NWC-900 Instruction Manual

Document No.
: TCI-0003E-M-ACU
Control Dept: Electrical Engineering
INSTRUCTION MANUAL
for Maintenance
WELD CONTROL FOR STATIONALY SPOT WELDER

NWC-900 series
Original instructions
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ij The instruction manual must be carefully ~

~.< read for proper machine operation. ~:·
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<~ No person is allowed to install, conduct test run of, operate, maintain, repair the ~<
>,' machine or do similar works, without having well understood what the manual refers >~
~ ~- ~
>,· The improper operation with inadequate knowledge may cause serious accident. >"
~~ Incidentally, the manual must be kept at a place accessible to any of the person ~
~ concerned. ~
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~~ Please inquire an uncertain point of our Sales Department/each office. ~~
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lmJ DENGENSHA
1-23-1 Masugata, Tama-ku, Kawasaki-shi, Kanagawa-ken, JAPAN
TEL : +81-44-922-1121 /FAX : +81-44-922-11 00
NOTICE
1. Please do not reprint contents of this instruction partially without permission.
2. The content of Instruction manuals might change without notifying beforehand.
3. Please contact us when there are any suggestions like an uncertain by any chance
point, mistake, and description leakage, etc.
Revision history
-
3 Change signal name
2010/
12/29
Nakano
·~ ('~"
'11. 1.01 l
\..~/
Change Temper cool cycle 2010/
~l
~a -
Ochiai
2 Nozaki 2010/ 2010/
Change Program sheet 09/21 09/22 09/22
Fukuta Ochiai
2010/
I Parts code is added to fuse. T.Nakano 2010/ 2010/
08/31 08/31 08/31
Fukuta Ochiai
2010/
- First edition M.Arima 2010/ 2010/
08/18 08/18 08/18
Revision code Revision item Date Drawn Verification Approved
B DENGENSHA
Instruction manuals
Instruction manuals are provided individually for the welder (Installation, operation, maintenance),
program box, monitor box and Special function.
• Resistance welder control unit instruction manual (for maintenance) This document
This manual provides instructions regarding the resistance welder control unit main body,
descriptions of the control unit (timer unit) functions, notes of operation, such as the
installation method, troubleshooting against errors and maintenance.
• Program box · Monitor program box instruction manual

Separate volume
This manual provides instructions regarding the program box and monitor box used as a
monitor for a resistance spot welder control unit, such as setting of program data, key
operations necessary for monitor display and display data.
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Contents
1. AFETY INSTRUCTIONS AND CONSIDERATIONS ....................................... 1-1
1 - 1. Product safety labels and symbols .................................................................................. 1-1

1-2. Application ofthe equipment and safety ......................................................................... 1-2
1 - 3. Safety considerations ....................................................................................................... 1-2
1 - 4. Safety during operation ................................................................................................... 1-2
1 - 5. Electrical safety ............................................................................................................... 1-3
1 - 6. Safety items on maintenance work. ................................................................................. 1-4
1 - 7. Accident prevention ........................................................................................................ 1-6
2. Outline ................................................................................................................... 2-1

2 - 1. Outline of Weld controls ................................................................................................. 2-1
2 - 2. Place of Weld controls .................................................................................................... 2-1
2- 3. Progratn Box ................................................................................................................... 2-2
2 - 4. Progratn cable ................................................................................................................. 2-3
3. Specification .......................................................................................................... 3-1

3- 1. Device ............................................................................................................................. 3-1
3 - 2. Functions ......................................................................................................................... 3-3
3- 3. Weld controls .................................................................................................................. 3-4
3 - 4. Jumper, DIP SW on Titner board .................................................................................... 3-6
3- 5. Timer Board Input/Output Signal ................................................................................... 3-8
4. Operation ............................................................................................................... 4-1

4 - 1. Basic operational sequences ............................................................................................ 4-1
5. Programming ......................................................................................................... 5-1

5- 1. Flow of Programming (Setting of Functions and Welding Conditions) ......................... 5-1
5 - 2. Progratn Contents ............................................................................................................ 5-1
5-3. Outline ofprogratn sheet ................................................................................................. 5-12
6. Special functions ................................................................................................... 6-1

6 - 1. Stepper function .............................................................................................................. 6-1
7. Current control mode ............................................................................................. 7-1

7- 1. Current control ................................................................................................................ 7-1
7 - 2. Voltage cotnpensation control. ........................................................................................ 7-1
7- 3. HCCL Control (Heat Control Current Limit) .................................................................. 7-2
7- 4. Setting ............................................................................................................................. 7-3
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8. Monitor function .................................................................................................... 8-1
8 - 1. Monitoring functions by the program box ...................................................................... 8-1
9. Fault code .............................................................................................................. 9-1

9- 1. Fault code List ................................................................................................................. 9-1
9 - 2. Fault code ........................................................................................................................ 9-2
10. Maintenances ....................................................................................................... 10-1

10 - 1. Notes when performing maintenance ............................................................................ 10-1
10 - 2. Fuse replace1nent. .......................................................................................................... 10-1
11. Maintenance and Spare parts list. ........................................................................ 11-1

11 - 1. Maintenance parts list ................................................................................................... 11-1
11 - 2. Spare parts list ............................................................................................................... 11-1
11 - 3. Replaceable component list 1 ........................................................................................ 11-2
11-4. Replaceable component list 2 ........................................................................................ 11-3
12. Program sheet ...................................................................................................... 12-1

13. Option .................................................................................................................. 13-1
13 - 1. Wrong nut and No nut function ..................................................................................... 13-1
13- 2. Table for not works detection operation ....................................................................... .13-3
13 - 3. Setdown detection ......................................................................................................... 13-4
13 - 4. Feeder Interface connector ............................................................................................ 13-5
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Iii DENGENSHA
1. AFETY INSTRUCTIONS AND CONSIDERATIONS
IT IS IMPERATIVE THAT :
Any person involved with the installation, functional testing, operation, maintenance and repair of
this machine must start the work with complete understanding of the machine after reading this
INSTRUCTION MANUAL carefully, to help prevent personal injury or damage to the equipment.
DENGENSHA equipment has been designed and produced with due consideration to safety. Be sure
to observe the instructions in this instruction manual. Failure to comply with these instructions may
cause personal injury.
1 - 1. Product safety labels and symbols

In this manual and the machine, the following labels or symbols are used.
( 1) General warning sign

This is the general warning sign. It is used to alert the user to potential
hazards. All safety messages that follow this sign shall be obeyed to avoid
possible hann.
(2) Hazard severity panels
Lh DANGER
Indicates a hazard with a high level of risk which, if
not avoided, will result in death or serious injury.
Lh WARNING
Indicates a hazard with a medium level of risk which, if
not avoided, could result in death or serious injury.
Lh CAUTION
Indicates a hazard with a low level of risk which, if not
avoided, could result in minor or moderate injury.
(3) Prohibition sign

t<:'\ A black graphical symbol inside a red circular band with a red diagonal bar
\J defines a safety sign that indicates that an action shall not be taken or shall
be stopped.
(4) Mandatory action
0 A white graphical symbol inside a blue circle defines a safety sign that
indicates that an action shall be taken to avoid a hazard.
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1 - 2. Application of the equipment and safety
This equipment is intended for use, exclusively, for the purpose specified in associated
documentation (instruction manual, specification sheet). Employment of the equipment for
any other purpose is regarded as a deviation from the intended application.
Improper usage other than intended may cause :
(a) Serious injury or death,
(b) Damage to this and/or other equipment
DENGENSHA equipment uses the latest state of the art technology and is made to operate
safely and reliably. The equipment should be used only for the intended purpose. Dengensha
will not accept liability for misuse of the equipment.
1 - 3. Safety considerations
We emphasize that DENGENSHA MFG.CO., LTD. disclaims all liability for damage and
malfunctions resulting from non-compliance with the following instructions in particular :
(a) The instruction manual must be read and strictly understood. If there are any questions,
contact our business department and/or each office.
(b) Unauthorized conversion and/or modification affecting the safety of the equipment are
not allowed.
(c) The equipment may not be equipped or operated with products of other manufacturers
whose use is not expressly pennitted in the associated manuals.
(d) For the items(b )and(c), consult with our business department/each office on safety.
1 - 4. Safety during operation
CAUTION
(1) Injury prevention from electrode or clamping force
Resistance welding machine generally uses electrode pressurizing force or clamping
force of several thousands Newtons or more.
Since this large force is dangerous, do not put hands, fingers, or any part of the body
between the electrodes, and between the clamps. Failure to observe this warning can
cause serious injury. The same warning applies to the electrodes when opening.
A guard is provided to protect against a pinch point when the upper electrode opens.
Do not put hands, fingers or any part of the body between the upper electrode and the
cylinder body. Operation should not occur unless the guard is in place.
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CAUTION
(2) Wearing safety gear
Spark or spatter that is produced during welding operation may cause eye injury.
Since it is difficult to eliminate spark or spatter completely, it is necessary to put on
protective glasses, helmet, gloves and non-combustible working clothes to safeguard
against splash and spatter.
(3) Prevention from bums or fire
Spark or spatter produced during welding operation or hot parts just after being
welded cause bums. Observe the following precautions and install fire extinguishers
close to the weld working area in case of an emergency.
(a) Remove flammable substances so that Spark or spatter do not fall on them or
drape them with a non-combustible cover.
(b) Do not perfonn welding work near the flammable gas.
(c) Do not bring hot parts immediately after being welded, close to the flammable
materials.
(d) Do not touch the parts just after being welded with bare hands. Even if they are
not red, the temperature may be very high, causing a bum.
(e) Keep any personnel other than workers away from a place where spark or spatter
is produced.
(4) Noise protection

Measure noise level of this equipment and its surroundings area. If the level is in
excess of 85db, use appropriate hearing protection.
1 - 5. Electrical safety
Li:'.i DANGER
( 1) In order to aroid electrical shock
In order to avoid electrical shock, be sure to observe the following items :
(a) Do not touch the parts bearing electrical charges other than secondary conductor.
Failure to observe this may result in a fatal electrical shock or severe bums.
(b) Do not touch both ends of secondary conductor simultaneously. Failure to
observe this may result in a slight electrical shock.
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(2) Connection to the power supply
The equipment should be connected properly to the power supply as per the instruction
manual. The power supply work should be carried out according to local laws and your
in-house standards.
(3) Qualifications for electrical work
Voltage of approx. 440V is supplied to the equipment according to the specification
(Higher voltage may be used depending on models. Refer to the specification).
1
Educated, trained and qualified personnel ) with regard to the potential hazards arising
from these dangerous voltages should be assigned, especially, to electrical work for
installation, maintenance and repair works.
Note : 1) For example, personnel who possess qualifications for electrical work or
authorized customer employee.
(4) Grounding work
An earth tenninal is provided with the equipment for safety.
A person qualified for conducting the electrical work should carry out the grounding
work according to the local laws and in house standards.
(5) Provision of properly sized conductors
The customer is responsible to provide properly sized conductors for the incoming
power feed to the welder. Do not use wire of insufficient capacity or damaged/exposed
wires. Failure to observe this may cause fire due to overheated electrical wire and
electrical shock or current leakage.
(6) Electric wire connection
The connection tenninal of the electrical wire should firmly be tightened and insulated.
In case of loose connection, the connection may become overheated and cause fire, and
insufficient insulation may cause electrical shock or current leakage.
1 - 6. Safety items on maintenance work
LL DANGER
(1) Promotion of safe system start-up and shut-down
There is a possibility of causing extremely dangerous condition when the sources of
power supply, pneumatic and water are turned on without warning to a worker during
maintenance/repair work. Systems that promote safe system start-up and shutdown
should be provided for personnel safety.
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(2) Before performing maintenance work
Lh DANGER
Before performing any maintenance and/or repair work, including cleaning, it must be
ensured that :
(a) The equipment has been disconnected, using a lock-out/tag-out procedure, from
all power supplies for welding, control and power.
(b) Perform plant lock-out/tag-out procedures on power sources of the equipment.
Lh CAUTION
(c) All sources of pneumatic pressure and cooling water have been locked-
out/tagged-out.
(d) Residual pressure of all pneumatic circuits and cooling water circuits have been
relieved.
(3) Perfonn maintenance work

