition. Alert conditions are usually less serious than faults and
are normally used to warn the operator that maintenance is
required.
This output turned on and off by the weld control in response to the
functions #50 & #51 in the weld schedule, TURN ON WELD
COMPLETE and TURN OFF WELD COMPLETE.
DeviceNet Bitmap
DEP-100S Abbreviations
Software Capabilities
01 SQUEEZE nn CYCLES
02 COOL nn CYCLES
03 HOLD nn CYCLES
04 OFF nn CYCLES
05 INITIAL SQUEEZE nn CYCLES
06 QUENCH nn CYCLES
07 WAIT nn CYCLES
08 PRE-COMPRESSION
09 GUN WAIT DELAY
10 DELAY
11 PLATEN DELAY
12 WELD DELAY
13 METAL FORM TIME
20 WELD nn CY/IMP mm %I
21 TEMPER nn CY/IMP mm %I
22 PREHEAT nn CY/IMP mm %I
23 POSTHEAT nn CY/IMP mm %I
24 PRE-WELD nn CY/IMP mm %I
26 WELD nnnn MSEC mm %I
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
35 MAXHEAT nn MSEC nnn uS nnnn0 AMPS
36 WELD nnnn MSEC nnnn0 AMPS
37 CHC WELD nn CY nnnn0 AMPS
40 UPSLOPE nn CY mm %I TO mm %I
41 DOWNSLOPE nn CY mm %I TO mm %I
42 PRESLOPE nn CY mm %I TO mm %I
43 POSTSLOPE nn CY mm %I TO mm %I
45 SLOPE nn CY nnnn0 AMPS TO nnnn0 AMPS
58 TURN ON WELD IN PROGRESS
59 TURN OFF WELD IN PROGRESS
60 IMPULSE = nn HEAT CY, nn COOL CY
61 ABORT IF NO INITIATE FOR nn CYCLES
62 REPEAT (AT NEXT FUNCTION)
63 TURN ON WELD COMPLETE
Function Descriptions
Delay Functions Delay functions all have the same effect on the weld schedule: They
cause the control to wait for the number of cycles specified. (Different
names are assigned for describing the reasons for a delay.)
During these functions, weld current does not flow and I/O status is not
changed. Open the list of delay functions on the DEP by pressing F1.
01 SQUEEZE nn CYCLES
02 COOL nn CYCLES
03 HOLD nn CYCLES
04 OFF nn CYCLES
05 INITIAL SQUEEZE nn CYCLES
06 QUENCH nn CYCLES
07 WAIT nn CYCLES
08 PRE-COMPRESSION
09 GUN WAIT DELAY
10 DELAY
11 PLATEN DELAY
12 WELD DELAY
13 METAL FORM TIME
Weld Weld functions provide a specified amount of weld current for the
Functions number of cycles programmed. The function entered also selects the
type of firing mode desired.
NOTE: Faults may occur when the control is firing at or near the high and low
range of current for both ACC or AVC. The current range for each
control is unique and depends on factors such as the size of the weld
transformer, actual power capacity and nominal line voltage.
Experiment with the control to determine the upper and lower range of
current each control can provide.
20 WELD nn CY/IMP mm %I
21 TEMPER nn CY/IMP mm %I
22 PREHEAT nn CY/IMP mm %I
23 POSTHEAT nn CY/IMP mm %I
24 PRE-WELD nn CY/IMP mm %I
26 WELD nnnn MSEC mm %I
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 nnnn MSEC nnnn0 AMPS
37 CHC WELD nn CY nnnn0 AMPS
40 UPSLOPE nn CY nn %I TO nn %I
41 DOWNSLOPE nn CY nn %I TO nn %I
42 PRESLOPE nn CY nn %I TO nn %I
43 POSTSLOPE nn CY nn %I TO nn %I
45 SLOPE nn CY nnnn0 AMPS TO nnnn0 AMPS
The weld function you select also tells the timer unit 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.
Weld functions having %I at the end of the function (shown in function
numbers 20-26) use Automatic Voltage Compensation. Functions using
the AVC firing mode specify weld current as nn%I when firing in cycles
or mm %I when firing in milliseconds (represent the percentage of
maximum available current). AVC monitors primary voltage. It uses a
nominal voltage reference point (programmed in the setup parameters)
to determine when compensation is required for voltage swings on the
weld bus.
