NOTE: This portion of the documentation covers the weld schedule programming 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.
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A weld schedule is a list of commands (or functions), which are used to instruct the weld control to deliver a combination of heat (weld current) and time (weld time) to the weld interface, to create a weld nugget.
Essentially, the weld schedule is a "recipe" and the functions within it are the "ingredients". Just as it is important to use the right ingredients in the correct measure to make a good culinary dish, it is likewise important to use the right functions (properly programmed and in the correct order) to make a good weld nugget.
Every weld schedule contains four baisc functions: Squeeze, Weld, Hold and Weld Complete:
FUNCTION |
DESCRIPTION |
---|---|
Squeeze |
Apply pressure (electrode force) to the weld interface. |
Weld |
Deliver weld current to the weld interface. |
Hold |
Apply wait time after the weld current stops to allow the nugget time to cool. |
Weld Complete |
End of schedule. |
All weld functions can be divided into six basic types:
FUNCTION TYPE |
DESCRIPTION |
---|---|
Delay |
Delay functions are used to cause a wait time to occur for a specified amount of time. |
Weld |
Weld functions are used to provide a specified amount of weld current for a specified amount of time. |
Slope |
Slope functions are used to provide either a linear increase or decrease in welding current for a specified amount of time. |
I/O |
I/O functions are used to verify, change the status of, or wait for certain I/O points to change. |
Extended |
Extended functions are used to extend the weld time until certain conditions exist. |
Special |
Special functions are used to create special conditions within the weld schedule. |
For a complete list of weld schedule functions and descriptions, see Reference Chapter F: Schedule Function List.
The following is an example of a typical weld schedule. The functions used and how they are programmed, are solely dependent upon the customers application. Notice that each function has a corresponding number. This allows the user to select functions by number when programming or editing weld schedules.
FUNCTION NO. |
FUNCTION NAME |
00: |
START OF SCHEDULE # 1 |
82: |
LINEAR STEPPER #1 ASSIGNED (0=0FF) |
76: |
SEC. CURR LIMITS: HI=00 LOW=99990 |
81: |
TRANSFORMER TURNS RATIO 73:1 |
88: |
TURN ON ISOLATION CONTACTOR |
58: |
TURN ON WELD IN PROGRESS |
01: |
SQUEEZE 30 CYCLES |
30: |
WELD 10 CY. 10000 AMPS |
03: |
HOLD 5 CYCLES |
63: |
TURN ON WELD COMPLETE |
59: |
TURN OFF WELD IN PROGRESS |
75: |
EXTEND UNTIL NO INITIATE |
64: |
TURN OFF WELD COMPLETE |
89: |
TURN OFF ISOLATION CONTACTOR |
100: |
END OF SCHEDULE # 1 |
NOTE: Functions (00) "Start of Schedule" and (100) "End of Schedule" are permanently programmed into each weld schedule and can be neither added nor deleted. Although, they appear in the weld schedules, they do not appear in the Insert Function Menu of the DEP-300s Data Entry Panel.
Weld schedules are read starting at the top and moving down, one line at a time. The time it takes the weld control to complete an entire weld schedule can be calculated by adding up all time parameters (cycle and/or milliseconds) programmed within each function throughout the entire schedule.
For example, in the weld schedule above, there is 30 cycles of squeeze time, 10 cycles of weld time and 5 cycles of hold time. Thus, the time to complete the entire weld schedule is approximately 45 cycles or 747 milliseconds (.75 seconds).