Installation, maintenance/inspection, repair work should be perfonned by trained
qualified personnee) according to the instruction manual for safety reasons.
Note : 2) Qualified personnel, authorized by the customer, who have received
manufacturer's or customer's in-house training and have clear understanding of the
equipment in question.
(4) Perfonn periodic maintenance
It is necessary to perfonn periodic maintenance and inspection of the equipment as
described in the manual.
(5) Water or pneumatic hoses
When the customer prepares to install water, or pneumatic hoses to the welder, make
sure they will sufficiently bear the pressure.
Possibilities of danger occur when these hoses have insufficient resistance to pressure
or are deteriorated or damaged, periodically perfonn maintenance and inspection and
repair the deteriorated or damaged parts before using the equipment.
(a) When hoses bursts or disconnected, the hose may act violently or the equipment
may operate unexpectedly.
(b) When a water hose bursts developing a leak, there is a possibility of deteriorated
insulation of the electrical circuit or deterioration of the control equipment
and/or current leakage.
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1 - 7. Accident prevention
( 1) Cooling water used for welding machine
Be sure to observe the following items for safe operation, to prevent accident and
maintain proper functioning of the equipment.
(a) Use water of the following quality or equivalent :
CD Rate of electric resistance : More than 5,000Q • em for thyristor cooling
water.
® Less deposit in water.
@ Ammonium ion content must be less than 1ppm.
Smaller resistance of water may cause current leakage. The cooling water with large
deposits may clog a circuit to degrade the circuit function, lowering the cooling
capacity and causing the circuit to malfunction or fail.
Cooling water containing a large amount of ammonium ions may have the possibilities
of corroding copper or copper alloy components on the cooling circuit and create water
leaks, leading to current leakage and electrical shock or electrical breakdown of
welding transfonner that can causes a fire on the equipment.
(b) When the cooling water is turned off, be sure to tum off the welding power supply.
Leakage current flowing for a long time may heat and damage thyristors,
depending on quality of cooling water.
(c) Amount of cooling water prescribed in the specification of the equipment should
be provided in the following manner. It is also important to keep water
temperature prescribed in the specification in order to maintain the cooling
capacity as well as water quantity :
CD Maintain a given water pressure prescribed in the specification.
® Check the water flow periodically to prevent clogging & overheation
conditions.
@ Perform maintenance of cooling water circuit as prescribed in the specification.
When cooling capacity is deteriorated, the equipment may generate faults or a fire may
generate due to overheated components such as welding transformers, conductors,
electrodes, thyristors.
1-6
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~ CAUTION
(2) Upper electrode falls when air supply is stopped
In general, when air supply for welding machine is stopped, the upper electrode falls
spontaneously due to deadweight. Though its falling speed is not high, there is a
possibility of occurring problems : injury may occur if hands, fingers, a part of
body are caught, or work piece be deformed if it is between the electrodes.
(3) Proper pressurizing force must be established
Proper pressurizing force must be established before passing welding current
through the electrodes. If current is passed through the electrodes when the
pressurizing force is too low, a dangerous explosion of sparks and splatter will
occur, causing serious injury or bums.
EXAMPLES:
(a) When pressure of O.lMpa or less has been established causing uncontrolled
drifting down of the electrode.
(b) When the squeeze time is set too short and the electrode completes the weld circuit
under load.
(4) Magnetic field effect
The resistance welding machine generates high magnetic field around the secondary
circuit when energized. This magnetic field has an influence on operation of certain
type of sensors, watch, and magnetic cards. For the same reason, a person who uses a
heart pace maker is prohibited from coming up to the resistance welding machine
during operation.
(5) Equipment fall down prevention
Equipment may fall down depending on models when an earthquake occurred. Perfonn
installation work of the equipment according to the instruction manual.
(6) Safety infonnation of peripheral devices
Infonnation about possibilities of danger of peripheral devices of this equipment such
as conveyors, feeders, robots should also be provided to workers.
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lml DENGENSHA
(7) To use within maximum input and allowable duty factor
The welding transformer has rated input, maximum input, allowable duty factor, and so
forth. This is the heat capacity of welding transfonner prescribed under the cooling
conditions (temperature and quantity of water). This specification indicates the upper
limit of operation of the welding transfonner. In excess of this limit, the welding
transfonner may be overheated or burnt in some cases. Since the heat capacity of
welding transformer is based predicated on being cooled, the welding transformer may
be overheated under normal operation or burnt in some cases if the cooling condition is
insufficient.
The welding machine and welding transformer should be used within prescribed
maximum input and allowable duty factor without fail. (For details, refer to the
REFERENCE "Maximum Input of Welding Transformer, allowable duty factor".)
@ Reference 1 : Maximum input and allowable duty factor of welding transformers

Rated input p so, maximum input p max, allowable duty factor Umax, etc. are prescribed
for welding transfonners.
Rated input P 50 indicates the input kVA of the welding machine when the duty factor is
assumed to be 50%.
The heat capacity of a welding transfonner can be indicated with the following formula,
using the input and duty factor.
Heat capacity= P50 x (0.5) 112
The heat capacity is constant, regardless of how the transfonner is to be used. Since
the heat capacity will be the same even when the transfonner is used with maximum
input Pmax, it follows that the duty factor will be restricted by a certain value, and this
value will be called the "allowable duty factor" Umax· That is, they will have the
following relationship.
112 112
Pso X (0.5) = Pmax X (amax)
In other words, the duty factor will have to be reduced when the welding machine or
welding transfonner is to be used with a large input kVA, and when using it with the
duty factor increased, it will exceed the heat capacity of the welding transformer unless
the input kVA is lowered. This can easily be examined, if you apply values to above-
mentioned fonnula.
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B DENGENSHA
@ Reference 2: Equivalent continuous current (continuous secondary current) of welding
machines
Welding current and duty factor are prescribed for welding transformers. Calculating
the following fonnula with these values will give you the equivalent continuous current
(continuous secondary current).
hp = Equivalent continuous current= Welding current x ~duty factor (A)
This is the maximum continuous current that this transfonner can allow to flow.
Example 1 : calculation formula of the equivalent continuous current that uses the
specification
When the welding current is 11,000 A, and the duty factor is 10% :
Equivalent continuous current= 11,000 x JOj = 3,470 A
Example 2 : calculation fonnula of the equivalent continuous current from the

welding condition
In the case of applying electrical current three times :
(A)
Production Cycle time (sec.) x frequency (Hz)
If a transfonner is to be used in excess of this equivalent continuous current, generation

of heat by this transfonner will cause damages and other accidents.
I1 : First current to be applied (A)
I2 : Second current to be applied (A)
I3 : Third current to be applied (A)
WT 1 : Period of time of the first current to be applied (cycle)
WT2 : Period of time of the second current to be applied (cycle)
WT 3 : Period of time of the third current to be applied (cycle)
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lEI DENGENSHA
2. Outline
2 - 1. Outline of Weld controls
This device is a control system for a single-phase alternative current spot welder with high
perfonnance and high reliability, which uses a microcomputer.
The control device portion (timer unit) built into this device is configured with a constant
current control function, voltage compensation control function, step-up function, various
monitors and error detection function.
2- 2. Place of Weld controls

• Type: NWC-900 series
Figure 1 Weld controls
(a) Weld controls is built into the main body.

(b) The settings are perfonned by the Program box.
2-1
m DENGENSHA
2 - 3. Program Box
• Type: PB-900-**
PROGRAM BOX MODEL : PB-900 MODEL : PB-900

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WELD WRITE
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C(x) ((fi) Weld Cur. G(x) (lifi) Step No. r (x) (rlill Resistance C(x) ((!J) l@IM![lm G(x) (!ili') :A.-7'·~"/'ifi§- r (x) (r!J) !!!:!.it
h (x) (hfi)Heat% A(x) (R8)Total Weld t P (/:P) T-Position h (x)(I!!J) t:-1-$ A(x) (Rill ~!Tf.\1~ t P (I:Pl '7-?i.!Lffii:
t (x)(/:/1) Weld Time b (x) (b8) Weld in StepS d (5d) S-down Dist. t (x)(b!i'li!i!Iaiir.~ b (x)(b8P:b11!J!T.M'< Sd (5dlS-1fS>:..-m
P F (PF) Power Factor P (x) (Pill Prod. Count F(x) (FB) Fault Hist. PF (PF):JJ$ P(x)(Pill!Eil~ F(x) (FB)~'II';~Jll'
LV (LU) Line Volt. n (x) (nli') Weld Count So (5o) S-ware Ver. LV (LU) ill:ili'-i!II± n (x) (nil) !Tf.\1~ So (5a) Y71-ll-:/3:--
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IIi DENGENSHA IIi DENGENSHA
English Japanese
Figure 2 Program box
(a) The Program box IS used to set the welding conditions and functions and to display
monitor data.
(b) The program box can be used by connecting the cable from the program box to the weld
controls of the main body.
• Refer to Program box Instruction Manual for operation.
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2 - 4. Program cable
• Type: CB-900-03 (Standard cable length is 3.0m)
Program box
Program cable
Figure 3 Program cable
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3. Specification
3- 1. Device
(1) Name: Weld controls
(2) Type: NWC-900 series

Specification
Model Destination
Compliance Voltage Timer board
NWC-902-11 Japan and Asia JIS AC380'"'-'415V GMP-0626B
NWC-902-51 Japan and Asia JIS AC440'"'-'480V GMP-0626B
NWC-902-21 North America Based on UL/CSA AC440'"'-'480V GMP-0626B
NWC-902-31 Europe CE Declaration AC380'"'-'480V GMP-0626B
NWC-902-41 Japan and Asia JIS AC200V GMP-0626B
NWC-903-11 Japan and Asia JIS AC380'"'-'415V GMP-0626E
NWC-903-51 Japan and Asia JIS AC440'"'-'480V GMP-0626E
NWC-903-21 North America Based on UL/CSA AC440'"'-'480V GMP-0626E
NWC-903-31 Europe CE Declaration AC380'"'-'480V GMP-0626E
NWC-903-41 Japan and Asia JIS AC200V GMP-0626E
(3) Rated voltage and frequency

Weld power source: AC200V I AC400V
Control power source: Internally reduces the welding source for use
Pennissible voltage fluctuation: ± 20% (Instant)
Frequency: 50/60 [Hz] (Automatic switching)
Power consumption: 45 [VA] (At idle time)
(4) Ambient conditions

Temperature: 5~40 [°C] (however without condensation)
Humidity: 90 [%] or less
Altitude: Average 1000 [m] or less above sea level.
Storage temperature: -25 to 55 (°C)
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Iii DENGENSHA
(5) Cooling conditions
(a) Timer board: Natural air-cooling
(b) Thyristor
Cooling water flow rate: 4 [1/min]
Feed water outlet temperature: 30 [°C] or less (No freezing)
Cut-off water pressure: 0.3 [MPa] or less
Electric resistivity: 5,000 [Q ·em] or more
(6) Thyristor
Size: Insulation typeD size (JIS equivalent)
Note) Use it below ratings of the equipment.
Maximum primary current: 1,500 [A]
(7) Control method: Synchronous method phase controlby the welding thyristor
(8) Welding current control method

(a) Constant current control: Loop control by secondary current feedback
Accuracy: ±2% of maximum current
(for disturbance of ±20%)
(b) Voltage compensation control: Open loop control by measuring
the welding source voltage
Accuracy: ±2% of maximum current
(for welding source voltage fluctuation of ±20%)
(c) HCCL control: WELD 1 : Voltage compensation control
WELD2 and WELD3 : Constant current control
Accuracy: Equal to each control
(9) Current detection method

Secondary detection: By toroidal coil
(10) Memory data storage

FRAM method (Batteries not required)
(11) Controllable ranges

0
Firing angle control range: 25 to 140 [ ]
Primary current control range: 50 to 1,500A

(Limited by the thyristor used and operating ratio)
Secondary current control range: 2.0 to 50.0kA
Welding transfonner tun1s ratio: 1.0 to 200
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3 - 2. Functions
( 1) Welding schedule
Number of welding schedule: 255 [schedule]
5 I 31 I 255 schedule switching is possible.
The pilot that specifies schedule from the outside
is possible up to 31 conditions.
(2) Stepper
Number of steps: 10 [steps]
Number of step spots: Each step 0 - 1,000 [spots]
Step control method: Step up I Linear up
(Increasing rate of first step is fixed at 100%)
(3) Connectable display setting
(a) Program box
Used to set the welding conditions and functions.
Specification
Model Destination
Compliance IP
PB-900-11 Japan JIS -
PB-900-21 North America and Asia Based on ULICSA -
PB-900-22 Europe CE Declaration IP54
(b) Monitor box

Used to display monitor data
Specification
Model Destination
Compliance IP
MB-900-11 Japan JIS -
MB-900-21 North America and Asia Based on ULICSA -
MB-900-22 Europe CE Declaration IP54
(c) Weld Data Manager

In this system, the welding conditions and environment can be set and its
welding-result data can be managed from a personal computer.
(software and transmitter are necessary)
Model Corresponding model
Software Weld Data Manager All
Transmitter TSM-900 All
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3 - 3. Weld controls
®
@
@
Figure 4 N arne of each part of weld controls
3-4
IEJ DENGENSHA
CD PCBOl Timer board
(GMP-0626B : Standard type, -0626E : Liner encoder type)
® CNTR Connector
® CNLS Connector
@ CNMON Connector
@ Fl Fuse (3A Normal type)
® F2 Fuse (2A Nonnal type)
(]) CNPWR Connector
® CNG Connector
® CNTRA Connector
@) CNSTHM Connector
@ CNl Connector
@ TBl Connector
@) TROl Control trans.
® FUOl Fuse ( 1A Time delay type)
® FU02 Fuse ( lA Time delay type)
@) SCROl Thyristor
@ ROl Resistor
@ COl Condenser
Lh Danger
Please work after confirming the welding source is doing "OFF" when you do the maintenance
check.
0 Mandatory item
There is fear of the breakdown of the malfunction and the device and destruction when the pulling
out opening and the board of the connector are detached with the power supply entered. Please
confinn the power supply is intercepted.
3-5
Iii DENGENSHA
3 - 4. Jumper, DIP SW on Timer board
There are some switches and jumpers mounted on the Timer board to select functions.
DIP SW JP3
~o
u 0
,,
JP4
2
~o <D
~o
1
JP1 JP2
--®--
TB1 I
CNPWR CNG
0 Slo ol1 o
Figure 5 Jumper, DIP SW on Timer board
0 Mandatory item
Do not rewrite CPU software for the welding control of the timer Board.
A correct welding control cannot be done.
And, the pressurizing operation is done regardless, and there is danger of placing the finger with
equipment worker's intention.
3-6
lEI DENGENSHA
(1) DIP SW
This 8 bit switch is for selecting the functions.
* Encoder option.
==..;...==...-.= :Factory setting of standard model

