STATUS DEP SCREENS


STATUS DEP SCREENS

1.  STATUS DEP SCREEN

Status mode allows you to monitor or change linear and sure-weld stepper status information, view active IWC faults, reset active IWC faults, view IWC hardware and software revisions, and monitor IWC I/O. Table 1, " Status Mode Choices " shows Status Mode Choices.

Table 1.  Status Mode Choices

To perform this operation

Press this function key

Description

STEPPER

F2

This item allows you to access the stepper status displays.

FAULT

F3

This item allows you to access the faults display.

REV

F4

This item allows you to display IWC hardware and software revision levels.

I/O

F5

This item allows you to display IWC inputs and outputs.


2.  STATUS STEPPER SCREEN

The IWC implements two kinds of steppers:

  • Traditional linear steppers

  • Intelligent sure-weld steppers

When you are viewing stepper status you must be aware of which kind of stepper is currently in use.

Note

Modifications to either the linear or sure-weld stepper's status are immediately saved on the robot and downloaded to the IWC.

Table 2.  Status Stepper Screen Items

ITEM DESCRIPTION

Linear stepper status

Select this item to view the Linear stepper status screen.

Sure-weld stepper status

Select this item to view the Sure-weld stepper status screen.

Table 3.  Status Stepper Screen Operations

FUNCTION KEY DESCRIPTION

[TYPE]

Press this key to access various application-specific options.

3.  STATUS LIN STEP SCREEN

Linear stepper status provides a detailed view of which linear stepper was last used along with its overall state. Refer to Table 4, " Linear Stepper Status Information " for linear stepper status information.

Table 4.  Linear Stepper Status Information

LINEAR STEPPER STATUS ITEM DESCRIPTION MODIFIABLE STATE

Boost

This item is the amount of additional current or percentage of current being added to a weld.

Read-Only

Total Welds

This item is the total number of welds made with this stepper.

Modifiable

STEP #

This item is the present stepper's step number.

Read-Only

Step Count

This item is the present stepper's step count.

Read-Only

Stepper #

This item is the present stepper number that is being viewed.

Modifiable

STATE:

This item indicates whether the stepper is ON or OFF. A stepper that has a status of OFF will not provide additional current or percentage of current during a weld.

Read-Only

4.  STATUS SURE STEP SCREEN

Sure-weld stepper status provides a detailed view of which Sure-weld stepper was last used and its overall state. Refer to Table 5, " Sure-weld Stepper Status Information " for Sure-weld stepper status information.

Table 5.  Sure-weld Stepper Status Information

SURE-WELD STATUS ITEM DESCRIPTION MODIFIABLE STATE

Max 1 cycle drop

This item is the largest 1 cycle power factor drop detected. Read-Only

BOOST

This item is the amount of additional current or percentage of current being added to a resistance weld. Modifiable

Total Welds

This item it the total number of welds made with the present stepper. Modifiable

UT

This item is the counter representing the number of up trends. Read-Only

DT

This item is the counter representing the number of down trends. Read-Only

Exp

This item is the counter representing the number of expulsion welds detected. Read-Only

No Exp

This item is the counter representing the number of non-expulsion welds detected. Read-Only

Stepper

This item is the present stepper number being viewed. Modifiable

STATE

This item indicates whether the stepper is ON or OFF. A stepper with a status of OFF will not provide additional current or percentage of current during a weld. Read-Only

Table 6. Status Sure Step Screen Operations

FUNCTION KEY DESCRIPTION

[TYPE]

Press this key to access various application-specific options.

SAVE

Press this key to save Sure-weld stepper status information to the default device.

RESET

Press this key to reset the Sure-weld stepper.

5.  STATUS FAULT SCREEN

The fault data display allows you to:

  • view the active IWC faults

  • view a history of faults on a global, part ID, or part ID/weld ID basis

  • reset active faults

Table 7.  Fault Data Choices

To perform this operation

Press this function key

Description

RESET

F2

This item allows you to reset active IWC faults.

