NOTE: This portion of the documentation covers the schedule function list for 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.

Table of Contents


« E: Inputs and Outputs | G: Help and Support »

Reference F: Schedule Function List

In this section:


Complete Schedule Function List


The following is a complete list of the default schedule functions for the WT6000 with weld timer software G08300. The default function timing is in Cycles (CY). To change the function timing to Milliseconds (MSEC), perform the following steps on the DEP-300s:

STEP
DESCRIPTION
01:
Press Program Mode (F2).
02:
Press More (F5).
03:

Press Reload Options (F4).

04:
Press the DOWN arrow key until the cursor is over the Function Timing field. Press Enter. A drop-down box will appear.
05:
Press the DOWN arrow key until the cursor is over the (MILLISECONDS) option. Press Enter.
06:
Press Execute (F2). This begins the process to download the change to the weld timer.
07:
The message "Do you want ot reload control information?" will appear. Press Confirm (F2).
08:
The message "Download complete power cycle required" will appear. Re-cycle power on the weld control to complete the process.


FUNCTION NO.
FUNCTION NAME
CATEGORY
1
SQUEEZE nn CYCLES
DELAY
2
COOL nn CYCLES
DELAY
3
HOLD nn CYCLES
DELAY
4
OFF nn CYCLES
DELAY
5
INITIAL SQUEEZE nn CYCLES
DELAY
6
 "*"
7
WAIT nn CYCLES
DELAY
8
 "*"
9
 "*"
10
 "*"
11
 "*"
12
 "*"
13
 "*"
14
 "*"
15
 "*"
16
MOTOR CURR LIMITS HI=nnnn ma LO=nnnn ma
SPECIAL
17
TIP DRESS TIME nn SEC BLANK nnnn ms
SPECIAL
18
START TIP DRESS MOTOR CHECK
SPECIAL
19
STOP TIP DRESS MOTOR CHECK
SPECIAL
20
WELD nn CY. nn %VS
WELD
21
TEMPER nn CY. nn %VS
WELD
22
PREHEAT nn CY. nn %VS
WELD
23
POSTHEAT nn CY. nn %VS
WELD
24
PRE-WELD nn CY. nn %VS
WELD
25
 "*"
26
 "*"
27
 "*"
28
 "*"
29
 "*"
30
WELD nn CY. nnnn0 AMPS
WELD
31
TEMPER nn CY. nnnn0 AMPS
WELD
32
PREHEAT nn CY. nnnn0 AMPS
WELD
33
POSTHEAT nn CY. nnnn0 AMPS
WELD
34
PRE-WELD nn CY. nnnn0 AMPS
WELD
35
 "*"
36
 "*"
37
WELD nnn IMP HI=nnnn0 A LO=nnnn0 A
WELD
38
 "*"
39
 "*"
40
SLOPE nn CY. nn%VS TO nn%VS
SLOPE
41
 "*"
42
 "*"
43
 "*"
44
 "*"
45
SLOPE nn CY. nnnn0 A TO nnnn0 A
SLOPE
46
 "*"
47
 "*"
48
 "*"
49
 "*"
50
TURN ON VALVE n
I/O
51
TURN OFF VALVE n
I/O
52
TURN ON OUTPUT n
I/O
53
TURN OFF OUTPUT n
I/O
54
TURN ON PRESSURE SELECT n
I/O
55
TURN OFF PRESSURE SELECT n
I/O
56
TURN ON CONTACTOR SELECT n
I/O
57
TURN OFF CONTACTOR SELECT n
I/O
58
TURN ON WELD IN PROGRESS
I/O
59
TURN OFF WELD IN PROGRESS
I/O
60
IMPULSE = nn HEAT CY, nn COOL CY
WELD
61
ABORT IF NO INITIATE FOR nn CYCLES
I/O
62
REPEAT (AT NEXT FUNCTION)
SPECIAL
63
TURN ON WELD COMPLETE
I/O
64
TURN OFF WELD COMPLETE
I/O
65
ISOLATION CONTACTOR DELAY = nn SEC.
EXTEND
66
WAIT nnn CY INP #n TO BE n (0 = OFF 1 = ON)
I/O
67
WAIT FOR INPUT #n TO BE n (0 = OFF 1 = ON)
I/O
68
WAIT nnn CY FOR PRESSURE SWITCH INPUT
I/O
69
WAIT FOR PRESSURE SWITCH INPUT
I/O
70
WAIT FOR WELD PROCEED
I/O
71
SET VALVE n CYLINDER PRESSURE nnnn PSI
I/O
72
SET VALVE n TOUCH DOWN PRESSURE nnnn PSI
I/O
73
SET VALVE n TIP DRESS PRESSURE nnnn PSI
I/O
74
WAIT nnn MS FOR PRESSURE ACHIEVED
I/O
75
EXTEND UNTIL NO INITIATE
EXTEND
76
SEC. CURR LIMITS: HI= nnnn0 LOW= nnnn0
SPECIAL
77
EXTEND WHILE INPUT #n IS n (0=OFF 1 = ON)
EXTEND
78
TURN ON FORGE VALVE
I/O
79
TURN OFF FORGE VALVE
I/O
80
FORGE DELAY nnnn MSEC
I/O
81
TRANSFORMER TURNS RATIO  nnn :1
SPECIAL
82
LINEAR STEPPER # nn ASSIGNED (0 = OFF)
SPECIAL
83
 "*"
84
 "*"
85
PROCESS WELD FAULTS
SPECIAL
86
VERIFY CYLINDER #n IS OUT OF RETRACT
I/O
87
 "*"
88
TURN ON ISOLATION CONTACTOR
I/O
89
TURN OFF ISOLATION CONTACTOR
I/O
90
SET SPC OFFSET TO nn
SPECIAL
91
SEND ALL SAMPLES UNTIL NEXT SPC OFFSET
SPECIAL
92
C-FACTOR LIMIT: HI=nnnn LO=nnnn
SPECIAL
93
TIP DRESS ADVANCE: GROUP nn - STEP n
SPECIAL
94
EXTEND WELD IF LOW CURRENT LIMIT FAULT
EXTEND
95
EXTEND WELD IF CURRENT LESS THAN nnnn0
EXTEND
96
 "*"  
97
 "*"  
98
 archive lut register n (WTC FIELD SERVICE USE ONLY)
N/A
99
 GOTO SEQ #nnn
SPECIAL

