WTC MedWeld 3005 Manual
MedWeld 3005
Resistance Weld Control
Operator’s Guide
for
T93300–20
Revision 01
February, 2002
Part No. M-032025
Copyright © 2001, WTC
WELDING TECHNOLOGY CORPORATION
150 East St. Charles Road 24775 Crestview Court
Carol Stream, IL 60188 U.S.A. Farmington Hills, MI 48335 U.S.A.
Voice: (800) 323-2903 Voice: (248) 477-3900
(630) 462-8250 Fax: (248) 477-8897
Fax: (630) 462-8259
YY =UTGU\T# %?`UbQd_bµc7eYTUV_bD)## "
= #" "%1`bY\" "
=UTGU\T# %?`UbQd_bµc7eYTUV_bD)## " YYY
= #" "%1`bY\" "
7DEOHRI&RQWHQWV
*HWWLQJ6WDUWHG L[
+RZWR*HW+HOS L[
%\3KRQHRU)D[L[
%\(PDLO L[
2QWKH:HE [
%\0DLO [
6\PEROV8VHGLQ7KLV0DQXDO [
5HYLVLRQ+LVWRU\[L
6DIHW\:DUQLQJ[L
7RWKH2SHUDWRU[L
/LPLWHG:DUUDQW\ [LL
&RS\ULJKW [LLL
$FNQRZOHGJPHQWV [LLL
3DWHQWV [LLL
:RUNLQJZLWK6WDWLF6HQVLWLYH'HYLFHV[LY
3HUVRQQHO*URXQGLQJ[LY
+DQGOLQJRU0RYLQJ(6'6'HYLFHV[LY
:RUNVWDWLRQ5HTXLUHPHQWV [LY
&RQWDFW,QIRUPDWLRQ[LY
&RROLQJ:DWHU5HTXLUHPHQWV[Y
:DWHU)ORZ5DWH [Y
+RVHV [YL
(OHFWULFDO&KDUDFWHULVWLFV [YL
&KDSWHU 0HG:HOG2YHUYLHZ
6\VWHP'HVFULSWLRQ
3K\VLFDO'HVFULSWLRQ
&KDVVLV
$OOHQ%UDGOH\3RZHU6XSSO\
6/&3URFHVVRU
:7&:HOG3URFHVVRU
5,2,QWHJUDWLRQ
5,21HWZRUN0RGXOH
DQR\U_V3_^dU^dc
Yf =UTGU\T# %?`UbQd_bµc7eYTUV_bD)## "
= #" "%1`bY\" "
'HYLFH1HW,QWHJUDWLRQ
'HYLFH1HW0RGXOH
02'8/(/('6WDWXV,QGLFDWLRQV
1(7/('6WDWXV,QGLFDWLRQV
1XPHULF6WDWXV&RGHV
&RPELQDWLRQ0RGXOH
'LVFUHWH,20RGXOHV
'LVFUHWH,QSXW0RGXOHV
'LVFUHWH2XWSXW0RGXOHV
&RPSRQHQW'HVFULSWLRQV
&LUFXLW%UHDNHU
,VRODWLRQ&RQWDFWRU
&RQWURO7UDQVIRUPHU
&XUUHQW&RLO
)LULQJ&DUG
)LULQJ&DUG,QSXW6LJQDOV
)LULQJ&DUG2XWSXW6LJQDOV
&DVFDGH)LULQJ%RDUG
2YHUYLHZRIWKH&)%
'HVFULSWLRQRI+DUGZDUH
6&5$VVHPEO\
6HFRQGDU\&XUUHQW,QWHUIDFH%RDUG
2YHUYLHZRIWKH6&,%
7KHRU\RI2SHUDWLRQ
+DUGZDUH6SHFLILFV
$SSOLFDWLRQ6RIWZDUH3DUDPHWHUV
$YDLODEOH&RQILJXUDWLRQV
&KDSWHU ,QVWDOOLQJWKH0HG:HOG
*HWWLQJ6WDUWHG
0DNLQJWKH5HTXLUHG&RQQHFWLRQV
5HPRWH,QWHJUDWLRQ
3URYLGLQJ/RFDODQG6DIHW\,2
6HWWLQJWKH',36ZLWFKHV
6HOHFWLQJWKH,2*URXS
