NOTE: This portion of the documentation covers the faults and setup parameters of the WT6000 Weld Control. This section of the manual is geared towards line builders, maintenance personnel and welding engineers to assist with procedures related to programming the weld control.

Table of Contents


« 6: Programming Schedules | 8: Linear Current Steppers »

Chapter 7: Faults and Setup Parameters

In this section:

 


Introduction


 

Below is a complete list of the Programmable Faults and Setup Parameters for the WT6000 weld control with timer software G08300. To view a detailed description, click on the name of the fault or setup parameter and the table will expand. Click on the name again to collapse the table.

Perform the following steps on the DEP-300s to edit either a Programmable Fault or Setup Parameter:

STEP
DESCRIPTION
01:
Press Program Mode (F2).
02:
Press Review Setups (F4).
03:
Press the UP or DOWN arrow keys to move the cursor to the fault or parameter line to be edited.
04:
Press ENTER.
05:
Press the UP or DOWN arrow keys to select a fault severity option or enter the required parameter value with the numeric keys.
06:
Press ENTER.
07:
Press APPLY (F2). [Saves changes to the DEP-300s only.]
08:
Press DOWNLOAD (F2). [Downloads the changes to the weld timer. When complete, a "Download Complete" message wil appear.]

 

FAULT SEVERITY

The user can set the severity of the programmable faults. The severity option tells the weld processor how to respond when a fault condition is detected. Conversely, the severity of non-programmable faults are fixed and cannot be changed. See Non-Programmable (Hidden) Faults below.

SEVERITY OPTIONS
SEVERITY DESCRIPTION
FAULT
When a fault condition is detected by the weld processor, the Fault bit will go HIGH and the No Fault bit will go LOW. Fault conditions generally (with a few exceptions) inhibit the initiation of a weld schedule.
ALERT
When an alert condition is detected by the weld processor, the Alert bit will go HIGH and the No Alert bit will go LOW. Alert conditions generally do not inhibit the initiation of a weld schedule.
NONE
When a fault condition is detected, the weld processor still logs the fault, but inhibits the Fault or Alert bits from turning on (HIGH). This condition will not inhibit the initiation of a weld schedule.

 

fault reset

Faults can be reset by either pressing the Reset (F5) button in the Fault Status Menu in the DEP-300s or turning the Fault Reset input bit HIGH. Perform the following steps to reset faults via the DEP-300s:

STEP
DESCRIPTION
01:
Press Status Mode (F3).
02:
Press Fault (F2).
03:
Press Reset (F5).

 

Press the Options (F3) button to filter what is viewed on the Fault Status Menu. Options include ALL, FAULTS, ALERTS or HISTORY.

STEP
DESCRIPTION
01:
Press Options (F3).
02:
Press the UP or DOWN arrow keys to move the cursor over the desired filter option.
03:
Press Enter.




Faults and Setup Parameters



PROGRAMMABLE FAULTS
WELD INITIATE NOT PRESENT
Options:
(FAULT) (ALERT)
Default:
(ALERT)
1
Occurs when function #61 (ABORT IF NO INITIATE FOR nn CYCLES) is used in the weld schedule and the Weld Initiate bit goes LOW within the amount of time programmed in the function.
2
Occurs when the Weld Initiate bit goes LOW before function #63 (TURN ON WELD COMPLETE) is executed in the weld schedule.
STEPPER APPROACHING MAX
Options:
(FAULT) (ALERT)
Default:
(ALERT)
1
Occurs at the 1st weld of step 5 in the stepper program. Indicates the final step in the stepper program has begun and the End of Stepper is approaching.
END OF STEPPER
Options:
(FAULT) (ALERT)
Default:
(FAULT)
1

Occurs at the last weld of step 5 in the stepper program.

EXTENDED WELD
Options:
(FAULT) (ALERT)
Default:
(FAULT)
1

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.

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.

NOTE: 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.

2
Occurs when the Excessive Extend Weld Limit is reached in the Setup Parameters.
HIGH C-FACTOR LIMIT
Options:
(FAULT) (ALERT)
Default:
(ALERT)
1

Occurs when function #92 (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.