 

NOTE: Numbers with "*" appearing in the line, indicate no function is assigned to that number.


Delay Functions


Delay functions cause a delay (or wait) time to occur in the weld schedule for a specified length of time. All delay functions essentially perform the same function, but are assigned different names to describe their purpose in the welding process. During delay functions, weld current does not flow and I/O status does not change.

DELAY FUNCTIONS
FUNCTION NO.
FUNCTION NAME
DESCRIPTION
01
SQUEEZE nnnn CYCLES Squeeze time in cycles
02
COOL nnnn CYCLES Cool time in cycles
03
HOLD nnnn CYCLES Hold time in cycles
04
OFF nnnn CYCLES Off time in cycles
05
INITIAL SQUEEZE nnnn CYCLES Initial squeeze time in cycles
07
WAIT nnnn CYCLES Wait time in cycles

 


Weld Functions


weld firing modes

The purpose of a weld function is to deliver a specific amount of weld current to the weld interface for a specific amount of time. The WT6000 weld control uses two modes to supply regulated current to the weld interface: Percent of Available Volt-Second Welding and Constant Current Welding. See Ch. 9: Advanced Topics for more information.

 

percent of available Volt-second Weld functions

In Percent of Available Volt-Second welding, the current value is entered as a percentage (e.g. 50%, 75%, etc.)

WELD FUNCTIONS (VOLT-SECOND MODE)
FUNCTION NO.
FUNCTION NAME
DESCRIPTION
20
WELD nnnn CY. nn %VS Weld time in cycles
21
TEMPER nnnn CY. nn %VS Temper time in cycles
22
PREHEAT nnnn CY. nn %VS Pre-Heat time in cycles
23
POSTHEAT nnnn CY. nn %VS Post-Heat time in cycles
24
PRE-WELD nnnn CY. nn %VS Pre-Weld time in cycles

 

constant current weld functions

In Constant Current welding, current value is entered as the actual amount of secondary current required (e.g. 5,000A, 10,000A, etc.)