WC_NUM

F3

This item allows you to change the IWC (if more than one IWC board is installed).

HIST

F4

This item allows you to display IWC fault distribution globally, per part identification, or per part identification and weld identification.

HELP

F5

This item allows you to display information on how to use the specific menu options.


6.  FAULT FREQUENCY SCREEN

Global fault history shows all IWC faults and their frequency with no filtering of part ID or weld ID. Refer to Table 8, " Global Fault History Choices " for more information.

Table 8.  Global Fault History Choices

To perform this operation

Press this function key

Description

PART_ID

F3

This item allows you to view fault distribution per part ID (style).

SAVE

F4

This item allows you to save 100 weld history data to default device as "weld.dt."

HELP

F5

This item allows you to view information on how to use the specific menu options.


7.  STATUS REVISION SCREEN

You can use the hardware and software revision screens when you need to report incompatibilities between the robot and the IWC software program.

Table 9.  IWC Status Revision Items

Item Description

CPU

This item displays the IWC hardware version and modification level.

SERIAL

This item displays the IWC hardware serial number.

LCA

This item displays the IWC Logic Cell Array (LCA) hardware logic controller version and revision level.

PRGM

This item displays the IWC application software program version and revision level.

EXEC

This item displays the IWC loader software program and revision level.


8.  STATUS INPUTS AND OUTPUTS

The robot and IWC directly communicate their control and status signals through Dual Port RAM (DPR). DPR inputs and outputs have no physical connections outside of the robot or IWC and therefore require no resource efforts to install or maintain. To troubleshoot or monitor the DPR I/O simply select the IWC I/O status menu.

Table 10.  Status Inputs Screen Items

ITEM DESCRIPTION

Ready to Weld

This IWC output indicates to the robot that the IWC is ready to execute a weld sequence. Refer to the MedWeld 3004 Integrated Weld Control Technical Reference Manual for further information.

Weld/No Weld

This signal indicates the weld controller status (WELD or NOWELD). If the input is ON (high) the weld controller is in the NOWELD mode. If the input is OFF (low) the weld controller is in the WELD mode.

Weld Complete

This signal indicates that the weld sequence is finished. NOTE: IWC might activate the weld complete output conditionally.

Stepper Reset

This item displays which stepper has been reset.

Alert

This signal indicates that a minor alarm/fault has been detected. When this signal is received during production, a fault recovery message is displayed. This signal is defined as active high or low during configuration setup. Refer to the Software Installation Manual.

Fault

This signal indicates that a major alarm/fault has been detected. When this signal is received during production, a fault recovery message is displayed. This signal is defined as active high or low during configuration setup. Refer to the Med Weld 3004 Integrated Weld Control Technical Reference Manual for additional information.

Weld In Progress

This signal indicates that the weld sequence is in progress.

Shunt Trip

This IWC output activates a coil within the weld contactor panel's circuit breaker. After it is activated, the coil will remove power from the welding secondary. The IWC will only activate this output if a threat to safety exists.

AIN1

This is the first of two analog input channels that monitors the set pressure feedback. Refer to the MedWeld 3004 Integrated Weld Control Technical Reference Manual for additional information.

AIN2

This is the second of two analog input channels that monitors the set pressure feedback. Refer to the MedWeld 3004 Integrated Weld Control Technical Reference Manual for additional information.

