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MedWeld 3005
WTC MedWeld 3005 User Manual
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MedW
eld 3005
Resistance W
e
ld Control
Ope
rator
’s
G
uide
for
T93300
–20
Re
vision 01
F
ebr
uar
y
, 2
002
P
ar
t No
. M
-032
025
Cop
yright © 2001
, WTC
WELDING TECHNOLOGY CORPORAT
ION
150 E
ast St. Charles R
oad
24775 C
restview Cour
t
Carol S
tream, IL
60188 U.S.A.
Farm
ington Hills, MI 48
335 U.S.A.
Voic
e:
(800
) 323-29
03
Voic
e:
(248) 47
7-3900
(630
) 462-82
50
Fax:
(248) 47
7-8897
Fax:
(63
0) 462-82
59
2
Table of Contents
Table of Contents
3
Getting Started
9
How to Get Help
9
By Phone or Fax:
9
By E-mail:
9
On the Web:
10
By Mail:
10
Symbols Used in This Manual
10
Revision History
11
Safety Warning
11
To the Operator:
11
Limited Warranty
12
Copyright
13
Acknowledgments
13
Patents
13
Working with Static-Sensitive Devices
14
Personnel Grounding
14
Handling or Moving ESDS Devices
14
Workstation Requirements
14
Contact Information
14
Cooling Water Requirements
15
Water Flow Rate
15
Hoses
16
Electrical Characteristics
16
MedWeld 3005 Overview 1
17
System Description
17
Physical Description
18
Chassis
20
Allen-Bradley™ Power Supply
20
SLC-500 Processor
20
WTC Weld Processor
21
RIO Integration
24
RIO Network Module
24
DeviceNet Integration
24
DeviceNet Module
25
MODULE LED Status Indications
26
NET LED Status Indications
26
Numeric Status Codes
27
Combination Module
28
Discrete I/O Modules
29
Discrete Input Modules
29
Discrete Output Modules
30
Component Descriptions
31
Circuit Breaker
31
Isolation Contactor
31
Control Transformer
32
Current Coil
32
Firing Card
32
Firing Card Input Signals
33
Firing Card Output Signals
33
Cascade Firing Board
34
Overview of the CFB
34
Description of Hardware
34
SCR Assembly
34
Secondary Current Interface Board
35
Overview of the SCIB
35
Theory of Operation
36
Hardware Specifics
37
Application Software Parameters
39
Available Configurations
40
Installing the MedWeld 3005 2
41
Getting Started
41
Making the Required Connections
41
Remote Integration
43
Providing Local and Safety I/O
43
Setting the DIP Switches
43
Selecting the I/O Group
44
Selecting the Rack Size
44
Setting the Rack Address
45
Selecting the Last Rack
45
Setting the CLEAR ON FAULT Status
46
Setting the BRS (Bit Rate Select)
46
DeviceNet Integration
46
Programming the DeviceNet Module
47
Hard Tool Procedures
47
Opening DEVICENET MANAGER
48
Going On-Line
48
Node Commissioning—1 to 6 WCUs
49
Node Commissioning—1 to 12 WCUs
50
PROJECT – HARD TOOL
51
Robot Procedures
52
Opening DEVICENET MANAGER
52
Going On-Line
52
Node Commissioning—Robot
53
PROJECT – ROBOT
54
Discrete Integration
55
Providing MedLAN Connections
55
MedLAN and DEP-100S Connections
56
MedLAN Wiring Specifications
56
Cable Requirements
56
Cable Routing Requirements
58
Setting the Weld Processor MedLAN Address
60
Programming the Weld Processor
62
DEP-100S Programming Device
63
MedLAP, MedVIEW and MedVIEW lite
63
Welding Support System (XWSS)
64
MedCommander
64
Communications and I/O 3
65
Local and Safety I/O
65
Local Inputs
66
Local Outputs
67
Remote I/O
68
Organization of the DeviceNet I/O
68
Discrete Integration
69
I/O Definitions
69
Inputs
69
Outputs
74
DEP-100S Abbreviations
77
Input Abbreviations
78
Output Abbreviations
79
DIO Abbreviations
80
Discrete Inputs
80
Discrete Outputs
81
DEP-100S P2 (MDS- 555-Style) Abbreviations
82
Inputs
82
Outputs
83
Weld Schedules 4
85
What is a Weld Schedule?
