WTC MedWeld 4000 Manual

MedWeld 4000
Resistance Weld Control
Operator’s Guide for Software Programs:
• #T03300 (AC Standard)
• #T03302 (AC w/Ohma Cylinder Support)
• #T03310 (AC - GM WS2)
• #T03311 (AC - GM WS2 / ABB Robot)
• #T02300 (MFDC Standard)
• #T02301 (MFDC Type 1 Inverter)
• #T02302 (MFDC w/Ohma Cylinder & Pressure Control)
• #T02304 (MFDC Multi-Inverter)
• #T02306 (MFDC Multi-Inverter w/Forge)
Revision 04
Modified: 09/17/08
Manual No. M-032116
Copyright © 2008, WTC

MedWeld 4000 Operator’s Guide Modified: 9/17/08 ii
M-032116 Programs #T03300, #T02300 and #T02400
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-ii
Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-x
If You Need Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-x
Welding Technology Corp. (WTC) . . . . . . . . . . . . . . . . . . . . . . . . 1-x
By Phone or Fax: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-x
By E-mail: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-x
On the Web: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-x
Symbols Used in This Manual . . . . . . . . . . . . . . . . . . . . . 1-xi
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-xii
Safety Dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-xii
How to Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . 1-xiii
Software Updates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-xiv
Cooling Water Requirements . . . . . . . . . . . . . . . . . . . . . .1-xv
Specifications on the Web . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-xv
Cooling Water Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-xv
Water Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-xv
SCRs with Hose Running Between Tangs at 480 VAC. . . . . . . .1-xvi
Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-xvi
Working with Static-Sensitive Devices . . . . . . . . . . . . . .1-xvii
ESD Costs! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-xvii
Personnel Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-xvii
Handling or Moving ESDS Devices . . . . . . . . . . . . . . . . . . . . . 1-xvii
Workstation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-xvii
Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-xvii
Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-xviii
Patents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-xviii
Problem Report Form . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-xx
Your Feedback Welcome Here! . . . . . . . . . . . . . . . . . . .1-xxii
Comments for Feedback Form . . . . . . . . . . . . . . . . . . . . . . . . . 1-xxii

Table of Contents
iii Modified: 9/17/08 MedWeld 4000 Operator’s Guide
M-032116 Programs #T03300, #T02300 and #T02400
Chapter 1 MedWeld 4000 Overview . . . . . . . . . . . . . . . 1-1
Control Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Physical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Type 1 (Medar) MFDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Type 1 Inverter Specifications . . . . . . . . . . . . . . . . . . . . . . 1-5
Type 1 (60 Hz) Inverter 600 Amp . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Type 1 (50 Hz) Inverter 600 Amp . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Type 2 (Common) MFDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Type 2 (60 Hz) Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Component Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Isolation Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Control Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Current Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Timer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
FieldBus Daughter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Configuring the FieldBus Daughter Board . . . . . . . . . . . . . . . . . 1-15
Module Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Network Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Configuration Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Switches (Fieldbus Specific Input Register) . . . . . . . . . . . . . . . . . . . 1-16
Discrete I/O Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
DC Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
AC Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Firing Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Firing Card Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Firing Card Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Cascade Firing Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
SCR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Secondary Current Interface Board . . . . . . . . . . . . . . . . . . . . . . 1-22
MFDC Control Description . . . . . . . . . . . . . . . . . . . . . . . 1-23
Weld Processor Interface to the Inverter . . . . . . . . . . . . . . . . . . . 1-23
Weld Processor Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Weld Processor Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
MFDC Control Component Descriptions . . . . . . . . . . . . .1-25
Charging Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Control Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
MFDC Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Weld Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

