Manual M032300 WT6000 G08600 Rev4 RAFT
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nathan0705appleManual M032300 WT6000 G08600 Rev4 RAFT
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USER MANUAL
G6 Weld Controls
Copyright 2014. All rights reserved.
Copyright 2014. All rights reserved.
TABLE OF CONTENTS
REGARDING THIS DOCUMENTATION...................................................... 8
- Revision History......................................................................................8
- Languages Available............................................................................... 8
CHAPTER: 1 UNPACKING THE CONTROL............................................... 15
- Lifting And Moving The Weld Control Cabinet .....................................16
- Lifting Brackets/Eye Bolts ......................................................................16
- Identifying Damaged or Missing Items ...................................................17
CHAPTER 2: SAFETY AND WARNINGS ..................................................... 18
- WT 6000 Cabinet Safety Concerns .........................................................18
CHAPTER 3: SYSTEM OVERVIEW .............................................................. 20
- Gen 6 weld processor ...............................................................................20
- Features .................................................................................................21
- Inside the Control ...................................................................................21
- Interior of the Cabinet ............................................................................23
- Weld Control Specifications.....................................................................24
CHAPTER 4: INSTALLING THE CONTROL ............................................. 28
- Standard Connections.............................................................................28
- Enclosure Safety Labeling .......................................................................29
- Installation Checklist ..............................................................................30
- Electrical Installation .............................................................................39
- Electrical Drawings................................................................................40
- Weld Control Programming and Setup....................................................42
CHAPTER 5: COMMUNICATIONS SETUP ................................................ 46
- EtherNet Setup.......................................................................................47
- ENET IP (EIP) Factory Default Settings ..............................................47
- ENET (Standard Ethernet) Factory Default Settings .............................51
- DeviceNet Setup.....................................................................................53
- WT 6000 Processor LED Descriptions ....................................................55
Copyright 2014. All rights reserved.
CHAPTER 6: PROGRAMMING SCHEDULES............................................ 56
- About Weld Schedules..............................................................................56
- The Four Basic Elements ........................................................................56
- Weld Schedule Functions.........................................................................57
- Example of a Weld Schedule....................................................................58
- How to Read a Weld Schedule.................................................................59
- Programming a Weld Schedule................................................................59
- Insert a Function into a Weld Schedule....................................................60
- Delete a Function from a Weld Schedule ..................................................66
- Copying a Weld Schedule ........................................................................70
- Spot ID Programming ............................................................................74
• Setup Procedures..........................................................................75
• RAFT™ Gateway Setup .............................................................76
• Editing the Schedule for a new Spot .............................................79
• Deleting a Function from the Schedule .........................................80
• Duplicating a Spot ......................................................................81
• Removing a Spot ID ...................................................................82
• Possible Error Messages ...............................................................83
• DEP 300s Setup .........................................................................84
• Editing a Schedule.......................................................................91
• List of Spot I/O Bits ....................................................................93
- Default Weld Schedules ...........................................................................94
CHAPTER 7: FAULTS AND SETUP PARAMETERS .................................. 96
- Fault Severity ......................................................................................101
- Fault Reset...........................................................................................102
- Programmable Faults ...........................................................................105
• Weld Initiate not Present...........................................................105
• Stepper Approaching Max ........................................................105
• End Of Stepper ........................................................................ 106
• Extended Weld..........................................................................107
• High C-factor Limit .................................................................108
• Low C-factor Limit ................................................................. 108
• Weld Proceed .............................................................................109
• Pressure Switch .........................................................................110
• Pressure Not Achieved ...............................................................110
• Control In No Weld ..................................................................111
• Retract Pilot .............................................................................111
• Weld Interruption .....................................................................112
• Low Line Voltage .....................................................................112
• Soft Over-current .....................................................................113
• Current Regulation ...................................................................114
• High/ No Motor Current...........................................................115
• Tip Dress ..................................................................................115
Copyright 2014. All rights reserved.
- Non-Programmable (Hidden) Faults....................................................116
• Invalid Sequence Selected ..........................................................116
• Control Stop .............................................................................116
• High Current Limit Fault ........................................................117
• Low Current Limit Fault .........................................................117
• ISO Cntr Off When Needed...................................................... 118
• ISO Cntr Err-brkr Tripped ......................................................118
• System Cooling......................................................................... 119
• IO............................................................................................ 119
• Initiation On Power-up ........................................................... 120
• Control Transformer Voltage ....................................................120
• IGBT Saturation ..................................................................... 120
• IGBT Power Supply .................................................................120
• AC Line Phase ..........................................................................121
• Bus Voltage .............................................................................. 121
• Bus Charging ...........................................................................121
• Secondary Diode....................................................................... 122
• Secondary Current Sensor ..........................................................122
• Output Ground ........................................................................ 122
• Temperature .............................................................................122
• Inverter System Failure .............................................................123
- Programmable Setup Parameters ..........................................................123
• Retract Mode ........................................................................... 123
• Cyl............................................................................................124
• Isolation Contactor Delay (Sec)................................................. 124
• High Current Limit Window (%) ............................................ 124
• Low Current Limit Window (%) .............................................124
• Data Collection Sample Size..................................................... 124
• Data Collection Sample Frequency ............................................125
• Analog Inputs............................................................................125
• Maximum Analog Pressure........................................................125
• Valve 1 Initial Pressure .............................................................125
• Valve 2 Initial Pressure .............................................................125
• Transformer Turns Ratio ..........................................................126
• Transformer Rated DC Voltage ................................................ 126
• Transformer Rated Frequency................................................... 126
• Firing Monitor/Mode ...............................................................127
• Ground Fault Limit..................................................................127
• Secondary Coil ..........................................................................128
CHAPTER 8: LINEAR CURRENT STEPPERS............................................ 129
- The Purpose of Linear Current Steppers ................................................129
- How Linear Current Steppers Work......................................................130
Copyright 2014. All rights reserved.
- Stepper Profiles.....................................................................................131
- Example of a Stepper Profile .................................................................131
- Stepper Groups .....................................................................................131
- Example of Stepper Program #1(No Tip Dress).....................................132
- Stepper Status.......................................................................................142
- Stepper Reset Options ...........................................................................145
- Editing the Stepper Profile....................................................................148
- Editing a Parameter on the Review Stepper Menu on the DEP 300s.....150
CHAPTER 9: ADVANCED TOPICS ............................................................ 152
- Percent of Available Volt-Second Welding Mode....................................152
- Constant Current Welding Mode ..........................................................154
- C- Factor .............................................................................................155
- SPC Indexing Capabilities ...................................................................161
- Application Error Codes........................................................................164
- Application Error Codes for WT6000 Timer Firmware G-08106/
G-08606/ G-8604 ............................................................................. 169
- Fault Family Cross-Reference to WT Weld Control Fault(s) ................. 170
CHAPTER 10: PREVENTATIVE MAINTENANCE .................................. 178
CHAPTER 11: INPUTS AND OUTPUTS...................................................... 180
- I/O List................................................................................................180
- Local Inputs .........................................................................................180
- Local Outputs.......................................................................................182
- Fixed CIOM Outputs ..........................................................................184
- I/O Descriptions ...................................................................................186
- I/O Status ............................................................................................194
- DIO Inputs - T1 ..................................................................................203
- DIO Outputs T1 ..................................................................................204
- DIO Inputs - T2 ..................................................................................206
- DIO Outputs T2 ..................................................................................206
- DIO Inputs - T3 ..................................................................................208
- DIO Outputs T3 ..................................................................................209
- Fieldbus Inputs- Default 1....................................................................211
- Fieldbus Outputs Default 1...................................................................213
- Fieldbus Inputs- Default 2....................................................................215
- Fieldbus Outputs Default 2...................................................................217
- EIP Inputs - Default 1 .........................................................................225
- EIP Outputs - Default 1 ......................................................................227
- EIP Inputs - Default 2 .........................................................................229
- EIP Outputs - Default 2 ......................................................................231
Copyright 2014. All rights reserved.
- I/O Mapping .......................................................................................234
- Fieldbus I/O Mapping..........................................................................240
CHAPTER 12: RAFT™ (RESISTIVE ADAPTIVE FEEDBACK TECHNOLOGY) ............. 249
- RAFT™ Hardware Installation ...............................................................250
- RAFT™ Set-up Process at a Glance ..........................................................251
- RAFT™ Welding Start-up Procedure .......................................................252
- Reference Weld ......................................................................................256
- Methods to take a Reference Weld...........................................................258
1. Taking a Reference Weld during a Part Run ............................259
2. Creating a Single Reference Weld from Past Weld Data ............262
3. Averaging a Reference Weld ....................................................264
4. Duplicating a Reference Weld...................................................266
5. Download a Reference Weld .....................................................267
- Begin RAFT Adaptive Welding.........................................................271
- Tuning the Adaptive Weld Schedule.......................................................273
-SoftQ Overview....................................................................................275
- Process Integrity ...................................................................................276
- Tooling Integrity ..................................................................................277
- Nugget Integrity...................................................................................278
- RAFT™ Menu (DEP 300s)....................................................................279
- Weld Data Menu (DEP 300s) ..............................................................282
- RAFT™ Schedule Functions ....................................................................284
- RAFT™ Set-Up Parameters ....................................................................286
- RAFT™ Fault Diagnostics ......................................................................287
• AdaptQ Tip To Tip Weld .........................................................287
• AdaptQ Tip Volt Wire Broken.................................................. 287
• AdaptQ Weld At Time Max Limit ...........................................288
• AdaptQ Gap Condition ............................................................289
• AdaptQ No Reference Weld ......................................................289
• AdaptQ R Measure ..................................................................289
• Tip Resistance Not In Window................................................. 289
• Reference Mode On ...................................................................289
• SoftQ Current.......................................................................... 290
• SoftQ Resistance....................................................................... 290
• SoftQ Sec V ..............................................................................290
• SoftQ Energy ...........................................................................291
• SoftQ Heat .............................................................................. 291
• SoftQ C Factor......................................................................... 292
• SoftQ T-integrity .....................................................................292
• SoftQ Weld Time .....................................................................293
• SoftQ P-integrity ..................................................................... 293
• SoftQ N-integrity .................................................................... 293
Copyright 2014. All rights reserved.
• SoftQ Current Trend ................................................................294
• SoftQ Resistance Trend ............................................................295
• SoftQ Sec V Trend ....................................................................295
• SoftQ Energy Trend .................................................................296
• SoftQ Heat Trend ....................................................................296
• SoftQ C Factor Trend ..............................................................297
• SoftQ T-integrity Trend ..........................................................298
• SoftQ Weld Time Trend ...........................................................299
• SoftQ P-integrity Trend ...........................................................299
• SoftQ N-integrity Trend ..........................................................300
SCHEDULE FUNCTIONS ............................................................................ 301
- Delay Functions ...................................................................................308
- Weld Functions ....................................................................................309
• Weld Firing Modes ...................................................................309
• Percent of Available Volt-second Weld Functions .......................309
• Constant Current Weld Functions ............................................309
• Temper, Pre-Heat, Post-Heat and Pre-Weld Functions .............311
• Impulse Weld Functions.............................................................312
• Slope Functions .........................................................................314
• I/O Functions ...........................................................................316
• Output Functions ......................................................................318
• Extend Functions......................................................................319
• Special Functions.......................................................................321
GLOSSARY ..................................................................................................................... 326
Copyright 2014. All rights reserved.
REGARDING THIS DOCUMENTATION
This documentation is written to support WT6000 Weld Control with timer
software G08600-00-13
It has been designed for planning, programming, start-up personnel,
operators, service technicians, plant operators, line builders and
maintenance personnel to assist with procedures related to installing the
weld control.
This instruction manual contains important information on the safe and
appropriate assembly, transportation, commissioning, maintenance and
simple trouble shooting of WTC6000 Weld Control
Some of the screen shots of the software application may appear different
and are used for illustrative purpose only.
REVISION HISTORY
REVISION REL. DATE COMMENTS
1.0 12/23/10 Initial release of manual M-032300, Software G08600-00-02
2.0 6/15/11 G08600-00-02: Added default DeviceNet I/O to Ch.E. Corrected
default LIO tags in Ch. E. Added note to DNET Factory Default Set-
tings section in Ch. 5.
3.0 5/1/12 Revised RAFT Ch. 12 to support software G08600-00-08. Centralized
all RAFT related functions, setup parameters and faults (from Ch. 7,
10 and F) into Ch. 12. Updated EIP Default Settings in Ch. 5. Added
Discrete I/O Defaults and updated FieldBus I/O Defaults in Ch. E.
Updated corporate logo and icon images. General grammatical main-
tenance to various chapters.
4.0 10/14/14 Updated the entire manual to incorporate changes with software
version G08600-00-13
LANGUAGES AVAILABLE
This documentation was originally published in English.
Copyright 2014. All rights reserved.
M032300 V4.0/ G08600-00-13_10/2014
SYMBOLS USED IN THIS DOCUMENTATION
Danger! and WARNING! messages indicate high-voltage hazards
in weld controls, MFDC inverters and weld monitoring
equipment.
This symbol will be used wherever failure to observe safety
measures may result in death, severe bodily injury o serious
damage to property.
This symbol will be used wherever insufficient or lacking
compliance with instructions may result in personal injury.
This symbol denotes when insufficient or lacking compliance
with instructions may damage equipment or files.
This symbol informs the user about special features, or where to
find more information.
NOTE: This symbol draws attention to specific instructions or product
features.
This symbol will be used to notify the operator when an
operation requires ESD safety precautions to be followed.Failure
to follow ESD precautions when performing certain procedures
may damage the equipment and void the warranty.
This symbol indicates that only WTC service personnel or WTC
repair partners should service or open this device. Breaking a
warranty seal will void the warranty of this device.
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M032300 V4.0/ G08600-00-13_10/2014
COMMON TECHNIQUES USED IN THIS MANUAL
The following conventions are used throughout this manual:
• Bulleted lists such as this one provide information, not
procedural steps.
Numbered lists provide sequential steps or hierarchical
information.
Italic type is used for emphasis.
WTC SUPPORT - INDUSTRIAL TECHNICAL SERVICES [ITS]
WTC tests all of our products to ensure that they are fully operational
when shipped from the manufacturing facility. If you are experiencing
installation or startup problems, please review the troubleshooting
information contained in this publication. If you need assistance to
get your module up and running, please contact Customer Support
(see the table below); our trained technical specialists are available to
help. When emailing please provide a photograph of the serial tag
and Hardware Status Screen on the DEP 300s if possible.
If the product is not functioning and needs to be returned, contact
your distributor. You must provide a Customer Support case number
to your distributor in order to complete the return process.
United States/Canada 1.248.477.3900 Ext: 3020
Phone Outside United States/
Canada
Worldwide Go to http://support.wtc.com
Internet
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M032300 V4.0/ G08600-00-13_10/2014
SAFETY INSTRUCTIONS
Safety Instructions call your attention specifically to danger potentials
or risks. We distinguish among the following places where safety
instructions may be required.
SAVE THESE INSTRUCTIONS.
FAILURE TO OBSERVE SAFETY MEASURES MAY RESULT IN DEATH,
SEVERE BODILY INJURY OR SERIOUS DAMAGE
TO PROPERTY.
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.
WHEN LIFTING ANY WEIGHT OVER 20 KG (~45 LB.), USE EITHER A
TWO-MAN LIFT OR AN ASSISTED LIFT.
TO REDUCE THE RISK OF FIRE OR ELECTRIC SHOCK, CAREFULLY
FOLLOW THESE INSTRUCTIONS.
ONLY qualified personnel are allowed to service the weld cabinet and
associated devices!
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M032300 V4.0/ G08600-00-13_10/2014
Make certain the circuit breaker handle on the enclosure is in the OFF
position before attempting to open the door.
Inspect the enclosure for any potential shipping damage, loose
connections, or packing materials inside the cabinet before
operation!
WTC does NOT recommend drilling any holes in the cabinet! If
additional holes are required, make certain all components are
covered to adequately protect from metal debris.
NEVER remove circuit boards or establish electrical connections with
power applied! Be certain to REMOVE POWER BEFORE servicing,
installing or removing components.
Always ensure proper flow rate, temperature and chemistry of
cooling water before operation. Obstructed or insufficient flow of
cooling water may damage components.
Adjust the magnetic trip setting on the circuit breaker to a value
appropriate for weld operation!
Verify all transformer tap voltages BEFORE attempting to apply power
or weld.
Verify the setup parameter “Nominal Line Voltage” to your facility
voltage if the operator ever reloads software to default settings.
Never use a personal grounding strap when working with voltages
above 220V.
Cu 75o ONLY
WORKING WITH STATIC-SENSITIVE DEVICES
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M032300 V4.0/ G08600-00-13_10/2014
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.
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.
NOTE:
Use ONLY static-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.
For detailed information about ESD contact:
WTC Industrial Technical Services
Phone: +1 248-477-3900 | Fax: +1 248-477-8897
Email: [email protected]
Website: www.weldtechcorp.com
NOTES:
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M032300 V4.0/ G08600-00-13_10/2014
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M032300 V4.0/ G08600-00-13_10/2014
Chapter 1: UNPACKING THE CONTROL
It is extremely important to examine the crate/packaging immediately
upon delivery to your freight dock. If there is evidence of any damage,
note it on the bill of lading before signing. If there is severe damage to
the crate/packaging, do not sign the bill of lading and refuse the
shipment.
WTC's freight terms are FOB: Shipping Point. This means once the
weld control is picked-up by the freight carrier at WTC's shipping
dock, it becomes the customers’ ownership and responsibility (the
company who issued the purchase order). Therefore, if any damage
occurs to the weld control by the freight carrier during transit, it is the
customer's responsibility to identify it upon receipt and file the
appropriate claim paperwork with the freight carrier to have it
resolved.
Typically, domestic welding control shipments are either skidded
standing upright, with multiple cabinet bolted together (back-to-
back), or skidded laying flat (for taller enclosures). If the shipment is
via ocean, welding controls are typically placed inside a special coated
bag to prevent any potential salt water induced corrosive damage to
the weld control.
WTC uses recycled shipping materials whenever possible (wood skids,
packaging materials, etc.)
If you have any concerns or questions regarding this
practice, please contact WTC at +1 248-477-3900.
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LIFTING AND
MOVING THE CRATED WELD CONTROLS ARE
WELD CONTROL NOT INTENDED TO BE STACKED.
CABINET MOVE ONLY BY EITHER
FORKLIFT OR ASSISTED LIFT.
WTC assembles most weld controls with a provision for lifting and
moving the cabinet. Never attempt to lift any size weld control
LIFTING cabinet without using the lifting brackets or eye bolts. Dropping the
BRACKETS / EYE welding control from even a short distance can cause severe damage
BOLTS and will void the warranty. NEVER put power on a welding control
that has been dropped. If the weld control has been dropped, contact
WTC as soon as possible.
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THOROUGHLY INSPECT THE WELD CONTROL
IDENTIFYING CABINET (INTERNALLY AND EXTERNALLY) FOR
DAMAGED OR ANY SHIPPING DAMAGE (DAMAGED CABLES/
MISSING ITEMS WIRING, BENT METAL, DAMAGED CIRCUIT
BOARDS, ETC.) BEFORE OPERATION.
PROBLEM SOLUTION
Obtain the shipping documentation that came
The welding control / parts order arrived, with with the weld control / parts order.
items missing from bill of lading. Contact WTC's Customer Service Department to
determine if the missing items are either on back-
order or if they are actually missing from the ship-
ment.
When contacting WTC for assistance, please have the following
information ready:
1. Sales order number (example: 122435-00)
2. Company Name
3. Part number from the shipper or bill of lading for the missing/
damaged part.
WTC Industrial Technical Services:
Phone: +1 248-477-3900 | Fax: +1 248-477-8897
Email: [email protected]
Website: www.weldtechcorp.com
NOTE: When emailing WTC for support with a shipment issue, please
include pictures of the problem (if possible), as they can be very
helpful in quickly understanding and resolving your problem.
NOTE: WTC's firewall will not accept compressed (.zip) files as email
attachments. If you need to email a .zip file to WTC, change the file
extension to .piz prior to attaching it to the email message. This will
allow both the email and the attachment to pass through the WTC
firewall. Thank you for your understanding.
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Chapter 2: SAFETY AND WARNINGS
WT6000 CABINET
SAFETY CONCERNS BEFORE YOU APPLY POWER!
LETHAL VOLTAGES ARE PRESENT WHEN APPLYING
POWER TO THE WELD CONTROL. EXPOSURE TO HIGH
VOLTAGE WILL CAUSE SEVERE ELECTRICAL BURNS AND
POSSIBLY DEATH.
ONLY QUALIFIED MAINTENANCE PERSONNEL SHOULD
PERFORM SERVICE ON THIS MACHINE!
NEVER DRILL INTO A WELD CONTROL CABINET WITHOUT FIRST
REMOVING POWER FROM THE CABINET AND PROPERLY
PROTECTING INTERNAL COMPONENTS FROM METAL DEBRIS /
SHAVINGS.
FAILURE TO FOLLOW THIS REQUIREMENT MAY LEAD TO A
POSSIBLE EXPLOSION HAZARD AND VOID THE WARRANTY.
ENSURE PROPER FLOW RATE, TEMPERATURE AND
CHEMISTRY OF COOLING WATER BEFORE RUNNING
PART PRODUCTION
OBSTRUCTED WATER PATHS OR LOW WATER FLOW
MAY DAMAGE THE WELDING EQUIPMENT.
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PRINTED CIRCUIT BOARDS MUST BE COMPLETELY POWERED DOWN
PRIOR TO PERFORMING ANY MAINTENANCE, TROUBLESHOOTING OR
REPLACEMENT.
CIRCUIT BOARDS OVER 24V SHOULD BE HANDLED WITH CARE AS
THEY POSE A POTENTIAL SHOCK HAZARD TO THE OPERATOR.
VERIFY THE VOLTAGE TAPS ON THE CONTROL TRANSFORMER ARE SET
CORRECTLY FOR YOUR PLANT LINE VOLTAGE PRIOR TO APPLYING
POWER TO THE WELD CONTROL CABINET.
NEVER USE A PERSONAL GROUND STRAP WHEN WORKING WITH VOLT-
AGES ABOVE 220V.
OTHER INSTRUCTIONS:
Use CU 75° rated cable only.
Adjust the magnetic trip setting of the circuit breaker to a proper
value based on your weld application.
NOTE: IF YOU ARE UNSURE OF EITHER A SAFETY OR MAINTENANCE
PROCEDURE, PLEASE CONTACT WTC'S SERVICE DEPARTMENT FOR
ASSISTANCE.
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Chapter 3: SYSTEM OVERVIEW
GEN6 WELD The WT6000 Weld Control converts three-phase (50/60Hz) AC line
PROCESSOR voltage into a single-phase (1000Hz- Default) AC square wave output.
The square wave output is fed to the primary of a MFDC welding
transformer, where it is rectified in the secondary to DC voltage. DC
welding has many advantages over AC welding, including a more
efficient consumption of plant power and the ability to make higher
quality welds by having more control over the welding process.
NOTE: The enclosure configuration shown below is for illustration purposes only. Your
cabinet configuration may differ depending on your specific application.
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FEATURES The weld processor module, internal to the WT6000, uses free format
programming and “Flexible I/O” to create weld parameters and
programs to fit any welding application.
• Up to 255 weld schedules.
• Built in Ethernet/IP.
• DeviceNet add-on available.
• 10 available linear current steppers, with 5 steps each.
• Internal web server allows the user to view and edit timer data
from web browser, robot teach pendant or touch panel (HMI)
device. [For additional information on this feature, refer to Web
Pages Manual M032360]
• Two weld firing modes: Percent of Available Volt-Seconds (%VS)
and Constant Current (nnnn0).
• Non-battery backed up memory.
• Inverter hardware supports either water or air cooling.
• Two weld timing modes: Cycles or Milliseconds.
INSIDE THE The WT6000 Weld Control contains the following sub-assemblies:
WELD CONTROL
• INVERTER ASSEMBLY: Converts three-phase (50/60Hz) AC line
voltage to single-phase (1000Hz) AC.
• WELD PROCESSOR ASSEMBLY (PROCESSOR): Brains of the weld
control and controls all Ethernet/DeviceNet communications.
• ISOLATION CONTACTOR: Located downstream of the inverter to
interrupt voltage/current to the MFDC welding transformer.
• CONTROL TRANSFORMER: Steps down line voltage to 120V and
24V for the cabinet power.
• CIRCUIT BREAKER: Supplies or interrupts line voltage to the entire
weld control cabinet.
• AIR / WATER MANIFOLD: Water standard, optional water cooling
available.
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SPACE SAVING ENCLOSURE DESIGN
The Minipak enclosure was designed for customers with plant floor
space limitations.
• Designed to mount on top of a standard robot controller cabinet.
• Inverter hardware supports either water or air cooling
ROBOT OR HARD TOOL USAGE
The WT 6000 MiniPak can be configured fro either robot or hard
tooling applications
Shown above Robot with MiniPak and mounting suggestion.
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A1 CONTROL
CIOM MODULE:
Local serial
interface to the CONTROL CIRCUIT BREAKER:
weld processor. TRANSFORMER: Supplies or
Has signal power Steps down line voltage interrupts line
distribution and to 120V and 24V for the voltage to the entire
controls local I/O cabinet power. weld control cabinet.
Interior View
for illustrative
purpose only.
Actual control
configuration
may vary.
ISOLATION CONTACTOR:
Located downstream of
WELD PROCESSOR
INVERTER ASSEMBLY: the inverter to interrupt
ASSEMBLY:
Converts three-phase (50/60Hz) AC line voltage/current to the
Brains of the weld control
voltage to single-phase (400Hz- 1300Hz) AC MFDC welding
and controls all Ethernet/
output depending on the setup parameters transformer.
DeviceNet communications
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WELD CONTROL SPECIFICATIONS
POWER SOURCE
STANDARD LINE VOLTAGE CONFIGURATION 3-Phase AC 220V - 480V (± 10%)
ALTERNATE LINE VOLTAGE CONFIGURATION 3-Phase AC 575V (± 10%)
LINE FREQUENCY: 50 / 60 Hz (Automatic Selection)
OUTPUT FREQUENCY 1,000 Hz Default (Range = 400Hz-2,000Hz)
STANDARD OUTPUT CURRENT CONFIGURA- 600 Amps Water (480 VAC)
TIONS AT 10% DUTY CYCLE 400 Amps Water (600 VAC)
OUTPUT CURRENT OPTIONS AT 10% DUTY 500 A Air-Cooled @ 480 VAC Line
CYCLE 350 A Water-Cooled @ 480 VAC Line
400 A Water-Cooled @ 480 VAC Line
1200 A Water-Cooled @ 480 VAC Line
600 A Water-Cooled @ 480 VAC Line
350 A Air-Cooled @600 VAC Line
400 A Water-Cooled @ 600 VAC Line
1000 A Water-Cooled @ 600 VAC Line
1800 A Water-Cooled @480 VAC/ 600 VAC Line
OUTPUT VOLTAGE OPTIONS @ 10% DUTY 305 VAC Nominal @ 220 VAC Line
CYCLE 525 VAC Nominal @ 380 VAC Line
650 VAC Nominal @ 480 VAC Line
800 VAC Nominal @ 575 VAC Line
OUTPUT VOLTAGE OPTIONS @ 5% DUTY 900 A Water-Cooled @ 480 VAC Line
CYCLE 1800 A Water-Cooled @ 480 VAC Line
OUTPUT VOLTAGE OPTIONS @ 3% DUTY 900 A Water-Cooled @ 600 VAC Line
CYCLE
OUTPUT VOLTAGE OPTIONS @ 2% DUTY 900 A Water-Cooled @ 480 VAC Line
CYCLE
MAXIMUM POWER 260 KVA @ 480 VAC Line Power
DEVICE TYPE IGBT
CURRENT RISE TIME < 4ms Into Resistive Load
POWER CONSUMPTION 70 VA (Idling condition)
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MONITORING AND CONTROL FUNCTIONS
FIRING CONTROL Fixed Frequency, Pulse Width Modulation
CURRENT CONTROL Primary Constant Current
Percent of Available Volt-Seconds
Adaptive Control
TIMING CONTROL Cycles or Milliseconds
PRIMARY CURRENT RANGE 10% TO RATED CURRENT LEVEL:
40 0400 A
120 1200 A
100 1000 A
180 1800 A
PRIMARY CURRENT ACCURACY ± 1% SETTING, ± .5% REPEATABILITY
DC BUS VOLTAGE MEASUREMENT ACCURACY ± 1% SETTING, ± .5% REPEATABILITY
SECONDARY CURRENT ACCURACY ± 2% SETTING, ± 1% REPEATABILITY
SECONDARY VOLTAGE ACCURACY ± 3%
SECONDARY RESISTIVE ACCURACY ± 3%
MFDC TRANSFORMER FLUX INCLUDED
PROTECTION
DUTY CYCLE PROTECTION MONITORS INVERTER AND WELD TRANSFORMER
DUTY CYCLE
MFDC WELD TRANSFORMER DIODE SHORT MONITORING
MONITORING
POWER CONSUMPTION 70VA (Idling Condition)
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PROCESSOR & FUNCTIONS
WELD PROCESSOR Series 6000
STANDARD COMMUNICATIONS Ethernet IP 10/100 BaseT
1MB SSPI (Smart Serial Peripheral Interface)
RS485
OPTIONAL COMMUNICATIONS DeviceNet
ON BOARD INPUTS (LIO) 2 x 24VDC
ON BOARD OUTPUTS (LIO) 3 x 120VAC
NUMBER OF WELD SCHEDULES 255
NUMBER OF STEPPERS 10
PROCESSOR STORAGE TYPE F-RAM (No Battery Required)
WELD PROCESSOR LANGUAGES English
ENVIRONMENTAL CONDITIONS
OPERATING TEMPERATURE +5° C to +50° C
HUMIDITY 0 - 90% (Relative, without Condensation)
ESD EN 61000-4-2 LEVEL 3
NOISE IMMUNITY EN 61000-4-4 LEVEL 3
SURGE IMMUNITY EN 61000-4-5 LEVEL 3
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WATER COOLING REQUIREMENTS
• Maximum temperature not to exceed 104° F. (40° C.), or fall below the dew point of
ambient air at about 70° F. (21° C.)
• pH maintained between 7.0 and 8.0
• Maximum chloride content 20 PPM (parts per million)
• Maximum nitrate content 10 PPM
• Maximum sulfate content 100 PPM
• Maximum suspended solids content 100 PPM (non-abrasive)
• Maximum total solids content 250 PPM (suspended and dissolved)
• Maximum calcium carbonate content 250 PPM
MINIMUM WATER FLOW RATE Greater than 5 liters/min (1.32 gal/min)
MAX PRESSURE DROP @ 5 LITERS/MIN FLOW Less than 70 kPa / .7 bar / 10 PSI
PRESSURE RATING Less than 620 kPa / 6.2 bar / 90 PSI
ELECTRICAL RESISTIVITY OF WATER Greater than 5000 ohms/cm
WATER INLET TEMPERATURE LESS THAN 95° F (35° C)
AIR COOLING REQUIREMENTS
AMBIENT AIR TEMPERATURE Less than 104° F (40° C)
MINIMUM FAN RATING 80 CFM
AIR MOUNTING LOCATION Minimum 200mm (3 inches) from wall or
object
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Chapter 4: INSTALLING THE CONTROL
STANDARD CONNECTIONS
CONTROL STOP (CSTOP) ETHERNET/IP FROM
FROM SAFETY MASTER ROBOT / SWITCH
WATER PORTS
Rear View
Side View
AIR CIRCULATION VENT
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ENCLOSURE SAFETY LABELING
WARNING! ARC FLASH
AND POWER SAFETY
WARNING!
STORED
ENERGY
DEVICE
WTC SERIAL TAG
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INSTALLATION CHECKLIST
1. Ensure electricity is locked out at welding bus, power distribution
panel, or other applicable power source.
2. Verify weld control cabinet circuit breaker is in the OFF position.
USE THE FOLLOWING CHECKLIST 3. Inspect interior of both weld control and Servo cabinet for loose
AS A GUIDE DURING THE and/or missing parts. Inspect for any shipping damage.
INSTALLATION PROCESS. IF YOU ARE
UNSURE HOW TO PROPERLY
INSTALL AND HOOKUP
4. Check and ensure the inverter cooling fan and all air circulation
THE WELD CONTROL
CABINET, CONTACT
vents on the back of the cabinet are unobstructed (if applicable).
WTC FOR ASSISTANCE.
5. Check and ensure all water drain holes are open and unblocked.
6. Mount weld control at desired location using appropriate mount-
ing hardware.
7. Remove access plates and drill / punch holes for:
• Three-phase AC line power and ground.
• Output power to MFDC welding transformer and ground.
• I/ O connections (if applicable).
8. Plumb cooling water to Supply (water-in) and Return (water-out)
bulk head fittings (if applicable).
9. Connect 3-phase AC line power cables (L1, L2, L3) to top of circuit
breaker (line side) and tighten according to manufacturer specifi-
cations. Run cables through cover plate on side of enclosure.
10. Connect plant ground cable to copper grounding post inside cabi-
net. Run cable through cover plate on side of enclosure.
11. Connect power cables from output of weld control (H1, H2) to pri-
mary of welding transformer. Run cables through pilot hole on
bottom of enclosure.
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12. Connect ground cable from copper ground bus inside cabinet to
welding transformer. Run cable through pilot hole on bottom of
enclosure.
13. Connect Data Entry Panel (DEP), EtherNet (MENET), EtherNet IP
(WBDP), DeviceNet (DNWC) and Voltage Sense (RAFT) cables to
appropriate connectors on cabinet.
14. Wire I/O connections.
15. Verify magnetic and thermal trip settings on circuit breaker, per
manufacturer specifications (if applicable).
16. Inspect cabinet and verify all wiring connections (high voltage,
terminals, crimp connections, etc.) are secure.
17. Close weld control cabinet door and lock with 1/4-turn fasteners.
18. Ensure cooling water circuit has no leaks and water is flowing at
specified rate (if applicable).
19. Remove electrical lock out devices.
20. Turn weld control cabinet circuit breaker ON.
21. Ensure cooling water is flowing at specified flow rate.
22. Use data entry panel or network software application to program
I/O parameters for Device Net, Ethernet/IP or specialty communi-
cation modules.
23. Use data entry panel or network software application to program
setup parameters, weld schedules and current steppers as
required for customer application.
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MECHANICAL The Mechanical installation of the WTC Weld Control requires
INSTALLATION the following:
• Control Placement
• Cabinet Mounting and Fastening
• Cooling Water and Connections
Shown above: Front and top view of the MiniPak weld control cabinet
MINIPAK CABINET PLACEMENT
The Minipak cabinet was primarily designed to mount on top of a
robot controller cabinet, but it can also be mounted along a fence line
or wall if required. The cabinet's water cooling circuit is externally
mounted underneath the vented back cover and is physically isolated
from the internal electrical components. Drain holes exist in the
bottom of the vented back cover in the event of a hose rupture or
water cooling manifold leak.
NOTE: In the event of a water hose rupture, keep external electrical
cables and wiring away from the vented back cover.
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MINIPAK CABINET MOUNTING AND FASTENING
Depending on the customers application requirements, additional
cabinet mounting hardware may be required. See the table below for
available options:
FANUC ROBOT CONTROLLER CABINET MOUNTING HARDWARE
QTY. DESCRIPTION WTC PART NUMBER
1 Robot Mounting Bracket Right - Fanuc 703-8320
1 Robot Mounting Bracket Left - Fanuc 703-8319
2 M12 Lock Washers Customer Supplied
2 M12 Nut Customer Supplied
WALL OR FENCE MOUNTING HARDWARE
QTY. DESCRIPTION WTC PART NUMBER
1 Wall Mount Bracket - Right 703-8321
1 Wall Mount Bracket - Left 703-8322
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IT IS IMPORTANT THAT THE WELD CONTROL IS MOUNTED ON A LEVEL
SURFACE. IF THE WELD CONTROL IS MOUNTED ON AN UNEVEN
SURFACE, THE CABINET DOORS MAY BE DIFFICULT TO OPEN. FAILURE
TO USE APPROVED MOUNTING HARDWARE MAY VOID YOUR
WARRANTY.
IT IS RECOMMENDED THAT THE WELD CONTROL IS MOUNTED A
MINIMUM OF 50 MILLIMETERS (2 IN) FROM A WALL OR OBJECT FOR
PROPER VENTILATION AND COOLING OF AIR-COOLED CONTROLS
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WATER COOLING CONNECTIONS
The MiniPak cabinet includes a vented back cover that isolates the
water cooling circuit from the internal electrical components.
Shown above: MiniPak Supply and Return Water Fittings
WATER COOLING REQUIREMENTS
The cooling water provided must comply with chemical and physical
specifications as stated in the Resistance Welder Manufacturers’
Association Bulletin 5–005.05. See Chp. 3: System Overview for
details.
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 - condensation may occur and
damage components.
Failure to maintain proper water cooling to the weld control cabinet
may cause damage to the weld control and void the warranty. contact
WTC if you have any questions regarding the water cooling
requirements listed above.
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IF NECESSARY, REMOVE RIGHT AND LEFT FEET USED FOR
SHIPPING PURPOSES PRIOR TO INSTALLATION
LEFT AND RIGHT FEET FOR
SHIPPING PURPOSES ONLY.
REMOVE DURING
INSTALLATION.
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DO NOT DRILL HOLES IN REMOVABLE COVER PLATES WHILE
ATTACHED TO THE CABINET. METAL SHAVINGS MAY
CONTAMINATE INTERNAL COMPONENTS AND CAUSE
ELECTRICAL DAMAGE. DRILL BIT OR HOLE SAW BLADE MAY
CAUSE DAMAGE TO INTERNAL COMPONENTS.
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ELECTRICAL INSTALLATION
PRIOR TO MAKING ANY CONNECTION INSIDE THE WELD CONTROL
CABINET:
1. REFER TO YOUR FACILITIES ELECTRICAL LOCKOUT POLICY AND
PROCEDURES.
2. BEFORE PROCEEDING, VERIFY NO HIGH VOLTAGE IS PRES-
ENT INSIDE THE CABINET WITH A MULTIMETER.
THE DOOR OF THE WELD CONTROL CABINET IS INTERLOCKED WITH
THE CIRCUIT BREAKER TO PREVENT THE DOOR FROM BEING OPENED
WHILE POWER IS ON. NEVER ATTEMPT TO DEFEAT THIS SAFETY
MECHANISM.
The weld control cabinet contains high voltage, grounding, and
external input/output connections. This section explains the
connection process.
PRIOR TO MAKING ANY CONNECTION INSIDE THE WELD CONTROL
CABINET:
1. REFER TO YOUR FACILITIES ELECTRICAL LOCKOUT POLICY AND
PROCEDURES.
2. BEFORE PROCEEDING, VERIFY NO HIGH VOLTAGE IS PRESENT
INSIDE THE CABINET WITH A MULTIMETER.
THE DOOR OF THE WELD CONTROL CABINET IS INTERLOCKED WITH
THE CIRCUIT BREAKER TO PREVENT THE DOOR FROM BEING OPENED
WHILE POWER IS ON. NEVER ATTEMPT TO DEFEAT THIS SAFETY
MECHANISM.
NOTE: For illustration purposes, the air-cooled enclosure
configuration is shown. Your cabinet configuration may differ
depending on your specific application. For standard application
specific electrical drawings, contact WTC.
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WIRING DIAGRAM INDEX:
STEP COLOR DESCRIPTION
B Verify the primary of 1T control transformer is correctly tapped for the plant line voltage.
C Connect plant line voltage to L1, L2, L3 terminals on 1CB circuit breaker.
D Connect ground cable from plant ground to weld enclosure copper ground lug. Connect
ground cable welding transformer to weld enclosure copper ground lug.
E Connect EtherNet cable from plant network to MENET connector. A
F Connect EtherNet cable from plant network to WBDP connector. A
G Connect voltage sense cable from welding transformer to RAFT connector.
F Connect DeviceNet cable from plant network to DNET connector.
G Connect weld transformer cables to 1H1 and 1H2 terminals on 1IC isolation contactor.
Some facilities use the MNET connector to
A connect to the Robot and the WBDP to
connect to the plant EtherNet network.
For technical support, contact WTC's Industrial Technical
Services Department:
Phone: +1 248-477-3900 | Fax: +1 248-477-8897
EMAIL: [email protected]
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RAFT VOLTAGE The following illustrates the hook-up of the RAFT voltage sense
SENSE WIRE wires to the RAFT connector on the weld control cabinet. Also
HOOK-UP shown is the interconnect between the RAFT connector and the
weld processor.
NOTE: The voltage sense wires are polarity sensitive. If the polarity is
reversed, the weld processor will report a zero or negative resistance
and an ADAPTQ TIP VOLT WIRE BROKEN fault will be generated at
sequence initiation.
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WELD CONTROL Before welding can begin, the following parameters need to be
PROGRAMMING programmed into the weld processor.
AND SETUP
PROGRAM SETUP PARAMETERS
Review and program the Setup Parameters as required for the
welding application.
The Review Setups Menu is found in the DEP-300s by pressing:
B Program Mode
NOTE: Refer to
Chapter 7: Faults
and Setup
Parameters for
detailed
information
regarding the
description and
programming of
setup parameters.
C Review Setups
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PROGRAM WELD SCHEDULES
Review and program the Weld Schedules as required for the welding
application.
The Review Schedule Menu is found in the DEP-300s by pressing:
B Program Mode
C Review Schedule
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SETUP LINEAR CURRENT STEPPER FUNCTIONS
Review and program the Linear Current Stepper Functions as required
for the welding application.
NOTE: Refer to
Chapter 6:
Programming
Schedules or Glossary
of Schedule Functions
for detailed
B Program Mode
information regarding
function descriptions
and the programming
of weld schedules.
C Review Stepper
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D Using the and arrow keys navigate to
the Stepper line to edit and press
NOTE: Refer to
Chapter 8: Linear
Current Steppers for
detailed information
regarding the
description and
programming of
linear current
steppers.
D Using the number keys edit the required functions and
press . This will turn “Apply” from gray to black. Press
to apply the changes.
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Chapter 5: COMMUNICATIONS SETUP
The following describes the communication ports located on the
WT6000 weld processor assembly with DeviceNet option shown
above.
PORT
COMMUNICATION TYPE DESCRIPTION
NAME
ENET IP Ethernet/IP (EIP) ENET IP is used for I/O communication between the weld pro-
cessor and other Ethernet enabled devices (e.g. a Robot or
PLC). Also used to communicate with Weld Gateway and
RAFT Gateway networking software.
ENET Ethernet ENET is used for Standard Ethernet communications.
SSPI WTC Proprietary I/O Communi- SSPI supports communication with optional WTC I/O peripheral
cation Protocol (Optional) devices.
LIO Local (Discrete) I/O Inputs - 2 x 24VDC
Outputs - 3 x 120VAC
COMM RS485 Serial Interface COMM is used for DEP-300s or DEP-100S data entry panel com-
munications.
DNET Device Net (Optional) DNET is used for DeviceNet I/O communications (slave only).
SEC I/V Secondary Current or Voltage Location for input wires for Secondary Current or Secondary
Monitoring Input (Optional) Voltage Monitoring.
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ETHERNET SETUP The WT6000 weld processor has two Ethernet communication ports:
PORT
COMMUNICATION TYPE DESCRIPTION
NAME
ENET IP is used for I/O communication between the weld processor
and other Ethernet enabled devices (e.g. a Robot or PLC). It also can
ENET IP Ethernet/IP (EIP) be used for updating timer software and maintenance functions.
ENET IP includes a web page interface for robot pendants or browser
enabled devices.
ENET is used for standard Ethernet communications. It also can be
ENET Standard Ethernet used for updating software and maintenance functions. ENET
includes a web page interface for robot pendants or browser enabled
devices.
ENET IP (EIP) How to navigate through the DEP-300s to the EIP Options menu:
FACTORY
DEFAULT
SETTINGS
B Press Program Mode
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C Press More
D Press EIP Options
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THE EIP FACTORY DEFAULT SETTINGS ARE AS FOLLOWS:
NAME ADDRESS
IP Address 192.168.0.250
Sub Net Mask 255.255.255.0
Gateway 0.0.0.0
Name Server 0.0.0.0
Input Instance 150 Type: 8bit Size: 2
Output Instance 100 Type: 8bit Size: 2
MAC Address 00:18:ec:01:79:19
DHCP On
DHCP MODE Retry disabled
PORT MODE Auto
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SETTING THE NUMBER OF AVAILABLE EIP INPUTS AND OUTPUTS
In timer software G08600, there are a maximum of 64 inputs and 64
outputs that can be mapped. The number of mapped inputs and
outputs is determined by selecting a Type and Size, whose product is
less than or equal to 64.
In the default settings chart on previous page, the Type is 8 and the
Size is 2 for both the inputs and outputs. Since the product of 8 and 2
is 16, the total mappable I/O is 16 for both the inputs and the
outputs.
The chart below shows all the possible combinations in which the
Type and Size can be configured and not exceed the maximum of 64
NOTE: If the Size is set to 0, the entire map is disabled and no I/O can
be mapped.
TYPE SIZE PRODUCT
8 0 0
8 1 8
8 2 16
8 3 24
8 4 32
8 5 40
8 6 48
8 7 56
8 8 64
16 0 0
16 1 16
16 2 32
16 3 48
16 4 64
32 0 32
32 1 32
32 2 64
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ENET (STANDARD
ETHERNET) How to navigate through the DEP-300s to the Local Ethernet menu:
FACTORY DEFAULT
SETTINGS
B Press Program Mode
C Press More
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D Press More
E Press Local Ethernet
ENET FACTORY DEFAULT SETTINGS:
NAME ADDRESS
IP Address 89.89.200.250
Sub Net Mask 255.0.0.0
Gateway 0.0.0.0
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DEVICENET SETUP The WT6000 weld processor is capable of DeviceNet I/O
communications. This requires the installation of an optional
DeviceNet peripheral board.
How to navigate through the DEP-300s to the FieldBus Mapping
menu:
B Press Program Mode
C Press More
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D Press More
E Press FieldBus Mapping
DEVICENET FACTORY DEFAULT SETTINGS:
NAME ADDRESS
NOTE: These settings
are the factory Reload Default OFF
defaults. The
customer's default Node Address 11
settings may differ
based on the welding Baud Rate 500K
application and the
requirements of the Byte Size 8by8
DeviceNet master.
Network Response Delay in mSEC. 1
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WT6000 PROCESSOR The WT6000 processor (weld processor) has four status LED's.
LED DESCRIPTION Through a combination of changing colors and flashing/solid states,
the LED's indicate the status of the EtherNet/IP Module, the
EtherNet/IP Status, Weld Sequence Status and the Weld Control
Status.
Below is an illustration and description of the LED's located on the
WT6000 weld processor:
MOD (ETHERNET/ NET (ETHERNET/IP SEQ (WELD
RUN (WELD
IP MODULE NETWORK SEQUENCE NOT USED
CONTROL STATUS)
STATUS) STATUS) STATUS)
EIP EIP Processing Control Stop input
GREEN functioning Connection functions prior to high
properly established weld
FLASHING EIP Waiting Weld control in NO Control Stop input
GREEN initializing on EIP WELD mode low
connection
Error Non- Duplicate EIP Processing WELD/
RED Recoverable Address HEAT
functions
EIP connection lost Fault
FLASHING Waiting to re-
RED establish
connection
Processing
AMBER functions after
weld
FLASHING Alert
AMBER
In weld mode- not
OFF in a sequence
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Chapter 6: PROGRAMMING SCHEDULES
ABOUT WELD What is a weld schedule?
SCHEDULES
A weld schedule is a list of commands (or functions), which are used
to instruct the weld control to deliver a combination of heat (weld
current) and time (weld time) to the weld interface, to create a weld
nugget.
Essentially, the weld schedule is a “recipe” and the functions within it
are the “ingredients”. Just as it is important to use the right
ingredients in the correct measure to make a good culinary dish, it is
likewise important to use the right functions (properly programmed
and in the correct order) to make a good weld nugget.
THE FOUR BASIC FUNCTION DESCRIPTION
ELEMENTS
SQUEEZE Apply pressure (electrode force) to the
weld interface
WELD Deliver weld current to the weld interface
HOLD Apply wait time after the weld current
stops to allow the nugget time to cool.
WELD End of schedule.
COMPLETE
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WELD SCHEDULE
FUNCTIONS FUNCTION
DESCRIPTION
TYPE
DELAY Delay functions are used to cause a wait time to
occur for a specified amount of time
WELD Weld functions are used to provide a specified
amount of weld current for a specified length of
time
SLOPE Slope functions are used to provide either a linear
increase or decrease in welding current for a speci-
fied length of time
I/O I/O functions are used to verify, change the status
of, or wait for certain I/O points to change
EXTENDED Extended functions are used to extend a particular
function within a schedule until certain conditions
are met
SPECIAL Special functions are used to create special condi-
tions within the weld schedule.
WELD SCHEDULE For a list of weld schedule functions and descriptions, see Chapter 13:
FUNCTION LIST Schedule Function List.
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EXAMPLE OF A The following is an example of a typical weld schedule. The functions
WELD SCHEDULE used and how they are programmed, are solely dependent upon the
customer's application. Notice that each function has a corresponding
number. This allows the user to select functions by number when
programming or editing weld schedules.
FUNCTION NO. FUNCTION NAME
00 START OF SCHEDULE # 1
82 LINEAR STEPPER #1 ASSIGNED (0=OFF)
88 TURN ON ISOLATION CONTACTOR
58 TURN ON WELD IN PROGRESS
78 CURRENT WINDOW: HI=15% L0=10%
92 C-FACTOR LIMIT: HI=999 LO=0
81 TRANSFORMER TURNS RATIO 72:1
1 SQUEEZE 500 MSEC
60 IMPULSE= 232 HEAT MS, 16 COOL MS
30 WELD 1 IMP 9000 AMPS
3 HOLD 83 MSEC
59 TURN OFF WELD IN PROGRESS
63 TURN ON WELD COMPLETE
75 EXTEND UNTIL NO INITIATE
64 TURN OFF WELD COMPLETE
89 TURN OFF ISOLATION CONTACTOR
100 END OF SCHEDULE
NOTE: Functions (00) “Start of Schedule” and (100) “End of Schedule”
are permanently programmed into each weld schedule and can be
neither added nor deleted. Although, they appear in the weld
schedules, they do not appear in the Insert Function Menu of any
programming interface device.
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HOW TO READ A Weld schedules are read starting at the top and moving down, one
WELD SCHEDULE line at a time. The time it takes the weld control to complete an entire
weld schedule can be calculated by adding up all time parameters
(cycle and/or milliseconds) programmed within each function
throughout the entire schedule.
For example, in the weld schedule above, there is 500 milliseconds of
squeeze time, 232 milliseconds of weld time, 16 milliseconds of cool
time and 83 milliseconds of hold time. Thus, the time to complete the
entire weld schedule is approximately 831 milliseconds (.83 seconds).
PROGRAMMING A There are several user interface options available to program a weld
WELD SCHEDULE schedule. They include the following:
• WTC DEP-300s Data Entry Panel
• WTC RAFT Gateway or Weld Gateway Network Software
• Robot Teach Pendant (via WTC's built-in web server)
• Touch Screen (HMI) Devices (via WTC's built-in web server)
In this manual, the DEP-300s data entry panel is
used in all programming instructions
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INSERT A FUNCTION Perform the following steps on the DEP-300s to insert a function into
INTO A WELD a weld schedule:
SCHEDULE
B Press Program Mode
C Press Review Schedule
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D Press Sch#
E Enter Schedule Number
F Press ENTER
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G Press MORE
H Press the or arrow keys to move the cursor
to the line above where the function is to be inserted.
I Press INSERT
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J Press INSERT BY FN. # [Insert
by Function Number.]
K Enter the Function Number.
L Press ENTER
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M If the
function requires parameters to be entered, proceed to
step 13. If not, proceed to step 17
* NOTE: In the RAFT
Gateway and DEP 300s
the zero in the ones N Enter parameter
placed is fixed. The
tenths, hundredths and
thousandths place are
programmable up to a O Press ENTER
maximum of 9999.
For example:
Enter 5O for 5OO Amps.
P For functions with two or more parameters, press the
RIGHT arrow key to move the cursor to the next parameter
box, then repeat steps 13 & 14. When complete, proceed to
step 16.
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Q Press APPLY (F2).
[Saves changes to the DEP-300s only.]
R Press DOWNLOAD.
[Downloads the changes to the weld
processor].
When complete, a “Download Complete” message will appear.
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DELETE A FUNCTION Perform the following steps on the DEP-300s to delete a function
FROM A WELD from a weld schedule:
SCHEDULE
B Press Program Mode
C Press Review Schedule
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D Press Sch#
E Enter Schedule Number
F Press ENTER
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G Press MORE
H Press the or arrow keys to move the cursor onto
the function line to be deleted
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I Press DELETE.
[The function is immediately
deleted from the DEP-300s.]
J Press DOWNLOAD
[Downloads the changes to the
weld processor. When complete, a
“Download Complete” message will appear]
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COPYING A WELD Perform the following steps on the DEP-300s to copy an entire weld
SCHEDULE schedule from one location and paste it into another:
B Press Program Mode
C Press Review Schedule
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D Press Sch#
E Enter Schedule Number
F Press ENTER
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G Press MORE
H Press COPY
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I FROM SCHEDULE #
(Current Schedule will be
displayed) TO [Blank Field] enter
the paste to Schedule Number
J Press ENTER
K The copy is immediately downloaded to the weld processor.
When complete, a “Download Complete” message will appear.
NOTE: When copying a weld schedule from one location to another,
any existing data in the paste location will be completely overwritten
and permanently lost.
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SPOT ID PROGRAMMING
The SPOT ID feature allows enhanced flexibility in setting up welding sched-
ules that are associated with spot numbers. This allows the user to associate
the spot number of the weld with programming data used to create the spot
and the welding data results of the spot. A second option with this feature is
to initiate the weld control based on spot numbers instead of schedule num-
bers. There are 255 weld schedules available for spot selection 1 -255. Spot
numbers higher than 255 can be assigned freely via the Spot ID system.
These schedules are a continuation of the binary sequence select bits (1-
255). With this feature additional schedules can be added to the 255 sched-
ules already available. Individual schedules can also be customized and dupli-
cated.
Another usage is to have all the spots of the plant programmed into one
timer (as long as the number of unique welding schedules is under the 255
schedule maximum) and the Robot picks the schedule based on the spot
number. This allows the welding timers to be preprogrammed with all the
data required to operate in any welder in the plant.
There is a limitation of 1000 associations of spot numbers to any one weld
schedule. If more than 1000 associations are attempted, then the program-
ming device will provide an error message. However, there is no limit on
how many of these 1000 associations can be assigned to a single schedule. It
is possible to have all 1000 associations with one schedule if the program-
mer desires.
If the SPOT ID is assigned, then the weld schedule associated with it will be
initiated. If the spot ID selected is not assigned, then an INVALID SEQUENCE
SELECTED fault is set.
The user will be able to select a schedule for view or edit through the use of
the spot numbers. When a schedule is chosen for edit based on a spot num-
ber, the schedule will be shown along with the other spot numbers which
are associated with that schedule.
SETUP PARAMETERS
ONE TO ONE (Default) One schedule assigned to one spot
MANY TO ONE One schedule assigned to Many spots
Min: 256
SPOT No.
Max: 1073741823
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SETUP PROCEDURES
Weld schedules with Spot ID feature can be programed via the RAFT
Gateway, DEP 300s or the WebView.
At the onset it is important to establish the system configuration by
selecting from the two modes available:
SPOT ID SETUP
ONE TO ONE MANY TO ONE
ASSIGN ASSIGN A
SCHEDULE SCHEDULE TO
TO SPOT MORE THAN ONE
SPOT WITH A MAX.
OF 1000
• Edit schedule list
• Modify schedule
• Duplicate Spots
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RAFT SETTING UP A NEW SPOT ID IN ONE TO ONE MODE (DEFAULT)
GATEWAY SETUP
B Launch RAFT Gateway and double-click the timer that is iden-
tified.
NOTE: Your timer screen
may display different
information depending
on software installed.
The screen shots used in
the following procedures
are for illustrative
purpose only.
C Select the Editor tab by clicking.
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D From Timer Data Type drop down list select System
Configuration
E Click on SPOT TO SCH ASSIGNMENT. Then select from one of the
two modes available. In our example we will leave it at default
mode ONE TO ONE.
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F Go back to SCHEDULE in Timer Data Type select schedule
number (4*)
G Enter valid spot number. This field will turn red if a number
<256 is entered. The Add Spot button will now turn yellow. Indi-
cating that schedule 4 has been assigned to spot 256.
H Click the Yellow Add Spot button.
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* For exemplary purpose only
EDITING THE SCHEDULE FOR A NEW SPOT
The pre-programmed schedules 1-255 can be individually changed
Note: Once depending on specific spot requirements.
a schedule
is edited the B To edit a schedule select the Spot from the Timer Data Type drop
change is down menu. Then make sure that the right spot number is
carried over to displayed in the Number field (256 in our example). Navigate to
all spots with the line in the schedule that has to be edited and click Insert.
the same This opens up a list of available schedule functions in a new
schedule.
window. Select EDGE WELD. Click OK.
C Click Apply Changes. Then Save Changes
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DELETING A FUNCTION FROM THE SCHEDULE
B Select the function line to be deleted and click the delete button.
C The Save Changes button will turn yellow, click to apply.
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DUPLICATING A SPOT
B To duplicate a Spot click the Duplicate button. This opens up
the spots list in a new window. Select the spots and click OK.
• To select a group of spots listed in order hold Shift + click.
• To select specific spots hold Ctrl + click on the spot. Exam-
ple Spots 1234 and 32165 as shown above.
C An alert is annunciated.
Click Yes to confirm.
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REMOVING A SPOT ID
B Spots are associated with schedules. Select Schedule from Timer
Data Type drop down menu. Then select the schedule number
from the list to find all the spots associated with the schedule.
Click on the down arrow under Associated Spots. This will display
a list of spots associated with the schedule.
C Select the Spot to delete and click Remove Spot button. This
also removes all changes made to the schedule associated with
the particular spot.
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POSSIBLE ERROR MESSAGES
1. When the weld program is configured in ONE TO ONE mode a
Duplicate Entry error message is generated when an attempt is
made to assign a previously assigned schedule to a new spot
2. When the weld program is configured in MANY TO ONE mode a
NAK returned is generated when an attempt is made to associate
more that 1000 spots to a single weld schedule.
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DEP 300s SETUP SETTING UP A NEW SPOT ID IN MANY TO ONE MODE
B Press Program Mode
NOTE:
Check your
DEP 300s
communication
settings - Local
Ethernet, Global
Ethernet or Serial
before proceeding.
C Press More
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D Press Reload Options
E Press the arrow key twice to bring the cursor to SPOT TO
SCH ASSIGNMENT. Press This opens up a drop down box
displaying the available modes. Press the arrow key to
select MANY TO ONE.
F Press
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F Press Execute
G Do you want to RELOAD CONTROL information will be displayed.
Press to confirm.
H Press to Execute and cycle power to the timer confirm
the change.
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I Press Program Mode
J Press More
K Press More
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L Press More
M Press Spots
N Press Spot
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O Press New
P Press the arrow key to move the cursor to the Assigned #
field. Enter the schedule number using the number keys
Then press Enter Wait for the Download complete mes-
sage before proceeding.
O Press Enter . Using the number keys enter spot number
(256 in our example)
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P Press the arrow key to move the cursor to the Assigned #
field. Enter the schedule number using the number keys
Then press Enter Wait for the Download
complete message before proceeding.
Q Press the arrow key to move the cursor to the Spot # field.
Enter the new spot number using the number keys
Then press Enter Wait for the Download complete mes-
sage before proceeding.
Repeat Step 16 to add new spots to the selected schedule. Up to a
maximum of 1000 associations to a single schedule are allowed.
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EDITING A SCHEDULE
B Use the or arrow keys to navigate to the line of the
Schedule that has to be edited.
C In this example we will edit the Stepper. Press Enter
D Using the numbers pad select the number to be
assigned to the Linear Stepper. 2 is used in our example.
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E Press Enter
F Press Apply
To insert a new function in the schedule use the arrow
keys to scroll to the line that new function will follow and click Insert.
To delete a function in the schedule use the arrow keys
to scroll to the line that has to be deleted and click delete.
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LIST OF SPOT I/O BITS
SPOT 9 (256)
SPOT 10 (512)
SPOT 11 (1024)
SPOT 12 (2048)
SPOT 13 (4096)
SPOT 14 (8192)
SPOT 15 (16384)
SPOT 16 (32768)
SPOT 17 (65536)
SPOT 18 (131072)
SPOT 19 (262144)
SPOT 20 (524288)
SPOT 21 (1048576)
SPOT 22 (2097152)
SPOT 23 (4194304)
SPOT 24 (8388608)
SPOT 25 (16777216)
SPOT 26 (33554432)
SPOT 27 (67108864)
SPOT 28 (134217728)
SPOT 29 (268435456)
SPOT 30 (536870912)
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DEFAULT WELD ROBOT MODE - DEFAULT WELD SCHEDULES
SCHEDULES
SCHEDULE # FUNC. # DESCRIPTION
00 START OF SCHEDULE #N
42 ADAPTQ MODE=0 RATE =100% WSLIDE =100%
82 LINEAR STEPPER #0 ASSIGNED (0=0FF)
76 SEC. CURR LIMITS: HI = 00 LO = 99990
81 TRANSFORMER TURNS RATIO 73:1
1-29 and 88 TURN ON ISOLATION CONTACTOR
32 - 255 58 TURN ON WELD IN PROGRESS
1 SQUEEZE 30 CYCLES
30 WELD 10 CYCLES 1000 AMPS
3 HOLD 5 CYCLES
63 TURN ON WELD COMPLETE
59 TURN ON WELD IN PROGRESS
75 EXTEND UNTIL NO INITIATE
64 TURN OFF WELD COMPLETE
89 TURN OFF ISOLATION CONTACTOR
100 END OF SCHEDULE
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ROBOT MODE - DEFAULT TIP DRESS SCHEDULE
SCHEDULE # FUNC. # DESCRIPTION
00 START OF SCHEDULE #N
58 TURN ON WELD IN PROGRESS
1 SQUEEZE 30 CYCLES
59 TURN OFF WELD IN PROGRESS
30 and 31
63 TURN ON WELD COMPLETE
3 HOLD 5 CYCLES
64 TURN OFF WELD COMPLETE
100 END OF SCHEDULE
MACHINE MODE - DEFAULT WELD SCHEDULE
SCHEDULE # FUNC. # DESCRIPTION
00 START OF SCHEDULE #N
46 ADAPTQ MODE=0 RATE= 100% WSLIDE=100%
82 LINEAR STEPPER #0 ASSIGNED (0 = OFF)
76 SEC. CURR LIMITS: HI =00 LOW =99990
81 TRANSFORMER TURNS RATIO 73:1
1-255 88 TURN ON ISOLATION CONTACTOR
58 TURN ON WELD IN PROGRESS
1 SQUEEZE 30 CYCLES
30 WELD 10 CYCLES 10000 AMPS
3 HOLD 5 CYCLES
63 TURN ON WELD COMPLETE
59 TURN OFF WELD IN PROGRESS
75 EXTEND UNTIL NO INITIATE
64 TURN OFF WELD COMPLETE
89 TURN OFF ISOLATION CONTACTOR
100 END OF SCHEDULE
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Chapter 7: FAULTS AND SETUP PARAMETERS
When Faults are detected, the WTC DEP-300s (Data Entry Panel) can
be used edit a Programmable Fault or Setup Parameter.
WTC DEP-300s is a portable, hand-held, programming device, used to
communicate with WTC weld processors through an EtherNet IP
network.
[For detailed information on how to use the DEP-300s refer to User
Manual # M-035030]
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PERFORM THE FOLLOWING STEPS ON THE DEP-300s TO EDIT
A PROGRAMMABLE FAULT OR SETUP PARAMETER
Press Program Mode
Press Review
Setups
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Press the arrow keys to move the cursor
to the fault or parameter line to be
edited.
Press ENTER
Press the arrow keys to select a fault
severity option or enter the required
parameter
Press ENTER
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Press APPLY
[Saves changes to the DEP-300s only]
Press DOWNLOAD
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Downloads the changes to the weld processor. When complete, a
“Download Complete” message will appear.
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FAULT SEVERITY The user can set the severity of the programmable faults. The severity
option tells the weld processor how to respond when a fault
condition is detected. Conversely, the severity of non-programmable
faults are fixed and cannot be changed. See Non-Programmable
(Hidden) Faults on Page 115.
When a fault condition is detected by the weld
processor, the Fault bit will go HIGH and the No
Fault bit will go LOW. Fault conditions generally
FAULT (with a few exceptions) inhibit the initiation of a
weld schedule. A fault condition is remembered by
the weld processor when power is re-cycled on the
weld control cabinet.
When an alert condition is detected by the weld
processor, the Alert bit will go HIGH and the No
ALERT Alert bit will go LOW. Alert conditions generally do
not inhibit the initiation or execution of a weld
schedule.
When a fault condition is detected, the weld
processor still logs the fault, but inhibits the Fault
NONE or Alert bits from turning on (HIGH). This condition
will not inhibit the initiation of a weld schedule.
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FAULT RESET Faults can be reset by either pressing the Reset (F5) button on the
Fault Status Menu in the DEP-300s or turning the Fault Reset input bit
HIGH. Perform the following steps to reset faults via the DEP-300s
Press Status Mode
Press Fault
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Press Reset
Press the Options to filter what is viewed on the Fault Status Menu.
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Press Options
Press the arrow keys to move the
cursor over the desired filter option
Press Enter
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PROGRAMMABLE FAULTS
USER DEFINED
DEFAULT
FAULT PROGRAMMABLE POSSIBLE CAUSES SOLUTIONS
VALUE
OPTIONS
Occurs when: 1. This is a pre-weld check.
Ensure the master con-
WELD 1. function #61 (ABORT IF troller (i.e. robot, PLC,
INITIATE NOT FAULT/ALERT ALERT NO INITIATE FOR nnnn etc.) is maintaining the
PRESENT CYCLES) is used in the Weld Initiate bit HIGH
weld schedule and the during the time function
Weld Initiate bit goes #61 is monitoring the bit.
LOW within the amount
of time programmed in 2. Ensure the master con-
the function. troller (i.e. robot, PLC,
etc.) is maintaining the
2. the Weld Initiate bit goes Weld Initiate bit HIGH
LOW before function #63 until function #63 is exe-
(TURN ON WELD COM- cuted in the weld sched-
PLETE) is executed in the ule.
weld schedule.
Occurs at: Indicates the final step in the
STEPPER stepper program has begun
APPROACHING FAULT/ ALERT ALERT 1 the 1st weld of step 2 in the and End of Stepper is
MAX stepper program, if the tip approaching.
dress feature is enabled,
and the Remaining Tip Perform a tip dress or tip
Dresses Count has decre- change.
mented to 0.
2 the 1st weld of step 5 in the
stepper program, if the
Remaining Tip Dresses
Count is > 0.
Occurs at the 1st weld of step
5 in the stepper program, if
the tip dress function is dis-
abled in the Setup Parame-
ters.
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USER DEFINED
DEFAULT
FAULT PROGRAMMABLE POSSIBLE CAUSES SOLUTIONS
VALUE
OPTIONS
Occurs at:
Reset the stepper (using
1 the 1st weld of step 3 in the either the external reset
END OF stepper program, if the tip input or the stepper display
STEPPER FAULT/ALERT FAULT dress feature is enabled mode). You should also dress
and the remaining Tip or replace the electrode caps.
Dresses Count has decre-
mented to 0.
NOTE: The first 40 welds
will be an ALERT. If the
stepper program is not
reset by the 41st weld, it
will change to a FAULT.
2 the last weld of step 5 in
the stepper program, if the
Remaining Tip Dresses
Count is > 0.
3 Occurs at the last weld of
step 5 in the stepper pro-
gram, if the tip dress func-
tion is disabled in the Setup
Parameters.
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USER DEFINED
DEFAULT
FAULT PROGRAMMABLE POSSIBLE CAUSES SOLUTIONS
VALUE
OPTIONS
Occurs when: 1. If using function #94, see
corrective action for
1. either function #94 LOW CURRENT LIMIT
(EXTEND WELD IF LOW FAULT.
CURRENT LIMIT FAULT)
or #95 (EXTEND WELD IF 2. If using function #95
CURRENT LESS THAN ensure the programmed
nnnn0) is used in the current value is correct
weld schedule and the for the welding applica-
condition is true. This tion.
typically occurs when
the required current can- 3. Ensure the value pro-
not be achieved. grammed into the Exces-
sive Extend Weld Limit in
EXTENDED FAULT/ALERT FAULT 2. if the extend weld (re- the Setup Parameters is
WELD weld) is successful, an correct for the welding
EXTENDED WELD application.
(ALERT) will occur and
the Weld Complete bit 4. Look for possible part fit-
will go HIGH. If the up and tooling wear
extend weld (re-weld) is issues.
unsuccessful, both an
EXTENDED WELD ALERT 5. Ensure proper air pres-
and a LOW CURRENT sure is being supplied to
LIMIT FAULT will occur the weld gun.
and the Weld Complete
bit will stay LOW.
3. the Excessive Extend
Weld Limit is reached in
the Setup Parameters.
NOTE: This fault must be set to
(ALERT) for the Weld Complete
bit to go HIGH after a successful
extend weld (re-weld). Other-
wise, if set to (FAULT), the Weld
Complete bit will stay LOW.
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USER DEFINED
DEFAULT
FAULT PROGRAMMABLE POSSIBLE CAUSES SOLUTIONS
VALUE
OPTIONS
1. Ensure the “HI” value
programmed into func-
tion #92 is correct for the
Occurs when function #92 welding application.
(C-FACTOR LIMIT: HI =nnnn
LO =nnnn) is used in the weld 2. High C-Factor Limit usu-
HIGH
FAULT/ALERT ALERT schedule and the C-Factor ally indicates current
C-FACTOR value calculated by the weld shunting is occurring in
LIMIT processor exceeds the high the secondary circuit.
limit value programmed in Typically this is caused by
the function. a build-up of expulsion
slag across the gun
pinch-point, the part
shorting to the electrode
arms or shorting caused
by broken leaf shunts.
See Ch. 9: Advanced Top-
ics for more information.
1. Ensure the “LO” value
programmed into func-
tion #92 is correct for the
welding application.
Occurs when function #92 2. Low C-Factor Limit usu-
(C-FACTOR LIMIT: HI =nnnn ally indicates an increase
LO =nnnn) is used in the weld in the resistance of the
LOW FAULT/ALERT ALERT schedule and the C-Factor secondary circuit. This
C-FACTOR value calculated by the weld can be caused by frayed
LIMIT processor exceeds the low or open welding cables.
limit value programmed in If water-cooled cables
the function. are used (braided copper
inside rubber jacket), the
frayed or open cable
may not be externally
visible and the cable
resistance will need to
be checked with a Micro
Ohm Meter. See Ch. 9:
Advanced Topics for
more information
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USER DEFINED
DEFAULT
FAULT PROGRAMMABLE POSSIBLE CAUSES SOLUTIONS
VALUE
OPTIONS
Occurs when:
1 function #70 [WAIT FOR
WELD PROCEED] is used in
the weld schedule and the
Weld Initiate input bit goes
LOW before the specified
input bit goes either OFF or
ON.
WELD FAULT/ALERT FAULT 2 function #67 [WAIT FOR WAIT FOR WELD PROCEED bit
PROCEED INPUT #n TO BE n (0 = OFF to go HIGH
1 = ON)] is used in the weld
schedule and the Weld Ini-
tiate input bit goes LOW
before the specified input
bit goes either OFF or ON.
3 Occurs when function #66
[WAIT nnn CY INP #n TO BE
n (0 = OFF 1 = ON)] is used
in the weld schedule and
the specified input bit does
not go either OFF or ON
within the number of
cycles specified.
NOTE: Allows welding current if
set as an ALERT and inhibits
welding current if set at a
FAULT.
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USER DEFINED
DEFAULT
FAULT PROGRAMMABLE POSSIBLE CAUSES SOLUTIONS
VALUE
OPTIONS
Occurs when: 1 Check analog feedback cir-
cuit for problems.
1 function #69 (WAIT FOR
PRESSURE SWITCH INPUT) 2 Check for mechanical prob-
is used in the weld sched- lems with the weld gun
ule and the Weld Initiate related to air pressure, e.g.
bit goes LOW before the water in air lines, pressure
Pressure Switch bit goes regulator set too low, etc.
HIGH.
3 Check sequence initiated. If
PRESSURE FAULT/ALERT ALERT 2 function #68 (WAIT nnnn the pressure select input is
SWITCH CY FOR PRESSURE SWITCH not required, remove the
INPUT) is used in the weld function checking the
schedule and the Pressure input.
Switch bit does not go
HIGH within the amount of 4 If the function is required,
time programmed in the check the switch, contact
function. or device providing the
input.
NOTE: Allows welding current if
set as an ALERT and inhibits 5 If the error was caused by
welding current if set at a the initiates being removed
FAULT. while waiting for the input,
check the initiates.
Occurs when function #74 1. Check analog feedback
(WAIT nnn MS FOR PRESSURE circuit for problems.
PRESSURE NOT ACHIEVED) is used in the
ACHIEVED FAULT/ALERT ALERT weld schedule and the pro- 2. Check for mechanical
grammed pressure is not problems with the weld
achieved within the amount gun related to air pres-
of time programmed in the sure, e.g. water in air
function. lines, pressure regulator
set too low, etc.
3. Increase the time pro-
grammed in the func-
tion if incorrect to
allow for pressure to
achieve the set limit.
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USER DEFINED
DEFAULT
FAULT PROGRAMMABLE POSSIBLE CAUSES SOLUTIONS
VALUE
OPTIONS
1. Ensure jumper wire is
securely connected to J5,
Pins 3 and 4, on the
CIOM module. This is the
Weld / No Weld hard-
Occurs when a weld schedule wired input. If the hard-
is initiated while the weld wired input is not used,
CONTROL FAULT/ALERT ALERT processor is in No Weld the jumper must be
IN NO WELD Mode (i.e. the Weld / No installed.
Weld bit is LOW).
2. Investigate why the mas-
ter DeviceNet or Ether-
Net IP controller (i.e.
robot, PLC, etc.) held the
Weld / No Weld input bit
LOW when the weld
sequence initiated.
3. Ensure the weld proces-
sor was not manually put
into No Weld Mode
through the DEP 300s (if
used).
Occurs during the welding 1 Troubleshoot why the
sequence when: retract cylinder is moving
to the retract position (full
1 function #86 (VERIFY CYL- open) during the welding
INDER #n IS OUT OF sequence.
RETRACT) is inserted in the
weld schedule, and the 2 Press the retract button on
weld gun moved out of the the weld gun and verify the
weld position (Close gun is out of retract (in the
RETRACT PILOT FAULT/ALERT FAULT Retract output bit HIGH) to weld position) before initi-
the retract position (Close ating the weld sequence.
Retract output bit LOW)
when checked by the weld
processor.
2 when the weld gun is in the
retract position (full open)
and the weld sequence for
that gun is initiated (Sched-
ule Pilot input bit is HIGH).
NOTE: Allows welding current
if set as an ALERT and inhibits
welding current if set at a
FAULT.
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USER DEFINED
DEFAULT
FAULT PROGRAMMABLE POSSIBLE CAUSES SOLUTIONS
VALUE
OPTIONS
Occurs when:
1. the Weld / No Weld bit Ensure weld gun is not open-
goes LOW while the weld ing early. Check for intermit-
control is passing current tent open connection in the
during the execution of a weld tooling (primary or sec-
WELD INTER- FAULT/ ALERT ALERT weld schedule. ondary).
RUPTION
2. the circuit breaker on
the weld cabinet is
switched OFF while the
weld control is passing
current during the exe-
cution of a weld sched-
ule. The fault will appear
after the circuit breaker
is switched back ON and
the weld processor re-
initializes.
3. the weld current is inter-
rupted during the weld
time.
Occurs when the AC line volt-
age drops below a point
where the DC power supply Inspect plant power and cor-
LOW LINE on the CIOM-TB module can rect what is causing the AC
VOLTAGE FAULT/ALERT FAULT no longer regulate the line voltage to drop.
+24VDC it supplies to the
devices downstream.
This fault is monitored con-
tinuously.
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USER DEFINED
DEFAULT
FAULT PROGRAMMABLE POSSIBLE CAUSES SOLUTIONS
VALUE
OPTIONS
Occurs when: 1. Check to make sure that
the current is not
1. the impedance of the exceeding the limits
secondary circuit cre- specified in the Setup
ates a current draw that Parameters.
causes the inverter to
reach or exceed its maxi- 2. Review the weld require-
mum output current rat- ments and verify the
ing. turns ratio is specified
correctly in the primary
2. when the target second- mode.
ary current programmed
into the weld schedule
causes the inverter to NOTE: When this fault occurs,
SOFT reach its maximum out- go to the Hardware Status
FAULT/ALERT FAULT screen in the DEP-300s by press-
OVERCURRENT put current rating.
NONE ing the Display Mode (F4) key.
The Hardware Status screen will
To determine the maximum tar- provide more specific informa-
get secondary current, multiply tion regarding the nature of the
the inverter maximum output fault.
current rating by the trans-
former turns ratio. For example,
400A inverter x 50:1 turns ratio =
20,000A max target secondary
current. Thus, programming
more than 20,000A into the weld
schedule may cause a SOFT
OVERCURRENT FAULT.
3. the inverter reaches its
maximum IGBT on-time
rating before the target
secondary current is
achieved. Thus, what-
ever current level is
achieved at max IGBT
on-time, is what will be
delivered to the welding
transformer.
4. the weld processor
detects the MFDC
inverter is passing weld
current at a duty cycle
that exceeds the duty
cycle rating of the IGBT
devices.
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USER DEFINED
DEFAULT
FAULT PROGRAMMABLE POSSIBLE CAUSES SOLUTIONS
VALUE
OPTIONS
1. Verify the primary and
secondary cables, isola-
tion contactor and weld
This fault is generated when transformer for any
the inverter reaches its maxi- damage.
mum IGBT on-time rating
before the target secondary 2. Ensure that the elec-
current is achieved. Thus, trodes and are making
CURRENT FAULT/ALERT/ whatever current level is contact with pressure
REGULATION NONE FAULT achieved at max IGBT on- and NO insulation mate-
time, is what will be deliv- rial is present on the part
ered to the welding trans- between the electrodes.
former.
3. Using a weld meter
This results in: determine if the second-
ary current matches the
1. Insufficient current weld control’s current
2. Missing weld on the part reading.
3. Open circuit of the weld- • If the secondary resis-
ing transformer primary tance is too high reduce
or secondary the length of the sec-
ondary cable and install
a cable with a larger
diameter.
• If the requested current
reading is higher than
the possible limit of the
welding transformer
and secondary resis-
tance, correct the dis-
crepancy in the weld
schedule or stepper
program. Tune the weld
transformer tap to a
higher ratio.
• If the weld control and
weld checker readings
MATCH and the control
continues to show
insufficient current and
weld expulsion occurs,
the inverter current
reading is defective. In
this situation replace
the inverter and weld
processor.
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USER DEFINED
DEFAULT
FAULT PROGRAMMABLE POSSIBLE CAUSES SOLUTIONS
VALUE
OPTIONS
1. Occurs when function 1. When No Motor Current
#16 (MOTOR CURR LIM- is detected check the
ITS HI =nnnn ma LO wiring to confirm that
=nnnn ma) is used in the the motor is properly
weld schedule and the connected.
measured tip dress
motor current is above 2. In case of High Current
the HIGH limit any time check the following:
HIGH / NO FAULT/ALERT/ FAULT during the 8 ms checking • Shorted cables
MOTOR NONE period. When this fault • Jammed Motor
CURRENT occurs, the motor is • Motor currents set
immediately turned off. improperly.
2. Occurs when the mea-
sured tip dress motor
current is <= 20 ma any
time during the 8ms
checking period. When
this fault occurs, the
motor is immediately
turned off.
NOTE: This parameter is used with
weld controls built with the tip
dress motor control option.
Occurs when function #16 1. Ensure the High and Low
(MOTOR CURR LIMITS HI limit thresholds (MOTOR
=nnnn ma LO =nnnn ma) is CURR LIMITS HI =nnnn
used in the weld schedule ma LO =nnnn ma) are set
TIP DRESS FAULT/ALERT/ FAULT and the measured tip dress correctly.
NONE motor current is above the
value programmed into the 2. Verify the accumulated
LOW limit for less than (1) time limit is set to 1 sec.
second of accumulated time. minimum since any time
Conversely, this fault will not less than that will cause
occur if the measured current the fault to be annunci-
remains above the LOW limit ated.
for (1) or more seconds of
accumulated time. 3. Check the gun to see if it
is closing on the cutter.
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NON-PROGRAMMABLE (HIDDEN) FAULTS
The following is a list of standard non-programmable faults in the
WT6000. Their default values are fixed and cannot be changed. Since
these faults are non-programmable, they are hidden from view in the
DEP-300s View Setups Menu.
DEFAULT
FAULT NAME POSSIBLE CAUSE SOLUTION
VALUE
Occurs when the Weld Initiate bit goes Ensure the schedule (sequence) number
HIGH and a schedule (sequence) num- selected via the Binary Select bits is not
ber is selected via the Binary Select bits, beyond the range of available sched-
INVALID which is beyond the range of available ules. For example, if there are 99 sched-
SEQUENCE FAULT schedules. ules available, selecting schedule 100 or
higher via the Binary Select bits will gen-
SELECTED
NOTE: This fault will only occur when the erate an INVALID SEQUENCE SELECTED
Retract Pilot input bit is mapped in the I/O. FAULT, when the Weld Initiate bit goes
HIGH.
Occurs when: 1 Ensure the red Control Stop push but-
ton on the 0perators Panel is pulled
1 the Control Stop input bit goes LOW out. The Control Stop input bit should
anytime during the initiation of the never go LOW unless a legitimate
weld sequence. This bit is normally Control Stop event has occurred.
FAULT maintained HIGH.
CONTROL
2 Ensure jumper wire is securely con-
STOP 2 in a single gun welding application nected to J5, Pins 7 and 8, on the
when the weld sequence is initiated CIOM module. This is the Control Stop
without the jumper plug inserted into hard-wired input. If the hard-wired
the weld gun 2 connector (2PL). input is not used, the jumper must be
installed.
3 Investigate why the master DeviceNet
or EtherNet IP controller (i.e. robot,
PLC, etc.) turned the Control Stop
input bit LOW during the weld
sequence (e.g. safety gates, light
screens, robot E-Stop, master E-stop,
etc).
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DEFAULT
FAULT NAME POSSIBLE CAUSE SOLUTION
VALUE
Occurs when: 1 Ensure the percentage value pro-
grammed into HIGH CURRENT LIMIT
1 the weld processor detects that the WINDOW% in the Setup Parameters is
current passed during the weld sched- correct for the welding application.
ule exceeded the value programmed
into the HIGH CURRENT LIMIT WIN- 2 Ensure the HI value programmed into
HIGH
DOW% in the Setup Parameters. function #76 (SEC. CURR LIMITS: HI =
CURRENT FAULT nnnn0 LOW = nnnn0) in the weld
LIMIT FAULT 2 the weld processor detects that the schedule is correct for the welding
current passed during the weld sched- application.
ule exceeded the HI value pro-
grammed into function #76 (SEC. 3 Ensure the value programmed into
CURR LIMITS: HI = nnnn0 LOW = TRANSFORMER TURNS RATIO in the
nnnn0) in the weld schedule. Setup Parameters is correct for the
welding application.
Occurs when: 1 Ensure the percentage value pro-
grammed into LOW CURRENT LIMIT
1 the weld processor detects that the WINDOW% in the Setup Parameters is
current passed during the weld sched- correct for the welding application.
ule was less than the value pro-
grammed into the LOW CURRENT 2 Ensure the LOW value programmed
LIMIT WINDOW% in the Setup Param- into function #76 (SEC. CURR LIMITS:
eters. HI = nnnn0 LOW = nnnn0) in the weld
schedule is correct for the welding
LOW FAULT 2 the weld processor detects that the application (if used).
CURRENT current passed during the weld sched-
LIMIT FAULT ule was less than the LOW value pro- 3 Ensure the value programmed into
grammed into either function #76 TRANSFORMER TURNS RATIO in the
(SEC. CURR LIMITS: HI = nnnn0 Setup Parameters is correct for the
LOW = nnnn0) in the weld schedule. welding application.
3 when mechanical issues exist in the 4 Look for possible part fit-up and tool-
weld transformer secondary circuit ing wear issues.
(weld tooling).
5 Ensure proper air pressure is being
Typical issues include: supplied to the weld gun.
• Bad jumper cables or leaf shunts
• Bad part fit-up
• Contaminated weld caps
• Insulation from sealer, tape or
labels on part
• Gun sticking or not closing prop-
erly
• Loose or open secondary diodes
in the welding transformer
• Loose or bad primary cables.
Inspect and correct as neces-
sary.
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DEFAULT
FAULT NAME POSSIBLE CAUSE SOLUTION
VALUE
1. Ensure function #88 (TURN ON ISO-
LATION CONTACTOR) is in the weld
schedule and inserted before the
squeeze function.
2. Check for defective isolation con-
tactor aux contact module (con-
tacts possible stuck closed). Check
for loose or open wire connections
between the isolation contactor
ISO CNTR Occurs when the isolation contactor is coil and the CIOM module.
OFF WHEN FAULT not energized (closed) when required by
NEEDED the weld schedule. This is monitored by 3. If the isolation contactor is not
the state of the isolation contactor aux defective, the solid state relay on
contact. the CIOM module, which drives the
isolation contactor coil, may be
open. Replace CIOM module.
4. The weld processor will not ener-
gize the isolation contactor if either
the Control Stop bit or the Weld /
No Weld bit are LOW. Ensure both
bits are HIGH during the execution
of the weld schedule.
1 Typically, this fault is caused by a
defective auxiliary contact block on
the isolation contactor. The contacts
Occurs when the weld processor detects can be cleaned by removing the auxil-
the isolation contactor is energized iary block, manually moving the aux
(closed) when it should be de-energized contact up and down a few times and
(open). When this fault occurs, the weld then reseting. If this does not resolve
processor activates the shunt-trip mech- the problem, replace the auxiliary
anism on the circuit breaker. This is contact block.
ISO CNTR FAULT monitored by the state of the isolation
ERR-BRKR contactor aux contact. 2 Inspect the isolation contactor for
TRIPPED damage. The high current contacts
may be frozen shut. If so, replace iso-
lation contactor.
3 Check for defective isolation contactor
aux contact module (contacts possible
stuck open). Check for loose or open
wire connections between the aux
contact module and the CIOM mod-
ule.
4 If the isolation contactor is not defec-
tive, the solid state relay on the CIOM
module, which drives the isolation
contactor coil, may be shorted.
Replace CIOM module.
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DEFAULT
FAULT NAME POSSIBLE CAUSE SOLUTION
VALUE
Occurs when the System Cooling bit 1 Troubleshoot and find out why the
goes LOW prior to and during the execu- system cooling input is going LOW.
tion of the weld schedule. This bit is Could be a robot / PLC issue logic
SYSTEM FAULT normally maintained HIGH. issue or a legitimate system cooling
COOLING problem.
This bit can be used to set a weld pro-
cessor fault when a system cooling 2 Identify and correct any water flow
problem exists somewhere in the weld- issues.
ing process. For example, it could be
used to indicate a transformer over-
temp condition.
NOTE: The inverter chill plate temperature
can be viewed in the Display Mode screen
of the DEP300s.
Occurs when: 1. Determine why EtherNet communi-
cations with the weld processor
1. an EtherNet/IP network communi- have been lost. Inspect for loose
cation timeout occurs. Once Ether- EtherNet cable connections or
Net/IP communication is re- defective cable.
established, the fault will automati-
cally reset. 2. Remove function #56 from the
weld schedule.
2. the weld processor looses commu-
nication with any device connected 3. Ensure all the 15-pin D-sub cables
on the SSPI communication link: on the SSPI communication link are
connected properly and not defec-
IO FAULT • CIOM (Contactor I/O Module) tive.
• AIOM (Analog I/O Module)
• DIOM (Discrete I/O Module) This link starts at the SSPI port on the
• GFM (Ground Fault Module) weld processor (1CPU) then goes to the
• MCCM (Multi-Contactor Control -
Module) CIOM Module (1CIOM)
NOTE: Prior to resetting this fault, go to the The 1st ground fault module
Hardware Status screen in the DEP-300s by (1GFM)
pressing the Display Mode (F4) key. The
The 2nd ground fault module
Hardware Status screen will provide more
specific information regarding the nature of (2GFM)
the fault. The discrete I/O module (1IO)
and
Finally to the analog I/O mod-
ule (1AIOM).
4. Also verify the modules in the com-
munication link are not defective.
5 Check to make sure that the screws
attaching the 5-pin Phoenix connector
are tight.
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DEFAULT
FAULT NAME POSSIBLE CAUSE SOLUTION
VALUE
Occurs when the weld cabinet is pow-
INITIATION FAULT ered-up (i.e. circuit breaker is switched Ensure the Weld Initiate and the Binary
ON ON) and the weld processor detects that Select input bits are set low by the
POWERUP both the Weld Initiate bit is HIGH and Robot / PLC logic at time of power-up of
one or more Binary Select bit is HIGH. In the weld control cabinet, clear faults
this condition, a weld schedule WILL and re-initiate weld schedule.
NOT initiate.
Occurs at power-up only, when an under
or over voltage condition exists on the
24VAC secondary tap of the control
transformer. The CIOM-TB module mon-
itors the 24VAC secondary tap of the
control transformer for either an under
or over voltage condition. This ensures
the primary of the control transformer
CONTROL FAULT is tapped properly for the incoming line
TRANS- voltage. Inspect control transformer and ensure
FORMER the primary is properly tapped for the
VOLTAGE NOTE: When an over voltage is detected at incoming line voltage.
power-up, the CIOM shuts down the 24VDC
to all downstream devices in the SSPI link to
prevent damage. The over voltage condi-
tion must be corrected and the CIOM must
be re-started to clear this condition and
restore 24VDC power to the devices in the
SSPI link.
Occurs when the weld processor detects
an instantaneous over-current event, Replace shorted primary cables or
IGBT which exceeds the design rating of the replace inverter assembly.
SATURATION FAULT IGBT modules within the inverter
assembly. This can be caused by either a
short across the welding transformer
primary cables or a defective inverter
assembly.
Occurs when: 1 Check to see if the 1FU and 2FU fuses
have blown on the control trans-
1 There is a loss of power to the IGBT former. If the fuses are blown, using a
IGBT POWER FAULT supply board within the inverter screwdriver, manually push the isola-
SUPPLY assembly. tion contactor in and out a few times
and make sure it is not stuck or frozen
2 Failed control transformer fuse caused in the open position.
by the Isolation Contactor mechani- 2 Replace the isolation contactor if sus-
cally hanging-up in the open state. pected bad. If the isolation contactor
is working, then-
3 Loose cable connections at:
• CNIG 3/4 @ 1 INV 3 Replace the CIOM module.
• J2/J3 @ 1 CIOM
4 If the CIOM Module is working then -
Replace the inverter assembly.
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DEFAULT
FAULT NAME POSSIBLE CAUSE SOLUTION
VALUE
Occurs when the weld processor detects
AC LINE a line phase is either incorrect or miss-
PHASE FAULT ing. This fault is monitored continuously. Correct power problem or replace /
This fault may also be accompanied by a install missing phase.
Low Line Voltage Fault and/or Bus Volt-
age Fault.
1 Check to make sure that the Trans-
Occurs when: former Voltage Setup Parameters
have been entered correctly.
1 The weld processor has detected the 2 Check for loose primary connections
DC bus within the inverter assembly at the top or bottom of the circuit
did not charge to the correct level. breaker or upper level bus fusing con-
nections.
BUS VOLTAGE FAULT 2 The bus voltage drops below 300V (or
42% of the set-up parameter - trans-
former voltage) while the DC bus is CAUTION: Use proper safety
charged or during welding. Should lock-out procedures.
this occur during welding the weld
3 Improve the current carrying capacity
time is truncated and the fault output
of the welding bus.
is energized. This particular weld spot
should be marked as suspect or 4 Change the sequence of welding to
should be re-welded. reduce the voltage drops.
5 Verify incoming line power is balanced
phase to phase (L1-L2, L2-L3, L3-L1).
On a 480VAC line, the DC Bus voltage
is approximately 700V (incoming
power x 1.414) and can be measured
at CNIG3. Prior to measuring the DC
Bus voltage, verify the multimeter and
test leads are rated for high voltage
measurement.
6 If the AC line voltage is properly bal-
anced, try resetting the circuit breaker
on weld control cabinet. If problem
persists, replace defective inverter
assembly.
Occurs when the weld processor has Reset circuit breaker on weld control
BUS detected the DC bus within the inverter cabinet. Replace inverter assembly if
CHARGING FAULT assembly did not charge correctly continually re-occurs.
(either too slow or too quickly). This
fault is monitored continuously.
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DEFAULT
FAULT NAME POSSIBLE CAUSE SOLUTION
VALUE
Occurs when: 1. Verify the welding transformer
1 The weld processor has detected a diodes are not shorted. If it has
SECONDARY FAULT shorted secondary diode within the been verified the welding trans-
DIODE welding transformer. former secondary diodes are not
shorted, then -
2 Missing gate signals from the weld
processor 2. Replace the weld processor. If
replacing the weld processor does
not correct the problem, then -
3. Replace the inverter assembly.
Occurs at the initiation of a weld The secondary current coil is either
sequence, when the weld processor improperly connected to the weld pro-
does not detect a proper connection to cessor or it is bad. If proper connection
SECONDARY the secondary current monitoring coil has been verified and the fault still per-
CURRENT FAULT when it should. sists, replace the coil with a known good
one.
SENSOR
This fault will only occur when the weld
processor is configured to either the
(PRI/SEC) or (SEC/SEC) Firing Monitoring
Mode in the Setup Parameters.
Occurs when a current imbalance exists Identify and correct unidirectional cur-
OUTPUT FAULT between the two output terminals of rent path to ground between the output
GROUND the inverter assembly. of the inverter assembly and the pri-
mary of the welding transformer.
1 WATER COOLED INVERTER:
This fault occurs when the timer senses Verify proper cooling water tempera-
a chill plate temperature of more than ture and flow.
60° C for an Air Cooled inverter or 70°
FAULT deg C for a Water cooled inverter. 2 AIR COOLED INVERTER:
Verify proper fan operation and clean-
TEMPERA-
To verify the real time temperature use liness of the air fins.
TURE the “Hardware Status Screen” of the
timer and look for “CHILL PLATE TEM- 3. Slow down the speed of welding
PERATURE”. (number of welds per minute)
If the fault is displayed during normal 4. Reduce welding current
operation, the cooling system is unable
to remove heat fast enough to protect 5. Reduce welding time (and/or fewer
the SCR/Diodes and IGBTs. Often this is weld pulses)
because the inverter is passing too
much current in a short amount of time 6. Reduce the ambient temperature
or the cooling system is not functioning around the inverter or supply
properly. cooler water temperature.
7. Select a higher tap setting (turns
ratio) for the welding transformer
(i.e. reduces the primary current for
the same secondary current)
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DEFAULT
FAULT NAME POSSIBLE CAUSE SOLUTION
VALUE
Occurs when:
INVERTER 1 a hardware failure is detected within Replace inverter assembly and weld
SYSTEM FAULT the inverter assembly or weld proces- processor module.
FAILURE sor module.
2 the weld processor is unable to read
the resistor that tell it what size
inverter it is connected to. The resis-
tor is located within the inverter
assembly and is either open, missing
or an unrecognizable value.
PROGRAMMABLE SETUP PARAMETERS
DEFAULT
SETUP DESCRIPTION PROGRAMMABLE OPTIONS
VALUE
LATCHED:
In Latched mode, a LOW to HIGH
transition on the Retract Pilot input
The Retract Mode setup parameter bit causes the state of the Retract
RETRACT MODE determines how the mapped Retract Valve output bit to latch ON or OFF. LATCHED
Valve output bit will react when the
control receives the mapped Retract UNLATCHED:
Pilot input bit: In Unlatched mode, the Retract
Valve output bit follows the state of
the Retract Pilot input bit.
AIR-NORMAL:
In Air-Normal mode, the weld tool-
ing uses an air-only cylinder that
requires a HIGH Retract Valve output
The Cylinder setup parameter bit to close the gun to the retracted
defines the type of weld gun air cyl- position. AIR-NOR-
CYL
inder being used: MAL
AIR-INVERTED:
In Air-Inverted mode, the weld tool-
ing uses an air-only cylinder that
requires a LOW Retract Valve output
bit to close the gun to the retracted
position.
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DEFAULT
SETUP DESCRIPTION PROGRAMMABLE OPTIONS
VALUE
When function #89 (TURN OFF ISO-
LATION CONTACTOR) is used in the
weld schedule, this parameter
delays the opening of the isolation
contactor for the number of seconds
programmed. Typically used in robot
applications, this parameter reduces
wear on the isolation contactor by
preventing it from unnecessarily
opening and closing during runs of
multiple welds.
ISOLATION
CONTACTOR NOTE: Function #65 (ISOLATION 0 to 99 10
DELAY (SEC) CONTACTOR DELAY = nnnn SEC.)
overrides this global setup parame-
ter, when used locally in a weld
schedule.
NOTE: This parameter and function
#89 are both disabled when the Iso-
lation Contactor Saver input bit is set
LOW or not mapped.
The High Current Limit Window is
calculated as a percentage above
HIGH the target secondary current (base
CURRENT LIMIT current + stepper boost). This is a 0% to 99% 20
WINDOW (%) dynamic window, which contours
with the linear current stepper pro-
gram in use.
The Low Current Limit Window is
calculated as a percentage below
LOW the target secondary current (base 0% to 99% 20
CURRENT LIMIT current + stepper boost). This is a
WINDOW (%) dynamic window, which contours
with the linear current stepper pro-
gram in use.
This parameter sets a global com-
mand, which allows the weld pro-
cessor (WCU) to sample data for
DATA analysis at controlled intervals. The
COLLECTION sample size is the number of consec- 0 to 99 1
utive welds collected for analysis
SAMPLE SIZE
(per bin). For more information, see
SPC Indexing Capabilities in Ch. 9:
Advanced Topics.
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DEFAULT
SETUP DESCRIPTION PROGRAMMABLE OPTIONS
VALUE
This parameter sets a global com-
mand, which allows the weld pro-
cessor (WCU) to sample data for
DATA analysis at controlled intervals. The
COLLECTION sample frequency is the total num- 1 to 9999 1
ber of welds, from which the sam-
SAMPLE
ples are taken from (per bin). For
FREQUENCY more information, see SPC Indexing
Capabilities in Ch. 9: Advanced Top-
ics.
This parameter tells the weld pro-
cessor what type of analog signal
will be sent to the Analog I/O Mod-
ANALOG INPUTS ule (AIOM). Either a Voltage (0-10V)
signal or a Current Loop (4-20ma) VOLTAGE / CURRENT LOOP VOLTAGE
signal.
NOTE: This parameter is used with weld
controls built with an analog pressure
control option.
This parameter sets the maximum
pressure limit an analog device can
MAXIMUM achieve at full output (10V or
ANALOG 20mA). This value can represent any
PRESSURE unit of measure (e.g. PSI, BAR, Mpa, 1 to 9999 100
etc.)
NOTE: This parameter is used with weld
controls built with an analog pressure
control option.
This parameter sets the initial pres-
sure of the Valve 1 output bit. This
value can represent any unit of mea-
VALVE 1 INITIAL sure (e.g. PSI, BAR, Mpa, etc.) 0 to 9999 5
PRESSURE
NOTE: This parameter is used with weld
controls built with an analog pressure
control option.
This parameter sets the initial pres-
sure of the Valve 2 output bit. This
VALVE 2 INITIAL value can represent any unit of mea- 0 to 9999
PRESSURE sure (e.g. PSI, BAR, Mpa, etc.) 5
NOTE: This parameter is used with weld
controls built with an analog pressure
control option.
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DEFAULT
SETUP DESCRIPTION PROGRAMMABLE OPTIONS
VALUE
This parameter is the turns ratio for
the welding transformer being used.
The weld processor uses this value
TRANSFORMER to calculate secondary current
TURNS RATIO during a weld.
1 to 256 73
(Secondary Current = Primary Cur-
rent x Turns Ratio).
NOTE: Function #81 (TRANSFORMER
TURNS RATIO nnn:1) overrides this
global setup parameter, when used
locally in a weld schedule.
This parameter is the rated DC volt-
age of the welding transformer. This
value can be found on the manufac-
turer's label affixed to the welding
TRANSFORMER transformer. 300 to 900 678
RATED DC
NOTE: If the manufacturer's label is
VOLTAGE either inaccessible or has been removed
from the welding transformer, contact
the manufacturer for assistance.
This parameter is the rated fre-
quency of the welding transformer.
This value can be found on the man-
ufacturer's label affixed to the weld-
ing transformer.
400 to 2000 1000
TRANSFORMER
NOTE: It is critical the value pro-
RATED grammed into this parameter is correct.
FREQUENCY An incorrect value could send the trans-
former into saturation, causing poten-
tial damage to the transformer. If the
manufacturer's label is either inaccessi-
ble or has been removed, contact the
manufacturer for assistance.
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DEFAULT
SETUP DESCRIPTION PROGRAMMABLE OPTIONS
VALUE
PRI/PRI:
Primary Current Regulation / Pri-
mary Current Monitoring (Default
The WT6000 inverter has three firing Mode). PRI/PRI
and monitoring modes. These
modes are distinguished by PRI/SEC:
Primary Current Regulation / Sec-
FIRING / 1. The method in which the current ondary Current Monitoring.
MONITOR is regulated
MODE NOTE: Requires additional hardware for
2. The feedback monitoring method secondary current feedback monitoring.
used to determine the proper out-
put. SEC/SEC:
Secondary Current Regulation / Sec-
ondary Current Monitoring.
NOTE: Requires additional hardware for
secondary current regulation and feed-
back monitoring.
This parameter sets the maximum
differential current between the two
output terminals (H1 and H2) of the
GROUND FAULT inverter assembly. This imbalance is 0 to 9999 5000
LIMIT caused by current leaking to ground
on one of the legs. The weld proces-
(milliamps)
sor monitors the current balance
between the H1 and H2 terminals. If
the differential current exceeds this
parameter, a GROUND FAULT is gen-
erated.
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DEFAULT
SETUP DESCRIPTION PROGRAMMABLE OPTIONS
VALUE
This parameter provides the weld
control with information on the
milli-Volts per 1000 AMPS that the
Secondary Coil will output. The typi-
cal secondary coil outputs 150mV/
KAmp. If this value is incorrect, the
amount of secondary current dis- 100 to 300 150
SECONDARY played in the Weld Status screen on
COIL mV/Kamp the DEP 300s will not match the
actual current in the secondary.
Changing this parameter will adjust
the secondary current value read by
the control. The output current
value that is entered into the Sec-
ondary Coil setup parameter is spec-
ified by the secondary coil that is
installed.
An external weld checker can also be
used to measure the secondary cur-
rent. If the value read by the control
does not match, this parameter can
be adjusted. Caution must be used
when using this method. The exter-
nal weld checker should have it's
blanking time set to 0 and longer
weld times will produce better read-
ings.
NOTE 1: This setup is only used
when the Firing/Monitoring Mode
(See Setup Parameters Pg 124) is set
to PRI/SEC or SEC/SEC.
NOTE 2: Secondary current monitor-
ing / control is supported in single-
contactor controls only.
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Chapter 8: LINEAR CURRENT STEPPERS
THE PURPOSE During the welding process, the face of the welding cap gradually
OF LINEAR deforms or “mushrooms.” As it does, the contact surface area with
CURRENT the work piece increases, which causes the current density at the
STEPPERS weld interface to decrease. As a result, the weld nugget gradually
becomes colder.
The purpose of a Linear Current Stepper is to gradually increase the
welding current, in incremental steps, to compensate for the gradual
decrease in current density at the weld interface, caused by the
“mushrooming” of the welding caps. This gradual increase in welding
current ensures the appropriate amount of heat is continuously
present at the weld interface to continually make good weld nuggets.
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HOW LINEAR The WT6000 weld control with timer software G08600 has 10
CURRENT available linear current stepper programs. Each stepper program has
STEPPERS 5 programmable steps.
WORK
Within each of the 5 steps, the user can program the current boost
(rise) over a number of welds (run). The current boost for each step
can be expressed as either a percentage value or an absolute Amps
value. The current boost (rise) is delivered in equal, incremental
steps, over the total number of welds (run) in each step.
To use a linear current stepper, function #82 (LINEAR STEPPER #nn
ASSIGNED) must be inserted before the main weld statement
(Function #20 or #30) in the weld schedule.
Stepper programs are only active during the execution of a weld
function and will increment when the following functions are used in
the weld schedule:
FUNCTION # PERCENTAGE OF AVAILABLE VOLT-SECONDS WELD FUNCTION
20 WELD nnnn <CY/IMP> nn %VS
21 TEMPER nnnn MS. nn %I
22 PREHEAT nnnn MS. nn %I
23 POSTHEAT nnnn MS. nn %I
24 PRE-WELD nnnn MS. nn %I
40 SLOPE nnnn MS. nn%I TO nn%I
FUNCTION # CONSTANT CURRENT WELD FUNCTION
30 WELD nnnn <CY/IMP> nnnn0 AMPS
31 TEMPER nnnn MS. nnnn0 AMPS
32 PREHEAT nnnn MS. nnnn0 AMPS
33 POSTHEAT nnnn MS. nnnn0 AMPS
34 PRE-WELD nnnn MS. nnnn0 AMPS
45 SLOPE nnnn MS. nnnn0 A TO nnnn0 A
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STEPPER Each stepper program has a stepper profile. In the example below,
PROFILES each step has two current values. The first value (blue) is a
percentage value and the second value (red) is an absolute Amps
value. If a Percentage of available Volt-Seconds weld function is used,
the current boost (rise) must be expressed in a percentage value. If a
Constant Current weld function is used, the current boost (rise) must
be expressed in absolute Amps.
NOTE: If a Percentage of Available Volt-Second weld function is used
in the weld schedule and both a percentage and absolute amps value
is entered in the step, the absolute amps value is ignored by the weld
processor. Conversely, if a Constant Current weld function is used, the
percentage value is ignored.
EXAMPLE OF A WELD
STEPPER PROFILE STEP % VALUE AMPS. VALUE
FUNCTION
B 00% 1000 AMPS 100 WELDS
C 00% 500 AMPS 100 WELDS
D 00% 200 AMPS 100 WELDS
E 00% 100 AMPS 100 WELDS
F 00% 050 AMPS 100 WELDS
Stepper Group 1
Maximum Tip Dresses = 1
Aux. Counter Max. Counts = 0
STEPPER GROUPS In a typical welding application, multiple weld schedules can be
assigned to a single stepper program. Also, if desired, the user may
assign a single weld schedule to an individual stepper program.
In the case of a specific weld gun, it is advantageous that all the
stepper programs used on that gun increment their weld counters,
each time the gun makes a weld. Assigning these stepper programs to
a common “Group” causes all the stepper programs within that group
to increment together each time a weld is made by that gun,
regardless of the weld schedule the stepper combination was
initiated with. In addition, stepper grouping allows the user to
advance or reset several stepper programs at one time. The stepper
group range is 0-99.
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EXAMPLE STEPPER The following is an example of a linear stepper program without tip
PROGRAM #1 dressing. This example would typically be used in either a hard-tool
(NO TIP DRESS) welding application or any other application where dressing of the
weld caps is not required.
1. Function #82 (LINEAR STEPPER #nn ASSIGNED) is inserted into the
first line of Weld Schedule #1 and is assigned to Linear Stepper
Program #1.
2. Current weld function #30 (WELD nnnn MS. nnnn0 AMPS) is used
and is programmed to deliver 10000A of base current for 160 mil-
liseconds.
EXAMPLE SCHEDULE #1
00 START OF SCHEDULE # 1
82 LINEAR STEPPER # 1 ASSIGNED (0=OFF)
76 SEC. CURR LIMITS: HI=00 LOW=99990
81 TRANSFORMER TURNS RATIO 73:1
88 TURN ON ISOLATION CONTACTOR
58 TURN ON WELD IN PROGRESS
01 SQUEEZE 250 MSEC
30 WELD 160 MS 10000 AMPS
03 HOLD 80 MSEC
63 TURN ON WELD COMPLETE
59 TURN OFF WELD IN PROGRESS
75 EXTEND UNTIL NO INITIATE
64 TURN OFF WELD COMPLETE
89 TURN OFF ISOLATION CONTACTOR
100 END OF SCHEDULE # 1
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Below is the stepper profile as viewed from the DEP-300s Data Entry
Panel.
THE FOLLOWING EXPLAINS EACH PARAMETER WITHIN THE
PROFILE:
3 STEP #01 = +00% + 1000 A AFTER 0100 WELDS
Step 1 is programmed to deliver a 1000A boost over 100 welds. If
the base current is 10000 Amps, the boost current will increment
by 10A after each weld, thus by the 100th weld, the target
current will be at 11000A.
STEPPER PROFILE
12000
11500
11000
10500
1
10000
9500
9000
48
72
96
120
144
168
192
216
240
264
288
312
336
360
384
408
432
452
480
Weld
F 30: Weld 160 Ms 1000 Amps - Base Weld Current
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3 STEP # 02 = + 00% + 0500 A AFTER 0100 WELDS
Step # 02 is programmed to deliver a 500A boost over 100 welds.
If the base current is 11000 Amps, the boost current will
increment by 5A after each weld, thus by the 100th weld, the
target current will be 11500A.
STEPPER PROFILE
12000
11500
11000 2
10500
10000
9500
9000
Weld
48
72
96
336
360
384
408
432
452
480
120
144
168
192
216
240
264
288
312
F 30: Weld 160 Ms 1000 Amps - Base Weld Current
3 STEP # 03 = + 00% + 0200 A AFTER 0100 WELDS
Step 3 is programmed to deliver a 200A boost over 100 welds. If
the base current is 11500 Amps, the boost current will increment
by 2A after each weld, thus by the 100th weld, the target current
will be 11700A.
STEPPER PROFILE
12000
11500 3
11000
10500
10000
9500
9000
Weld
48
72
96
120
144
168
192
216
240
264
288
312
336
360
384
408
432
452
480
F 30: Weld 160 Ms 1000 Amps - Base Weld Current
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3 STEP # 04 = + 00% + 0100 A AFTER 0100 WELDS
Step 4 is programmed to deliver a 100A boost over 100 welds. If the
base current is 11700 Amps, the boost current will increment by 1A
after each weld, thus by the 100th weld, the target current will be
11800A.
STEPPER PROFILE
12000
11500 4
11000
10500
10000
9500
9000
48
72
96
120
144
168
192
216
240
264
288
312
336
360
384
408
432
452
480
Weld
F 30: Weld 160 Ms 1000 Amps - Base Weld Current
3 STEP # 05 = + 00% + 0500 A AFTER 0100 WELDS
Step 5 is programmed to deliver a 50A boost over 100 welds. If
the base current is 11800 Amps, the boost current will increment
by 0.5A after each weld, thus by the 100th weld, the target
current will be 11850A.
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The following alerts are annunciated on the DEP 300s, RAFT
Gateway or other device used to communicate with the weld control
STEPPER APPROACHING MAX ALERT:
At the first weld of Step 5, a STEPPER APPROACHING MAX ALERT is
generated. This alert indicates the stepper program has started its
final step.
END OF STEPPER ALERT / FAULT:
At the last weld of Step 5, an END OF STEPPER FAULT is generated. The
first 50 welds thereafter will be an ALERT. If the stepper program is
not reset by the 51st weld, the ALERT will change to a FAULT. For more
information, see Stepper Reset Options below.
End of Stepper
Tip Change Required output bit HIGH
STEPPER PROFILE
12000 5
11500
11000
STEPPER APPROACHING MAX
10500
10000
9500
9000
Weld
48
72
96
336
360
384
408
432
452
480
120
144
168
192
216
240
264
288
312
F 30: Weld 160 Ms 1000 Amps - Base Weld Current
AUX. COUNTER MAX COUNTS:
Attached to each stepper program is an Auxiliary Weld Counter, which
is located in the Stepper Status Menu. When a stepper increments, its
auxiliary weld counter also increments. When the counter reaches
the value programmed in this parameter, the Aux Counter at Max
output bit goes HIGH. This output bit can be used for any purpose by
the user. Turning the Stepper Aux Weld Cntr Reset input bit HIGH
resets the Auxiliary Weld Counter to zero and turns the Aux. Counter
at Max output bit LOW. In example #1, the Aux. Counter Max Counts
is set to zero. Therefore, the Aux Counter at Max output bit is
disabled.
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EXAMPLE STEPPER The following is an example of a linear stepper program with tip
PROGRAM #2 dressing. This example would typically be used in a robot welding
(TIP DRESS) application.
• Function #82 (LINEAR STEPPER #nn ASSIGNED) is inserted into
the first line of Weld Schedule #1 and is assigned to Linear Step-
per Program #1.
• Current weld function #30 (WELD nnnn MSec. nnnn0 Amps) is
used and programmed to deliver 10000 Amps. of base current
for 160 Msec
EXAMPLE SCHEDULE #1 (TIP DRESS)
00 Start of Schedule # 1
82 Linear Stepper #1 Assigned (0 = OFF)
56 Set Pressure = 0
58 Turn ON Weld In Progress
52 Turn ON Isolation Contactor
01 Squeeze 100 Msec.
30 Weld 160 Ms. 10000 Amps
78 Process Weld Faults
03 Hold 80 Msec
50 Turn ON Weld Complete
59 Turn OFF Weld In Progress
75 Extend Until No Initiate
51 Turn OFF Weld Complete
56 Set Pressure = 0
53 Turn OFF Isolation Contactor
100 End of Schedule # 1
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BELOW IS THE STEPPER PROFILE AS VIEWED FROM THE DEP-300s
DATA ENTRY PANEL.
The following explains each parameter within the profile:
3 STEP # 01 = + 00% + 1000 A AFTER 100 WELDS
Step 1 is programmed to deliver a 1000A boost over 100 welds.
If the base current is 10000 Amps, the boost current will
increment by 10A after each weld, thus by the 100th weld, the
target current will be at 11000A.
12000
11500
11000
10500
1
10000
9500
9000
48
72
96
120
144
168
192
216
240
264
288
312
336
360
384
408
432
452
480
Weld
F 30: Weld 160 MS 1000 Amps - Base Weld Current
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3 STEP # 02 = + 00% + 0500 A AFTER 100 WELDS
Step 2 is programmed to deliver a 500A boost over 100 welds. If
the base current is 11000 Amps, the boost current will
increment by 5A after each weld, thus by the 100th weld, the
target current will be 11500A.
12000
11500
2
11000
10500
10000
9500
9000
48
72
96
120
144
168
192
216
240
264
288
312
336
360
384
408
432
452
480
Weld
F 30: Weld 160 MS 1000 Amps - Base Weld Current
3 STEP # 03 = + 00% + 0200 A AFTER 100 WELDS (FIRST TIP DRESS)
At the first weld of Step 3 the weld processor will turn the Tip
Dress Request output bit HIGH. Upon receiving the request, the
robot initiates a tip dress schedule. Upon completion of the tip
dress schedule, the weld processor will return the stepper
program back to the first weld of Step 2.
TIP DRESS REQUEST
12000
11500 3
11000
10500
10000
9500
9000
48
72
96
120
144
168
192
216
240
264
288
312
336
360
384
408
432
452
480
Weld
F 30: Weld 160 MS 1000 Amps - Base Weld Current
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ROBOT INITIATES A TIP DRESS SCHEDULE UPON RECEIVING REQUEST
TIP DRESS SCHEDULE
00 Start of Schedule # 61
56 Set Pressure = 0
58 Turn ON Weld In Progress
86 Tip Dress Advance: Group 01 - Step 2
56 Set Pressure =00
Weld Control Unit
50 Turn ON Weld Complete will return all
steppers of the
59 Turn OFF Weld In Progress Group to the first
weld of Step 2 (as
75 Extend Until No Initiate
programmed)
51 Turn OFF Weld Complete
100 End of Schedule # 1
3 STEP # 02
If the Remaining Tip Dresses Count is > 0, the stepper program
will continue towards Step 3 again.
Step 2 is programmed to deliver a 500A boost over 100 welds. If
the base current is 11000 Amps, the boost current will
increment by 5A after each weld, thus by the 100th weld, the
target current will be 11500A.
3 STEP # 03: (SECOND TIP DRESS)
At the first weld of Step 3 the weld processor will turn the Tip
Dress Request output bit HIGH. Upon receiving the request, the
robot initiates a tip dress schedule. Upon completion of the tip
dress schedule, the weld processor will return the stepper
program back to the first weld of Step 2.
3 STEP 02: (ZERO TIP DRESSES REMAINING)
Step 2 is programmed to deliver a 500A boost over 100 welds. If
the base current is 11000 Amps, the boost current will
increment by 5A after each weld, thus by the 100th weld, the
target current will be 11500A.
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3 STEPPER APPROACHING MAX:
If the Remaining Tip Dresses Count has decremented to 0, a
STEPPER APPROACHING MAX ALERT is generated at the first
weld of Step 2.
TIP DRESSING
12000
11500
2
11000
10500
10000
9500
9000
48
72
96
120
144
168
192
216
240
264
288
312
336
360
384
408
432
452
480
Weld
F 30: Weld 160 MS 1000 Amps - Base Weld Current
3 STEP #03 END OF STEPPER
If the Remaining Tip Dresses Count has decremented to 0, an
END OF STEPPER ALERT is generated at the first weld of Step 3.
The first 40 welds thereafter will be an ALERT. If the stepper
program is not reset by the 41st weld, the ALERT will change to a
FAULT. For more information, see Stepper Reset Options on Page
144.
3 STEP #04 AND #05
Steps 4 & 5 are not used in stepper programs with tip dressing.
3 STEPPER GROUP:
In example #2, Stepper #1 is assigned to Stepper Group 1. For
more information, see Stepper Groups.
3 AUX. COUNTER MAX COUNTS:
Included in each stepper program is an Auxiliary Weld Counter,
which is located in the Stepper Status screen. When a stepper
increments, its auxiliary weld counter also increments. When the
counter reaches the value programmed in this parameter, the
Aux Counter at Max output bit goes HIGH. This output bit can be
used for any purpose by the user. Turning the Stepper Aux Weld
Cntr Reset input bit HIGH resets the Auxiliary Weld Counter to
zero and turns the Aux. Counter at Max output bit LOW. In this
example, the Aux. Counter Max Counts is set to zero. Therefore,
the Aux Counter at Max output bit is disabled.
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STEPPER STATUS Perform the following steps on the DEP-300s to navigate to the
Stepper Status Screen:
B Press Status Mode
C Press Stepper Status
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D Press Stepper#
E Enter Stepper Number.
F Press ENTER
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The following chart describes the parameters, which appear on the
Stepper Status Menu:
PARAMETER DESCRIPTION
STEPPER Turns the stepper either ON or OFF. The default position is ON.
NOTE: This parameter is disabled in timer software version G08760
STEP # The step number the stepper program is currently in (1 through 5)
STEP COUNT The weld count within the step, the stepper program is currently in.
The current boost being applied to each weld.
BOOST% I NOTE: If a Percentage of Available Volt-Seconds weld function is used, this value will be
displayed as a percentage. Conversely, if a Constant Current weld function is used, this
value will be displayed in absolute amps.
TOTAL WELD The total weld count since the beginning of the stepper program.
COUNT
TIP DRESSES The Remaining Tip Dresses Count is a decrementing counter, which starts at the num-
ber entered in GROUP (1-4) MAXIMUM TIP DRESSES in the setup parameters. This
counter defines the maximum number of times the weld caps may be dressed before
they must be changed. Each time the weld processor receives a tips dressed index, the
Remaining Tip Dresses Count decrements by one. When this count decrements to zero,
an END OF STEPPER FAULT is generated. This indicates the weld caps must be changed.
NOTE: A tip dress advance request occurs when:
1. Either the Tip Dress - Tip Dress Group 1 or Tip Dress Group 2 Input bits go HIGH
2. Function #93 (TIP DRESS ADVANCE: GROUP nn - STEP n) is used in the schedule.
AUX. The Auxiliary Counter is an incrementing counter, which mirrors the Total Weld Count
COUNTER counter above. Its max count is set by the value entered in the Aux Counter Max
Counts parameter in the stepper profile.
STEPPER # The stepper program number currently displayed. Pressing the Stepper # (F3) key,
allows the user to change the stepper program that is displayed.
Pressing the Advance (F2) key, advances the stepper program to the first weld of the
next step. When the stepper advances, the following changes will occur in the Stepper
Status Menu:
• The STEP COUNT will reset to zero.
ADVANCE
• The TOTAL WELD COUNT will advance to where its count would be at the first
weld of the next step.
• The Aux. Counter will not change when the stepper is advanced. If the user wants
the Aux. Counter count to match the Total Weld Count, the value will have to be
manually entered here.
RESET ALL Pressing the Reset ALL (F4) key, globally resets all stepper programs.
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STEPPER RESET An END OF STEPPER FAULT indicates the stepper program has ended.
OPTIONS At this point, the weld caps must be replaced on the gun and the
stepper program(s) must be reset. Stepper Reset changes all counts
within the stepper program back to their beginning value. See
example below.
In weld processor software G08600, there are three ways in which the
user can reset stepper programs:
OPTION 1: GLOBAL STEPPER RESET
Stepper programs can be globally reset by pressing the Reset ALL
(F4) button in the Stepper Status Menu. When this is done, all 10
stepper programs are “globally” reset, regardless of what group
they are assigned to. The user needs to be cautious to only use this
method if they are absolutely certain they want to globally reset
every stepper program within the weld processor simultaneously.
Perform the following steps from the DEP-300s Stepper Status Menu
to globally reset the stepper programs:
B Press Reset ALL
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C The message “Do you want to reset all Steppers” will appear.
D Press Confirm
OPTION 2: GROUP STEPPER RESET (I/O)
Stepper programs can be globally reset by turning the Stepper
Reset input bit HIGH. When this is done, all 10 stepper programs
are “globally” reset, regardless of what group they are assigned to.
The user needs to be cautious to only use this method if they are
absolutely certain they want to globally reset every stepper
program within the weld processor simultaneously.
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OPTION 3: GROUP STEPPER RESET
Stepper programs assigned to either Group 1 or Group 2 can be
reset as a group. When the Stepper Reset Group 1 input bit is
turned HIGH, all the stepper programs assigned to Group 1 will be
reset. Likewise, when the Stepper Reset Group 2 input bit is turned
HIGH, all the stepper programs assigned to Group 2 will be reset.
THE FOLLOWING OCCURS AT STEPPER RESET:
• STEPPER APPROACHING MAX ALERT is reset.
• END OF STEPPER FAULT is reset.
• All counts within the stepper program are changed back to their
beginning value.
NOTE: Pressing the Fault Reset button on the DEP-300s will only reset
the STEPPER APPROACHING MAX ALERT and the END OF STEPPER
FAULT. It does not reset the stepper program(s)
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EDITING THE Perform the following steps on the DEP-300s to navigate to the
STEPPER PROFILE Review Stepper Menu:
B Press Program Mode
C Press Review Stepper
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D Press Stepper #
E Enter Stepper Number
F Press ENTER
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EDITING A PARAMETER ON THE REVIEW STEPPER MENU
ON THE DEP 300s:
B
Press the or arrow keys to move the cursor
onto the parameter line to be edited.
ENTER
C Press
D Enter parameter
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ENTER
E Press
F For parameters with two or more data fields, press the
arrow key to move the cursor to the next data
field box, then repeat steps 3 & 4. When complete,
proceed to step 6.
G Press APPLY
[Saves changes to the DEP-300s only.]
H To edit more parameter lines, repeat steps 1
through 6. When complete, proceed to step 8.
I Press DOWNLOAD
[Downloads the changes to the weld processor. When complete, a
“Download Complete” message will appear]
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Chapter 9: ADVANCED TOPICS
PERCENT OF Percent of Available Volt-Second (%VS) welding can be viewed as a
AVAILABLE way of accomplishing AVC control in an MFDC inverter. In the example
VOLT-SECONDS below, “S” (IGBT on-time) is adjusted to keep the effective voltage
WELDING MODE applied to the welding transformer constant. So, if the DC bus voltage
goes higher, the IGBT's shut off earlier. Conversely, if the DC bus
voltage goes lower, the IGBT's shut off later. This allows the volume of
the shaded area to remain constant.
In the above example, let's assume that V=5 and S=4. Then the total
shaded area would equal (V x S) or 20. Now suppose that V drops to 4.
Then S would be increased to 5 to maintain a total value of 20 in the
shaded area.
NOTE: Percent of Available Volt-Second welding only keeps the
applied voltage to the welding transformer constant. Current will
fluctuate depending on variations in the secondary resistance.
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SETUP 1. To use Percent of Available Volt-Second welding, insert function
#20 in the weld schedule. In the example below, the function was
programmed to weld at 50% of Available Volt-Seconds for 500
milliseconds.
20 WELD 500 MS. 50%VS
2. Ensure the TRANSFORMER RATED DC VOLTAGE (programmed in
the Setup Parameters) is set correctly. This parameter is the rated
DC voltage of the welding transformer and can be found on the
manufacturer's label affixed to the welding transformer. In the
example below, the parameter is to 680V.
TRANSFORMER RATED DC VOLTAGE: 680
In this example, the weld function is programmed at 50% of the
Transformer Rated DC Voltage (680V). Therefore, the effective voltage
applied to the welding transformer will be 340V for 500 ms.
APPLICATION It may be desirable to use Percent of Available Volt-Second welding
instead of Constant Current welding in any application where extreme
resistance changes occur during normal welding operations. Such
applications may include:
• Projection Welding
• Butt Welding
• Flash-Butt Welding
• Aluminum Welding
• Welding through Sealant
• Poor Metal Fit-up / Gaps
You may also use a Percent of Available Volt-Second weld function in
conjunction with a Constant Current weld function. For example, if
you are welding through sealant, you may want to use a %VS up-slope
or preheat weld function to displace the sealant and then form the
weld nugget using a Constant Current weld function, for example:
40 SLOPE 500 MS. 20%VS TO 50%VS
30 WELD 500 MS. 10000 AMPS
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CONSTANT Constant Current welding is a method of keeping the current applied
CURRENT to the welding transformer constant, regardless of variations in
WELDING secondary resistance, during normal welding operations.
MODE
To use Constant Current welding, insert function #30 in the weld
schedule, for example:
30 WELD 500 MS. 10000 AMPS
In this example, 10,000 Amps target current is programmed into the
weld function. The weld processor calculates secondary current by
measuring the primary current at the output of the MFDC inverter
and multiplying it by the transformer turns ratio (programmed in the
Setup Parameters). If the calculated secondary current is less than the
target current, the IGBT's shut off later. Conversely, if the calculated
secondary current is greater than the target current, the IGBT's shut
off earlier. This allows the current applied to the welding transformer
to remain constant.
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C-FACTOR C-Factor (or Capacity Factor) is a parameter, which is used to track
changes in the weld tooling. C-Factor is calculated by determining the
amount of total capacity utilized to create the target current and
dividing this value by the actual current created.
The C-Factor feature can be used as a maintenance tool to monitor
the following:
• Weld tooling degradation
• Current shunting paths (primary or secondary)
C-Factor is calculated by the weld processor after each weld and is
displayed in the Weld Data Display of the DEP-300s.
PERFORM THE FOLLOWING STEPS ON THE DEP-300S TO NAVIGATE
TO THE WELD DATA MENU:
B Press Status Mode
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C Press More
D Press Weld Data
E Press ENTER
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DECREASING As the weld tooling degrades over time, its resistance (either primary
C-FACTOR or secondary) increases. As the resistance increases, the weld control
must compensate for this change, otherwise the welds will gradually
grow colder. Weld tooling degradation can be caused by the following
conditions:
• Frayed or undersized (MCM) welding cables.
• Welding cables too long for application.
• Broken or undersized leaf shunts.
• Loose hardware connections.
• Incorrect hardware (mild steel vs. stainless steel).
• Incorrect weld caps for application.
• Lower tip pressure.
As the resistance of the weld tooling gradually increases,
the weld control gradually increases its “on-time” (or
use more of its available capacity) to deliver the
Example of the Weld Data Menu. requested target current. This gradual decrease in
The C-Factor parameter is circled in red. available capacity of the weld control is reflected by a
gradually decreasing C-Factor parameter.
INCREASING Current shunting (either primary or secondary) is essentially an
C-FACTOR unintended, alternate path of current flow occurring in the weld
tooling. Current shunting causes the overall resistance of the weld
tooling to decrease. As current is shunted across the alternate path,
less current passes through the work piece, resulting in colder welds.
Secondary current shunting paths can be caused by the following
conditions:
• Cable shorts to weld tooling or part.
• Weld expulsion (slag) build-up around the hinge of the weld gun
• Higher tip pressure
• Cooling water conductivity issues
As the resistance of the weld tooling gradually decreases, the weld
control gradually decreases its “on-time” (or uses less of its available
capacity) to deliver the requested target current. This gradual
increase in available capacity of the weld control is reflected by a
gradual increase in the C-Factor parameter.
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C-FACTOR SETUP 1. Prior to using the C-Factor feature, it is important to establish a
reference C-Factor parameter for a known good weld tool. After
completing several test welds, record the C-Factor parameter dis-
played in the Weld Data Menu of the DEP-300s for future refer-
ence.
2. Insert function #92 (C-FACTOR LIMIT: HI= nnnn LOW= nnnn) near
the beginning of the weld schedule. See example schedule below:
NOTE: Function #92 must be inserted in the weld schedule before
functions #85 (PROCESS WELD FAULTS).
FUNCTION # FUNCTION NAME
00 START OF SCHEDULE # 1
82 LINEAR STEPPER #1 ASSIGNED (0=0FF)
92 C-FACTOR LIMIT: HI= 220 LOW= 150
76 SET CURRENT LIMITS: HI=00 LOW= 99990
81 TRANSFORMER TURNS RATIO 73:1
88 TURN ON ISOLATION CONTACTOR
58 TURN ON WELD IN PROGRESS.
01 SQUEEZE 30 CYCLES
30 WELD 10 CYCLES 10000 AMPS
85 PROCESS WELD FAULTS
03 HOLD 5 CYCLES
63 TURN ON WELD COMPLETE
59 TURN OFF WELD IN PROGRESS
75 EXTEND UNTIL NO INITIATE
64 TURN OFF WELD COMPLETE
89 TURN OFF ISOLATION CONTACTOR
100 END OF SCHEDULE # 1
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CALCULATE THE NOTE: The following instruction provides a starting point for the C-
C-FACTOR HI / LOW Factor HI / Low limits. These values will require adjustment
LIMIT VALUES: as the user becomes more familiar with the weld tooling and
what the C-Factor parameters are when weld quality issues
occur (caused by either weld tooling degradation or current
shunting).
Actual C-Factor variances may be less than or greater than
20%. Anything that effects change of the resistance during a
weld will also change the C-Factor variance. Some examples
are changing from mild to high strength steel, part fit-up,
sealant on part, etc.
LOW C-FACTOR LIMIT
The Low C-Factor Limit is used to detect an increase in resistance in the
weld tooling, which is caused by cable and connection degradation.
To calculate the Low C-Factor Limit value, subtract a 20% margin from the
reference (tip-to-tip) C-Factor parameter for a known good weld tool.
For Example:
For example, if the reference C-Factor parameter is 200:
200 *.80 = 160. Therefore, the Low C-Factor Limit would be 160.
HIGH C-FACTOR LIMIT
The High C-Factor Limit is used to detect a decrease in resistance in the
weld tooling, which is caused by shunting paths.
To calculate the High C-Factor limit value, add a 20% margin to the refer-
ence (tip-to-tip) C-Factor parameter for a known good weld tool.
For Example:
If the reference C-Factor parameter is 200:
200 * 1.2 = 240. Therefore, the High C-Factor Limit would be 240.
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SETTING THE HI AND LOW C-FACTOR LIMIT FAULTS IN THE SETUP
PARAMETERS:
FAULT NAME VALUE
LOW C-FACTOR LIMIT ALERT
HIGH C-FACTOR LIMIT FAULT
• Gradual weld tool degradation is an expected process. There-
fore, Low C-Factor is set as an ALERT.
• Secondary current shunting is not an expected process and
requires immediate attention. Therefore, High C-Factor is set as a
FAULT.
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SPC INDEXING SPC (STATISTICAL PROCESS CONTROL) FUNCTIONS
CAPABILITIES
Function #90: SET SPC OFFSET TO nn
For the purpose of statistical data collection, each weld is assigned a
data storage bin number (00-99). This function establishes the
starting bin number for SPC Indexing.
Consider the following example:
CAR TYPE #1
Weld Schedule #20 SET SPC OFFSET TO 01
Weld Schedule #01 15 Welds Made (Bins 1-15)
Weld Schedule #02 15 Welds Made (Bins 16-30)
Weld Schedule #03 15 Welds Made (Bins 31-48)
CAR TYPE #2
Weld Schedule #21 SET SPC OFFSET TO 51
Weld Schedule #04 12 Welds Made (Bins 51-62)
Weld Schedule #05 12 Welds Made (Bins 63-74)
Weld Schedule #06 15 Welds Made (Bins 75-88)
After establishing a bin number, the processor stores the data for each weld
made in its own individual bin. The bin numbers increase by one each time a
weld is made. This will continue until another schedule containing function
#90 (SET SPC OFFSET) is executed.
Bin #99 is the last usable bin. If the weld processor reaches bin #99 and is
still collecting data, the data for each weld will be stored in bin #99 until a
new offset is assigned, therefore making the data unsuitable for analysis.
NOTE: This function does not tell the weld processor to collect weld data.
It only assigns a data storage bin number. To setup SPC data
collection parameters, see SPC Setup Parameters.
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Function #91: SEND ALL SAMPLES UNTIL NEXT SPC OFFSET
This function is useful to verify tool conditions after a tip-dress
operation.
This function tells the weld processor to collect and sample 100% of
the weld data within the schedule. It overrides the “global” Data
Collection Sample Size and Data Collection Sample Frequency setup
parameters, described in SPC Setup Parameters below.
Function #90 (SET SPC OFFSET) should be inserted before #91 in the
weld schedule, to ensure the data is sent to the appropriate bin.
Otherwise, it will be sent to default bin #0.
The processor will continue collecting and sampling 100% of the weld
data within the schedule until the weld processor executes another
weld schedule containing function #90 (SET SPC OFFSET). At which
point, the “global” Data Collection Sample Size and Data Collection
Sample Frequency setup parameters regain their hierarchical priority.
SPC SETUP PARAMETER RANGE
PARAMETERS
Data Collection Sample Size: n 1-99
Data Collection Sample Frequency: nnn 1-9999
These two parameters set a global command, which allows the weld
processor (WCU) to sample data for analysis at controlled intervals.
• The sample size is the number of consecutive welds collected for
analysis (per bin).
• The sample frequency is the total number of welds, from which
the samples are taken from (per bin).
FOR EXAMPLE:
Let's assume function #90 (SET SPC OFFSET) is inserted in the weld
schedule and set to bin #1:
90 SET SPC OFFSET TO 01
Let's also assume in the Setup Parameters, the Data Collection
Sample Size is set to (2) and the Data Collection Sample Frequency is
set to (8):
DATA COLLECTION SAMPLE SIZE: 2
DATA COLLECTION SAMPLE FREQUENCY: 8
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By setting the Data Collection Sample Size to (2) and the Data
Collection Sample Frequency to (8), the WCU will collect data for the
first two consecutive welds (in bin #1) and flag the WebView to
retrieve the data. It will then collect data for the six remaining welds
(without flagging the WebView) before repeating the process.
THE FOLLOWING TABLE ILLUSTRATES THE EXAMPLE ABOVE:
BIN # 1
SAMPLE / FREQUENCY WCU PROCESS WEBVIEW PROCESS
1/8 Data Flagged for Retrieval Data Uploaded
2/8 Data Flagged for Retrieval Data Uploaded
3/8 Data Collected Data Ignored
4/8 Data Collected Data Ignored
5/8 Data Collected Data Ignored
6/8 Data Collected Data Ignored
7/8 Data Collected Data Ignored
8/8 Data Collected Data Ignored
1/8 Data Flagged for Retrieval Data Uploaded
2/8 Data Flagged for Retrieval Data Uploaded
3/8 Data Collected Data Ignored
4/8 Data Collected Data Ignored
5/8 Data Collected Data Ignored
6/8 Data Collected Data Ignored
7/8 Data Collected Data Ignored
8/8 Data Collected Data Ignored
NOTE: Weld data collection is bin dependent. Each bin has its own
independent counter and is uploaded to the Web View separately.
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APPLICATION I/O STATUS
ERROR CODES
To navigate to the I/O Status Menu, perform the following steps on
the DEP-300s
B Press Status Mode
C Press More
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D Press IO Status
E Press Page 2 to view more bits (if applicable)
In this example the I/O Status Menu shows the mapped bits relating
to the application error codes (circled in red). It should be noted this is
a simplified example and the customers application requirements
may prescribe these bits to be mapped to different I/O locations.
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Each bit is represented by a tag. Each tag will have either a “1” or “0”
underneath it:
• “1” indicates the bit is HIGH or ON.
• “0” indicates the bit is LOW or OFF.
TAG NAME BIT NAME BIT TYPE
FACK APP ERR ACKNOWLEDGE Input
EVAL APP ERROR AVAILABLE Output
ER1 APP ERROR BIT 1 Output
ER2 APP ERROR BIT 2 Output
ER4 APP ERROR BIT 4 Output
ER8 APP ERROR BIT 8 Output
ER16 APP ERROR BIT 16 Output
FERR FAULT ERROR Output
AERR ALERT ERROR Output
NOTE: For more information on mapping I/O bits, see Chapter 11:
Inputs and Outputs.
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HOW WTC The following example is a robot welding application where the weld
ERROR CODES processor is reporting three application error codes:
ARE REPORTED
ERROR CODE FAULT FAMILY WELD CONTROL FAULT TYPE
5 END OF STEPPER End of Stepper FAULT
7 HIGH/ LOW CURRENT LIMIT Low Current Limit Fault FAILT
19 C-FACTOR LIMIT Low C-Factor Limit ALERT
NOTE: Multiple application error codes are reported in ascending
order.
1. When a faults occurs, the EVAL output bit goes HIGH and applica-
tion error code (5) is binarily displayed on the ER1-ER16 output
bits. Since the End of Stepper is configured as a FAULT in the weld
processor, the FERR output bit will also go HIGH.
2. The HIGH EVAL output bit tells the robot to read the ER1-ER16
and FERR output bits.
3. When the robot has read these output bits, it toggles the FACK
input bit.
4. The toggling FACK input bit causes the EVAL output bit to toggle.
When this toggle occurs, the next application error code (7) is
binarily displayed on the ER1-ER16 output bits. Since the Low
Current Limit Fault is configured as a FAULT in the weld processor,
the FERR output bit will also go HIGH.
5. The toggling EVAL output bit tells the robot to read the ER1-ER16
and FERR output bits a second time.
6. When the robot has read the ER1-ER16 output bits, it toggles the
FACK input bit.
7. The toggling FACK input bit causes the EVAL output bit to toggle.
When this toggle occurs, the next application error code (19) is
binarily displayed on the ER1-ER16 output bits. Since the Low C-
Factor Limit is configured as an ALERT in the weld processor, the
AERR output bit will also go HIGH.
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8. The toggling EVAL output bit tells the robot to read the ER1-ER16
output bits a third time.
9. When the robot has read the ER1-ER16 output bits, it toggles the
FACK input bit.
10. The toggling FACK input bit causes the EVAL output bit to toggle.
When this toggle occurs, the weld processor scrolls and re-dis-
plays application error code (5) on the ER1-ER16 output bits.
Since the End of Stepper is configured as a FAULT in the weld pro-
cessor, the FERR output bit will also go HIGH.
11. The toggling EVAL output bit tells the robot to read the ER1-ER16
and FERR output bits a fourth time.
12. When the robot reads the ER1-ER16 output bits, it recognizes
that it has previously read application error code (5) and the
reporting process ends.
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APPLICATION ERROR CODES FOR WT6000 TIMER FIRMWARE G08600
SETUP ERROR APPLICATION ERROR
NO. FAULT FAMILY CODE BINARY OUTPUT BITS
ER1 ER2 ER4 ER8 ER16
1. INPUT / OUTPUT ERROR 1 1 0 0 0 0
2. INPUT / OUTPUT ALARM 2 0 1 0 0 0
3. INCOMPLETE WELD 3 1 1 0 0 0
4. STEPPER APPROACHING MAX 4 0 0 1 0 0
5. END OF STEPPER 5 1 0 1 0 0
6. HIGH / LOW CURRENT LIMIT 7 1 1 1 0 0
7. COMPENSATION ERROR 12 0 0 1 1 0
8. INSUFFICIENT LINE VOLTAGE 13 1 0 1 1 0
9. EXTENDED WELD 14 0 1 1 1 0
10. ISOLATION CONTACTOR ERROR 15 1 1 1 1 0
11. ANALOG PRESSURE 18 0 1 0 0 1
12. C-FACTOR LIMIT 19 1 1 0 0 1
13. EXTERNAL SENSOR 20 0 0 1 0 1
14. WELDING TRANSFORMER 21 1 0 1 0 1
15. OVER TEMPERATURE 22 0 1 1 0 1
16. INVERTER FAULT 25 1 0 0 0 1
17. WELDING ERROR 26 0 1 0 1 1
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FAULT FAMILY CROSS-REFERENCE TO WTC WELD CONTROL FAULT(S)
ERROR FAULT FAMILY WTC WELD CONTROL FAULT(S)
CODE
• INVALID SEQUENCE SELECTED
• WELD PROCEED
1 INPUT / OUTPUT ERROR • PRESSURE SWITCH
• IO
• INITIATION ON POWER-UP
• RETRACT PILOT
• SECONDARY CURRENT SENSOR
• WELD INTERRUPTION
• WELD INITIATE NOT PRESENT
2 INPUT / 0UTPUT ALARM • CONTROL IN NO WELD
• CONTROL STOP
3 INCOMPLETE WELD • WELD INTERRUPTION
4 STEPPER APPROACHING MAXIMUM • STEPPER APPROACHING MAX
5 END OF STEPPER • END OF STEPPER
• HIGH CURRENT LIMIT FAULT
7 HIGH / LOW CURRENT LIMIT • LOW CURRENT LIMIT FAULT
• SOFT OVERCURRENT
12 COMPENSATION ERROR • CURRENT REGULATION
• CONTROL TRANSFORMER VOLTAGE
13 INSUFFICIENT LINE VOLTAGE • LOW LINE VOLTAGE
• AC LINE PHASE
• EXTENDED WELD
14 EXTENDED WELD • EXCESSIVE REWELD
• ISO CNTR OFF WHEN NEEDED
15 ISOLATION CONTACTOR ERROR • ISO CNTR ERR BRKR TRIPPED
• HIGH C-FACTOR LIMIT
19 C-FACTOR LIMIT • LOW C-FACTOR LIMIT
• SECONDARY DIODE
21 WELDING TRANSFORMER • GROUND
• SYSTEM COOLING
22 OVER TEMPERATURE • TEMPERATURE
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ERROR FAULT FAMILY WTC WELD CONTROL FAULT(S)
CODE
• IGBT SATURATION
25 INVERTER FAULT • IGBT POWER SUPPLY
• BUS VOLTAGE
• BUS CHARGING
26 WELDING ERROR • ADAPTQ TIP TO TIP WELD
• ADAPTQ TIP VOLT WIRE BROKEN
• ADAPTQ WELD AT MAX TIME LIMIT
• SOFTQ P-INTEGRITY OVER WELDED
• SOFTQ P-INTEGRITY UNDER WELDED
• SOFTQ T-INTEGRITY SHUNTING
• SOFTQ T-INTEGERITY RESISTANCE
• SOFTQ N-INTEGRITY HIGH
• SOFTQ N-INTEGRITY LOW
• ADAPTQ GAP CONDITION
• ADAPTQ NO REFERENCE WELD
• ADAPTQ R MEASURE
• ADPTQ MAX FACE DIAMETER ADJ
• ADAPTQ MIN FACE DIAMETER ADJ
• ADAPTQ APPROACHING MAX TIME
• ADAPTQ APPROACHING MAX CURRENT
• ADAPTQ APPROACHING MIN CURRENT
• ADAPTQ REF ON IN ADAPTIVE MODE
• TIP RESISTANCE NOT IN WINDOW
• SOFTQ P-INTEGRITY TREND
• SOFTQ N-INTEGRITY TRENT
• SOFTQ WELD TIME TREND
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TIP DRESS STANDARD TIP DRESS SCHEDULE
SCHEDULE SETUP
The following is an example tip dress schedule when the weld control
is not controlling the tip dress motor.
FUNCTION # FUNCTION NAME
00 START OF SCHEDULE # 1
58 TURN ON WELD IN PROGRESS
01 SQUEEZE 30 CYCLES
93 TIP DRESS ADVANCE: GROUP 1 - STEP 2
59 TURN OFF WELD IN PROGRESS
63 TURN ON WELD COMPLETE
03 HOLD 5 CYCLES
51 TURN OFF WELD COMPLETE
100 END OF SCHEDULE # 1
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TIP DRESS CHECK SCHEDULE
The following is an example tip dress schedule where the weld control
is controlling the tip dress motor. This feature requires an optional tip
dress motor control circuit installed in the weld control cabinet (see
note below). This schedule also monitors or “checks” the current
draw of the tip dress motor.
The purpose of this check is to:
B Protect the motor from damage
C Determine if the weld caps were properly cut.
NOTE: If your weld control cabinet does not have the optional motor
control circuit installed and you are interested in using this feature,
contact your WTC sales representative for assistance.
FUNCTION # FUNCTION NAME
00 START OF SCHEDULE # 1
16 MOTOR CURRENT LIMITS HI =6000 ma LO = 1000 ma
58 TURN ON WELD IN PROGRESS
18 START TIP DRESS MOTOR CHECK
17 TIP DRESS TIME 5 SEC BLANK 500 ms
19 STOP TIP DRESS MOTOR CHECK
59 TURN OFF WELD IN PROGRESS
63 TURN ON WELD COMPLETE
03 HOLD 5 CYCLES
51 TURN OFF WELD COMPLETE
100 END OF SCHEDULE # 1
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DESCRIPTION OF THE SPECIAL FUNCTIONS (IN RED ABOVE) USED IN
THE TIP DRESS CHECK SCHEDULE:
Function #16 (MOTOR CURRENT LIMITS HI =nnnn ma LO =nnnn ma)
sets the HIGH and LOW current limits for the tip dress motor current
being measured.
Function #18 (START TIP DRESS MOTOR CHECK) tells the weld
processor to turn the tip dress motor ON.
NOTE: This function must be inserted in the schedule after function
#16 (MOTOR CURRENT LIMITS HI =nnnn ma LO =nnnn ma).
Function #17 (TIP DRESS TIME nn SEC BLANK nnnn ms) sets the total
amount of time (in seconds) the tip dress motor is ON. The blanking
time (in milliseconds) is the period of time the weld processor does
not measure the motor starting (in-rush) current.
NOTE: This function must be inserted in the schedule after function
#18 (START TIP DRESS MOTOR CHECK) and before function #19 (STOP
TIP DRESS MOTOR CHECK).
Function #19 (STOP TIP DRESS MOTOR CHECK) tells the weld
processor to turn the tip dress motor OFF.
MODE OF OPERATION:
B After the blanking time, the motor current is checked
every 8ms until either a function #19 (STOP TIP DRESS
MOTOR CHECK) is reached or a fault occurs.
C If the measured motor current is above the LOW limit for 1
or more seconds of accumulated time, the tip dress is
considered good.
D If the measured current is above the LOW limit for less
than 1 second of accumulated time, a TIP DRESS FAULT is
generated. Probable causes include:
• Insufficient gun pressure on the cutting blades.
• Weld caps did not come in contact with cutting
blades (no load on motor).
• Improper weld cap fit-up on the cutting blades.
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E If the measured motor current is above the HIGH limit any
time during the 8ms checking period, the motor is
immediately turned off and a HI / NO MOTOR CURRENT
FAULT is generated. Probable causes include:
• Motor stall caused by a mechanical failure in the cut-
ting head.
• Motor stall caused by a Jam in the cutting blades.
• Too much gun pressure on the cutting blades (exces-
sive load on motor).
F If the measured current is <=20ma any time during the
8ms checking period, the motor is immediately turned off
and a HI / NO MOTOR CURRENT FAULT is generated.
Probable causes include:
• Motor did not turn on (motor starter relay did not
energize).
• Current feedback coil did not measure any current
(loose/open wire).
NOTES:
B The Tip Dress Time includes the Blanking Time. Therefore,
If the Tip Dress Time minus the Blanking Time is less than 1
second, a TIP DRESS FAULT will occur.
C As a good starting point:
Tip Dress Time = Blanking Time + 1010ms (1.01 sec). The
idea is to ensure the time the motor current is actually
being measured is greater than 1 second (1 second =
1000ms).
D Set properly, the Blanking Time prevents erroneous HIGH /
NO MOTOR CURRENT FAULTS from occurring, caused by
the motor starting (in-rush) current. The Blanking Time will
vary depending on the design specifications of the motor
being used. The idea is to blank-out (or not measure) the
motor starting (in-rush) current.
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MOTOR CURRENT MEASUREMENT RESULTS
The results of the tip dress motor current check are displayed in the
Weld Data Menu. Perform the following steps on the DEP-300s to
navigate to the Weld Data Menu.
B Press Status Mode
C Press More
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D Press Weld Data
In the example above the results are displayed in the Sec I column
(circled in red) in milliamps. There are three current measurements
displayed: MAX current, AVG current and MIN current.
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Chapter 10: PREVENTATIVE MAINTENANCE
The WT6000 weld control requires periodic preventative
maintenance. The following chart can be used to design a
preventative maintenance schedule for the entire weld control.
FREQUENCY ACTION CABINET POWER?
ISOLATION CONTACTOR
Monthly Ensure that the Contactor operates properly.
Contactor should turn OFF/ON smoothly.
Monthly
CIRCUIT BREAKER
Test shunt trip button on circuit breaker.
MOUNTING BOLTS
3 Months
Verify all mounting bolts holding cabinet in place
are tight.
CABLES & CONNECTIONS INSIDE
WELD CABINET
3 Months
Verify tight connections and that internal cables
show no wear.
CABLING OUTSIDE CABINET
3 Months
External cabling should be secure and show little
to no wear.
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FREQUENCY ACTION CABINET POWER?
WATER COOLING SYSTEM
Inspect water-cooling circuit for leaking fittings,
hoses, etc. Inspect for worn or cracked hoses and
3 Months replace as required. Ensure all hose clamps are
tight. Check for proper water flow in accordance
with specifications in Chapter 1. (Water-Cooled
models only)
TERMINALS & TERMINAL STRIPS
3 Months
All screw connections should be tightened.
FUSES AND FUSE TERMINALS
3 Months
Inspect for damaged fuses and that fuses fit prop-
erly in holders.
INVERTER COOLING FINS AND FANS
6 Months Remove dust build-up between inverter cooling
fins and within air circulation fans. Ensure fans are
functioning properly. (Air-Cooled models only)
12 Months
EXTERNAL CABINET
Inspect for damage external to cabinet and that
labels are intact.
12 Months
CABINET DOOR
Inspect that door opens and closes smoothly and
that seals are not cracked or broken.
LED'S & LAMPS
12 Months
Inspect for damaged LED's or warning lamps
internal and external to the weld controller.
WELD CONTROL GROUNDING
12 Months
Verify weld control cabinet is properly connected
to earth ground, using either a multimeter or other
suitable test equipment.
Contact WTC for spare parts information:
WTC Industrial Technical Services
Phone: +1 248-477-3900 | Fax: +1 248-477-8897
Email: [email protected]
Website: www.weldtechcorp.com
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Chapter 11: INPUTS AND OUTPUTS
I/O LIST The following is a complete list of the available I/O bits for the
WT6000 weld control with timer software G08600. Each I/O bit has a
tag name assigned to it. The tag name is used to identify the bit on
the DEP-300s I/O Status Menu. These bits are applicable to Ethernet
IP (EIP), Fieldbus and Discrete I/O
INPUTS
INPUT NAME TAG
NONE (BLANK)
BINARY SELECT 1 BS1
BINARY SELECT 2 BS2
BINARY SELECT 4 BS4
BINARY SELECT 8 BS8
BINARY SELECT 16 BS16
BINARY SELECT 32 BS32
BINARY SELECT 64 BS64
BINARY SELECT 128 BS128
WELD INITIATE INT
WELD / NO WELD WLD
ISOLATION CONTACTOR SAVER CSVR
FAULT RESET FR
WELD PROCEED WP1
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STEPPER RESET SR
STEPPER RESET GROUP 1 SRG1
STEPPER RESET GROUP 2 SRG2
TIP DRESS TIPD
TIP DRESS GROUP 1 TDG1
TIP DRESS GROUP 2 TDG2
STEPPER AUX WELD CNTR RESET SACR
APP ERR ACKNOWLEDGE FACK
CONTROL STOP CSTP
PRESSURE SWITCH PS1
SYSTEM COOLING COOL
PROGRAM DISPLAY SECURITY PSEC
HEAT DISPLAY SECURITY HSEC
USER INPUT 1 UI1
USER INPUT 2 UI2
USER INPUT 3 UI3
USER INPUT 4 UI4
USER INPUT 5 UI5
USER INPUT 6 UI6
RETRACT PILOT 1 RP1
RETRACT PILOT 2 RP2
SPOT 9 (256) S9
SPOT 10 (512) S10
SPOT 11 (1024) S11
SPOT 12 (2048) S12
SPOT 13 (4096) S13
SPOT 14 (8192) S14
SPOT 15 (16384) S15
SPOT 16 (32768) S16
SPOT 17 (65536) S17
SPOT 18 (131072) S18
SPOT 19 (262144) S19
SPOT 20 (524288) S20
SPOT 21 (1048576) S21
SPOT 22 (2097152) S22
SPOT 23 (4194304) S23
SPOT 24 (8388608) S24
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SPOT 25 (16777216) S25
SPOT 26 (33554432) S26
SPOT 27 (67108864) S27
SPOT 28 (134217728) S28
SPOT 29 (268435456) S29
SPOT 30 (536870912) S30
GUN RES. CHECK GCHK
REWELD NON-RAFT RWLD
TIP DRESS MOTOR ON TDMI
OUTPUTS
OUTPUT NAME TAG
NONE (BLANK)
VALVE 1 V1
VALVE 2 V2
VALVE 3 V3
VALVE 4 V4
VALVE 5 V5
VALVE 6 V6
NO FAULT NFLT
NO ALERT NALT
FAULT FLT
ALERT ALT
WELD MODE ON WMON
NO WELD NWM
WELD IN PROGRESS WIP
WELD COMPLETE WCPL
READY TO WELD RTW
STEPPERS ARE RESET SRST
STEPPERS ARE RESET GROUP 1 SRG1
STEPPERS ARE RESET GROUP 2 SRG2
END OF STEPPER EOS
END OF STEPPER GROUP 1 ESG1
END OF STEPPER GROUP 2 ESG2
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STEPPER APPROACHING MAX SALT
STPR APPROACHING MAX GROUP 1 SAG1
STPR APPROACHING MAX GROUP 2 SAG2
TIP CHANGE REQUIRED TCR
TIP CHANGE REQUIRED GROUP 1 TCG1
TIP CHANGE REQUIRED GROUP 2 TCG2
TIP DRESS REQUEST TDR
TIP DRESS REQUEST GROUP 1 TDG1
TIP DRESS REQUEST GROUP 2 TDG2
STEPPER AUX COUNTER AT MAX SACM
APP ERROR AVAILABLE EAVL
APP ERROR BIT 1 ER1
APP ERROR BIT 2 ER2
APP ERROR BIT 4 ER4
APP ERROR BIT 8 ER8
APP ERROR BIT 16 ER16
PRESSURE SELECT 1 PS1
PRESSURE SELECT 2 PS2
PRESSURE SELECT 3 PS3
PRESSURE SELECT 4 PS4
USER OUTPUT 1 UO1
USER OUTPUT 2 UO2
USER OUTPUT 3 UO3
USER OUTPUT 4 UO4
USER OUTPUT 5 UO5
USER OUTPUT 6 UO6
RETRACT VALVE 1 RT1
RETRACT VALVE 2 RT2
INVERTED RETRACT VALVE 1 IRT1
INVERTED RETRACT VALVE 2 AERR
WATER SAVER VALVE WSVR
FORGE FRG
GAP GAP
CONTACTOR SELECT 1 CSO1
CONTACTOR SELECT 2 CSO2
CONTACTOR SELECT 3 CSO3
CONTACTOR SELECT 4 CSO4
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CONTACTOR SELECT 5 CSO5
CONTACTOR SELECT 6 CSO6
ADAPTQ MISMATCH ADQX
SOFTQ MISMATCH SFQX
RAFT CAPABLE RAFT
ADAPTQ ENABLED ADPQ
SOFTQ ENABLED SFTQ
TIP DRESS MOTOR RUNNING TDMR
FIXED CIOM INPUTS
INPUT NAME TAG
ISOC AUX CONTACT IC
CONTROL STOP 2 CS2
WELD / NO WELD 2 NW2
AUXILLIARY COOLING TS2
OVER VOLTAGE OV
UNDER VOLTAGE UV
LOW VOLTAGE LV
FIXED CIOM OUTPUTS
OUTPUT NAME TAG
ISOC ISOC
SHUNT TRIP 1 ST
TIP DRESS MOTOR TDMO
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FIXED LIO INPUTS
INPUT NAME TAG
CONTROL STOP 2 CS2
ISOC AUX CONTACT IC
FIXED LIO OUTPUTS
OUTPUT NAME TAG
ISOC ISOC
SHUNT TRIP 1 ST
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I/O DESCRIPTIONS INPUT DESCRIPTIONS
INPUT BIT NAME DESCRIPTION
When the NONE bit is assigned to an input, the input is disabled and not
NONE used by the weld processor.
BINARY SELECT 1 / 2 / 4 / 8 / 16 These bits are used to binarily select which of the 255 available weld sched-
/ 32 / 64 / 128 ules to run. The schedule is selected by turning the appropriate bits HIGH.
WELD INITIATE When this bit goes HIGH, the weld processor will initiate the weld schedule
selected through the Binary Select Inputs.
When this bit is HIGH, the weld control is in WELD MODE. When this bit is
WELD / NO WELD LOW, the weld control is in NO WELD MODE.
This bit is used to either enable or disable the ISOLATION CONTACTOR
DELAY feature in the Setup Parameters. If this bit is HIGH at the end of a
weld schedule, the weld processor will hold the isolation contactor closed
ISOLATION CONTACTOR SAVER for the amount of time programmed into the ISOLATION CONTACTOR DELAY
setup parameter. If this bit is LOW at the end of a weld schedule, the isola-
tion contactor will drop out immediately at the end of the weld schedule.
This bit is HIGH when the Fault Status illuminated pushbutton in the opera-
FAULT RESET tor's panel is pressed. When this bit goes HIGH, the weld processor will reset
all faults.
WELD PROCEED This bit is used to force the weld processor to pause the execution of a weld
schedule until the bit goes HIGH. It is used with function #70 (WAIT FOR
WELD PROCEED).
STEPPER RESET When this bit goes HIGH the weld processor will “globally” reset all 10 step-
per programs to Step 1 and Weld Count 0.
STEPPER RESET GROUP 1 When this bit goes HIGH the weld processor will reset only the stepper pro-
grams assigned to Group 1, to Step 1 and Weld Count 0.
STEPPER RESET GROUP 2 When this bit goes HIGH the weld processor will reset only the stepper pro-
grams assigned to Group 2, to Step 1 and Weld Count 0.
When this bit goes HIGH, the weld processor will:
TIP DRESS
1. Turn the Tip Dress Request output bit LOW
2. Return the stepper program to the 1st weld of step 2.
This applies “globally” for all stepper programs.
STEPPER AUX WELD CNTR RESET When this bit goes HIGH, the weld processor resets the Auxiliary Weld
Counter to zero and turns the Aux. Counter at Max output bit LOW.
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INPUT BIT NAME DESCRIPTION
APP ERR ACKNOWLEDGE The robot turns this bit HIGH to:
1 Send an acknowledgment to the weld processor that it has read the binary
fault code from the App Error output bits.
2 To send the next binary fault code to the App Error output bits.
CONTROL STOP This bit is normally maintained HIGH. When this bit goes LOW, the weld pro-
cessor will generate a CONTROL STOP FAULT.
This bit is used to force the weld processor to pause the execution of a weld
PRESSURE SWITCH schedule until the bit goes HIGH or until the wait time in function #68 has
elapsed. It is used with function #68 (WAIT nnnn CY FOR PRESSURE SWITCH
INPUT) and function #69 (WAIT FOR PRESSURE SWITCH INPUT).
This bit is normally maintained HIGH. When a System Cooling problem exists
external to the weld control unit (i.e. welding transformer, gun, etc.) this bit
will go LOW.
The weld schedule will initiate if the bit is LOW, but no current will be
passed. At the end of the schedule, the weld processor will generate a LOW
SYSTEM COOLING CURRENT FAULT and SYTEM COOLING FAULT.
If this bit goes LOW anytime during the execution of a weld schedule, the
weld processor will generate a SYSTEM COOLING FAULT. Conversely, if this
bit goes LOW before the weld function, a SYSTEM COOLING FAULT and LOW
CURRENT LIMIT FAULT will occur.
When this bit is held LOW, only data within the Stepper Status menu can be
edited.
PROGRAM DISPLAY SECURITY
When this bit is held HIGH, all data can be edited.
When this bit is held HIGH, only data in the Stepper Status and Heat Display
Menus can be edited.
HEAT DISPLAY SECURITY
When the Heat Display Security and Program Display Security bits are held
LOW simultaneously, only data in the Stepper Status, and Network Address
menus can be edited.
USER INPUT 1 / 2 / 3 / 4 / 5 / 6 Spare user definable input bit. It is used with functions #66 (WAIT nnn CY
INP #n TO BE n) and #67 (WAIT FOR INPUT #n TO BE n) in the weld schedule.
This input bit changes the state of the Close Retract 1 and Open Retract 1
output bits. A LOW to HIGH transition on the Retract Pilot input bit causes
RETRACT PILOT 1 the state of the Close Retract 1 and Open Retract 1 output bits to change.
NOTE: Both retract output bits remain off after the control is powered up
and/or after a Control Stop condition. The retract input bit must always be
toggled after these events to return the retract output bits to their expected
states.
NOTE: This bit must be mapped in the I/O to enable retraction. Operation is
fixed in LATCHED mode only.
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INPUT BIT NAME DESCRIPTION
RETRACT PILOT 2 This input bit changes the state of both Retract Valve 2 and Inverted Retract
Valve 2 output bits. How these output bits react to the input depends on the
parameters programmed into the Retract Mode and Cylinder Setup Parame-
ters.
This bit is used by the robot to initiate a schedule by SPOT ID (SPOT ID = 3
digit Weld Body ID + 6 digit Location ID). When this bit goes high the robot
SPOT 9 - 30 will look for the weld schedule that has been previously assigned to the
Spot.
NOTE: For more details on Programming with Spot ID refer to Chp. 6: Pro-
gramming Schedules - Spot ID Programming.
• When the combination of Binary Select Input bits and Spot ID input bits is
greater than 1 and less than 256, the weld processor Request(s) Pressure
and Initiate(s) Schedule assigned to the Spot.
• When the combination of Binary Select Input bits and Spot ID is greater
than 255,the weld processor performs a ‘Look Up” in the SPOT ID Refer-
ence Table:
If there is no Schedule associated with the specific SPOT ID and this
is:
A. REQUEST FOR PRESSURE, then do not change the pressure
output bits.
B. INITIATE WELD, then an “INVALID SEQUENCE” Fault is annun-
ciated.
If there is a Schedule associated with the specific SPOT ID and this
is:
A. REQUEST FOR PRESSURE, then set the appropriate pressure
output bits.
B. INITIATE WELD request, then execute the desired weld
schedule and place the Spot ID in the weld result data for
tracking purposes.
The Weld Summary Record format will add the SPOT ID to the summary
information.
GUN RES CHECK This bit is used to assess the gun resistance and annunciate “WELD PROCESS
STOP” fault if resistance falls outside the acceptable range.
When this input bit goes HIGH at TURN ON WELD COMPLETE, an average
resistance of the weld is checked within the Schedule’s SOFTQ Monitor
Resistance Average settings. If the Average Resistance exceeds the fault
level limits it will turn on the Weld Process Stop output.
NOTE: This input bit ignores the “Reweld Non-RAFT” input.
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INPUT BIT NAME DESCRIPTION
REWELD NON-RAFT This input bit allows the robot to request a reweld and make decisions on
whether to reweld with adaptive ON or OFF in the following situations:
B If the ADAPTQ MODE = 0 and there is a valid Reference and R-Measure for
a given schedule then ADAPTQ Mismatch Output bit can be turned ON.
C If there was an Internal reweld or a request for an External Re-Weld then
the ADAPTQ Mismatch output will remain high. In all other cases it will
be remain LOW.
If there are any SOFTQ settings set to check for either PI-Envelope, Monitor-
ing, or Trending the output SOFTQ Mismatch will turn OFF.
If the SOFTQ settings have been turned off by using the “RAFT” screen and
disabling the SOFTQ Monitoring the output SOFTQ Mismatch will turn ON.
If there are at least X SOFTQ exceptions or more within the Part Exceptions
buffer then turn on the WELD PROCESS STOP Output. This output will go
low with a valid Weld Initiate, or fault reset.
If the automation process desires a Re-Weld then they can monitor the state
of the No Fault / Weld Complete to assess if a RE-Weld is required and turn
on the Reweld Non-RAFT. This along with a valid schedule and Weld Initiate
will Execute the schedule and turn off the ADATPQ and SOFTQ Monitoring
features.
The schedule will use the programmed current plus stepper boost.
NOTE: 1. RAFT™ Capable is only available if the timer hardware supports
the Secondary Voltage wires required for RAFT™.
2. When used in conjunction with Gun Resistance Check do not
bypass SOFTQ limits.
TIP DRESS MOTOR ON This input functions as an external request which is independent of the weld
schedule and allows the Robot or PLC to start the tip dress motor.
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OUTPUT DESCRIPTIONS
OUTPUT BIT NAME DESCRIPTION
NONE When the NONE bit is assigned to an output, the output is disabled and not
used by the weld processor.
This bit goes HIGH when function #50 (TURN ON VALVE 1) is executed in the
VALVE 1 weld schedule and goes LOW when function #51 (TURN OFF VALVE 1) is exe-
cuted.
VALVE 2 This bit goes HIGH when function #50 (TURN ON VALVE 2) is executed in the
weld schedule and goes LOW when function #51 (TURN OFF VALVE 2) is exe-
cuted.
VALVE 3 This bit goes HIGH when function #50 (TURN ON VALVE 3) is executed in the
weld schedule and goes LOW when function #51 (TURN OFF VALVE 3) is exe-
cuted.
VALVE 4 This bit goes HIGH when function #50 (TURN ON VALVE 4) is executed in the
weld schedule and goes LOW when function #51 (TURN OFF VALVE 4) is exe-
cuted.
VALVE 5 This bit goes HIGH when function #50 (TURN ON VALVE 5) is executed in the
weld schedule and goes LOW when function #51 (TURN OFF VALVE 5) is exe-
cuted.
VALVE 6 This bit goes HIGH when function #50 (TURN ON VALVE 6) is executed in the
weld schedule and goes LOW when function #51 (TURN OFF VALVE 6) is exe-
cuted.
NO FAULT This bit is normally maintained HIGH and indicates a FAULT condition does
not exist. When a FAULT occurs, this bit will go LOW.
This bit is normally maintained HIGH and indicates an ALERT condition does
NO ALERT not exist. When an ALERT occurs, this bit will go LOW.
FAULT This bit will go HIGH when a FAULT condition exists.
ALERT This bit will go HIGH when an ALERT condition exists.
WELD MODE ON This bit goes HIGH when the weld control is in WELD MODE.
NO WELD This bit goes HIGH when the weld control is in NO WELD MODE.
This bit goes HIGH when function #58 (TURN ON WELD IN PROGRESS) is exe-
WELD IN PROGRESS cuted in the weld schedule and goes LOW when function #59 (TURN OFF
WELD IN PROGRESS) is executed.
This bit goes HIGH when function #63 (TURN ON WELD COMPLETE) is exe-
WELD COMPLETE cuted in the weld schedule and goes LOW when function #64 (TURN OFF
WELD COMPLETE) is executed.
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OUTPUT BIT NAME DESCRIPTION
This bit goes HIGH when all the following conditions are true:
READY TO WELD 1 The weld control is in WELD MODE
2 No fault condition exists
3 The Control Stop input bit is HIGH
4 The System Cooling input bit is HIGH.
STEPPERS ARE RESET This bit goes HIGH when all 10 stepper programs are globally reset.
STEPPERS ARE RESET GROUP 1 This bit goes HIGH when the stepper programs assigned to group 1 are
reset.
STEPPERS ARE RESET GROUP 2 This bit goes HIGH when the stepper programs assigned to group 2 are
reset.
When the tip dress feature is enabled, this bit will go HIGH on the first weld
END OF STEPPER of step 3 in the stepper program, if the Remaining Tip Dresses Count has
decremented to 0. It will only go HIGH on the last weld of step 5 in the step-
per program, if the tip dress function is disabled in the Setup Parameters or
the tip dress count is greater than 0 when the tip dress feature is enabled.
This bit will go LOW when either the Stepper Reset, Stepper Reset Group 1
or Stepper Reset Group 2 input bits go HIGH.
END OF STEPPER GROUP 1 This bit will go HIGH on the last weld of step 5 in the stepper program. This
bit will go LOW when either the Stepper Reset or Stepper Reset Group 1
input bit goes HIGH.
END OF STEPPER GROUP 2 This bit will go HIGH on the last weld of step 5 in the stepper program. This
bit will go LOW when either the Stepper Reset or Stepper Reset Group 2
input bit goes HIGH.
When the tip dress feature is enabled, this bit will go HIGH on the 1st weld
STEPPER APPROACHING MAX of step 2 in the stepper program, if the Remaining Tip Dresses Count has
decremented to 0. It will only go HIGH on the 1st weld of step 5 in the step-
per profile, if the tip dress function is disabled in the Setup Parameters or
the tip dress count is greater than 0 when the tip dress feature is enabled.
This bit will go LOW when either the Stepper Reset, Stepper Reset Group 1
or Stepper Reset Group 2 input bits go HIGH.
STPR APPROACHING MAX This bit will go HIGH on the 1st weld of step 5 in the stepper profile. This bit
GROUP 1 will go LOW when either the Stepper Reset, Stepper Reset Group 1 or End of
Stepper Group 1 input bit goes HIGH.
STPR APPROACHING MAX This bit will go HIGH on the 1st weld of step 5 in the stepper profile. This bit
GROUP 2 will go LOW when either the Stepper Reset, Stepper Reset Group 2 or End of
Stepper Group 2 input bit goes HIGH.
TIP CHANGE REQUIRED This bit will go HIGH at the end of any stepper program, if the Remaining Tip
Dress Count (Tip Dresses) has decremented to zero in the Stepper Status
Menu. This bit will go LOW when the Stepper Reset input bit goes HIGH.
TIP CHANGE REQUIRED GROUP This bit will go HIGH at the end of any stepper program assigned to Group 1,
1/2 if the Remaining Tip Dress Count (Tip Dresses) has decremented to zero in
the Stepper Status Menu. This bit will go LOW when either the Stepper
Reset or Stepper Reset Group 1 / 2 input bit goes HIGH.
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OUTPUT BIT NAME DESCRIPTION
TIP DRESS REQUEST This bit will go HIGH at the first weld of Step 3 in the stepper program, if the
Remaining Tip Dresses Count is > 0. It is used as an indicator to the robot
that a tip dress is required for the weld caps. This bit will go LOW when (1)
the Tip Dress Request, Tip Dress Request Group 1 or Tip Dress Request
Group 2 input bits go HIGH or (2) the tip dress schedule is initiated.
NOTE: This bit does not latch on. It will turn off when the initiate bit is
turned off.
TIP DRESS REQUEST GROUP I / 2 This bit will go HIGH at the first weld of Step 3 in the stepper program, if the
Remaining Tip Dresses Count is > 0. It is used as an indicator to the robot
that a tip dress is required for the weld caps. This bit will go LOW when the
Tip Dress Group 1 / 2 input bit goes HIGH.
STEPPER AUX COUNTER AT MAX This output bit goes HIGH when the Auxiliary Weld Counter has reached the
value programmed in the Aux. Counter Max Counts field in the Stepper Pro-
file.
APP ERROR AVAILABLE When a fault occurs, this bit goes HIGH to advise the robot to read the
binary fault code on the App Error Bit output bits.
APP ERROR BIT 1 / 2 / 4 / 8 / 16 These bits are used by the weld processor to send binary fault codes to the
robot.
During the execution of a weld schedule, the weld processor takes the value
programmed in function #54 (TURN ON PRESSURE SELECT nnn) and turns
PRESSURE SELECT 1 / 2 / 3 / 4 the corresponding binary Pressure Select output bits HIGH. If SET PRESSURE
= 0, all four bits (1, 2, 3, 4) are LOW.
USER OUTPUT 1 / 2 / 3 / 4 / 5 / 6 This bit goes HIGH when function #52 (TURN ON OUTPUT 1 / 2 / 3/ 4 / 5/ 6)
is executed in the weld schedule and goes LOW when function #53 (TURN
OFF OUTPUT 11 / 2 / 3/ 4 / 5/ 6) is executed.
RETRACT VALVE 1 The state of this bit changes according to the status of the Retract Valve 1
input bit. How this bits reacts depends on the parameters programmed into
the Retract Mode and Cylinder Setup Parameters.
RETRACT VALVE 2 The state of this bit changes according to the status of the Retract Valve 2
input bit. How this bits reacts depends on the parameters programmed into
the Retract Mode and Cylinder Setup Parameters.
INVERTED RETRACT VALVE 1 The state of this bit changes according to the status of the Retract Pilot 1
input bit.
NOTE: This bit is functional when the Retract Pilot 1 input bit is mapped.
NOTE: Both retract output bits remain off after the control is powered up
and/or after a control stop condition. The retract input bit must always be
toggled after these events to return the retract output bits to their expected
states.
INVERTED RETRACT VALVE 2 The state of this bit changes according to the status of the Retract Valve 2
input bit. How this bits reacts depends on the parameter programmed into
the Retract Mode Setup Parameter.
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OUTPUT BIT NAME DESCRIPTION
WATER SAVER This bit goes HIGH when a weld schedule initiates. After the weld schedule
is complete, the weld processor starts an internal timer holding the bit HIGH
for an additional three minutes. When the timer has ended, the bit goes
LOW.
FORGE This bit goes HIGH when function #78 (TURN ON FORGE VALVE) is executed
in the weld schedule and goes LOW when function #79 (TURN OFF FORGE
VALVE) is executed.
GAP This bit goes HIGH when the part being welded with ADAPTQ mode enabled
detects a gap due to high resistance or an instantaneous drop in resistance.
CONTACTOR SELECT 1-6 This output works in conjunction with the MCCM (Multi Contactor Control
Module). Weld controls installed with the MCCM which is a multiplexer,
have the capability of functioning in cascade mode where one inverter
power supply allows connections to up to 3 welding transformers. The Con-
tactor Select output is used to determine which welding unit (named by
numbers 1-6) and will be active during the specified schedule and receive
feedback from the specified tip voltage sense wires in RAFT™ mode.
ADAPTQ MISMATCH This output bit goes HIGH when:
B the Reference weld and R-Measure for the given schedule is indexed.
C An internal or external reweld was performed
SOFTQ MISMATCH This out put bit goes HIGH when SOFTQ settings have been turned OFF
using RAFT™
RAFT CAPABLE This bit goes HIGH when both hardware and software to support RAFT™ is
detected.
ADAPTQ ENABLED This output bit goes HIGH when a schedule is welded in the adaptive mode.
SOFTQ ENABLED This output bit goes HIGH when a schedule is welded with SOFTQ monitor-
ing is available for the schedule.
TIP DRESS MOTOR RUNNING This output goes HIGH as a handshake acknowledgment of the TIP DRESS
MOTOR ON input.
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I/O STATUS To navigate to the I/O Status Menu, perform the following steps on
the DEP-300s:
B Press Status Mode
C Press More
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D Press IO Status
EACH I/O BIT IS REPRESENTED BY A
TAG WHICH WILL HAVE EITHER A “1”
OR “0” UNDERNEATH IT:
“1” indicates the bit is HIGH or ON
“0” indicates the bit is LOW or OFF
Press Page 2 to view more bits (if applicable).
The I/O Status Screen shows the status of every mapped I/O bit in the
WT6000. Depending on the customer's application, this can include:
• Fieldbus I/O
• Ethernet I/O
• Local I/O
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I/O DEFAULTS
DISCRETE I/O
Weld processor software G08600 offers two default Discrete I/O (DIO)
lists. The following instructions show navigation to Default 1 on the
DEP-300s. Use the same procedure to navigate to Default 2.
B Press Program Mode
NOTE: The available
DIO depends on
the number of
DIO cards
installed. Each
card allows 16
Mappable I/O.
G08600 allows
for a total of 32
DIO with two
DIO cards
installed.
C Press More
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D Press More
E Press I/O Mapping.
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F Press This opens a drop-down box with options
available. Using the arrow key navigate to the desired
default (DEFAULT 1 or DEFAULT 2) and press
G Press Execute
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H The message: “Do you want to change 1/O
Information?” is displayed. Press to Confirm.
I “Download Complete Power Cycle Required” is
displayed. Cycle power to apply the selection.
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MAPPING THE DISCRETE I/O (DIO)
B Press Program Mode
C Press More
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D Press More
E Press I/O Mapping.
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F Press Input Mapping.
F Press to open a drop down box which will show the
available mappable inputs. The total number of available
inputs is dependent on the type and number of I/O cards
installed. They work in multiples of 8. A single card allows 16
inputs and 10 outputs and two cards allow 32 inputs and 20
outputs.
Using the arrow key navigate to the default line you
want mapped. For detailed instructions on mapping I/O refer
to I/O Mapping on page 00
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DIO (DISCRETE I/O) INPUTS - T 1
INPUT # INPUT NAME TAG
1. BINARY SELECT 1 BS1
2. BINARY SELECT 2 BS2
3. BINARY SELECT 4 BS4
4. BINARY SELECT 8 BS8
5. BINARY SELECT 16 BS16
6. BINARY SELECT 32 BS32
7. WELD INITIATE INT
8. FAULT RESET FR
9. PRESSURE SWITCH PS1
10. WELD PROCEED WP1
11. STEPPER RESET SR
12. TIP DRESS TIPD
13. SYSTEM COOLING COOL
14. WELD / NO WELD WLD
15. NONE -
16. NONE -
17. NONE -
18. NONE -
19. NONE -
20. NONE -
21. NONE -
22. NONE -
23. NONE -
24. NONE -
25. NONE -
26. NONE -
27. NONE -
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28. NONE -
29. NONE -
30. NONE -
31. NONE -
32. NONE -
DIO (DISCRETE I/O) OUTPUTS - T 1
OUTPUT # OUTPUT NAME TAG
1. VALVE 1 V1
2. VALVE 2 V2
3. VALVE 3 V3
4. VALVE 4 V4
5. PRESSURE SELECT 1 PS1
6. PRESSURE SELEECT 2 PS2
7. WELD COMPLETE WCPL
8. END OF STEPPER EOS
9. ALERT ALT
10. FAULT FLT
11. NONE -
12. NONE -
13. NONE -
14. NONE -
15. NONE -
16. NONE -
17. NONE -
18. NONE -
19. NONE -
20. NONE -
21. NONE -
22. NONE -
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23. NONE -
24. NONE -
25. NONE -
26. NONE -
27. NONE -
28. NONE -
29. NONE -
30. NONE -
31. NONE -
32. NONE -
NOTE: Default lines 11 to 16 and 27 to 32 labeled NONE (shaded gray)
are not mappable. If mapping is attempted at these points it
will show in the window but will not be executed. The available
I/O points are determined by the type and number of I/O cards
installed. Software G08600 allows 10 mappable outputs when
a single I/O card is installed and 20 if two I/O cards are
installed.
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DIO (DISCRETE I/O) INPUTS - T 2
INPUT # INPUT NAME TAG
1. BINARY SELECT 1 BS1
2. BINARY SELECT 2 BS2
3. BINARY SELECT 4 BS4
4. BINARY SELECT 8 BS8
5. BINARY SELECT 16 BS16
6. BINARY SELECT 32 BS32
7. WELD INITIATE INT
8. WELD / NO WELD WLD
9. PRESSURE SWITCH PS1
10. FAULT RESET FR
11. WELD PROCEED WP1
12. STEPPER RESET SR
13. SYSTEM COOLING COOL
14. NONE -
15. CONTROL STOP CSTP
16. USER INPUT 1 UI1
17. NONE -
18. NONE -
19. NONE -
20. NONE -
21. NONE -
22. NONE -
23. NONE -
24. NONE -
25. NONE -
26. NONE -
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27. NONE -
28. NONE -
29. NONE -
30. NONE -
31. NONE -
32. NONE -
DIO (DISCRETE I/O) OUTPUTS - T 2
OUTPUT # OUTPUT NAME TAG
1. FAULT FLT
2. ALERT ALT
3. WELD COMPLETE WCPL
4. READY TO WELD RTW
5. END OF STEPPER EOS
6. STEPPER APPROACHING MAX SALT
7. VALVE 1 V1
8. VALVE 2 V2
9. VALVE 3 V3
10. USER OUTPUT 1 UO1
11. NONE -
12. NONE -
13. NONE -
14. NONE -
15. NONE -
16. NONE -
17. NONE -
18. NONE -
19. NONE -
20. NONE -
21. NONE -
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22. NONE -
23. NONE -
24. NONE -
25. NONE -
26. NONE -
27. NONE -
28. NONE -
29. NONE -
30. NONE -
31. NONE -
32. NONE -
DIO (DISCRETE I/O) INPUTS - T 3
INPUT # INPUT NAME TAG
1. BINARY SELECT 1 BS1
2. BINARY SELECT 2 BS2
3. BINARY SELECT 4 BS4
4. BINARY SELECT 8 BS8
5. BINARY SELECT 16 BS16
6. BINARY SELECT 32 BS32
7. BINARY SELECT 64 BS64
8. WELD INITIATE INT
9. WELD / NO WELD WLD
10. STEPPER RESET GROUP 1 SRG1
11. STEPPER RESET GROUP 2 SRG2
12. FAULT RESET FR
13. NONE -
14. WELD PROCEED WP1
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15. NONE -
16. NONE -
17. NONE -
18. NONE -
19. NONE -
20. NONE -
21. NONE -
22. NONE -
23. NONE -
24. NONE -
25. NONE -
26. NONE -
27. NONE -
28. NONE -
29. NONE -
30. NONE -
31. NONE -
32. NONE -
DIO (DISCRETE I/O) OUTPUTS - T 3
OUTPUT # OUTPUT NAME TAG
1. WELD COMPLETE WCPL
2. NO FAULT NFLT
3. ALERT ALT
4. END OF STEPPER EOS
5. READY TO WELD RTW
6. STEPPER APPROACHING MAX SALT
7. TIP DRESS REQUEST TDR
8. VALVE 1 V1
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9. VALVE 2 V2
10. VALVE 3 V3
11. NONE -
12. NONE -
13. NONE -
14. NONE -
15. NONE -
16. NONE -
17. CONTACTOR SELECT 1 CSO1
18. CONTACTOR SELECT 2 CSO2
19. CONTACTOR SELECT 3 CSO3
20. NONE -
21. NONE -
22. NONE -
23. NONE -
24. NONE -
25. NONE -
26. NONE -
27. NONE -
28. NONE -
29. NONE -
30. NONE -
31. NONE -
32. NONE -
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FIELDBUS INPUTS- DEFAULT 1
TAG
INPUT # FIELDBUS INPUT BIT NAME BYTE SIZE
NAME
1 WELD / NO WELD WLD
2 FAULT RESET FR
3 APP ERR ACKNOWLEDGE FACK
4 BINARY SELECT 1 BS1
5 BINARY SELECT 2 BS2
6 BINARY SELECT 4 BS4
7 BINARY SELECT 8 BS8
8 BINARY SELECT 16 BS16
9 BINARY SELECT 32 BS32 2 by 2
10 WELD INITIATE INT
11 NONE -
12 NONE -
13 STEPPER RESET SR
14 ISOLATION CONTACTOR SAVER CSVR
15 CONTROL STOP CSTP
16 TIP DRESS TIPD
17 NONE -
18 STEPPER RESET GROUP 1 SRG1
19 STEPPER RESET GROUP 2 SRG2
20 NONE - 4 by 4
21 TIP DRESS GROUP 1 TDG1
22 TIP DRESS GROUP 2 TDG2
23 NONE -
24 NONE -
25 NONE -
26 NONE -
27 NONE -
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28 NONE -
29 NONE -
30 NONE - 6 by 6
31 NONE -
32 NONE -
33 NONE -
34 NONE -
35 NONE - 8 by 8
36 NONE -
37 NONE -
38 NONE -
39 NONE -
40 NONE -
41 NONE -
42 NONE -
43 NONE -
44 NONE -
45 NONE -
46 NONE -
47 NONE -
48 NONE -
49 NONE -
50 NONE -
51 NONE -
52 NONE -
53 NONE -
54 NONE -
55 NONE -
56 NONE -
57 NONE -
58 NONE -
59 NONE -
60 NONE -
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61 NONE -
62 NONE -
63 NONE -
64 NONE -
FIELDBUS OUTPUTS - DEFAULT 1
OUTPUT TAG
FIELDBUS OUTPUT BIT NAME BYTE SIZE
# NAME
1 WELD MODE ON WMON
2 NO FAULT NFLT
3 NO ALERT NALT
4 APP ERROR AVAILABLE EVAL
5 APP ERROR BIT 1 ER1
6 APP ERROR BIT 2 ER2 2 by 2
7 APP ERROR BIT 4 ER4
8 APP ERROR BIT 8 ER8
9 APP ERROR BIT 16 ER16
10 WELD COMPLETE WCPL
11 WELD IN PROGRESS WIP
12 STEPPERS ARE RESET SRST
13 STEPPER APPROACHING MAX SALT
14 END OF STEPPER EOS 4 by 4
15 READY TO WELD RTW
16 TIP DRESS REQUEST TDR
17 NONE -
18 STEPPERS ARE RESET GROUP 1 SRG1
19 STEPPERS ARE RESET GROUP 2 SRG2
20 NONE -
21 END OF STEPPER GROUP 1 ESG1 6 by 6
22 END OF STEPPER GROUP 2 ESG2
23 NONE -
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24 STPR APPROACHING MAX GROUP 1 SAG1
25 STPR APPROACHING MAX GROUP 2 SAG2
26 NONE -
27 TIP DRESS REQUEST GROUP 1 TDG1 8 by 8
28 TIP DRESS REQUEST GROUP 2 TDG2
29 NONE -
30 NONE -
31 NONE -
32 NONE -
33 NONE -
34 NONE -
35 NONE -
36 NONE -
37 NONE -
38 NONE -
39 NONE -
40 NONE -
41 NONE -
42 NONE -
43 NONE -
44 NONE -
45 NONE -
46 NONE -
47 NONE -
48 NONE -
49 NONE -
50 NONE -
51 NONE -
52 NONE -
53 NONE -
54 NONE -
55 NONE -
56 NONE -
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57 NONE -
58 NONE -
59 NONE -
60 NONE -
61 NONE -
62 NONE -
63 NONE -
64 NONE -
FIELDBUS INPUTS - DEFAULT 2
INPUT TAG
FIELDBUS INPUT BIT NAME BYTE SIZE
# NAME
1 WELD / NO WELD WLD
2 FAULT RESET FR
3 ISOLATION CONTACTOR SAVER CSVR
4 NONE -
5 NONE -
6 NONE -
7 WELD INITIATE INT
8 STEPPER RESET SR
9 BINARY SELECT 1 BS1
10 BINARY SELECT 2 BS2
11 BINARY SELECT 4 BS4 2 by 2
12 BINARY SELECT 8 BS8
13 BINARY SELECT 16 BS16
14 BINARY SELECT 32 BS32
15 BINARY SELECT 64 BS64
16 BINARY SELECT 128 BS128
17 SPOT 9 (256) S9
18 SPOT 10 (512) S10
19 SPOT 11 (1024) S11
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20 SPOT 12 (2048) S12 4 by 4
21 SPOT 13 (4096) S13
22 SPOT 14 (8192) S14
23 SPOT 15 (16384) S15
24 SPOT 16 (32768) S16
25 SPOT 17 (65536) S17 6 by 6
26 SPOT 18 (131072) S18
27 SPOT 19 (262144) S19
28 SPOT 20 (524288) S20
29 SPOT 21 (1048576) S21
30 SPOT 22 (2097152) S22
31 SPOT 23 (4194304) S23
32 SPOT 24 (8388608) S24
33 SPOT 25 (16777216) S25
34 SPOT 26 (33554432) S26
35 SPOT 27 (67108864) S27
36 SPOT 28 (134217728) S28
37 SPOT 29 (268435456) S29
38 SPOT 30 (536870912) S30
39 NONE -
40 NONE -
41 NONE -
42 NONE -
43 NONE - 8 by 8
44 NONE -
45 NONE -
46 NONE -
47 NONE -
48 NONE -
49 NONE -
50 NONE -
51 NONE -
52 NONE -
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53 NONE -
54 NONE -
55 NONE -
56 NONE -
57 NONE -
58 NONE -
59 NONE -
60 NONE -
61 NONE -
62 NONE -
63 NONE -
64 NONE -
FIELDBUS OUTPUTS - DEFAULT 2
OUTPU TAG
FIELDBUS OUTPUT BIT NAME BYTE SIZE
T# NAME
1 WELD MODE ON WMON
2 NO FAULT NFLT
3 NO ALERT NALT
4 APP ERROR AVAILABLE EVAL
5 APP ERROR BIT 1 ER1
6 APP ERROR BIT 2 ER2 2 by 2
7 APP ERROR BIT 4 ER4
8 APP ERROR BIT 8 ER8
9 APP ERROR BIT 16 ER16
10 WELD COMPLETE WCPL
11 WELD IN PROGRESS WIP
12 STEPPERS ARE RESET SRST
13 STEPPER APPROACHING MAX SALT
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14 END OF STEPPER EOS
15 READY TO WELD RTW 4 by 4
16 TIP DRESS REQUEST TDR
17 NONE -
18 STEPPERS ARE RESET GROUP 1 SRG1
19 STEPPERS ARE RESET GROUP 2 SRG2
20 NONE -
21 END OF STEPPER GROUP 1 ESG1
22 END OF STEPPER GROUP 2 ESG2 6 by 6
23 NONE -
24 STEPPER APPROACHING MAX GROUP 1 SAG1
25 STEPPER APPROACHING MAX GROUP 2 SAG2
26 NONE -
27 TIP DRESS REQUEST GROUP 1 TDG1
28 TIP DRESS REQUEST GROUP 2 TDG2 8 by 8
29 NONE -
30 NONE -
31 NONE -
32 NONE -
33 NONE -
34 NONE -
35 NONE -
36 NONE -
37 NONE -
38 NONE -
39 NONE -
40 NONE -
41 NONE -
42 NONE -
43 NONE -
44 NONE -
45 NONE -
46 NONE -
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47 NONE -
48 NONE -
49 NONE -
50 NONE -
51 NONE -
52 NONE -
53 NONE -
54 NONE -
55 NONE -
56 NONE -
57 NONE -
58 NONE -
59 NONE -
60 NONE -
61 NONE -
62 NONE -
63 NONE -
64 NONE -
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EIP IP I/O DEFAULTS
In weld processor software G08600, there are a maximum of 64
inputs and outputs that can be mapped. The number of mapped
inputs and outputs is determined by selecting a Type and Size in the
EIP configuration options, whose product is less than or equal to 64.
The default map below is configured for 64 inputs and outputs. For
more information, see EtherNet Setup in Chapter 5: Communications
Setup.
Timer software G08600 offers 2 EIP I/O defaults. The following
procedure describes navigation to EIP I/O Default 1 using the DEP
300s.
B Press Program Mode.
C Press More.
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D Press EIP Options
E Press Reload
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F Press This opens a drop down list of Reload
Defaults. Use the Select your desired default
option and press
As the selected default is displayed in the Reload
Default window press Execute
G The message “Do you want to RELOAD Ethernet IP
Information?” is displayed. Press to Confirm
the selection. This is followed by the prompt
“Download Complete Power Cycle Required.” Cycle
power to apply the selection.
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Having made the selection of default options (IO Default 1, IO Default
2, EIP Factory Default) as detailed in the procedure on the previous
pages, follow the steps below to map the available EIP I/O points.
B Press Program Mode.
C Press More.
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D Press EIP Options
E Press Input Mapping.
For Output Mapping follow the same procedure until step 4 and
press
For detailed I/O mapping instructions refer to Page 232.
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EIP I/O INPUTS DEFAULT 1
INPUT # EIP INPUT BIT NAME TAG NAME
1. WELD / NO WELD WLD
2. FAULT RESET FR
3. ISOLATION CONTACTOR SAVER CSVR
4. NONE -
5. NONE -
6. NONE -
7. WELD INITIATE INT
8. STEPPER RESET SR
9. BINARY SELECT 1 BS1
10. BINARY SELECT 2 BS2
11. BINARY SELECT 4 BS4
12. BINARY SELECT 8 BS8
13. BINARY SELECT 16 BS16
14. BINARY SELECT 32 BS32
15. NONE -
16. NONE -
17. NONE -
18. NONE -
19. NONE -
20. NONE -
21. NONE -
22. NONE -
23. NONE -
24. NONE -
25. NONE -
26. NONE -
27. NONE -
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28. NONE -
29. NONE -
30. NONE -
31. NONE -
32. NONE -
33. NONE -
34. NONE -
35. NONE -
36. NONE -
37. NONE -
38. NONE -
39. NONE -
40. NONE -
41. NONE -
42. NONE -
43. NONE -
44. NONE -
45. NONE -
46. NONE -
47. NONE -
48. NONE -
49. NONE -
50. NONE -
51. NONE -
52. NONE -
53. NONE -
54. NONE -
55. NONE -
56. NONE -
57. NONE -
58. NONE -
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59. NONE -
60. NONE -
61. NONE -
62. NONE -
63. NONE -
64. NONE -
EIP OUTPUTS DEFAULT 1
OUTPUT
EIP OUTPUT BIT NAME TAG NAME
#
1. NO ALERT NALT
2. STEPPER APPROACHING MAX SALT
3. END OF STEPPER EOS
4. VALVE 1 V1
5. VALVE 2 V2
6. VALVE 3 V3
7. VALVE 4 V4
8. NONE -
9. NO FAULT NFLT
10. WELD MODE ON WMON
11. WELD COMPLETE WCPL
12. WELD IN PROGRESS WIP
13. STEPPERS ARE RESET SRST
14. TIP DRESS REQUEST TDR
15. NONE -
16. NONE -
17. NONE -
18. NONE -
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19. NONE -
20. NONE -
21. NONE -
22. NONE -
23. NONE -
24. NONE -
25. NONE -
26. NONE -
27. NONE -
28. NONE -
29. NONE -
30. NONE -
31. NONE -
32. NONE -
33. NONE -
34. NONE -
35. NONE -
36. NONE -
37. NONE -
38. NONE -
39. NONE -
40. NONE -
41. NONE -
42. NONE -
43. NONE -
44. NONE -
45. NONE -
46. NONE -
47. NONE -
48. NONE -
49. NONE -
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50. NONE -
51. NONE -
52. NONE -
53. NONE -
54. NONE -
55. NONE -
56. NONE -
57. NONE -
58. NONE -
59. NONE -
60. NONE -
61. NONE -
62. NONE -
63. NONE -
64. NONE -
EIP INPUTS DEFAULT 2
INPUT # EIP INPUT BIT NAME TAG NAME
1. WELD / NO WELD WLD
2. FAULT RESET FR
3. ISOLATION CONTACTOR SAVER CSVR
4. NONE -
5. NONE -
6. NONE -
7. WELD INITIATE INT
8. STEPPER RESET SR
9. BINARY SELECT 1 BS1
10. BINARY SELECT 2 BS2
11. BINARY SELECT 4 BS4
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12. BINARY SELECT 8 BS8
13. BINARY SELECT 16 BS16
14. BINARY SELECT 32 BS32
15. BINARY SELECT 64 BS64
16. BINARY SELECT 128 BS128
17. SPOT 9 (256) S9
18. SPOT 10 (512) S10
19. SPOT 11 (1024) S11
20. SPOT 12 (2048) S12
21. SPOT 13 (4096) S13
22. SPOT 14 (8192) S14
23. SPOT 15 (16384) S15
24. SPOT 16 (32768) S16
25. SPOT 17 (65536) S17
26. SPOT 18 (131072) S18
27. SPOT 19 (262144) S19
28. SPOT 20 (524288) S20
29. SPOT 21 (1048576) S21
30. SPOT 22 (2097152) S22
31. SPOT 23 (4194304) S23
32. SPOT 24 (8388608) S24
33. SPOT 25 (16777216) S25
34. SPOT 26 (33554432) S26
35. SPOT 27 (67108864) S27
36. SPOT 28 (134217728) S28
37. SPOT 29 (268435456) S29
38. SPOT 30 (536870912) S30
39. NONE -
40. NONE -
41. NONE -
42. NONE -
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43. NONE -
44. NONE -
45. NONE -
46. NONE -
47. NONE -
48. NONE -
49. NONE -
50. NONE -
51. NONE -
52. NONE -
53. NONE -
54. NONE -
55. NONE -
56. NONE -
57. NONE -
58. NONE -
59. NONE -
60. NONE -
61. NONE -
62. NONE -
63. NONE -
64. NONE -
EIP OUTPUTS DEFAULT 2
OUTPUT
EIP OUTPUT BIT NAME TAG NAME
#
1. NO ALERT NALT
2. STEPPER APPROACHING MAX SALT
3. END OF STEPPER EOS
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4. VALVE 1 V1
5. VALVE 2 V2
6. VALVE 3 V3
7. VALVE 4 V4
8. NONE -
9. NO FAULT NFLT
10. WELD MODE ON WMON
11. WELD COMPLETE WCPL
12. WELD IN PROGRESS WIP
13. STEPPERS ARE RESET SRST
14. TIP DRESS REQUEST TDR
15. NONE -
16. NONE -
17. NONE -
18. NONE -
19. NONE -
20. NONE -
21. NONE -
22. NONE -
23. NONE -
24. NONE -
25. NONE -
26. NONE -
27. NONE -
28. NONE -
29. NONE -
30. NONE -
31. NONE -
32. NONE -
33. NONE -
34. NONE -
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35. NONE -
36. NONE -
37. NONE -
38. NONE -
39. NONE -
40. NONE -
41. NONE -
42. NONE -
43. NONE -
44. NONE -
45. NONE -
46. NONE -
47. NONE -
48. NONE -
49. NONE -
50. NONE -
51. NONE -
52. NONE -
53. NONE -
54. NONE -
55. NONE -
56. NONE -
57. NONE -
58. NONE -
59. NONE -
60. NONE -
61. NONE -
62. NONE -
63. NONE -
64. NONE -
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I/O MAPPING The WT6000 is designed with Flexible I/O. This means the user has
the capability of reconfiguring the I/O to meet the requirements of a
particular application. There are 16 configurable inputs and 10
configurable outputs.
FIELDBUS INPUT MAPPING
The following explains how to reconfigure the FieldBus Input Map. In
this example, Input 8 will be re-mapped from the BINARY SELECT 128
bit to the TIP DRESS bit:
B Press Program Mode
C Press More
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D Press More
E Press Fieldbus Mapping
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F Press Input Mapping
G Press the arrow key to move the cursor to the “Input
8" field.
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H Press A drop-down box will appear containing all
the available input bits.
I Press the arrow key until the cursor is on the
TIP DRESS bit.
J Press ENTER
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K BINARY SELECT 128 will be replaced with TIP DRESS
in the Input 8 field.
L Press Execute. This begins the process
to download the change to the weld
processor.
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M The message “Do you want to Change
FIELD BUS Information” will appear.
Press Confirm.
N The message “Download Complete Power Cycle Required”
will appear. Re-cycle power on the weld control to complete
the process.
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FIELDBUS OUTPUT MAPPING
The following explains how to reconfigure the FieldBus Output Map.
In this example, Output 11 will be re-mapped from the NONE bit to
the TIP DRESS REQUEST bit.
B Press Program Mode
C Press More
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D Press More
E Press Fieldbus Mapping
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F Press output Mapping
G Press A drop-down box will appear.
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H Press the arrow key once to move the cursor to
“Outputs 9-16”
I Press ENTER
J Press the arrow key to move the cursor to the
“Output 11" field.
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K Press A drop-down box will appear containing all the
available output bits.
L Press the arrow key until the cursor is on the TIP
DRESS REQUEST bit.
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M Press NONE will be replaced with TIP
DRESS REQUEST in the Output 11 field.
N Press Execute
This begins the process to download the change
to the weld processor.
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O The message “Do you want to Change
FIELD BUS Information” will appear.
Press Confirm.
P The message “Download Complete Power Cycle Required”
will appear. Re-cycle power on the weld control to complete
the process.
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EIP I/O MAPPING
The steps to re-configure the EIP I/O Mapping is identical to the steps
to re-configure the FieldBus I/O Mapping. First, follow the steps
below to navigate to the EIP Options Menu on the DEP-300s. Then
follow the steps explained in the previous pages on either FieldBus
Input Mapping or FieldBus Output Mapping (whichever is applicable).
B Press Program Mode
C Press More
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D Press EIP Options
E Press either Input Mapping or
Output Mapping
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Chapter 12: RAFT TM (RESISTIVE ADAPTIVE FEEDBACK TECHNOLOGY)
RAFTTM HARDWARE In order to use the RAFT adaptive welding, the installation
INSTALLATION of voltage sense wires between the gun tips and the weld control
cabinet are required. Stainless steel terminals, cables and fasteners are
used at the weld gun to minimize cable failure caused by snagging and
wear due to gun and wrist movement. On a typical robot installation,
stainless steel cables are installed from the gun back to the robot arm/
wrist. At that point, the stainless steel cables are terminated to a
two-conductor copper cable (shielding is optional). The two-conductor
copper cable continues back to the weld control cabinet, where it is
terminated at the weld processor. Service connections can be made for
easier cable replacement but no more than 5 connections are
recommended. The use of the copper cable is a cost effective
alternative to running stainless steel cable all the way back to the weld
control cabinet.
RAFTTM VOLTAGE SENSE WIRE INSTALLATION KIT
WTC offers a stainless steel voltage sense wire installation kit.
The part number is 830-0970. This kit includes all required
hardware, drawings and documentation. For more information,
contact your WTC Sales Representative.
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• Place the
wires near the
water ports
located on the
welding gun
arms. This
area is ideal
since it is
unlikely to get
damaged over
time and the
resistance will
be constant.
• The secondary
voltage tip
wires are
required to be
installed
before the cap
adapter and
after the leaf
shunts. The
leaf shunts
will break over
time changing
their
resistance
which will
adversely
effect the
feedback
signal.
NOTE: This drawing is a general guide for installation. Specific installation is the responsibility of the customer
NOTE: The placement of the Tip Wires is a balance of
determining points where the resistance will not change
over time and placing the wires at a point where they will
not get damaged over the life of the tool.
Clean installation point with an Emery Cloth to allow the tip
wire to make good contact with the surface of the weld arm.
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RAFT SET-UP PROCESS AT A GLANCE
ADAPTQ HARDWARE
SETUP WITH VOLTAGE
SENSE WIRES
SETUP THE RMEASURE OR
GUN RESISTANCE MEASURE
CAPTURE AND SAVE
THE REFERENCE WELD
BEGIN RAFT ADAPTIVE WELDING
TUNE THE ADAPTIVE
SCHEDULE
SETUP SOFTQ
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RAFTTM WELDING PERFORMING A GUN RESISTANCE MEASUREMENT
START-UP
PROCEDURE RAFT™ requires a weld gun resistance measurement (R Measure) to
be performed prior to turning on adaptive welding. This is established
by performing a Resistance Measure tip to tip weld. Up to four guns
can be used with a gun changer per timer.
To perform an R Measure, a tip to tip weld (without metal) is made for
210ms or 13 cycles at 10K amps and at a tip force of 600lbs.
On a non tip dressing weld application the R Measure is performed
with brand new tips.
On a tip dress application where the tips are dressed immediately
after changing the weld caps, the R Measure is performed on a
dressed tip.
B Setup a simple constant current weld schedule. See sample
schedule below:
• If function (ADAPTQ MODE=0 RATE=nnn%
WSLIDE=nnn%) is inserted in the schedule, ensure the
mode is set to 0 (OFF). This puts the weld control in Con-
stant Current Mode.
• Recommended weld current range: 10, 000 Amps.
• Recommended weld time range: 13 CY / 210 Msec.).
WARNING!
If application requires
either the linear
stepper function to be
turned off (0=OFF) or
the stepper group
number to be changed,
a new R Measure
procedure must be
performed to ensure
the correct R Measure
data is stored in the
new stepper group.
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• The R Measure for the specific weld gun data is stored
NOTE: If a tip dresser is based on the stepper group that is associated with the
being used, dress the weld schedule. Therefore, ensure the linear stepper function is
caps prior to performing inserted into the schedule and the correct linear stepper
the R-Measure weld. and group numbers are assigned for the application.
Assign the
correct Stepper
number in the
weld schedule
Assign the
correct Group
number in the
stepper profile
REFERENCE TABLE
For portable gun welding WELD GUN # ASSIGN STEPPER # ASSIGN GROUP #
applications:
1 1 1
Gun1 = (Stepper #1 / Group #1)
Gun2 = (Stepper #2 / Group #2) 2 2 2
3 3 3
4 4 4
If only one gun is used, assign Stepper #1 to
Example:
schedules and assign Group #1 to Stepper #1.
all weld
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Program the
weld
function in
the weld
schedule for
210ms or 13
cycles at
10K amps.
C Set gun force as required for the welding application.
• Recommended force range: 600 lbs. / 2.7 kN
D Install new weld caps on the gun or dress the caps depending on
the application.
E Verify that 2.7kN or 600 lbs. of force will be present at tips when
the weld schedule is initiated.
F Reset Steppers.
G Initiate the weld schedule and verify that the R Avg. (Resistance
Average) value is between 30 and 150 micro-ohms. (Ex. R Avg. 52
micro-ohms). Repeat 2-3 times and ensure the R Avg. value is
stable.
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If the R Avg is
1000 Micro-
ohms, the
polarity of the
tip wires is
incorrect at the
weld timer.
Swap the tip
wires at the weld
timer (Pins 1&2
of the SEC I/V
connector)
H On the last Weld Status Screen, click the R Measure toggle
button from “R Measure is OFF” to “R Measure is ON”. See
example below.
WHEN TO PERFORM
A NEW R MEASURE?
The voltage wire
termination
points on the
weld gun are
changed.
New gun arm or
new gun is
installed.
The R Measure does
not need to be
performed if weld
caps, weld adapters,
or leaf shunts are
changed.
I Close the weld gun tip-to-tip, and initiate the weld sequence.
When the sequence is complete, the R Measure toggle button
will automatically switch from “R Measure ON” to “R Measure
OFF”.
The Gun Resistance Measurement has now been established and the
R Measure weld procedure is complete. R Measure is enabled for only
one weld and then turns off automatically. RAFTstores the R
Measure data in the stepper group # that was assigned.
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REFERENCE WELD After establishing the R Measure, the next step in the RAFTGateway
procedure is setting the Reference weld.
A reference weld is the stored Constant Current (CC) weld data set
that AdaptQ™ compares the weld in process to.
The reference weld cannot have any expulsion.
A proper reference weld is:
• Free of weld disturbances (gaps, misaligned or worn tips,
edge welds, gun to metal misalignment, etc.)
• The reference weld nugget size is at user determined
standard (Plant Standards) or slightly above.
• The Resistance curve shapes are smooth instead of sharp
inclines or declines.
• “Resistance Drop” desired ranges are 15.0 to 50.0,
depending on the metal stack-up.
To optimize RAFT™, each spot must be assigned to a unique weld
schedule. Each time a new reference weld is stored, a stepper reset is
required before the schedule is placed in Adaptive Mode.
NOTE: When taking a Reference Weld the current boost in the
stepper program should be temporarily set to 0 Amps. This prevents
improper references by restricting the addition of current to the core
weld schedule by the stepper.
HOW TO TAKE REFERENCE WELD FOR ADAPTIVE WELDING:
A reference weld is created by seasoning new/dressed tips with
minimum 6-8 welds and no more than 40. A “seasoned” weld tip face
produces better results for adaptive referencing.
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DATA COLLECTED FROM THE REFERENCE WELD
PEAK RESISTANCE (RP)
The highest resistance value during the weld. (micro-
Ohms)
END RESISTANCE (RE)
The lowest resistance value after RP. (micro-Ohms)
RESISTANCE DROP (RD)
The change in resistance from RP to RE. (%)
TOTAL ENERGY
The total energy of the weld. (Joules)
TOTAL HEAT
The total heat of the weld. (Watts)
RESISTANCE CURVE
The values of resistance at tips for every Msec. of the
weld.
CURRENT LEVEL
The current values for every Msec. of the weld. (Amps)
RE
RP
MELTING PHASE FINAL NUGGET GROWTH
NUGGET GROWTH
COUPLING PHASE
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METHODS TO TAKE 1. Taking references during a part run.
A REFERENCE WELD • Turn “Reference On”.
• Weld the part in Auto.
• Turn “Reference OFF”.
2. Creating a Single Reference.
• Using the last weld while viewing the weld graph in the
Status tab.
• While viewing weld data graphs from a weld spot in the
History/Graphs/Spot tab.
• When viewing weld graphs from off-line data files in the
History/Graphs/Spot tab.
3. Averaging a Reference.
• Averaging multiple weld graphs in the History/Graphs/
Spot tab.
4. Duplicating a Reference
• Duplicate schedule references through the Editor tab.
5. Download a Reference
• Download a .wdf reference file from a timer Status page.
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1. TAKING A B Left click mouse on the Timer tab that reference welds will be
REFERENCE taken on.
WELD DURING
A PART RUN
C In the Status screen, left click mouse “Ref. is OFF” button which
will then change to “Ref. is ON”.
D A Verification message will be displayed. Click OK.
E Reference is now turned ON
F Run a part in Auto mode.
ONCE THE “REF. IS ON” BUTTON IS PRESSED AGAIN ONLY THE LAST WELDS
MADE WHILE REFERENCE WAS ON WILL BE STORED.
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HOW DOES REFERENCE MODE WORK?
Assume that a part has 10 spot welds. Each is assigned an individual
schedule #, and the part is run in Reference Mode.
Situation A:
Ref. is ON and 10 welds are made.
The weld control will fire the schedules in order from 1 to 10.
When Ref Mode is turned OFF, these welds will be saved as
Reference welds, each with its own schedule.
Situation B:
Part 1
Schedules 1 to 5 are fired before Ref. Mode is turned ON.
Then schedules 6 to 10 are fired.
Part 2
The process is restarted with a new part where all 10
schedules are fired, in order this time. Reference mode is
turned OFF after the last weld on Part 2.
Which of these welds will be saved as references?
None from the Part 1. Although schedules 6-10 were executed after
the Ref mode was turned ON, the welds were overwritten by the
same schedule # welds made on part #2.
For schedules 1 to 5, only the Part 2 welds were captured and saved
as reference welds.
It is important to remember that, if Ref mode is kept ON, it will
automatically overwrite the reference record when the same
schedule is called (fired) again.
NOTE: Reference must be turned OFF for the reference weld data
to be stored into memory of the weld timer as a Reference
weld. Loading references to the weld timer may take several
seconds and will disable the timer momentarily.
If Reference is turned ON and more than 10 welds are
made, the weld control will set an ALERT to indicate that
Reference has been left ON. This Alert is indicated as
“REFERENCE MODE ON”.
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VERIFY ALL WELDS MADE WHILE REFERENCE IS TURNED ON, SATISFY THE
REQUIREMENTS BELOW:
• View all of the weld graphs in the History/Graphs/Spot
screen and verify that all welds made in Constant Cur-
rent mode were expulsion free.
• Ensure that all the welds made in Constant Current
mode have R Drop for the metal being welded (15-30%
for galvanized and 30-50% for bare metals).
In case of expulsion – Decrease the weld
current and make another weld with the programmed
weld schedule.
In case the R Drop is low – Increase the weld
current and make another weld with the programmed
weld schedule.
In case R Drop is high – Decrease the weld
current and make another weld with the programmed
weld schedule.
• Verify that all the welds made produced a minimum
weld nugget set-up size by destructing the part and mea-
suring all weld nuggets.
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2. CREATING A The History/Graphs/Spot tab displays many logged welds. Open the
SINGLE REFERENCE spot data for the weld that you want to reference.
WELD FROM
PAST WELD
DATA
Double click on
the weld to view
the weld graph
Check all welds that were made satisfy the requirements below:
• Had NO expulsion.
• Had the proper R Drop for the metal being welded (15-30%
for galvanized and 30-50% for bare metals).
In case of expulsion – Decrease the weld current and
make another weld with the programmed weld schedule.
In case the R Drop is low – Increase the weld current
and make another weld with the programmed weld
schedule.
In case R Drop is high – Decrease the weld current and
make another weld with the programmed weld schedule.
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EXAMPLES OF REFERENCE WELDS:
Good Constant Current Weld
EXPULSION DETECTION IS SEEN
AS A SHARP RESISTANCE DROP
WITHIN THE WELD GRAPH
Expulsion
icon and the
time of the
expulsion
detected
during the
weld.
Bad Constant Current weld with Expulsion
SELECT THE CREATE REFERENCE BUTTON
If the weld spot had NO expulsion, proper Rdrop was made
throughout the weld and the nugget set-up size measurement
meets the minimum set-up size requirement, click to select the
“Create Reference” button while viewing the weld graph.
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3. AVERAGING A Select multiple welds of the same schedule with the same time and
REFERENCE current programmed from the History/Graphs/Spot screen.
WELD
Same schedules are Selected schedules Selected schedules MUST use
selected for MUST use the same the same weld current for
Reference Averaging. weld time for Reference Averaging.
Reference Averaging.
IT IS A GOOD PRACTICE TO SET
ALL STEPS TO 0% BOOST.
NOTE: The stepper boost
changes the current in
every weld made with the
same schedule. RAFT
Gateway does not average
welds made with different
current values.
VERIFY ALL WELDS SELECTED FOR AVERAGING TO CREATE A REFERENCE
WELD:
• Have the same schedule
• Used the same time and weld current that is currently
programmed in the weld schedule.
• Were not made in adaptive mode.
• Had NO expulsion.
• Had the proper Rdrop for the metal being welded (15-
30% for galvanized and 30-50% for bare metals).
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In case of expulsion – Decrease the weld current and make
another weld with the programmed weld schedule.
In case the R Drop is low – Increase the weld current and
make another weld with the programmed weld schedule.
In case R Drop is high – Decrease the weld current and make
another weld with the programmed weld schedule.
Highlight the
selected weld
spots. Right
click and select
“Compare with
Each Other”. All
the welds
selected will
now be overlaid
in one weld
graph window. Note: “Create
Reference”
button is only
available
AFTER the
Average
Resistance
curve is
generated.
Single click on the
“Avg. Res” button in
the lower right
corner of the weld
graph window.
Single click on the
“Create Reference”
button. The
average resistance
curve is now used
for the Reference
weld.
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4. DUPLICATING
A REFERENCE
WELD
B In the timer Editor tab, select “Reference Program” from the
Timer Data Type drop down menu.
C Select the Reference Number to copy. (Weld spot made on the
same metal stack-up with the same current, time and gun
pressure)
NOTE: When duplicating
schedules any associated
reference welds are not
automatically copied and have
to be duplicated as a separate
function step. This function is
annunciated with a reminder
pop-up box when duplicating
schedules.
D Single click on the “Duplicate” button.
E A drop down menu will be displayed. Select the Reference
Program to copy to. Then, press “OK” to save the reference
weld.
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5. DOWNLOAD A
REFERENCE WELD
B In the timer Status Screen, select Download: File To Timer.
C A pop-up window will appear. Select the backup file. Then Click
“Open”.
D Uncheck all data types by clicking the Timer Data check box.
E Expand the Reference Record folder by clicking the + icon.
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F Select the desired reference record and click OK.
G A pop-up window will display the download process followed by
“Transfer Complete” message. Click OK to acknowledge.
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EXAMPLES OF ACCEPTABLE REFERENCE RESISTANCE CURVE:
Plain Steel: 0.7mm to 0.7mm bare mild, R Drop = 45.8
High Strength Steel: 1.25mm to 1.25mm DP780, R Drop = 37.0
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Preheat and Pulsing: 1.6mm to 1.6mm BORON, R Drop= 40.5
Preheat: 0.7mm HDG / 1.5mm HDG / 1.5mm HDG (all MILD), R Drop = 22.8
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BEGIN RAFT
ADAPTIVE
WELDING
B Start by selecting the weld schedule to edit. Click on the Editor
tab which will open a drop down menu. Select Schedule.
C Select the schedule number
Verify the AdaptQ™ function is inserted in each weld schedule
NOTE: If the intended for Adaptive. Default values are programmed.
AdaptQ function is
not inserted in the “ADAPTQ MODE = 0 RATE =100% WSLIDE = 100%”
weld schedule,
when the schedule RATE and WSLIDE are initially set to 100%
is executed, the
message D Ensure the High & Low Current Limit Windows in the Setup
“Thickness not Parameters are set to the appropriate percentage of the target
programmed” will current for the welding application. This also sets the adaptive
be displayed in the
current window.
Status tab of the
RAFT Gateway.
