Flashing Procedure for WTC Timers

In all cases, the procedure for setting up the timer for the
appropriate I/O interface is to follow 5-Steps:

1) Backup the timer files using RAFT Gateway

2) Flash the timer with new operating firmware

3) Setting up the I/O for proper use (Global 2, 3 or 4)

4) Restore and check the timer for proper settings

5) Qualify the operation of the weld timer in production

1
Flashing Procedure for WTC Timers

You can upgrade weld timers using RAFT Gateway Network Software from a
networked system such as Workstations on the factory floor and linking to the
weld processor via the Ethernet IP.

You can also use a portable laptop computer running RAFT Gateway and
connecting to a weld processor via the door port that is itself connected to the
local Ethernet port.

The timer must be powered up either by its placement within its inverter in the
weld control cabinet that is itself powered up -OR- the timer can be on a table
powered up using a power supply.

Step 1: Backing up timer files using RAFT Gateway 2

Flashing Procedure for WTC Timers
Power Supply: 24VDC Output

To flash a weld timer with application

Gen 6 Weld Timer firmware or FPGA firmware, you will need to
have access to a timer with power. This can
be done while the timer is inserted into the
inverter or be under power on a test bench as
shown in this case.

Here is shown a Gen 6 timer on a test bench,

powered by 24VDC power supply via a ribbon
cable.
Ethernet IP Port
An Ethernet CAT cable plugged into the local
Ethernet Cable from computer to timer
Ethernet port. The flashing of timer can also
local Ethernet port (89.89.200.250)
be performed via the Ethernet IP port.

Step 1: Backing up timer files using RAFT Gateway 3

Flashing Procedure for WTC Timers

To flash a weld timer with application

Gen 6A Weld Timer firmware or FPGA firmware, you will need to
have access to a timer with power. This can
be done while the timer is inserted into the
inverter or be under power on a test bench as
shown in this case.

Here is shown a Gen 6A timer on a test

bench, powered by 24VDC power supply.

An Ethernet CAT cable plugged into the local

Ethernet IP Port
Ethernet port. The flashing of timer can also
be performed via the Ethernet IP port.

Ethernet Cable from computer to timer

local Ethernet port (89.89.200.250)

Step 1: Backing up timer files using RAFT Gateway 4

Flashing Procedure for WTC Timers

Power up the timer by means of a ribbon

cable plugged into the far left “INTERFACE“
connector.

Step 1: Backing up timer files using RAFT Gateway 5

Flashing Procedure for WTC Timers
If you are flashing an upgrade software to a welding timer that is currently in use
in production, you need to make sure that you have saved all the programs and
the current stepper status and reference information from that timer.

Timer firmware is A15311 version 09;

INVAL is shown because the timer is not in an inverter

Double-click on the timer line to open a dialog and open another TAB with the timer name as its
identifier. This will open a new TAB as appears on page 7.

Step 1: Backing up timer files using RAFT Gateway 6

Flashing Procedure for WTC Timers

Timer identifier TAB

You will need to backup the files that are in the timer if the timer is currently in use in production. The backup files may already be
stored on the network however if not, then execute the UPLOAD button to create a backup file (wdf file will be generated)

Step 1: Backing up timer files using RAFT Gateway 7

Flashing Procedure for WTC Timers
Once you press UPLOAD, RAFT Gateway will request what files you desire to
backup. Checking “Timer Data” box will automatically select every single
element below.

You can limit the selection by un-clicking boxes and also pressing the “+” icon
to expand the sub selection to limit the number of schedules, steppers, and
other status as examples.

In this example, the Offset Resistance Data is

un-checked.

Since this timer does not have RAFT license

activated, this is an appropriate selection

Step 1: Backing up timer files using RAFT Gateway 8

Flashing Procedure for WTC Timers

You will be prompted to save the file in a place with a name. Navigate to the desired folder and type in a file name.

Then press Save button.

Step 1: Backing up timer files using RAFT Gateway 9

Flashing Procedure for WTC Timers

You can see here the

file “2000-TEST.wdf”
which is now the
backup file.