Weld functions that have AMPS at the end of the function (shown in
functions 30-37) have Automatic Current Compensation. Functions
using the ACC firing mode specify a set amount of secondary current,
displayed as nnnnn AMPS. ACC monitors the current during each
cycle. It compensates for changes detected during the next cycle, to
maintain secondary current at the level programmed. This method does
NOT compensate for changes in the welder secondary circuit.
NOTE: The weld data generated by the control (and displayed at the DEP or a
data monitoring device) does NOT include every function that provides
weld current. Keep this in mind when programming a weld schedule.
Only the following functions are included in the Weld Data display:
WELD 20 CY 60%I
%I
99%
60%I
20%
Weld Functions Using ACC is the Automatic Current Compensation firing mode. This mode
Automatic Current programs all values of weld current in A. For a programmed value of
weld current, the control will pass this amount of current during the
Compensation WELD function, regardless of the amount of metal in the weld guns
throat or the stack-up of metal. (This applies ONLY if the welding
system can deliver the requested current.)
The following weld functions will select the ACC firing mode.
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
35 MAXHEAT nn MS BELOW nnn us nnnn0 AMPS
36 WELD nnnn MSEC nnnn0 AMPS
37 CHC WELD nn CY nnnn0 AMPS
*The stepper is active during this function.
Secondary
current (A.)
05000 A.
This example depicts firing in ACC mode. The WELD function fires a
secondary current of 5,000 A. The specified 5,000 A. of current will be
maintained for 20 cycles. ACC functions apply current either by cycles,
or in impulses. These functions weld, temper, pre-heat, post-heat or pre-
weld.
Weld Functions that Functions #4043 use AVC firing to adjust weld current. Function #45
Adjust Current provides firing in constant current (ACC).
40 UPSLOPE nn CY nn %I TO nn %I
41 DOWNSLOPE nn CY nn %I TO nn %I
42 PRESLOPE nn CY nn %I TO nn %I
43 POSTSLOPE nn CY nn %I TO nn %I
45 SLOPE nn CY nnnn0 AMPS TO nnnn0 AMPS
These functions provide weld current that starts at the first value and
slopes linearly to the second value over the number of cycles specified.
Every function fires for the number of cycles specified. For example,
the function
For example, the following two functions will have the action shown in
the diagram below
20%
8cy 8cy
3cy 3cy 3cy Time (Cycles)
Special Functions These functions allow the control to turn outputs on or off within a weld
schedule.
again checks the status of the WELD INITIATE input, and repeats the
rest of the schedule. This continues until the processor detects that the
WELD INITIATE input has been removed.
NOTE: Functions #62 and #75 are mutually exclusive. They should NOT appear
in the same sequence.
setup parameters. They apply only to the weld schedule where they
appear. They also take priority over any other limits established.
The control normally processes all fault conditions at the end of the
weld schedule. This function allows forcing the control to process fault
conditions before it completes the weld schedule. It should appear in the
weld schedule BEFORE any functions that check fault status or require
current weld data.
NOTE: The Machine defaults were designed as a testing solution for the WTC
control test department. Reloading from Machine defaults will load the
WTC standard control test defaults for firing loads. WTC does not
recommend using these defaults in an actual welding application.
C-Factor
You can define a window of acceptable values for current. To define this
window, use the setup parameters: High Current Limit and Low Current
Limit.
Function #84 defines a current limit window with high and low limit
values and a new nominal C-Factor. (Refer to the discussion of C-Factor
on page 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 equation:
(
Limit = Target current + Target current x
HI or LO Limit percentage
100 % )
AVC Example In this mode, the target value is determined by the following calculation:
Target current =
%I in Function #20 + Stepper boost x C-factor
Target current =
(%I programmed in Function #20 + Stepper boost) x C-Factor
ACC Firing Mode In this firing mode, the target value is established by the following
calculation:
Target current = A. in Function #30 + Stepper boost
After establishing a bin number, the program stores the data for each
weld made in its own individual bin. The bin numbers increase by one
each time a weld is made, until another schedule with a different offset
is executed.
Bin #99 is the last usable bin. If the weld control reaches bin #99 and is
still collecting data, the data for each weld will be stored in bin #99 until
a new offset is assigned. For this reason, the data unsuitable for analysis.
NOTE: This function does NOT tell the control to collect weld data. It only
assigns a data storage bin number. Refer to the Data Collection Sample
Size and Data Collection Sample Frequency setup parameters described
below for instructions on how to specify data collection.
This function tells the control to start collecting weld data for all welds.
This function should follow the SET SPC OFFSET function in the weld
schedule because it is still necessary to assign a starting bin number.
