Resistance Welding Controller Instruction Manual: Nawootec Co., LTD

Read First
Resistance Welding Controller
Instruction Manual
♦ DECOMSTAR-70 SERIES ♦
 Separation of fault messages output

 Detection of electrode tip stuck
 Control of electrode force
 Detection of short of secondary cable
 Detection of break of secondary cable
NAWOOTEC CO., LTD.
NAWOOTEC CO., LTD. 0 Sep. 2001

Special features of Decomstar - 70 Series
Type DECOMSTAR SERIES

Special features 70 72 73 74 75 76 77 78 79
Standard features         
Separation of fault messages output     
Detection of electrode tip stuck      
Control of electrode force      
Detection of break of secondary cable     
Detection of short of secondary cable 
Auto stepper ( ) 
Max. number of weld sequences 15 15 15 15 15 15 15 15 31
: Auto stepper (Automatic Current Density Control)

Read First
Important
Read first this manual before operate this controller.
In some case, failure to follow the instruction manual can lead to control or machine
damage.
In other cases failure to follow instructions can lead to injury, or death of personnel.
This manual explains some instructions depend on the level of danger as follow.
DANGER
It shows readers where people will be hurt if procedures are not followed properly.
To use this welding controller in safety, the operator should follow industry
standards and safety senses whenever working on, or near the welding machine.
In some case, failure to follow the warning instructions can lead to control or
machine damage. In other cases failure to follow this instructions can lead to
injury, or death of personnel.
Some examples of safe practices are listed below. These examples are not to be
considered a comprehensive listing of safety practices. Always use safety senses
when working with any type of machinery.
During electrical power is ON, this controller is charged with high voltage
electricity. Electrical power must turn-OFF, before open the door.
In the case the door is opened, as it is not turn-OFF can lead to injury by an
electric shock, or death of personnel.
WARNING
It shows readers where people may be hurt if procedures are not followed properly.
In some case failure to follow these instructions as follows can lead to control
damage or injury of personnel.
1. Ensure that control/machine is connected to the correct voltage before turning
electrical power ON
2. Whenever power is ON, stand clear of moving parts. This practice should be
used even if the machine is not actually in use.
3. Before turning electrical power OFF, ensure that personnel are standing clear
of moving parts that are pneumatic or hydraulic powered.
4. Whenever electrical power is turned OFF, install a "look-out" device at the
main disconnected prevents power from being accidentally turned ON.
NAWOOTEC CO., LTD. i Sep. 2001

Read First
CAUTION
It shows readers where machinery may be damaged or economic loss can occur, or
people may be hurt if procedures are not followed properly.
1.Turn electrical power OFF before changing the tap switch at the weld
transformer.
In the case failure to follow the instruction like a welding at changing the tap
switch can lead to injury to personnel.
2. Turn stop water cocks OFF before some piping work.
In the case failure to follow the instruction like the electrical circuit is splashed
with cooling water can lead to control damage.
RISK OF ELECTRIC SHOCK

It shows readers where people will be struck by an electric shock if procedures are
not followed properly.
NAWOOTEC CO., LTD. ii Sep. 2001

Contents
Special features of Decomstar - 70 Series.................................................0

1. Connection of welding power, transformer, signals, cooling water. .1
1) Timer / Contactor (Separate type).........................................................................1
2. Setting of DIP switch.............................................................................2
1) DIP Switch Function.............................................................................................2
2) Explanation of DIP Switch...................................................................................2
3. Programming method of welding condition.......................................3
1) Explain of program box (Remote type)................................................................3
2) Explain of monitoring box (Remote type)............................................................4
3) Explain of panel key (Panel type).........................................................................6
4) Function of keys....................................................................................................7
5) Programming of sequence “F”.............................................................................8
6) Programming of sequence “0”..............................................................................9
7) Programming of sequence “1 ∼ 15(1 ∼ 31)”.......................................................9
8) Selection of sequence Monitor “M”...................................................................10
4. Setting of welding condition...............................................................11
1) Setting of sequence “F”......................................................................................11
2) Setting of Sequence “0”......................................................................................14
3) Setting of Sequence “1 ∼ 15(1 ∼ 31)”...............................................................15
4) Setting of “STEPPER”(“STEP” and “LINEAR”)...........................................16
5) Monitoring..........................................................................................................17
5. Welding flowchart...............................................................................18
6. Fault warning.......................................................................................19
1) Fault code and fault message..............................................................................19
2) Setting of Fault limitation...................................................................................19
3) Fault output and reset..........................................................................................21
4) Fault reset............................................................................................................21
5) Architectures of fault ruling................................................................................21
7. Trouble shooting method....................................................................22
1) Defect without output fault signal..........................................................................22
2) Defect with fault output......................................................................................23
NAWOOTEC CO., LTD. Sep. 2001

