MedWeld 3000 Series Welding Controls

1 MedWeld 3000 Catalog Revision 8 July 2002 MedWeld 3000 Series Welding Controls Technical Reference Catalog Medar is a brand name for Welding Controls belonging to the Welding Technology Corporation the world s largest supplier of resistance Welding Controls and innovator for resistance Welding technologies. MedWeld 3000 Catalog Revision 8 July 2002 Table of Content MedWeld 3000 Series Welding Controls .. 1 Table of Content .. 2 resistance Welding Application .. 5 Part and Model Numbers ..6 Configurations and Packages ..8 Other available platforms for integrators: ..8 What type of package to order? ..8 Kit Format ..8 Remote Integrated Welding Systems ..8 MedWeld 3005 Kits.

2 9 Single Phase Circuit Cascade Circuit Boards ..9 Note on Current Monitoring for AC and 3-Phase to DC Controls : ..9 Single Phase Power Module ..10 Tripack Multi-Phase Power Multi Timer and Cascade Modules ..12 Interface Door Port Kits ..14 Integrator s Documentation Circuit Breaker with Operator Handle Kits ..15 Isolation Contactor Kits ..15 Power Bus Bar Remote Power Enclosure Solutions .. 16 Note on Current Monitoring for AC and 3-Phase to DC Controls : ..16 Single and Dual Remote Cabinet ..17 Tripack Remote Cabinet ..18 Six-Pack Remote Integrated Single-Phase Weld control Enclosure Solution .. 20 Note on Current Monitoring for AC and 3-Phase to DC Controls : ..20 MedWeld MedWeld MedWeld MedWeld MedWeld MedWeld MedWeld MedWeld Options and Accessories for Integrated Solutions.

3 29 Circuit Breakers with Operating Handles ..29 Isolation Contactors ..29 SCR Power Transformers ..30 Special Multitap Power DC Power Supplies ..30 Power Bus Multi-pin Connectors and Terminal Door Port Access Water Flow Switches and Valves ..31 Secondary Current Monitoring Kits ..31 MedWeld 3000 Catalog Revision 8 July 2002 Allen-Bradley TM 32 Fixed I/O Configuration ..32 Flexible I/O Configurations ..32 Chassis and Interconnect Cables ..33 Power Supplies ..33 Modular Processors ..34 Memory Input and Output Modules ..35 Remote I/O and Device Net Analog and Encoder Modules ..36 Cascade Weld control Solutions .. 37 Single Timer - Multiple SCR Systems ..38 Multiple Timers - Multiple SCR Systems ..38 Model Number Review for Cascade Systems.

4 39 Mid-Frequency to DC (MFDC) Weld control 40 Benefits of MFDC Welding Systems ..41 MF600 Inverter for all Steel Caliber MF600 Inverter Kit ..42 MF1200 Inverter for Aluminum Welding Caliber Range ..43 MF1200 Inverter Kit ..43 Milli-Second Interface Option ..44 Medar MFDC System with Millisecond MedWeld 3005 3-Phase to DC Weld Controls .. 46 Single MedWeld 3-Phase Multiple MedWeld 3-Phase Model Numbers for 3-Phase Systems ..48 Note on Current Monitoring for AC and 3-Phase to DC Controls : ..48 MedWeld MedWeld MedWeld MedWeld Model Number Review for 3-Phase Systems ..53 Safety Ground Fault Systems for Manually Operated Transguns .. 54 2-Level Detection System ..55 2-Level Manual Gun Safety Protection System Option Installed ..55 Touchsafe Switch & Power Supply Installed.

5 55 3-Level Detection System ..56 3-level Manual Gun Safety Protection System Installed ..56 Programming Devices for MedWeld Controls .. 57 DP200s ..58 Network Power Pack ..59 Brad Harrison Cable for Network Power Pack ..59 Medar Networking Products .. 60 Weld Support Systems ..60 Medar WebVIEW (Phase 1)..61 WebVIEW Phase 1 Features: ..61 Sample page of WebVIEW ..61 WebVIEW Phase 2 ..62 WebVIEW Phase 2 Additional Features:..62 Weld Support Systems (Bank System Software)..63 MedWeld 3000 Catalog Revision 8 July 2002 Sizing Circuit Breaker and Isolation Contactors .. 64 RULES FOR SELECTING CIRCUIT BREAKER FRAME SIZES ..64 DISCLAIMER:..64 ASSUMPTIONS: ..64 PART 1: CIRCUIT BREAKER MINIMUM FRAME SIZE SELECTION GUIDE ..65 PART 2: MAGNETIC TRIP RANGE SELECTION.