Weld data collection continues until the control executes another
schedule containing this function (without the offset function), to reset
the global data collection process.
This function overrides the global Data Collection Sample Size and
Data Collection Sample Frequency setup parameters. These are
described next.
These two parameters set a global command which allows the weld
control to sample data for analysis at controlled intervals.
The sample size is the amount of weld data collected for analysis
(number of consecutive welds, per bin). The sample frequency is the
total number of welds per bin, where data was collected (the samples are
taken from).
For example, by setting the Data Collection Sample Size parameter to 2
and the Data Collection Sample Frequency parameter to 8, the control
will collect weld data for 2 consecutive welds (in bin #1), and flag the
XWSS to retrieve the data. It will then collect data for 6 more cycles
(without flagging XWSS) before starting the process again.
The example table on the next page is for Bin #1 ONLY.
Sample/
WCU Process WIS/WSS Process
Frequency
1/8 Data flagged for retrieval Data uploaded
2/8 Data flagged for retrieval Data uploaded
3/8 Data collected Data ignored
4/8 Data collected Data ignored
5/8 Data collected Data ignored
6/8 Data collected Data ignored
7/8 Data collected Data ignored
8/8 Data collected Data ignored
1/8 Data flagged for retrieval Data 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
NOTE: Weld Data Collection is bin dependent. Each bin has its own independent
counter and is uploaded to WebVIEW separately.
Retract Features
This section details the retract operation and how certain programmable
functions and setup parameters affect the operation:
Retract Mode
Initiate from Retract.
Retract Mode Setup The Retract Mode setup parameter determines how the control will react
Parameter to the presence of an active RETRACT PILOT input.
UNLATCHED tells the control to let the output for the Retract
valve follow the state of the RETRACT PILOT input. This is for
applications which use a toggle or selector switch. (The output will
be active while the input is active.) For air-only and OHMA
cylinders, the HIGH state of the RETRACT PILOT input(s)
indicates the partially-closed position. The LOW state indicates the
fully-open position.
LATCHED tells the control to change the state of the output each
time it receives a pulse from the RETRACT PILOT input. (The
control expects a brief pulse from the input, such as from a push
button.)
For air-normal operation, the HIGH state of the RETRACT valve(s)
indicates the partially-closed position. The LOW state indicates the
fully-open position.
For air-inverted operation, the LOW state of the RETRACT
valve(s) indicates the partially-closed position. The HIGH state
indicates the fully-open position.
NOTE: Selecting LATCHED retract may require toggling the state of the
RETRACT PILOT input at power-up (to change the state of the
RETRACT VALVE output). This will be required if the control powers up
in the incorrect retract state, or if the of the RETRACT PILOT input
status changes while the control is in a C-Stop condition (the CONTROL
STOP input is LOW).
Initiation From The processor also provides a function which you can place in a weld
Retract schedule to tell the control to check whether the selected cylinder is out
of retract. Function #89 (VERIFY CYLINDER #n IS OUT OF
RETRACT) will abort the schedule and generate a RETRACT PILOT
fault if the cylinder is NOT out of retract.
NOTE: Program the RETRACT PILOT fault as an ALERT condition in the setup
parameters, so the operator can place the valve in the partial retract
position and re-initiate the weld schedule.
The software or greater has features that modify operation of the DEP-
100S (Data Entry Panel). These include changes to the operation of the
stepper, the ability to select No Weld operation and restrictions on
inserting and deleting certain functions.
Weld/No Weld The DEPs Display Mode provides an option called W/NW STATUS. It
Status allows changing the software setting at the weld processor from Weld to
NoWeld.
Viewing Weld Data Software supporting the MFDC displays data on the Weld Data screen
on the DEP-100S (Hand-Held Terminal) differently from that for AC
welding controls. This section describes the differences in the Weld
Data screen:
POWER ON COMM ON
........................................
busV secI priI hfc 0000 cf 000
max 000 00000 0000 on time dcv 000
avg 000 00000 0000 0000 sch 00
low 000 00000 0000 %I 00 WCU #00*
........................................
X F1 XX F2 XX F3 XX F4 X
priI This shows the primary current the inverter is firing. This
value can be very low, as it indicates the current being
delivered during the first MFDC half-cycle. During this
half-cycle, the inductance of the transformer is
overcome.
Regardless of the setting in the Firing Mode setup
parameter, the primary current shown will be the actual
primary current read from the primary current sensor.
Where
f = the Operating High Frequency setup parameter
value.