Table of Contents
MedWeld 4000 Operator’s Guide iv
M-032116 Programs #T03300, #T02300 and #T02400
Chapter 2 Installing the MedWeld 4000 . . . . . . . . . . . . 2-1
Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Wire Routing and Separation Guidelines . . . . . . . . . . . . . .2-4
Providing I/O Connections . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Providing Local I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
FieldBus Communications . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Providing MedLAN Connections . . . . . . . . . . . . . . . . . . . . 2-6
MedLAN and
DEP-100S Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
MedLAN Wiring Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Cable Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Cable Routing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Setting the Weld Processor MedLAN Address . . . . . . . . . . . . . . 2-10
Programming the Weld Processor . . . . . . . . . . . . . . . . . . .2-12
DEP-100S Programming Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
How to Program I/O Mappings . . . . . . . . . . . . . . . . . . . . .2-14
Initial Preparation for I/O Assignment . . . . . . . . . . . . . . . . . . . . 2-14
T03300 (AC Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
T02300 (Type 1 Inverter Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Options for Mapping I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
The I/O Options Screen (Discrete) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
The I/O Options Screen (FieldBus) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Mapping Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Mapping Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Required Electrical Connections . . . . . . . . . . . . . . . . . . . .2-24
Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
I/O Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Required Torque for Electrical Connections . . . . . . . . . . .2-25
Required Torque: SCRs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Required Torque: Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . 2-26
Required Torque: Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

Table of Contents
v Modified: 9/17/08 MedWeld 4000 Operator’s Guide
M-032116 Programs #T03300, #T02300 and #T02400
Chapter 3 Communications and I/O . . . . . . . . . . . . . . . 3-1
Local I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Local Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Local Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Programmable Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . .3-4
Example Input Mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Example Output Mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Supported I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Input Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Input Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Output Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Other I/O: Program T02300 . . . . . . . . . . . . . . . . . . . . . . .3-13
FieldBus Inputs: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
FieldBus Outputs: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Discrete Inputs: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Discrete Outputs: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
fInput/Output Mappings (T02300) . . . . . . . . . . . . . . . . . .3-18
Input Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Output Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Input/Output Mappings (T03300) . . . . . . . . . . . . . . . . . . . 3-20
Input Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Output Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Setting the Word Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Chapter 4 Weld Schedules . . . . . . . . . . . . . . . . . . . . . . 4-1
What is a Weld Schedule? . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Software Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
List of Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Delay Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Weld Functions and Firing Modes . . . . . . . . . . . . . . . . . . . . . . . . 4-3
AVC Firing Mode (%I) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Automatic Current Compensation Firing Mode . . . . . . . . . . . . . . . . . 4-5
Other Functions Controlling Weld Current . . . . . . . . . . . . . . . . . . 4-6
Output Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Input Monitoring Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Extend/Repeat Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Stepper Assignment Functions . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Functions that Override Setup Parameters . . . . . . . . . . . . . . . . . 4-14
Test Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Special Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
SPC Indexing Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Analog Pressure Control Functions . . . . . . . . . . . . . . . . . . . . . . 4-21
Cascade Firing Board Support . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Table of Contents
MedWeld 4000 Operator’s Guide vi
M-032116 Programs #T03300, #T02300 and #T02400
Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Delay Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
AVC Firing Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
ACC Firing Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Other Functions Providing Weld Current . . . . . . . . . . . . . . . . . . 4-24
Output Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Input Monitoring Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Extend/Repeat Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Stepper Assignment Functions . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Functions that Override Setup Parameters . . . . . . . . . . . . . . . . . 4-25
Test Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Special Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
SPC Index Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Analog Pressure Control Functions. . . . . . . . . . . . . . . . . . . . . . . 4-25
CFB Support Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Default Weld Schedules in Program #T03300 . . . . . . . . . 4-26
Default Weld Sequence: Robot . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Default Weld Sequence: Machine . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Default Weld Sequence: Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Default Weld Schedules in Program #T02300 . . . . . . . . . 4-27
Default Weld Schedule: Robot . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Default Weld Schedule: Machine . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Default Weld Schedule: Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Default Weld Schedules in Program #T02301 . . . . . . . . . 4-29
Default Weld Schedule: Robot . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Default Weld Schedule: Machine . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Default Weld Schedule: Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Default Weld Schedules in Program #T02302 . . . . . . . . . 4-31
Default Weld Schedule: Robot . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Default Weld Schedule: Machine . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Default Weld Schedule: Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Default Weld Schedules in Program #T02304 . . . . . . . . . 4-33
Default Weld Schedule: Robot . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Default Weld Schedule: Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Default Weld Schedules in Program #T02306 . . . . . . . . . 4-34
Default Weld Schedule: Machine . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Default Weld Schedule: Seam . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Function List T03300 (Standard AC) . . . . . . . . . . . . . . . .4-35
Function List T03302 (AC w/Ohma Cylinder Support) . . 4-37
Function List T03310 (AC - GM WS2 Specification) . . .4-39
Function List T03311 (AC - GM WS2 / ABB Robot) . . .4-41
Function List T02300 (Standard MFDC Software) . . . . .4-43
Function List T02301 (Medar MFDC Inverter Type 1) . .4-45

