WTC MedWeld 5000 Manual

MedWeld 5000
Integrated Weld Control
Operator’s Guide for
Software #F04200
Revision 01
Modified: 6/6/07
Part No. M-032175
Copyright © 2007, WTC

MedWeld 5000 Operator’s Guide for #F04200
M-0273 June, 2007

MedWeld 5000 Technical Reference Manual Modified: 6/6/07
If You Need Help . . . ............................................................vii
Welding Technology Corp. (WTC) ................................................. vii
By Phone or Fax: ............................................................................ vii
By E-mail: ....................................................................................... vii
On the Web: .................................................................................... vii
Symbols Used in This Manual ............................................ viii
Revision History ....................................................................ix
Safety Dangers .......................................................................ix
How to Use this Manual .........................................................xi
Software Updates ..................................................................xii
Working with Static-Sensitive Devices ............................... xiii
ESD Costs! ..................................................................................... xiii
Personnel Grounding ..................................................................... xiii
Handling or Moving ESDS Devices .............................................. xiii
Workstation Requirements ............................................................. xiii
Contact Information ....................................................................... xiii
Copyright .............................................................................xiv
Patents ..................................................................................xiv
Problem Report Form ...........................................................xvi
Your Feedback Welcome Here! ........................................ xviii
Comments for Feedback Form ....................................................xviii
Chapter 1 MedWeld 5000 Overview ..................................1
System Description ............................................................................1
Welding with an AC Control .............................................................2
Timer Unit ..........................................................................................4
Ethernet/IP .........................................................................................4
DeviceNet Integration ........................................................................5
Component Descriptions ....................................................................6
Circuit Breaker ...................................................................................6
Isolation Contactor .............................................................................6
Control Transformer ..........................................................................6
SCR Assembly ...................................................................................7
Firing Card .........................................................................................7
Firing Card Input Signals ...................................................................7
Firing Card Output Signals ................................................................7
Timer Unit ..........................................................................................8
Optional Components ........................................................................8
Chapter 2 Installing the MedWeld 5000 ............................1
Getting Started ........................................................................1
Making the Required Connections ....................................................1

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DeviceNet Integration ........................................................................2
Providing MedLAN Connections ......................................................3
MedLAN and DEP-100S Connections ..............................................3
MedLAN Wiring Specifications ...............................................................3
Cable Requirements ..................................................................................3
Cable Routing Requirements .............................................................4
Setting the timer MedLAN Address ..................................................4
Programming the Timer Unit .............................................................6
Example ....................................................................................................6
Flexible I/O List .................................................................................7
Flexible Inputs ..........................................................................................7
...........................................................................................................9
DEP-100S Programming Device .......................................................9
Ethernet/IP DEP ...............................................................................10
WebVIEW ........................................................................................10
WTC Network Software ..................................................................11
Robot Manufacturer Pendant ...........................................................11
Available Configurations ......................................................11
Chapter 3 Communications and I/O ..................................1
CIOM and Local I/O ...............................................................1
Local Inputs .......................................................................................1
Local Outputs .....................................................................................2
Organization of the DeviceNet I/O ....................................................3
I/O Definitions ........................................................................3
Inputs .................................................................................................3
User Inputs 1 – 8 ................................................................................7
Outputs ...............................................................................................8
WELD COMPLETE Output .....................................................................9
DeviceNet Bitmap .................................................................11
Ethernet/IP Bitmap ................................................................13
DEP-100S & Ethernet/IP DEP Abbreviations ......................14
Input Abbreviations .........................................................................14
Output Abbreviations .......................................................................15
Chapter 4 Weld Schedules .................................................1
What is a Weld Schedule? .......................................................1
Software Capabilities ..............................................................2
List of Functions .....................................................................3
MedWeld 5000 Functions ..................................................................3
Function Descriptions .............................................................4
Delay Functions .................................................................................4
Weld Functions ..................................................................................5

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Weld Functions Using Automatic Current Compensation .................7
Weld Functions that Adjust Current ..................................................8
Special Functions .............................................................................10
Special Function Definitions ...........................................................10
Default Weld Schedule ..........................................................16
Chapter 5 Advanced Software Features ............................1
C-Factor ..................................................................................1
Dynamic Current Windows .....................................................2
AVC Example ....................................................................................2
ACC Firing Mode ..............................................................................3
SPC Indexing Capabilities ......................................................4
SPC Functions ....................................................................................4
SPC setup Parameters ........................................................................5
Retract Features .......................................................................7
Retract Mode Setup Parameter ..........................................................7
Initiation From Retract .......................................................................8
DEP-100S Programming Restrictions ....................................8
Weld/No Weld Status .........................................................................8
Viewing Weld Data ............................................................................9
Stepper Function ..............................................................................10
Chapter 6 Setup Parameters ..............................................1
Parameter Descriptions ...........................................................2
Default Settings .......................................................................9
Chapter 7 Stepper Data .....................................................1
What is a Stepper? ...................................................................1
Linear Steppers ..................................................................................2
Auxiliary Weld Counters ...................................................................2
Default Linear Stepper Profile ...........................................................3
Display at the DEP-100S ........................................................4
Chapter 8 Fault Conditions ...............................................1
Chapter 9 Hardware Troubleshooting ...............................1
Power Supply .........................................................................1
Processor .................................................................................2

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Weld Processor .......................................................................3
Solving Typical Problems .......................................................5

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Getting Started
If You Need Help . . .
Welding Technology
Corp. (WTC)
WTC is committed to quality products, service and support. Our service
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:
Industrial Technical Service (ITS) Voice: [phone]
Fax: [phone]
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 -xvi.
By E-mail: When an immediate response is not critical, contact WTC at the
following e-mail addresses:
WTC’s technical support will respond within 24 hours, Monday through
Friday, to your e-mail requests. Please include your name, company
name, location, product part and serial number and a description of the
problem with your request. Be sure to indicate how you want us to
respond, and include applicable phone and fax numbers with your e-
mail address.
On the Web: Visit our Web site at: www.weldtechcorp.com.
[email protected]
[email protected]
Sales/Marketing Comments
Technical Support

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Symbols Used in This Manual
Danger! and WARNING! messages indicate high-voltage hazards in
weld controls, SCRs, MFDC inverters and weld monitoring equipment.
Danger! This symbol will be used wherever 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 files.
NOTE:
This convention informs the user about special features, or where to find
more information.