Stepper Function The primary change to the stepper operation is addition of the Tip Dress
functionality. However, this version of the software also inhibits the
ability to turn the stepper on or off. The software in the MedWeld 5000
does allow the stepper to be advanced or reset as needed. See the chapter
on Steppers for more information.
NOTE: The SureWeld stepper is not available in controls equipped with the
MFDC inverter.
Parameter Descriptions
To override the turns ratio parameter setting in the weld schedule, use
Function #81.
Caution:
The Control uses this value to determine the secondary
current provided. For this reason, be certain to correctly
program this parameter for the operating environment
BEFORE attempting to use weld functions relating to
Automatic Current Compensation mode (ACC).
Setting function #81 in the weld schedule overrides this
setup parameter.
OFFSET RESISTANCE:
In CHC, the resistance value of the work is detected by the weld control
to control the weld current. Offset resistance is used to determine the
resistance of the weld delivering components (such as the electrode tip
and shank).
NOTE: The following four setup parameters (velocity of close, velocity of open,
velocity of soft touch and max force) are only used when a servo style
weld gun is used.
VELOCITY OF CLOSE:
In constant velocity mode, this is the maximum speed reached by the
gun as it approaches the soft touch position.
Default Settings
What is a Stepper?
Linear Steppers The conventional linear stepper tracks the number of welds completed.
It increases the heat provided to the weld at several programmed set
points. This serves to compensate for drifts in the welding process.
The stepper profile consists of a number of linear steps, and a parameter
to allow stepper grouping. Each linear step applies additional weld
current over a number of welds.
Because the stepper is linear, if a step is programmed to add 3% current
over 100 welds, it will actually add 1% after 33 welds, and another 1%
after 66 welds. (Heat is added in minimum increments of 1%, based on
the function selected.) By the 100th weld, the stepper is adding the full
3% current boost to the amount of current programmed in the weld
function.
At the end of a weld schedule, the control will verify the stepper that
was activated to see which group it belongs to. The control then
increments the weld count on all steppers that are associated to the
group. (Use the DEP-100S or other programming device to assign
steppers to a group.)
For example, if one gun (tips) was used to several different schedules
using different steppers, grouping allows you to automatically
increment the stepper 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 functions that provide weld current:
20 WELD 00 CY 00 %I
26 WELD 0000 MSEC 00 %I
30 WELD 00 CY 00000 AMPS
36 WELD 0000 MSEC 00000 AMPS
40 SLOPE 00 CY 00% TO 00% I
45 SLOPE 00 CY 00000 AMPS TO 00000 AMPS
Auxiliary Weld Attached to each linear stepper is an Auxiliary Weld Counter. When a
Counters stepper increments, its auxiliary weld counter also increments. When
the counter reaches the programmed value for the Aux. Counter Max
Counts = nnnnn setup parameter, the AUX. COUNTER AT MAX
output will be turned on. This gives the operator another output to alert
them to a condition without having to reset the steppers or rely on the
STEPPER ALERT alone.
Default Linear As shipped from the factory, the linear steppers use this profile by
Stepper Profile default:
START OF STEPPER
STEP #1 00 %i 0700 AMPS IN 0060 WELDS
STEP #2 00 %i 0700 AMPS IN 0180 WELDS
STEP #3 00 %i 0700 AMPS IN 0300 WELDS
STEP #4 00 %i 0700 AMPS IN 0600 WELDS
STEP #5 00 %i 0700 AMPS IN 0800 WELDS
STEPPER GROUP #00
END OF STEPPER
When you select the Linear Stepper Status display from the DEP-100S,
use this display to view the stepper status:
This display shows the amount of energy being added to each weld
function (Boost), the present step and the selected stepper (stpr), as well
as the total weld count and the step count (the number of welds
completed during the present step).
From the stepper status display,
Press F1 to see a different stepper
Press F3 to advance the stepper
Press F4 to see the stepper settings for a different timer unit (wcu#)
Press F5 to see additional stepper options. The asterisk (*) indicates
that additional displays or information are available. When you
press F5, you see the stepper reset option at F3; or
Press F5 a second time to present a display showing the status of
every linear stepper:
Press F5 a third time to return to the initial stepper display.
An inverter fault will activate the NO FAULT output at the timer unit,
and the READY TO WELD (RTW) output.
The following tables list each fault:
List of Faults
Invalid The combination of The weld initiate was on but Turn on the BINARY SELECT
Sequence BINARY SELECT no BINARY SELECT inputs input(s) required.
Selected inputs was invalid. were active.