Table 11.  IWC Inputs and Outputs - Dual Port RAM

I/O Name Communication Type Signal Source Signal Destination IWC Style

Weld Schedule

DPR

Robot

IWC

AC/MFDC

Reset Stepper

DPR

Robot

IWC

AC/MFDC

Weld Mode

DPR

Robot

IWC

AC/MFDC

Init Weld

DPR

Robot

IWC

AC/MFDC

Reset Faults

DPR

Robot

IWC

AC/MFDC

Control Stop

DPR

Robot

IWC

AC/MFDC

Ready to Weld

DPR

IWC

Robot

AC/MFDC

Weld/No-Weld

DPR

IWC

Robot

AC/MFDC

Weld Complete

DPR

IWC

Robot

AC/MFDC

Stepper Reset

DPR

IWC

Robot

AC/MFDC

Alert

DPR

IWC

Robot

AC/MFDC

Fault

DPR

IWC

Robot

AC/MFDC

Weld in Progress

DPR

IWC

Robot

AC/MFDC


Table 12.  IWC Inputs and Outputs - Discrete Wiring

I/O Name Communication Type Signal Source Signal Destination IWC Style Description

Isolation Contactor Auxiliary Status

Discrete Wiring

IWC Contactor Panel

IWC

AC/MFDC

Robot pass through

System Cooling

Discrete Wiring

IWC Contactor Panel

IWC

AC/MFDC

Robot pass through

Inverter Ready to Weld

Discrete Wiring

IWC Contactor Panel

IWC

MFDC

Robot pass through

Isolation Contactor Control

Discrete Wiring

IWC

IWC Contactor Panel

AC/MFDC

Robot pass through

Shunt Trip

Discrete Wiring

IWC

IWC Contactor Panel

AC/MFDC

Robot pass through


Table 13.  IWC Inputs and Outputs - Analog

I/O Name Communication Type Signal Source Signal Destination IWC Style Description

AIN1

Analog

Dense Pack

IWC

AC/MFDC

Robot display

AIN2

Analog

Dense Pack

IWC

AC/MFDC

Robot display

AOUT1

Analog

IWC

Dense Pack

AC/MFDC

Robot display

AOUT2

Analog

IWC

Dense Pack

AC/MFDC

Robot display


Table 14.  Status Inputs Definitions

ITEM DEFINITION

Ready to Weld

This IWC output indicates to the robot that the IWC is ready to execute a weld sequence. Refer to the MedWeld 3004 Integrated Weld Control Technical Reference Manual for further information.

In No Weld

This signal indicates the weld controller status (WELD or NOWELD). If the input is ON (high) the weld controller is in the NOWELD mode. If the input is OFF (low) the weld controller is in the WELD mode.

Weld Complete

This signal indicates that the weld sequence is finished. NOTE: IWC may activate weld complete output conditionally.

Stepper Reset

This item displays which stepper has been reset.

Alert

This signal indicates that a minor alarm/fault has been detected. When this signal is received during production, a fault recovery message is displayed. This signal is defined as active high or low during configuration setup. Refer to the Software Installation Manual.

Fault

This signal indicates that a major alarm/fault has been detected. When this signal is received during production, a fault recovery message is displayed. This signal is defined as active high or low during configuration setup. Refer to the MedWeld 3004 Integrated Weld Control Technical Reference Manual for additional information.

Weld In Progress

This signal indicates that the weld sequence is in progress.

Shunt Trip

This IWC output activates a coil within the weld contactor panel's circuit breaker. Once activated, the coil will remove power from the welding secondary. The IWC will only activate this output if a threat to safety exists.

AIN1

This is the first of two analog input channels that monitors the set pressure feedback. Refer to the MedWeld 3004 Integrated Weld Control Technical Reference Manual for additional information.

AIN2

This is the second of two analog input channels that monitors the set pressure feedback. Refer to the MedWeld 3004 Integrated Weld Control Technical Reference Manual for additional information.

Table 15.  Status Outputs Definitions

ITEM DEFINITION

Weld Schedule

This item signals to the weld controller that the weld sequence group output (GO) is valid and can proceed with the weld.

Reset Stepper

This item tells the controller which stepper to reset.

Weld Mode

This signal is used to set the weld controller into WELD or NOWELD mode. If enable weld is OFF (low), the weld controller will be placed in a NOWELD mode. If enable weld is ON (high) the weld controller will be placed in the WELD mode.

