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.

Table of Contents | 2: Unpacking the Control »

Chapter 1: System Overview

In this section:


Introduction


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.

 

WT6000_cabinet_small

minipak_small

Features

  • WT6000 Weld Timer Module

    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.

    • Up to 255 weld schedules.
    • Built in Ethernet/IP.
    • DeviceNet add-on available.
    • 10 available linear current steppers, with 5 steps each.
    • Internal web server allows the user to view and edit timer data from web browser, robot teach pendant or touch panel (HMI) device.
    • Two weld firing modes: Percent of Available Volt-Seconds (%VS) and Constant Current (nnnn0).
    • Non-battery backed up memory.
  • Space-saving enclosure design

    The MiniPak enclosure was designed for customers with plant floor space limitations.

    • Designed to mount on top of a standard robot controller cabinet (see Robot Usage below).
    • Inverter hardware supports either water or air cooling.

 


Robot or Hard Tool Usage


The WT6000 MiniPak enclosure can be configured for either robot or hard tooling applications.

Robot with MiniPak

fanucfanuc with WTC

 


Inside the Weld Control


overview

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.

Specifications


Weld COntrol SPecifications

Power Source

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
525 VAC Nominal @ 380 VAC Line
650 VAC Nominal @ 480 VAC Line
800 VAC Nominal @ 575 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
Firing Control:
Fixed Frequency, Pulse Width Modulation
Current Control:

Primary Constant Current
Secondary Constant Current
Adaptive Control

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
Weld Processor:
Series 6000
Standard Communicatons:

Ethernet IP 10/100 BaseT
1MB SSPI (Smart Serial Pheripheral Interface)
RS485

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

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

Click Here for Detailed Information

  • Maximum temperature not to exceed 104° F. (40° C.), or fall below the dew point of ambient air at about 70° F. (21° C.).
  • pH maintained between 7.0 and 8.0
  • Maximum chloride content 20 PPM (parts per million)
  • Maximum nitrate content 10 PPM
  • Maximum sulfate content 100 PPM
  • Maximum suspended solids content 100 PPM (non-abrasive)
  • Maximum total solids content 250 PPM (suspended and dissolved)
  • Maximum calcium carbonate content 250 PPM

Minimum Water Flow Rate:

Greater than 5 liters/min (1.32 gal/min)

Max Pressure Drop @ 5 liters/min flow:

Less than 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
Ambient Air Temperature:
Less than 104° F (40° C)

Minimum Fan Rating:

80 CFM
Output Current - Air Cooled:
400 Amps
WTC
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