85
Software Capabilities
86
List of Functions
87
Delay Functions
87
Weld Functions and Firing Modes
87
AVC Firing Mode (%I)
88
Automatic Current Compensation Firing Mode
89
Other Functions Controlling Weld Current
90
Output Control Functions
92
Input Monitoring Functions
93
Extend/Repeat Functions
95
Stepper Assignment Functions
96
Functions that Override Setup Parameters
97
Test Functions
97
Special Functions
101
SPC Indexing Functions
103
Analog Pressure Control Functions
104
Quick Reference
105
Delay Functions (pg. 4-3)
105
AVC Firing Mode (pg. 4-4)
105
ACC Firing Mode (pg. 4-5)
106
Other Functions Providing Weld Current (pg. 4-6)
106
Output Control Functions (pg. 4-8)
106
Input Monitoring Functions (pg. 4-9)
106
Extend/Repeat Functions (pg. 4-11)
107
Stepper Assignment Functions (pg. 4-12)
107
Functions that Override Setup Parameters (pg. 4-13)
107
Test Functions (pg. 4-13)
107
Special Functions (pg. 4-17)
107
SPC Index Functions (pg. 4-19)
107
Analog Pressure Control Functions (pg. 4-20)
107
Default Weld Schedule
108
Default Weld Sequence: Machine
108
Default Weld Sequence: Robot
108
Tip Dress Sequence #14
109
Tip Dress Sequence #15
109
Default Weld Sequence: Manual/ Portable Gun
109
Advanced Software Features 5
111
C-Factor
111
Example of Decreasing C- Factor
112
Example of Increasing C-Factor
112
Low C-Factor Limit
113
Determining a Low Limit:
113
High C-Factor Limit
113
Determining a High Limit
113
KVAT
114
Dynamic Current Windows
114
AVC Example
115
ACC Firing Mode
116
Dynamic Squeeze Features
117
Specifying the Test Fire Current
117
Defining the Current Threshold
117
Dynamic Squeeze Functions
118
SPC Indexing Capabilities
119
SPC Functions
119
SPC setup Parameters
120
SCR Short Detection
121
Retract Features
123
Retract Mode Setup Parameter
123
Cylinder Type
124
Air-Only Cylinders:
124
Initiation From Retract
125
Setup Parameters 6
127
Parameter Descriptions
128
Quick Reference to Setup Parameters
142
Stepper Data 7
145
What is a Stepper?
145
Linear Steppers
146
Default Linear Stepper Profile
147
Display at the DEP-100S
147
SureWeld Steppers
148
SureWeld Parameters
149
Display at the DEP-100S
151
Fault Conditions 8
153
Hardware Troubleshooting 9
165
Power Supply
165
SLC Processor
166
Weld Processor
168
RIO Network Module
170
Combination I/O:
171
Input Module
171
Output Module
173
Solving Typical Problems
174
Appendix: I/O Image Tables
179
RIO Image Tables
179
Host PLC Output Image Table (Welder Inputs):
179
Host PLC Input Image Table (Welder Outputs)
181
RIO_2 Host PLC Output Image Table (Welder Inputs):
183
RIO_2 Host PLC Input Image Table (Welder Outputs)
185
RIO_3 Host PLC Output Image Table (Welder Inputs):
187
RIO_3 Host PLC Input Image Table (Welder Outputs)
189
RIO_4 Host PLC Output Image Table (Welder Inputs):
191
RIO_4 Host PLC Input Image Table (Welder Outputs)
193
RIO_5 Host PLC Output Image Table (Welder Inputs):
195
RIO_5 Host PLC Input Image Table (Welder Outputs)
197
DeviceNet I/O Tables
199
dnet_map Welder Inputs—Node 30
199
dnet_map Welder Outputs—Node 30
200
dnet_map Welder Inputs—Node 30
201
dnet_map Welder Outputs—Node 30
202
dnet1_map Welder Inputs—Node 30
203
dnet1_map Welder Outputs—Node 30
205
4
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WTC MedWeld 3005 Specifications
General
Brand
WTC
Model
MedWeld 3005
Category
Control Unit
Language
English
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