Step 1: Backing up timer files using RAFT Gateway 10

Flashing Procedure for WTC Timers

Once you have a backup file for the timer, you can
upgrade the timer with an updated firmware.

2: Flashing timer using RAFT Gateway 11

Flashing Procedure for WTC Timers

Timer identifier TAB

You can see that the RAFT Gateway is setup to be able to do Upgrade. If this TAB is not present for you, please refer to next page 13.

If this TAB is present, you can skip to page 14.

2: Flashing timer using RAFT Gateway 12

Flashing Procedure for WTC Timers

From the Menu bar, click on Settings. From the drop down menu, click on Configuration. Scroll down in the Configuration menu until
you find the Upgrade Panel option. Click the Enabled check box. Then click the Save button to save the changes. A Service Reset
dialog box will appear. Click the Yes button to restart the Services and for the changes to take effect. A Configuration Changed dialog
box will appear. Click the Yes button for the changes to take effect and to proceed with the close and re-start of Raft Gateway.

2: Flashing timer using RAFT Gateway 13

Flashing Procedure for WTC Timers
If you want to re-flash the timer
with new application firmware or
FPGA firmware, you will click the
button Timer Software.

The Upgrade TAB will identify all

the hardware and firmware
Present firmware: A15311-50-09 revision level of the timer.
Present FPGA firmware: f15103 Rev04

For example, this timer already

The Upgrade button is ghosted when there is no selected Timer has firmware A15311 and it is
Firmware link. To get the link, you will have to press the Timer
Software button revision 09. The nomenclature
following the firmware is to
indentify the inverter. Since this
timer is powered on the bench
and not powered by means of its
FPGA firmware can also be flashed into the timer using this procedure.
inverter, the word INVALID is
shown.

The FPGA is the inverter current

regulation firmware and this one
shows it is f15103. The timer
used in this test has a PROFINET
expansion board.

2: Flashing timer using RAFT Gateway 14

Flashing Procedure for WTC Timers
Note:
Timer Software files
are normally ending
with a suffix of a
version number. The
“bin” suffix shown
here designates a
pre-release version of
software.

Normally the file

name would be
something like
“a1561100.12”

Locate the desired timer firmware to flash into the present timer. Here is selected
“a15611.bin” firmware in a version 12 folder. You will then click on Open button.

2: Flashing timer using RAFT Gateway 15

Flashing Procedure for WTC Timers

The Upgrade button is active when there is a selected Timer Firmware link.

Pressing “Upgrade” button will immediately send the file to the timer
with the evidence of the reception LED on the Ethernet connector will
show a continuous stream. If this does not happen, your computer
firewall is blocking transmission.

Please refer to “How to Disable Firewall” document. (2017-05-11)

You will see that the timer firmware is identified and then you can press the Upgrade button. Then you will have to be patient
for about 4 to 6 minutes while the timer re-loads itself with new operating firmware. During the flashing process, the timer’s
5 LEDs will now change to rapid sequencing orange that loop around.

2: Flashing timer using RAFT Gateway 16

Flashing Procedure for WTC Timers

Windows Firewall will block transmission of the file to the timer hence the “hourglass” icon will continue until it times out and
then the RAFT Gateway will report an error: I/O exception occurred while sending file.

2: Flashing timer using RAFT Gateway 17

Flashing Procedure for WTC Timers

Click on “Turn Windows

Firewall on or off” to
change condition

For downloading the file to the timer for flashing its operating system, you will need to make sure that Windows Firewall is
OFF. Here shows the condition of Windows Firewall being ON.

2: Flashing timer using RAFT Gateway 18

Flashing Procedure for WTC Timers

Set radio buttons to Turn off Windows Firewall for flashing timer then press OK

2: Flashing timer using RAFT Gateway 19

Flashing Procedure for WTC Timers

Windows Firewall is now turned OFF

2: Flashing timer using RAFT Gateway 20

Flashing Procedure for WTC Timers

RX LED

With Firewall turned off, the timer will receive the file from RAFT Gateway. You will see the receive LED on the
incoming port show that data is streaming into it by appearing constantly on. This yellow LED on this Gen 6A
time on the local Ethernet port shows this condition.