Table of Contents
vii Modified: 9/17/08 MedWeld 4000 Operator’s Guide
M-032116 Programs #T03300, #T02300 and #T02400
Function List T02302 (MFDC w/Pressure Control and Ohma
Cylinder) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47
Function List T02304 (MFDC for Multi-inverter Systems) 4-49
Function List T02306 (MFDC for Multi-inverter Systems with
Forge Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-51
Chapter 5 Setup Parameters . . . . . . . . . . . . . . . . . . . . . 5-1
Parameter Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Inverter Fault Status (MFDC - T023xx Softwares) . . . . . . . . . . 5-17
Inverter Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Quick Reference to Setup Parameters (T03300) . . . . . . . .5-22
Quick Reference to Setup Parameters (T03302) . . . . . . . .5-24
Quick Reference to Setup Parameters (T03310) . . . . . . . .5-26
Quick Reference to Setup Parameters (T03311) . . . . . . . .5-28
Quick Reference to Setup Parameters (T02300) . . . . . . . .5-30
Quick Reference to Setup Parameters (T02301) . . . . . . . .5-32
Quick Reference to Setup Parameters (T02302) . . . . . . . .5-34
Quick Reference to Setup Parameters (T02304) . . . . . . . .5-36
Quick Reference to Setup Parameters (T02306) . . . . . . . .5-38
Chapter 6 Stepper Data . . . . . . . . . . . . . . . . . . . . . . . . 6-1
What is a Stepper? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Linear Steppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Default Linear Stepper Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Display at the
DEP-100S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Table of Contents
MedWeld 4000 Operator’s Guide viii
M-032116 Programs #T03300, #T02300 and #T02400
Chapter 7 Advanced Software Features . . . . . . . . . . . . 7-1
C-Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Example of Decreasing C-Factor . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Example of Increasing C-Factor . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Low C-Factor Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Determining a Low Limit: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
High C-Factor Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Determining a High Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Dynamic Current Windows . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
AVC Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
ACC Firing Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Dynamic Squeeze Features . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Specifying the Test Fire Current . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Defining the Current Threshold . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Dynamic Squeeze Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
SPC Indexing Capabilities . . . . . . . . . . . . . . . . . . . . . . . . .7-8
SPC Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
SPC Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
SCR Short Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Retract Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12
Retract Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Cylinder Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Air-Only Cylinders: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Air Over Oil Cylinders: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Example Weld Schedule: Air Over Oil Cylinder Operation . . . . . . . 7-18
Initiation From Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
DEP-100S Programming Restrictions . . . . . . . . . . . . . . .7-21
Weld/No Weld Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Viewing Weld Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Stepper Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Chapter 8 Fault Conditions . . . . . . . . . . . . . . . . . . . . . 8-1
AC Control Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
MFDC Fault Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
MFDC Fault Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . .8-15
Chapter 9 Hardware Troubleshooting . . . . . . . . . . . . . 9-1
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2
Weld Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Solving Typical Problems . . . . . . . . . . . . . . . . . . . . . . . . . .9-5

Table of Contents
ix Modified: 9/17/08 MedWeld 4000 Operator’s Guide
M-032116 Programs #T03300, #T02300 and #T02400
Chapter 10 Application Note: Current Compensation . 10-1
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Current Compensation Information for AC Products . . . .10-1
Background Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Chapter 11 Application Note: Cascade Welding . . . . . 11-1
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Cascade Welding Information for AC Products . . . . . . . . 11-1
Background Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Parallel Cascade Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Multiple Output Cascade Method . . . . . . . . . . . . . . . . . . . . . . . . 11-2
The Differences Between Method 1 and 2 . . . . . . . . . . . . . . . . . 11-3
Weld Schedules in Cascade Welds . . . . . . . . . . . . . . . . . . 11-3