6HOHFWLQJWKH5DFN6L]H
6HWWLQJWKH5DFN$GGUHVV
6HOHFWLQJWKH/DVW5DFN
6HWWLQJWKH&/($521)$8/76WDWXV
6HWWLQJWKH%56%LW5DWH6HOHFW
'HYLFH1HW,QWHJUDWLRQ
3URJUDPPLQJWKH'HYLFH1HW0RGXOH
+DUG7RRO3URFHGXUHV
2SHQLQJ'(9,&(1(70$1$*(5
*RLQJ2Q/LQH
1RGH&RPPLVVLRQLQJ³WR:&8V
1RGH&RPPLVVLRQLQJ³WR:&8V
DQR\U_V3_^dU^dc
=UTGU\T# %?`UbQd_bµc7eYTUV_bD)## " f
= #" "%1`bY\" "
352-(&7²+$5'722/
5RERW3URFHGXUHV
2SHQLQJ'(9,&(1(70$1$*(5
*RLQJ2Q/LQH
1RGH&RPPLVVLRQLQJ³5RERW
352-(&7²52%27
'LVFUHWH,QWHJUDWLRQ
3URYLGLQJ0HG/$1&RQQHFWLRQV
0HG/$1DQG'(36&RQQHFWLRQV
0HG/$1:LULQJ6SHFLILFDWLRQV
&DEOH5HTXLUHPHQWV
&DEOH5RXWLQJ5HTXLUHPHQWV
6HWWLQJWKH:HOG3URFHVVRU0HG/$1$GGUHVV
3URJUDPPLQJWKH:HOG3URFHVVRU
'(363URJUDPPLQJ'HYLFH
0HG/$30HG9,(:DQG0HG9,(:OLWH
:HOGLQJ6XSSRUW6\VWHP;:66
0HG&RPPDQGHU
&KDSWHU &R XQLFDWLRQVDQG,2
/RFDODQG6DIHW\,2
/RFDO,QSXWV
/RFDO2XWSXWV
5HPRWH,2
2UJDQL]DWLRQRIWKH'HYLFH1HW,2
'LVFUHWH,QWHJUDWLRQ
,2'HILQLWLRQV
,QSXWV
2XWSXWV
'(36$EEUHYLDWLRQV
,QSXW$EEUHYLDWLRQV
2XWSXW$EEUHYLDWLRQV
',2$EEUHYLDWLRQV
'LVFUHWH,QSXWV
'LVFUHWH2XWSXWV
'(3630'66W\OH$EEUHYLDWLRQV
,QSXWV
2XWSXWV
&KDSWHU :HOG6FKHGXOHV
:KDWLVD:HOG6FKHGXOH"
6RIWZDUH&DSDELOLWLHV
DQR\U_V3_^dU^dc
fY =UTGU\T# %?`UbQd_bµc7eYTUV_bD)## "
= #" "%1`bY\" "
/LVWRI)XQFWLRQV
'HOD\)XQFWLRQV
:HOG)XQFWLRQVDQG)LULQJ0RGHV
$9&)LULQJ0RGH,
$XWRPDWLF&XUUHQW&RPSHQVDWLRQ)LULQJ0RGH
2WKHU)XQFWLRQV&RQWUROOLQJ:HOG&XUUHQW
2XWSXW&RQWURO)XQFWLRQV
,QSXW0RQLWRULQJ)XQFWLRQV
([WHQG5HSHDW)XQFWLRQV
6WHSSHU$VVLJQPHQW)XQFWLRQV
)XQFWLRQVWKDW2YHUULGH6HWXS3DUDPHWHUV
7HVW)XQFWLRQV
6SHFLDO)XQFWLRQV
63&,QGH[LQJ)XQFWLRQV
&DVFDGH)LULQJ%RDUG6XSSRUW
$QDORJ3UHVVXUH&RQWURO)XQFWLRQV
4XLFN5HIHUHQFH
'HOD\)XQFWLRQVSJ
$9&)LULQJ0RGHSJ
$&&)LULQJ0RGHSJ
2WKHU)XQFWLRQV3URYLGLQJ:HOG&XUUHQWSJ
2XWSXW&RQWURO)XQFWLRQVSJ
,QSXW0RQLWRULQJ)XQFWLRQVSJ
([WHQG5HSHDW)XQFWLRQVSJ
6WHSSHU$VVLJQPHQW)XQFWLRQVSJ
)XQFWLRQVWKDW2YHUULGH6HWXS3DUDPHWHUVSJ
7HVW)XQFWLRQVSJ
6SHFLDO)XQFWLRQVSJ
63&,QGH[)XQFWLRQVSJ
&)%6XSSRUW)XQFWLRQVSJ
