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

MedWeld 5000 Technical Reference Manual Modified: 6/6/07
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

MedWeld 5000 Technical Reference Manual Modified: 6/6/07
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

MedWeld 5000 Technical Reference Manual Modified: 6/6/07
Weld Processor .......................................................................3
Solving Typical Problems .......................................................5

MedWeld 5000 Operator’s Guide for #F04200 Modified: 6/6/07 vii
M-032175
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

Getting Started
viii Modified: 6/6/07 MedWeld 5000 Operator’s Guide
M-032175
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.

Getting Started
MedWeld 5000 Operator’s Guide Modified: 6/6/07 ix
M-032175
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

Getting Started
x Modified: 6/6/07 MedWeld 5000 Operator’s Guide
M-032175
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