While the download of the file occurs, RAFT Gateway will have an “hourglass” icon (or whatever the user’s
computer is setup to show waiting state).

2: Flashing timer using RAFT Gateway 21

Flashing Procedure for WTC Timers

The Gen 6A timer will flash itself in a very quick instant.

5 4 3 2 1
The Gen 6 timer will take several minutes to flash itself

Gen 6 Timer

On Gen 6 timers ONLY, during the flashing process, the timer’s 5 L.E.D. will sequence by rotating an increasing
rotation of orange illuminations at positions 1, 2, 3, 4, 5 and then back to 1 .

Gen 6A timers flash themselves very quickly – there will not be any LED illumination sequence apparent.

Once complete, all LED will go off and then the timer will repower itself.

Both the Gen 6 and the Gen 6A timer after its flashing will reboot and come up with a RAM DATA FAILURE fault

2: Flashing timer using RAFT Gateway 22

Flashing Procedure for WTC Timers

Timer identifies its software now as A15311 version 12

RAM Data Failure indicated once the timer cycles from its flashing procedure.

2: Flashing timer using RAFT Gateway 23

Flashing Procedure for WTC Timers

Timer identifies its software now as A15311 version 12

This particular version also has the text “GM12” in the

version identification – this one being a beta version of 12
for GM for trial and validation purpose only

2: Flashing timer using RAFT Gateway 24

Using G14611/A15611 Software for GM Global 2 and GM Global 3/4 Robot Interface

Now that the timer has the right software and appropriate revision level, it needs to
be setup for use for the right robot interface.

The timer can be setup manually point by point for any type of I/O points however
there are three standards for GM Global interface

 64 In / 64 Out – used for Global 3 or Global 4 robots (Pages 26 - 33)

 16 In / 16 Out – used for Global 2 robots (Pages 34 - 36)
 32 In / 32 Out – used for Global 2 robots with modified use for RAFT (Pages 37 - 40)

Step #1 is to set up the proper I/O space on the timer (System Default)

Step #2 is to populate the I/O points (EIP Default)

Step #3 is to verify that the I/O points are set correctly

3: Setting up the I/O for proper use (Global 2 / 3) 25

Using G14611/A15611 Software for GM Global 2 and GM Global 3/4 Robot Interface
Preparing Weld Timer for Global 3 or Global 4 (64 In / 64 Out)
For 64 Bit Interface, on Reload Defaults, select
“Single + RAFT + SPOTID”.

Apply Changes and Save Changes.

You will get a statement above to cycle

power. Do not cycle yet, you will do one
more default loading to the timer and when
the second load is complete, then you will
cycle power to the timer.

Just click OK to acknowledge the statement.

Step 1: Setup size of the interface

3: Setting up the I/O for proper use (Global 2 / 3) 26

Using G14611/A15611 Software for GM Global 2 and GM Global 3/4 Robot Interface
Preparing Weld Timer for Global 3 or Global 4 (64 In / 64 Out)

For 64 Bit Interface, on Reload Defaults,

select “64 x 64 SpotID + RAFT”.

Apply Changes and Save Changes.

You will get a statement above to cycle

power. You will cycle power to render the
changes.

First click OK to acknowledge the statement

then cycle power to the timer.

Step 2: Download the appropriate I/O points into the memory

3: Setting up the I/O for proper use (Global 2 / 3) 27

Using G14611/A15611 Software for GM Global 2 and GM Global 3/4 Robot Interface
Verifying I/O for Weld Timer for Global 3 or Global 4 (64 In / 64 Out)

There are 64 inputs, too many to

display on this page however there is
a scroll bar that you can push down to
see the remaining inputs

Inputs 1 to 22 seen here

Step 3: Verify that the I/O is correctly set

3: Setting up the I/O for proper use (Global 2 / 3) 28

Using G14611/A15611 Software for GM Global 2 and GM Global 3/4 Robot Interface
Verifying I/O for Weld Timer for Global 3 or Global 4 (64 In / 64 Out)

There are 64 inputs, too many to

display on this page however there is
a scroll bar that you can push down to
see the remaining inputs