$QDORJ3UHVVXUH&RQWURO)XQFWLRQVSJ
'HIDXOW:HOG6FKHGXOHV
'HIDXOW:HOG6HTXHQFH0DFKLQH
'HIDXOW:HOG6HTXHQFH5RERW
7LS'UHVV6HTXHQFH
7LS'UHVV6HTXHQFH
'HIDXOW:HOG6HTXHQFH0DQXDO3RUWDEOH*XQ
&KDSWHU $GYDQFHG6RIWZDUH)HDWXUHV
&)DFWRU
([DPSOHRI'HFUHDVLQJ&)DFWRU
([DPSOHRI,QFUHDVLQJ&)DFWRU
/RZ&)DFWRU/LPLW
'HWHUPLQLQJD/RZ/LPLW
+LJK&)DFWRU/LPLW
'HWHUPLQLQJD+LJK/LPLW
DQR\U_V3_^dU^dc
=UTGU\T# %?`UbQd_bµc7eYTUV_bD)## " fYY
= #" "%1`bY\" "
.9$7
'\QDPLF&XUUHQW:LQGRZV
$9&([DPSOH
$&&)LULQJ0RGH
'\QDPLF6TXHH]H)HDWXUHV
6SHFLI\LQJWKH7HVW)LUH&XUUHQW
'HILQLQJWKH&XUUHQW7KUHVKROG
'\QDPLF6TXHH]H)XQFWLRQV
63&,QGH[LQJ&DSDELOLWLHV
63&)XQFWLRQV
63&VHWXS3DUDPHWHUV
6&56KRUW'HWHFWLRQ
5HWUDFW)HDWXUHV
5HWUDFW0RGH6HWXS3DUDPHWHU
&\OLQGHU7\SH
$LU2QO\&\OLQGHUV
,QLWLDWLRQ)URP5HWUDFW
&KDSWHU 6HWXS3DUD HWHUV
3DUDPHWHU'HVFULSWLRQV
$QDORJ3UHVVXUH&RQWURO
4XLFN5HIHUHQFHWR6HWXS3DUDPHWHUV
&KDSWHU 6WHSSHU'DWD
:KDWLVD6WHSSHU"
/LQHDU6WHSSHUV
'HIDXOW/LQHDU6WHSSHU3URILOH
'LVSOD\DWWKH'(36
6XUH:HOG6WHSSHUV
6XUH:HOG3DUDPHWHUV
'LVSOD\DWWKH'(36
&KDSWHU )DXOW&RQGLWLRQV
&KDSWHU +DUGZDUH7URXEOHVKRRWLQJ
3RZHU6XSSO\
6/&3URFHVVRU
:HOG3URFHVVRU
5,21HWZRUN0RGXOH
DQR\U_V3_^dU^dc
fYYY =UTGU\T# %?`UbQd_bµc7eYTUV_bD)## "
= #" "%1`bY\" "
&RPELQDWLRQ,2
,QSXW0RGXOH
2XWSXW0RGXOH
6ROYLQJ7\SLFDO3UREOHPV
$SSHQGL[,2, DJH7DEOHV $
5,2,PDJH7DEOHV $
+RVW3/&2XWSXW,PDJH7DEOH:HOGHU,QSXWV $
+RVW3/&,QSXW,PDJH7DEOH:HOGHU2XWSXWV $
5,2B+RVW3/&2XWSXW,PDJH7DEOH:HOGHU,QSXWV$
5,2B+RVW3/&,QSXW,PDJH7DEOH:HOGHU2XWSXWV$
5,2B+RVW3/&2XWSXW,PDJH7DEOH:HOGHU,QSXWV$
5,2B+RVW3/&,QSXW,PDJH7DEOH:HOGHU2XWSXWV$
5,2B+RVW3/&2XWSXW,PDJH7DEOH:HOGHU,QSXWV$
5,2B+RVW3/&,QSXW,PDJH7DEOH:HOGHU2XWSXWV$
5,2B+RVW3/&2XWSXW,PDJH7DEOH:HOGHU,QSXWV$
5,2B+RVW3/&,QSXW,PDJH7DEOH:HOGHU2XWSXWV$
'HYLFH1HW,27DEOHV $
GQHWBPDS:HOGHU,QSXWV³1RGH $
GQHWBPDS:HOGHU2XWSXWV³1RGH $
GQHWBPDS:HOGHU,QSXWV³1RGH $
GQHWBPDS:HOGHU2XWSXWV³1RGH $
GQHWBPDS:HOGHU,QSXWV³1RGH $
GQHWBPDS:HOGHU2XWSXWV³1RGH $
=UTGU\T# %?`UbQd_bµc7eYTUV_bD)## " Yh