Init Weld

This item signals to the weld controller that the weld sequence group output (GO) is valid and can proceed with the weld.

Reset Fault

Resets weld faults from the robot. When invoked, it pulses for 0.5 seconds. If the weld controller is faulted prior to the weld, the Reset Welder output is pulsed automatically in an attempt to clear the fault. If the fault cannot be cleared, a "Reset Welder timeout" fault is posted. On a Retry or Skip, the Reset Welder output is pulsed prior to performing the weld.

Iso Contactor

An output signal to close isolation contactor so that current can be sent to the gun. This signal is set to ON when the close contactor is executed. This signal is automatically set to OFF whenever a HOLD or ESTOP is encountered during production, or set OFF when the open contactor is executed.

Control Stop

The IWC input is similar to an E-STOP except that the IWC will stop welding and deactivate all outputs when it determines the time is correct.

AOUT1

This is the first of two analog output channels that controls valve pressure settings. Refer to the MedWeld 3004 Integrated Weld Control Technical Reference Manual for additional information.

AOUT2

This is the second of two analog output channels that controls valve pressure settings. Refer to the MedWeld 3004 Integrated Weld Control Technical Reference Manual for additional information.

9. STATUS OUTPUTS SCREEN

The robot and IWC directly communicate their control and status signals through Dual Port RAM (DPR). DPR inputs and outputs have no physical connections outside of the robot or IWC and therefore require no resource efforts to install or maintain. You can troubleshoot or monitor the DPR I/O from the Status Outputs screen.

The Status Outputs screen displays the items in Table 16, "Status Outputs Screen Items " and allows you to perform the operations in Table 17, "Status Outputs Screen Operations " .

Table 16. Status Outputs Screen Items

ITEM DESCRIPTION

Weld Schedule

This item signals to the weld controller that the weld sequence group output (GO) is valid and can proceed with the weld.

Reset Stepper

This item tells the controller which stepper to reset.

Weld Mode

This signal is used to set the weld controller into WELD or NOWELD mode. If enable weld is OFF (low), the weld controller will be placed in a NOWELD mode. If enable weld is ON (high) the weld controller will be placed in the WELD mode.

Init Weld

This item signals to the weld controller that the weld sequence group output (GO) is valid and can proceed with the weld.

Reset Fault

Resets weld faults from the robot. When invoked, it pulses for 0.5 seconds. If the weld controller is faulted prior to the weld, the Reset Welder output is pulsed automatically in an attempt to clear the fault. If the fault cannot be cleared, a "Reset Welder timeout" fault is posted. On a Retry or Skip, the Reset Welder output is pulsed prior to performing the weld.

Iso Contactor

An output signal to close isolation contactor so that current can be sent to the gun. This signal is set to ON when the close contactor is executed. This signal is automatically set to OFF whenever a HOLD or ESTOP is encountered during production, or set OFF when the open contactor is executed.

Control Stop

The IWC input is similar to an E-STOP except that the IWC will stop welding and deactivate all outputs when it determines the time is correct.

AOUT1

This is the first of two analog output channels that controls valve pressure settings. Refer to the MedWeld 3004 Integrated Weld Control Technical Reference Manual for additional information.

AOUT2

This is the second of two analog output channels that controls valve pressure settings. Refer to the MedWeld 3004 Integrated Weld Control Technical Reference Manual for additional information.

Table 17. Status Outputs Screen Operations

FUNCTION KEY DESCRIPTION

[TYPE]

Press this key to access various application-specific options.

SCHED

Press this key to display or modify welding sequences.

STEPPER

Press this key to access the stepper status displays.

SETUP

Press this key to access and set up schedule data.

DEFLTS

Press this key to reload factory defaults.

SAVE

Press this key to save IWC information to the default device.

RELOAD

Press this key to restore IWC information from the default device.

MEDNET

Press this key to reprogram the IWC's MedLAN network address.