There are several user interface options available to program a weld schedule. They include the following:
Perform the following steps on the DEP-300s to insert a function into a weld schedule:
STEP |
DESCRIPTION |
01: |
Press Program Mode (F2). |
02: |
Press Review Schedule (F2). |
03: |
Press Sch# (F2). |
04: |
Enter Schedule Number. |
05:
|
Press ENTER. |
06: |
Press MORE (F5). |
07: |
Press the UP or DOWN arrow keys to move the cursor to the line above where the function is to be inserted. |
08: |
Press INSERT (F1). |
09: |
Press INSERT BY FN. # (F4) [Insert by Function Number.] |
10: |
Enter the Function Number. |
11: |
Press ENTER. |
12: |
If the function requires parameters to be entered, proceed to step 13. If not, proceed to step 17. |
13: |
Enter parameter. |
14: |
Press ENTER. |
15: |
For functions with two or more parameters, press the RIGHT arrow key to move the cursor to the next parameter box, then repeat steps 13 & 14. When complete, proceed to step 16. |
16: |
Press APPLY (F2). [Saves changes to the DEP-300s only.] |
17: |
Press DOWNLOAD (F4). [Downloads the changes to the weld timer. When complete, a "Download Complete" message wil appear.] |
Perform the following steps on the DEP-300s to delete a function from a weld schedule:
STEP |
DESCRIPTION |
01: |
Press Program Mode (F2). |
02: |
Press Review Schedule (F2). |
03: |
Press Sch# (F2). |
04: |
Enter Schedule Number. |
05:
|
Press ENTER. |
06: |
Press MORE (F5). |
07: |
Press the UP or DOWN arrow keys to move the cursor onto the function line to be deleted. |
08: |
Press DELETE (F2). [The function is immediately deleted from the DEP-300s.] |
09: |
Press DOWNLOAD (F4). [Downloads the changes to the weld timer. When complete, a "Download Complete" message wil appear.] |
Perform the following steps on the DEP-300s to copy an entire weld schedule from one location and paste it into another:
STEP |
DESCRIPTION |
01: |
Press Program Mode (F2). |
02: |
Press Review Schedule (F2). |
03: |
Press Sch# (F2). |
04: |
Enter (Copy From) Schedule Number. |
05:
|
Press ENTER. |
06: |
Press MORE (F5). |
07: |
Press COPY (F3). |
08: |
Enter (Paste To) Schedule Number. |
09: |
Press ENTER. [The copy is immediately downloaded to the weld timer. When complete, a "Download Complete" message will appear.] |
NOTE: When copying a weld schedule from one location to another, any existing data in the paste location will be completely overwritten and permanently lost.
The following are the default weld schedules for Robot mode in weld timer software G08300:
Default Weld Schedule
|
||
Schedule No. |
Function No. |
Function Name |
1-29 and 32-255 |
00 |
START OF SCHEDULE # n |
82 |
LINEAR STEPPER #0 ASSIGNED (0=0FF) | |
76 |
SEC. CURR LIMITS: HI=00 LOW=99990 | |
81 |
TRANSFORMER TURNS RATIO 73:1 | |
88 |
TURN ON ISOLATION CONTACTOR | |
58 |
TURN ON WELD IN PROGRESS | |
01 |
SQUEEZE 30 CYCLES | |
30 |
WELD 10 CY. 10000 AMPS | |
03 |
HOLD 5 CYCLES | |
63 |
TURN ON WELD COMPLETE | |
59 |
TURN OFF WELD IN PROGRESS | |
75 |
EXTEND UNTIL NO INITIATE | |
64 |
TURN OFF WELD COMPLETE | |
89 |
TURN OFF ISOLATION CONTACTOR | |
100 |
END OF SCHEDULE # n |
Default Tip Dress Schedule
|
||
Schedule No. |
Function No. |
Function Name |
30 and 31 |
00 |
START OF SCHEDULE # n |
58 |
TURN ON WELD IN PROGRESS | |
01 |
SQUEEZE 30 CYCLES | |
59 |
TURN OFF WELD IN PROGRESS | |
63 |
TURN ON WELD COMPLETE | |
03 |
HOLD 5 CYCLES | |
51 |
TURN OFF WELD COMPLETE | |
100 |
END OF SCHEDULE |
The following are the default weld schedules for Machine mode in weld timer software G08300:
Default Weld Schedule
|
||
Schedule No. |
Function No. |
Function Name |
1-255 |
00 |
START OF SCHEDULE # n |
82 |
LINEAR STEPPER #0 ASSIGNED (0=0FF) | |
76 |
SEC. CURR LIMITS: HI=00 LOW=99990 | |
81 |
TRANSFORMER TURNS RATIO 73:1 | |
88 |
TURN ON ISOLATION CONTACTOR | |
58 |
TURN ON WELD IN PROGRESS | |
01 |
SQUEEZE 30 CYCLES | |
30 |
WELD 10 CY. 10000 AMPS | |
03 |
HOLD 5 CYCLES | |
63 |
TURN ON WELD COMPLETE | |
59 |
TURN OFF WELD IN PROGRESS | |
75 |
EXTEND UNTIL NO INITIATE | |
64 |
TURN OFF WELD COMPLETE | |
89 |
TURN OFF ISOLATION CONTACTOR | |
100 |
END OF SCHEDULE # n |