WELD FUNCTIONS (CONSTANT CURRENT MODE)
FUNCTION NO.
FUNCTION NAME
DESCRIPTION
30
WELD nnnn CY. nnnn0 AMPS Weld time in cycles
31
TEMPER nnnn CY. nnnn0 AMPS Temper time in cycles
32
PREHEAT nnnn CY. nnnn0 AMPS Pre-Heat time in cycles
33
POSTHEAT nnnn CY. nnnn0 AMPS Post-Heat time in cycles
34
PRE-WELD nnnn CY. nnnn0 AMPS Pre-Weld time in cycles

 

MAIN WELD FUNCTION (#20)

In the following Volt-Second Mode example, the processor will weld for 20 cycles at 65% volt-seconds:

20
WELD 20 CY. 65 %VS

 

MAIN WELD FUNCTION (#30)

In the following Constant Current Mode example, the processor will weld for 20 cycles at 10000A current:

30
WELD 20 CY. 10000 AMPS

 

temper, pre-heat, post-heat and pre-weld functions

Temper, Pre-Heat, Post-Heat and Pre-Weld are material heating functions and are inserted either before or after main weld functions (#20 or #30). They all essentially perform the same function, but are assigned different names to describe their purpose in the welding process. These functions are not figured into the weld data collection algorithm. For example:

 

Example 1: Using a Pre-Heat Function Before the Weld Function

32
PREHEAT 20 CY. 5000 AMPS
30
WELD 20 CY. 10000 AMPS

When the weld sequence is complete, the last weld data in the Weld Data Menu will display 10,000 Amps. As mentioned above, the pre-heat function is not figured in the weld data collection algorithm.

 

Example 2: Using two weld functions, with the first as a pre-heat

30
WELD 20 CY. 5000 AMPS
30
WELD 20 CY. 10000 AMPS

When the weld sequence is complete, the last weld data in the Weld Data Menu will display 7,500 Amps. This is because when two or more weld functions are used in the same weld schedule, the weld data collection algorithm calculates the average current for all the weld functions and displays the results.

 

impulse welding functions

Weld timer software G08300 offers two different methods of pulsation (impulse) welding. The first method has NO-HEAT cool times between the impulses and the second has LOW-HEAT cool times between the impulses.


Method #1: Impulse Welding with "No-Heat" Cool Time:

In this method, the impulse instruction (function #60) is inserted in the weld schedule before the main weld function (#20 or #30).

FUNCTION NO.
FUNCTION NAME
DESCRIPTION
60
IMPULSE= nn HEAT CY nn COOL CY Impulse heat and cool times in cycles

Function #60 defines the length of the impulse heat time and the length of the cool time between each impulse.

When this function is used in conjunction with the main weld function (#20 or #30), the weld processor changes the weld function to display impulses (IMP) rather than cycles (CY).

In the example below, the weld processor will weld (heat) for 10 cycles at 65% volt-seconds, then wait (cool) for 10 cycles. This heat and cool impulse pattern will occur (4) times. As illustrated in the timing chart, no current is flowing during the cool times.

60
IMPULSE= 10 HEAT CY 10 COOL CY
20
WELD 4 IMP 65%VS

NOTE: Although function #60 is typically used in conjunction with main weld functions (#20 or #30), it can also be used before any weld or slope function.



Method #2: Impulse Welding with "Low-Heat" Cool Time:

In this method, the impulse instruction (function #60) is inserted in the weld schedule before Constant Current function #37 (WELD nnn IMP HI=nnnn0 A LO=nnnn0 A).

FUNCTION NO.
FUNCTION NAME
DESCRIPTION
60
IMPULSE= nn HEAT CY nn COOL CY Impulse heat and cool times in cycles
37
WELD nnn IMP HI=nnnn0 A LO=nnnn0 A The number of weld impulses and the amount of current during the impulse (HI) and cool (LO) times.

