MedWeld 3000 Series Welding Controls Technical Reference Catalog Medar is a brand name for welding controls belonging to the Welding Technology Corporation – the world’s largest supplier of resistance welding controls and innovator for resistance welding technologies. http://www.weldtechcorp.
Table of Content MedWeld 3000 Series Welding Controls ................................................................................... 1 Table of Content........................................................................................................................ 2 Resistance Welding Application ................................................................................................ 5 Part and Model Numbers ................................................................................
Allen-Bradley TM Components.................................................................................................. 32 Fixed I/O Configuration .................................................................................................................32 Flexible I/O Configurations ............................................................................................................32 Chassis and Interconnect Cables.........................................................................
Sizing Circuit Breaker and Isolation Contactors ..................................................................... 64 RULES FOR SELECTING CIRCUIT BREAKER FRAME SIZES ...............................................................64 DISCLAIMER:............................................................................................................................64 ASSUMPTIONS: ........................................................................................................................
Resistance Welding Application WTC provides control systems for resistance welding applications such as spot, projection, seam, butt, flash, and upset welding. The MedWeld controls that are shown in this catalog can also be used for other applications requiring the control of electrical current such as brazing, annealing, forging, and tempering applications amongst others.
Part and Model Numbers There are various numbers that can identify a Medar welding control. The part number is referenced on the serial tag. This number appears such as 952-1196 as an example, which identifies item specific designs with distinct bills of materials. Please use the part number if you wish to re-order an identical control. As a general guide to the composition of a welding control, a model number is also provided.
poles. The next set of digits (400-3) signifies the breaker size and the number of The next set of digits (1=#5) signifies the number of isolation contactors and their size. The last set of digits (4806) signifies the voltage and frequency. The first three is the voltage where 480 mean that the control is wired to accept 480 Volts, and the last number 6 means that components are rated for 60 Hz operations. Enclosure & Model No. of SCRs SCR or Inverter Circuit Rating Breaker No.
Configurations and Packages The MedWeld 3000 Series resistance welding controls have welding processor boards that integrate into the hardware platform of machine or robotic controllers. This eliminates redundant hardware such as input and output modules, multi-conductor cables, terminal points, and rack assemblies. This makes the overall system more reliable in its production environment.
MedWeld 3005 Kits Single Phase Circuit Boards Part No 830-0147 - software: T93300 Please refer to the section on programming devices for editing and reviewing data and parameters stored in the MedWeld 3005 module. Please refer to the Interface Cables table. The MedWeld 3005 Welding Control kit comprises of a resistance-welding processor module that resides in the Allen-Bradley TM SLC 500 rack, a firing card to interface to customer’s own SCR, and a current monitoring coil.
Single Phase Power Module Part No 830-0209 – software: T93300 Part No 830-0210 – software: T93301 Part No 830-0409 – software: T93308 The single power module viewed from the bottom. The current monitoring coil that surrounds the SCR’s tang provides welding data information to the welding processor shown on the left. Choose an appropriate length of interface cable listed in the table on following pages.
Tripack Multi-Phase Power Modules Part No. 830-0168V2 (distributed over three phases) Part No. 830-0168 (distributed over one phase) Software T93300 Please refer to the section on programming devices for editing and reviewing data and parameters stored in the MedWeld 3005 module. Please refer to the Interface Cables table. Tripack power module viewed from the bottom. The return line from the weld transformer must go through the appropriate current monitoring coil that is found beneath the SCRs.
Multi Timer and Cascade Modules Description Part or Model Numbers Multi - 3 Timer & 3 SCR Multi - 2 Timer & 2 SCR Multi - 1 Timer & 1 SCR Multi - 1 Timer & 2 SCR Multi - 1 Timer & 3 SCR Multi - 2 Timer & 3 SCR Cascades Cascade - 1 Timer & 3 SCR Cascade - 1 Timer & 2 SCR Cascade - 1 Timer & 1 SCR Cascade - 0 Timer & 3 SCR Cascade - 0 Timer & 2 SCR Cascade - 0 Timer & 1 SCR 830-0168V2 830-0478 830-0471 830-0555 830-0556 830-0557 120 VAC input switch 24 VAC or DC input switch 830-0481V120 830-0481V24 830-04
Interface Cables Firing Cables 205-1212V2 205-1212V4 205-1212V6 205-1212V8 205-1212V10 205-1212V12 205-1212V16 Length ( ft ) 205-1212V25 25 205-1212V50 50 205-1212V75 75 205-1212V100 100 2 4 6 8 10 12 16 These cables are used to interface the MedWeld 3005 module that resides in the Allen-Bradley TM SLC 500 rack and the firing card that is mounted on the SCR. Please use the proper length of cable for the application.