Inputs 22 to 46 seen here

Step 3: Verify that the I/O is correctly set

3: Setting up the I/O for proper use (Global 2 / 3) 29

Using G14611/A15611 Software for GM Global 2 and GM Global 3/4 Robot Interface
Verifying I/O for Weld Timer for Global 3 or Global 4 (64 In / 64 Out)

There are 64 inputs, too many to

display on this page however there is
a scroll bar that you can push down to
see the remaining inputs

Inputs 41 to 64 seen here

Step 3: Verify that the I/O is correctly set

3: Setting up the I/O for proper use (Global 2 / 3) 30

Using G14611/A15611 Software for GM Global 2 and GM Global 3/4 Robot Interface
Verifying I/O for Weld Timer for Global 3 or Global 4 (64 In / 64 Out)

There are 64 outputs, too many to

display on this page however there is
a scroll bar that you can push down to
see the remaining outputs

Outputs 1 to 22 seen here

Step 3: Verify that the I/O is correctly set

3: Setting up the I/O for proper use (Global 2 / 3) 31

Using G14611/A15611 Software for GM Global 2 and GM Global 3/4 Robot Interface
Verifying I/O for Weld Timer for Global 3 or Global 4 (64 In / 64 Out)

There are 64 outputs, too many to

display on this page however there is
a scroll bar that you can push down to
see the remaining outputs

Outputs 22 to 46 seen here

Step 3: Verify that the I/O is correctly set

3: Setting up the I/O for proper use (Global 2 / 3) 32

Using G14611/A15611 Software for GM Global 2 and GM Global 3/4 Robot Interface
Verifying I/O for Weld Timer for Global 3 or Global 4 (64 In / 64 Out)

There are 64 outputs, too many to

display on this page however there is
a scroll bar that you can push
upwards to see the remaining outputs

Outputs 41 to 64 seen here

Step 3: Verify that the I/O is correctly set

3: Setting up the I/O for proper use (Global 2 / 3) 33

Using G14611/A15611 Software for GM Global 2 and GM Global 3/4 Robot Interface
Preparing Weld Timer for Global 2 - Non RAFT (16 In / 16 Out)
For 16 Bit Interface, on Reload
Defaults, select “Single Gun”.

Apply Changes and Save Changes.

You will get a statement above to cycle

power. Do not cycle yet, you will do one
more default loading to the timer and when
the second load is complete, then you will
cycle power to the timer.

Just click OK to acknowledge the statement.

Step 1: Setup size of the interface

3: Setting up the I/O for proper use (Global 2 / 3) 34

Using G14611/A15611 Software for GM Global 2 and GM Global 3/4 Robot Interface
Preparing Weld Timer for Global 2 - Non RAFT (16 In / 16 Out)
For 16 Bit Interface, on Reload Defaults,
select “16 x 16 Single”.

Apply Changes and Save Changes.

You will get a statement above to cycle

power. You will cycle power to render the
changes.

First click OK to acknowledge the statement

then cycle power to the timer.

Step 2: Download the appropriate I/O points into the memory

3: Setting up the I/O for proper use (Global 2 / 3) 35

Using G14611/A15611 Software for GM Global 2 and GM Global 3/4 Robot Interface
Verifying I/O for Weld Timer for Global 2 - Non RAFT (16 In / 16 Out)

16 INPUTS 16 OUTPUTS

Step 3: Verify that the I/O is correctly set

3: Setting up the I/O for proper use (Global 2 / 3) 36

Using G14611/A15611 Software for GM Global 2 and GM Global 3/4 Robot Interface
Preparing Weld Timer for Global 2 - RAFT (32 In / 32 Out)
For 32 Bit Interface, on Reload
Defaults, select “Single + RAFT”.

Apply Changes and Save Changes.

You will get a statement above to cycle

power. Do not cycle yet, you will do one
more default loading to the timer and when
the second load is complete, then you will
cycle power to the timer.

Just click OK to acknowledge the statement.

Step 1: Setup size of the interface

3: Setting up the I/O for proper use (Global 2 / 3) 37

Using G14611/A15611 Software for GM Global 2 and GM Global 3/4 Robot Interface
Preparing Weld Timer for Global 2 - RAFT (32 In / 32 Out)

For 32 Bit Interface, on Reload Defaults,

select “32 x 32 Single + RAFT”.