= #" "%1`bY\" "
*HWWLQJ6WDUWHG
+RZWR*HW+HOS
WTC is committed to quality products, service and support. Our
service department maintains an assistance hotline to assist with
application or troubleshooting problems during normal business
hours.
%\3KRQHRU)D[
To arrange for field service or warranty repair, call one of these
numbers:
ITS (877) 982-7378 Fax: (248) 477-5263
WTC Canada (905) 433-1230 Fax: (905) 433-1257
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.
%\(PDLO
When an immediate response is not critical, contact WTC at the
following e-mail addresses:
WTC’s technical support will respond within 24 hours, Monday
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.
welding-sales@weldtechcorp.com
welding-support@its-wtc.com Sales/Marketing Comments
Technical Support
7UddY^WCdQbdUT
h=UTGU\T# %?`UbQd_bµc7eYTUV_bD)## "
= #" "%1`bY\" "
2QWKH:HE
Visit our Web site at:
www.weldtechcorp.com
%\0DLO
Contact us by mail at the following addresses:
6\PEROV8VHGLQ7KLV0DQXDO
Danger! This symbol will be used wherever failure
to observe safety measures may result in
death, severe bodily injury or considerable
damage to property.
WARNING! This symbol will be used wherever insufficient
or lacking compliance with instructions may
result in personal injury.
3QedY_^*
DXYcci]R_\gY\\RUecUTgXU^Y^ceVVYSYU^d_b\QS[Y^W
S_]`\YQ^SUgYdXdXUY^cdbeSdY_^c]QibUce\dY^
TQ]QWUd_UaeY`]U^d_bVY\Uc
>?D5*
This convention informs the user about special features, or where to find
more information.
WTC
24775 Crestview Court
Farmington Hills, MI 48335
WTC Canada
240 Cordova Road
P. O. Box 8858
Oshawa, Ontario L1J 1N9
7UddY^WCdQbdUT
=UTGU\T# %?`UbQd_bµc7eYTUV_bD)## " hY
= #" "%1`bY\" "
5HYLVLRQ+LVWRU\
6DIHW\:DUQLQJ
7RWKH2SHUDWRU
Danger!
Lethal voltages are present when power is
applied to the welding control. Refer all
necessary service on this machine ONLY to
qualified maintenance personnel.