Door Port Kits Part No 830-0350V10 The HHT door port kit is used for providing environmentally protected access to the MedWeld 3005 resistance-welding processor module to the exterior of the cabinet. The cable plugs into the weld board and extends to the connector board that mounts on a plate to be mounted on the main enclosure. Going clockwise from the bottom, the kit comprises of various bags of hardware, hinged door, gasket, cable, connector board, and mounting plate with access hole.
Circuit Breaker with Operator Handle Kits Circuit Breakers with Operating Handles Kit Part Number Handle 100 amp 3 pole breaker 830-0530 Rotary 100 amp 3 pole breaker 830-0531 Flange 250 amp 2 pole breaker 830-0532 Flange 250 amp 3 pole breaker 830-0533 Flange 400 amp 2 pole breaker 830-0534 Flange 400 amp 3 pole breaker 830-0535 Flange 600 amp 2 pole breaker 830-0536 Flange 600 amp 3 pole breaker 830-0537 Flange Isolation Contactor Kits Kit Part Number Isolation Contactors 24 V
Remote Power Enclosure Solutions Available in AC or MFDC models! The remote power enclosures are suitable for integrated welding control solutions such as the MedWeld 3005 (Allen-Bradley TM SLC500 System), the MedWeld 3003 (Nachi Robotics TM System), the MedWeld 3004 (Fanuc Robotics TM System) and the MedWeld 3006 (Motoman Robotics). It is selected where the user requires a separation of the higher welding bus voltages from the control circuits.
Single and Dual Remote Cabinet Model No. 3003-x=1200-xxxx-…. (Nachi ® Robotics) Model No. 3004-x=1200-xxxx-…. (Fanuc ® Robotics) Model No. 3005-x=1200-xxxx-…. (Allen-Bradley ® SLC 500) Model No. 3006-x=1200-xxxx-….
Tripack Remote Cabinet The Tripack distribution remote enclosure measures 43.5 H x 28 W x 16 D (1105mm x 711 x 406). It is a NEMA 12 enclosure and is equipped with up to three 1200 amp SCRs, three firing modules and three current monitoring sensors. The distribution remote enclosure provides a three-phase bus bar for convenient weld transformer hookup. The resistance-welding processor modules are shipped with the enclosure to be installed in the main processor rack.
Six-Pack Remote Cabinet The six-pack distribution remote enclosure measures 43.5 H x 40 W x 16 D (1105mm x 1016 x 406). It is a NEMA 12 enclosure and is equipped with up to six 1200 amp SCRs, six firing modules and six current monitoring sensors. The distribution remote enclosure provides a three-phase bus bar for convenient weld transformer hookup. The resistance-welding processor modules are shipped with the enclosure to be installed in the main processor rack.
Integrated Single-Phase Weld Control Enclosure Solution The MedWeld 3005 system can be fully configured Welding Control Units (WCU) that is immediately ready for use. It is available in several enclosures in various configurations. There are various standard packages as shown from pages 12 to 16. Should their need to be other customized integrated control packages, please call Medar or its distributor.
MedWeld 3015 Model No. 3015-1=1200-xxxx-…. (Allen-Bradley ® SLC 500) Base includes Nema 12, Type 5 Enclosure One MedWeld 3005 WCU module One 1200 amp SCR One Firing Card One Current Monitoring Coil Options: Maximum: One 4-slot rack with AB modules. 250 / 500 VA Valve Power Supply & Fusing Power lugs or Circuit Breaker (250/400 amp) Isolation Contactor (sizes 4 or 5) HHT Port Kit & I/O Connectors Installed MedWeld 3015 English Metric Approximate Weight 155 lbs 70 Kg Dimensions 33H x 20W x 10.
MedWeld 3025 Model No. 3025-1=1200-xxxx-….