*: It has set it according to the specification. Please do not change.
0 Mandatory item
When shipping it, DIP-SW on the board is set according to the specification. The current control
cannot be correctly done when carelessly moving it. In addition, the equipment breakdown and
destruction might be caused. Please do not change.
(2). Jumper
• JP 1 : Constant 2-3 short
• JP2 : Constant 2-3 short
• JP3 : Constant 1-2 short
• JP4 : Input common switch (At shipment 1-3,2-4short:Minus common)
0 Mandatory item
When shipping it, Jumper on the board is set according to the specification. The current control
cannot be correctly done when carelessly moving it. In addition, the equipment breakdown and
destruction might be caused. Please do not change.
3-7
[il DENGENSHA
3 - 5. Timer Board Input/Output Signal
( 1) Electric specifications
• Input open circuit voltage DC 24 V, Input short circuit current 10 rnA
• Photo MOS relay output (all A contact)
Maximum load voltage: DC24V
Maximum load current: 0.12A
• Pressure valve output capacitance: DC24V,O.l2A
• (direct drive of the direct-acting valve is not possible)
Note) DC24V power supply is not stabilized. The total maximum load current is 0.5A.
Note) A buzzer is output when the counter function is executed.
(2) Signal names, operations and functions
I/0 Signal names Operation and function Connect
Input common Input common TBl-0
Pilot common Pilot common TBl-20
When it is "ON", it is selected in
Pilot 1 (1) TBl-21
the 1st welding schedule.
Pilot 2 (2) TBl-1
the 2nd welding schedule. When a 31 SCHE.
Input
When it is "ON", it is selected in is used, it becomes
Pilot 4 (3) TBl-22
the 4th welding schedule. a 5 bit binary code
When it is "ON", it is selected in input
Pilot 8 (4) TBl-2
the 8th welding schedule.
Pilot 16 (5) TBl-23
the 16th welding schedule.
It usually operates in the state of "ON".
TBl-24,
Timer stop Welding sequence is interrupted, and gun 1S opened
TBl-25
when entering the state of "OFF".
Fault reset Faults are cleared when turned "ON". TBl-4
When started in the "ON" state, normal welding is
executed.
Weld /No weld TBl-26
When started in the "OFF" state, the welding sequence is
executed without weld.
Stepper rest All the stepper counters are initialized by "ON". TBl-6
The count value of product count and weld count is
Input Counter reset TBl-7
cleared by "ON".
In the state of "ON", it enters the state of the energizing
Interlock TBl-28
standby.
The pressurizing operation is done when starting in the
Press test state of "ON". However, the welding sequence is not TBl-29
executed.
Flow switch Cooling water flow switch is connected TBl-9
Pressure switch Pressure switch is connected TBl-10
TBl-3,
Input common Input common
8,27,30
Thermostat signal from the welding transformer 1S CNTRA-1
Trans thermo
connected. CNTRA-3
Input
Thermostat signal of the thyristor cooling fin 1S CNTHM-1
SCR thermo
connected. CNTHM-3
3-8
Iii DENGENSHA
IIO Signal names Operation and function Connect
Turns ON when the sequence is completed, and turns
OFF when the pilot input is turned OFF. When pilot is
HOLD
End turned OFF midway or pulse pilot is executed, the signal
of is output for at least 1OOms. TB1-12
hold Regardless of pilot input status, it turns ON upon
50,200ms completion of sequence for designated duration. (50,
200ms)
Fault Turns ON when alarm goes off. TB1-31
Turns ON during current application (after the squeeze
Output Interlock output TB1-13
has been completed- immediately before hold)
Step completion Turns ON upon completion of stepper. TB1-32
Product count Turns ON when the product count reaches the set
TB1-34
completion product count.
"OFF" It does abnormally.
Timer ready Timer ready is turned OFF by doing either of Flow TB1-35
switch or pressure switch in "OFF".
TB1-
Output common Output common
11,33,14
Valve Output for Valve. TB1-36
Buzzer Output for buzzer. TB1-37
DC power
Output TB1-15
(N24)
Valve I Buzzer
Valve I Buzzer common. (+DC24) TB1-16
common
3-9
[il DENGENSHA
4. Operation
4 - 1. Basic operational sequences
r-1---1
Pilot input ~ ~~--~--------------------------------------------
r---
1
~L------1fr----
1
Val ve output _J l
I
I
I
Weld current --!-----,:----1

I
: I I
I I I
I
I I I I I I : I
I I I
: : : : : : :
SDT ! SQ ! US ! WTl :I CTl :I WT2 :I CT2 :I TCL :I WT3 :1 DS :I HT OT
I I I
:?'<::: :;;;:.:::: :?i< ;o;k ;;;k :; ;:.: : :;;;:~------:;?~
i I I I I 1 I 1
: EOHD I
1PULSATI ON I ~
I I
1 REPEAT
I I
I
I
t RE-WELD
End of hold
output
Fault output-------------------------------------------
Fault reset
SDT : Squeeze delay HT : Hold time

SQ : Squeeze OT : Off time
US : Up Slop EOHD : End of hold delay
WTl : Weld time 1
CTl : Cool time 1 PULSATION : Only the set number repeats the WT2 and the CT2.
WT2 : Weld time 2 REPEAT : Range to which it is repeated that repet operates.
CT2 : Cool time 2 ;>.::: Repet operation becomes OFF by setting the Off time to "o".
TCL : Temper cool RE-WELD: Range of repetition of RE-WELD operation
WT3 : Weld time 3 ;>.::: When RE-WELD, the wait time of 50 cycles is inserted.
DS : Down Slope
Figure 6 Weld sequence
4-1
Iii DENGENSHA
5. Programming
5- 1. Flow of Programming (Setting of Functions and Welding Conditions)
• The programming is performed in the program box.
• Programming can be perfonned at all times. When using this unit for the first time or the
unit has not been used for a long period, confirm the setting contents first, and reconfirm
that the correct values are set.
5 - 2. Program Contents
(1 ). Setting Function (F schedule)
CD Maximum schedule :5 I 31 I PNL Address: 1
[5 SCHE. I 31 SCHE. I Panel255 SCHE.]
• 5 SCHE. o o o Pilot input will be individually for Pilot 1 - 5.
• 31 SCHE. o o o Input will be a 5 bit binary using start 1 - 5.(Start 1 is LSB)
• PNL o o o Pilot schedule is selected in the program box. (255 SCHE.)
@ Selfhold:OFF I WELD I PULS Address: 3

[Self hold OFF I Weld time self hold I Pulse pilot]
• Self hold OFF
o o o The sequence is not completed unlesspilot signal is input to the end
(end of hold signal is output). When the pilot signal is turned OFF
midway, the sequence will stop immediately.
• Weld time self hold
o o o Even though the pilot signal is turned OFF, the welding sequence will
be executed to the end, once the weld is started (up slope or later).
• Pulse pilot
o o • The pulse signal can be used for a pilot input. A pulse width of 40ms
or more is required.
@ End ofhold:50 I 200 I HOLD Address: 4

[50msec I 200msec I HOLD]
Select the output time of the end of hold signal (contact output).
• 50msec, 200msec · · · Signal is output for a specified time.
• HOLD • o ·Signal output is held until start is turned OFF. However,
the signal is output for at least 1OOmsec even when start is
turned OFF midway.
5-1
lEI DENGENSHA
@ Reweld: OFF I ON Address: 5
[OFF I Reweld]
When an alann occurs such as a excessively low current, the status returns to squeeze
and the welding is executed again without outputting an error or releasing the gun. As a
result, the sequence will be completed if there is no error. An error will be output if an
error occurs again. Retry can be perfonned 1 time.
When performing a re-weld, a wait of about 50 cycles is inserted instead of a hold time.
Alarms
• Weld current low
• Heat% high
• Weld time short
• No current
@ Fault reset by start input: OFF I ON Address: 6

[OFF I Fault reset by start input]
After an alann is detected, reset start is executed by the start input, not by the alarm
reset input. However, this function will not be activated for serious alann, such as a
memory error, thenno alann, SCR shorted and etc. Reset the error by the program box,
or the exte1nal error reset input signal.
Alanns
• N onnal alann
• Notification warning (stepper completed, etc.)
® Select buzzer mode:O I 1 I 2 Address: 7

• 0 ···Buzzer ON when an error occurs, or weld completed in work
• 1 · · · Buzzer ON when an error occurs
• 2 · · ·Buzzer ON when weld completed in work
(/) Stepper: OFF I STEP I LINR Address: 8

[OFF I Step up I Liner up]
Select the stepper function.
5-2
B DENGENSHA
® Interlock mode:O I 1 Address: 9
• 0 · · · Interlock selection between 2 systems
Waits until the interlock input is turned OFF by pilot input, and when the
interlock is turned OFF, the interlock output is turned ON and the weld is started.
• · · ·Interlock selection with multiple systems
The interlock output turns ON by pilot input, and waits until the interlock input
is turned OFF, and when the interlock is turned OFF, the weld is started.
(Interlock control panel required)
® Select toroidal type: STD I ISO Address: 10

• STD· · ·DG standard toroidal (230 mVIl,OOO A)
• ISO·· ·ISO toroidal (150m VllOOO A)
(Only DSW-5 "ON")

@) Nut detection: OFF I ON Address: 20
A linear encoder is used to measure the work height under pressure, and defective
items and substances are detected.
(Only DSW-5 "ON")

@ Electrode position compensation: OFF I ON Address: 21
While adjusting the amount of electrode wear using a linear encoder, defective items
and foreign substances are detected.
(Only DSW-5 "ON'')

@ Setdown: OFF I ON Address: 22
A linear encoder is used to measure the amount of weld penetration, from the electrode
position before and after weld.
5-3
III DENGENSHA
(2). Setting Common (0) schedule
CD Squeeze delay: 0 - 50 [Cycle] Address: 1
The delay time can be set for the period after pilot signal is accepted until the welding
sequence is started.
® End ofhold delay: 0- 50 [Cycle] Address: 2

The delay time can be set for the period after the welding sequence is completed until
the end of hold signal is output.
@ Weld time compensation: 0 - 50 [Cycle] Address: 3

The lack of weld time is compensated for but is limited to the compensation value.
For example, when the value was set to '3rd Cycle', even though there was a lack in the
4th Cycle and later, only the value in the 3rd Cycle is compensated for.
@ Insufficient weld time: 0 - 50 [Cycle] Address: 4

An error is output when the detected weld time was less than the set weld time. This is
the allowed value.
@ Over time: 10- 2000 [Cycle] Address: 5

An error is output when the set weld time was longer than the set over time. This is the
allowed value.
@ Line volt: 100 - 1000 [V] Address: 6

Input the voltage of the weld power source. If the value is not set correctly, the value
on the voltage monitor will not be displayed correctly. However, there is no effect on
welding control at all.
(J) Line volt high limit: 5 -50 [%] Address: 7

Set the detection level for the abnormal increase in the weld power voltage.
® Line volt low limit: 5 - 50 [%] Address: 8

Set the detection level for the abnonnal decrease in the weld power voltage.
® Password (weld off): 0 - 9999 Address: 30

Set the password to turn off the weld.
@) Password (write enable): 0- 9999 Address: 31

Set the password to write the data.
5-4
mil DENGENSHA
(3). Setting GUN No. (G) schedule
CD Global maximum current: 2.0- 60.0 [kA] Address: 1
The maximum current setting of each weld schedule can be omitted (OFF) by setting
the data.
Note) The weld schedule is given to priority when the maximum current is set with the
weld schedule.
® Global current control mode: CC I VC I HCCL Address: 2

The current control select of each weld schedule can be omitted (OFF) by setting the
data.
• CC: From the weld 1 to weld3 is a constant current control.
• VC: From the weld! to weld3 is a voltage compensation control.
• HCCL: The weld 1 controls the heat control current limit.
W eld2 and weld3 is a constant current
Note) The weld schedule is given to priority when the current control mode is set with
the weld schedule.
® 2 point calibration: OFF I ON Address: 4

The test weld is perfonned in advance for each point near the upper limit and lower
limit of the current to be actually used, and the values are adjusted based on the results
to improve the current accuracy of the constant current control.
Set the current set values and measured values as in the following (4)- (7).
@ Calibration basel: 2.00-50.00 [kA] Address: 5

Set the current setting value for the high limit from the weld test that was perfonned in
advance for the 2 point calibration.
@ Calibration base2: 2.00- 50.00 [kA] Address: 6

Set the current setting value for the low limit from the weld test which was perfonned
in advance for the 2 point calibration.
@ Calibration current!: 2.00- 50.00 [kA] Address: 7

Set the current measurement value for the high limit from the weld test which was
perfonned in advance.
(j) Calibration current: 2.00 - 50.00 [kA] Address: 8

Set the current measurement value for the low limit from the weld test which was
perfonned in advance.
5-5
lEI DENGENSHA
® Weld count: 0 - 9999 Address: 9
Set the number of welds per work piece.
When the actual number of welding spots reaches the set value, the production counter
starts to count. (The number of spots can not be counted if the weld is OFF, or a
trouble occurs.)
® Product count: 0 - 9999 Address: 10

Set the production number. When the production counter reaches the set value, a
buzzer is output to notify the worker.
@) Global original position: 0 I 1.0- 200.0 [mm] Address: 14

Set the original pressure position of the electrode, to detect a defective item with the
linear encoder.
• When referring to the condition with a work piece, set the distance in which the
thickness of the work piece is deducted from the stroke amount of the maximum
open position to the pressure position.
• When referring to the condition without a work piece, set the stroke amount of the
maximum open position to the pressure position.
Note) The weld schedule is given to priority when the original position is set with the
weld schedule.
@ Nut detection at "Weld OFF" : OFF I ON Address : 15