Failure to observe basic electrical
safety practices may cause
serious injury or death.
Revision Release Date Comments
09/04/98 Released as program #T93300-00-16-26-36.
06/07/00 Released as #T93300-00-18-40-64.
06/30/00 Released as #T93300-00-19-42-67.
01/29/02 Released as #T93300-00-20-48-85.
7UddY^WCdQbdUT
hYY =UTGU\T# %?`UbQd_bµc7eYTUV_bD)## "
= #" "%1`bY\" "
/LPLWHG:DUUDQW\
WTC warrants that this product is free from defects in design,
materials and workmanship for a period of one (1) year from the
date of delivery. IN CASE OF SUCH DEFECTS, WTC’S
LIABILITY IS STRICTLY LIMITED TO REPAIR OR
REPLACEMENT, FOB WTC, WTCOF ANY MATERIALS,
PARTS, OR GOODS WHICH MAY BE DEFECTIVE, AT
WTC’S EXCLUSIVE OPTION.
The foregoing is subject to written notice of any defect being
provided within one (1) year period. WTC shall make no
allowance for repairs or alterations made by the buyer, and
assumes no liability for costs of disassembly and reassembly of
defective materials, parts or goods.
MATERIALS, PARTS OR GOODS FURNISHED BY SUPPLIERS
ARE GUARANTEED ONLY TO THE EXTENT OF THE
ORIGINAL MANUFACTURER’S EXPRESS WARRANTY. WTC
SHALL NOT BE LIABLE FOR DEFECTS WITH RESPECT TO
GOODS WHICH ARE MANUFACTURED AND CONFORM TO
SPECIFICATIONS, DESIGNS, AND PRINTS SUPPLIED BY THE
PURCHASER.
THIS WARRANTY IS MADE IN LIEU OF ALL OTHER
CONDITIONS, WARRANTIES, REPRESENTATIONS, OR
GUARANTEES. THERE ARE NO OTHER CONDITIONS,
REPRESENTATIONS, WARRANTIES, OR GUARANTEES,
WRITTEN OR ORAL, EXPRESS OR IMPLIED, STATUTORY OR
NON-STATUTORY, INCLUDING ANY CONDITION,
WARRANTY, REPRESENTATION OR GUARANTEE OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE. THIS STATES WTC’S ENTIRE LIABILITY FOR
DEFECTS IN THE GOODS, INCLUDING DEFECTS IN DESIGN,
MATERIALS, WORKMANSHIP OR OTHERWISE. WTC SHALL
NOT IN ANY EVENT BE LIABLE FOR PENALTIES OR DIRECT,
INDIRECT, SPECIAL, CONSEQUENTIAL, INCIDENTAL, OR
LIQUIDATED DAMAGES OF ANY KIND, INCLUDING
LIABILITY FOR LOSS OF PROFIT, LOSS OF USE, COSTS OF
CAPITAL, DOWNTIME COSTS, COSTS OF SUBSTITUTIVE
MATERIALS, COSTS OF SUBSTITUTIVE GOODS, FACILITIES,
OR SERVICES, LIABILITY TO THIRD PARTIES, FAILURE TO
MEET THE BUYER’S OR ANY THIRD PARTY
SPECIFICATIONS, PURPOSES OR DESIGNS, OR FOR FAILURE
TO WARN.
7UddY^WCdQbdUT
=UTGU\T# %?`UbQd_bµc7eYTUV_bD)## " hYYY
= #" "%1`bY\" "
&RS\ULJKW
WTC software is copyrighted and all rights are reserved by WTC.
The distribution and sale of this 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 without prior written authorization and
payment of royalty fees.
FNQRZOHGJPHQWV
MedLAN is the proprietary local area network used to
interconnect products manufactured by WTC.
The following companies own the marks following their names:
•Allen-Bradley, SLC
•Microsoft Windows ™
3DWHQWV
WTC products are covered by one or more of the following
patents held by WTC:
Additional patents are pending.