MedWeld 3035 Model No. 3035-x=1200-xxxx-….
MedWeld 3045 Model No. 3045-x=1200-xxxx-….
MedWeld 3055 Model No. 3055-x=1200-xxxx-….
MedWeld 3065 Model No. 3065-x=1200-xxxx-….
MedWeld 3075 Model No. 3075-x=1200-xxxx-….
MedWeld 3095 Model No. 3095-x=1200-xxxx-….
Options and Accessories for Integrated Solutions Circuit Breakers with Operating Handles Circuit Breakers with Operating Handles 100 amp 3 pole breaker 100 amp 3 pole breaker 250 amp 2 pole breaker 250 amp 3 pole breaker 400 amp 2 pole breaker 400 amp 3 pole breaker 600 amp 2 pole breaker 600 amp 3 pole breaker 800 amp 3 pole breaker 1200 amp 3 pole breaker 1600 amp 3 pole breaker 2000 amp 3 pole breaker Note: Maximum rack size stated in MedWeld 3015, 3025, 3035, 3045, 3055, 3065, 3075, and 3095 are given
SCR Upgrades Additional MedWeld 3005 Controls & SCRs Additional MedWeld 3005 module & 1200 amp SCR Additional 1200 amp SCR cascade Upgrade to 1750 amp SCR from 1200 amp (per SCR) Upgrade to 2500 amp SCR from 1200 amp (per SCR) Upgrade to 3300 amp SCR from 1200 amp (per SCR) Power Transformers Power Transformers (120V: 220/480/600V) & Fusing 250 VA 500 VA 1000 VA 1500VA 2000 VA 3000 VA 5000 VA 250 VA Transformer Special Multitap Power Transformers Power Transformers 14Pri Taps/10Sec Taps & Fusing 500 VA
Power Bus Bars Power Bus Bars Med3045 Bars - one Tripack wide Med3055-Med3095 Bars - two Tripack wide 3-Terminal Power Distribution Block Multi-pin Connectors and Terminal Strips Installed Multi-pin Connectors or Terminals 11 pos. Sine A 16 pos. Sine A 21 pos. Sine A 31 pos. Sine A 41 pos. Sine A 10 pos. Harting 16 pos. Harting 24 pos. Harting 32 pos.
Allen-Bradley TM Components Please refer to Allen-Bradley TM Publication: 1746-PL001D-EN-P -November 2001 for description and specifications of these versatile products. Please reference descriptions below as a guide sheet for most common parts used in the MedWeld 3005 Integrated System. These prices are subject to change since Rockwell Automation controls them. Fixed I/O Configuration The fixed I/O configuration will provide the basic necessary I/O control engine to complete a standard welding control.
Chassis and Interconnect Cables The first slot of the first chassis is always reserved for the processor module or the 1747-ASB modules. The chassis houses the processor and the I/O modules. The power supply mounts on the left side of the chassis. Chassis do not include interconnect cables. If an interconnect cable is required, refer to the chassis interconnect cable price table.
Modular Processors The processor is to be inserted in the first slot in the first chassis. There are various processors available that come with varying capabilities. Some welding applications will require some minimal configuration. For example, the full protection level-3 manual transgun system with advanced redundancies described on later pages requires a 5/03 processor as a minimum due to speed and timing requirements.
Input and Output Modules A wide variety of discrete I/O modules are available. The table is a partial listing of the most popular modules that have been used for a MedWeld 3005 system. Please refer to the Allen-Bradley TM publication for detailed specifications of each module.
Remote I/O and Device Net Modules Rather than cabling a multi-wire discrete I/O interface between a host PLC TM and a MedWeld 3005 control, a remote I/O or device net module can be used in place. This configuration will facilitate installation. RIO Device Net Scanner Device Net Interface Control Net Scanner Medar-RIO 1747-SDN 1761-NET-DNI 1747-SCNR Analog and Encoder Modules Allen-Bradley TM provides several options for analog I/O interfaces that can be used for varying resistance-welding applications.
Cascade Weld Control Solutions The MedWeld 3005 Cascade system is available in kit, remote enclosures or fully integrated formats. In the remote enclosure format, a NEMA 12 enclosure is equipped with multiple 1200 amp SCRs, the cascade cards, one firing module, one current monitoring sensor, and the optional circuit breaker and isolation contactor. One MedWeld 3005 resistancewelding processor module is shipped with the enclosure to be installed in the main processor rack.