Weld Initiate The WELD INITIATE Weld schedule contains Remove Function #63 from the
Not Present input was not active Function #63 TURN ON weld schedule.
when checked by the WELD COMPLETE, but the
control in Function function is not required by the
#63 TURN ON application.
WELD COMPLETE
The ROBOT or PLC is not Repair ROBOT or PLC
holding the INITIATE input program.
high for the amount of time
required by the application.
Control Stop The control detected The CONTROL STOP input Check/repair ladder logic. Note
that the CONTROL from the ROBOT or PLC was if the Control Stop message is
STOP input (normally not active when the control both DIO and DEVICE NET.
HIGH) dropped out. tried to initiate a weld.
Stepper The linear stepper assigned to the schedule initiated The electrodes will soon need
Approaching has started the first weld in the last step. maintenance. Dress or replace
Maximum the electrodes to avoid the END
OF STEPPER fault condition.
End of A linear stepper in the group # assigned to the sched- Dress or replace the electrode
Stepper ule initiated completed the last step in the profile. tips. Reset the stepper.
High Current The control detected The limit is set too low. Reprogram high current limit
Limit that the current fired (Function 76 SEC CURR LIM-
during the weld ITS).
schedule exceeded
the high current limit. Welder impedance is lower Check for improper installation
(This could be the than it was when the current of either a kickless cable or
limit in the setup limit was set. The welder may shunt cable.
parameters OR set be drawing more current than
by Function 76 SEC the originally-calculated
CURR LIMITS in the maximum.
weld schedule.)
Pressure being maintained to With a pressure gauge, verify
the tips changed during the that constant pressure is being
weld, so less pressure to the maintained. Check for things
welding spot was provided. affecting pressure (such as
The timer unit will hoses binding in the weld gun
compensate, and possibly tooling, faulty or sticky solenoid
generate a HIGH CURRENT valves or slow-moving cylin-
LIMIT fault. ders.
Low Current The current fired fell Limit is set too high. Reprogram the limit in Function
Limit below the limit pro- (Function 76 SEC CURR LIM-
grammed, either in ITS).
the setup parame-
ters or Function 76 Unusual condition in the Check the secondary. Look for
SEC CURR LIMITS secondary. dirty material, bad kickless
in a schedule. cables or shunts, tip alignment,
loose connections or reduced
weld force due to hoses binding
in the weld gun tooling, faulty or
sticking solenoid valves or
slow-moving cylinders.
Control The MFDC inverter Faulty cabling. (The inverter Check the timer to inverter con-
Failed to Fire assembly failed to fire did not receive the firing sig- nections. Verify that they are
for a half-cycle. nal.) secure.
Extend Weld The control had to Low current limit is set too Re-program the Low Current
restart the weld high. Limit setup parameter.
schedule due to
insufficient secondary Unusual condition in the Check for improper part fit-up,
current during a weld. secondary. dirty material, worn electrodes,
bad kickless cables or shunts,
or loose connections in the
secondary circuit.
Isolation Isolation contactor The instruction to activate the Verify that the schedule
Contactor Off was not pulled in by isolation contactor (Function contains Function #88 TURN
When the control when #88 TURN ON ISOLATION ON ISOLATION CONTAC-
required by the weld CONTACTOR) was missing TOR.
Needed
schedule. from the weld schedule.
The timer unit controls the Verify that the Ready to Weld
isolation contactor, which is signal was HIGH (= 1) when
driven by a single solid-state required.
relay. The timer unit signal is
based on status of the CON- Verify that the Ready to Weld
TROL STOP and WELD/NO signal was HIGH (= 1) when
WELD Inputs. (Voltage must required.
be present at these inputs to
allow the timer unit to open or
close the isolation contactor.)
ISO CNTR The control has A welding condition has Verify any other welding typ
ERR-BRKR issued a shunt trip caused the control to shunt faults that may appear in the
TRIPPED condition. This fault trip to protect the hardware or fault list with a breaker tripped
will remain until a a user. message. Check the Isolation
fault reset is issued contactor for it being stuck
even if a power cycle
is conducted
Control in The control moved Robot or PLC de- Check robot or PLC to verify
No Weld from Weld Mode to activated the WELD/NO that the input is being held
No Weld Mode while WELD input. HIGH throughout the schedule.
executing a weld Use the DEP I/O Status display
schedule. to observe the status of this
input.
Data entry device is pro- Verify that the data entry device
grammed in No Weld mode. is in Weld Mode.