3,736,445
4,001,540
4,104,724
4,251,764
4,254,466
4,282,417
4,289,948
4,289,951
4,301,351
4,388,515
4,399,511
4,456,809
4,459,456
4,459,457
4,463,244
4,513,363
4,516,008
4,733,045
4,804,819
4,831,229
4,849,873
4,851,635
4,885,451
4,945,201
5,386,096
5,449,877
5,128,507
5,424,506
5,589,088
5,757,176
5,793,243
5,128,507
5,424,506
5,589,088
5,757,176
5,793,243
7UddY^WCdQbdUT
hYf =UTGU\T# %?`UbQd_bµc7eYTUV_bD)## "
= #" "%1`bY\" "
:RUNLQJZLWK6WDWLF6HQVLWLYH'HYLFHV
This equipment contains electronic devices which are sensitive to
electrostatic discharge. Observe the following warnings AT ALL
TIMES, to prevent damage to these devices. Disregarding any of
these warnings may cause damage to the equipment.
WARNINGS! NEVER remove any circuit board
with AC power applied.
NEVER use the personnel grounding system
described below when working with
voltages above 220 VAC.
3HUVRQQHO
*URXQGLQJ
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.
+DQGOLQJRU0RYLQJ
(6'6'HYLFHV
Handle all circuit boards by their edges ONLY. NEVER touch the
traces or edge pad connectors.
Transport, store and ship ESDS devices and circuit boards in a
static shielding container. An acceptable container is either a
static shielding bag or a static shielding tote. To be effective,
either type of container MUST be closed.
>?D5*
UseONLYstatic-shielding containers fortransportingESDSdevicesor
circuit boards.
:RUNVWDWLRQ
5HTXLUHPHQWV
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.
&RQWDFW
,QIRUPDWLRQ
For detailed information about ESD precautions, contact
ESD Association
Phone: 315–339–6937
Fax: 315–339–6793
e-mail: eosesd@aol.com
Web: www.esda.org
7UddY^WCdQbdUT
=UTGU\T# %?`UbQd_bµc7eYTUV_bD)## " hf
= #" "%1`bY\" "
&RROLQJ:DWHU5HTXLUHPHQWV
The cooling water provided must comply with chemical and
physical specifications as stated in the Resistance Welder
Manufacturers’Association Bulletin 5–005.05:
•Maximum temperature not to exceed 104°F. (40°C.), or fall
below the dew point of ambient air at about 70°F. (21°C.).
•Maximum pressure not to exceed 90 PSIG
•pH maintained between 7.0 and 8.0
•Maximum chloride content 20 parts per million (PPM)
•Maximum nitrate content 10 PPM
•Maximum sulfate content 100 PPM
•Maximum suspended solids content 100 PPM, non-abrasive
•Maximum total (suspended and dissolved) solids content 250
PPM
•Maximum calcium carbonate content 250 PPM
•Resistivity less than 2,000 ohms/cm at 25°C. (500 µS)
•The hose used must be NO LESS THAN 18 in. long across the
power voltages.
>?D5*
Water that is safe for drinking is generally sufficient for cooling water,
provided it is filtered to eliminate sand and rust particles. In addition,
temperature of the cooling water must NOT fall more than 2°C. below
the temperature of the surrounding air.
:DWHU)ORZ5DWH
In general, the SCRs require a MINIMUM flow rate of 0.5 gallon
(2 liters) per minute. The recommended maximum is 1.0 gal (4 l.)
per minute. Larger SCRs (2,100 A. or greater) may require a
higher flow rate. Consult WTC for more information.
WARNING! This warning applies ONLY to SCRs having cooling-
water hosing connected either between tangs, or
between tang and ground:
REMOVE POWER from the SCR if the cooling water
is not flowing and the resistivity of the water is less
than 2,000 ohms/cm @ 25°C, or conductivity is
greater than 500 µS @ 25°C.