Apply Changes and Save Changes.

You will get a statement above to cycle

power. You will cycle power to render the
changes.

First click OK to acknowledge the statement

then cycle power to the timer.

Step 2: Download the appropriate I/O points into the memory

3: Setting up the I/O for proper use (Global 2 / 3) 38

Using G14611/A15611 Software for GM Global 2 and GM Global 3/4 Robot Interface
Verifying I/O for Weld Timer for Global 2 - RAFT (32 In / 32 Out)

32 INPUTS

Step 3: Verify that the I/O is correctly set

3: Setting up the I/O for proper use (Global 2 / 3) 39

Using G14611/A15611 Software for GM Global 2 and GM Global 3/4 Robot Interface
Verifying I/O for Weld Timer for Global 2 - RAFT (32 In / 32 Out)

32 OUTPUTS

Step 3: Verify that the I/O is correctly set

3: Setting up the I/O for proper use (Global 2 / 3) 40

Using G14611/A15611 Software for GM Global 2 and GM Global 3 Robot Interface

You will need to restore from the backup file. Click on the Download Button

4: Restore and Checking Timer for Correct Settings 41

Using G14611/A15611 Software for GM Global 2 and GM Global 3 Robot Interface

Select the backup file and then click on the Open button

4: Restore and Checking Timer for Correct Settings 42

Using G14611/A15611 Software for GM Global 2 and GM Global 3 Robot Interface

You will get a warning that the online timer has a software version that is different than the offline
file that was created.

The online timer software is A15311-50-12 however the backup file was created from a timer that
had software A15311-50-09.

You will proceed past the warning and click the Yes button

You will get a second warning that you can

potentially corrupt the timer if the data is
incompatible. In this case, we are certain
that the software is compatible and we will
proceed by clicking the Yes button again.

4: Restore and Checking Timer for Correct Settings 43

Using G14611/A15611 Software for GM Global 2 and GM Global 3 Robot Interface
You can select all or partial data to download to the timer.

In this case, we download all the data with the exception of the
EIP Input and EIP Output

After you Press OK, you will see progress bar for the download

After the download, you will be prompted to cycle power

4: Restore and Checking Timer for Correct Settings 44

Using G14611/A15611 Software for GM Global 2 and GM Global 3 Robot Interface

Now you will check to see if the timer is populated with all the correct
settings. You will select the Reports tab

4: Restore and Checking Timer for Correct Settings 45

Using G14611/A15611 Software for GM Global 2 and GM Global 3 Robot Interface

Now you will check to see if the timer is populated with all the correct
settings. You will compare the timer to the backup file that you saved.

4: Restore and Checking Timer for Correct Settings 46

Using G14611/A15611 Software for GM Global 2 and GM Global 3 Robot Interface

Select the backup file and then click on the Open button

You will compare to all the data by pressing Yes

4: Restore and Checking Timer for Correct Settings 47

Using G14611/A15611 Software for GM Global 2 and GM Global 3 Robot Interface

A report will be generated to show the differences discovered in the timer as compared to the backup file. In
this example, there are 33 differences. You will need to review the differences and reconcile the differences.

4: Restore and Checking Timer for Correct Settings 48

Using G14611/A15611 Software for GM Global 2 and GM Global 3 Robot Interface

In this example, all the differences relate to a change in feature introduced into
version 12 software as compared to version 9.

This particular difference is accepted - understanding that now the timer has a %VS
function that can abort the welding sequence if a target current is not achieved. A
separate document discussing the feature of the new %VS with target checking is
available for review.

4: Restore and Checking Timer for Correct Settings 49

Using G14611/A15611 Software for GM Global 2 and GM Global 3 Robot Interface

The timer is ready for use in production. As in all other cases, you will treat this as a
spare parts replacement – after commissioning the new timer software into
production, you will verify its performance in production.

5: Qualify the operation of the weld timer in production 50

Using G14611/A15611 Software for GM Global 2 and GM Global 3 Robot Interface

END

51