MedWeld 4000 Operator’s Guide Modified: 9/17/08 x
M-032116 Programs #T03300, #T02300 and #T02400
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 -xx.
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
xi Modified: 9/17/08 MedWeld 4000 Operator’s Guide
M-032116 Programs #T03300, #T02300 and #T02400
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 4000 Operator’s Guide Modified: 9/17/08 xii
M-032116 Programs #T03300, #T02300 and #T02400
Revision History
Safety Dangers
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.
Danger! NEVER drill into the control cabinet without
properly protecting internal components from
metal debris and removing power. Failure to
observe this requirement may cause a
potential EXPLOSION HAZARD.
Revision Release Date Comments
1 01/0/03 Released as program #T03300-01.
2 06/05/03 Release of preliminary manual for beta test
sites.
3 07/14/03 Release of Revision 03 manual reflecting addi-
tion of inverter Type 1 and Type 2 functionality.
4 09/15/08 Added other MW4000 softwares for AC and
MFDC.

Getting Started
xiii Modified: 9/17/08 MedWeld 4000 Operator’s Guide
M-032116 Programs #T03300, #T02300 and #T02400
Danger! Always ensure proper flow rate, temperature
and chemistry of cooling water. Obstructed or
insufficient flow of cooling water may damage
welding transformers, SCRs or MFDC inverters.
Refer to “Cooling Water Requirements” on page
-xv for more details.
Danger! NEVER remove circuit boards with
110 VAC (or higher voltage) power applied. Be
certain to REMOVE POWER BEFORE servicing,
installing or removing circuit boards.
Caution:
When lifting any weight over 20 kg (~45 lb.),
use either a two-man lift or an assisted lift.
How to Use this Manual
This manual is designed as a reference guide. Use it as you would a
dictionary. See the Table of Contents to locate the instructions or
information you require. For additional details, you are referred to the
appropriate sections and page numbers.
The Table of Contents lists each section and subsection. In these
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.

Getting Started
MedWeld 4000 Operator’s Guide Modified: 9/17/08 xiv
M-032116 Programs #T03300, #T02300 and #T02400
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 -xxii, or by visiting WTC’s Web site: www.weldtechcorp.com.

Getting Started
xv Modified: 9/17/08 MedWeld 4000 Operator’s Guide
M-032116 Programs #T03300, #T02300 and #T02400
Cooling Water Requirements
Specifications on the
Web The specifications for cooling water are subject to change. For the latest
specifications, go to the WTC Web site:
http://www.weldtechcorp.com/documentation/index.html.
Cooling Water
Specifications 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.
NOTE: Water that is safe for drinking is generally sufficient for cooling water,
provided it is filtered to eliminate sand and rust particles. In addition,
water temperature must NOT fall more than 2°C. below the temperature
of the surrounding air.
Water Flow Rate 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.

Getting Started
MedWeld 4000 Operator’s Guide Modified: 9/17/08 xvi
M-032116 Programs #T03300, #T02300 and #T02400
SCRs with Hose
Running Between
Tangs at 480 VAC.
The following warning applies ONLY to SCRs which have the water
cooling hose running between tangs at 480 VAC (non-isolated).
WARNING! 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 μSiemens @ 25°C.
If water circulation (in hosing between tangs) 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 in 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 EXCLUDES such failures.)
Hoses If a cooling hose (for non-isolated SCRs) 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 the SCR tangs are directly cooled.

Getting Started
xvii Modified: 9/17/08 MedWeld 4000 Operator’sGuide
M-032116 Programs #T03300, #T02300 and #T02400
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]

Getting Started
MedWeld 4000 Operator’s Guide Modified: 9/17/08 xviii
M-032116 Programs #T03300, #T02300 and #T02400
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

Getting Started
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This page is intentionally left blank.

Getting Started
MedWeld 4000 Operator’s Guide Modified: 9/17/08 xx
M-032116 Programs #T03300, #T02300 and #T02400
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 ###: