WT6000

TRAINING PROGRAM

1
"top mount" designed for
robot controller panels

2
 INSIDE THE WELD CONTROL

CIOM
Control transformer
120 circuit Breaker
Main circuit Breaker
Isolation contactor
Gen 6 Inverter
Gen 6 Timer

3
 CIOM (Cabinet I/O Module)

The CIOM module is used for

interfacing the weld timer to
internal input and outputs. The
CIOM is also used to monitor the
control voltage to sense if the
user has tapped the control
transformer to the right voltage.

4
5
Control transformer
Steps down line voltage to 120V and
24V for the cabinet power.

120 circuit Breaker

Interrupts 120 voltage and is
upstream of the CIOM.

6
Main circuit Breaker
Interrupts customer supplied line
voltage and is upstream of the
inverter.

7
Isolation contactor
Device placed downstream of the
inverter, used to interrupt current to
the customer supplied weld
transformer.

8
Gen 6 Inverter
Converts 3-phase AC to MFDC
current.

Gen 6 Timer
Brains of weld control and
Ethernet/DeviceNet
communications

9
ENET IP
EtherNet/IP (EIP)is used for I/O communication between the weld timer 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 is used for Standard EtherNet communications.

SSPI WTC Proprietary I/O Communication Protocol (Optional)

SSPI supports communication with optional WTC I/O peripheral 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 communications.
DNET
DeviceNet (Optional) is used for DeviceNet I/O communications (slave only).
SEC I / V
Secondary Current or Voltage Monitoring Input (Optional)
Location for input wires for Secondary Current or Secondary Voltage Monitoring. 10
11
12
Inverter replaces the SCR and Firing Circuit used in conventional
Single-Phase welding.

Power Factor is near unity (100%) whereas AC power factor

ranges from 50% to 95% - depending on secondary cables.

The welding transformer for MFDC must be matched for the weld
current requirement - depends on the applied voltage and circuit
resistance.
Incoming
Three Phase
AC

Stage 1
Full Wave
Rectification

Stage 2
High Frequency
AC

Stage 3
DC Current
Output
 Entry phase rotation to control
circuit breaker is not relevant.
(ABC) or (ACB)

Weld Power is supplied by Three Phase Line

Voltage which is rectified and used to charge
the DC Bus.

The inverter produces a

DC voltage source
The Inverter converts the DC Voltage source to Mid
Frequency / High Voltage AC square wave pulses. The
Frequency can vary from 400 Hz to 2000 Hz.

Typical is 1000 Hz, each period is 1 millisecond.

Each bipolar pulse is nearly 500 microseconds.
This is accomplished by the
controlled switching of the IGBTs.

Control

Insulated Gate Bipolar System
Transistors
(IGBT) act as switches
to produce a 1000 Hz
bipolar square wave.
Reference Inverter System Diagram
Diodes
Diodes in inverter applications have similar
characteristics to those of thyristors
(SCRs). They can be constructed in such
a way that any heat generated in the silicon
can be removed quickly. They are typically
used for line voltage rectification and are
subject to similar conditions as would be
found in an AC welding.
 Capacitors
Capacitors are a vital component in inverter controls. They
serve as a power reservoir lowering the peak demand on
the rectifier diodes and absorbing any voltage overshoot
caused by AC line and weld load inductances.

The inverter diodes full wave rectifies the three-phase

power to obtain approximately 1.42 times the mains voltage.
The capacitor must be sized accordingly.

380VAC to 537VDC
400VAC to 565VDC
480VAC to 679VDC
575VAC to 813VDC
IGBTs

Insulated gate bipolar transistors (IGBTs)

are used to change the DC buss in the
capacitors into high frequency AC. A
1000Hz frequency AC output, although the
controls can set this frequency between
400 and 2000Hz. This high frequency AC
is the inverter output to the weld
transformer.
 MFDC Welding
The IGBTs are turned on and off in pairs (1
with 4, and 2 with 3).

Since IGBTs are turned ON and OFF by the

control system, the algorithms for controlling
the welding output are deterministic rather
than predictive. The length of time that the
IGBTs are left on (pulse width or ON TIME)
determines the output to the welding
transformer. There are significant advantages
for using MFDC systems.
 MFDC Welding
AC welding uses the nomenclature of “cycles” or “periods” to
determine duration of time.

When F=50Hz, one cycle equals 1/50th of a second, and 50 cycles

or periods equals one second.

When F=60Hz, one cycle equals 1/60th of a second, and 60 cycles

or periods equals one second.

Inverters can also use cycles to determine time durations however.

 Points Regarding the Weld Transformer

The MFDC transformer has three parts,

the windings

the iron core

and the secondary diodes.

The core and winding determine how much current you can deliver, which
varies with the duty cycle at which you are using it.

A very large amount of current can be delivered if the duration is short. A

low level of current can be maintained for a longer time, and if the current is
low enough, indefinitely.
 Points Regarding the Weld Transformer

Also, it is important to keep in mind that the MFDC transformer uses

secondary diodes which have a maximum current capacity. These can be
damaged by a single weld over their rating, which can occur if the inverter
can deliver more current that the diodes can handle.
Points Regarding the Weld Transformer

The MFDC power transformer is similar to the low

frequency DC transformer. The major difference lies in the
size of the magnetic iron core that transform primary
current into secondary current.

Since the MFDC transformer relies on the control to

provided it with frequency pulses of 400 to 2,000 Hz
instead of the base 50 or 60 Hz, the amount of iron in the
core is reduced significantly.

This allows the manufacture of a MFDC power transformer

much smaller in size. This allows the transformer to be
placed much closer to the welding tool in some cases
hence providing further benefits.
Diodes in the Weld Transformer modify
the AC Square Pulses to a DC Pulse.
Inductance in the Transformer smoothes
the pulses into a DC signal.
 Advantages of MFDC

The System Power Factor is High, Constant and Leading.

Weld Power is Generally Independent of the Magnetic Effects of the

Secondary Circuit.

Less RMS Current from the Mains is required.

The Load is automatically distributed over Three Phases

Better Process Control With MFDC

More accurate current control

Deterministic rather than Predictive Current Control allows Greater Accuracy.

Corrections can be made up to 2000 times per second.

Cycle by cycle current allows many more than one correction per mains half cycle

Can achieve Target Currents up to 90% faster than AC Weld Controls.

Medium frequency can shift the secondary current value faster than AC

More Tolerant of Line Disturbances.

Energy is supplied by the inverter rather than directly off the mains
 WTC
WT6000
Fault Diagnostics
 Topics of Discussion

1. Fault Diagnostics and Troubleshooting

2. GEN6 Weld Timer Diagnostic LED’s

Fault Diagnostics and
Troubleshooting
 Weld Initiate Not Present Fault
Description 1:
• Occurs when function #61 (ABORT IF NO INITIATE
FOR nn MSEC) is used in the weld schedule and the
Weld Initiate bit goes LOW within the amount of
time programmed in the function.

Corrective Action 1:
• Ensure the master controller (i.e. robot, PLC, etc.) is
maintaining the Weld Initiate bit HIGH during the
time function #61 is monitoring the bit.
 Weld Initiate Not Present Fault
Description 2:
• Occurs when the Weld Initiate bit goes LOW before
function #50 (TURN ON WELD COMPLETE) is
executed in the weld schedule.

Corrective Action 2:
• Ensure the master controller (i.e. robot, PLC, etc.) is
maintaining the Weld Initiate bit HIGH until function
#50 is executed in the weld schedule.
 Control Stop Fault
Description:
• Occurs when the Control Stop bit goes LOW anytime during
the execution of the weld sequence. This bit is normally
maintained HIGH.
Corrective Actions:
• Ensure the Control Stop pushbutton is pulled out and +24VDC is on Pins 6
and 7 of the LIO connector on the processor module (1CPU). This is the
Control Stop hard-wired input.
• Investigate why the master EtherNet IP controller (i.e. robot, PLC, etc.)
turned the Control Stop input bit LOW during the weld sequence.

Look at safety gates, light screens, robot E-Stop, master E-Stop, etc.
Light screens can be localized to just the loading station or may cover
an entire cell.
 Stepper Approaching Max Fault
Description 1:
• Occurs at the 1st weld of step 2 in the stepper
program, if the Remaining Tip Dresses Count has
decremented to 0.

Corrective Action:
• Indicates the final step in the stepper program has
begun and End of Stepper is approaching.
 Stepper Approaching Max Fault
Description 2:
• Occurs at the 1st weld of step 5 in the stepper
program, if the Remaining Tip Dresses Count is > 0.

Corrective Action:
• Indicates the final step in the stepper program has
begun and End of Stepper is approaching.
 Stepper Approaching Max Fault
Description 3:
• Occurs at the 1st weld of step 5 in the stepper
program, if the tip dress function is disabled in the
Setup Parameters.

Corrective Action:
• Indicates the final step in the stepper program has
begun and End of Stepper is approaching.
 End of Stepper Fault
Descriptions:
• Occurs at the first weld of step 3 in the stepper program, if the Remaining
Tip Dresses Count has decremented 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.
• Occurs at the last weld of step 5 in the stepper program, if the Remaining
Tip Dresses Count is > 0.
• Occurs at the last weld of step 5 in the stepper program, if the tip dress
function is disabled in the Setup Parameters.
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.

Corrective Action:
• Reset the stepper program and replace the weld caps on the gun.
 High Current Limit Fault
Description 1:
• Occurs when the weld processor detects that the
current passed during the weld sequence exceeded
the value programmed into the HIGH CURRENT LIMIT
WINDOW % in the Setup Parameters.

Corrective Action 1:
• Ensure the percentage value programmed into HIGH
CURRENT LIMIT WINDOW % in the Setup Parameters
is correct for the welding application.
 High Current Limit Fault
Description 2:
• Occurs when the weld processor detects that the current passed
during the weld sequence exceeded the HI value programmed
into function #76 (SEC. CURR LIMITS: HI = nnnn0 LOW = nnnn0) or
function #84 (CURRENT WINDOW: HI= nn% LOW= nn%) in the
weld schedule (if used).
• Ensure the percentage value programmed into HIGH CURRENT L

Corrective Action 2:
• Ensure the HI value programmed into function #76 (SEC. CURR
LIMITS: HI = nnnn0 LOW = nnnn0) or function #84 (CURRENT
WINDOW: HI= nn% LOW= nn%) in the weld schedule is
correct for the welding application (if used).
 High Current Limit Fault
Description 3:
• Occurs if the Transformer Turns Ratio is set too low for
the welding application.

Corrective Action 3:
• Ensure the value programmed into the Transformer
Turns Ratio in either function #90 (TRANSFORMER
TURNS RATIO nnn :1) or the Setup Parameters
matches the turns ratio stated on the serial tag affixed
to the welding transformer.
 High Current Limit Fault
Description 4:
• May occur if there is insufficient gun pressure, poor
part fit-up or loose connections in the secondary
circuit. All of these conditions may cause expulsion or
exploding welds.

Corrective Action 4:
• Ensure gun pressure is correct for the welding application.
• Check for proper part fit-up and correct as required.
• Periodically inspect weld tooling (transformer secondary circuit)
for loose connections and correct as required.
 Low Current Limit Fault
Description 1:
• Occurs when the weld processor detects that the
current passed during the weld sequence was less
than the value programmed into the LOW CURRENT
LIMIT WINDOW % in the Setup Parameters.

Corrective Action 1:
• Ensure the percentage value programmed into LOW
CURRENT LIMIT WINDOW % in the Setup Parameters
is correct for the welding application.
 Low Current Limit Fault
Description 2:
• Occurs when the weld processor detects that the current
passed during the weld sequence was less than the LOW
value programmed into function #76 (SEC. CURR LIMITS: HI =
nnnn0 LOW = nnnn0) or function #84 (CURRENT WINDOW:
HI= nn% LOW= nn%) in the weld schedule (if used).

Corrective Action 2:
• Ensure the LOW value programmed into function #76 (SEC.
CURR LIMITS: HI = nnnn0 LOW = nnnn0) or function #84
(CURRENT WINDOW: HI= nn% LOW= nn%) in the weld
schedule is correct for the welding application (if used).
 Low Current Limit Fault
Description 3:
• Occurs if the Transformer Turns Ratio is set too high
for the welding application.

Corrective Action 3:
• Ensure the value programmed into the Transformer
Turns Ratio in either function #90 (TRANSFORMER
TURNS RATIO nnn :1) or the Setup Parameters matches
the turns ratio stated on the serial tag affixed to the
welding transformer.
 Low Current Limit Fault
Description 4:
• May occur when mechanical issues exist in the weld
transformer secondary circuit (weld tooling).

Corrective Action 4:
• Typical issues include:

Bad jumper cables or leaf shunts

Bad part fit-up

Contaminated weld caps

Insulation from sealer, tape or labels on the part

Gun sticking or not closing properly

Loose or open secondary diodes in the welding transformer

Loose or bad primary cables
 Extended Weld Fault
Description:
• Occurs when either function #94 (EXTEND WELD IF LOW
CURRENT LIMIT FAULT) or #95 (EXTEND WELD IF CURRENT LESS
THAN nnnn0) is used in the weld schedule and the condition is
true. This typically occurs when the required current cannot be
achieved.

Corrective Action:
• See corrective action for LOW CURRENT LIMIT FAULT. Also,
ensure the value programmed into function #95 is correct for
the welding application.
 Extended Weld Fault
Additional Comments:
• If the extend weld (re-weld) is successful, an EXTENDED WELD
(ALERT) will occur and the Weld Complete bit will go HIGH. If the
extend weld (re-weld) is unsuccessful, both an EXTENDED WELD
ALERT and a LOW CURRENT LIMIT FAULT will occur and the Weld
Complete bit will stay LOW.
• This fault must be set to (ALERT) for the Weld Complete bit to go
HIGH after a successful extend weld (re-weld). Otherwise, if set
to (FAULT), the Weld Complete bit will stay LOW.
Isolation Contactor Off When Needed Fault
Description:
• Occurs when the isolation contactor is not energized when
required by the weld schedule.

Corrective Actions:
• Ensure function #52 (TURN ON ISOLATION CONTACTOR) is in the weld
schedule and inserted before the squeeze function.
• Inspect isolation contactor for damage. The auxiliary contactor block may be
defective. Replace the entire isolation contactor or the auxiliary contact block
as required.
• If the isolation contactor is not defective, the solid state relay that drives the
isolation contactor coil may be shorted. Replace the solid state relay.
Isolation Contactor Error - Breaker Tripped Fault
Description:
• Occurs when the weld processor detects the isolation contactor is energized
(closed) when it should be de-energized (open). When this fault occurs, the
weld processor activates the shunt-trip mechanism on the circuit breaker.

Corrective Actions:
• Typically, this fault is caused by a defective auxiliary contact block on the
isolation contactor. The contacts can be cleaned by removing the auxiliary
block, manually moving the aux contact up and down a few times and then
reseating. If this does not resolve the problem, replace the auxiliary contact
block.
• Inspect isolation contactor for damage. The high current contacts maybe
frozen shut. If so, replace isolation contactor.
• If the isolation contactor is not defective, the solid state relay that drives the
isolation contactor coil may be shorted. Replace the CIOM.
 High C-Factor Limit Fault
Description:
• Occurs when function #97 (C-FACTOR LIMIT: HI=nnnn LO=nnnn)
is used in the weld schedule and the C-Factor value calculated by
the weld processor exceeds the high limit value programmed in
the function.
Corrective Actions:
• Ensure the "HI" value programmed into function #97 is correct
for the welding application.
• High C-Factor Limit usually indicates current shunting in the
secondary circuit. Typically this is caused by 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.
 Low C-Factor Limit Fault
Description:
• Occurs when function #97 (C-FACTOR LIMIT: HI=nnnn LO=nnnn)
is used in the weld schedule and the C-Factor value calculated by
the weld processor is less than the low limit value programmed
in the function.
Corrective Actions:
• Ensure the "LO" value programmed into function #97 is correct for the
welding application.
• Low C-Factor Limit usually indicates an increase in the resistance of the
secondary circuit. This can be caused by frayed or open welding cables. If
water-cooled cables 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.
 Low C-Factor Limit Fault
Troubleshooting:
• For all secondary issues, a standard multimeter (Fluke) can not measure the
resistance of the electrode arms (weld tip to transformer connection point).
This resistance is usually in the range of 50-150µΩ and a standard
multimeter and test lead set can only measure to a minimum of
approximately 0.3Ω. Therefore, a Micro-Ohm Meter is required to measure
this resistance.
• In MFDC applications, the welding transformer has diodes in its secondary.
With the gun closed and an insulator between the tips, take a standard
multimeter (in Diode Check Mode) and place the leads across the weld tips.
The multimeter should measure between 0.25V and 0.3V in one direction
and 1.7V and OL (over range) in the other. If the meter measures 0.00V,
either the transformer diodes are shorted or a short exists elsewhere in the
weld tooling (secondary circuit).
 System Cooling Fault
Descriptions:
• Occurs when the System Cooling bit goes LOW anytime during
the execution of the weld sequence. This bit is normally
maintained HIGH.
• Occurs when function #79 (WAIT nnnn MS FOR SYSTEM
COOLING) is used in the weld schedule and the System Cooling
bit does not go HIGH within the amount of time programmed in
the function.
Corrective Actions:
• Identify and correct any water flow issues.
• Note: The inverter chill plate temperature can be seen in the
Display Mode screen of the DEP-300s.
 Weld Interruption Fault
Descriptions:
• Occurs when the Weld / No Weld bit goes LOW while the weld control is
passing current during the execution of a weld schedule.

• Occurs when the circuit breaker on the weld cabinet is switched OFF while
the weld control is passing current during the execution of a weld schedule.
The fault will appear when the circuit breaker is switched back ON and the
weld processor re-initializes.
 I/O Fault
Description:
• Occurs when either an EtherNet IP network communication
timeout occurs.

Occurs when the weld processor looses communication with any

device connected to the SSPI port:
• CIOM (Contactor I/O Module
• AIOM (Analog I/O Module
• DIOM (Discrete I/O Module)
• GFM (Ground Fault Module)
• MCCM (Multi-Contactor Control Module)
 Weld Proceed Fault
Descriptions:
• Occurs when function #70 (WAIT FOR WELD PROCEED) is used in
the weld schedule and the Weld Initiate bit goes LOW before the
Weld Proceed bit goes HIGH.
• Occurs when function #71 (WAIT FOR WELD PROCEED) is used in
the weld schedule and the Weld Initiate bit goes LOW before the
Weld Proceed bit goes HIGH.
 Pressure Switch Fault
Descriptions:
• Occurs when function #69 (WAIT FOR PRESSURE SWITCH INPUT)
is used in the weld schedule and the Weld Initiate bit goes LOW
before the Pressure Switch bit goes HIGH.
• Occurs when function #68 (WAIT nnnn MS FOR PRESSURE
SWITCH INPUT) is used in the weld schedule and the Pressure
Switch bit does not go HIGH within the amount of time
programmed in the function.
 Control In No Weld Fault
Description:
• Occurs when a weld sequence is initiated while the weld
processor is in No Weld Mode (i.e. the Weld / No Weld input bit
is LOW).
Corrective Actions:
• Investigate why the master DeviceNet or EtherNet IP controller
(i.e. robot, PLC, etc.) held the Weld / No Weld input bit LOW
when the weld sequence initiated.
• Ensure the weld timer was not manually put into No Weld Mode
through the DEP100s (if used).
 Initiation On Power-Up Fault
Description:
• Occurs when the weld cabinet is powered-up (i.e. circuit breaker
is switched ON) and the weld processor detects that both the
Weld Initiate bit is HIGH and one or more Binary Select bit is
HIGH. In this condition, a weld sequence WILL NOT initiate.
Corrective Action:
• Remove Weld Initiate bit, clear faults and re-initiate the weld
sequence.
 Control Transformer Voltage Fault
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 monitors the 24VAC secondary tap of the
control transformer for either an under or over voltage condition.
This ensures the primary of the control transformer is tapped
properly for the incoming line voltage.
 Low Line Voltage Fault
Description:
Occurs when the AC line voltage drops below a point where
the DC power supply on the CIOM-TB module can no
longer regulate the +24VDC it supplies to the devices
downstream. This fault is monitored continuously
 Soft Overcurrent Fault
Description:
• Occurs when the impedance of the secondary circuit creates a current draw
that causes the inverter to reach or exceed its maximum output current
rating.
• Occurs when the target secondary current programmed into the weld
schedule causes the inverter to reach its maximum output current rating.
To determine the maximum target secondary current, multiply the inverter
maximum output current rating by the transformer 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.
• Occurs when the inverter reaches its maximum IGBT on-time rating before
the target secondary current is achieved. Thus, whatever current level is
achieved at max IGBT on-time, is what will be delivered to the welding
transformer.
 Bus Voltage Fault
Description:
• Occurs when the weld processor has detected the DC bus within the inverter
assembly did not charge to the correct level. This fault is monitored
continuously.
Corrective Actions:
• Verify incoming 480VAC line power is balanced phase to phase (L1-L2, L2-L3,
L3-L1).
• Verify the DC Bus voltage is approximately 700V (incoming power x 1.414),
which can be measured at the 4-pin CNPL connector located on top of the
inverter assembly.
• If the AC line power is properly balanced, try resetting the circuit breaker on
weld control cabinet. If problem persists, replace defective Inverter.
 Inverter Over Temperature Fault
Description:
• Occurs when the weld processor has detected the temperature
of the inverter cooling manifold (chill plate) had exceeded safe
operating limits.

Corrective Actions:
• Water Cooled Inverter: Ensure the cooling water inlet
temperature is < 95 F (35 C).
• Air Cooled Inverter: Ensure the ambient air temperature around
the weld cabinet does not exceed 104 F (40 C).
• Note: The inverter chill plate temperature can be seen in the
Display Mode screen of the DEP-300s.
 Output Ground Fault
Description:
• Occurs when a current imbalance exists between the two output
terminals of the inverter assembly.

Corrective Action:
• Identify and correct the unidirectional current path (shunting) to
ground between the output of the inverter assembly and the
primary of the welding transformer.

Typical problem areas include the rubber boot connectors at
the base of the robot, junction box on the robot and the
primary of the welding transformer.
 IGBT Saturation Fault
Description:
• Occurs when the weld processor detects an instantaneous over-
current event, which exceeds the design rating of the 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.

Corrective Action:
• Use troubleshooting method described in Low Current Limit
Fault. Replace shorted primary cables and/or replace defective
Minipak enclosure.
 IGBT Power Supply Fault
Description:
• Occurs when the IGBT Gate Board within the inverter assembly
has failed. This fault is monitored continuously.

Corrective Action:
• Replace defective Inverter.
 Bus Charging Fault
Description:
• Occurs when the weld processor has detected the DC bus within
the inverter assembly did not charge correctly (either too slow
or too quickly). This fault is monitored continuously.

Corrective Action:
• Try resetting the circuit breaker on weld control cabinet. If
problem persists, replace defective Inverter.
 AC Line Phase Fault
Description:
Occurs when the weld processor detects a line phase is either
incorrect or missing. This fault is monitored continuously.

Corrective Action:
Correct power problem or replace / install missing phase.
 Secondary Current Sensor Fault
Description:
Occurs at the initiation of a weld schedule, when the weld
processor does not detect a proper connection to the secondary
current monitoring coil when it should.
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.
Corrective Action:
The secondary current coil is either improperly connected to the
weld processor or it is bad. If proper connection has been verified
and the fault still persists, replace the coil with a known good one.
 Current Regulation Fault
Description:
Occurs when the inverter reaches its maximum IGBT on-time rating
before the target secondary current is achieved. Thus, whatever
current level is achieved at max IGBT on-time, is what will be
delivered to the welding transformer.
 PRESSURE NOT ACHIEVED
Occurs when function #74 (WAIT nnn MS FOR PRESSURE ACHIEVED) is
used in the weld schedule and the programmed pressure is not achieved
within the amount of time programmed in the function.

Check analog feedback circuit for problems.

Check for mechanical problems with the weld gun related to air pressure, e.g.
water in air lines, pressure regulator set too low, etc.
 SECONDARY DIODE
Occurs when the weld processor has detected a shorted secondary diode within the
welding transformer.

With the gun closed and an insulator between the tips, take a standard multimeter
(in Diode Check Mode) and place the leads across the weld tips. The multimeter
should measure between 0.25V and 0.3V in one direction and about .7V and in the
other. If the meter measures 0.00V, the secondary diodes are shorted and the
transformer must be replaced.
MedWeld 6000 Weld Cabinet Safety Concerns
 What is a weld schedule
A weld schedule is a list of commands that the control is to execute. For example, to
perform a simple spot weld, you might use a weld schedule consisting of the following
functions:

00: START OF SCHEDULE 236

82: LINEAR STEPPER #02 ASSIGNED (0=0FF)
56: SET PRESSURE = 03
58: TURN ON WELD IN PROGRESS
52: TURN ON ISOLATION CONTACTOR
01: SQUEEZE 0080 MS
30: WELD 0230 MSEC 15000 AMPS
78: PROCESS WELD FAULTS
94: EXTEND WELD IF LOW CURRENT LIMIT FAULT
03: HOLD 0020 MS
50: TURN ON WELD COMPLETE
59: TURN OFF WELD IN PROGRESS
75: EXTEND UNTIL NO INITIATE
51: TURN OFF WELD COMPLETE
56: SET PRESSURE = 00
53: TURN OFF ISOLATION CONTACTOR
154: END OF SCHEDULE 236
 The Series 6000 provides commands for:
Assigning a schedule to a stepper,
Turning selected outputs on or off and
Providing weld current.

Other functions enable

Overriding the setup parameters,

Controlling the I/O by monitoring inputs and activating outputs,
Regulating weld current to fall within a prescribed range
Repeat the weld if the current is not within that range,
Statistical process control (SPC) functions,
Selecting the firing mode (% of max current or Absolute Current)
Pausing in a schedule to wait for certain operating conditions to become true.
You can add functions from this list, or delete functions from it.
You may also change any of the numeric values specified in a function.
This lets you create a schedule that meets your application requirements.
The following sections describe the functions available for use in a weld schedule, including
the two-digit function code and the action each function produces.
 Delay Functions

Delay functions all have the same effect on the weld schedule.
They cause the control to wait for the amount of time specified.

During these functions, weld current does not flow and I/O status is not changed.
The time for these delays may be extended in such case where additional de-bounce time is
required for activation of I/O devices.

01: SQUEEZE nnnn MS

02: COOL nnnn MS
03: HOLD nnnn MS
04: OFF nnnn MS
05: INITIAL SQUEEZE nnnn MS
07: WAIT nnnn MS

(Different names are assigned for describing the reasons for a delay).
 Extend Function
75: EXTEND UNTIL NO INITIATE
This function is used to latch in the handshaking between the Series 6000 control and
the robot or automation control.
Normally, the schedule is programmed as follows after the weld function:

30: WELD 0230 MS 15000 AMPS

78: PROCESS WELD FAULTS
03: HOLD 0020 MS
50: TURN ON WELD COMPLETE
75: EXTEND UNTIL NO INITIATE
56: SET PRESSURE = 00
51: TURN OFF WELD COMPLETE
59: TURN OFF WELD IN PROGRESS
51: TURN OFF ISOLATION CONTACTOR
154: END OF SCHEDULE # NNN
The function EXTEND UNTIL NO INITIATE forces the Series 6000 to continually loop in
the execution of the prior function while it perceives that the initiates are maintained.
Once the initiates are removed, the Series 6000 will then complete the remainder of the
weld schedule.
After the weld function, the Series 6000 processes weld data to determine if there is one or
more weld faults. While it is processing this, a hold time delay is also executed. If a fault
is detected, the control will NOT turn on the WELD COMPLETE output but will
activate the FAULT output. If no faults are detected, then the control will turn on
WELD COMPLETE output then will wait for the robot or automation control to remove
the initiates. Proper "handshaking" between the weld control and the robot or
automation control is for the robot or automation control to maintain weld initiate to
the weld control until a WELD COMPLETE is detected or a FAULT is annunciated. This
latches the proper "handshaking" routine.
 Re-Weld Functions
94: EXTEND WELD IF LOW CURRENT LIMIT FAULT
Function #94 tells the weld processor to automatically repeat the weld function if it detects
a LOW CURRENT LIMIT fault. This function must appear immediately after the
PROCESS WELD FAULTS function in the schedule. If it detects the LOW CURRENT
LIMIT fault, the control restarts the weld schedule and generates the EXTENDED WELD
fault/alert condition. The control will repeat the weld only once. If the desired current is
not provided on the re-weld, the control generates a LOW CURRENT LIMIT fault/alert
condition.
95: EXTEND WELD IF CURRENT LESS THAN nnnn0
Function #95 has the same result as Function #94, but monitors secondary current instead
of the LOW CURRENT LIMIT fault. If the secondary current provided during the
schedule does not reach the minimum value programmed, the control restarts the weld
schedule and generates the EXTENDED WELD fault condition. The control will repeat
the schedule only once. If the desired current is not provided on the re-weld, the control
generates an EXTENDED WELD fault.

There is a fault conditions associated with re-welding. Each time the weld is extended; there
is an "EXTEND WELD" which can be set as a FAULT or ALERT. The normal setting is
ALERT. Also, there is a FAULT condition associated with EXCESSIVE REWELDS that can
be set up to detect if the control performs a high rate of extended welds.
 99: GOTO SEQ#nnn (nnn = 1-255)

This function is an unconditional jump to another weld schedule.

It tells the control to stop the present weld schedule, and continue with the first function in
another schedule.
This function can be used to save memory space in the control, by allowing multiple
schedules to execute commonly-used functions.
The control considers the schedule originally initiated as the last schedule.
The stepper assigned to the original schedule is also the only one incremented.
This function should appear as the last function in a schedule, because the control will not
return to the original schedule when it completes the new schedule
 Weld Current Functions

60: IMPULSE= nnnn HEAT MS, nnnn COOL MS – DC Systems

60: IMPULSE= nnn HEAT CY, nnn COOL CY - AC Systems

This function defines the length of a weld impulse. It tells the weld processor that the next
function in the schedule should be a pulsation weld (providing heat times followed by
cool times in repetitive fashion, rather than just heat cycles).
When this function appears before any weld function(s), the control displays IMP
(impulse) rather than MS (milliseconds) to indicate the weld control will do a pulsation
weld.
Pulsation welding provides a specified number of impulses
 Input Monitoring Functions
These functions require specific inputs.
Before programming these functions, check the packet of drawings that came with your
Series 6000 for I/O availability.
61: ABORT IF NO INITIATE nnnn MSEC
65: WAIT nnnn MS INP #n TO BE 0 (0=OFF 1=ON)
66: WAIT FOR INPUT #n TO BE 0 (0=OFF 1=ON)
67: EXTEND WHILE INPUT #n IS 0 (0=OFF 1=ON)
68: WAIT nnnn MS FOR PRESSURE SWITCH INPUT
69: WAIT FOR PRESSURE SWITCH INPUT
70: WAIT nnnn MS FOR WELD PROCEED INPUT
71: WAIT FOR WELD PROCEED INPUT
79: WAIT nnnn MS FOR SYSTEM COOLING
85: WAIT FOR NO INITIATE IF FAULT
These functions allow the control to react to inputs coming to the control from welding
machines and automation equipment. Special sequencing for seam welding and other
applications can be solved using these functions. For example, varying the current
intensity of a seam welding process around corners can be solved by using function #67
following a weld current function.
 Output Functions
These functions require specific outputs. Before programming these functions, check the
packet of drawings that came with your Series 6000 for I/O availability.
50: TURN ON WELD COMPLETE
51: TURN OFF WELD COMPLETE
52: TURN ON ISOLATION CONTACTOR
53: TURN OFF ISOLATION CONTACTOR
54: TURN ON VALVE #n (n = 1-6)
55: TURN OFF VALVE #n (n=1-6)
56: SET PRESSURE #nn (n=01-15)
58: TURN ON WELD IN PROGRESS
59: TURN OFF WELD IN PROGRESS
63: TURN ON OUTPUT #n
64: TURN OFF OUTPUT #n
These functions allow the control to turn outputs on or off within a weld schedule. Even
though these functions are available, certain versions of the software do NOT allow
inserting or deleting the following functions from a weld schedule using the DEP
 Overide Functions
Overriding Setup Parameter Functions
76: SEC. CURR LIMITS: HI=nnnn0 LOW=nnnn0
77: ISOLATION CONTACTOR DELAY = nn SEC.
84: CURRENT WINDOW HI=nn% LO=nn%
90: TRANSFORMER TURNS RATIO nnn:1 (nnn=1-256)
97: C-FACTOR LIMIT: HI=nnn LO=nnn
The functions above allow setting programming limits that are unique to a given weld
schedule. The new limits override the limits programmed in the setup parameters,
and apply only to the weld schedule where they appear. They also take priority over
any other limits established
 Process Weld Faults Function
Process Weld Faults
78: PROCESS WELD FAULTS

This function sets the Series 6000 timer to indicate any faults that may have been
generated so far in the schedule. The control normally processes all fault conditions at
the end of the weld schedule. This function allows forcing the control to process fault
conditions before it completes the weld schedule and before it activates the WELD
COMPLETE output .
Repeat Function

62:REPEAT (AT NEXT FUNCTION)

.
This function also monitors the status of the weld initiate. When the control completes
a weld schedule, it repeats the remaining functions in the schedule. At the end of
the schedule, it returns to the repeat function, again checks the status of the WELD
INITIATE input, and repeats the rest of the schedule. This continues until the
processor detects that the WELD INITIATE input has been removed.
Functions #62 and #75 are mutually exclusive. They should NOT appear in the same
sequence
 Weld Functions and Firing Modes:

Weld functions provide a specified amount of weld current for the number of cycles
programmed. The weld function you select also tells the weld processor the type of
firing mode to use to control the energy provided to a weld. Specify weld current as
either:
A percentage of maximum available current, or
By the amount of secondary current desired.
These functions tell the control how to compensate for changes in the welding
environment:
%I determines the inverter firing point to achieve a set percentage of the maximum rated
inverter current.
Automatic Current Compensation. ACC monitors the current during each millisecond. It
compensates for changes detected during the millisecond firing point, to maintain
secondary current at the level programmed.
While the weld function used in the weld schedule will determine how weld current is
applied, the inverter setup parameters and firing modes determine how weld energy is
regulated, and when fault conditions will be generated.
 Slope Current Functions

Percentage Firing Mode Slope Function

40: SLOPE nnnn MS / IMP mm %I TO mm %I
mm = 20 - 99. The processor can fire from 20% to 99% I

Current Regulation Firing Mode Slope Function

45: SLOPE nnnn Msec / IMP nnnn0 AMPS TO nnnn0 AMPS
These functions provide weld current that starts at the first value and increases or
decreases linearly to the second value over the time specified.

Either function (40 or 45) will fire for the time specified. For example, the function 40
SLOPE 200 MS 45% I TO 65% I tells the control to fire one millisecond at 45% of
the maximum available current. Then, over the next 199 milliseconds, it gradually
increases the heat provided to 65%.
 I/O Needed
Input - Binary Selects

Binary Selects (1, 2, 4, 8, 16, 32, 64, 128)

These inputs select the schedule to be initiated (1 - 255). The schedule is selected by a
combination of these inputs. Each input has a weighted value (1, 2, 4, 8, 16, 32, 64 or 128).
The schedule initiated is the one selected by adding the weighted values of the active
inputs. For example, to initiate schedule #4, activate BINARY SELECT Input #4. To
initiate schedule #7, activate BINARY SELECT inputs #1, #2 and #4 (because 1 + 2 + 4 = 7).
 I/O Needed
Input - Isolation Contactor Saver
CSVR

This input tells the weld processor to enable the isolation contactor delay timer. The delay
timer (), holds the isolation contactor closed after a weld schedule is completed, to
prevent it from dropping out between welds. If this input is active at the end of a
schedule, the weld processor will hold the isolation contactor closed for the amount of
time programmed. If this input is not active, the isolation contactor will drop out at the
end of the weld schedule. However, if this input drops out during the delay time, the
remaining time on the delay timer is aborted and the isolation contactor is immediately
opened.
 I/O Needed
Input - Fault Reset
FR
This input allows the control to remotely reset all faults.

Input - Weld Initiate

INT
When this input is activated, the weld control executes the schedule that was selected by
the BINARY SELECT inputs. There are 255 that can be initiated.

Input - Request Pressure

PREQ
When this input is high along with the sequence BINARY SELECTs, the sequence is
searched for the first instance of the function. The PRESSURE BITs outputs #1, 2, 4, and
8 are set to the PRESSURE = nn value accordingly.
 I/O Needed
Input - Stepper Reset
SR
This input will reset all the steppers to Step 1 and the weld count to 0.

Input - Weld / No Weld

WLD
This input is provided to the weld timer to sequence the weld schedule with or without
firing weld current. Input is ON to indicate to sequence in WELD. Input is OFF to
indicate to sequence in NO WELD.
 I/O Needed
Output - End of Stepper
EOS

This output indicates that one or more of the 32 steppers has arrived to the last weld of a
stepper. It is normally OFF. It turns ON to indicate the condition. The End of Stepper is
usually set up as a Fault condition. The End of Stepper will activate a Fault. In most recent
software, the End of Stepper will continue to a maximum of 40 welds before causing a
Fault thus allowing a robot to finish its welding cycle on a part.

Output - Isolation Contactor is Open

WMO
This output is used to indicate that the isolation contactor is open
(ON) or closed (OFF).
 I/O Needed
Output - No Alert
NALT

This output is the invert of the Alert condition. It is normally ON. It turns OFF to indicate
an alert condition. Alert conditions are usually less serious than faults and normally serve
to warn the operator that maintenance is required. The weld control will automatically
reset the Alert condition upon a Fault Reset input, the execution of a weld schedule, or
upon a reset from a programming device. Programming of conditions as being an Alert is
done in the setup parameters.
 I/O Needed
Output - No Fault

NFLT

This output is the invert of the Fault condition. This output is normally ON to indicate that
no fault conditions exist. If the control shuts down as the result of a fault condition, this
output will be turned OFF. The weld control will automatically reset the Fault condition
upon a Fault Reset input or upon a reset from a programming device. In some versions,
the Fault will inhibit the initiation of weld schedules so a fault reset would be required in
such case. Programming of conditions as being a Fault is done in the setup parameters.
 I/O Needed
Output - No Control Stop
NCS

This output is ON to indicate that the control is not in control stop. If the timer detects a
control stop condition, this output will go OFF.

Output - Pressure Bits 1, 2, 4, 8

PV1 PV2 PV4 PV8
These outputs are used to set pressure values in a robot pressure table. The outputs are set
by a function in the weld schedule .
 I/O Needed
Output - Read Pressure
RDP
This output is used to handshake with the robot to set pressure values in a robot pressure
table. The output is set by in a special schedule (usually set as schedule 061 and 062).

Output - Stepper Approaching Max

SALT
This output indicates that one or more of the 32 steppers is on the last step of a stepper. It is
normally OFF. It turns ON to indicate the condition.

Output - Weld Mode On

WMO
This output is used to indicate to robot or automation controls that the weld control is in
WELD MODE.
 I/O Needed
Output - Steppers are Reset
SRST

This output indicates that all steppers in the timer have been reset. Usually, this output is
used for handshaking purposes with a robot to confirm that the robot initiated stepper
reset has been accomplished. The output will be ON when all steppers are on the first
weld of step #1. As soon as one of the steppers have advanced, the output will be OFF.

Output - Tip Dress Request

TDR
This output is used to handshake with the robot to indicate that the electrodes need to pass
through a tip dressing operation. As long as there are remaining available tip dressing
operations, the output will turn ON on the first weld of step #3 of any stepper.
 I/O Needed
Output - Weld Complete
WCMP

This output is used to handshake with the robot or automation to indicate that welding is
complete without fault. This output turned on and off by the weld control in response to .

Output - Weld In Progress

WIP

This output is used to handshake with the robot or automation to indicate that welding is
occuring. This output turned on and off by the weld control in response to .
Stepper Profile Step 1 = + 00% + 1000 A after 0100 welds
Step 2 = + 00% + 0500 A after 0100 welds
Current Regulation mode Step 3 = + 00% + 0200 A after 0100 welds
Step 4 = + 00% + 0100 A after 0100 welds
Step 5 = + 00% + 0050 A after 0100 welds
1 Step 1 = +00% + 1000 A after 0100 welds
Stepper Profile

12000

11500

11000

10500
1
10000

9500

9000
24
48
72
96
120
144
168
192
216
240
264
288
312
336
360
384
408
432
456
480
Weld

F30: WELD 160 MS 10000 AMPS - base weld current

Stepper Profile Step 1 = + 00% + 1000 A after 0100 welds
Step 2 = + 00% + 0500 A after 0100 welds
Current Regulation mode Step 3 = + 00% + 0200 A after 0100 welds
Step 4 = + 00% + 0100 A after 0100 welds
Step 5 = + 00% + 0050 A after 0100 welds
2 Step 2 = +00% + 0500 A after 0100 welds
Stepper Profile

Tip Dress Request

12000

11500
Tip Dress Remain > 0
11000 2
10500

10000

9500

9000
24
48
72
96
120
144
168
192
216
240
264
288
312
336
360
384
408
432
456
480
Weld

F30: WELD 160 MS 10000 AMPS - base weld current

Stepper Profile Step 1 = + 00% + 1000 A after 0100 welds
Step 2 = + 00% + 0500 A after 0100 welds
Current Regulation mode Step 3 = + 00% + 0200 A after 0100 welds
Step 4 = + 00% + 0100 A after 0100 welds
Step 5 = + 00% + 0050 A after 0100 welds
3 Step 3 = +00% + 0200 A after 0100 welds

Stepper Profile

Tip Dress Request

12000

11500 3

11000
Tip Dress Remain > 0
10500

10000

9500

9000
24
48
72
96
120
144
168
192
216
240
264
288
312
336
360
384
408
432
456
480
Weld

F30: WELD 160 MS 10000 AMPS - base weld current

Stepper Profile Step 1 = + 00% + 1000 A after 0100 welds
Step 2 = + 00% + 0500 A after 0100 welds
Current Regulation mode Step 3 = + 00% + 0200 A after 0100 welds
Step 4 = + 00% + 0100 A after 0100 welds
Step 5 = + 00% + 0050 A after 0100 welds
Step 4 = +00% + 0100 A after 0100 welds
Stepper Profile
Stepper Approach Max
Tip Dress Request
12000

11500

11000
Tip Dress Remain > 0
10500

10000

9500

9000
24
48
72
96
120
144
168
192
216
240
264
288
312
336
360
384
408
432
456
480
Weld

F30: WELD 160 MS 10000 AMPS - base weld current

 Step 1 = + 00% + 1000 A after 0100 welds
Stepper Profile Step 2 = + 00% + 0500 A after 0100 welds
Step 3 = + 00% + 0200 A after 0100 welds
Current Regulation mode Step 4 = + 00% + 0100 A after 0100 welds
Step 5 = + 00% + 0050 A after 0100 welds
Step 5 = +00% + 0050 A after 0100 welds
Stepper Profile
End of Stepper

12000

11500

11000

10500

10000

9500

9000
24
48
72
96
120
144
168
192
216
240
264
288
312
336
360
384
408
432
456
480
Weld

F30: WELD 160 MS 10000 AMPS - base weld current

Stepper Profile Step 1 = + 10% + 1000 A after 0100 welds
Step 2 = + 05% + 0500 A after 0100 welds
Step 3 = + 03% + 0200 A after 0100 welds
AVC mode
Step 4 = + 02% + 0100 A after 0100 welds
Step 5 = + 01% + 0050 A after 0100 welds
1 Step 1 = +10% + 1000 A after 0100 welds

Stepper Profile

80
70
60
50 1

40
30
20
10
0
23
46
69
92
115
138
161
184
207
230
253
276
299
322
345
368
391
414
437
460
483
Weld

F20: WELD 160 MS 50% I - base weld current

Stepper Profile Step 1 = + 10% + 1000 A after 0100 welds
Step 2 = + 05% + 0500 A after 0100 welds
AVC mode Step 3 = + 03% + 0200 A after 0100 welds
Step 4 = + 02% + 0100 A after 0100 welds
Step 5 = + 01% + 0050 A after 0100 welds
2 Step 2 = +05% + 0500 A after 0100 welds

Stepper Profile
Tip Dress Request
80
70
60 2

50 Tip Dress Remain > 0

40
30
20
10
0
23
46
69
92
115
138
161
184
207
230
253
276
299
322
345
368
391
414
437
460
483
Weld

F20: WELD 160 MS 50% I - base weld current

Stepper Profile Step 1 = + 10% + 1000 A after 0100 welds
Step 2 = + 05% + 0500 A after 0100 welds
AVC mode Step 3 = + 03% + 0200 A after 0100 welds
Step 4 = + 02% + 0100 A after 0100 welds
Step 5 = + 01% + 0050 A after 0100 welds
3 Step 3 = +03% + 0200 A after 0100 welds

Stepper Profile
Tip Dress Request
80
70
3
60
50 Tip Dress Remain > 0
40
30
20
10
0
23
46
69
92
115
138
161
184
207
230
253
276
299
322
345
368
391
414
437
460
483
Weld

F20: WELD 160 MS 50% I - base weld current

Stepper Profile Step 1 = + 10% + 1000 A after 0100 welds
Step 2 = + 05% + 0500 A after 0100 welds
Step 3 = + 03% + 0200 A after 0100 welds
AVC mode Step 4 = + 02% + 0100 A after 0100 welds
Step 5 = + 01% + 0050 A after 0100 welds
Step 4 = +02% + 0100 A after 0100 welds

Stepper Profile Stepper Approach Max

Tip Dress Request
80
70
60
50 Tip Dress Remain > 0
40
30
20
10
0
23
46
69
92
115
138
161
184
207
230
253
276
299
322
345
368
391
414
437
460
483
Weld

F20: WELD 160 MS 50% I - base weld current

Stepper Profile Step 1 = + 10% + 1000 A after 0100 welds
Step 2 = + 05% + 0500 A after 0100 welds
Step 3 = + 03% + 0200 A after 0100 welds
AVC mode
Step 4 = + 02% + 0100 A after 0100 welds
Step 5 = + 01% + 0050 A after 0100 welds
Step 5 = +01% + 0050 A after 0100 welds

Stepper Profile
End of Stepper

80
70
60
50
40
30
20
10
0
23
46
69
92
115
138
161
184
207
230
253
276
299
322
345
368
391
414
437
460
483
Weld

F20: WELD 160 MS 50% I - base weld current

Tip Dressing Step 1 = + 00% + 1000 A after 0100 welds
Step 2 = + 00% + 0500 A after 0100 welds
Step 3 = + 00% + 0200 A after 0100 welds
Step 4 = + 00% + 0100 A after 0100 welds
Step 5 = + 00% + 0050 A after 0100 welds
1 Step 1 = +00% + 1000 A after 100 welds
Stepper Profile

12000

11500

11000

10500
1
10000

9500

9000
24
48
72
96
120
144
168
192
216
240
264
288
312
336
360
384
408
432
456
480
Weld

F30: WELD 160 MS 10000 AMPS - base weld current

Tip Dressing Step 1 = + 00% + 1000 A after 0100 welds
Step 2 = + 00% + 0500 A after 0100 welds
Step 3 = + 00% + 0200 A after 0100 welds
Step 4 = + 00% + 0100 A after 0100 welds
Step 5 = + 00% + 0050 A after 0100 welds
2 Step 2 = +00% + 0500 A after 100 welds
Stepper Profile

12000

11500

11000 2
10500

10000

9500

9000
24
48
72
96
120
144
168
192
216
240
264
288
312
336
360
384
408
432
456
480
Weld

F30: WELD 160 MS 10000 AMPS - base weld current

Tip Dressing Step 1 = + 00% + 1000 A after 0100 welds
Step 2 = + 00% + 0500 A after 0100 welds
Step 3 = + 00% + 0200 A after 0100 welds
Step 4 = + 00% + 0100 A after 0100 welds
Step 5 = + 00% + 0050 A after 0100 welds
3 Step 3 = +00% + 0200 A after 100 welds
Stepper Profile
Tip Dress Request
12000
3
11500