High C- The C-factor read Unusual conditions in the Check for causes of shunting or
Factor during the weld part secondary. conducting water.
of the schedule
exceeded the value The High C-factor limit was Raise the high C-factor limit.
programmed in programmed too low.
Function #92.
Low C-Factor The C-factor read Unusual conditions in the Check for worn cables, loose
during the weld part secondary. connections, low air pressure or
of the schedule fell other causes of decreased sec-
below the value ondary current.
programmed in
Function #92. The Low C-factor limit was Lower the Low C-factor limit.
programmed too high.
Tips closing too slowly, due Check for sticking gun cylinder.
to a dirty or poorly-lubricated
cylinder.
Heat Cycle The control reached Weld schedule programming Lower the number of cycles
Limit the programmed limit was incorrect, or the heat when the weld control is firing.
of consecutive weld cycle limit in the setup param-
cycles where conduc- eters was set too low. Your application does not need
tion was detected. the Heat Cycle Limit setup
parameter. To disable this
parameter, set it to 0.
Weld WELD PROCEED Faulty robot or ladder logic. Check ladder logic to verify that
Proceed input did not become the input is being activated.
active when required
by the control, or it Loose or incorrect wiring to Check for proper I/O designa-
was removed while the input module. tions. Check to make sure all
the control was exe- wiring connections are secure.
cuting a schedule.
Faulty input module. Replace input module.
Pressure The PRESSURE Faulty robot or ladder logic. Check ladder logic to verify that
Switch SWITCH input was the input is being activated.
not active when
required by the Loose or incorrect wiring to Check for proper I/O designa-
control, or it was the input module. tions. Check to make sure all
removed while the wiring connections are secure
control was executing
a schedule. Faulty input module. Replace input module.
INITIATION The weld control had Latched or stuck I/O from the Check all inputs to the weld
ON POWER- valid inputs and robot or PLC control to verify that there is not
UP attempted to fire a a latched bit for weld initiate
weld durring the with a valid binary select.
power-up process
NO WORK This is only used No part to weld or tip to tip Place the proper work piece to
DETECTED when using CHC and weld. be welded in the welding inter-
(CHC) represents the sec- face
ondary resistance is
low and repersents
that there is nothing
to weld
LOW HEAT This is only used Resistance of the work piece Increase the weld level to
DETEC- when using CHC and is limiting the energy to be increase the total energy.
TION(CHC) repersents that there applied durring the weld.
was not enough
energy delivered to
complete the weld
WIRE BREAK This is only used When no wires are connected Check the tip wires to verify
DETEC- when using CHC and to the secondary then the proper connection back to the
TION(CHC) repersents that there CHC process cannot regulate cabinet.
is no wires to the current
electrode to measure
the secondary resis-
tance
BREAK- This is only used Breakthrough limit is set to Check that sealer was used,
THROUGH when using the low. No sealer used on the check limis for breakthrough
LOW LIMIT Breakthrough func- part which would bring the function
tion in a welding ontime below the break-
sequence and the through level early.
ontime level is below
the breakthrough limit
before blanking time
is over.
BREAK- This is only used Breakthrough limit is set to Check that proper sealer was
THROUGH when using the high. Too much sealer used used, check limis for break-
HIGH LIMIT Breakthrough func- on the part which would bring through function
tion in a welding the ontime above the break-
sequence and the through level.
ontime level is above
the breakthrough limit
before blanking time
is over.
LOW POWER LINE: AC line voltage is too low. (Primary Check AC power line voltage, Check
Current and input phases for bad
Primary Voltage firing modes). connections.
~or~
Three or more mid-frequency half-
cycles ended due to maximum on
time reached. Check 'On-time' dis-
play.
SOFT At least two (but less than six) mid- Check Weld Transformer
OVERCURRENT: frequency half-cycles ended because secondary load, secondary resistance
inverter reached Soft Overcurrent, or may be abnormally low. Set Soft
Maximum Primary Current Limit. Overcurrent Limit higher if there is no
Inverter was able to limit current in the problem with secondary resistance.
Safe Operating Area.
Maximum Primary Current Limit may
indicate that the weld load is poorly
matched to the inverter with the
installed welding transformer, or that
the inverter is too small for the appli-
cation.
CURRENT The inverter could not reach the Check Weld Transformer
REGULATION: requested current (programmed cur- secondary load. Secondary resis-
rent plus any additions from stepper tance may be abnormally high.
program) during three or more con- Requested current may be too high
secutive mid-frequency half-cycles. due to programmed value plus step-
per program.