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• HIGH CURRENT LIMIT WINDOW% - 20 RANGE (1-99)
Constant Current Mode: A HIGH CURRENT LIMIT fault is generated
when the current exceeds (programmed value + stepper boost) x
setup percentage.
Example: Programmed current in schedule: 8,800 A
- Stepper Boost: 200 A
- High Current Limit Window% = 20
The fault is generated if current exceeds 9,000 x 120% = 10,800 A.
Adaptive Mode: Half of the percentage set in this parameter applied
to the programmed weld schedule current determines the high
current operating limit of the adaptive algorithm.
Example: Programmed current in schedule: 9,000 A
- High Current Limit Window% = 20
AdaptQ High Current Limit = 9,000 x 110% = 9,900 A.
• LOW CURRENT LIMIT WINDOW%- 20 RANGE (1-99)
Constant Current Mode: A LOW CURRENT LIMIT fault is generated
when the current falls under (programmed value + stepper boost) x
setup percentage.
Example: Programmed current in schedule: 8,800 A
- Stepper Boost: 200 A
- Low Current Limit Window% = 20
The fault is generated if current is less than 9,000 x 80% = 7,200 A.
Adaptive Mode: Half of the percentage set in this parameter applied
to the programmed weld schedule current determines the low
current operating limit of the adaptive algorithm.
Example: Programmed current in schedule: 9,000 A
- Low Current Limit Window% = 20
AdaptQ Low Current Limit = 9,000 x 90% = 8,100 A.
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TUNING THE Follow the procedure below to tune the RATE% and WSLIDE%
ADAPTIVE WELD parameters in the main adaptive function ADAPTQ MODE=1
SCHEDULE RATE=100% WSLIDE=100%.
RATE: Range = (95-105); Default = 100
RATE modifies the current reaction levels (aggressiveness) of the
Adaptive system.
WHEN TO ADJUST RATE%
DECREASE RATE (BELOW 100%):
• When the adaptive current increase causes expulsion in
the first half of the weld time.
• Reduce the RATE by 1%, maximum 2% at a time and
observe the effect of the change.
• If RATE = 95 and no improvement is detected, the Refer-
ence weld for that spot is “too hot” and must be re-done
using a lower current value.
INCREASE RATE (ABOVE 100%):
• When the weld has NO expulsion and weld time is
extended by more than 10% of the Reference Weld time.
• Increase RATE by 1%, maximum 2% at a time and
observe the effect of the change.
• If RATE = 105 and no improvement is noticed, the Refer-
ence weld for that spot is “too cold” and must be re-
done using a higher current value.
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WSLIDE: Range = (95-105); Default = 100
WSLIDE adjusts the adaptive weld time by modifying the Reference
Resistance Drop and the Reference Total Energy targets.
When to adjust WSLIDE%:
DECREASE (below 100%)
When ALL the following conditions are true:
Tear down inspection shows oversized nuggets
Welds have no expulsion during the reference weld time
Weld time is extended by more than 10% of the reference weld
time
• Decreasing WSlide% will reduce time extension by
lowering target Resistance drop and target energy.
• It will also reduce the nugget size, which is why the
change MUST be validated by tear down inspection.
INCREASE (above 100%)
When tear down report shows nugget size approaching minimum
size.
• Increasing WSlide will increase the adaptive nugget size
by raising the target for Resistance drop and Energy.
• Increasing WSlide will also extend the weld time.
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SOFTQ OVERVIEW SOFTQ is a RAFTTM feature that alerts the weld engineer/maintenance
staff when the weld process has changed. Examples of process change
include missing part, extra part, changes in water cooling, tip dress
cutter failure, tooling wear, etc.
SOFTQ uses a defined benchmark of the welding system to analyze
the weld process.
The SOFTQ benchmark is created by the weld engineer from known
good production weld data.
The benchmark is created through an automated feature of data
processing to provide production faults and maintenance alerts based
on SPC trends.
WHAT IS THE SOFTQ BENCHMARK?
The weld engineer selects the group of welds from which the
benchmark will be created. This group of welds should include all the
“normal” disturbances, i.e. cap wear, part placement and fit-up
variations.
When the benchmark is created, it includes parameters such as
Current, Resistance, Secondary Voltage, Energy, Heat, C-factor,
Tooling Integrity (TI), weld time, Process Integrity (PI) and Nugget
Integrity (NI).
The automated process of creating the benchmark puts intelligent
limits on all of these parameters. These limits can also be manually
adjusted for specific conditions.
NOTE: SOFTQ functions with both constant current and adaptive
welding modes. For SOFTQ to work, Reference Welds must be taken
for each weld schedule.
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PROCESS Process Integrity (P-Integrity) is a percentage value provided post
INTEGRITY (PI) weld, which represents the quality of the last weld as compared to
the Reference Weld. Process Integrity also identifies weld nuggets,
which may be undersized based on a lower percentage.
Process Integrity values benefit the user because normal Constant
Current values cannot indicate if the weld control created enough
heat to form a good weld nugget. Constant Current welding only
identifies the output of the weld control. Process Integrity values
allow the user to identify a relationship between last weld and the
ideal weld nugget created during the Reference Weld.
The AdaptQ module examines the characteristics of the Reference
Weld and compares that to the weld in progress. As variations in
characteristics are detected, the AdaptQ module compensates by
adjusting the current, energy and time of the weld in progress. Once
the weld is completed, the SoftQ module analyzes the performance of
the AdaptQ module and calculates a Process Integrity.
The PI value is a percentage of the weld, which is within the process
envelope as setup in the RAFTTM Gateway software.
The range of PI values are between 0% and 100%:
• A lower percentage represents a cooler weld nugget.
• A higher percentage represents a hotter weld nugget.
The SoftQ module allows users to set limits for acceptable Process
Integrity values, as defined in SoftQ monitoring and trending within
the RAFTTM Gateway software.
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TOOLING Tooling Integrity (T-Integrity) is a percentage value provided post
INTEGRITY (TI) weld, which represents the electrical effort required to make the last
weld as compared to the status of the weld tooling when the
Reference Weld was made. As more welds are made, the resistance
characteristics of the weld tooling changes. The Tooling Integrity
percentage shifts as the weld tooling becomes more or less resistive
as compared to what the tooling characteristics were when the
Reference Weld was made.
The range of TI values are between 1% and 150%, where 100%
represents the tooling integrity of the reference weld.
• A lower percentage represents increased resistance of
the weld tooling.
• A higher percentage represents current shunting in the
weld tooling.
The SoftQ module allows users to set limits for acceptable Tooling
Integrity values, as defined in SoftQ monitoring and trending within
the RAFTTM Gateway software.
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NUGGET Nugget Integrity (N-Integrity) is a percentage value provided post
INTEGRITY (NI) weld, which represents a confidence level that the weld produced an
acceptable nugget.
NI is the result of a complex calculation that uses Resistance values (R
Drop, R Peak, R Graph), Heat, Energy, Weld Current and Time of both
the Reference and the last weld.
Due to the multitude of process variables involved, NI cannot be used
as an absolute nugget size indicator.
Example: The following assumption is FALSE -
If reference weld nugget diameter avg. was 6.0 mm, then a weld with
NI=120 will generate a 6.0 x 1.2 = 7.2 mm avg. diameter nugget.
In the tip life cycle of a stable welding process, typical NI values are
from 80% to 120%.
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RAFT TMMENU The RAFTTM Menu allows the user to view RAFTTM data and perform
(DEP-300S) certain RAFTTM functions. This feature is customer application specific
and may be inaccessible. For more information, see the DEP-300s
manual PN: M-035030.
To access the RAFTTM functions on the DEP-300s:
B Press Status Mode
C Press RAFT
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NOTE: The data
displayed in this menu
may vary depending
upon the customer's
application
requirements. For
application specific
information, consult
the weld processor
firmware manual.
The following options are available within the RAFTTM Menu by
pressing the corresponding keys, [F1] through [F5]:
This key returns the user back to the
previous Status Menu screen.
BACK
This key allows the user to copy the
RAFTTM Reference Weld data from one
REF COPY schedule to another.
This key allows the user to turn the
R Measure Mode ON or OFF.
R MEASURE
This key allows the user to turn the
Reference Mode ON or OFF.
REF OFF
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The following describes the data tags displayed in the RAFTTM Status
Menu:
NOTE: The data displayed in this menu may vary depending upon the
customers’ application requirements. For application specific
information, consult the weld processor Firmware Manual.
DATA TAG DESCRIPTION
SEQ# Sequence (schedule) number
Mode AdaptQ Mode ON/OFF (0=OFF, 1=ON)
ref h Total heat of the Reference Weld
h Total heat
exp cy The number of milliseconds since the
beginning of the weld at which expul-
sion was detected
PI Process Integrity
ref e Total energy of the Reference Weld
e Total energy
NI Nugget Integrity
TF Tool Factor: The C-Factor of the last 3/4
of the weld time, minus the blanking
period
TI Tooling Integrity
RA Average Resistance
RD Resistance Drop
RE End Resistance
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WELD DATA MENU The Weld Data Menu allows the user to view various Weld and
(DEP-300S) RAFTTM data values, which occurred during the last weld.
In the above example of the DEP-300s Weld Data Menu, the data
circled in blue is Constant Current and Percent of Available Volt-
Seconds weld data. The data circled in red is RAFTTM weld data.
The following describes the data tags displayed in the DEP menu:
WELD DATA
DATA TAG DESCRIPTION
bus V DC bus voltage (MAX, AVG, MIN)
Sec I Secondary current (MAX, AVG, MIN)
Pri I Primary current (MAX, AVG, MIN)
hfc High frequency cycles (inverter output)
ont On-time of the inverter in microseconds
%I Percent of available volt-seconds mea-
surement
cfactor C-Factor calculation
sch# Schedule number
lv Inverter DC bus voltage (updated fre-
quently)
cont# Contactor number
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RAFTTM DATA
DATA TAG DESCRIPTION
Mode AdaptQ Mode ON/OFF (0=OFF, 1=ON)
ref h Total heat of the Reference Weld
h Total heat
The number of cycles since the begin-
exp cy ning of the weld at which expulsion was
detected
The running adaptive current, as
Learned I learned by the adaptive algorithm, from
the last weld
PI Process Integrity
ref e Total energy of the Reference Weld
e Total energy
wslide Programmed WSLIDE from the AdaptQ
function
The estimated stack-up thickness based
thick on the resistance reading during the
weld.
NI Nugget Integrity
TI Tooling Integrity
RA The average resistance of the last 166
mid-frequency cycles
RD The resistance drop since the peak resis-
tance (RP)
osr Offset resistance as calculated for the
stepper group
rise time Number of MFDC half cycles to reach
current
% saturation Percent of MFDC half cycles terminated
by primary current
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RAFTTM SCHEDULE The following is a list of all the RAFTTM AdaptQ and SoftQ functions
FUNCTIONS that can be programmed in the weld schedule.
To find the corresponding function number to a RAFTTM function
below, see Ch. 13 Schedule Function List.
FUNCTION NAME DESCRIPTION
This function is inserted in the weld schedule when using the AdaptQ fea-
PORTABLE GUN MODE ture to weld various metal stack-up thicknesses with one schedule. This
function should be inserted before the weld function.
This function sets the percent of resistance drop at which an ADAPTQ GAP
CONDITION FAULT is set. This is used in applications where it is necessary to
GAP RULE RD=nn eliminate false gap detection. This function overrides the default percent-
age of resistance drop set in the software.
Range: 15-99%
Default = 15
This function is used to provide higher detailed data to the RAFTTM Gateway
DETAIL MODE network gateway software.
3T MODE This function allows more or less current to be added at the beginning of
the weld, based on the part resistance versus the reference weld resistance.
No current changes will occur until the end of the blanking time.
This function is added into the schedule when the operator knows that edge
welding will occur, but still wants to accept the integrity of the nugget. An
EDGE WELD edge weld results in a number of milliseconds of heat falling under the heat
of the reference weld. Adding this function into the schedule prevents the
Nugget Integrity (NI) from changing (typically decreasing) when this occurs.
This function should be inserted before the weld function.
This function is inserted in the weld schedule when welding advanced high
HIGH STRENGTH STEEL strength steels (tensile strength > 600MPa). Because high strength steels
MODE have a small current welding window, this function modifies the algorithm
so that the current increases gradually.
CONTROL: The percentage of resistance drop that is used to identify an
expulsion event.
EXP nnnn% CONTROL Range: 5-50%
nnn% HEAT nnn% Default = 9% for Robot Mode / 12% for Portable Gun Mode
ENERGY
HEAT: The percentage of heat to be applied after an expulsion occurs, based
on the reference heat.
Range: 50-150%
Default = 50%
ENERGY: The percentage of energy to be applied after an expulsion occurs,
based on the reference energy.
Range: 50-150%
Default = 50%
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FUNCTION NAME DESCRIPTION
TIME: Weld time in Cycles (CY).
Range: 0-99 CY
TIME: Weld time in Milliseconds (MSec)
Range: 0-9999 MSEC
CURRENT: Weld current in Amps (A).
Range: 0-99990
WINDOW: Resistance tolerance window n micro-ohms (uOHM).
TIP CHECK nn CY/IMP. Range: 0-99
nnnn0 A +/-nn uOHM This is a specialized Constant Current weld function, which is used after a tip
dress is performed to verify that the average resistance (RA) measurement
of the tip-to-tip weld is within a certain tolerance of the Master Offset Resis-
tance. This function is typically inserted into its own separate schedule,
which must have the same stepper group assigned to it as the schedule that
is to be validated. If the average resistance (RA) measurement falls outside
the tolerance window, a TIP RESISTANCE NOT IN WINDOW FAULT is gener-
ated.
For example: Assuming the Master Offset Resistance is 60 micro-ohms and
after the Tip Check weld was made, the tip-to-tip average resistance mea-
sured 50 micro-ohms. If the tolerance window was set to +/- 5 micro-ohms,
then a TIP RESISTANCE NOT IN WINDOW FAULT would be generated.
NOTE: For information regarding the setup of the Master Offset Resistance,
see AdaptQ Welding Startup Procedure above.
MODE: This parameter turns the RAFTTM AdaptQ module either ON or OFF
for the weld schedule it is inserted into.
Range: 0-1
1=Adaptive welding mode
ADAPTQ MODE=nn
0= Constant Current Mode
RATE=nnn%
RATE: Adjusts the current control levels of the adaptive weld. The default
WSLIDE=nnn%
value is 100%.
Range: 90-120%
WSLIDE: Adjusts the Reference Resistance Drop and the Reference Total
Energy target. The default value is 100%.
Range: 95-105%
NOTE: This function must be inserted in the weld schedule prior to the
weld function and is typically the first function in the schedule.
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FUNCTION NAME DESCRIPTION
IMX (Current Max): Sets the maximum secondary current limit for the adap-
tive weld (in amps).
Range:0-25,500A
IMN (Current Min): Sets the minimum secondary current limit for the adap-
tive weld (in amps).
Range: 0-25,500A
TMX (Time Max): Sets the maximum limit the AdaptQ algorithm will extend
ADAPTQ IMX=nnnn0 the weld time (in milliseconds) to achieve the Reference Weld energy and
IMN=nnnn0 TMX=nn produce a good weld.
CY Range: 0-60 CY
Range: 0-1000 MS
Programming Example:
ADAPTQ IMX=8000 IMN=7000 TMX=30 CY
WELD 15 CY. 7500 AMPS
The AdaptQ algorithm will automatically compensate by staying within a
window of 7000-8000 amps, while maintaining the Reference Weld energy.
The algorithm will also limit the weld time with the minimum being the tar-
get weld time of 15 CY and the maximum not exceeding 30 CY as pro-
grammed in the TMX parameter.
NOTE 1: When this function is used in the weld schedule, the TMX parame-
ter overrides the “global” ADAPTQ MAX TIME LIMIT setup parameter.
NOTE 2: This function must be inserted in the weld schedule prior to the
weld function.
Range: 0-2
ROBOT MODE=nn 0= Disabled
ROBOT MODE=1: Designed for very thin stack-ups 1.4 mm or below.
ROBOT MODE=2: Designed for materials with heavy coatings and higher tip
contamination. After 100 welds, the starting current of the schedule is auto-
matically increased and the adaptive current decrease is limited.
RAFT TM SETUP PARAMETERS
DESCRIPTION RANGE DEFAULT
ADAPTQ MAX TIME LIMIT (ms)
This parameter sets the maximum limit for the adaptive weld time.
When the weld time reaches the programmed value:
• The adaptive weld is terminated 0 to 1000 1000
• The ADAPTQ WELD AT TIME MAX LIMIT condition is generated
(Fault/Alert/none)
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RAFTTM FAULT DIAGNOSTICS
PROGRAMMABLE/
FAULT NON- POSSIBLE CAUSE SOLUTIONS
PROGRAMMABLE
Occurs when: 1 Verify welding on the correct metal
1 a tip-to-tip weld is made in stack-up and not tip to tip.
adaptive mode (AdaptQ
ADAPTQ FAULT/ALERT/NONE Mode=1). 2 Verify Offset Resistance is correct. If
TIP TO not, a new R Measure may need to be
TIP WELD DEAFAULT: ALERT 2 The AdaptQ algorithm mea- done.
sured an average resistance
value (RA) within 20 micro-
ohms of the R Measure (offset)
resistance.
Occurs when the voltage sense Verify the voltage sense wires coming
wires that run between the gun from the weld gun are properly con-
tips and the weld processor are nected to the weld processor.
ADAPTQ either broken, loose or discon-
TIP VOLT FAULT/ALERT/NONE nected.
WIRE
BROKEN DEAFAULT: FAULT Alert/ None levels are only avail-
able for Constant Current weld-
ing. For an adaptive mode weld,
the Fault level will be generated
even when this parameter is set
as Alert/ None.
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PROGRAMMABLE/
FAULT NON- POSSIBLE CAUSE SOLUTIONS
PROGRAMMABLE
1 Occurs when function #47 Determine what has changed in the
(ADAPTQ IMX=nnnn0 welding process from when the refer-
IMN=nnnn0 TMX=nnnnMS) Is ence weld was made and return it back
used in the weld schedule and to the conditions at the time of the Ref-
the AdaptQ algorithm erence Weld.
extended the weld time to the
maximum limit (TMX) that was Compare the last weld graph to the ref-
programmed. erence weld:
• Occurs when the AdaptQ algo- The last weld current should always
ADAPTQ FAULT/ALERT/NONE rithm extended the weld time start at the reference weld current
WELD AT to the maximum limit that is value; if the starting value is visibly
TIME programmed into the ADAPTQ lower, ensure the programmed current
MAX DEFAULT: FAULT MAX TIME LIMIT in the Setup matches the current of the reference
LIMIT Parameters. weld.
If there is a significant deviation in
the Resistance curve, answer the follow-
ing questions to find the cause of the
process change:
• Was the weld spot moved from the
original setup position?
• Was the position of the voltage sense
wires changed as a result of mainte-
nance work?
If so, the R Measure needs to be
redone since the resistance of the
tool might have changed.
• Is the metal stack-up correct?
• Is the gun pressure correct?
• Is the turn ratio setting correct?
• Are the weld caps worn?
• Are the tips properly dressed?
Inspect gun condition, ensure voltage
sense wires connections are not loose.
• Inspect cooling tubes for weld tips.
If the cause of the change in conditions
cannot be found, take a new Reference
weld for that spot.
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PROGRAMMABLE/
FAULT NON- POSSIBLE CAUSE SOLUTIONS
PROGRAMMABLE
Occurs at the beginning of an Verify metal fit-up is correct. If a gap is
ADAPTQ Adaptive Weld and the AdaptQ present and can not be corrected, then
GAP FAULT/ALERT /NONE algorithm detects a resistance at add a pre-heat function in the weld
CONDI- DEFAULT: FAULT the weld interface greater than schedule before the adaptive weld func-
TION 350 micro-ohms. tion.
ADAPTQ Occurs if a Reference Weld was Perform a Reference Weld for the
NO REF- Non- not performed prior to executing appropriate metal stack-up.
ERENCE Programmable an Adaptive Weld.
WELD DEFAULT: FAULT
Occurs if the AdaptQ algorithm
detects an R Measure (offset)
ADAPTQ Non- resistance check had never been Perform an R Measure for the appropri-
R MEA- Programmable made for the assigned stepper ate weld gun, or assign the correct step-
SURE group (gun). This fault can occur per/ group.
DEFAULT: FAULT in either Reference or Adaptive
mode.
Occurs when: 1 Verify the window around the Master
Offset is correct.
1 function #43 (TIP CHECK nn CY.
nnnn0 A +/-nn uOHM) is used 2 Verify the tip dresser is functioning
in the weld schedule and the properly and dressing the caps cor-
TIP average resistance (Ra) mea- rectly.
RESIS- FAULT/ALERT surement of the last tip-to-tip
TANCE weld falls outside the parame- • Is the tip dresser cleaning the tips
NOT IN DEFAULT: FAULT ter programmed in the toler- properly?
WINDOW ance window (+/-nn).
• Is the dresser blade spinning properly?
• Is the correct pressure being applied
to the dresser blades?
• Is the weld gun tip alignment correct
to the dresser blades?
• Are the dresser blades worn?
• Are the correct caps being used?
If all the above is correct, then most
likely the R Measure is bad and needs to
be re-done.
REFER- Occurs after 10 consecutive
ENCE FAULT/ALERT /NONE welds are made while Reference Turn Reference Mode OFF in the
MODE Mode is turned on. This alert is RAFTTM Gateway software.
ON DEFAULT: ALERT set as a reminder to the operator
that Reference Mode is still on.
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PROGRAMMABLE/
FAULT NON- POSSIBLE CAUSE SOLUTIONS
PROGRAMMABLE
Occurs when the SOFTQ level is
setup and enabled for current, 1 In Adaptive Mode, verify the SOFTQ
and the average secondary cur- current hard limit window is set cor-
rent exceeds the SOFTQ hard rectly for the High and Low Current
limit window (either high or Limit Windows in the Setup Parame-
low). ters or the ADAPTQ IMX IMN Function
in the weld schedule.
NOTE: Applies only if the SOFTQ
SOFT Q FAULT/ALERT Fault Enable check box is 2 In Constant Current Mode, verify the
CURRENT enabled in the RAFTTM Gate- SOFTQ current hard limit window is
DEFAULT: ALERT way software. set correctly for the linear current
stepper assigned to the weld sched-
ule.
3 If the SOFTQ Current Fault occurs in
conjunction with a Current Regulation
or Low Current Limit Fault, then fol-
low the troubleshooting procedure
for the respective fault in the manual.
1 Verify the SOFTQ resistance hard limit
window is set correctly for the weld
Occurs when the SOFTQ level is schedule’s total workpiece resistance.
setup and enabled for resistance,
and the average resistance 2 Verify nothing changed in the weld
exceeds the SOFTQ hard limit tooling:
window (either high or low). • Check for proper tip dress.
SOFTQ FAULT/ALERT • Confirm the RMeasure value.
RESIS- NOTE:
TANCE DEFAULT: ALERT Applies only if the SOFTQ Fault If no workpiece is in the gun during
Enable check box is enabled in Adaptive Mode, the SOFTQ Resistance
the RAFT Gateway software. Fault will occur in conjunction with an
ADAPTQ Tip to Tip Weld Fault.
1 Verify the SOFTQ secondary voltage
hard limit window is set correctly for
Occurs when the SOFTQ level is the weld schedule’s total workpiece
setup and enabled for second- resistance.
ary voltage, and the average sec-
ondary voltage exceeds the 2 Verify nothing changed in the weld
SOFTQ hard limit window (either tooling:
high or low). • Check for proper tip dress.
SOFTQ FAULT/ALERT • Confirm the RMeasure value.
SEC V NOTE: Applies only if the SOFTQ
DEFAULT: ALERT Fault Enable check box is If no workpiece is in the gun during
enabled in the RAFTTM Gateway Adaptive Mode, the SOFTQ Sec V Fault
will occur in conjunction with an
software.
ADAPTQ Tip to Tip Weld Fault.
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PROGRAMMABLE/
FAULT NON- POSSIBLE CAUSE SOLUTIONS
PROGRAMMABLE
1 Verify the SOFTQ energy hard limit
window is set correctly to include all
the data in one tip dress or cap life (as
Occurs when the SOFTQ level is applicable).
setup and enabled for energy,
and the average energy exceeds 2 Verify the workpiece is in the gun. If
the SOFTQ hard limit window no workpiece is in the gun, the SOFTQ
SOFTQ FAULT/ALERT (either high or low). ENERGY fault will occur in conjunction
ENERGY with an ADAPTQ TIP TO TIP WELD
DEFAULT: ALERT NOTE: Applies only if the SOFTQ FAULT.
Fault Enable check box is
enabled in the RAFTTM Gateway 3 In Adaptive Mode- verify the weld
software. time is not being extended due to
excessive wear on the weld caps:
• Open up the windows.
• Decrease RATE and WSLIDE where
applicable.
1 Verify the SOFTQ heat hard limit win-
dow is set correctly to include all the
Occurs when the SOFTQ level is data in one tip dress or cap life (as
setup and enabled for heat, and applicable).
the average heat exceeds the
FAULT/ALERT SOFTQ hard limit window (either 2 Verify the workpiece is in the gun. If
SOFT Q high or low). no workpiece is in the gun, the SOFTQ
HEAT DEFAULT: ALERT Heat Fault will occur in conjunction
NOTE: with an ADAPTQ TIP TO TIP WELD
Applies only if the SOFTQ Fault FAULT.
Enable check box is enabled in
the RAFTTM Gateway software. 3 In Adaptive Mode, verify the weld
time is not being extended due to
excessive wear on the weld caps:
• Open up the windows.
• Decrease RATE and WSLIDE where
applicable.
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PROGRAMMABLE/
FAULT NON- POSSIBLE CAUSE SOLUTIONS
PROGRAMMABLE
1 Verify the SOFTQ C-factor hard limit
window is set correctly for the data
Occurs when the SOFTQ level is set.
setup and enabled for c-factor,
and the average c-factor exceeds 2 Verify there is no slag build-up on the
SOFTQ FAULT/ALERT the SOFTQ hard limit window gun, shorts between transformer con-
C DEFAULT: ALERT (either high or low). nections or defective diodes in the
FACTOR transformer secondary since these
NOTE: Applies only if the SOFTQ may lead to a High C-factor.
Fault Enable check box is
enabled in the RAFTTM Gate- 3 Look for any resistance changes in the
way software. secondary of the weld tooling. Loose,
frayed or incorrect length shunts;
loose transformer connections; worn
transformer cables; bad or incorrect
weld caps are all causes for Low C-fac-
tor.
1 Verify the SOFTQ T-Integrity hard limit
window is set correctly for the data
Occurs when the SOFTQ level is set.
setup and enabled for T-Integrity,
and the average T-Integrity 2 Verify there is no slag build-up on the
exceeds the SOFTQ hard limit gun, shorts between transformer con-
window (either high or low). nections or defective diodes in the
SOFTQ FAULT/ALERT transformer secondary since these
T-INTEG- NOTE: Applies only if the SOFTQ may lead to a High TI.
RITY DEFAULT: ALERT Fault Enable check box is
enabled in the RAFTTM Gate- 3 Look for any resistance changes in the
way software. secondary of the weld tooling. Loose,
frayed or incorrect length shunts;
loose transformer connections; worn
transformer cables; bad or incorrect
weld caps are all causes for Low TI.
4 Check for proper tip dress.
5 Confirm the RMeasure value.
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PROGRAMMABLE/
FAULT NON- POSSIBLE CAUSE SOLUTIONS
PROGRAMMABLE
1 Verify the SOFTQ weld time hard limit
window is set correctly under normal
conditions.
Occurs when the SOFTQ level is
setup and enabled for weld time, 2 In Adaptive Mode, verify the RATE or
and the average weld time WSLIDE parameters are not set incor-
exceeds the SOFTQ hard limit rectly.
SOFTQ FAULT/ALERT window (either high or low).
WELD 3 Verify there are no changes in the
TIME DEFAULT: ALERT NOTE: welding process or any part distur-
Applies only if the SOFTQ Fault bances that would cause weld time to
Enable check box is enabled in be extended.
the RAFTTM Gateway software.
4 The only way a SOFTQ Weld Time Fault
can occur in Constant Current Mode is
if the weld time is changed and is lon-
ger than it was when the SOFTQ weld
time hard limit window was set.
1 Verify the SOFTQ P-Integrity hard limit
window is set correctly under normal
Occurs when the SOFTQ level is conditions.
setup and enabled for P-Integ- 2 Verify the process envelope is set up
rity, and the average P-Integrity correctly in the RAFTTM Gateway soft-
exceeds the SOFTQ hard limit ware.
SOFTQ P- FAULT/ALERT window (either high or low).
INTEG- 3 If a problem still exists, then it is
RITY DEFAULT: ALERT NOTE: caused by a workpiece disturbance:
Applies only if the SOFTQ Fault • Tooling disturbance.
Enable check box is enabled in • Part disturbance, i.e. excessive gap,
the RAFTTM Gateway software. stack-up change, poor tip dressing,
etc.
Occurs when the SOFTQ level is 1 Verify the SOFTQ N-Integrity hard limit
setup and enabled for N-Integ- window is set correctly under normal
rity, and the average N-Integrity conditions.
exceeds the SOFTQ hard limit
SOFTQ N- FAULT/ALERT window (either high or low). 2 Verify a part disturbance doesn’t exist,
INTEG- NOTE: i.e. excessive gap, stack-up change,
RITY DEFAULT: ALERT Applies only if the SOFTQ Fault poor tip dressing, etc.
Enable check box is enabled in
the RAFTTM Gateway software.
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PROGRAMMABLE/
FAULT NON- POSSIBLE CAUSE SOLUTIONS
PROGRAMMABLE
Occurs when the SOFTQ level is 1 Verify the SOFTQ current trend limit
setup and enabled for current, window is set correctly under normal
and the number of exceptions conditions.
that occurred outside the SOFTQ
trend limit window (either high 2 Verify the Sample Size parameter is
SOFTQ or low), exceeded the trend limit set correctly for each weld schedule in
CUR- FAULT/ALERT while within the trend sample the RAFTTM Gateway software.
RENT size.
TREND DEFAULT: ALERT 3 Verify the Exceptions parameter is set
NOTE 1: correctly for each weld schedule in
Applies only if the SOFTQ Trend the RAFTTM Gateway software.
Enable check box is enabled in
the RAFTTM Gateway software. 4 If the SOFTQ Current Trend Fault
occurs in conjunction with a Current
NOTE 2: Regulation or Low Current Limit Fault,
Normally, the trend window is then follow the troubleshooting pro-
set inside the fault limit win- cedure for the respective fault in the
dow. manual.
When the value of a parameter
falls outside the fault window,
both fault and trend conditions
are generated,
Example:
SOFTQ CURRENT
SOFTQ CURRENT TREND
The trend conditions are gener-
ated independently only when a
parameter value is:
> than trend limit
< than fault limit
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PROGRAMMABLE/
FAULT NON- POSSIBLE CAUSE SOLUTIONS
PROGRAMMABLE
1 Verify the SOFTQ resistance trend limit
window is set correctly under normal
conditions.
2 Verify the Sample Size parameter is
Occurs when the SOFTQ level is set correctly for each weld schedule in
setup and enabled for resistance, the RAFTTM Gateway software.
SOFTQ and the number of exceptions
RESIS- FAULT/ALERT that occurred outside the SOFTQ 3 Verify the Exceptions parameter is set
TANCE trend limit window (either high correctly for each weld schedule in
TREND DEFAULT: ALERT or low), exceeded the trend limit the RAFTTM Gateway software.
while within the trend sample
size. 4 Verify nothing changed in the weld
tooling:
NOTE: Applies only if the SOFTQ • Check for proper tip dress.
Trend Enable check box is
• Confirm the RMeasure value.
enabled in the RAFTTM Gate-
way software. 5 If no workpiece is in the gun during
Adaptive Mode, the SOFTQ Resistance
Trend Fault will occur in conjunction
with an ADAPTQ TIP TO TIP WELD
FAULT.
1 Verify the SOFTQ secondary voltage
trend limit window is set correctly
under normal conditions.
Occurs when the SOFTQ level is 2 Verify the Sample Size parameter is
setup and enabled for second- set correctly for each weld schedule in
ary voltage, and the number of the RAFTTM Gateway software.
exceptions that occurred out-
SOFTQ side the SOFTQ trend limit win- 3 Verify the Exceptions parameter is set
SEC V FAULT/ALERT dow (either high or low), correctly for each weld schedule in
TREND exceeded the trend limit while the RAFTTM Gateway software.
DEFAULT: ALERT within the trend sample size.
4 Verify nothing changed in the weld
NOTE: Applies only if the SOFTQ tooling:
Trend Enable check box is • Check for proper tip dress.
enabled in the RAFTTM Gate- • Confirm the RMeasure value.
way software.
5 If no workpiece is in the gun during
Adaptive Mode, the SOFTQ Sec V
Trend Fault will occur in conjunction
with an ADAPTQ TIP TO TIP WELD
FAULT.
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PROGRAMMABLE/
FAULT NON- POSSIBLE CAUSE SOLUTIONS
PROGRAMMABLE
1 Verify the SOFTQ energy trend limit
window is set correctly under normal
conditions.
Occurs when the SOFTQ level is
setup and enabled for energy, 2 Verify the Sample Size parameter is
SOFTQ FAULT/ALERT and the number of exceptions set correctly for each weld schedule in
ENERGY that occurred outside the SOFTQ the RAFTTM Gateway software.
TREND DEFAULT: ALERT trend limit window (either high
or low), exceeded the trend limit 3 Verify the Exceptions parameter is set
while within the trend sample correctly for each weld schedule in
size. the RAFTTM Gateway software.
NOTE: 4 Verify the workpiece is in the gun. If
Applies only if the SOFTQ Trend no workpiece is in the gun, the SOFTQ
Enable check box is enabled in Energy Trend Fault will occur in con-
the RAFTTM Gateway software junction with an ADAPTQ TIP TO TIP
WELD FAULT.
5 In Adaptive Mode, verify the weld
time is not being extended due to
excessive wear on the weld caps:
• Open up the windows.
• Decrease RATE and WSLIDE where
applicable.
1 Verify the SOFTQ heat hard limit win-
dow is set correctly to include all the
data in one tip dress or cap life (as
Occurs when the SOFTQ level is applicable).
SOFTQ setup and enabled for heat, and
HEAT FAULT/ALERT the average heat exceeds the 2 Verify the workpiece is in the gun. If
TREND SOFTQ hard limit window (either no workpiece is in the gun, the SOFTQ
DEFAULT: ALERT high or low). Heat Fault will occur in conjunction
with an ADAPTQ TIP TO TIP WELD
NOTE: FAULT.
Applies only if the SOFTQ Trend
Enable check box is enabled in 3 Verify the Sample Size parameter is
the RAFTTM Gateway software. set correctly for each weld schedule in
the RAFT Gateway software.
4 In Adaptive Mode, verify the weld
time is not being extended due to
excessive wear on the weld caps:
• Open up the windows.
• Decrease RATE and WSLIDE where
applicable.
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PROGRAMMABLE/
FAULT NON- POSSIBLE CAUSE SOLUTIONS
PROGRAMMABLE
1 Verify the SOFTQ C-factor trend limit
window is set correctly under normal
conditions.
Occurs when the SOFTQ level is
setup and enabled for c-factor, 2 Verify the Sample Size parameter is
and the number of exceptions set correctly for each weld schedule in
SOFTQ C FAULT/ALERT that occurred outside the SOFTQ the RAFTTM Gateway software.
FACTOR trend limit window (either high
TREND DEFAULT: ALERT or low), exceeded the trend limit 3 Verify the Exceptions parameter is set
while within the trend sample correctly for each weld schedule in
size. the RAFTTM Gateway software.
NOTE: 4 Verify there is no slag build-up on the
Applies only if the SOFTQ Trend gun, shorts between transformer con-
Enable check box is enabled in nections or defective diodes in the
the RAFTTM Gateway software. transformer secondary since these
may lead to a High C-factor.
5 Look for any resistance changes in the
secondary of the weld tooling. Loose,
frayed or incorrect length shunts;
loose transformer connections; worn
transformer cables; bad or incorrect
weld caps are all causes for Low C-fac-
tor.
6 Check for proper tip dress.
7 Confirm the RMeasure value.
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PROGRAMMABLE/
FAULT NON- POSSIBLE CAUSE SOLUTIONS
PROGRAMMABLE
1 Verify the SOFTQ T-Integrity trend
limit window is set correctly under
normal conditions.
