NOTE: This portion of the documentation covers the system overview of the WT6000 Weld Control. This section of the manual is geared towards line builders and maintenance personnel to assist with procedures related to installing the weld control.
The WT6000 Weld Control converts three-phase (50/60Hz) AC line voltage into a single-phase (1000HZ) AC square wave output. The square wave output is fed to the primary of an MFDC welding transformer, where it is recified in the secondary to DC current. DC welding has many advantages over AC welding, including a more efficient consumption of plant power and the ability to make higher qulaity welds by having more control over the welding process.
The weld timer module, internal to the WT6000, uses free format programming and "Flexible I/O" to create weld parameters and programs to fit any welding application.
The MiniPak enclosure was designed for customers with plant floor space limitations.
The WT6000 MiniPak enclosure can be configured for either robot or hard tooling applications.
The WT6000 Weld Control contains the following sub-assemblies:
Inverter Assembly: Converts three-phase (50/60HZ) AC line voltage to single-phase (1000HZ) AC.
Weld Timer Assembly (processor): Brains of the weld control and controls all Ethernet/DeviceNet communications.
Isolation Contactor: Located downstream of the inverter to interrupt current to the MFDC welding transformer.
Control Transformer: Steps down line voltage to 120V and 24V for the cabinet power.
Circuit Breaker: Supplies or interrupts line voltage to the entire weld control cabinet.
Water/Air Manifold: Water standard, optional air cooling available.
Power Source |
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Standard Line Voltage Configurations: |
3-Phase AC 220V-480V (± 10%) |
Alternate Line Voltage Configuration: |
3-Phase AC 575V (± 10%) |
Line Frequency: |
50/60 Hz (Automatic Selection) |
Output Frequency: |
1,000 Hz Default (Range = 400Hz - 2,000Hz) |
Output Current at 10% Duty Cycle: |
400 Amps |
Output Voltage: |
305 VAC Nominal @ 220 VAC Line |
Maximum Power: |
260 KVA @ 480 VAC Line Power |
Device Type: |
IGBT |
Current Rise Time: |
< 4ms Into Resistive Load |
Power Consumption: |
70VA (Idling condition) |
Monitoring and Control Functions |
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Firing Control: |
Fixed Frequency, Pulse Width Modulation |
Current Control: |
Primary Constant Current |
Primary Current Range: |
10A to Rated Current Level |
Primary Current Accuracy: |
± 1% Setting, ± .5% Repeatability |
DC Bus Voltage Measurement Accuracy: |
± 1% Setting, ± .5% Repeatability |
Secondary Current Accuracy: |
± 2% Setting, ± 1% Repeatability |
Secondary Voltage Accuracy: |
± 3% |
Secondary Resistive Accuracy: |
± 3% |
MFDC Transformer Flux Protection: |
Included |
Duty Cycle Protection: |
Monitors Inverter and Weld Transformer Duty Cycle |
MFDC Weld Transformer Monitoring: |
Diode Short Monitoring |
Power Consumption: |
70VA (Idling Condition) |
Processor & Functions |
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Weld Processor: |
Series 6000 |
Standard Communicatons: |
Ethernet IP 10/100 BaseT |
Optional Commnications: |
DeviceNet |
Onboard Inputs (LIO): |
2 x 24VDC |
Onboard Outputs (LIO): |
3 x 120VAC |
Number of weld schedules: |
255 |
Number of steppers: |
10 |
Processor Storage Type: |
F-RAM (No Battery Required) |
Weld Processor Languages: |
English |
Environmental Conditions |
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Operating Temperature: |
5° C to +50° C |
Humidity: |
0 - 90% (Relative, without Condensation) |
ESD: |
EN 61000-4-2 Level 3 |
Noise Immunity: |
EN 61000-4-4 Level 3 |
Surge Immunity: |
EN 61000-4-5 Level 3 |
Water Cooling Requirements |
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Click Here for Detailed Information
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Minimum Water Flow Rate: |
Greater than 5 liters/min (1.32 gal/min) |
Max Pressure Drop @ 5 liters/min flow: |
Less than 70kPa / .7 bar / 10 PSI |
Pressure Rating: |
Less than 620 kPa / 6.2 bar / 90 PSI |
Electrical Sensitivity of Water: |
Greater than 5000 ohms/cm |
Water Inlet Temperature: |
Less than 95° F (35° C) |
Output Current - Water Cooled: |
400 Amps |
Air Cooling Requirements |
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Ambient Air Temperature: |
Less than 104° F (40° C) |
Minimum Fan Rating: |
80 CFM |
Output Current - Air Cooled: |
400 Amps |