LOW C-FACTOR LIMIT
Options:
(FAULT) (ALERT)
Default:
(ALERT)
1
Occurs when function #92 (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.
WELD PROCEED
Options:
(FAULT) (ALERT)
Default:
(FAULT)
1
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.
2
Occurs when function #67 [WAIT FOR INPUT #n TO BE n (0 = OFF 1 = ON)] is used in the weld schedule and the Weld Initiate input bit goes LOW before the specified input bit goes either OFF or ON.
3
Occurs when function #66 [WAIT nnn CY INP #n TO BE n (0 = OFF 1 = ON)] is used in the weld schedule and the specified input bit does not go either OFF or ON within the number of cycles specified.
PRESSURE SWITCH
Options:
(FAULT) (ALERT)
Default:
(ALERT)
1
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.
2
Occurs when function #68 (WAIT nn CY 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.
PRESSURE NOT ACHIEVED
Options:
(FAULT) (ALERT)
Default:
(FAULT)
1
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 ot fime programmed in the function.
CONTROL IN NO WELD
Options:
(FAULT) (ALERT)
Default:
(ALERT)
1
Occurs when a weld schedule is initiated while the weld processor is in No Weld Mode (i.e. the Weld / No Weld bit is LOW).
RETRACT PILOT
Options:
(FAULT) (ALERT)
Default:
(FAULT)
1
Occurs when function #86 (VERIFY CYLINDER #n IS OUT OF RETRACT) is used in the weld schedule and the specified retract cylinder was in retraction when checked by the weld processor.
2
Occurs when function #86 (VERIFY CYLINDER #n IS OUT OF RETRACT) is used in the weld schedule and the weld schedule initiates without the appropriate Retract Pilot input bit mapped.
WELD INTERRUPTION
Options:
(FAULT) (ALERT)
Default:
(FAULT)
1
Occurs when the Weld / No Weld bit goes LOW while the weld control is passing current during the execution of a weld schedule.
2
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 after the circuit breaker is switched back ON and the weld processor re-initializes.
3
Occurs when the weld current is interrupted during the weld time.
LOW LINE VOLTAGE
Options:
(FAULT) (ALERT)
Default:
(FAULT)
1

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.

NOTE: This fault is not used on the WT6000 in the Mini-Pak enclosure configuation.

SOFT OVERCURRENT
Options:
(FAULT) (ALERT) (NONE)
Default:
(ALERT)
1
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.
2

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.

CURRENT REGULATION
Options:
(FAULT) (ALERT) (NONE)
Default:
(ALERT)
1
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.
HIGH / NO MOTOR CURRENT
Options:
(FAULT) (ALERT) (NONE)
Default:
(FAULT)
1
Occurs when function #16 (MOTOR CURR LIMITS HI=nnnn ma LO=nnnn ma) is used in the weld schedule and the measured tip dress motor current is above the HIGH limit any time during the 8ms checking period. When this fault occurs, the motor is immediately turned off.
2
Occurs when the measured tip dress motor current is <= 20ma any time during the 8ms checking period. When this fault occurs, the motor is immediately turned off.
TIP DRESS
Options:
(FAULT) (ALERT) (NONE)
Default:
(FAULT)
1
Occurs when function #16 (MOTOR CURR LIMITS HI=nnnn ma LO=nnnn ma) is used in the weld schedule and the measured tip dress motor current is above the value programmed into the LOW limit for less than (1) second of accumulated time. Conversely, this fault will not occur if the measured current remains above the LOW limit for (1) or more seconds of accumulated time.
PROGRAMMABLE SETUP PARAMETERS
RETRACT MODE
Options:
(LATCHED) (UNLATCHED)
Default:
(LATCHED)
Desc.