Single Timer - Multiple SCR Systems The MedWeld 3005 control can be shared amongst multiple SCRs in a cascade circuit. This system allows for individual control for each welding application by time-sharing the welding processor. Simple SCR selection scheme Full-featured welding functions of the MedWeld 3005 are standard. Available in kit formats. Available in remote enclosures. Available in integrated systems.
Model Number Review for Cascade Systems The model of the above configuration can be as follows: 3095-3W9C=1200-xxxx-….. This means that this cascade system has 3 resistance-welding processor modules (-3W) and 9 SCRs in total (9C=1200). Part numbers are used to classify a product in a detailed manner. There are distinct bills of materials that are associated to a part number hence if you want to reorder an identical system to one that has been purchased before; you would specify a “Part Number”.
Mid-Frequency to DC (MFDC) Weld Control Solutions The MedWeld MFDC 600 Amp Inverter shown here is available to systems integrators for use with the MedWeld 3005 interface module or can be interfaced to your own proprietary analog output control systems. The MedWeld MFDC 1200 Amp and MFDC 300 Amp inverters are also available for your integration requirements. All Medar Inverters (MF300, MF600, and MF1200) can be interfaced to other control systems.
Benefits of MFDC Welding Systems There are applications and situations where the MFDC resistance welding is the best choice available. Although there are significantly higher initial prices, the overall cost of using MFDC over single and three-phase SCR control may actually be significantly lower. Consider these advantages: Significant Energy Savings: - for plants that cannot purchase more electrical power, the MFDC approach may allow you to do more projects with less energy.
MF600 Inverter for all Steel Caliber Range Model No. 3005-1=MF600-xxxx-….
MF1200 Inverter for Aluminum Welding Caliber Range Model No. 3005-1=MF1200-xxxx-….
Milli-Second Interface Option This illustration shows the interface to a millisecond control that is required for high-speed welding machines that are found for the assembly of specialized cross wire applications, electrical contacts, and other very high-speed applications. Please consult with a WTC representative for the latest interface specifications that are subject to change.
Medar MFDC System with Millisecond Interface The millisecond interface is equipped with a 25-pin female D-Sub connector. The table below defines the required pin-outs. The interface consists of three digital and four analog inputs and the figure to the left illustrate the interface connections.
MedWeld 3005 3-Phase to DC Weld Controls The MedWeld 3005 can be configured for ThreePhase to DC applications. The flexibility of the Allen-Bradley SLC 500 system permits some unique and innovative solutions for welding. Analog interface solutions are readily available. Even more unique is the possibility of configuring cascade three phase systems. Single MedWeld 3-Phase System WTP – Single MedWeld Three-Phase The MedWeld processor resides in the Allen-Bradley SLC 500 rack.
Multiple MedWeld 3-Phase Systems W2TP – Cascade Three-Phase Control A single MedWeld module (W) can interface to multiple Three-Phase assemblies (TP). In this drawing, we are showing one MedWeld module controlling in cascade, two Three-Phase assemblies hence “W2TP”. The cascade configuration time-shares one MedWeld 3005 control for each three-phase assembly. 4WTP – Multiple Three-Phase Control A single enclosure can host multiple MedWeld modules each controlling one Three-Phase assembly.
Model Numbers for 3-Phase Systems MedWeld 3005 Three Phase to DC MedWeld 3035 -WTP=1200 MedWeld 3035 -WTP=1750 MedWeld 3035 -WTP=2500 MedWeld 3035 -WTP=3300 MedWeld 3065 -WTP=1200 MedWeld 3065 -WTP=1750 Additional Three Phase to DC MedWeld 3065 -WTP=2500 additonal WTP=1200 MedWeld 3065 -WTP=3300 additonal TP=1200 MedWeld 3075 -WTP=1200 additonal WTP=1750 MedWeld 3075 -WTP=1750 additonal TP=1750 MedWeld 3075 -WTP=2500 additonal WTP=2500 MedWeld 3075 -WTP=3300 additonal TP=2500 MedWeld 3095 -WTP
MedWeld 3035-WTP Model No. 3035-WTP=1200-xxxx -….