The height of the pressurizing work is measured in the state of Weld OFF with a
linear encoder. Confinning the operation of the stock out detection and the
foreign body detection can be done with weld off.
@ Step count
The number of ten steps of each step runs batted in is set (Each weld schedule sets the
increase).
• StepO count: 0- 1000 [count] Address: 20
• Step 1 count: 0- 1000 [count] Address: 21
• Stes2 count: 0- 1000 [count] Address: 22
• Step3 count: 0- 1000 [count] Address: 23
• StepS count: 0- 1000 [count] Address: 25
• Step? count: 0- 1000 [count] Address: 27
5-6
IEJ DENGENSHA
(4). Setting Weld (W) schedule (SCHE.No.1-255)
CD Squeeze: 0- 100 [Cycle] Address: 1
® Up slope: 0- 100 [Cycle] Address: 2
@ Weldl: 0- 100 [Cycle] Address: 3
® Current!: 2.0 - 50.0 [kA] Address: 4
15- 100 [%](VC mode)
@ Cooll: 0- 100 [Cycle] Address: 5
® Weld2: 0- 100 [Cycle] Address: 6
(]) Current2: 2.0 - 50.0 [kA] Address: 7
15- 100 [%] (VC mode)
® Cool2: 0- 100 [Cycle] Address: 8
® Weld3: 0- 100 [Cycle] Address: 9
@) Current3: 2.0- 50.0 [kA] Address: 10
15- 100 [%] (VC mode)
@ Down slope: 0 - 50 [Cycle] Address: 11
It becomes a demagnetization function because of the setting of 31 Cycle or
more.
@ Hold: 1 - 100 [Cycle] Address: 12
@ Off: 0- 100 [Cycle] Address: 13
0 Mandatory item
Please give the setting of Off to me as "0" when the worker welds. The repetition hangs in the
automatic operation when the start maintains turning on, except when a set value is 0. And, there
is danger such as scissors of the finger. Please make the setting "0" when the worker welds.
® Pulsation: 1 - 20 [times] Address: 14
5-7
fml DENGENSHA
® Initial current heat%: OFF I 15 - 80 [%] Address: 15
The current heat% of the 0.5 cycle that starts to weld can be freely set. It weld
for "OFF" at the current heat% calculated from the maximum current.
The initial current heat % is a function that the current heat % from the weld
beginning (The up slope is contained) to 0.5cycle can be arbitrarily set.
(Before setting) (After setting)
Figure 7 Initial current heato/o
eusage
When the projection is welded, this function is used.
ePreparation
~
2) Test weld
Work is welded by an appropriate welded condition.
3) Confinnation
Heat % 1 is confinned by monitoring Program box.
eweld
I 4) Setting
Confirmed heat % 1 is set to the initial current heat %.
• 5) Weld
5-8
lml DENGENSHA
@ Maximum current: OFF I 2.0- 60.0 [kA] Address: 16
The maximum current value of the welding machine is set. The current value
when firing because of a full wave is input. Please set a correct value that
corresponds to the ability of the welding machine.
@ Current control mode: OFF ICC I VC I HCCL Address: 17
The current control method is selected.
@ Current1 high limit: 3 -50 [%] Address: 19
The disregard level of a high abnonnal current is set.
An increase to the set current value is set with%.
@) Currentl low limit: 3 - 50 [%] Address: 20
The disregard level of low abnormal current is set.
@) Current2 high limit: 3 -50 [%] Address: 21
@ Current2 low limit: 3 - 50 [%] Address: 22
The disregard level of low abnonnal current is set.
An increase to the set current value is set with %.
@ Current3 high limit: 3- 50[%] Address: 23
@ Current3 low limit: 3 - 50 [%] Address: 24
The disregard level of low abnormal current is set.
@ Heat high limit: 20-200 [%] Address: 25
The disregard level of heat high abnormal % is set.
@ Heat low limit: 10 - 100 [%] Address: 26
The disregard level of heat low abnormal % is set.
~ HCCL mode current limit: 2.0- 50.0 [kA] Address: 28
The current limit value of the HCCL control mode is set.
(The weld 1 controls with the current limit the heat control.)
5-9
lEI DENGENSHA
@ Stepper increase
The increasing rate of each step is set. The current value of each step is input
with% based on the set current value.
When 100% is input, the current value of the step reaches the same current value
as a set value. The value is input from 1 to 9 steps. Increasing rate 0 is 100%
fixation.
• Increase!: 50-200 [%] Address: 41
• Increase2: 50-200 [%] Address: 42
• IncreaseS: 50-200 [%] Address: 45
• Increase?: 50-200 [%] Address: 47
• IncreaseS: 50- 200 [%] Address: 48
• Increase9: 50- 200 [%] Address: 49
5-10
lml DENGENSHA
@ Temper cool: 0- 1000 [Cycle] Address: 50
The cool time added for cool2 and weld3 is set.
@ Original position: OFF I 1.0- 200.0 [mm] Address 56
When it detects the foreign body, and the no Nut is detected with a linear
encoder, the distance from the position of the gun maximum open to the
pressurizing position (There is an work or is no work) is set.
@ Nut high limit: 0.1-20.0 [mm] Address: 57
When the foreign body is detected with a linear encoder, the distance of a
pressurizing position and an original position in which the foreign body
detection is judged is set.
@ Nut low limit: -9.9 - 0.1 , 0.1 - 20.0 [mm] Address: 58
When the no Nut is detected with a linear encoder, the distance of a pressurizing
position and an original position in which the no Nut detection is judged is set.
The direction of the gun opening sets the positive value from a standard position
and the direction of pressurizing sets a minus value.
@ Setdown high limit: 0.00- 20.00 [mm] Address: 59
The distance at the gun position before and after the welding of the projection
welding etc. is set with a linear encoder and when the quality is judged, the
distance in which the setdown high limit is detected is set. It is abnonnally
judged that the distance at the gun position before and after the welding
becomes more than a set value.
@ Setdown low limit: 0.00- 10.00 [mm] Address: 60
The distance at the gun position before and after the welding of the projection
welding etc. is set with a linear encoder and when the quality is judged, the
distance in which the setdown low limit is detected is set. It is abnonnally
judged that the distance at the gun position before and after the welding
becomes below a set value.
@Attention in program
Data that exceeds the data range cannot be set.
5-11
IEJ DENGENSHA
CJ1
J NWC-900 Program sheet ( 1/2) J c.v

DATE: NAME:
0
c:
FUNCTION (f) SCHEDULE *2 *2 *2 ~
I
I I I *' I I ~ltlon I i!'W?;..
ITEM Maximum schedule Self hold End of hold
l Reweld Fault reset by
start Input
Sel ct b
e
od ,
uzzer m e Stepper
_i Interlock mode Select toroidal type Hut detection Electrode . ·- ::::::1
CD
-a
compenS4tion
1
ADDRESS 1 3 ' 10 20 ; 21 ' 22 0
SETIING RANGE 5/31/PNL OFF/Wa.D/PULS 50/2 STD/ISO OFF/ON
-- i OFF/ON OFF/ON
lNITII\LSETTIN<l 31 WELD ~ Function (F) schedule STD I OFF I OFF l OFF "'0
0 05 SCHE, OSelf hold OFF ... __ ~ ~system ODG standard
!---=----
_ IOOFF . IOOFF IOOFF
co
1 031 SCHE. f OWeld time self hold 0200 m .u.,, ;'-'nu,.u•~ 1'-'"g~u• 1wraur< •U;)<OP up IUMUI<I O!SO !DON iOON I DON
--- -
_2_ _ 0255 SCHE. (Pane~ OPulse start OHold i I IDGomp.- 'Dlinerup I ____L_
-I
--·--- ---
03
3
(/)
:r
1
COMMON (0) SCHEDULE
~ ITEM Squeeze .
delay
r End of hold i compensation
Weld tim~ I In•uffc!•nt
!
weld trne
Over time I Une volt I Line ~0~ high
l1mit
I Line ~o.lt low I
limit
Password
(weld off) '"<.:: CD
CD
JQ· ADDRESS 1 I 2 I 3 I 4 I 5 I 6 I 7 : 8 30
enable)_
31
.-+
=
"1
~
SElllNG RANG
Unit
o- 50
Cycle I
l
I
0-9999
-
0-9999
-
00 INITIALSETTl~C 0 I r'rYtl'l'fY\1"\n ({)\ Cl"hPrllllP I 0 0
0 I
=
e.
,....
Settvalue
I I I I I I
"(1
.......
=
~
0
GUN No.
(0) SCHEDULE
~al
*3 1
*4
Giobal current 2points Calibration Calibration Calibration : Calibration W ld unt Product Global origina
*2
'""'l ITEM
i
1
N ";,~::.m 1control mode I cafibration base 1 i base 2 current 1 current 2 e

00
count position
"'0 1--:-AD::-:D::-:RE=ss:-ll- 1 10 14
"1
0
~ SEITING ~Q
Unit
2.0-
I<
GUN N 0. (G) h d 1
SC e U e
0- 9999 0/1.0- 200.0
mm
"1
~ lNITIAl SETTJNC 60 0 0
9
'71
~=-
Sett value
J I I I
~
.....
~
*l;Only setting.This welder doesn't correspond to the ISO toroidal coil.
1§1
*2;0nly as for the linear encoder specification, the display and the setting beoome possible.
*3;When shipping it. the setting matched to a fixed welder is dane. (Muximum road current rating + 20!t.)
*4; CO; Constant current. VC;Voltage compensation, HGCL;Heat control curretn limit
*5:0nly HCCL mode 01:2009/3
*6:1t becomes a demagnetization function because of the setting of 31Cycle or more. ON:2009/2
c ORW#: U990-40-3985-1
m
z
G)
m
z
en
:I:
)>
I NWC-900 Program sheet (2/2) I
DATE: NAME:
WELD ly() SCHEDULE (SCHE. No. 1-255) *6

~- Sq1.1ee2 e Up slope Weld 1 CC
Current 1
! VC · · - Cool! Weld 2
I
. ·[ CC
Current
j
2_~
VC I Cool 2
I Weld 3
~ Current 3
CC . . I VC Down slope ,
I H_ol_d -+-·__oo__
J
Pulsatir>n
ADDRESS 1 2 3 4 5 6 7 8 9 10 11 i 12 13 14
SETTINGRANG'E 0-100 0-100 0-100 2.0-50.0 i 15-100 0-100 0-100 --. 2.0-50.0 I 15..:100 0-100 ' 0-100 ~0.0 15-100 I 0-50 1-100 0-100 1-20
Unit C_yC>J~ Cycle Cycte _ Cycle ! Cycl': Cycle -~
lNITIALSEmN~ 50 0 0 h d 0 l 0 1
Weld (W) sc e u1e __
SOH~ -· : I -- : ! I :- ·-
1 '
~
.....
~ l l _ I ~~----~--~--~~----~--~--~----~---
=
~
~ WELD ly() SCHEDULE (SCHE. No. 1-255)
---
*4 *5 *2
~·
*2 ~I'. >!12 *2
....,./II.
Fa''""" *2
1.0
ITEM
Initial curr&nt Maximum Current control! Current 1 Current 1 low I Current 2 Current 1
limit
low~ Current 2JCurrent 1 low( Heat high
high limit limit j r.mlt
, 't' current
IIHeat low limit HCCL mode
limit Temper cool Ori~~al INut high limit INut low limit ISetd~w~ high Set~~ low J
0 he~ current mode high limit ~mit· highlimit posr tOn : 1m : · rm
=
::;
ADDRESS
SEITING
15
OFF/ OFF/
16 17
OFF/CO
19 20 I 21 ! 22 I 23 I 24 25 26 L 28 50 56
OFF/
57 !
I
58
-9.9- -o.1
59 60
I o.oo - 1o.oo
Ul =·
~
RANGE 15-80 2.0-60.0
kA
NC!HCCL
-
3
Weld (W) schedule

0-500
Cycle
1.0-200.0
Cycle
0·1 - 20·0
mm I
0.1 - 20.0
mm
o.oo - 2o.oo
mm mm
I
....... Q
Unit
" 0 20.00
w I '""'l
"0
INITIAl SETTING OFF OFF
---
OFF OFF 20.0
I
1.0 10.00
~
Q
I I I J I -
~ -- I I I I I I
~ SCHE. I I I
~
I
·--- i I I I
I I I I
=
rll
=-
~
-
i
I I I
i
I I I I
~
t""'-
N STEPPER
ITEM
'"""'"
•.~?~?.a!~}"~·~ Arr" I Weld count [Count]
(GUN No, (G) SCHEDULE)
...
ADDRESS
~-~ 2a I 24 1 . 2s I 26 27 I
28
SETmoiV.NC!E
IN!TI/ILSEmNO
.... ----- Stepper 0-1000
0
Step 1 I 2 4 I 5 I 6 7 ! 8 I 9
-
c:!!~ i 1 ',
I I -, I I
I I I
l I
I
I \_ I
~--·-
* 1;Only setting.This welder doesn't correspond to the !SO toroidal coil.
Ic !:!:!2;0nly as for the linear encoder specification, the display and the setting become possible.
*3:When shipping it, the setting matched to a fixed welder is done. (Muximum road current rating+ 20%)
!:!:!4;CC;Constant current. VC;Voltage compensation, HCOL;Heat control curretn limit
*5: Only HCCL mode
*6: It becomes a demagnetization function because of the setting of 31 Cycle or more.
DRW#: U990-4Q-3985-2
01:2009/3
0N:2009/2
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6. Special functions
6 - 1. Stepper function
• This is a function that gradually increases current corresponding to weld count.
• When weld count increases defonnation and expansion of welding tip occurs. This causes
weakening of welding strength. Linear I step-up function prevents weakening of welding
strength.
• With step-up increase is made step by step and with linear-up change is made linearly
towards set ratio of increase as its target value.
Weld current
Increase 9
Increase 8
Increase 7
Step up
Increase 6
Increase 5
Increase 4
Increase 3
Max.200%
Increase 2
Increase 1
1100%
?.::il
• I
I
I
I I
I I I I
1
I
I I I I I I
~---------
I
I Weld counts
1 I I I I 1 I I I I I
Count 0 1Count 1 1Count 21Count 31Count 4!Count 5 1Count 61Count 7 1Count 81Count.,9 1
1
,• •1• •1• •1• •1• •1• •,• •1• •1• •1• I :
I I
I I
I I
I I
_ _ _ _____.nL..---,
Stepper camp.
I
I
I
Stepper reset
_ _ _ _-------lfl_
* With linear-up increase is not made during 1st region.
* Ratio of increase 100% = set current, at step 0.
Figure 10 Stepper sequsence
6-1
Iii DENGENSHA
• Stepper setting items
(1) Ratio of increase (step 1 - 9) 50- 200 (%)(step 0 is fixed at 100%)
(2) Weld count (each step) 0- 1000
• The stepper schedule are two affiliates, and each of ten steps.
• Setting unit of weld count is 1 spot. If "1 00" is input then step-up is performed after the
1OOth weld count is made.
• The rate of increase functions independently in each weld schedule.
• Set units of the number of runs batted in are one runs batted in. The step improves when
the 1OOth runs batted in end when inputting as "1 00".
• Setting value of weld count is for each step, and not total weld count. Step is complete
with maximum of 999 weld count.
Stepper
Step No.
Weld count [count] Increase [%]
0 o~1ooo 100
1 o~1ooo so~2oo
2 o~1ooo so~2oo
3 o~1ooo 50~200
4 o~1ooo 50~200
5 o~1ooo 50~200
6 o~1ooo 50~200
7 o~1ooo so~2oo
8 o~1ooo 50~200
9 o~1ooo 50~200
6-2
Iii DENGENSHA
7. Current control mode
The current control mode consists of a constant current control and voltage compensation
control. Select a control mode suitable for the operating conditions.
7 - 1. Current control
The current feedback is measured for each half cycle, and based on this data the firing angle is
calculated to send a current closer to the specified current value in the next cycle. Therefore,
it responds at a high speed when a fluctuation occurs in the power supply voltage or the load.
(1) Current setting mode: The current value is set directly.
Minimum unit: 100 (A)
Allowable setting range : 2,000 ,. . ._, 50,000 (A)
(2) Factors for compensation: Fluctuation in power supply voltage and load
7 - 2. Voltage compensation control