NOTE: This fault is not generated at
the beginning of a weld to avoid false
detection during current ramp-up.
WELDING Six consecutive mid-frequency half- Check the Weld Transformer for
TRANSFORMER: cycles, or four consecutive mid-fre- shorted secondary diodes (follow the
quency half-cycles of the same polar- manufacturers recommended proce-
ity ended because the Maximum dure
Primary Current Limit was exceeded.
This may indicate a shorted second- ~or~
ary diode in the weld transformer. Replace the weld transformer with a
known good unit.
DC BUS The DC bus voltage is too high, based Check the AC line voltage.
OVERVOLTAGE: on an abnormally high AC Line volt-
age
INVERTER BUS: The DC fell more than 40% from the Check the AC power line for voltage
value measured at the start of weld sags, missing phases or loose con-
time. This is calculated from the AC nections.
Line Voltage reading.
INVERTER OVER The chill plate temperature exceeded Assure proper water flow to the
TEMPERATURE: +60o C, or the thermistor sensor on inverter. Check chill plate tempera-
the chill plate is open circuit. ture. Remove inverter for service if the
chill plate is NOT hot and the condi-
NOTE: Do not confuse this fault with tion persists.
TRANSFORMER OVER TEMPERA-
TURE fault.
OUTPUT GROUND: A current imbalance exists in the Check weld transformer primary cir-
inverter output, indicating that some cuit for shorts to ground,
current has found a shunt path. especially from primary cables with
worn or damaged insulation.
HARD The inverter IGBT drive circuit Check the weld transformer
OVERCURRENT: detected an uncontrolled overcurrent primary circuit for shorted or damaged
(desaturation). cables.
ILLEGAL POWER The inverter cannot Check power line for proper
FREQUENCY: determine the power line frequency. voltage, all phases present, absence
of excessive noise, spikes, sags or
dropouts on power line.
MAIN FUSE OPEN: The inverter did not detect output volt- Check inverter unit for:
age when an IGBT is turned on - Proper line voltage on pins 2 and 3
(beginning of weld time). of CNIG4.
- Proper 120V on pins 3 and 4 of
NOTE: This fault is typically caused CNIG3.
by a disruption of power. Please verify - Verify that fuses are not blow and
all power sources supplying the that the control transformer is operat-
inverter unit are correct. This fault ing properly.
may occur when using an external
120V power source. A faulty power
supply will generate a MAIN FUSE
OPEN fault.
Replace inverter.
SEC CURRENT The Secondary Current Sensor is Check continuity of secondary current
SENSOR: open-circuited. This condition is not sensor circuit (if used). Replace sec-
checked if set to NONE. ondary current
sensor if defective. Set this condition
to NONE if no secondary current sen-
sor is used.
Power Supply
No 480/600 VAC power at the control Check the control circuit breaker. Verify
transformer. 480/600 VAC is present in incoming lines.
Verify that operator handle is UP to turn ON
the breaker.
Blown fuse in timer assembly. Check the fuse to see if it is blown. Replace
if necessary.
I/O point is shorted. Inspect all I/O points for correct and secure
connections. Correct and/or tighten any
suspect connection(s).
Processor
Inadequate power or Line power is not con- Verify that line power has been connected
loss of power to the nected to the power to the power supply.
processor supply.
Check the jumper setting to verify that it
(All LEDs are off) matches the input voltage.
Controller is inoper- Defective I/O devices or Test inputs and outputs, according to the
able, but no major I/O wiring. I/O Troubleshooting section.
CPU faults are
detected
Weld Processor
Inadequate or no Bad connectors or improper Remove power and inspect the power
power to the timer seating of power supply supply and timer unit connections.
unit and/or timer unit in the
(Power supply LED is chassis. Remove power from the chassis and
on) re-seat modules.
Power has been cycled too Remove power from the rack for AT
fast, causing a large current LEAST two minutes. Then restore
inrush resulting in a thermal power.
overload.
Blown fuse on the power Check the fuse. Replace if blown.
supply.
Loss of RAM memory The battery on the timer Replace the battery on the timer. (The
unit is low or dead. battery is soldered in place. Only quali-
(Batt LED is on) fied personnel should attempt battery
replacement in an ESD-safe environ-
ment.)
Timer cannot com- Bad connectors or improper Remove power. Inspect timer unit con-
municate (CPU Fault seating of the timer unit in nections. Then cycle power.
LED on processor is the chassis.
on) Remove power from the chassis, re-
seat modules and restore power.