The Retract Mode setup parameter determines how the mapped Retract Valve output bit will react when the control receives the mapped Retract Pilot input bit:

MODE
DESCRIPTION
LATCHED In Latched mode, a LOW to HIGH transition on the Retract Pilot input bit causes the state of the Retract Valve output bit to change.
UNLATCHED

In Unlatched mode, the Retract Valve output bit follows the state of the Retract Pilot input bit.


CYL
Options:
(AIR-NORMAL) (AIR-INVERTED)
Default:
(AIR-NORMAL)
Desc.

The Cylinder setup parameter defines the type of weld gun air cylinder being used:

MODE
DESCRIPTION
AIR-NORMAL In Air-Normal mode, the weld tooling uses an air-only cylinder that requires a HIGH Retract Valve output bit to close the gun to the retracted position.
AIR-INVERTED

In Air-Inverted mode, the weld tooling uses an air-only cylinder that requires a LOW Retract Valve output bit to close the gun to the retracted position.


ISOLATION CONTACTOR DELAY (SEC)
Range:
00 to 99
Default:
10
Desc.

When function #89 (TURN OFF ISOLATION CONTACTOR) is used in the weld schedule, this parameter delays the opening of the isolation contactor for the number of seconds programmed. Typically used in robot applications, this parameter reduces wear on the isolation contactor by preventing it from unnecessarily opening and closing during runs of multiple welds.

NOTE: Function #65 (ISOLATION CONTACTOR DELAY = nn SEC.) overrides this global setup parameter, when used locally in a weld schedule.

NOTE: This parameter and function #89 are both disabled when the Isolation Contactor Saver input bit is set LOW.

HIGH CURRENT LIMIT WINDOW (%)
Range:
0% to 99%
Default:
20
Desc.

The High Current Limit Window is calculated as a percentage above the target secondary current (base current + stepper boost). This is a dynamic window, which contours with the linear current stepper program in use.

Ref:
Welding Current Limits PowerPoint Presentation
LOW CURRENT LIMIT WINDOW (%)
Range:
0% to 99%
Default:
20
Desc.

The Low Current Limit Window is calculated as a percentage below the target secondary current (base current + stepper boost). This is a dynamic window, which contours with the linear current stepper program in use.

Ref:
Welding Current Limits PowerPoint Presentation
DATA COLLECTION SAMPLE SIZE
Range:
0 to 99
Default:
5
Desc:
This parameter sets a global command, which allows the weld processor (WCU) to sample data for analysis at controlled intervals. The sample size is the number of consecutive welds collected for analysis (per bin). For more information, see SBC Indexing Capabilities in Ch. 9: Advanced Topics.
Ref:
SPC Data Collection PowerPoint Presentation
DATA COLLECTION SAMPLE FREQUENCY
Range:
0 to 9999
Default:
100
Desc:
This parameter sets a global command, which allows the weld processor (WCU) to sample data for analysis at controlled intervals. The sample frequency is the total number of welds, from which the samples are taken from (per bin). For more information, see SBC Indexing Capabilities in Ch. 9: Advanced Topics.
Ref:
SPC Data Collection PowerPoint Presentation
ANALOG INPUTS
Range:
(VOLTAGE) (CURRENT LOOP)
Default:
(VOLTAGE)
Desc.

This parameter tells the weld processor what type of analog signal will be sent to the Analog I/O Module (AIOM). Either a Voltage (0-10V) signal or a Current Loop (4-20ma) signal.

NOTE: This parameter is used with weld controls built with an analog pressure control option.

MAXIMUM ANALOG PRESSURE
Range:
1 to 9999
Default:
100
Desc.

This parameter sets the maximum pressure limit an analog device can achieve at full output (10V or 20mA). This value can represent any unit of measure (e.g. PSI, BAR, Mpa, etc.)

NOTE: This parameter is used with weld controls built with an analog pressure control option.

VALVE 1 INITIAL PRESSURE
Range:
0 to 9999
Default:
5
Desc.

This parameter sets the initial pressure of the Valve 1 output bit. This value can represent any unit of measure (e.g. PSI, BAR, Mpa, etc.)

NOTE: This parameter is used with weld controls built with an analog pressure control option.

