NOTE: This portion of the documentation covers the installation 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


«3: Safety & Warnings | 5: Communications Setup »

Chapter 4: Installing the Control

In this section:

 


Weld Control Cabinet Overview


stand enclosure standard connections

 

minipak enclosure standard connections

 


NUMBER
DESCRIPTION
1
Ethernet/IP from Robot / Switch
2
Control Stop (CSTOP) from safety master
3
Output Power and Ground to MFDC Weld Transformer
4

3-Phase AC Line Power and Ground

5
Cooling Water Connections (In / Out)

 

stand enclosure Safety Labeling

 

minipak enclosure safety labeling


warnings

T2H Short Circuit Stored Energy Warning Arc Flash Warning MiniPak Door Latch Diagram MiniPak Serial Label


NUMBER
DESCRIPTION
1
Circuit Breaker Short Circuit Rating
2
Warning! Stored Energy Device
3
Warning! Arc Flash and Power Safety
4
Door Latch Diagram
5
Serial Tag

 


Installation Checklist


Use the following checklist during the installation process. If you are unsure how to proper install and hookup the weld control cabinet, see Reference Chapter G: Help and Support to contact WTC for assistance.

 

STEP NO.
ACTION
1
Ensure electricity is locked-out at welding bus, power distribution panel, or other applicable power source.
2
Verify weld control cabinet circuit breaker is in the OFF position.
3
Inspect interior of weld control cabinet for loose and/or missing parts. Inspect for any shipping damage.
4
Check and ensure all water drain holes are open and unblocked.
5
Mount weld control at desired location using appropriate mounting hardware (see Cabinet Mounting and Fastening below).
6

Remove access plate and drill / punch holes for:

  • Three-phase AC line power and ground.
  • Output power to MFDC welding transformer and ground.
  • I/O connections (if applicable).
7
Plumb cooling water to supply and return fittings.
8
Connect three-phase AC line power cables (L1, L2, L3) to top of circuit breaker (line side) and tighten according to manufacturer specifications.
9
Connect plant ground cable to copper grounding post inside cabinet.
10
Connect power cables from output of weld control (H1, H2) to primary of welding transformer.
11
Connect ground cable from copper grounding post inside cabinet to welding transformer.
12
Connect data entry panel, Control Stop (CSTOP) and EtherNet (ENET1) cables.
13
Wire I/O connections (if applicable).
14
Verify magnetic and thermal trip settings on circuit breaker, per manufacturer specifications (if applicable).
15
Inspect cabinet and verify all wiring connections (high voltage, terminals, crimp connections, etc.) are secure.
16
Close weld control cabinet door and lock with 1/4-turn fasteners.
17
Remove electrical lock-out devices.
18
Turn weld control cabinet circuit breaker ON.
19
Ensure cooling water is flowing at specified flow rate.

20
Use data entry panel or network software application to program I/O parameters for DeviceNet, Ethernet/IP or speciality communication modules.
21
Use data entry panel or network software application to program setup parameters, weld schedules and current steppers as required for customer application.

 


Mechanical Installation


Mechanical installation overview

The mechanical installation of the WTC weld control requires the following:

  1. Cabinet Placement
  2. Cabinet Mounting and Fastening
  3. Cooling Water and Connections

Shown above: Front and top view of the MiniPak weld control cabinet

 

minipak Cabinet Placement

The Minipak cabinet was primarily designed to mount on top of a robot controller cabinet, but it can also be mounted along a fenceline or wall if required. The cabinet's water cooling circuit is externally mounted underneath the vented back cover and is physically isolated from the internal electrical components. Drain holes exist in the bottom of the vented back cover in the event of a hose rupture or water cooling manifold leak.

NOTE: In the event of a water hose rupture, keep external electrical cables and wiring away from the vented back cover.