Function #60 defines the length of the impulse heat time and the length of the cool time after each impulse. Function #37 defines the number of impulses and the amount of (HIGH) current during each impulse and the (LOW) current during each cool time.

In the example below, the weld processor will weld (heat) for 10 cycles and then wait (cool) for 10 cycles. This heat and cool impulse pattern will occur (4) times at 10,000 Amps during each impulse and 5000 Amps during each cool time.

60
IMPULSE= 10 HEAT CY 10 COOL CY
37
WELD 4 IMP HI=10000 A LO=5000A

 


Slope Functions


Slope functions are used when either a linear increase (Up-Slope) or decrease (Down-Slope) in welding current is required over a specified amount of time.

  • Up-Slope: Provides current at the first value and increases it to the second value over the length of time specified.
  • Down-Slope: Provides current at the first value and decreases it to the second value over the length of time specified.

Typically, Up-Slope functions are used before main weld functions (#20 or #30) and Down-Slope functions are used after main weld functions (#20 or #30).

 

SLOPE FUNCTION (VOLT-SECOND MODE)
FUNCTION NO.
FUNCTION NAME
DESCRIPTION
40
SLOPE nn CY. nn%VS TO nn%VS Slope time in cycles from percent heat value 1 (nn%VS) to percent heat value 2 (nn %VS)

 

SLOPE FUNCTION (CONSTANT CURRENT MODE)
FUNCTION NO.
FUNCTION NAME
DESCRIPTION
45
SLOPE nn CY. nnnn0 A TO nnnn0 A Slope time in cycles from current value 1 (nnnn0 A) to current value 2 (nnnn0 A)

 

In the following up-slope weld example, the weld processor will begin welding at 35% volt-seconds and increase to 65% volt-seconds over a 40 cycle time period. Then the processor will weld at 65% volt-seconds for 20 cycles.

40
SLOPE 40 CY. 35%VS TO 65%VS
20
WELD 20 CY 65%VS

 

NOTE: Just as the heat functions mentioned above, the slope functions are not figured into the weld data collection algorithm. Therefore, their value is not averaged into the last weld data viewed in the Weld Data Menu.

 


I/O Functions


I/O functions are used to verify the status of, change status of, or wait for certain I/O points to change states before continuing with the weld schedule.

There are two types of I/O Functions:

  • Functions that interact with inputs
  • Functions that interact with outputs
INPUT FUNCTIONS
FUNCTION NO.
FUNCTION NAME
DESCRIPTION
61
ABORT IF NO INITIATE FOR nn CYCLES This function monitors the Weld Initiate bit for the number of cycles specified. If the Weld Initiate bit goes LOW anytime during this period, the weld sequence will abort and a WELD INIITATE NOT PRESENT FAULT will be generated.
66
WAIT nnn CY INP #n TO BE n (0 = OFF 1 = ON)

This function waits the specified amount of time (cycles) for the specified User Input bit (1-6) to go either OFF (0) or ON (1). If the bit does not go either OFF or ON during this time period, a WELD PROCEED FAULT is generated.

67
WAIT FOR INPUT #n TO BE n (0 = OFF 1 = ON) This function waits for the specified User Input bit (1-6) to go either OFF (0) or ON (1). If the Weld Initiate input bit goes LOW before this occurs, a WELD PROCEED FAULT is generated.
68
WAIT nnn CY FOR PRESSURE SWITCH INPUT

This function waits the specified amount of time (cycles) for the Pressure Switch bit to go HIGH. If the bit does not go HIGH during this time period, a PRESSURE SWITCH FAULT is generated.

NOTE: If the Pressure Switch bit is LOW and the PRESSURE SWITCH parameter is set to FAULT, the weld processor will execute the weld schedule in NO-WELD mode. If the Pressure Switch bit is LOW and the PRESSURE SWITCH parameter is set to ALERT, the weld processor will execute the weld schedule in WELD mode.