2 Verify the Sample Size parameter is
set correctly for each weld schedule in
Occurs when the SOFTQ level is the RAFTTM Gateway software.
setup and enabled for T-Integrity,
and the number of exceptions 3 Verify the Exceptions parameter is set
SOFTQ T- that occurred outside the SOFTQ correctly for each weld schedule in
INTEG- FAULT / ALERT trend limit window (either high the RAFTTM Gateway software.
RITY or low), exceeded the trend limit
TREND DEFAULT: ALERT while within the trend sample 4 Verify there is no slag build-up on the
size. gun, shorts between transformer con-
nections or defective diodes in the
NOTE: transformer secondary since these
Applies only if the SOFTQ Trend may lead to a High TI.
Enable check box is enabled in
the RAFTTM Gateway software. 5 Look for any resistance changes in the
secondary of the weld tooling. Loose,
frayed or incorrect length shunts;
loose transformer connections; worn
transformer cables; bad or incorrect
weld caps are all causes for Low TI.
6 Check for proper tip dress.
7 Confirm the RMeasure value.
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PROGRAMMABLE/
FAULT NON- POSSIBLE CAUSE SOLUTIONS
PROGRAMMABLE
1 Verify the SOFTQ weld time trend limit
window is set correctly under normal
conditions.
2 Verify the Sample Size parameter is
set correctly for each weld schedule in
Occurs when the SOFTQ level is the RAFTTM Gateway software.
setup and enabled for weld time,
and the number of exceptions 3 Verify the Exceptions parameter is set
that occurred outside the SOFTQ correctly for each weld schedule in
SOFTQ trend limit window (either high the RAFTTM Gateway software.
WELD FAULT / ALERT or low), exceeded the trend limit
TIME while within the trend sample 4 In Adaptive Mode, verify the RATE or
TREND DEFAULT: ALERT size. WSLIDE parameters are not set incor-
rectly.
NOTE: 5 Verify there are no changes in the
Applies only if the SOFTQ Trend welding process or any part distur-
Enable check box is enabled in bances that would cause weld time to
the RAFTTM Gateway software. be extended.
6 The only way a SOFTQ Weld Time
Trend Fault can occur in Constant Cur-
rent Mode is if the weld time is
changed and is longer than it was
when the SOFTQ weld time trend hard
limit window was set.
1 Verify the SOFTQ P-Integrity trend
limit window is set correctly under
normal conditions.
Occurs when the SOFTQ level is 2 Verify the Sample Size parameter is
setup and enabled for P-Integ- set correctly for each weld schedule in
rity, and the number of excep- the RAFTTM Gateway software.
tions that occurred outside the
SOFTQ trend limit window 3 Verify the Exceptions parameter is set
SOFTQ P- FAULT / ALERT (either high or low), exceeded correctly for each weld schedule in
INTEG- the trend limit while within the the RAFTTM Gateway software.
RITY DEFAULT: ALERT trend sample size.
TREND 4 Verify the process envelope is set up
correctly in the RAFTTM Gateway soft-
NOTE: Applies only if the SOFTQ ware.
Trend Enable check box is
enabled in the RAFTTM Gateway 5 If a problem still exists, then it is
software. caused by a workpiece disturbance:
• Tooling disturbance.
• Part disturbance, i.e. excessive gap,
stack-up change, etc.
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PROGRAMMABLE/
FAULT NON- POSSIBLE CAUSE SOLUTIONS
PROGRAMMABLE
1 Verify the SOFTQ N-Integrity trend
limit window is set correctly under
Occurs when the SOFTQ level is normal conditions.
setup and enabled for N-Integ-
rity, and the number of excep- 2 Verify the Sample Size parameter is
tions that occurred outside the set correctly for each weld schedule in
SOFTQ N- SOFTQ trend limit window the RAFTTM Gateway software.
INTEG- FAULT / ALERT (either high or low), exceeded
RITY the trend limit while within the 3 Verify the Exceptions parameter is set
TREND DEFAULT: ALERT trend sample size. correctly for each weld schedule in
the RAFTTM Gateway software.
NOTE: Applies only if the SOFTQ 4 Verify a part disturbance doesn’t exist,
Trend Enable check box is i.e. excessive gap, stack-up change,
enabled in the RAFTTM Gateway etc.
software.
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SCHEDULE The default function timing for Schedule Functions is in Cycles (CY). To
FUNCTIONS change the function timing to Milliseconds (MSEC), perform the
following steps on the DEP-300s:
NOTE: When switching
between Cycles to
Milliseconds or vice
versa. It is important
to go back and check
the timing on all
weld schedules since
the switch may not
change the weld
times.
Press Program Mode
When using a DEP
300s pay close
attention to the weld
times since it
displays only 2 digits
and any number
above 100 can be
erroneously
interpreted. For
example 112 Msec
from a Millisecond
mode may show up
as 12 Cycles in the
Cycle mode which if
not confirmed will
weld 112 cycles.
Press More
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Press Reload Options
Press the arrow key until the cursor is over
the Function Timing field.
Press ENTER
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A drop-down box will appear. Press the key until the
cursor is over the (MILLISECONDS) option.
Press ENTER
Press Execute.
This begins the process to
download the change to the weld
processor.
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The message “Do you want to RELOAD CONTROL information?”
will appear. Press Confirm
The message “Download Complete Power Cycle Required”
will appear. Re-cycle power on the weld control to
complete the process.
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SCHEDULE FUNCTIONS LIST
FUNC. CATEGORY
FUNCTION NAME
#
1 SQUEEZE nnnn CYCLES DELAY
2 COOL nnnn CYCLES DELAY
3 HOLD nnnn CYCLES DELAY
4 OFF nnnn CYCLES DELAY
5 INITIAL SQUEEZE nnnn CYCLES DELAY
6 “*”
7 WAIT nn CYCLES DELAY
8 PORTABLE GUN MODE RAFT™
9 “*”
10 “*”
11 “*”
12 “*”
13 GAP RULED = nn RAFT™
14 DETAIL MODE RAFT™
15 “*”
16 MOTOR CURR LIMITS HI = nnn ma LO = nnn ma SPECIAL
17 TIP DRESS TIME nnn SEC BLANK nnn MS SPECIAL
18 START TIP DRESS MOTOR CHECK SPECIAL
19 STOP TIP DRESS MOTOR CHECK SPECIAL
20 WELD nnnn CY/IMP nn %VS WELD
21 TEMPER nnnn CY/IMP nn %VS WELD
22 PREHEAT nnnn CY/IMP nn %VS WELD
23 POSTHEAT nnnn CY/IMP nn %VS WELD
24 PRE-WELD nnnn MS/IMP nn %VS WELD
25 “*”
26 3T MODE RAFT™
27 EDGE WELD RAFT™
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28 “*”
29 “*”
30 WELD nnnn CY/IMP nnnn0 AMPS WELD
31 TEMPER nnnn CY/IMP nnnn0 AMPS WELD
32 PREHEAT nnnn CY/IMP nnnn0 AMPS WELD
33 POSTHEAT nnnn MS/IMP nnnn0 AMPS WELD
34 PRE-WELD nnnn MS/IMP nnnn0 AMPS WELD
35 “*”
36 “*”
37 WELD nnn IMP HI = nnnn 0A LO - nnnn 0A WELD
38 “*”
39 EXP nnn% CONTROL nnn% HEAT nnn% ENERGY RAFT™
40 SLOPE nn CY/IMP nn%VS TO nn%VS SLOPE
41 “*”
42 “*”
43 TIP CHECK nnnn MS/IMP nnnn 0a =/-nn uOHM RAFT™
44 “*”
45 SLOPE nnnn CY/IMP nnn0 A TO nnn0 A SLOPE
46 ADAPTQ MODE =nn RATE =nnn% WSLIDE =nnn% RAFT™
47 ADAPTQ IMX =nnnn 0 IMN =nnnn 0 TMX =nnnn MS RAFT™
48 “*”
49 “*”
50 TURN ON VALVE nnnn I/O
51 TURN OFF VALVE nnnn I/O
52 TURN ON OUTPUT nn I/O
53 TURN OFF OUTPUT nnnn I/O
54 TURN ON PRESSURE SELECT nnnn I/O
55 TURN OFF PRESSURE SELECT nn I/O
56 TURN ON CONTACTOR SELECT nnnn I/O
57 TURN OFF CONTACTOR SELECT nnnn I/O
58 TURN ON WELD IN PROGRESS I/O
59 TURN OFF WELD IN PROGRESS I/O
60 IMPULSE= nnnn HEAT CY nnnn COOL CY WELD
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61 ABORT IF NO INITIATE FOR nn CYCLES I/O
62 REPEAT (AT NEXT FUNCTION) SPECIAL
63 TURN ON WELD COMPLETE I/O
64 TURN OFF WELD COMPLETE I/O
65 ISOLATION CONTACTOR DELAY = nnnn SEC. EXTEND
66 WAIT nnn CY INP #nn TO BE nn (0 = OFF 1 = ON) I/O
67 WAIT FOR INPUT #nn TO BE nn (0 = OFF 1 = ON) I/O
68 WAIT nnnn CY FOR PRESSURE SWITCH INPUT I/O
69 WAIT FOR PRESSURE SWITCH INPUT I/O
70 WAIT FOR WELD PROCEED I/O
71 SET VALVE nnn CYLINDER PRESSURE nnn PSI I/O
72 SET VALVE nnn TOUCH DOWN PRESSURE nnnn I/O
73 SET VALVE nn TIP DRESS PRESSURE nnn PSI I/O
74 WAIT nnn CY FOR PRESSURE ACHIEVED I/O
75 EXTEND UNTIL NO INITIATE EXTEND
76 SEC. CURR LIMITS: HI=nnnn0 LOW=nnnn0 SPECIAL
77 EXTEND WHILE INPUT #nnnn IS nn (0=OFF 1 = ON) EXTEND
78 TURN ON FORGE VALVE I/O
79 TURN OFF FORGE VALVE I/O
80 FORGE DELAY nnn MS I/O
81 TRANSFORMER TURNS RATIO nnnn:1 SPECIAL
82 LINEAR STEPPER #nn ASSIGNED (0 = OFF) SPECIAL
83 “*”
84 “*”
85 PROCESS WELD FAULTS SPECIAL
86 VERIFY CYLINDER # nnn IS OUT OF RETRACT I/O
87 “*”
88 TURN ON ISOLATION CONTACTOR I/O
89 TURN OFF ISOLATION CONTACTOR I/O
90 SET SPC OFFSET TO nnnn SPECIAL
91 SEND ALL SAMPLES UNTIL NEXT SPC OFFSET SPECIAL
92 C-FACTOR LIMIT: HI=nnnn LO=nnnn SPECIAL
93 TIP DRESS ADVANCE: GROUP nnnn - STEP nn SPECIAL
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94 EXTEND WELD IF LOW CURRENT LIMIT FAULT EXTEND
95 EXTEND WELD IF CURRENT LESS THAN nnnn0 EXTEND
96 “*”
97 ROBOT MODE =nn RAFT™
98 HIGH STRENGTH STEEL MODE RAFT™
99 GOTO SEQ#nnn SPECIAL
NOTE: Numbers with “*” appearing in the line, indicate no function is
assigned to that number. Unassigned function numbers are not
displayed.
DELAY FUNCTIONS Delay functions cause a delay (or wait) time to occur in the weld
schedule for a specified length of time. All delay functions essentially
perform the same function, but are assigned different names to
describe their purpose in the welding process. During delay functions,
weld current does not flow and I/O status does not change.
FUNC. # FUNCTION NAME CATEGORY
01 SQUEEZE nnnn CYCLES Squeeze time in cycles
02 COOL nnnn CYCLES Cool time in cycles
03 HOLD nnnn CYCLES Hold time in cycles
04 OFF nnnn MSEC OFF time in cycles
05 INITIAL SQUEEZE nnnn CYCLES Initial Squeeze time in cycles
07 WAIT nnnn CYCLES Wait time in cycles
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WELD FUNCTIONS WELD FIRING MODES
The purpose of a weld function is to deliver a specific amount of weld
current to the weld interface for a specific amount of time. The
WT6000 weld control uses two modes to supply regulated current to
the weld interface: Percent of Available Volt-Second Welding and
Constant Current Welding. See Ch. 9: Advanced Topics for more
information.
PERCENT OF AVAILABLE VOLT-SECOND WELD FUNCTIONS
In Percent of Available Volt-Second welding, the current value is
entered as a percentage (e.g. 50%, 75%, etc.)
CATEGORY
FUNC. # FUNCTION NAME
20 WELD nnnn CY. nn %VS Weld time in cycles
21 TEMPER nnnn CY. nn %VS Temper time in cycles
22 PREHEAT nnnn CY. nn %VS Pre-Heat time in cycles
23 POSTHEAT nnnn CY. nn%VS Post-Heat time in cycles
24 PRE-WELD nnnn CY. nn%VS Pre-Weld time in cycles
CONSTANT CURRENT WELD FUNCTIONS
In Constant Current welding, current value is entered as the actual
amount of secondary current required (e.g. 5,000A, 10,000A, etc.)
CATEGORY
FUNC. # FUNCTION NAME
30 WELD nnnn CY. nnnn0 AMPS Weld time in cycles
31 TEMPER nnnn CY. nnnn0 AMPS Temper time in cycles
32 PREHEAT nnnn CY. nnnn0 AMPS Pre-Heat time in cycles
33 POSTHEAT nnnn CY. nnnn0 AMPS Post-Heat time in cycles
34 PRE-WELD nnnn CY. nnnn0 AMPS Pre-Weld time in cycles
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MAIN WELD In the following Volt-Second Mode example, the processor will weld
FUNCTION (#20) for 20 cycles at 65% volt-seconds:
20 WELD 20 CY. 65%VS
MAIN WELD In the following Constant Current Mode example, the processor will
FUNCTION (#30) weld for 20 milliseconds at 10000A current:
30 WELD 20 MS. 10000 AMPS
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TEMPER, PRE HEAT, Temper, Pre-Heat, Post-Heat and Pre-Weld are material heating
POST HEAT AND functions and are inserted either before or after main weld functions
PRE WELD (#20 or #30). They all essentially perform the same function, but are
FUNCTIONS assigned different names to describe their purpose in the welding
process. These functions are not figured into the weld data collection
algorithm. For example:
Example 1: Using a Pre-Heat Function Before the Weld Function
32 PREHEAT 20 CY. 5000 AMPS
30 WELD 20 CY. 10000 AMPS
When the weld sequence is complete, the last weld data in the Weld
Data Menu will display 10,000 Amps. As mentioned above, the pre-
heat function is not figured in the weld data collection algorithm.
Example 2: Using two weld functions, with the first as a pre-heat
30 WELD 20 CY. 5000 AMPS
30 WELD 20 CY. 10000 AMPS
When the weld sequence is complete, the last weld data in the Weld
Data Menu will display 7,500 Amps. This is because when two or
more weld functions are used in the same weld schedule, the weld
data collection algorithm calculates the average current for all the
weld functions and displays the results.
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IMPULSE WELDING weld processor software G08300 offers two different methods of
FUNCTION pulsation (impulse) welding. The first method has NO-HEAT cool times
between the impulses and the second has LOW-HEAT cool times
between the impulses.
METHOD #1: IMPULSE WELDING WITH “NO-HEAT” COOL TIME:
In this method, the impulse instruction (function #60) is inserted in
the weld schedule before the main weld function (#20 or #30).
FUNC. # FUNCTION NAME DESCRIPTION
60 IMPULSE= nnnn HEAT CY nn COOL CY Impulse heat and cool times in cycles
Function #60 defines the length of the impulse heat time and the
length of the cool time between each impulse.
When this function is used in conjunction with the main weld
function (#20 or #30), the weld processor changes the weld function
to display impulses (IMP) rather than cycles (CY).
In the example below, the weld processor will weld (heat) for 10
cycles at 65% volt-seconds, then wait (cool) for 10 cycles. This heat
and cool impulse pattern will occur (4) times. As illustrated in the
timing chart, no current is flowing during the cool times.
60 IMPULSE= 10 HEAT CY 10 COOL CY
20 WELD 4 IMP 65%VS
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METHOD #2: IMPULSE WELDING WITH “LOW-HEAT” COOL TIME:
In this method, the impulse instruction (function #60) is inserted in
the weld schedule before Constant Current function #37 (WELD nnn
IMP HI=nnnn0 A LO=nnnn0 A).
FUNC. # FUNCTION NAME DESCRIPTION
60 IMPULSE= nnnn HEAT CY nn COOL CY Impulse heat and cool times in cycles
The number of weld impulses and the
37 WELD nnn IMP HI =nnn A LO =nnn 0 A amount of current during the impulse (HI)
and cool (LO) times.
Function #60 defines the length of the impulse heat time and the
length of the cool time after each impulse. Function #30 defines the
number of impulses and the amount of current during each impulse
and the LOW current during each cool time.
In the example below, the weld processor will weld (heat) for 10
cycles and then wait (cool) for 10 cycles. This heat and cool impulse
NOTE: Although
function #60 is pattern will occur (4) times at 10,000 Amps during each impulse and
typically used in 5000 Amps during each cool time.
conjunction with
main weld functions
(#20 or #30), it can
also be used before 60 IMPULSE= 10 HEAT CY 10 COOL CY
any weld or slope 37 WELD 4 IMP HI=10000 A LO=5000A
function.
NOTE: Function # 37 may not be available in certain software.
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SLOPE FUNCTIONS Slope functions are used when either a linear increase (Up-Slope) or
decrease (Down-Slope) in welding current is required over a specified
amount of time.
UP-SLOPE: Provides current at the first value and increases it to
the second value over the length of time specified.
DOWN-SLOPE: Provides current at the first value and decreases it to
the second value over the length of time specified.
Typically, Up-Slope functions are used before main weld functions
(#20 or #30) and Down-Slope functions are used after main weld
functions (#20 or #30).
SLOPE FUNCTION (VOLT-SECOND MODE)
FUNC. # FUNCTION NAME DESCRIPTION
40 SLOPE nn CY. nn%VS TO nn%VS Slope time in cycles from percent volt-second
1 (nn%VS) to percent volt-second 2 (nn%VS)
SLOPE FUNCTION (CONSTANT CURRENT MODE)
FUNC. # FUNCTION NAME DESCRIPTION
45 SLOPE nn MS. nnnn0 A TO nnnn0 A Slope time in milliseconds from current value
1 (nnnn0 A) to current value 2 (nnnn0 A)
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In the following up-slope weld example, the weld processor will begin
welding at 35% volt-seconds and increase to 65% volt-seconds over a
40 cycle time period. Then the processor will weld at 65% volt-
seconds for 20 cycles.
40 SLOPE 40 CY. 35%VS TO 65%VS
20 WELD 20 CY. 65%VS
NOTE: Just as the heat functions mentioned above, the slope functions are
not figured into the weld data collection algorithm. Therefore, their value is
not averaged into the last weld data viewed in the Weld Data Menu
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I/O FUNCTIONS I/O functions are used to verify the status of, change status of, or wait
for certain I/O points to change states before continuing with the
weld schedule.
There are two types of I/O Functions:
• Functions that interact with inputs
• Functions that interact with outputs
INPUT FUNCTIONS
FUNC. # FUNCTION NAME DESCRIPTION
This function monitors the Weld Initiate bit for the
number of cycles specified. If the Weld Initiate bit
61 ABORT IF NO INITIATE FOR nn CYCLES goes LOW anytime during this period, the weld
sequence will abort and a WELD INIITATE NOT
PRESENT FAULT will be generated.
This function waits the specified amount of
time (cycles) for the specified User Input bit
(1-6) to go either OFF (0) or ON (1). If the bit
does not go either OFF or ON during this
time period, a WELD PROCEED FAULT is
66 WAIT nnn CY INP #N TO BE n (0 =OFF 1 =ON) generated.
NOTE: If either function #66 or #67 are false
and the WELD PROCEED fault is set to FAULT
in the Setup Parameters, the weld processor
will execute the weld schedule in NOWELD
mode. If either function #66 or #67
are false and the WELD PROCEED fault is set
to ALERT in the Setup Parameters, the weld
processor will execute the weld schedule in WELD
mode.
67 WAIT FOR INPUT #n TO BE n (0 =OFF 1= ON) This function waits for the specified User Input bit
(1-6) to go either OFF (0) or ON (1). If the Weld Ini-
tiate input bit goes LOW before this occurs, a
WELD PROCEED FAULT is generated.
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This function waits for the specified amount of
68 WAIT nnnn CYFOR PRESSURE SWITCH INPUT time (milliseconds) for the Pressure Switch bit to
go HIGH. If the bit does not go HIGH during this
time period, a PRESSURE SWITCH FAULT is gener-
ated.
NOTE: If the Pressure Switch bit is LOW and the
PRESSURE SWITCH parameter is set to FAULT, the
weld processor will execute the weld schedule in
NO-WELD mode. If the Pressure Switch bit is LOW
and the PRESSURE SWITCH parameter is set to
ALERT, the weld processor will execute the weld
schedule in WELD mode
69 WAIT FOR PRESSURE SWITCH INPUT This function waits for the Pressure Switch bit to
go HIGH.
70 WAIT nnnn MS FOR WELD PROCEED INPUT This function waits for the specified amount of
time (milliseconds) for the Weld Proceed bit to go
HIGH. If the bit does not go HIGH during this time
period, a WELD PROCEED FAULT is generated.
NOTE: If the Weld Proceed bit is LOW and the
WELD PROCEED parameter is set to FAULT, the
weld processor will execute the weld schedule in
NO-WELD mode. If the Weld Proceed bit is LOW
and the WELD PROCEED parameter is set to ALERT,
the weld processor will execute the weld schedule
in WELD mode.
71 WAIT FOR WELD PROCEED This function waits for the Weld Proceed bit to go
HIGH.
72 SET VALVE n TOUCH DOWN PRESSURE nnnn This function sets the specified valve bit (1-2) to
PSI the specified touch down pressure in PSI.
NOTE: This function requires the optional Analog I/
O Module (AIOM) to be installed in the weld con-
trol.
73 SET VALVE n TIP DRESS PRESSURE nnnn PSI This function sets the specified valve bit (1-2) to
the specified tip dress pressure in PSI.
NOTE: This function requires the optional Analog I/
O Module (AIOM) to be installed in the weld con-
trol.
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74 WAIT nn MS FOR PRESSURE ACHIEVED This function waits for the number of milliseconds
specified for the cylinder pressure to be achieved.
If the pressure is not achieved during this time
period, a PRESSURE NOT ACHEIVED FAULT is gener-
ated.
NOTE 1: This function must be used after any set
pressure function. Otherwise, the weld processor
will not know if pressure was achieved before exe-
cuting the weld function.
NOTE 2: This function requires the optional Analog
I/O Module (AIOM) to be installed in the weld con-
trol.
79 WAIT nnnn MS FOR SYSTEM COOLING This function waits the specified amount of time
(milliseconds) for the System Cooling bit to go
HIGH. If the bit does not go HIGH during this time
period, a SYSTEM COOLING FAULT is generated.
86 TIP DRESS ADVANCE: GROUP nn - STEP n This function advances all the steppers assigned to
the specified GROUP number, to the specified STEP
number.
For example, if this function was programmed: TIP
DRESS ADVANCE: GROUP 02 - STEP 05, every step-
per assigned to Group #2 would advance to Step
#5.
NOTE: This function can advance several steppers
simultaneously. For example, your application may
use several different weld schedules to execute a
weld on the same tool, but those schedules may be
assigned to different steppers (to account for weld
variations). This function allows you to advance
every stepper assigned to a group, each time any
schedule completes a weld.
OUTPUT FUNCTIONS
FUNC. # FUNCTION NAME DESCRIPTION
50 TURN ON VALVE n Turn ON Valve bit (1-6).
51 TURN OFF VALVE n Turn OFF Valve bit (1-6).
52 TURN ON OUTPUT n Turn ON User Output bit (1-6).
53 TURN OFF OUTPUT n Turn ON User Output bit (1-6).
54 TURN ON PRESSURE SELECT n Turn ON Pressure Select bit (1-4).
55 TURN OFF PRESSURE SELECT n Turn OFF Pressure Select bit (1-4).
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56 TURN ON CONTACTOR SELECT n Turn ON Contactor Select bit (1-6)
57 TURN OFF CONTACTOR SELECT n Turn OFF Contactor Select bit (1-6)
58 TURN ON WELD IN PROGRESS Turn on Weld in Progress bit.
59 TURN OFF WELD IN PROGRESS Turn off Weld in Progress bit.
Turn on the Weld Complete bit.
63 TURN ON WELD COMPLETE NOTE: This function also processes weld
faults. For more information, see function
#85 PROCESS WELD FAULTS below.
64 TURN OFF WELD COMPLETE Turn off the Weld Complete bit.
78 TURN ON FORGE VALVE Turn on the Forge Valve bit.
79 TURN OFF FORGE VALVE Turn off the Forge Valve bit.
80 FORGE DELAY nnn MSEC Inserted in the weld schedule before function
#78 (TURN ON FORGE VALVE), this function
delays turning on the Forge Valve bit for the
number of milliseconds specified
88 TURN ON ISOLATION CONTACTOR Turn on the Isolation Contactor bit.
89 TURN OFF ISOLATION CONTACTOR Turn off the Isolation Contactor bit.
EXTEND FUNCTIONS Extend functions are used to extend a function under certain
conditions.
FUNC. # FUNCTION NAME DESCRIPTION
This function delays the opening of the isolation
contactor for the number of seconds specified, if
65 ISOLATION CONTACTOR DELAY = nn SEC. the Isolation Contactor Saver bit is HIGH.
75 EXTEND UNTIL NO INITIATE This function tells the processor to monitor the
status of the Weld Initiate bit and to repeat the
previous function in the weld schedule until the
Weld Initiate bit goes LOW.
This function tells the processor to monitor the
status of the specified input bit (1-6) and to extend
the previous function in the weld schedule while
77 EXTEND WHILE INPUT #n IS n (0=OFF 1 = ON) the specified input bit is either OFF (0) or ON (1).
NOTE: Repeat and Extend functions are mutually
exclusive. Do not use the Repeat function with any
Extend function in a weld schedule.
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This function tells the processor to extend the weld
function if a LOW CURRENT LIMIT FAULT occurs. An
EXTEND WELD FAULT is generated.
94 EXTEND WELD IF LOW CURRENT LIMIT FAULT
The weld function is extended only once. If the
desired current is not reached on the re-weld, a
LOW CURRENT LIMIT FAULT is generated.
NOTE: Repeat and Extend functions are mutually
exclusive. Do not use the Repeat function with any
Extend function in a weld schedule.
This function tells the processor to extend the weld
function if secondary current is less than the value
programmed (nnnn0).
The weld function is extended only once. If the
95 EXTEND WELD IF CURRENT LESS THAN nnnn0 desired current is not reached on the re-weld, an
EXTEND WELD FAULT is generated.
NOTE: Repeat and Extend functions are mutually
exclusive. Do not use the Repeat function with any
Extend function in a weld schedule
The following is an example of an extend function in a weld schedule:
30 WELD 20 CY. 5000 AMPS
75 EXTEND UNTIL NO INITIATE
NOTE: If the weld initiate input is removed before function #75
EXTEND UNTIL NO INITIATE is executed in the weld schedule, a WELD
INITIATE NOT PRESENT FAULT will occur and only 20 cycles of weld
time will be executed. Otherwise, the weld time would be extended
indefinitely until the weld initiate input is removed. This example is
how a seam weld is accomplished.
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SPECIAL FUNCTIONS Special functions are used to either create special conditions inside
the welding schedule, set local schedule features that over-ride global
setup parameters or to chain multiple weld schedules together.
FUNC. # FUNCTION NAME DESCRIPTION
16 MOTOR CURR LIMITS HI =nnnn Used in a tip dress schedule, this function sets the
HIGH and LOW current limits (in milliamps) for the
tip dress motor. For more information see "Tip
Dress Schedule Setup" in Ch 9 Advanced Topics.
NOTE: This function must be inserted in the sched-
ule before function #18 (START TIP DRESS MOTOR
CHECK).
17 TIP DRESS TIME nn SEC BLANK nnnn ms Used in a tip dress schedule, this function tells the
weld processor to start measuring the current
draw of the tip dress motor for the number of sec-
onds specified. In addition, it identifies the blank-
ing time. This is the time period at the start of the
function, during which the motor current is not
measured. For more information see "Tip Dress
Schedule Setup" in Ch 9 Advanced Topics.
NOTE 1: This function must be inserted in the
schedule after function #18 (START TIP DRESS
MOTOR CHECK).
NOTE 2: If the welding application requires func-
tion #63 (TURN ON WELD COMPLETE) to be used in
the tip dress schedule, function #17 must be
inserted before function #63 to ensure proper
measurement of the tip dress motor current.
18 START TIP DRESS MOTOR CHECK Used in a tip dress schedule, this function tells the
weld processor to turn the tip dress motor ON. For
more information see "Tip Dress Schedule Setup "
in Ch 9 Advanced Topics.
19 STOP TIP DRESS MOTOR CHECK Used in a tip dress schedule, this function tells the
weld processor to turn the tip dress motor OFF. For
more information see "Tip Dress Schedule Setup "
in Ch 9 Advanced Topics.
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This function monitors the status of the Weld Initi-
ate input bit. When the last function in the weld
schedule is complete, the weld processor checks
the status of the Weld Initiate input bit. If the bit is
HIGH, the weld processor will repeat the weld
schedule, starting at the first line following func-
tion #62. When the last function is again complete,
62 REPEAT (AT NEXT FUNCTION) the weld processor checks the status of the Weld
Initiate input bit. If the bit is still HIGH, the weld
processor repeats the weld schedule again, start-
ing at the first line following function #62.This
repeat loop will continue until the Weld Initiate
input bit goes LOW.
NOTE 1: This function should be placed in the weld
schedule before the squeeze function.
NOTE 2: Repeat and Extend functions are mutually
exclusive. Do not use the Repeat function with any
Extend function in a weld schedule.
This function assigns a static HI / LOW current limit
window in the “local” weld schedule only.
76 SEC. CURR LIMITS: HI=nnnn0 LOW=nnnn0
This function overrides the “Global” HI / LOW CUR-
RENT LIMIT WINDOW parameters described in Ch.
7: Faults and Setup Parameters.
This function assigns a transformer turns ratio in
the “Local” weld schedule only. It overrides the
81 TRANSFORMER TURNS RATIO nnn :1 “Global” transformer turns ratio parameters
described in Ch. 7: Faults and Setup Parameters.
82 LINEAR STEPPER #nn ASSIGNED (0 = OFF) This function assign linear stepper 1-10 (0=OFF).
This function allows a one-cycle delay in the weld
schedule for the weld processor to identify any
fault conditions, which may have been generated
thus far in the weld schedule.
NOTE 1: This function must be inserted after the
main weld function (#20 or #30) in the weld sched-
ule. If it is inserted prior to the weld function, all
zeros will be reported in the Weld Data Menu.
NOTE 2: This function only processes the weld data
and sets the fault bits. The FAULT and ALERT out-
puts are not turned on until the end of the sched-
85 PROCESS WELD FAULTS ule.
NOTE 3: The weld processor will execute this func-
tion only once during the weld schedule. If the
function appears in more than one location in the
schedule, the first occurrence will be executed and
all others will be ignored.
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This function is inserted at the beginning of the
weld schedule. It checks the status of the mapped
86 VERIFY CYLINDER #n IS OUT OF RETRACT Retract Valve output bit. A HIGH bit indicates the
gun is out of retraction (closed) and it is OK to pro-
ceed with the weld schedule. A LOW bit indicates
the gun is in retraction (open). When this occurs, a
RETRACT PILOT FAULT is generated and the weld
schedule is immediately terminated.
This function assigns the starting bin number (0-
90 SET SPC OFFSET TO nn 99) for SPC Indexing. See Ch. 9: Advanced Topics
for more information.
This function tells the processor to begin collecting
weld data for all welds. This should follow function
91 SEND ALL SAMPLES UNTIL NEXT SPC OFFSET (#90) SET SPC OFFSET. See Ch. 9: Advanced Topics
for more information.
This function sets HIGH and LOW C-Factor limits in
92 C-FACTOR LIMIT: HI=nnnn LO=nnnn the weld schedule. See Ch. 9: Advanced Topics for
more information.
This function advances all the steppers assigned to
the specified GROUP number, to the specified STEP
number.
93 TIP DRESS ADVANCE: GROUP nn - STEP n
For example, if this function was programmed: TIP
DRESS ADVANCE: GROUP 02 - STEP 05, every step-
per assigned to Group #2 would advance to Step
#5.
NOTE 1: This function must be inserted into a tip
dress schedule, if the tip dress schedule is used in
lieu of the Tip Dress input bit.
NOTE 2: This function can advance several step-
pers simultaneously. For example, your application
may use several different weld schedules to exe-
cute a weld on the same tool, but those schedules
may be assigned to different steppers (to account
for weld variations). This function allows you to
advance every stepper assigned to a group, each
time any schedule completes a weld.
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This function is an unconditional jump to another
weld schedule. It tells the processor to stop the
present schedule and continue with the first func-
tion in another schedule. This is also known as
weld schedule chaining.
NOTE 1: This function can be used to save memory
in the weld processor by allowing multiple sched-
ules to execute commonly used functions.
99 GOTO SEQ#nnn
NOTE 2: Caution should be observed when using
this function. An infinite loop of repeatedly initi-
ated weld schedules can be inadvertently created if
the last schedule in the chain is programmed to
return to the first schedule in the chain.
NOTE 3: Only the originating weld schedule num-
ber is displayed in the weld data.
NOTE 4: If function #85 (PROCESS WELD FAULTS) is
inserted before function #99 in the originating
schedule, only weld data from that schedule is dis-
played. If you wish to average weld data from all
the schedules in the chain, function #85 (PROCESS
WELD FAULTS) must be placed after function #99 in
each schedule.
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The following is an example of special function (#81) TRANSFORMER
TURNS RATIO:
When this function is used in a weld schedule, its “local” parameters
override the “global” turns ratio parameters described in Ch. 7: Faults
and Setup Parameters. That is, the “local” turns ratio for schedule 1 is
50:1, but the “global” turns ratio for schedules 2 through 255 remain
unchanged at 75:1.
00 START OF SCHEDULE # 1
54 TURN ON VALVE 1
90 TRANSFORMER TURNS RATIO 50:1
01 SQUEEZE 15 MSEC
30 WELD 80 MS. 4000 AMPS
78 PROCESS WELD FAULTS
03 HOLD 02 MSEC
55 TURN OFF VALVE 1
03 HOLD 10 MSEC
100 END OF SCHEDULE # 1
For description of RAFT™ functions see Chapter 12: RAFT™
- 325 of 325/Chp13_Schd_Func.fm -
GLOSSARY
C-Factor
C-Factor (or Capacity Factor) is a parameter, which is used to track changes in the weld tooling.
C-Factor is calculated by determining the amount of total capacity utilized to create the target
current and dividing this value by the actual current created. The C-Factor feature can be used
as a maintenance tool to monitor weld tooling degradation and current shunting paths
(primary or secondary).
ENET
ENET is used for Standard Ethernet communications.
ENET IP
ENET IP is used for I/O communication between the weld processor and other Ethernet enabled devices
(e.g. a Robot or PLC). Also used to communicate with Weld Gateway and RAFT Gateway networking
software.
FieldBus I/O
Configuration of fieldbus input output of the weld processor. Fieldbus network system is a real-
time distributed control for industrial networks. Fieldbus works on a network structure which
typically allows daisy-chain, star, ring, branch, and tree network topologies. Fieldbus
communication scheme gives the weld processor the ability to control and allow multiple
analog and digital points to be connected at the same time.
LIO
Local (Discrete) I/O. Inputs - 2 x 24VDC Outputs - 3 x 120VAC
Schedule
A (Weld) Schedule is a list of commands or functions which are used to instruct the weld
processor to deliver a combination of heat (weld current) and time (weld time) to the weld
interface to create a weld nugget.
SSPI
WTC Proprietary I/O Communication Protocol (Optional) . SSPI supports communication with optional
WTC I/O peripheral devices.
326
SPC - Statistical Process Control
SPC data collection and binning provides the capability of compiling weld data within pre-
defined criterion established in the Setup Parameters.
Spot
Another name for a weld.
Spot ID
User assigned unique identification number that defines a specific spot created with a weld
schedule. This feature is only available with certain software.
Station ID
User defined identification number for the weld interface.
V Avg
Average secondary voltage drop of the last weld.
WebView
An interconnect between the RAFT™ Gateway and WTC legacy weld timers that use either
serial networks or are otherwise not compatible with the RAFT™ Gateway.
327
Notes:
328
Welding Technology Cor por ation
24775 CRESTVIEW COURT | FARMINGTON HILLS, MI USA 48335 | PHONE: +1 248-477-3900
329
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