6 66 RULES FOR SIZING ISOLATION CONTACTORS ..67 DISCLAIMER:..67 ASSUMPTIONS: ..67 PART 1:CALCULATION OF AVERAGE CURRENT DRAW PER Welding TRANSFORMER ..68 PART 2: ISOLATION CONTACTOR CURRENT RATING SELECTION BASED ON TRANSFORMER CONNECTION..69 Directory of Resources .. 71 WTC - Corporate Office ..71 WTC Automotive ..71 WTC Technitron Industrial Division ..71 Industrial Technical Services Division ..71 Quality .. 72 QS 9000 with TE Supplement ..72 Acknowledgements ..72 MedWeld 3000 Catalog Revision 8 July 2002 resistance Welding Application WTC provides control systems for resistance Welding applications such as spot, projection, seam, butt, flash, and upset Welding . The MedWeld Controls that are shown in this catalog can also be used for other applications requiring the control of electrical current such as brazing, annealing, forging, and tempering applications amongst others.

7 The hardware solutions that are presented within this catalog have been designed to operate in harsh environments and have been validated to acceptance tests to perform reliably in industrial plants all over the world. The software solutions that are embedded within the product line in this catalog have been esteemed as some of the most advanced yet simple to use. Please ask your Medar distributor how these WTC Controls can provide answers to some of your most difficult application problems. MedWeld 3000 Catalog Revision 8 July 2002 Part and Model Numbers There are various numbers that can identify a Medar Welding control . The part number is referenced on the serial tag. This number appears such as 952-1196 as an example, which identifies item specific designs with distinct bills of materials.

8 Please use the part number if you wish to re-order an identical control . As a general guide to the composition of a Welding control , a model number is also provided. It is normal however for various Controls of differing part numbers to share a common model number. The following describes the model number scheme. 3095-12=1200-4003-1=#5-4806 The first four digits signify a weld processor and enclosure model. The 30xx means that it is an integration control . The xx9x signifies a specific enclosure (see MedWeld 3095 in table of content). The xxx5 signifies that the weld processor is integrated in the Allen-Bradley SLC 500 rack. The next set of digits (12=1200) signifies the power switches and their configurations. As shown, the 12=1200 signifies that there are twelve Welding processors each with their own 1200 amperes SCRs.

9 A model numbers that indicates 12C=1200 would mean that there is one Welding processor being shared by twelve 1200 amp SCRs in cascading fashion. A model number that indicates 4W12C=1200 would mean that there is four Welding processors being shared by twelve 1200 amp SCRs in cascading fashion. A model number that indicates WTP=1750 would mean that there is a Welding processor controlling a 3-Phase to DC power distribution where the SCRs are rated at 1750 amperes. A model number that indicates 4 WTP=3300 would mean that there is four Welding processors each controlling a 3-Phase to DC power distribution where the SCRs are rated at 3300 amperes. A model number that indicates 2W4TP=3300 would mean that there are two Welding processors controlling four 3-Phase to DC power distribution where the SCRs are rated at 3300 amperes.

10 A model number that indicates 1=MF300 would mean that one Welding processor is controlling a 300 ampere mid frequency inverter. MedWeld 3000 Catalog Revision 8 July 2002 The next set of digits (400-3) signifies the breaker size and the number of poles. The next set of digits (1=#5) signifies the number of isolation contactors and their size. The last set of digits (4806) signifies the voltage and frequency. The first three is the voltage where 480 mean that the control is wired to accept 480 Volts, and the last number 6 means that components are rated for 60 Hz operations. Enclosure & Model No. of SCRs SCR or Inverter Rating Circuit Breaker No. of Poles No of Contactors Rating of Contactors Primary Voltage Line Frequency 3003 - 1 = 1200 - 000 2 - 1 = #3 - 240 5 (50 Hz) 3004 - 2 = 1750 - 150 3 - 2 = #4 - 380 6 (60 Hz) 3006 - 3 = 2500 - 250.