When multiple guns are weld simultaneously, select the voltage compensation.
( 1) Current setting mode: Current setting method: Set the full wave current at the rated
voltage to 100%.
Allowable setting range: 15 to 100%
(2) Factor for compensation: Fluctuation of the power supply voltage only
7-1
lEI DENGENSHA
7 - 3. HCCL Control (Heat Control Current Limit)
Please select HCCL when you remove the garbage etc. that attach to work by the first weld.
Weld secondarily and thirdly controls a constant current.
( 1) Method of setting current : Individual welding schedule
Weld 1 (Heat %[% D~
Weld2, 3 (Current Value [kA])
HCCL mode current limit is set.
(2) Factors for compensation: Fluctuation in power supply voltage and load
Note) In the first weld HCCL, the current might flow up to the HC limit current
regardless of set value kA.
e Preparation
1) Test weld
The current control method is set to CC, and work is weld by an appropriate
welded condition.
2) Confinnation
Heat % 1 is confinned by monitoring Program box.
eweld
3) Setting
CD The current control method is changed from CC to HCCL.
® Heat % 1 confinned to one in the current by 2) is set.
@The current in which one in the current is set to the HC limit current by 1) is set.
4) Weld
Individual welding schedule Individual welding schedule
I Current control method : CC Current control method : CC
Weld1: OOkA Weld1: LL%
Monitor HCCL mode current limit : 0 OkA

Heat%1: LL%
Preparation HCCL setting method
Figure 11 Setting method ofHCCL
7-2
IEJ DENGENSHA
7 - 4. Setting
The settings for the current control are the 'constant current control' selected in 'CC', 'voltage
compensation control' in 'VC', 'HCCL control' in 'HCCL', and 'Global current control mode' in
'OFF'.
7-3
lEI DENGENSHA
8. Monitor function
• The function in this system monitors the results of the welding in the program box.
8- 1. Monitoring functions by the program box
Items Monitor Content
Sn Sn Schedule No.
C1 [I Weld current 1
C2 [2 Weld current2
C3 [3 Weld current3
h1 hi Heat% 1
h2 h2 Heat% 2
h3 h3 Heat% 3
t1 tl Weld1 time
t2 t2 Weld2 time
t3 t3 Weld3 time
tA l:R Total weld time
PF PF Power factor
LV LU Line volt
Gn Un Gun No.
G1 ul Step No
A1 Rl Total weld count
b1 bl Weld in step
P1 PI Product count
nl nl Weld count
tP l:P Touch position
Sd 5d Setdown distance
F1 Fl Fault history 1
F2 F2 Fault history 2
F3 F:3 Fault history 3
F4 FY Fault history 4
FS F5 Fault history 5
F7 F~ Fault history 7
F8 FB Fault history 8
So 5o Software version
Id ld Password
8-1
B DENGENSHA
9. Fault code
9 - 1. Fault code List
Group Code English type Fault output Remarks
Stepper FOll Gunl step complete Warning Step completion
Counter F021 Gunl product count complete Warning Product count comp.
FlOl Weld currentl low Error 0
F102 Weld current2 low Error 0
Weld F103 Weld current3 low Error 0
current F151 Weld currentl high Error 0
F152 Weld current2 high Error 0
F153 Weld current3 high Error 0
Heat% F200 Heat% low Error 0
low/high F250 Heat% high Error 0
F300 Memory error of function parameter Major Error 0*
F301 Memory error of common parameter Major Error 0*
F302 Memory error of weld parameter Major Error 0*
F303 Memory error of gun parameter Major Error 0*
F304 Memory error of counter parameter Major Error 0*
Wrong
F306 Memory error of fault history Major Error 0*
parameter
F307 Memory error of encoder parameter Major Error 0*
F350 Current low limit Major Error 0
F360 Current high limit Major Error 0
F370 Over time Major Error 0
F390 Wrong parameter Major Error 0
F400 Line volt low Alarm 0
Line volt F410 Line volt high Alarm 0
fault F450 Line clock error Fault 0
F480 Timer stop Fault 0
F500 No current Error 0
F521 Weldl time short Error 0
Welder
fault
F522 W eld2 time short Error 0
F523 W eld3 time short Error 0
F550 Transformer over temperature Fault 0
Power F600 Thyristor over temperature Fault 0
module F650 Thyristor shorted Fault 0
fault F660 Thyristor half cycle Fault 0
F810 Not complete welding Fault 0
F825 Water flow fault Fault 0
I/0 fault
F830 Air pressure fault Fault 0
F840 Weld I No weld signal error Fault 0
F930 Original position not initialized Fault 0
F931 Wrong Nut Fault 0
Liner
encoder
F932 No Nut Error 0
F933 Setdown distance low Error 0
F934 Setdown distance high Error 0
Hard F990 Timer board fault Fault 0
*:external reset is invalid. It is possible to release it abnormally only with the RESET button of the
program box.
At this time, the memory of a pertinent part in the timer board is initialized.
9-1
lEI DENGENSHA
9- 2. Fault code
• Fault codes are assigned for each error. The fault code will be displayed and blinking
in the data display of the program box (PB-900-**).
• The contents of the error, typical detection period and detection contents, and an
example of a countermeasure will be displayed for each fault code therefore
countermeasures should be performed according to the conditions.
(1 ). F011: Gun1 step complete

(a) The step-up completion of gun 1 is displayed.
(b) The stepper complete is output.
(c) When the stepper reset input is turned ON, or the program box reset button is pressed, the
weld counter, the number of steps and the error will be cleared.
(2). F021: Gun1 product count complete

(a) The production count completion of gun 1 is displayed.
(b) The product count complete is output.
(c) When the counter reset input is turned ON, the production counter and errors will be
cleared.
(3). F1 01-103: Weld current (1 ,2,3) low

(a) When the welding current becomes lower than the low limit of the set value during
constant current control, an alann will be output after the welding sequence is
completed.
(b) This function will not activate during the voltage compensation control.
(c) The 1st digit of the fault code refers to the weld number (weld 1 to 3) in which the error
occurred.
(d) Confinn that there is no wire breakage of the wire cable, no dust or etc. is adhered to the
weldment or the electrode tip. The capacity of the transfonner may be insufficient.
Confinn that the power supply voltage has not deteriorated by simultaneous weld, and
that the current is set correctly.
9-2
Iii DENGENSHA
(4). F151-153: Weld current (1,2,3) high
(a) When the welding current is higher than the set value of the current high limit during
constant current control, an alarm will be output after the welding sequence ts
completed.
(b) This function will not activate during the voltage compensation control.
(c) The 1st digit of the fault code refers to the weld number (weld I to 3) in which the error
occurred.
(d) Confirm that the current or the current high limit is set correctly.
(5). F200: Heato/o low

(a) When the heat % during weld is lower than the set value of the heat rate low limit, an
alann will be output after the welding sequence is completed. This function will be
activated for both the constant current and voltage compensation controls.
(b) This shows that the heat% was excessively low in any of the weldl to 3.
(c) Confinn that the current and the heat % low limit is set correctly.
(d) Con finn if there is a short in the secondary circuit.
(6). F250: Heato/o high

(a) When the heat % during weld is larger than the set value of the heat % high limit, an
alann will be output after the welding sequence is completed. This function will be
activated for both the constant current and voltage compensation controls.
(b) This shows that the heat % was excessively high in any of the 1st to 3rd weld.
(c) Confinn that the current and the heat % high limit is set correctly.
(d) The capacity of the transfonner may be insufficient.
(e) Confinn that the line voltage has not deteriorated by simultaneous weld.
9-3
lEI DENGENSHA
(7). F300-307: Memory error (305 unused)
(a) The system checks for errors when the power is turned ON, and notifies immediately. An
alann will not be output. The error can only be cleared by pressing the RESET button
on the program box. At this time, the memory in the applicable area of the timer is
initialized.
• 300: Memory error of function parameter
• 301: Memory error of common parameter
• 302: Memory error of weld parameter
• 303: Memory error of gun parameter
• 304: Memory error of counter parameter
• 306: Memory error of fault history
• 307: Memory error of encoder parameter
(b) This shows that the system data set in the memory is out of the set range.
(c) Reset the data.
(d) Please measure an original position etc. for "307":
(8). F350: Current low limit

(a) When the welding current value of the started sequence exceeds the control range lower
limit (2000 A), an alann will be output when started.
(b) Confinn that the current value is set correctly.
(9). F360: Current high limit

(a) When the welding current value of the started sequence exceeds the control range upper
limit (50000 A), an alann will be output when started.
(b) Confinn that the current value is set correctly.
(1 0). F370: Over time

(a) When the total set value of the weld time when started is longer than the set value of the
over time, an alann will be output.
(b) This is detennined for the total weld time of weld 1, weld 2 and weld 3.
(c) Confinn that the over time is set correctly.
(11 ). F390: Wrong parameter

(a) When all of the weld times of weld 1, weld 2 and weld 3 are set to 0 cycles, an alann will
be output when started.
9-4
mil DENGENSHA
(12). F400: Line volt low
(a) When the welding source voltage becomes lower than the set value of the line volt low
limit during weld, an alarm will be output after the welding sequence is completed.
(b) Confirm the power supply capacity, and perform a countermeasure to prevent
simultaneous weld.
(13). F41 0: Line volt high

(a) When the welding source voltage becomes higher than the set value of the line volt high
limit during weld, an alann will be output after the welding sequence is completed.
(b) Confinn the facility power supply. Confirm that the value is set correctly.
( 14 ). F450: Line clock error

(a) When the power supply frequency can not be identified as 50 Hz or 60Hz, an alann will
be output when started.
(b) Confirm that the power supply is stable.
(15). F480: Timer stop

(a) When the stop timer input turns OFF, an alann will be output.
(16). F500: No current

(a) When the welding current could not be detected during the weld of 1 - 3, an alann will be
output.
(b) Confinn that there is no dust on the work piece, no impurity of the chip, and that the
pressure time or welding pressure is not insufficient.
(17). F521-523: Weld (1 ,2,3) time short

( 1) When the number of weld cycles which are actually detected is less than the number of
set cycles, an alann will be output.
(2) The 1st digit of the fault code refers to the weld number (weld I - 3) in which the error
occurred.
(3) Confinn that the squeeze time is sufficient, there are no impurities on the chip and work
piece and that the work piece was welded correctly, no deterioration of the secondary
cable, tightening of each secondary part is sufficient, and that the welding pressure is
sufficient.
9-5
lEI DENGENSHA
(18). F550: Transformer over temperature
(a) When the transfonner thermostat input is turned OFF when started, an alarm will be
output.
(b) This shows that the welding transformer had overheated.
(c) Confirm the duty factor, the circulating water temperature, and the amount of water.
Confinn that the thermostat detection line is not disconnected.
(19). F600: Thyristor over temperature

(a) When the thyristor thermostat input is turned OFF during continuous monitoring, an
alarm will be output.
(b) This shows that the thyristor had over temperature.
(c) Confinn the operating ratio, the circulating water temperature, and the amount of water.
Confinn that the thennostat detection line is not disconnected.
(20). F650: Thyristor shorted

(a) When the thyristor short circuits during start, an alann will be output.
(b) This shows that the thyristor had short circuited.
(c) Replace the thyristor, and confinn that the welding current and the duty factor are within
the rating.
(21 ). F660: Thyristor half cycle

(a) If there was polarity only on one side in all of the 1 - 3 weld in the current detection
results, an alann will be output.
(b) This shows that one of the thyristors did not fire.
(c) Confinn that there was no excessive voltage fluctuation, no deterioration of the
secondary-coil, poor tightening of the secondary circuit, condition of the gate signal
wiring, and that the welding pressure is sufficient.
(d) Confinn that the maximum current is set correctly.
(22). F810: Not complete welding