VALVE 2 INITIAL PRESSURE
Range:
0 to 9999
Default:
5
Desc.

This parameter sets the initial pressure of the Valve 2 output bit. This value can represent any unit of measure (e.g. PSI, BAR, Mpa, etc.)

NOTE: This parameter is used with weld controls built with an analog pressure control option.

TRANSFORMER TURNS RATIO
Range:
1 to 256
Default:
73
Desc.

This parameter is the turns ratio for the welding transformer being used. The weld processor uses this value to calculate secondary current during a weld (secondary current = primary current x turns ratio).

NOTE: Function #81 (TRANSFORMER TURNS RATIO nnn:1) overrides this global setup parameter, when used locally in a weld schedule.

TRANSFORMER RATED DC VOLTAGE
Range:
300 to 999
Default:
678
Desc.

This parameter is the rated DC voltage of the welding transformer. This value can be found on the manufacturer's label affixed to the welding transformer.

NOTE: If the manufacturer's label is either inaccessible or has been removed from the welding transformer, contact the manufacturer for assistance.

TRANSFORMER RATED FREQUENCY
Range:
400 to 2000
Default:
1000
Desc.

This parameter is the rated frequency of the welding transformer. This value can be found on the manufacturer's label affixed to the welding transformer.

NOTE: It is critical the value programmed into this parameter is correct. An incorrect value could send the transformer into saturation, causing potential damage to the transformer. If the manufacturer's label is either inaccessible or has been removed, contact the manufacturer for assistance.

FIRING / MONITOR MODE
Range:
(PRI/PRI) (PRI/SEC) (SEC/SEC)
Default:
(PRI/PRI)
Desc.

The WT6000 inverter has three firing and monitoring modes. These modes are distinguished by (1) the method in which the current is regulated, and (2) the feedback monitoring method used to determine the proper output:

MODE
DESCRIPTION
Primary/Primary (PRI/PRI) Primary Current Regulation / Primary Current Monitoring (Default Mode).
Primary/Secondary (PRI/SEC)

Primary Current Regulation / Secondary Current Monitoring.

NOTE: Requires additional hardware for secondary current feedback monitoring.

Secondary/Secondary (SEC/SEC)

Secondary Current Regulation / Secondary Current Monitoring.

NOTE: Requires additional hardware for secondary current regulation and feedback monitoring.


GROUND FAULT LIMIT (milliamps)
Range:
0 to 9999
Default:
5000
Desc.

This parameter sets the maximum differential current between the two output terminals (H1 and H2) of the inverter assembly. This imbalance is caused by current leaking to ground on one of the legs. The weld processor monitors the current balance between the H1 and H2 terminals. If the differential current exceeds this parameter, a GROUND FAULT is generated.

 


Non-Programmable (Hidden) Faults


The following is a list of the non-programmable faults in the WT6000. Their default values are fixed and cannot be changed. Since these faults are non-programmable, they are hidden from view in the DEP-300s View Setups Menu. For more information regarding these faults, see Ch. 10: Fault Diagnostics.

FAULT NAME
DEFAULT VALUE
INVALID SEQUENCE SELECTED
(FAULT)
CONTROL STOP
(FAULT)
HIGH CURRENT LIMIT FAULT
(FAULT)
LOW CURRENT LIMIT FAULT
(FAULT)
ISO CNTR OFF WHEN NEEDED
(FAULT)
ISO CNTR ERR-BRKR TRIPPED
(FAULT)
SYSTEM COOLING
(FAULT)
IO
(FAULT)
INITIATION ON POWER-UP
(FAULT)
CONTROL TRANSFORMER VOLTAGE
(FAULT)
IGBT SATURATION
(FAULT)
IGBT POWER SUPPLY
(FAULT)
AC LINE PHASE
(FAULT)
BUS VOLTAGE
(FAULT)
BUS CHARGING
(FAULT)
SECONDARY DIODE
(FAULT)
SECONDARY CURRENT SENSOR
(FAULT)
GROUND
(FAULT)
TEMPERATURE
(FAULT)

 

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