Control and DEP- Bad connection between Check connection. Verify that it is
100S cannot timer unit and DEP-100S. secure.
communicate
(DEP and MedLAN Check for bad/faulty connector and/or
LEDs may be off or cable.
blinking)
Cycle power.
Communication over Improper or loose MedLAN Check for secure and correct wiring.
the MedLAN channel wiring.
is inoperable.
(MedLAN LEDs may Two or more controls have Check MedLAN address of each
be off or blinking) the same network address control. Each control must have a
number. UNIQUE address.
This table describes some of the typical problems you may see in the
field. The recommended procedure to troubleshoot each problem is
provided.
Circuit breaker SHUNT TRIP output on the I/O is If YES, check the following:
trips on power- becoming active. - Primary transformer cables grounded?
up. - SCR breaking over at low potential, or
shorted?
Circuit breaker The magnetic trip on the circuit Adjust the circuit breakers magnetic trip
trips while breaker is set too low. (This causes threshold.
welding the control to trip during the weld time
of a schedule.)
SHUNT TRIP output on the I/O Faulty firing card or I/O module. Replace
module is active when the SCR is not as necessary.
shorted.
Control does not Control is not receiving BINARY Check the device supplying the inputs.
initiate a weld SELECT inputs. Check the timer module and check input
schedule. supply voltage to the timer module. Check
the I/O Status Display at the DEP.
The INITIATE WELD input is not Check the device supplying the INITIATE
being supplied with the BINARY WELD input. Check the timer and the
SELECT inputs. (Certain applications input supply voltage to the timer module.
require this.) Check the I/O Status Display at the DEP.
The PARITY input is required (to Check the device supplying the PARITY
supply an ODD number of inputs. input. Check the timer module and the
Certain applications require this input input supply voltage to the timer module.
when the total number of inputs in the Check the I/O Status Display at the DEP.
weld initiate is an even number.
Control is in retract, and the setup Check the setup parameters. Either take
parameter specifies that initiation is the control out of retract before initiating,
INHIBITED from retract. or re-program the Initiation from Retract
setup parameter. After changing the state
of the retract setup parameters, you must
also cycle power.
Control has detected a fault condition. Check the DEP-100S to determine which
(Faults must be reset before initiating fault condition was detected. Clear the
a schedule when the setup para- fault(s) and re-initiate.
meters INHIBIT initiation on faults.)
Change the setup parameters to ALLOW
initiation when fault conditions are active.
Control not Bad connection between timer unit Check the connection between the timer
responding to and DEP-100S. unit and DEP-100S.
DEP-100S.
Check for faulty connector or cable.
If networking, check for improper or Check for secure and proper wiring. Refer
loose wiring at MedLAN connection. to MedLAN wire designations described in
Providing MedLAN Connections on
page 2-5.
Two controls share the same Check each controls address. Verify that
MedLAN address. each has a UNIQUE address.
Control The control is in No Weld. Check the status of the WELD/NO WELD
sequences input. Verify that the control and all data
without firing. entry devices are in Weld mode.
A fault occurred, causing the control Check the data entry device to determine
to complete the weld schedule in No any fault conditions. Clear the fault(s),
Weld. correct the problem and re-initiate.
Timer is not sending firing signals. Remove power from the chassis and
check for faulty connectors or cables and
cycle power.
Is the inverter receiving firing If YES, check the timer for loose or dis-
signals? connected wires. Also, check to see if fir-
ing into an open primary or secondary of
the weld transformer.
I/O not respond- Problem with the I/O. Check the device supplying the input or
ing as expected. receiving the output.
Isolation con- The weld schedule does not contain Check the weld schedule to confirm that it
tactor not being the function to activate the isolation contains Function #88.
pulled in contactor (Function #88).
The isolation contactor is driven by a Use the I/O Status display on the DEP-
single solid-state relay (based on the 100S to verify that the inputs are HIGH
status of the CONTROL STOP and (= 1).
WELD/NO WELD inputs). Voltage
must be present at these inputs to
allow the timer unit to open or close
the isolation contactor.
The control was unable to pull in the Check the wiring diagram that came with
isolation contactor due to incorrect or your control for proper I/O designations.
loose wiring to the output module. Make sure all connections are secure.
Isolation contactor is not being held in Check the I/O point enabling the
between weld sequence. ISOLATION CONTACTOR SAVER Input.
No current Did the control weld? If NO, check the weld schedule.
reading (10 A. or
less) If YES, check for part fit-up, foreign
material between electrodes and work
piece, electrode pressure and tooling.