(a) When the pilot signal input is turned OFF during the welding sequence, the weld will
stop and an alann will be output.
(b) This is only detected when the self hold is set to OFF.
9-6
mil DENGENSHA
(23). F825; Water flow fault
(a) When the flow switch signal is turned OFF, the timer ready signal is output an.
(b) When the flow switch input signal does start signal "ON" in the state of"OFF", warning
is output.
(c) Please confirm it though cooling water flows normally.
(24). F830: Air pressure fault

(a) When the air pressure signal is turned OFF, the timer ready signal is output and OFF.
(b) During weld, the weld will stop and an alarm will be output.
(c) Confirm that the air pressure is sufficient.
(25). F840: Weld I No weld signal error

(a) When the Weld I No weld signal is turned ON, OFF and ON during the welding
sequence, and alarm will be output.
(b) The weld was turned ON~OFF~ON during the welding sequence.
(c) Do not tum the weld ON~OFF~ON during the welding sequence.
(d) Confinn that the wiring for the Weld IN o weld I/0 is not loose.
(26). F930: Original position not initialized

(a) If the collective reference position is set to "0" while the original position for each pilot
schedule is set to OFF when started, an alarm will be output.
(b) Set the original position or the global original position.
(27). F931: Wrong Nut

(a) When the gun position after the squeeze is completed is located above the nut high limit
when started, an alarm will be output.
(b) Confirm that the squeeze time is set correctly.
(c) Confirm that the nut high limit and the original position are correct.
(d) Check the work piece.
(28). F932: No Nut

(a) When the gun position after the squeeze is completed is located below the nut low limit
when started, an alarm will be output.
(b) Confirm that the foreign substance detection position and the reference position are
correct.
(c) Check the work piece.
9-7
fml DENGENSHA
(29). F933: Setdown distance low
(a) When the gun position after the welding is completed is higher than the set position of
the setdown low limit, an alarm will be output.
(b) Confirm that the setdown low limit is set correctly.
(30). F934: Setdown distance high

(a) When the gun position after the welding is completed is lower than the set position of the
setdown high limit, an alann will be output.
(b) Confirm that the setdown high limit is set correctly.
(31 ). F990: Timer board fault

(a) When a current of 10 cycles or more is detected while not being energized, an alann will
be output.
(b) Replace the timer board.
When abnonnally generated, the fault code might not be displayed. Please refer to the trouble
shoot of the attachment.
Please describe details of the situation of the occurrence etc. to 'Troubleshooting for NDZ',
and transmit to our window when abnonnality is not canceled by the trouble shoot.
9-8
mil DENGENSHA
Troubleshooting for NDZ
Symptoms Items to be Checked Content to be Checked
1 It will not run Checking what is displayed on If nothing is displayed on the program box, please check
·The power supply the program box whether the source power supply is turned on, and check the
will not turn on state of the four fuses of this machine.
· It will not start up If any ofthe fuses is blown out, exchange it with a fuse ofthe
·The power supply same standard. There may be malfunctioning if it gets
will not turn on blown out again, so consult our company's contact person.
Checking the input of the pilot When the start-up switch or signal is inputted, the input can
· It will not be
signal be checked by whether the Start Up LED of the program box
weld
is turned on.
If the Start Up LED does not turn on, check the operating
condition of the switch, and also check whether the
connector or cable at the connecting portion is damaged.
Operation of the timer If it does not accept the start-up input, check the monitoring
display on the program box.
The timer is running, if the monitoring is displayed.
Air pressure gauge, pressure Check the air pressure with the pressure gauge. Refer to the
reducing valve "Air pressure- welding pressure" diagram in the Instruction
Manual, and adjust it so that the necessary air pressure will
be applied.
Checking the operation of the Check the operation and power supply of the solenoid valve
solenoid valve (electromagnetic valve).
2 An fault code is displayed on the program box Refer to the explanations on fault codes, written in the
Instruction Manual.
Refer to the following items as necessary.
3 The welding is The state of the electrode (dirt) Cleaning and exchanging of the electrode
abnonnal The state of the work pieces, Cleaning and management of the work pieces
whether there is dirt on them
·No current Whether the welding conditions Check whether there are any anomalies, using the monitoring
• Weld current high are appropriate items of the program box.
· Weld current low Whether errors are being issued There are cases in which fault codes will not be able to be
Checking the monitoring values issued when the tolerance range is too broad, such as for the
• The current is
line volt value or welding current.
unstable
Displaying of the fault codes Please refer to the explanations on fault codes.
· There is error in
Whether it is set to be "Weld If it is set to be "Weld off' on the program box, switch it to
comparison with the
off' "Weld on."
welding ammeter
Whether the Stop button is If the Stop button is switched on, switch it off.
turned on ("F480" will be displayed on the program box, when the Stop
• There is faulty button is switched on)
welding Air pressure If the air pressure is insufficient, check and adjust the source
Squeeze time pressure, and adjust the pressure reducing valve of the
• The energizing machine.
(welding) duration If the Squeeze time is insufficient, it will enter into the
is long welding cycle before the electrode arrives at the prescribed
position, and proper welding will not be possible anymore.
·There are Checking the welding There are some ammeters that wili not be able to display the
explosions conditions welding current and the number of cycles accurately, when
the down slope setting is set to anything other than "0."
• There are line Set the down slope setting to the initial value "0," except in
volt drops special cases.
Checking it with the welding If there is a considerable amount of error between the display
ammeter of the welding ammeter and the monitoring value of the
program box, damages to the toroidal coil or wiring are
conceivable. Please check whether there is any anomaly in
the appearance of the toroidal coil or wiring, and notify our
company's contact person.
9-9
IEJ DENGENSHA
Drops in the power supply Check whether there is any drop in the power supply voltage
voltage at the primary side at the primary side, upon welding.
The following reasons are conceivable for drops in the power
supply voltage at the primary side.
• The capacity of the power supply to be supplied is too
small.
· Aren't there any voltage-drops when welding is conducted
in synchronization with the other welding machines?
· It will cause voltage drops if the diameter of the wires used
for the primary side wiring is too small, or if their length is
too long.
Loosening of the power supply If any loosening of the power supply terminals is found, be
tenninals sure to cut off the power supply, check that it is in OFF state
with an electroscope, and then retighten the terminals.
4 The welding will Malfunctioning of the timer Please confinn welding condition LED display on the
not be completed program box, and confinn which state the control is.
If the displaying is not appropriate, check whether the
monitoring will be displayed.
Air pressure gauge, pressure If the air pressure is insufficient, check and adjust the source
reducing valve pressure, and adjust the pressure reducing valve of the
Foreign substances or machine.
deformation at the sliding Remove any foreign substances at the sliding portions.
portions If you find any deformation, consult our company's contact
person.
5 It gets heated up Identifying the source of the Identify the source of the smell, and if it is a smell caused by
·There is an smell being heated up, take measures according to the cause of the
abnonnal smell heating.
• There is a burnt Water temperature, transformer Check the temperature and flow rate of the cooling water,
or discolored temperature and if the flow rate is insufficient, adjust it by adjusting the
portion Duty factor (usage state) valve, etc.
• There is Using the machine in excess of the welding conditions and
overheating duty factor written on the specification name plate will cause
malfunctioning, and may greatly shorten the lifespan of the
• The temperature
product.
of the drainage of
Please use it within the range indicated on the specification
the cooling water is
name plate.
high
Identifying the source of the Investigate the flow rate of the cooling water in accordance
• The thennostat
overheating with the location of overheating, and fix it or exchange it if
will function
there is clogging.
Checking the welding Using the machine in excess of the welding conditions and
conditions and duty factor duty factor written on the specification name plate will cause
malfunctioning, and may greatly shorten the lifespan of the
product.
Please use it within the range indicated on the specification
name plate.
Fault code Please refer to the explanations on fault codes.
6 Memory Check Fault code Please refer to the explanations on fault codes.
error when the
power supply is
turned on
7 The program box is Fuse If the power supply is turned on and the displaying of the
abnormal Connecter connections at both program box is off, the fuse may have blown out.
sides of program box Check the electrical continuity of the fuse, and exchange it if
The harness it is blown out. There may be malfunctioning if it gets
blown out again, so consult our company's contact person.
If there is any loosening in the connection of the connectors,
cut off the power supply temporarily, connect the connectors
securely, and then turn on the power supply again.
Notify our company's contact person ifthere are damages to
the harness.
9-10
fEI DENGENSHA
8 There are abnormal Identifying the portion where Please identify the portion where the abnonnal noises are
noises the abnonnal noises are generated, and take measures corresponding to that portion.
generated
9 Air leakage Identifying the portion where Please fix the portion where air leakage occurs.
air leakage occurs Water hose is a component specified to be inspected upon
periodical inspections, and also a component to be exchanged
periodically.
10 Water leakage Identifying the portion where Please fix the portion where water leakage occurs or
water leakage occurs exchange it.
Air hose is a component specified to be inspected upon
periodical inspections, and also a component to be exchanged
periodically.
11 There is abnormal Play or loosening at the sliding Please retighten any loosening at the tightening portions.
vibration portions
12 Sparks are emitted Identifying the portion where Sparks may be emitted from the terminal portion ifthere is
sparks are emitted loosening at the power supply terminal.
Squeeze time It will cause faulty welding or malfunctioning, so cut off the
Poor insulation? power supply temporarily, and retighten the tenninals.
Loosening of the tenninals Check whether the air pressure and squeezing time are
Fault code appropriate. If the squeezing time is insufficient, the
welding current will flow before the electrode arrives at the
welding position, and cause explosion.
Please refer to the explanations on fault codes.
13 The configured data The configured data has Please press the Write key, when configuring with the
has disappeared disappeared program box.
Timer trouble There may be malfunctioning if the configured data
disappears even when this writing has been conducted, so
please notify our company's contact person.
14 The power supply The settings The two wires may move in repulsion when a big current is
wires will "kick" Measurement of the welding applied to them, due to influence by the magnetic field.
current using the welding Secure the wires as necessary, in such cases.
ammeter
15 The Earth Leakage Whether there is any water If there is a water leak, cut off the power supply, fix the
circuit Breaker will leaks water leaking portion, and run it again after the portion has
trip Whether there is any line-to- dried.
ground faults Identify the location of the line-to-ground fault, and apply
insulation treatment.
9-11
lEI DENGENSHA
Operation-check settings for NDZ
Squeeze Up slope Weld1 Cool1 Weld2 Cool2 Weld3
50cyc 3cyc lOcyc Ocyc Ocyc Ocyc Ocyc
Down Hold Off Pulsation
Ocyc 15cyc Ocyc lcyc
Maximum Cunent (1,2,3) Cunent (1,2,3) low

Cunent1 Cunent2 Cunent3 Heat high limit
cunent high limit limit
8.0kA 2.0kA 2.0kA 20.0kA 20% 20% 100%
Heat low limit Cunentmode Gun No.
10% cc 1
Fault reset End ofhold

Reweld Weld I No weld Self hold Endofhold Squeeze delay
by start input delay
Weld time self
Off Off ON Hold Ocyc Ocyc
hold
~
Weld time Insufficient weld
Line volt Line volt low limit Line volt high limit
compensation time
3cyc 1cyc (Users line volt) 20% 20%
Caution!
1.When conducting operation-checks using these welding conditions, write down the conditions that
have previously been set on a program sheet, before setting them, so as not to lose the welding
conditions set by the customer.
2.The content of these settings is not anything that will assure an actual welding.
Set welding conditions appropriate for the work pieces, etc., after the operation-check is over.
9-12
Iii DENGENSHA
Sheet for notifying malfunctioning state, for NDZ (for FAX transmission) (p. 1 I p .)
Date of issue:
*Please use this sheet after consulting the explanations on troubleshooting and fault codes in the Instruction Manual.
Your section name, Tel number:
company name FAX number:
Cell phone:
Your name
e-mail:
Your address Postal code:
*About the applicable machine
Model type I Product code I
Serial number IDate of I IPeriod
use of IA pprox. months
delivery
Machines connected to it I Feeder Robot Others ( )
*Your current state of usage
Main workpieces Material: IThickness: mm
Number of
points I workpiece I sec I unit I workpieces /day
welding points
Welding Squeeze: eye, Up Slope: eye, Weldl eye, Down Slope eye
conditions
Hold: eye, Cunent: A, Cunent eont mode: cc vc HCCL , pressure kN
Please fill your configuratiOn data mto the program sheet of the InstructiOn Manual, and attach It to th1s sheet.
Voltage Standby: V(AC) Energization (welding): V(AC)
Cooling Amount: l/min. Quality: Tap water Groundwater

