WTC MedWeld 5000 Product manual

MedWeld 5000
Integrated Weld Control
Technical Reference Manual
Software #F04100 and #F04300
Revision 02
Modified: 1/31/06
Part No. M-032170
Copyright © 2006, WTC

MedWeld 5000 Technical Reference Manual Modified: 1/31/06
M-032170

MedWeld 5000 Technical Reference Manual Modified: 1/31/06
Chapter 1 MedWeld 5000 Overview .............................. 1-1
System Description ........................................................................ 1-1
Welding with the MFDC Inverter .................................................. 1-1
Timer Unit ...................................................................................... 1-3
DeviceNet Integration .................................................................... 1-4
Timer Interface to the Inverter ....................................................... 1-4
Timer Unit Output ................................................................................ 1-4
Timer Unit Input ................................................................................... 1-4
Component Descriptions ................................................................ 1-5
Circuit Breaker ............................................................................... 1-5
Isolation Contactor ......................................................................... 1-5
Charging Pack ................................................................................ 1-5
Control Transformer ...................................................................... 1-6
MFDC Inverter .............................................................................. 1-6
Timer Unit ...................................................................................... 1-6
Chapter 2 Installing the MedWeld 5000 ........................ 2-1
Getting Started .................................................................... 2-1
Making the Required Connections ................................................ 2-1
DeviceNet Integration .................................................................... 2-2
Providing MedLAN Connections .................................................. 2-3
MedLAN and DEP-100S Connections .......................................... 2-3
MedLAN Wiring Specifications ........................................................... 2-3
Cable Requirements .............................................................................. 2-3
Cable Routing Requirements ......................................................... 2-4
Setting the timer MedLAN Address .............................................. 2-4
Programming the Timer Unit ......................................................... 2-5
Flexible I/O List ............................................................................. 2-7
Flexible Inputs ...................................................................................... 2-7
DEP-100S Programming Device ................................................... 2-9
Chapter 3 Communications and I/O .............................. 3-1
Local and Safety I/O ........................................................... 3-1
Local Inputs ................................................................................... 3-1
Local Outputs ................................................................................. 3-2
Organization of the DeviceNet I/O ................................................ 3-3
I/O Definitions .................................................................... 3-3
Inputs ............................................................................................. 3-3
Outputs ........................................................................................... 3-8
DeviceNet Bitmap ..............................................................3-11
DEP-100S Abbreviations .................................................. 3-13
Input Abbreviations ..................................................................... 3-13
Output Abbreviations ................................................................... 3-14

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Chapter 4 Weld Schedules ............................................. 4-1
What is a Weld Schedule? ................................................... 4-1
Software Capabilities .......................................................... 4-2
List of Functions ................................................................. 4-3
MedWeld 5000 Funcitons .............................................................. 4-3
Function Descriptions ......................................................... 4-4
Delay Functions ............................................................................. 4-4
Weld Functions .............................................................................. 4-5
Weld Functions Using Automatic Current Compensation ............. 4-7
Weld Functions that Adjust Current .............................................. 4-9
Special Functions ......................................................................... 4-11
Special Function Definitions ....................................................... 4-11
Default Weld Sequence: Robot ......................................... 4-15
Default Weld Sequence: Machine ..................................... 4-15
Chapter 5 Advanced Software Features ........................ 5-1
C-Factor .............................................................................. 5-1
Dynamic Current Windows ................................................. 5-2
AVC Example ................................................................................ 5-2
ACC Firing Mode .......................................................................... 5-3
SPC Indexing Capabilities .................................................. 5-4
SPC Functions ................................................................................ 5-4
SPC setup Parameters .................................................................... 5-5
Retract Features ................................................................... 5-7
Retract Mode Setup Parameter ...................................................... 5-7
Initiation From Retract ................................................................... 5-8
DEP-100S Programming Restrictions ................................ 5-8
Weld/No Weld Status ..................................................................... 5-8
Viewing Weld Data ........................................................................ 5-9
Stepper Function .......................................................................... 5-11
Chapter 6 Setup Parameters .......................................... 6-1
Parameter Descriptions ....................................................... 6-2
Default Settings ..................................................................6-11
Chapter 7 Stepper Data ................................................. 7-1
What is a Stepper? ............................................................... 7-1
Linear Steppers .............................................................................. 7-2
Auxiliary Weld Counters ............................................................... 7-2
Default Linear Stepper Profile ....................................................... 7-3