MedWeld 3065-WTP Model No. 3065-xWxTP=1200-xxxx -….
MedWeld 3075-WTP Model No. 3075-xWxTP=1200-xxxx -….
MedWeld 3095-WTP Model No. 3095-xWxTP=1200-xxxx -….
Model Number Review for 3-Phase Systems The model numbering scheme is the same for 3-Phase systems as they are for singlephase systems and cascades with the difference being that the second grouping of alpha-numeric characters calls out for “WTP” for “Welding Three Phase”. 3065-1W2TP=1750-xxxx-….. Part numbers are used to classify a product in a detailed manner.
Safety Ground Fault Systems for Manually Operated Transguns Monitoring and control circuits are required for ensuring the safety of human beings who operate a welding gun that is integrated with a welding transformer. There is high voltage cables that come in close proximity to the person who manipulates the “transgun” hence several designs need to be incorporated into the tool to make sure that the person does not become the easy path to ground for a primary electrical short circuits.
2-Level Detection System The simpler design is available with the MedWeld 3005 control. This design incorporates the use an independent safety monitoring system to supervise the integrity of the ground cable and monitors for primary current imbalance. If a fault is detected, the safety system will isolate the welding gun from the power lines by tripping the circuit breaker. An under-voltage trip breaker is used for failsafe condition.
3-Level Detection System A more advanced safety design is available with the MedWeld 3005. This design incorporates the monitoring of the ground integrity, imbalance of current and also monitors the resistance of the insulation covering the primary cables to verify that it is greater than 250 K ohms to 2 M ohms. The verification of adequate primary insulation is accomplished with the use an independent monitoring system.
Programming Devices for MedWeld Controls DEP100s Part No. 937-0009 (as shown) 937-0009V2 (with mounting tabs for panel mount) Equipped with a 10ft (3.05 meter) cable Part No.
DP200s DP200A – Annunciator DP200 – Data Programmer Part No. 937-0010 – Data Programmer – rear port Part No. 937-0010V1 – Data Programmer – bottom port Part No. 937-0010V2 – Annunciator – bottom port Part No. 937-0010V3 – Annunciator – rear port Equipped with a 10ft (3.05 meter) cable Part No.
Network Power Pack Part No. 907-0020V1 – for MedWeld 3000s –3 pin Allows networking up to 30 WCU modules to central point 120 VAC Brad Harrison Connector Plug in port for DEP100s (HHT) Cable Phoenix connector for network cable Strain Relief for network cable Convenient suspension bracket for the DEP100s Network Power Pack (Photo of 907-0014V1) Brad Harrison Cable for Network Power Pack Part No. 205-1004 - 12 ft (3.65 meters) Part No. 205-1005 - 20 ft (6.
Medar Networking Products Weld Support Systems WebVIEW Web Browser TCP/IP Ethernet Medar WebVIEW Phase 1: Released March 2001 Power Supply 120 / 220 VAC Remote Front End Processor External Modem Daisy Chain MedLAN (RS485) Factory Mount Medar WebVIEW Interface Module WCU 1 WCU 2 WCU 30 The daisy chain MedLAN network now will remain at the tool. The tools would be equipped with an industrial module that acts as “front end processing”. This module is complete and with few connecting ports.
Medar WebVIEW (Phase 1) WebVIEW consists of a remote front-end processor unit in a small industrial enclosure that is to be mounted near the welding tools. The FEP is a microprocessor-based device that has memory and communications channels. WebVIEW has complete software functionality in its first phase to behave as a stand-alone unit. Included below are some of these features. WebVIEW Phase 1 Features: Interface on MedLAN network (RS485) optically isolated up to 30 MedWeld controls.
WebVIEW – Phase 2 Web Browser Medar WebVIEW Phase 2: Q3 of 2002 TCP/IP Ethernet Daisy Chain MedLAN (RS485) 120 / 220 VAC Remote Front End Processor Medar Power Supply and Network Board with LED Diagnostics WCU 1 WCU 2 WCU 30 Daisy Chain DEPs Data Entry Panel Data Entry Panel Data Entry Panel Data Entry Panel WTC is planning to release Phase 2 WebVIEW in Q3 of Year 2002.