7UddY^WCdQbdUT
hfY =UTGU\T# %?`UbQd_bµc7eYTUV_bD)## "
= #" "%1`bY\" "
If water circulation stops or is interrupted while the power is on,
leakage current through the water in the hose between the SCR
tangs will cause gas bubbles to form. Current will arc across these
voids, weakening or destroying the hose. Putting the water into
circulation again develops pressure in the cooling circuit,
consequently causing the hose to rupture. Therefore, WTC does
NOT recommend the use of water savers with these SCRs.
When magnetic contactors are used, they remove power from the
SCR module and prevent destruction of the hose. If cooling
manifolds are used (rather than hose), leakage current through
the water can cause the same destructive action to occur while
power is being applied. This can destroy the cement holding the
manifold together, resulting in serious water leaks. (WTC’s
warranty specifically does NOT cover such failures.)
+RVHV
If a cooling hose needs replacing, use a certified non-electrically
conductive hose. Its inside diameter must NOT exceed 3/8”. The
hose between SCR tangs must be at least 18 inches long across the
power voltages, where SCR tangs are directly cooled.
(OHFWULFDO
&KDUDFWHULVWLFV
The SCR module has three main electrical ratings:
•PIV—Peak inverse voltage rating,
•Insulation voltage rating and
•Nominal current rating.
The PIV rating represents the maximum voltage allowed across
the SCR inverse parallel pair before damage occurs. The PIV for
the standard SCR module (p/n #304-0081) is 1,800 V. If the PIV is
exceeded, the control attempts to protect the SCR by activating
the shunt trip.
The insulation voltage rating represents the maximum voltage
allowed between the SCR tang (L or H) and ground before
damage can occur. The insulation voltage rating of a standard
SCR module (p/n #304-0081) is approximately 2,500 V.
continuous and 3,200 V. for transients.
The nominal current rating is the maximum current (at 50% duty
cycle and 0.5 sec. maximum on-time per weld) that the SCR can
withstand before damage occurs. (For a weld on-time exceeding
0.5 sec., the SCR should NOT be used above its continuous-duty
rating. This is 70 percent of the nominal current rating.)
The nominal current rating for a standard SCR (p/n # 304-0081)is
1,100 A. at 50% duty cycle and 0.5 sec. maximum on-time per
weld. If using this SCR for on-time longer than 0.5 sec., the
maximum allowable current is reduced to 70 percent, or 770 A.
=UTGU\T# %?`UbQd_bµc7eYTUD)## " !!
= #" "%1`bY\" "
0HG:HOG2YHUYLHZ
The MedWeld 3005 welding control represents a new phase in
resistance welding technology. The unit integrates a weld control
with a programmable controller located in the weld control
enclosure.
The card rack design allows the control to communicate with the
welding automation: either machine controllers, factory
automation or manually operated welders. (The type of
integration is determined by the ladder software program loaded
into the SLC processor.)
6\VWHP'HVFULSWLRQ
The MedWeld 3005 weld control sits as a combination of modules
mounted in the controller chassis for an Allen-Bradley ™SLC-
500 Programmable Controller. A weld processor sends firing
signals to its firing card through a firing cable harness plugged
directly into the weld processor card.
This modular design allows use in a number of applications. Two
forms of integration are possible:
•Discrete interface (DIO), where the weld control can exchange
I/O with a machine, robot or portable gun controller. The
control communicates using inputs from the automation and
outputs to the automation.
•A remote I/O (RIO)interface, providing a direct link to the
Allen-Bradley RIO network in a host PLC. This scheme
allows the weld processor to emulate a logical quarter-rack
on an Allen-Bradley RIO bus, where standard remote I/O is
shared by the weld control and PLC.
•The DeviceNet ™ interface. This open communications
standard provides a low-cost communications link with I/O
messaging between the welding control and tool.
=UTGU\T# %?fUbfYUg
!" =UTGU\T# %?`UbQd_bµc7eYTUD)## "
= #" "%1`bY\" "
With the RIO interface, the rack contains an RIO network
module. In addition, a combination I/O module provides
discrete (local) inputs and outputs for safety interlocks. See “RIO
Integration”on page 1-8.
