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MedWeld 5000
WTC MedWeld 5000 Technical Reference Manual
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MedW
eld 5000
Integrated W
eld Contr
ol
T
echni
cal Reference M
anual
Software #F04100 an
d #F0430
0
Revision
02
Modified: 1
/31/06
Part No. M-
032170
Copyright ©
2006
, WTC
2
Table of Contents
Default Chapter
3
Table of Contents
3
Revision History
9
How to Use this Manual
10
Chapter 1 Medweld 5000 Overview
19
System Description
19
Welding with the MFDC Inverter
19
Timer Unit
21
Devicenet Integration
23
Timer Interface to the Inverter
23
Timer Unit Output
23
Timer Unit Input
23
Component Descriptions
24
Circuit Breaker
24
Isolation Contactor
24
Charging Pack
24
Control Transformer
25
MFDC Inverter
25
Timer Unit
25
Chapter 2 Installing the Medweld 5000
27
Getting Started
27
Making the Required Connections
27
Devicenet Integration
28
Providing Medlan Connections
29
Medlan and DEP-100S Connections
29
Medlan Wiring Specifications
29
Cable Requirements
29
Cable Routing Requirements
30
Setting the Timer Medlan Address
30
Programming the Timer Unit
31
Flexible I/O List
33
DEP-100S Programming Device
37
Chapter 3 Communications and I/O
39
Local and Safety I/O
39
Local Inputs
39
Local Outputs
40
Organization of the Devicenet I/O
41
I/O Definitions
41
Inputs
41
Outputs
46
Devicenet Bitmap
49
DEP-100S Abbreviations
51
Output Abbreviations
52
Chapter 4 Weld Schedules
53
What Is a Weld Schedule
53
Software Capabilities
54
List of Functions
55
Medweld 5000 Funcitons
55
Function Descriptions
59
Delay Functions
59
Weld Functions
61
Weld Functions Using Automatic Current Compensation
62
Weld Functions that Adjust Current
64
Special Functions
66
Special Function Definitions
66
Default Weld Sequence: Robot
70
Default Weld Sequence: Machine
70
Chapter 5 Advanced Software Features
71
C-Factor
71
Dynamic Current Windows
72
AVC Example
72
ACC Firing Mode
73
SPC Indexing Capabilities
74
SPC Functions
74
SPC Setup Parameters
75
Retract Features
77
Retract Mode Setup Parameter
77
Initiation from Retract
78
DEP-100S Programming Restrictions
78
Weld/No Weld Status
78
Viewing Weld Data
79
Stepper Function
81
Chapter 6 Setup Parameters
83
Parameter Descriptions
84
Default Settings
93
Chapter 7 Stepper Data
95
What Is a Stepper
95
Linear Steppers
96
Auxiliary Weld Counters
96
Default Linear Stepper Profile
97
Display at the DEP-100S
98
Chapter 8 Fault Conditions
99
List of Faults
100
Chapter 9 Hardware Troubleshooting
111
Power Supply
111
Processor
112
Weld Processor
113
Solving Typical Problems
115
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WTC MedWeld 5000 Specifications
General
Category
Welding System
Duty Cycle
60% at 500A
Output Current Range
50A - 500A
Welding Processes
MIG, TIG, MMA
Power Supply
380-415V, 3-phase, 50/60Hz
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