water Timing to exchange the circulating water: times/year
Note· About the Issue that has ansen
1 What kind of a symptom was it? (Please enter it in as much detail as possible)
2 Upon what kind of operation did it occur? (Or, in which cycle did it occur?)
Installation Start of work During operation After a day off After changing the settings
Others ( )
3 Did you do any irregular manipulation before it happened? Or, was there anything different from usual?
4 Is there anything that you added or changed, regarding this machine?
5 Is this the first time this symptom occurred? If it wasn't the first time, please fill in the frequency of its
occurrence, or the number of times it happened.
6 Is it currently usable? If it is, please fill-in how you recovered?
7 Has this machine malfunctioned in the past? If there is a history of malfunctioning, please write an
outline of the history.
8 Please fill in any requests.
If there is not enough space to till in your answers, please fill them onto the additiOnal sheet mdtcated in the next
page, referring to the fill-in example.
Thank you for tilling in your answers.
9-13
m DENGENSHA
Sheet for notifying malfunctioning state, for NDZ (for FAX transmission) (p. 1 I p .)
Note: Please append your answers onto this sheet if there wasn't enough space on the first page.
(Fill-in example)
3 It entered into a state with multiple alarms being issued, when trying to weld a
prototype.
t The material quality of the prototype was XXX, and its shape was as indicated below.
Corresponding (You can attach drawings or pictures, as necessary.)
item number
in the previous
page
I(Drawing)
(Filling-in space)
9-14
Iii DENGENSHA
10. Maintenances
10 - 1. Notes when performing maintenance
• Be sure to confirm that the welding power supply is shut down.
• Only specified parts can be used for replacement.
10 - 2. Fuse replacement
Two fuses (F1, F2) are located on the printed circuit board of the timer unit, and two fuses
(FUO 1, FU02) are located on the contactor.
When a fuse is blown, replace with the following parts.
• F1 : 125V 3A Normal type size cf> 5.2 X 20mm
• F2 : 125V 2A Normal type size cf> 5.2 X 20mm
• FU01,02:600V 1A Time delay type size cf> 10.4 X 38.1mm
10-1
IEJ DENGENSHA
11. Maintenance and Spare parts list
11 - 1. Maintenance parts list
Parts Name Type/Model Unit Name Q'ty Manufacturer Parts Number Parts Code Remarks
Fuse (F1) ULTSC3AN1
Timer Board
1 soc ULTSC3AN1 9000244315
Fuse (F2) ULTSC2AN1 1 soc ULTSC2AN1 9000244327
Fuse (FU01, FU02) ATQR1 2 FERRAZ ATQR1 9000003200
Timer Unit
SCR unit U911-01-6876-{A} 1 DENGENSHA U911-01-6876-{A} 3001465003
ATQR3 2 FERRAZ ATQR3 9000002498 UL/CSA
Fuse (FU03, FU04) Breaker box
KLDR3 2 Littel Fuse KLDR3 9000003945 CE
ATQR3 2 FERRAZ ATQR3 9000002498 For include SDTr model
Fuse (FU03, FU04) Step Down Trans.
ATQR6 2 FERRAZ ATQR6 9000002513 For include SDTr model
Troidal coil 1B4Nl.5D NDZ 1 DENGENSHA U911-30-7080-{A} 3001465344
11 - 2. Spare parts list

Parts Name Type/Model Unit Name Q'ty Manufacturer Parts Number Parts Code Remarks
GMP-0626B-1 1 DENGENSHA GMP-0626B-1 9000244149 Standard
Timer board (PCB01) Timer Unit
GMP-0626E-1 1 DENGENSHA GMP-0626E-1 9000244163 Linear encoder
ND-035-ZD 1 DENGENSHA ND-035-ZD 3001464897 35KVA
Welding transformer ND-050-ZD 1 DENGENSHA ND-050-ZD 3001464912 50KVA
NDZ
(WT01) ND-070-ZD 1 DENGENSHA ND-070-ZD 3001464936 70KVA
ND-100-ZD 1 DENGENSHA ND-100-ZD 3001464950 100KVA ------------------
11-1
lmJ DENGENSHA
11 - 3. Replaceable component list 1
Parts Name Type/Model Q'ty Manufacturer Parts Number Parts Code Remarks
NWC-902-11 1 DENGENSHA U911-01-7014-{A} 3001465104 JIS and Asia, Standard (AC400V)
NWC-902-21 1 DENGENSHA U911-01-7016-{A} 3001465154 UL, Standard
NWC-902-31 1 DENGENSHA U911-01-7024-{A} 3001465178 CE, Standard
Timer/Contactor
NWC-903-11 1 DENGENSHA U911-01-7029-{A} 3001465231 JIS and Asia, Linear type (AC400V)
NWC-903-21 1 DENGENSHA U911-01-7030-{A} 3001465243 UL, Linear type
NWC-903-31 1 DENGENSHA U911-01-7031-{A} 3001465255 CE, Linear type i
MCCBBOX-01 1 DENGENSHA U920-20-2633-{A} 1101000214 UL, 35kKVA I 50kVA
MCCBBOX-02 1 DENGENSHA U920-20-2634- {A} 1101000226 UL, 70kVA
MCCBBOX-03 1 DENGENSHA U920-20-2635-{A} 1101000238 UL, 100kVA
Breaker box
ELCEBOX-01 1 DENGENSHA U920-20-2646-{A} 1101000240 CE, 35kVA I 50kVA
ELCEBOX-02 1 DENGENSHA U920-20-2647-{A} 1101000252 CE, 70kVA
ELCEBOX-03 1 DENGENSHA U920-20-2648-{A} 1101000264 CE, 100kVA
11-2
Iii DENGENSHA
11 - 4. Replaceable component list 2
Parts Name Type/Model Q'ty Manufacturer Parts Number Parts Code Remarks
PB-900-11 1 DENGENSHA U911-01-1743-{A} 1101000137 JIS
Program Box PB-900-21 1 DENGENSHA U911-01-3812-{A} 1101000149 Asia and UL
PB-900-22 1 DENGENSHA U911-01-1399-{A} 1101000151 CE
MB-900-11 1 DENGENSHA U911-01-2527-{A} 1101000276 JIS
Monitor Box MB-900-21 1 DENGENSHA U911-01-3825-{A} 1101000288 Asia and UL
MB-900-22 1 DENGENSHA U911-01-2528-{A} 1101000290 CE
CB-900-03 1 DENGENSHA U911-00-1349-{A} 1101000163 Length: 3m I
Program Cable CB-900-05 1 DENGENSHA U911-00-3937-{A} 1101000391 Length:5m

CB-900-10 1 DENGENSHA U911-00-3938-{A} 1101000389 Length: 10m
TSM-900J 1 DENGENSHA U911-00-4432-{A} 1101000517 Japanese
Transmitter
TSM-900E 1 DENGENSHA U911-00-4433-{A} 1101000529 English
11-3
lml DENGENSHA
I NWC-900 Program sheet (1/2) I
DATE: NAME:
FUNCTION (F) SCHEDULE *1 *2 9.::2 *2

ITEM Maximum S If h ld E d f h ld i
; R ld Fault reset by I Select buzzer St 1t 1 k d Select Nt d t f i Electrode position 1 S td
~- ~-~~c_fl_~~-~~~-- ~---e~---~- _ _____ ~-~ -~--: e:~-----~-s~a~~~~t_ ___ j ___ . mode . ----~ ~:r:__~_o__~~--~roida~~~ -t--~-~-~~n__
epp::__ - - - . l __~()rTlpen:_~io_" _ _J ____ ~_
ADDRESS 1 3 i 4 1 5 ' 6 1
7 • 8 . 9 10 ' 20 : 21 i 22
-~ ~-- \_0FF/STEP/LIN~ ------o/1-· ---·-r--OFF/ON--~,--OFF/O_N__ _
I
I sEmNG RANG --5131/PNL_-- l OFF/WELD/PULS j 50/200/HOLD OFF/ON OFF/ON 0/1/2____ STD/ISO l --OFF/ON
INmALS-EmNa 31 ~---- WELD---- ,---HOLD ---~-ofF- ----T OFF i 0 i OFF I 0 ST~--OFF-----~--- OFF ---'---OFF---
-~~----
0 D5__ SOH~--~--- DSelf hold OFF D50 msec. _ DOFF
J I DOFF [OFault and weld comp. i DOFF _ I DBetween 2_syste~@DG ~~~~rei ___ _]DOFF --=~_-=-___J_g~----~ __ j D~F____ _
1 D31 SOH~. DWeldtimeselfhold 020~~~-~~~~------~g_~~----jDFault _ji:]Stepup _=lDMulti ________ tDISO iDON [DON _ !_D_O_N_ _ _ __
D255 SCHE. (Panel) DPulse start OHold i ! !Dcomp. iDLiner up -1 j ! i _____ I
COMMON (C) SCHEDULE

ITEM ~ Squeeze I End of hold Wetdti~suffcient l 0 t" I L" It ! Line volt f Line volt i Password Pts~word
delay i delay , compensation i weld time i ver tme 1 tne vo i high limit I low limit I (weld off) e::~~)
--~- -···--------,---~-- -- -----:--------r----~--! ----------r--··-----~1--- ----~-----------i--------.-------
ADDRESS . . 1 i . 2 . i 3 . I 4 i 5 ! 6 i 7 i 8 : 30 . i 31
~E~N~ ~~aE :=_:~-=-5o-~.--=l~~-=----;__.--=--o-=-5o_~~--=~ - 50-=-~.--_ 1o - 2000 l~~~~--:- 1oo~l--~-5_~ -5o___l_~s-=-so---~. ___o~~?I- ~=--~-?~~~=
1__ur1~~--- --~c~---~-~.C:': ___ ;__c_Y_<:':___~--~~-_j__c_~!:___j ___~----~----~~--i___%_ _ _: ___ __::-___ _(____-_ _
INITIAL SEmNG 0 i 0 ! 0 0 i 1000 i 400 ; 25 i 25
f ; 0
Sett value
GUN No.
(G) SCHEDULE
*3 *4 *2
ITEM
______ ---------~ _
ADDRESS
G.l~ba·l·-
-~:~~~;
1
__ .. · G.contr~~
..i·
:
~~de,
2
t_~i
. c:_~~~a~ion
...n. •_.· ___
l.oba. I cu·r-re
4 i 5
~~~-~---~--~a~~~--
2po.ints . _.. J.:••.. _Cali·b· r-ation
j,_·
'
Cal.ibratio. n__ ~·., ---~rren~_1
..
6 ;
Ca-libration~ J!•..
7 . i 9
c~rrent 2
. ---We ld_ c-~u~-----
... Calibratio-n
8 i
-~~~-
t -•. ----P·r·o·
!.
10
-~o~it~~-l
du. ct j-_ --·Global orig.inal
14
sE"TTiNo-RA"... NGE -2.6=-eo~o--
- -······- .. ---·-·.
:Ccivc!Hcc-c -- oFFioo.. T2.iio = 5o.oo~-i.oo=--5o.ooii.oo- 5o.ooT2~oo-=5o.oo-~ o-=-99-99-;- o-..: 9999 -o;l.O-- 2oo-:o
------·-----·--·------c.---------·--:----------'------·~~-----i----·-·-~- +-··------- ------1----·- ----~:------------· -----·--·----1
!
Unit
-~---
INmALSEmNG
kA .
-6o:o-- ;·-cc··- -r---ol=i= - i - :
~~~---:-to:oa
kA ! kA i
____ kA ; kA
1o])o:--1o.o_o_r ____ ii- ___ l: --
-a·~-----o--
mm
Sett value
:>:<: 1;Only setting. This welder doesn't correspond to the ISO toroidal coil.
:i.<:2;0nly as for the linear encoder specification, the display and the setting become possible.
:i.<:3;When shipping it, the setting matched to a fixed welder is done. (Muximum road current rating+ 20%)
:i.<:4; CC;Constant current, VC;Voltage compensation, HCCL;Heat control curretn limit
:::.:<:5: Only HCCL mode 02:2010/9
:i.<:6: It becomes a demagnetization function because of the setting of 31 Cycle or more. QN; ZOO!J(i:
DRW#: U990-40-3985-1
I NWC-900 Program sheet- (2/2) I
DATE: NAME:
WELD (W) SCHEDULE (SCHE. No. 1-255) *6

ITEM Squeeze Up slope Weld 1 '------~~~t-1 ----~ Cool1 ' Weld 2 ~---~-~~E!I'It_3____; Coo12 i Weld 3 ~----_9~~!!2~--~J Down slope i Hold i Off Pulsation
_j
1=-~oo~Ess
sETTINGRANG
=-- 1_
0-100
1
: 0-100
1
l 0-100
: 00
• 2.0-50.0 i
VC
-~-~~-~-:J_ ___ J____-_=~~~~~--r--=----~=- ---4-==-=-l~-=~=:-=-~=:-i-=-__r_=·===~I=-===~=--=s
15-100 [ 0-100'
•
0-100 i
CC
2.0-50.0'
i VC
15-100
!
· 0-100
__=J_-_
t
0-100
9 __
i 00
2.0-50.0
l
i
VC
_-:J_:=-=_---~o-----_-l___=_II=i
! 15-100
i
0-50
:
· 1-100
i
__-__ -:-__L=-_1£_=-----::=:!.4-
12
i 0-100 · 1-20
unit ---6~fQ~~=-I=~L~~h~-~r-~-+-- -c~~~~r-- ~-~----:; ---~~H'i=;-~~==t=+.--===~~~-~~-~-,----c~; 1=----~
SCHE.~~~~~~~~--_;- -~~;~~~--~~ 2_~- ._j~~==<-·- .• ~~--~~· :~r~~~±.~-~=~-= -:~~~~~=~~~~< l ! i ---
WELD (W) SCHEDULE (SCHE. No. 1-255)

*4 *5 *2 I
*2 *2 *2 .
*2
Initial current i Maximum Current Current1 Current1 Current2 Current2 Heat HCCL mode Original i Nut high limit Nut low limit : Setdown high Setdown low
ITEM Temper cool 1
heat% current high limit low limit current limit position limit limit
control mode low limit low limit
--------~
1
-~--~-~--- high limit
--- --- --- - -......,....-- -~-- ----- ----------'-------- --1---------------1------ -----'--- ------ ----'-- -------------- ----------------
ADDRESS 15 16 17 2 56 57 58 60
SETTING OFF/ OFF/ OFF/CO
RANGE 15-80 2.0-60.0 /VC/HCCL
3-50 3-50 3-50 3-50 10- 100 i 2.0-50.0 0- 1000
Unit %
1------~11----------------------
INITIAL SETTING OFF
kA
OFF OFF 20
%
20
%
20
%
20
-----·----1o --
% , kA
--~----z:o-----
t-_o______I
-+--------------1-----------------" ----------------- -----------
Cycle Cycle
--oFF----- mm
"---2o.o-- --------(o_________
mm mm
-2o.oo _____ -1o.mmoo
~---•1--- ---- - ~------------··-
SCHE. ----11-~--~i ________ -+----------~---

:
I
--+"--------- -----1--- ------ -- ---7-------- ----------; --------------- ---

-- --- ---
I
STEPPER
Increase [%] Weld count [Count]
ITEM
(WELD (W) SCHEDULE (SCHE. No. 1-255)) (GUN No. (G) SCHEDULE)
ADDRESS ~~-~
SETTING RANGE 00
_i__~----===~-_]~~--44 -~~=~ ~I__ 46==I~---47=-L__4f"_[__4~-l----~-~~·_!1_~-=-~=-=)~ ~ }~~~
0 : -~--]- -2~---1~27-=J--~-=-~
-~---~
INITIAL SETTING 1oo I _ _()_

Step 4 1 j 4
GUN i I
No. I
L
*l;Only setting.This welder doesn't correspond to the ISO toroidal coil.