1. Connection of welding power, transformer, signals, cooling water
1) Timer / Contactor (Separate type)
DECOMSTAR-70 100
SCR
600
Cooling
Water
O1 O2 O3
Earth
From welding To welding I/O signal

power source transformer
332 390
4 - hole
30 210
270

2. Setting of DIP switch
1) DIP Switch Function
This switch is on main board of control unit.
SW No Function
1
2 Select Timer No.
in communication networking
3 ( Binary code, “0” : communication off )
4
5
Not used
6
7 ON : Weld/No Weld switch is in toggle mode
8 ON : Data protect mode ( Write inhibit )
2) Explanation of DIP Switch

Switch No. 1~4: When the system connects to communication network system,
This designates timer number in binary code.
When power on, timer memorizes timer number.
Turn off all when network system is not in use.
Switch No. 5~6: Not used
Switch No. 7: Off; During “No-Weld” key of timer panel or “No-Weld” key of program
box is pressed, current does not flow.
When released, current flows.
On; Each time “No-Weld” key of timer panel or program box is pressed,
current flow is on off toggled.
You can confirm current flow via corresponding LEDs.
Switch No. 8: Off; Able to change programming data. (In networking)

On; Unable to change programming data.

3. Programming method of welding condition
1) Explain of program box (Remote type)
PROGRAM BOX
PB-70
1) SQUZE 16 CYC
1) UP-SL 3 CYC
LCD
1) WELD 1 20 CYC
1) CUR 1 12000 CYC
On: internal
weld SW is on WELD
On: External NO
ADRS Address Key
weld SW is on WELD
: Forward
: Reverse
Thermo switch THERMO END
On: normal STEP DATA Data Key
End of step : Increment
: Decrement
RUN FAULT
RST SEQ WR Write Key
Sequence Key
Fault reset
Step advance/ reset
Fault indicator (if fault, blinking)
Run indicator

2) Explain of monitoring box (Remote type)
1. No. of step
000 memory error
2. Current(x100)
100 under current 150 over current
3. Heat(%) 200 under heat% 250 over heat%
4. Time(cycle) 300 under time 350 over time
5. Line voltage 400 under line volt. 450 over line volt.
6. Power factor 500 no current 550 thermo
7. No. of sequence 600 SCR short 650 SCR half cycle
2 125
SEL STEP STEP

RST A B
MONITOR BOX MB-70

Step B increment
Step A increment
Selection of monitor item / reset at fault
No. of selected monitor item
(Ex: display of welding current)

3) Explain of panel key (Panel type)
RESISTANCE
WELD CONTROL
DECOMSTAR
 70 RWC-70P
Valve power
Power
FUSE
Source Firing signal
SEQUENCE 15
CURRENT 12500
FUSE
Fault End Weld Thermo Run
SEQ ◀ADRS▶ ▼DATA▲ WR RST STEP WELD NAWOOTEC CO., LTD.