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Revision History
Safety Dangers
Save these instructions.
Danger! FAILURE TO OBSERVE SAFETY MEASURES
MAY RESULT IN DEATH, SEVERE BODILY
INJURY OR SERIOUS DAMAGE TO PROPERTY.
Danger! LETHAL voltages are present when applying
power to the weld control. Exposure to high
voltage WILL CAUSE SEVERE ELECTRICAL
BURNS, INTERNAL INJURIES and/or DEATH.
Refer all necessary service on this machine
ONLY to qualified maintenance personnel.
Caution:
When lifting any weight over 20 kg (~45 lb.),
use either a two-man lift or an assisted lift.
Revision Release Date Comments
1 06/07/07 Released as program #F04200

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DANGER!
To reduce the risk of fire or electric shock,
carefully follow these instructions.
DANGER! ONLY qualified personnel are allowed to service
the weld cabinet and associated devices!
DANGER! Make certain the circuit breaker handle on the
enclosure is in the OFF position before
attempting to open the door.
WARNING! Inspect the enclosure for any potential shipping
damage, loose connections, or packing
materials inside the cabinet before operation!
WARNING! WTC does NOT recommend drilling any holes in
the cabinet! If additional holes are required,
make certain all components are covered to
adequately protect from metal debris.
DANGER! NEVER remove circuit boards or establish
electrical connections with power applied! Be
certain to REMOVE POWER BEFORE servicing,
installing or removing components.
WARNING! Always ensure proper flow rate, temperature
and chemistry of cooling water before
operation. Obstructed or insufficient flow of

Getting Started
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cooling water may damage components.
WARNING! Adjust the magnetic trip setting on the circuit
breaker to a value appropriate for weld
operation!
WARNING!
Verify all transformer tap voltages BEFORE
attempting to apply power or weld.
WARNING! Verify the setup parameter "Nominal Line
Voltage" to your facility voltage if the operator
ever reloads software to default settings.
WARNING!
Never use a personal grounding strap when
working with voltages above 220V.
WARNING!
Cu 75
o
ONLY
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.

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The Table of Contents lists each section and subsection. In these
sections, descriptive subheadings indicate the information provided.
Simply flip to the page number and subheading indicated.
Detailed procedures describe the steps required to perform each
programming task. Other descriptions explain the procedures for
installation, initialization and troubleshooting, along with explanations
of the hardware and each weld function.
Software Updates
WTC reserves the right to make substitutions or changes as required to
the hardware or software described in this manual.
This manual may be periodically updated to reflect software changes
that will affect operation of the equipment described. Request copies of
the latest updates by completing the “Comments for Feedback Form” on
page -xviii, or by visiting WTC’s Web site: www.weldtechcorp.com.

Getting Started
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Working with Static-Sensitive Devices
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:
Danger! NEVER use the personnel grounding system
described below when working with
voltages above 220 VAC.
Personnel
Grounding
Before touching any Electrostatic Discharge Sensitive (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 shielding
bag or a static shielding tote. To be effective, either type of container
MUST be closed.
NOTE: Use ONLYstatic-shielding containers for transporting ESDS devices or
circuit boards.
Workstation
Requirements
If diagnostics are required, move the circuit board to an approved ESD
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.
Contact
Information
For detailed information about ESD precautions, contact
ESD Association
Voice: 315–339–6937
Fax: [phone]
e-mail: [email protected]
Web: www.esda.org
e-mail: [email protected]

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Copyright
WTC software and publications are copyrighted and all rights are
reserved by WTC. Distribution and sale of software is intended for the
use of the original purchaser, and only for use on a single machine.
Copying, duplicating, selling or otherwise distributing this software is a
violation of law.
WTC specifically does not authorize duplication of the software stored
in the EEPROM, distribution media (magnetic or CD-ROM) or in print
form, without prior written 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 of this product.
4,388,515
4,493,040
4,804,819
4,973,419
5,386,096
5,483,035
4,399,511
4,513,363
4,831,229
4,945,201
5,424,506
5,589,088
4,459,456
4,516,008
4,849,873
5,128,507
5,440,092
5,667,704
4,459,457
4,721,840
4,851,635
5,276,308
5,449,887
5,757,176
4,463,244
4,733,045
4,885,451
5,347,105
5,471,028
5,793,243
4,973,815
6,130,396
6,215,086
6,225,590
6,342,686
6,359,566

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Problem Report Form
PlantNameandLocation:
Phone:
YourName: Date:
Time:
Program#(Timerpower-upmessage): – – / /
Part#:
Fault code display. When a fault or error occurs, the Product ### displays
a status code. Indicate each code that is displayed:
Descriptionoftheproblem:
Sequenceofeventsleadingtotheproblem:
Drawing number(s) of schematic(s) shipped with the Product ###:

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Your Feedback Welcome Here!
We welcome your feedback on the accuracy and usefulness of 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 [phone].
Comments for
Feedback Form
YourName: Date: Time:
CompanyName: Phone:
CompanyAddress:
City:
State: ZIP:
Program/Revision#:
#ofManualsatyoursite:
DocumentNumber/Name:
Your comments:

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