*2;0nly as for the linear encoder specification, the display and the setting become possible.
*3;When shipping it, the setting matched to a fixed welder is done. (Muximum road current rating+ 20%)
*4; CC;Constant current, VC;Voltage compensation, HCCL;Heat control curretn limit 02:2010/9
*5: Only HCCL mode qN:2009/2
*6: It becomes a demagnetization function because of the setting of 31 Cycle or more.
DRW#: U990-40-3985-2
13. Option
For the model equipped with the linear encoder, functions of the no nut detection and the
detection etc. of the amount of the setdown of the nut are provided.
13 - 1. Wrong nut and No nut function
The function becomes effective by turning ON 'Nut detection' ofF schedule.
• It is a function to detect the height of the nut (work) and to detect the no Nut.
• It is a function to detect the foreign body when a foreign body that is higher than
the height of the nut is placed.
• Operation explanation
Figure below CD is nonnal when the position of the upper electrode point is between the
Nut high limit and the Nut low limit. ® the upper electrode positions are higher than the
Nut high limit, and it becomes a Wrong nut.
When the position of the upper electrode is lower than that of the Nut low limit, ®
becomes a No nut.
CDNormal ®Wrong nut @No nut
Nut high limit setting - - - - - ·

Nut low limit setting - - - - - ~·~~f:l
Figure 12
• Setting items
Nut high limit:
The pennissible value of the height when the nut (work) is placed is set by the
distance from a original position. Figure 14
Nut low limit:
The lower bound value to detect the pennissible value or the no nut of the low
degree when the nut (work) is placed is set by the distance from an original
position. Figure 14
Original position:
The position that becomes the standard of the nut high limit and the nut low
limit is set by the distance from the electrode liberating position. A standard
position can be measured by the automatic operation by doing the test
pressurizing. It becomes standard CD or standard ® positional work of a
lower electrode. Figure 13
13-1
lEI DENGENSHA
Position of op<:n_ _
CD Electrode Nut high limit

original position
®Touch position
Figure 13 Figure 14
• Measurement of original position

<Auto input procedure of the original position by pressure test operation>
CD Tum "ON" the Nut detection, and set the timer to the pressure test mode.
® Set the work piece (condition without a work piece can be used as a reference)
@ Tum ON the "Pilot" input signal.
@ After the electrode is lowered save the current position where the timer checks the
stopping of the electrode by the predetennined time (I OOmsec or more), into the
'collective reference position' of the gun schedule and the 'Global original
position' of the weld schedule. (The measurement results are also memorized in
the Touch position monitor.)
@ When the saving is completed nonnally, "Set" will be displayed on the data
display of the Program box or Monitor box.
• Setting method at nut high limit and nut low limit

Nut high limit :
An initial value is 20.0mm.
The pennissible value is set by the distance from a standard position if necessary.
Nut ow limit : (Figures 14)
An initial value is l.Omm.
The pennissible value is set by the distance from a standard position if necessary.
The distance is set for a work positional standard by "Value of the minus".
* Please set or measure a standard position again might mis-detect error when you exchange
electrodes.
13-2
mil DENGENSHA
• Confirming the operation of foreign body and no works detecting function
"OFF" Weld is done. It is possible to confirm the operation by setting the 'Nut
detection at "Weld OFF"' setting of the cancer system to "ON" like the foreign
body and the no works detecting function.
13- 2. Table for not works detection operation

Setting/input
Error
Nut Weld/No 'Nut detection at judgment Note
detection weld "Weld OFF"' operation
Setting Input setting
OFF OFF Set invalidity - -
OFF ON Set invalidity - -
When trying
It doesn't
ON OFF OFF (The weld complete signal is
judge.
output.)
When confirming the operation
ON OFF ON It judges.
detecting the no works
When the Weld /No weld is
turning on, the setting 'Nut
ON ON Set invalidity It judges.
detection at "Weld OFF"' detection
becomes invalid.
* The detect function doesn't operate normally when it makes a mistake in the setting.
Please use it after confinning the function operates nonnally by the test operation before it
actually uses it.
13-3
B DENGENSHA
13- 3. Setdown detection
The function becomes effective by turning ON 'Setdown' ofF schedule.
• The amount of the setdown when the nut projection etc. are welded is detected.
• Abnormality of Setdown distance low and Setdown distance high is detected from
the detected amount of the setdown.
• Operation explanation
The position in which the electrode placed the nut (work) is detected. And, the
distance of the electrode from after it welds to end of hold is measured, and the
amount of the setdown is detected.
If the detected amount of the setdown is a pennissible value in Setdown low
limit/Setdown high limit, it becomes a normal tennination. It becomes abnonnal
of Setdown distance low when the detected amount of the setdown is smaller
than that of Setodown low limit, and when it is larger than Setdown higt limit, it
becomes abnonnal of Setdown distance high.
• Setting items
Setdown high limit: The high limit of the amount of the setdown is set.
Setdown low limit: The low limit of the amount of the setdown is set.
End of hold position Setdown distance high

Weld start position Setdown distance low
Figure 15
13-4
Iii DENGENSHA
13 - 4. Feeder Interface connector
It is possible to connect it easily with the feeder by one connector.
( 1) Outline and connector
~ i~ A -1
'J f- ffl =:J ~ ~ 5 ( C N0 1 )
Start Switch Connector
-$-
~ ---r ~ j' ~ IFffi =:J ~ ~ 5

(CN02,CN03)
Feeder IF Connector
Figure 16 NUT Feeder Interface connector
CNO 1 : Connector for start switch

The start switch such as the foot switches is connected.
The connection can be selected from the following connector.
HARTING HAN4A
NANAHOSHI NCS-25
CN02 : Connector for feeder IF

It is possible to connect from the feeder, and to start with the start switch of
CNO 1.When the nut and the bolt feeder is connected, it uses it.
HARTING HAN7D
CN02 : Connector for feeder IF (for bolt feeder)

The pressurizing signal from the bolt feeder is connected.
HARTING HANQ5/0
13-5
lEI DENGENSHA
(2) Connector wiring diagram
Feeder Start
I
~eeder
I Press
I
I I
~d_ering ~ochine _j
* :(TB02-AOOO) t;L !~li'G%~!9, ~~d"o':l':nti!v-l::')i-'§-
( TB02-Aooo l connection destination is shown.

Parts symbol - Pin number
Figure 17 Connector wiring diagram
• Main body connector and wiring are common in the model for all feeders. (bolt/nut).
Feeder side wiring :
Only CN02 is a connection at the nut feeder specification.
CN02 and CN03 are connections at the bolt feeder specification.
• Feeder start signal

The CN02 of the feeder connection model is connected with the start switch pin 1,pin2
(foot switch etc.) and TB01 pin38,pin39.
In a standard setting when it shipping, the feeder starts with start switch ON. And, the
welding machine starts by the signal from the feeder.
The welding machine is not started with start switch ON when there ts no feeder
connection in the feeder connection model.
13-6
B DENGENSHA
(3) Feeder connector wiring (spot and direct feeder wiring)
CD When the feeder is connected and used for start switch connector (CN01)
Please change from 39 pins to 0 pins until20 pins from 38 pins ofTB 1.
Before
After
(at shipping)
Pin 1(TB138) TB1 Pin 38 -----7 Pin20
CN01
Pin 2(TB 139) (PCB01) Pin 39 -----7 PinO
-E-----------+---------'-A'-=-00=--::0:____-t~---ifB~2- ;ower Sou~c~

AC1 OOV /SA max.
A100 I A11 0 i c--=TB=-=o-=-2_--,. A-:-:-1*-;:--,0) AC 115V/SA '""'.
CN01
-- llmeCTt I
f}-----+--+------'-1--71 ITB138
-l
I
r
Timer Start
212J_ltli_39 I --~ (to Main board) I
FSO 1(I) o~------'----'--3>-t------o-<o------,---1--+--7 ~

I
I
. -
Feeder Start
>o r__t]
@@ ffi
l'0 I
I I
I @_[ I I I
~o~t Switch_
I I
o~~----~72~7_ _~1 ->7~

I I
I
Press Press signal
o~-4----~73~1--~·->~~
I
lJ?~ Feeder _ _ J I
I I
* :(TB02-AOOO) t;L t~~~JIG~t9, ~~~:,)!1\'Jv-t':Ji~ / Weld_ering r:0achin~ _j

(TB02-Aooo) connection destination is shown.
Parts symbol - Pin number
(2) When using it without connecting the feeder (Excluding the spot specification)
Please buy a feeder short connector .A feeder short connector is connected with
connector (CN02) for feeder IF
Or, please change wiring like CD.
13-7
liJ DENGENSHA
Head Office & Plant 1-23-1 Masugata, Tama-ku, Kawasaki-shi,
Kanagawa-ken, Japan Tel: +81(44)922-1121
Aichi Plant 111 Takane, Toei-cho, Anjo-shi, Aichi-ken, Japan Tel: +81(566)97-9530
Toyama Plant 2-27-2 Ariiso, Imizu-shi, Toyama-ken, Japan Tel: +81(766)86-31 13
Kita-Kanto Office 216 Iida-cho, Ohta-shi, Gunma-ken, Japan Tel: +81(276)46-6621

Osaka Office 1-9-16 Yamabiko-Bldg. Oyodo-Minami, Kita-ku, Tel: +81(6)6451-0521
Osaka-shi, Osaka-hu, Japan
Hiroshima Office 15-10 Central-Bldg. Hachobori, Naka-ku, Tel: +81(82)225-2573
Hiroshima-shi, Hiroshima-ken, Japan
Kyusyu Office 1-9-1 Katanoshinmachi, Kokurakita-ku, Tel: +81(93)922-4442
Kitakyusyu-shi, Fukuoka-ken, Japan
Dengensha America 7647 First Place Drive Bedford, Ohio 44146, USA Tel:+ 1(440)439-8081
Dengensha Europe Unit 8, Birchbrook Industrial Park Birchbrook Lane, Tel:+44-1543-481844

Shenstone, Staffs WS14 ODJ, ENGLAND
lEI DENGENSHA

NWC-900 Instruction Manual

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What safety considerations should be observed when using the equipment?

What safety considerations should be observed when using the equipment?

What are the different types of connectors used for the equipment?

What are the different types of connectors used for the equipment?

Document No.

WELD CONTROL FOR STATIONALY SPOT WELDER

ij The instruction manual must be carefully ~

Revision code Revision item Date Drawn Verification Approved

• Program box · Monitor program box instruction manual

1. AFETY INSTRUCTIONS AND CONSIDERATIONS ....................................... 1-1

1 - 1. Product safety labels and symbols .................................................................................. 1-1

2. Outline ................................................................................................................... 2-1

3. Specification .......................................................................................................... 3-1

4. Operation ............................................................................................................... 4-1

5. Programming ......................................................................................................... 5-1

6. Special functions ................................................................................................... 6-1

7. Current control mode ............................................................................................. 7-1

9. Fault code .............................................................................................................. 9-1

10. Maintenances ....................................................................................................... 10-1

11. Maintenance and Spare parts list. ........................................................................ 11-1

12. Program sheet ...................................................................................................... 12-1

1 - 1. Product safety labels and symbols

( 1) General warning sign

(2) Hazard severity panels

(3) Prohibition sign

(4) Mandatory action

1 - 4. Safety during operation

(4) Noise protection

1 - 6. Safety items on maintenance work

(3) Perfonn maintenance work

@ Reference 1 : Maximum input and allowable duty factor of welding transformers

hp = Equivalent continuous current= Welding current x ~duty factor (A)

Equivalent continuous current= 11,000 x JOj = 3,470 A

Example 2 : calculation fonnula of the equivalent continuous current from the

If a transfonner is to be used in excess of this equivalent continuous current, generation

2- 2. Place of Weld controls

Figure 1 Weld controls

(a) Weld controls is built into the main body.

PROGRAM BOX MODEL : PB-900 MODEL : PB-900

MONITOR ITEM =£:=. 5 Jj'jEJ

Figure 2 Program box

• Refer to Program box Instruction Manual for operation.

Figure 3 Program cable

(2) Type: NWC-900 series

(3) Rated voltage and frequency

(4) Ambient conditions

(8) Welding current control method

(9) Current detection method

(10) Memory data storage

(11) Controllable ranges

Primary current control range: 50 to 1,500A

(b) Monitor box

(c) Weld Data Manager

Transmitter TSM-900 All

Figure 4 N arne of each part of weld controls

Figure 5 Jumper, DIP SW on Timer board

==..;...==...-.= :Factory setting of standard model

Weld current --!-----,:----1

SDT : Squeeze delay HT : Hold time

Figure 6 Weld sequence