Weld Support Systems (Bank System Software) The Medar WebVIEW product is a product that can stand by itself. Users would simply use the WebVIEW with a computer or other device that has web-browsing software. The user interacts with the MedWeld controls as the user navigates through the various screens of the WebVIEW.
Sizing Circuit Breaker and Isolation Contactors RULES FOR SELECTING CIRCUIT BREAKER FRAME SIZES By Jack Farrow, WTC R&D Center July 7, 1993 For WTC Resistance Welding Controls rev. 11/3/95, 8/6/97 and 2/7/01 DISCLAIMER: The purpose of this document is to assist in selecting the proper size circuit breaker for a given welding application. This document does not constitute any recommendation, warranty or obligation on the part of WTC or any of its employees.
PART 1: CIRCUIT BREAKER MINIMUM FRAME SIZE SELECTION GUIDE There are three classes of duty cycle to consider: A HIGH duty cycle application is seam welding. For HIGH DUTY CYCLE applications, the circuit breaker size should be: CIRCUIT BREAKER SIZE (amps) = TRANSFORMER NAMEPLATE KVA x 2 A MEDIUM duty cycle application is defined as 7 spot welds or more in any 30-second time interval. This corresponds to a duty cycle of more than 5%.
PART 2: MAGNETIC TRIP RANGE SELECTION. The selection of magnetic trip range is determined by maximum peak current draw, not duty cycle or average current. In order to compute maximum peak current draw, maximum welding current, type of welding machine, and number of welds made simultaneously need to be known. The following generalizations are biased toward worst-case; they will usually indicate a need for a higher magnetic trip range than what is actually needed.
RULES FOR SIZING ISOLATION CONTACTORS By Jack Farrow, WTC R&D Center, February 7, 2001 Copyright, 2001 by WTC FOR WTC RESISTANCE WELDING CONTROLS DISCLAIMER: The purpose of this document is to assist in selecting the proper size isolation contactor for a given welding application. This document does not constitute any recommendation, warranty or obligation on the part of Welding Technology Corporation or any of its employees, representatives or distributors.
PART 1:CALCULATION OF AVERAGE CURRENT DRAW PER WELDING TRANSFORMER There are three classes of duty cycle to consider: A HIGH duty cycle application is seam welding. For HIGH DUTY CYCLE applications, the average primary current draw per transformer is: AVERAGE CURRENT DRAW (amps) = TRANSFORMER NAMEPLATE KVA x 2 A MEDIUM duty cycle application is defined as 7 or more spot-welds in any 30-second time interval. This corresponds to a duty cycle of more than 5%.
PART 2: ISOLATION CONTACTOR CURRENT RATING SELECTION BASED ON TRANSFORMER CONNECTION. CASE 1: (simplest) If just one single-phase transformer is connected to an isolation contactor, the required isolation contactor current rating is the value of average current calculated for that transformer from Part 1.
CASE 4: If two or more transformers are connected to different poles of the isolation contactor (three-phase operation), whether the transformers are welding simultaneously or not, the required isolation contactor current rating is the highest sum of average currents for the all the transformers on one phase, times 1.7 (the approximate square root of 3). For example, four 75 KVA fixture welding transformers are connected to all three poles of an isolation contactor.
Directory of Resources WTC - Corporate Office 150 St. Charles Road Carol Stream IL 60188-2083 Tel: 630-462-8250 Fax: 630-462-8259 Email: corporate@weldtechcorp.com Web: www.weldtechcorp.com WTC Automotive 24775 Crestview Court Farmington Hills, MI 48335-1563 Tel: +1 248-477-3900 Fax: +1 248-477-8897 Email: welding@weldtechcorp.com Web: www.weldtechcorp.com WTC Canada 240 Cordova Road P.O. Box 858 Oshawa, Ontario L1H 7N1 Tel: +1 905-433-1230 Fax: +1 905-433-1257 Email: sales@wtc.
Quality QS 9000 with TE Supplement Medar and other WTC brand welding controls are manufactured in WTC’s Farmington Hills, Michigan facility. BSI registers this facility along with the WTC Canada facility and ITS in Farmington Hills Michigan under certificate FM52727 for QS9000 with TE Supplement.