 

minipak Cabinet Mounting and Fastening

Depending on the customers application requirements, additional cabinet mounting hardware may be required. See the table below for available options:

Fanuc Robot Controller Cabinet Mounting Hardware
Qty
Description
WTC Part Number
1
Robot Mounting Bracket Right - Fanuc
703-8320
1
Robot Mounting Bracket Left - Fanuc
703-8319
2
M12 Lock Washers
Customer Supplied
2
M12 Nut
Customer Supplied
Wall or Fence Mounting Hardware
Qty
Description
WTC Part Number
1
Wall Mount Bracket - Right
703-8321
1
Wall Mount Bracket - Left
703-8322

 

WARNINGIt is important that a level surface is provided for installation. If the weld control is mounted on an uneven surface, the cabinet doors may be difficult to open.

 

Failure to use approved mounting hardware may void your warranty.

 

 

Water cooling Connections

The MiniPak cabinet includes a vented back cover that isolates the water cooling circuit from the internal electrical components.

Sideview False Back Water label

Shown above: MiniPak Supply and Return Water Fittings

 

Water cooling Requirements

The cooling water provided must comply with chemical and physical
specifications as stated in the Resistance Welder Manufacturers’
Association Bulletin 5–005.05:

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


NOTE: Water that is safe for drinking is generally sufficient for cooling water,
provided it is filtered to eliminate sand and rust particles. In addition, water temperature must NOT fall more than 2° C. below the temperature of the surrounding air - condensation may occur and damage components.

 

WARNINGfailure to maintain proper water cooling to the weld control cabinet may cause damage to the weld control and void the warranty. contact WTC if you have any questions regarding the water cooling requirements listed above.

 

 

DANGERDo Not drill holes in removable coverplates while attached to weld control.

 

 


Electrical Installation


Cabinet Connections

The weld control cabinet contains high voltage, grounding, and external input/ouput connections. This section explains the connection process.

DANGERprior to making any connection inside the weld control cabinet: (1) refer to your facilities electrical lockout policy and procedures. (2) before proceeding, verify no High voltage is present inside the cabinet with a mutlimeter.

 

 

DANGERTHe door of the weld control cabinet is interlocked with the circuit breaker to prevent the door from being opened while power is ON. never attempt to defeat this safety mechanism.

 

Below is a standard electrical drawing for the WT6000 MiniPak enclosure. Follow the steps below when making connections to the weld control. Following this perscribed order will ensure no connections are overlooked:

NOTE: For other enclosure types, see Reference Chapter A: Electrical Drawings. For application specific electrical drawings, contact WTC.

STEP
Color
DESCRIPTION
1
  Connect line voltage to circuit breaker.
2
  Connect ground for line voltage wiring
3
  Connect isolation contactor to weld transformer
4
  Connect ground for weld transformer
5
  Verify control transformer voltage tap setting for your application
6
  Connect control stop (from Robot +24 VDC)
7
  Connect Ethernet/IP cable from switch

Electrical MiniPak

Shown above: Removable and service connections

NOTE 1: Click the image above to view a larger image.

NOTE 2: Dashed lines on WTC prints show connections that are customer responsibility.

 


Weld Control Programming and Setup


Before welding can begin, the following parameters need to be programmed into the weld timer.


program Setup Parameters

Review and program the Setup Parameters as required for the welding application.

The Review Setups Menu is found in the DEP-300s by pressing: Program Mode (F2) -> Review Setups (F4).

NOTE: Refer to Chapter 7: Faults and Setup Parameters for detailed information regarding the description and programming of setup parameters.

 

program weld schedules

Review and program the Weld Schedules as required for the welding application.

The Review Schedule Menu is found in the DEP-300s by pressing: Program Mode (F2) -> Review Schedule (F2).

NOTE: Refer to Chapter 6: Programming Schedules or Reference Chapter F: Schedule Function List for detailed information regarding function descriptions and the programming of weld schedules.

 

setup Linear Current stepper functions

Review and program the Linear Current Stepper Functions as required for the welding application.

The Review Stepper Menu is found in the DEP-300s by pressing: Program Mode (F2) -> Review Stepper (F3).

NOTE: Refer to Chapter 8: Linear Current Steppers for detailed information regarding the description and programming of linear current steppers.

WTC
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