69
WAIT FOR PRESSURE SWITCH INPUT This function waits for the Pressure Switch bit to go HIGH.
70
WAIT FOR WELD PROCEED This function waits for the Weld Proceed bit to go HIGH.
71
SET VALVE n CYLINDER PRESSURE nnnn PSI

This function sets the specified valve bit (1-2) to the specified cylinder pressure in PSI.

NOTE: This function requires the optional Analog I/O Module (AIOM) to be installed in the weld control.

72
SET VALVE n TOUCH DOWN PRESSURE nnnn PSI

This function sets the specified valve bit (1-2) to the specified touch down pressure in PSI.

NOTE: This function requires the optional Analog I/O Module (AIOM) to be installed in the weld control.

73
SET VALVE n TIP DRESS PRESSURE nnnn PSI

This function sets the specified valve bit (1-2) to the specified tip dress pressure in PSI.

NOTE: This function requires the optional Analog I/O Module (AIOM) to be installed in the weld control.

74
WAIT nnn MS FOR PRESSURE ACHIEVED

This function waits for the number of milliseconds specified for the cylinder pressure to be achieved. If the pressure is not achieved during this time period, a PRESSURE NOT ACHEIVED FAULT is generated.

NOTE 1: This function must be used after any set pressure function. Otherwise, the weld processor will not know if pressure was achieved before executing the weld function.

NOTE 2: This function requires the optional Analog I/O Module (AIOM) to be installed in the weld control.

93
TIP DRESS ADVANCE: GROUP nn - STEP n

This function advances all the steppers assigned to the specified GROUP number, to the specified STEP number.

For example, if this function was programmed: TIP DRESS ADVANCE: GROUP 02 - STEP 05, every stepper assigned to Group #2 would advance to Step #5.

NOTE 1: This function must be inserted into a tip dress schedule, if the tip dres schedule is used in lieu of the Tip Dress, Tip Dress Group 1 or Tip Dress Group 2 input bits.

NOTE 2: This function can advance several steppers simultaneously. For example, your application may use several different weld schedules to execute a weld on the same tool, but those schedules may be assigned to different steppers (to account for weld variations). This function allows you to advance every stepper assigned to a group, each time any schedule completes a weld.

 

OUTPUT FUNCTIONS
FUNCTION NO.
FUNCTION NAME
DESCRIPTION
50
TURN ON VALVE n Turn on Valve bit (1-6).
51
TURN OFF VALVE n Turn off Valve bit (1-6).
52
TURN ON OUTPUT n Turn on User Output bit (1-6).
53
TURN OFF OUTPUT n Turn on User Output bit (1-6).
54
TURN ON PRESSURE SELECT n Turn on Pressure Select bit (1-4).
55
TURN OFF PRESSURE SELECT n Turn off Pressure Select bit (1-4).
56
TURN ON CONTACTOR SELECT n Turn on Contactor Select bit (1-9).
57
TURN OFF CONTACTOR SELECT n Turn off Contactor Select bit (1-9).
58
TURN ON WELD IN PROGRESS Turn on Weld in Progress bit.
59
TURN OFF WELD IN PROGRESS Turn off Weld in Progress bit.
63
TURN ON WELD COMPLETE

Turn on the Weld Complete bit.

NOTE: This function also processes weld faults. For more information, see function #85 PROCESS WELD FAULTS below.

64
TURN OFF WELD COMPLETE Turn off the Weld Complete bit.
78
TURN ON FORGE VALVE Turn on the Forge Valve bit.
79
TURN OFF FORGE VALVE Turn off the Forge Valve bit.
80
FORGE DELAY nnnn MSEC Inserted in the weld schedule before function #78 (TURN ON FORGE VALVE), this function delays turning on the Forge Valve bit for the number of milliseconds specified.
88
TURN ON ISOLATION CONTACTOR Turn on the Isolation Contactor bit.
89
TURN OFF ISOLATION CONTACTOR Turn off the Isolation Contactor bit.

 


Extend Functions


Extend functions are used to extend a function under certain conditions.