11000
Tip Dress Remain > 0
10500

10000

9500

9000
24
48
72
96
120
144
168
192
216
240
264
288
312
336
360
384
408
432
456
480
Weld

F30: WELD 160 MS 10000 AMPS - base weld current

Tip Dressing Step 1 = + 00% + 1000 A after 0100 welds
Step 2 = + 00% + 0500 A after 0100 welds
Step 3 = + 00% + 0200 A after 0100 welds
Step 4 = + 00% + 0100 A after 0100 welds
Step 5 = + 00% + 0050 A after 0100 welds

Robot Initiates A Tip Dress Schedule Upon Receiving Request

START OF SEQUENCE #061
56 SET PRESSURE = 02
58 TURN ON WELD IN PROGRESS
86 TIP DRESS ADVANCE: GROUP 01 - STEP 2
56 SET PRESSURE = 00
50 TURN ON WELD COMPLETE
59 TURN OFF WELD IN PROGRESS
75 EXTEND UNTIL NO INITIATE WCU will return all steppers of
51 TURN OFF WELD COMPLETE group to first weld of Step 2
END OF SEQUENCE # 061 (as programmed)
Tip Dressing Step 1 = + 00% + 1000 A after 0100 welds
Step 2 = + 00% + 0500 A after 0100 welds
Step 3 = + 00% + 0200 A after 0100 welds
Step 4 = + 00% + 0100 A after 0100 welds
Step 5 = + 00% + 0050 A after 0100 welds
2 Step 2 = +00% + 0500 A after 100 welds
Stepper Profile
Tip Dress Request
12000
3
11500

11000
2
Tip Dress Remain Count Decrease
10500
If count still > 0, stepper will continue towards step 3
10000

9500

9000
24
48
72
96
120
144
168
192
216
240
264
288
312
336
360
384
408
432
456
480
Weld

F30: WELD 160 MS 10000 AMPS - base weld current

Tip Dressing
As long as Tip Dress Remaining Counts is > 0
WCU will provide a Tip Dress Request on Step 3
for Robot to initiate A Tip Dress Schedule

START OF SEQUENCE #061

56 SET PRESSURE = 02
58 TURN ON WELD IN PROGRESS
86 TIP DRESS ADVANCE: GROUP 01 - STEP 2
56 SET PRESSURE = 00
50 TURN ON WELD COMPLETE
59 TURN OFF WELD IN PROGRESS
75 EXTEND UNTIL NO INITIATE WCU will return all steppers of
51 TURN OFF WELD COMPLETE group to first weld of Step 2
END OF SEQUENCE # 061 (as programmed)
Tip Dressing Step 1 = + 00% + 1000 A after 0100 welds
Step 2 = + 00% + 0500 A after 0100 welds
Step 3 = + 00% + 0200 A after 0100 welds
Step 4 = + 00% + 0100 A after 0100 welds
Step 5 = + 00% + 0050 A after 0100 welds
2 Step 2 = +00% + 0500 A after 100 welds
Stepper Profile
Stepper Approach Max
12000

11500

11000 2
Tip Dress Remain Count Decrease
10500

10000 If count becomes 0,

Stepper Approach Max is turned on at 1st weld of step
9500
2
9000
24
48
72
96
120
144
168
192
216
240
264
288
312
336
360
384
408
432
456
480
Weld

F30: WELD 160 MS 10000 AMPS - base weld current

Tip Dressing Step 1 = + 00% + 1000 A after 0100 welds
Step 2 = + 00% + 0500 A after 0100 welds
Step 3 = + 00% + 0200 A after 0100 welds
Step 4 = + 00% + 0100 A after 0100 welds
Step 5 = + 00% + 0050 A after 0100 welds
3 Step 3 = +00% + 0200 A after 100 welds
Stepper Profile
End of Stepper
12000

11500 3

11000
If Tip Dress Remain Count is decreased to 0,
10500 End of Stepper is activated at start of Step 3
10000 1st 40 welds will be ALERT then
9500 FAULT will occur on 41st weld if Stepper is not
reset
9000
24
48
72
96
120
144
168
192
216
240
264
288
312
336
360
384
408
432
456
480
Weld

F30: WELD 160 MS 10000 AMPS - base weld current

Stepper Status

The weld control unit has many steppers that can be assigned to a weld
schedule. Press F1 to select the stepper (example Stpr#24) for which you
want to review status.
Stepper Status

The status of stepper #24 here reveals the following:

It is currently in the second step of its profile
It is currently at weld number 259 of the second step
It will add 1025 amps to the next weld schedule using stepper 24
There are 43 more tip dresses allowed on the set of caps
Stepper Status

From this status screen, you can Advance the stepper by activating the F3
key
Software overview
• View Data
Weld, Steppers and Active Faults
• Reset Faults and Steppers
• Programming
Setup Parameters
Faults Severity
Operating Parameters
• Weld Schedules
Inserting / Editing Instructions
weld Instructions
Delay Instructions
Input & Output Monitoring
• Steppers
Counts and Boosts
The WTC EDEP ( Ethernet Data Entry Panel) Is a compact programming
device. That communicates with the weld timers though the local or the EIP
Ethernet Ports on the timer and also by the Serial Port on the timer.
The EDEP allows you to program weld schedules, Set-up parameters,
networking and a stepper profile then download the information to the weld
control. It also receives and displays the weld control weld summary data,
Stepper data, Active Faults and view the I/O
When the EDEP is plug in to the local port on the timer the EDEP will only
look for IP address 89.89.200.250. It will only communicate with the timer
which the EDEP is plug into.
If the local IP address is changed the EDEP will not communicates with the
timer. Local IP address does not need to be changed with the EDEP.
To communicates to the timer remotely though the EIP board the timer must
be set up with the IP address and subnet mask will cover this in the program
section there is no limit of timers that this EDEP can talk to.
There is no reason for you as a customer to need to used that serial port
(9 pin D shell type connector) unless both Ethernet ports not communicating
 EDEP Display
IP Address for the timer you are commutating with
The welder ID
if there are active faults or alerts
 The Key Pad
The EDEP provides push button keys to request status displays or making programming
changes.
The 5 “soft” keys F1
through F5 perform
different functions based
Leds 1 through 5 do nothing
on the mode you are in.
The symbols are only used up and down arrow keys
with the shift key pressed. scroll up and down
they are used for the letters to though the display
Program the timer ID.
Left and Right arrow keys
When the Shift key is light it move the cursor within a
allows you to used the top display
lettering in blue on the press
key the number keys 0 – 9 are
used to enter new values.
Power key is for the EDEP
only will not effect the weld Press the Enter key to
timer. place a new value into the
ESC key is used to undo EDEP memory. You must
unsaved data during DOWNLOAD your
programming changes
137
 Power Up
The EDEP requires power from the timer when the EDEP is plug into the local Ethernet
port on the timer. The power comes from the CNMN1 the 9pin connector. Both the cables
have to be plug into the timer for the EDEP to work and have power.
If you are using the EDEP in a remotely you will still have to get power to the
EDEP with the cable that is provided with the EDEP.
When you are trying to talk to the timer remotely remember you will need to program the
EDEP IP address and subnet mask to talk to the timers. when you plug in the switch for
communication you will also need to have a plug for the power.
** The customer that is you, will need to provide the IP addresses and subnet mask all WTC
products will be set the EIP standard defaults.**
There are different cables for the EDEP One for communication locally and different one
for remotely.
When you apply power and plug in the EDEP you will have select local or global Ethernet.
That will be determined by where you plug in the cable.
Remember if the EDEP is plug in to the timer then you want local Ethernet.
If the EDEP is communicating remotely then you will want to select Global Ethernet.