MedWeld 5000 Technical Reference Manual Modified: 1/31/06
Display at the DEP-100S .................................................... 7-4
Chapter 8 Fault Conditions ........................................... 8-1
List of Faults ....................................................................... 8-2
MFDC Fault Status LEDs .............................................................. 8-3
Chapter 9 Hardware Troubleshooting ........................... 9-1
Power Supply ..................................................................... 9-1
Processor ............................................................................. 9-2
Weld Processor ................................................................... 9-3
Solving Typical Problems ................................................... 9-5

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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 -xv.
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.
[e-mail]
[e-mail]
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.
WA R N IN G ! 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
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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 01/31/05 Initial release of manual.
2 09/07/05 Added F04300 MFDC software parameters.

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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
-xii 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
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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 -xvii, or by visiting WTC’s Web site: www.weldtechcorp.com.

Getting Started
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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.
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 ONLY static-shielding containers for transporting ESDS devices or
circuit boards.

Getting Started
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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
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.
ESD Association
Voice: 315–339–6937
Fax: [phone]
e-mail: [email protected]
Web: www.esda.org
e-mail: [e-mail]
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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MedWeld 5000 Technical Reference Manual 1 - 1
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MedWeld 5000 Overview 1
System Description The MedWeld 5000 provides firing signals to the MFDC inverter, in
turn, the MFDC provides DC welding current.
This modular design allows use in a number of applications and
provides two forms of integration:
• Discrete interface (DIO). The weld control can exchange I/O with a
machine, robot or portable gun controller. The weld control
communicates using inputs from the automation and outputs to the
automation.
• A DeviceNet ™ interface. This open communications standard
provides a low-cost communications link with I/O messaging
between the weld control and tool.
These advanced integration options provide added flexibility to the
WTC design, which provides full-function and programming
capabilities.
The control compensates for changes in the welding environment by
monitoring the voltage and increasing the current as required to ensure
consistent welds. The primary current (I) changes as the voltage
fluctuates (for example, if the weld energy (E) drops, the timer firing
phase shifts forward (to increase I) until E stabilizes.).
You program a weld function specifying current in two ways:
• To use either Automatic Voltage Compensation (to maintain a
desired primary voltage) or
• Automatic Current Compensation (to maintain constant secondary
current).
The MedWeld 5000 can perform the weld, delay, slope, pulsation or
timing functions required by your application. Other functions allow
you to control outputs and monitor the status of inputs.
Welding with the
MFDC Inverter
The MFDC Inverter replaces the silicon-controlled rectifiers (SCR
packs) used to provide the high-voltage welding current to the welding
transformer.
The inverter and timer unit replace both the firing card and the thyristors
used in conventional, single-phase welding. The “intelligent” timer or
regulator/driver allows the inverter to be driven by firing signals from

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the timer unit. It also provides fault detection. Finally, mid-frequency
conversion reduces the size of the welding transformer and the power
line demand required.
• SPC data (Group, bin and part number)
This data can be reviewed this data with a programming device
(such as the WTC DEP-100S Hand-Held Terminal), or use it for
data analysis by programs such as WTC’s WebVIEW.
• Sequence number executed
• Transformer turns ratio
• Minimum, average and maximum DC bus voltage
• Minimum, average and maximum secondary current
•C-factor
• Average on-time
• Number of cycles in the last weld
• Line cycle or milisecond timing
• Stepper data and
• Desired constant current.
The MFDC is different from “traditional” single-phase welding and
high-frequency DC welding in the following ways:
• There is essentially no power factor or impedance in high-
frequency welding that corresponds to the power factor issues of
AC welding. The power factor is high and constant, and the welder
transformer secondary circuit is direct current (DC).
• The welding transformer depends on the applied voltage and circuit
resistance. It is generally independent of the magnetic effects of the
secondary circuit. (Magnetic material in the secondary is not a
consideration.)
• Given a constant applied voltage, the weld current depends
primarily on the resistance of the weld itself. (Welds with different
resistances will result in different weld current.)