EXTEND FUNCTIONS
FUNCTION NO.
FUNCTION NAME
DESCRIPTION
65
ISOLATION CONTACTOR DELAY = nn SEC. This function delays the opening of the isolation contactor for the number of seconds specified, if the Isolation Contactor Saver bit is HIGH.
75
EXTEND UNTIL NO INITIATE

This function tells the processor to monitor the status of the Weld InItiate bit and to extend the previous function in the weld schedule until the Weld Initiate bit goes LOW.

NOTE: Repeat and Extend functions are mutually exclusive. Do not use the Repeat function with any Extend function in a weld schedule.

77
EXTEND WHILE INPUT #n IS n (0=OFF 1 = ON)

This function tells the processor to monitor the status of the specified input bit (1-6) and to extend the previous function in the weld schedule while the specified input bit is either OFF (0) or ON (1).

NOTE: Repeat and Extend functions are mutually exclusive. Do not use the Repeat function with any Extend function in a weld schedule.

94
EXTEND WELD IF LOW CURRENT LIMIT FAULT

This function tells the processor to extend the weld function if a LOW CURRENT LIMIT FAULT occurs. An EXTEND WELD FAULT is generated.

The weld function is extended only once. If the desired current is not reached on the re-weld, a LOW CURRENT LIMIT FAULT is generated.

NOTE: Repeat and Extend functions are mutually exclusive. Do not use the Repeat function with any Extend function in a weld schedule.

95
EXTEND WELD IF CURRENT LESS THAN nnnn0

This function tells the processor to extend the weld function if secondary current is less than the value programmed (nnnn0).

The weld function is extended only once. If the desired current is not reached on the re-weld, an EXTEND WELD FAULT is generated.

NOTE: Repeat and Extend functions are mutually exclusive. Do not use the Repeat function with any Extend function in a weld schedule.

 

The following is an example of an extend function in a weld schedule:

30
WELD 20 CY. 5000 AMPS
75
EXTEND UNTIL NO INITIATE

NOTE: If the weld initiate input is is dropped before function #75 EXTEND UNTIL NO INITIATE is executed in the weld schedule, a WELD INITIATE NOT PRESENT FAULT will occur.


Special Functions


Special functions are used to either create special conditions inside the welding schedule, set local schedule features that over-ride global setup parameters or to chain multiple weld schedules together.

SPECIAL FUNCTIONS
FUNCTION NO.
FUNCTION NAME
DESCRIPTION
16
MOTOR CURR LIMITS HI=nnnn ma LO=nnnn ma

Used in a tip dress schedule, this function sets the HIGH and LOW current limits (in milliamps) for the tip dress motor. For more information see "Tip Dress Schedule Setup" in Ch 9 Advanced Topics.

NOTE: This function must be inserted in the schedule before function #18 (START TIP DRESS MOTOR CHECK).

17
TIP DRESS TIME nn SEC BLANK nnnn ms

Used in a tip dress schedule, this function tells the weld processor to start measuring the current draw of the tip dress motor for the number of seconds specified. In addition, it identifies the blanking time. This is the time period at the start of the function, during which the motor current is not measured. For more information see "Tip Dress Schedule Setup" in Ch 9 Advanced Topics.

NOTE 1: This function must be inserted in the schedule after function #18 (START TIP DRESS MOTOR CHECK).

NOTE 2: If the welding application requires function #63 (TURN ON WELD COMPLETE) to be used in the tip dress schedule, function #17 must be inserted before function #63 to ensure proper measurement of the tip dress motor current.

18
START TIP DRESS MOTOR CHECK

Used in a tip dress schedule, this function tells the weld processor to turn the tip dress motor ON. For more information see "Tip Dress Schedule Setup " in Ch 9 Advanced Topics.

19
STOP TIP DRESS MOTOR CHECK

Used in a tip dress schedule, this function tells the weld processor to turn the tip dress motor OFF. For more information see "Tip Dress Schedule Setup " in Ch 9 Advanced Topics.

