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. |
The IWC implements two kinds of steppers:
When you are viewing stepper status you must be aware of which kind of stepper is currently in use.
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. |
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 |
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. |
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. |
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. |
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. |
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. |
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. |