By using the soft “F” keys on the keypad you will

select F2 for Local Ethernet

F3 for Global Ethernet

But First you will have to go into

system setting “EDEP setting” and
set the IP address and the Subnet mask

Change is so you can select a different

language to be display on the EDEP.
To select a language press F5 scroll
To view the data or to program the timer data will work the same way in all three modes
Local or Global Ethernet and Serial communication.
So if you know how to work the EDEP in local Ethernet then you will be able to use
Global Ethernet and even Serial.
To get into Local Ethernet all you have to do it make sure the EDEP is plug into the timer
in the CNMN1 and the CNEN after a few Seconds you will see the screen below
press the F2 key
 Local Ethernet
F1 Key (home) takes you back to the power up screen
F2 Key (Program Mode) is used to see or change the weld control data
F3 Key (Status Mode) to see the overall welding status information
F4 Key (Display Mode) used to see the Timer software and Rev # also Inverter Temp
F5 Key (Change Timer) only used when in Multi timer
 F4 Display Mode
Timer software with rev and Inverter type internal clock with date “programmable” and
internal temp of the inverter with both the EIP and the FTE board Rev level
F1 (back) goes back one screen
 F3 Status Mode
Use the Status Mode to see the overall welding status information about
F1 Back one screen
F2 Stepper status
F3 I/O status
F4 Weld Data
F5 Faults
 F2 Stepper Status
shows the step in & counts done for that step
that boost added to your weld the total
number of welds done the remaining tip
dresses
 F3 I/O Status
This display allows you to monitor the status of the I/O for the selected timer.
The display shows a 1 in the input is or output is active or a 0 if the input or output is
inactive. The display uses abbreviations to show the state of the inputs and outputs as show
here. This display will vary based in the I/O provided with the weld control unit
 F4 Weld Data
Bus v shows the primary inverter voltage detected by the weld timer Sec I shows the
secondary current read during the last weld Pri I shows the inverter primary current during
the last weld
Msec weld time in the weld
sch Ont Ysec used during
the half cy %I the amount
of primary current used
during the weld
Cfact is a parameter, which
is used to track changes in
the weld tooling.
BusV inverter DC voltage
cont# which contactor was
fired with that weld
schedule

Previous will let you look up to the last 30 weld Reset takes you to most resent weld
 F5 Faults

F1 Back one previous screen

F2 Faults view faults only
F3 Alerts view alerts only
F4 All multi mode only
F5 Reset clear faults
 F2 Program Mode
Program Mode is used to see or change the weld schedule, stepper and set-up parameters
for a weld control. you can also reload the default values stored in the weld control assign
an alphanumeric id and program the Ethernet IP Address.

Page 1 Page 2
 F2, F5 Program Mode Page 2

F1 EIP Options setup the commutation to be able to talk to the weld timer by EIP
F2 Welder ID is where you can give your timer a Alfa numeric ID
F3 were you can set the date time and set defaults values
F4 Local Ethernet will change the setting talking to the EDEP only there is no
needed to change it and the only way to change it is by using serial communication.
F5 more takes you back to the first page of the Program menu
 EIP Options
New timers are not set up to commutate you will need to Program the weld timer.
The IP Address and sub net Mask are set by the customer. Also If used by the customer you
will have to set the Gateway and Name Server.
Input and Output Instance are set and should be programmed. They can not be
programmed by the EDEP unless you reload defaults.
Mac Address is the hardware ID and can not be changed.
You will have to set the DHCP most of the time it will need to be changed to off.
The DHCP will set the retry and is only used when DHCP is turned on.
Port Mode should be set to auto. If the mode does not match the
with the Robot or PLC the timer will not talk.
If you set it to auto then it will match
what the robot is set to.
The other options are 10 half and 100 full
 Programming EIP Options

To Program the data use the arrow keys to move the cursor to area you need to edit Type in
the new data and press enter. Finish changing all of the data on the screen
Then you need to press the F2 for download
You must download and cycle power to the timer before the date will take effect.
 F3 Reload for EIP Options
(off) means will we not do any thing
(clear I/O) will erase all programmed I/O
(I/O default) will reset all the I/O back to factory setting
(EIP Factory Default) will reset all your EIP setting back to original setting meaning that
you will have to reprogram all the data in the EIP screen including the DHCP.

If you have to do any of the

reloads press the enter key scroll
to the function that you want
then enter again then you will
have to press the F2 key to
execute then press the F2 key to
confirm that you want to do the
change. then you will have to
cycle power to the timer.
Make sure that you cycle power
because the data will be saved in
the timer but it will not active
until you cycle the timer power
 F5 F2 Welder ID
Welder ID option enables you to assign a 20 digit alphanumeric code to a weld timer. To
program a name press the shift key to light the led, then press the key with the correct letter
or number needed remember to download before leaving this screen. Use the enter to add
a space and esc key to delete the old ID.
 F5 F3 Reload options
Each control stores default values for every programmable setting. The reload option allows
you to reset the control to a known condition. When you reload the default values the
stepper set-up parameters and all of the weld schedules revert to their default values the
EIP setting and the welder ID are not change here. In this screen you can reload to a single
or multi you will only use multi if you have a MCCM board in your weld controller. You can
also set the language date and time. the date and time has no reference to faults or data
changes.
To select a different language scroll to the correct area and press the enter key, then scroll to
the language needed press enter and then F2 to execute then F2 to confirm the EDEP will
cycle power automatically.
 F2 Program Mode Page 1

F1 Back moves you one previous screen

F2 Review Schedule lets you add or delete functions from a weld schedule or change the
values programmed for a function
F3 Review Stepper displays the stepper parameters or profile for a weld schedule
F4 Review Setups shows the control’s programmable set-up parameters.
F5 More takes you to the Second Page.
Pressing the F2 key the review weld schedule is used to program a weld schedule by adding
or deleting functions or by changing the value programmed for a function.
F1 takes you back one previous screen
F2 allow you to select which weld schedule you want to view or edit.
F3 is the download you will need to do that before you exit the screen
F5 more takes you to the second screen
F5 F1 allows you to insert a new weld function in to the weld schedule
F5 F2 lets you delete any weld function in that weld schedule
F5 F3 lets you copy a weld schedule into any weld schedule in that timer.
 To edit a weld function
You First have to select the right weld schedule by pressing F2 then you will type in the
weld schedule that you want to view or edit.
To change the values programmed for a function use the up or down arrows to scroll
though the weld schedule until the cursor is next to the function you want to change.
Press the enter button and type in the new data, press enter then press the F2 Key to apply
the changes, then you will have to press the F3 to download.
You will see a download complete in the lower right side of the screen.
 Insert a weld function
After you select the right weld schedule, use the up and down arrows keys to place the
cursor into the right position the new function will inserted below the line where the
cursor appears. Press the F5
key then you press the F1 key to bring up a list of weld functions available for you to use.
Scroll up and down to find the function needed press the enter key then add the value
needed for the new function press enter the F2 for apply then you will have to go back to
the first screen by pressing the F5 key (more) then press F3 for download you will see
download complete in the lower right side of the screen
 To Delete a weld Function
Use the up and down arrow keys to scroll to the function that you want to delete
Press the F2 key to delete, then F5 key, then the F3 key to download the change.
You will see download compete in the lower right side of the display.
If you exit the program schedule before you download the change will not be in the timer.
 To Copy a weld schedule
Press the F3 key on the second weld schedule screen.
Once the correct weld schedule is display on the screen press the copy key (F3) type in the
correct schedule that you want to copy that data into then press enter you will see a
download complete in the lower right side of the screen.
This will over write every thing in that weld schedule and copy all of the function from that
weld schedule you selected.
 Stepper Program F2 in Program mode
WTC provides a linear stepper that keeps track of the weld count and gradually increases
the heat after a programmed number of welds. Heat is added in several steps until the
programmed set-point where the electrodes must be dressed or replaced. The amount of
energy of the stepper profile is either % heat or Secondary current based on the firing
mode used by the weld function in the weld schedules.
 Edit Stepper Program
You First have to select the right Stepper by pressing F2 then you will type in the number
that you want to view or edit. To change the values programmed for a function use the up
or down arrows to scroll though the steps until the cursor is next to the function you want
to change. Press the enter button and type in the new data, press enter then press the F2
Key to apply the changes, then you will have to press the F3 to download. You will see a
download complete in the lower right side of the screen.
 Review Setup F3 in Program mode
WTC weld controls use a number of programmable settings called set-up parameters to
enable you to customize a weld control to meet your application requirements.
The set-up parameters tell the control about its operating environment and how to react to
certain conditions as a fault or alert.
 Edit Setup Parameters
scroll though the list of parameters to the function that you want to change. Press the enter
key you will see the list of options. scroll though the options to the function you want press
the enter key again the you will have to press the apply and download