62
REPEAT (AT NEXT FUNCTION)

This function monitors the status of the Weld Initiate input bit. When the last function in the weld schedule is complete, the weld processor checks the status of the Weld Initiate input bit. If the bit is HIGH, the weld processor will repeat the weld schedule, starting at the first line following function #62. When the last function is again complete, the weld processor checks the status of the Weld Initiate input bit. If the bit is still HIGH, the weld processor repeats the weld schedule again, starting at the first line following function #62.This repeat loop will continue until the Weld Initiate input bit goes LOW.

NOTE 1: This function must be placed after the weld function or continual welding will occur.

NOTE 2: Repeat and Extend functions are mutually exclusive. Do not use the Repeat function with any Extend function in a weld schedule.

76
SEC. CURR LIMITS: HI=nnnn0 LOW=nnnn0

This function assigns a static HI / LOW current limit window in the "local" weld schedule only.

This function overrides the "global" HI / LOW CURRENT LIMIT WINDOW parameters described in Ch. 7: Setup Parameters.

81
TRANSFORMER TURNS RATIO  nnn :1 This function assigns a transformer turns ratio in the "local" weld schedule only. It overrides the "global" transformer turns ratio parameters described in Ch. 7: Setup Parameters.
82
LINEAR STEPPER #nn ASSIGNED (0 = OFF) This function assign linear stepper 1-10 (0=OFF).
85
PROCESS WELD FAULTS

This function allows a one-cycle delay in the weld schedule for the weld processor to identify any fault conditions, which may have been generated thus far in the weld schedule.

NOTE 1: This function must be inserted after the main weld function (#20 or #30) in the weld schedule. If it is inserted prior to the weld function, all zeros will be reported in the Weld Data Menu.

NOTE 2: This function only processes the weld data and sets the fault bits. The FAULT and ALERT outputs are not turned on until the end of the schedule.

NOTE 3: The weld processor will execute this function only once during the weld schedule. If the function appears in more than one location in the schedule, the first occurance will be executed and all others will be ignored.

86
VERIFY CYLINDER #n IS OUT OF RETRACT

This function is inserted at the beginning of the weld schedule. It checks the status of the mapped Retract Valve output bit. A HIGH bit indicates the gun is out of retraction (closed) and it is OK to proceed with the weld schedule. A LOW bit indicates the gun is in retraction (open). When this occurs, a RETRACT PILOT FAULT is generated and the weld schedule is immediately terminated.

90
SET SPC OFFSET TO nn

This function assigns the starting bin number (0-99) for SPC Indexing. See Ch. 9: Advanced Topics for more information.

91
SEND ALL SAMPLES UNTIL NEXT SPC OFFSET

This function tells the processor to begin collecting weld data for all welds. This should follow function (#90) SET SPC OFFSET. See Ch. 9: Advanced Topics for more information.

92
C-FACTOR LIMIT: HI=nnnn LO=nnnn This function sets HIGH and LOW C-Factor limits in the weld schedule. See Ch. 9: Advanced Topics for more information.
99
GOTO SEQ#nnn

This function is an unconditional jump to another weld schedule. It tells the processor to stop the present schedule and continue with the first function in another schedule. This is also known as weld schedule chaining.

NOTE 1: This function can be used to save memory in the weld processor by allowing multiple schedules to execute commonly used functions.

NOTE 2: Caution should be observed when using this function. An infinite loop of repeatedly initiated weld schedules can be inadvertently created if the last schedule in the chain is programmed to return to the first schedule in the chain.

 

The following is an example of special function (#81) TRANSFORMER TURNS RATIO:

When this function is used in a weld schedule, its "local" parameters override the "global" turns ratio parameters described in Ch. 7: Setup Parameters. That is, the "local" turns ratio for schedule 1 is 50:1, but the "global" turns ratio for schedules 2 through 255 remain unchanged at 75:1.

00
START OF SCHEDULE # 1
50
TURN ON VALVE 1
81
TRANSFORMER TURNS RATIO 50:1
01
SQUEEZE 15 CYCLES
30
WELD 80 CY. 4000 AMPS
85
PROCESS WELD FAULTS
03
HOLD 02 CYCLES
51
TURN OFF VALVE 1
03
HOLD 10 CYCLES
100
END OF SCHEDULE # 1

WTC
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