The DeviceNet interface also requires a module in the control
rack and uses the Combination I/O module to provide discrete
(local) inputs and outputs for safety interlocks. This is described
in “DeviceNet Integration”on page 1-8.
When the control uses a discrete interface, the rack contains an
input module and an output module, described in “Discrete I/O
Modules”on page 1-13.
These advanced integration options add flexibility to the WTC
design, providing full-function and programming capabilities.
You can program 31 independent weld schedules, then assign a
weld schedule to one of 62 independent steppers (to compensate
for lost current density).
The control compensates for changes in the welding environment
by monitoring the voltage and increasing the current as required
to assure consistent welds. The primary current (I) changes as the
voltage fluctuates. For example, if E drops, the processor firing
phase shifts forward (to increase I) until E stabilizes.
You can program a weld function to use either Automatic Voltage
Compensation (to maintain a desired primary voltage) or
Automatic Current Compensation (to maintain constant
secondary current).
The MedWeld 3005 can perform the weld, delay, slope, pulsation
or timing functions that your application requires. Other features
allow control of outputs, and monitor the status of inputs.
3K\VLFDO'HVFULSWLRQ
The MedWeld 3005 weld processor consists primarily of two
printed circuit boards: The weld processor and the firing card.
The weld processor is mounted in the chassis of an Allen-Bradley
programmable controller, to support the integration options.
Figure 1 on the facing page illustrates the weld control.
=UTGU\T# %?fUbfYUg
=UTGU\T# %?`UbQd_bµc7eYTUD)## " !#
= #" "%1`bY\" "
Figure 1:
=UTGU\T# %GU\T
3_^db_\
The Allen-Bradley chassis houses these major components:
•Allen-Bradley power supply, mounted on the left side of the
chassis. (See Figure 2 on page 1-4.)
•SLC-500 processor (Figure 3 on page 1-4)
•MedWeld 3005 weld processor (Figure 4 on page 1-6)
•Communications modules (for RIO, DeviceNet or DIO).
The following sections describe these components.
ALLEN-BRADLEY
PROGRAMMABLE
CONTROLLER
MEDAR FIRING
MODULE
=UTGU\T# %?fUbfYUg
!$ =UTGU\T# %?`UbQd_bµc7eYTUD)## "
= #" "%1`bY\" "
&KDVVLV
A 4-slot chassis mounts the SLC processor, WTC weld processor
and two interface modules. (The latter can be either RIO Network
and local modules or the DIO input and output modules.)
Figure 2:
1\\U^2bQT\Ui$C\_d
3XQccYcgYdX@_gUbCe``\i
$OOHQ%UDGOH\
3RZHU6XSSO\
The power supply provides power to the Allen-Bradley
programmable controller. It also supplies the power needed for
I/O communications and external programming devices.
>?D5*
The power supply DOES NOT occupy a slot in the chassis. It mounts on
the left side with two Phillips-head screws located in the top and bottom
right corners, under the faceplate.
6/&3URFHVVRU
The Allen-Bradley SLC-500 processor provides the interface
between the MedWeld 3005 processor module and any
automation system or welding station.
(Refer to “Available Configurations”on page 1-24, and the
integration options described in “RIO Integration”on page 1-8
and “Discrete I/O Modules”on page 1-13.)
Figure 3:
1\\U^2bQT\UiC<3%
@b_SUcc_b
A-B Power
Supply
SLC-500 Module MedWeld 3005
Weld Processor Integration
modules
Table of contents
Other WTC Control Unit manuals
Popular Control Unit manuals by other brands
Advantech
Advantech PCM-3526 Startup manual
Delta
Delta DVPEN01-SL Operation manual
Control Technology Inc.
Control Technology Inc. CTI 2559-TC Installation and operation guide
morse
morse 5154 Series Operator's manual
Honeywell
Honeywell PW6K1R1E Installation and configuration guide
Marmitek
Marmitek W home TM13AU manual