INCHON KOREA
SCR Firing signal

Write key Weld/ No weld
Run indicator
Data key
Thermo
▲: Increment Step advance
Address key
▼: Decrement On: Internal weld SW is on
Sequence ◀: Reverse Fault reset
Key ▶: Forward On: External weld SW is on
End of step
Fault indicator (if fault, blinking)

4) Function of keys
(1) [SEQ] Key:
This key is used for selection of sequence number for programming or checking of
programmed data. The sequence display on the fourth line of LCD (in case of remote type) is
changed as follows by this key.
 Sequence “4(5)” Mode:
F  M  0  1  2  3  4 ( 5)
 Sequence “15(31)” Mode:

F  M  0  123456789
10
15  14  13  12  11
 Notes 31  30  29  ∼ ∼ ∼  16 15  14  13  12 
11 “M” is selected, The second line of LCD shows contents of monitoring data.
a. When
Ex) CURRENT 12000 A
b. “F” means that function selection mode.
(2) [◄ADRS►] Key:

This key is used for selection of address for programming or checking of programmed data.
The address displayed on second line of LCD is changed as follows.
Sequence “F”:
SEQUENCE  SLFHOLD  REPEAT  EOH  REWELD  RESTART
TIP STUCK  SENSOR  CONSTANT CUR  WELDER  STEPPER
Sequence “M”:
CURRENT  PRIM  CUR  %HEAT  W-TIME  LINE-VOLT
NETWORK No  STEP No A , B  COUNT of A , B  Power-FACT
SEQUENCE No  FIX SIDE  MOV SIDE  SENSTIVTY ACT
CURRENT RATIO  TOTAL CNT  Normal CNT  Expulsn CNT
 Sequence “O”:
SQEZ DLY  EOH DLY  CMP TIM  TIM LIM  MAX TIM  REF VOLT
STIC TST  COUNT B5…B1  COUNT A5 …A1  MIN VOLT  MAX
VOLT
FIX SIDE MIN  FIX SIDE MAX  MOVE SIDE MIN  MOVE SIDE MAX
 Sequence “1∼15(1∼31)”:
SQUEZE  UP-SL  WELD 1  COOL 1  WELD 2  COOL 2  WELD 3
%HEAT1  CUR3  CUR2  CUR1  PULSE  OFF  HOLD  DOWN-SL
%HEAT 2  %HEAT 3  TRANS  LOW-CUR  HI-CUR  MIN HEAT
PRESSUR  VALVE No  INCR 5 … INCR 2  MONITOR  MAX HEAT
SENSISTIVITY  NORMAL CNT  EXPULSION CNT  BLANKING TIME
CUR RATIO MIN  CURR RATIO MAX
When ADRS ► key is pushed, display advances in the direction marked as .

When ◄ ADRS key is pushed, display advances in reverse direction.

(3) [▼DATA▲] Key:
This key is used to change data.
When DATA ▲ key is pushed, The programming data on the LCD is increased.
DATA ▼ key is used to decrement data.
(4) [WR] Key:

When this key is pushed, data is stored into memory and the line is scrolled up automatically
and next new item appears on LCD.
(5) [NO WELD] Key:

Use this key when no-weld operation is required. Function switches decide function of this
key on main board.
(6) [STEP] Key:

This key is used to advance step when current (linear) stepper is in operation.
If second line of LCD displays step No., this key can increase the number.
When second line of LCD display another item, which is not about step number by pressing,
this key you can make second line of LCD display step number and then you can advance step
number using this key again.
(7) [RST] Key:

This key resets fault if any.
When a fault is detected, LCD displays a message, which tells about the fault.
Note) '#' mark displayed on LCD means item which need not programming.
5) Programming of sequence “F”

(1) Push [SEQ] key and select sequence number “F”
0) REF VOLT 380V

F) SELFHOLD WELD Second line
(2) Push [◄ADRS►] key and select SEQUENCE No.
F) SELFHOLD WELD
F) REPEAT OFF Second line
(3) Push [▼DATA▲] key and change data to what you need.
F) SELFHOLD WELD
F) REPEAT  ON Second line
You may see  mark blinking; this shows that data is in preset stage.
At this time, data is not stored to memory yet.

(4) Push [WR] key,  mark disappear and data is stored into memory.
F) SELFHOLD WELD
F) REPEAT ON Second line
Likewise, program all items, which you need to change.
6) Programming of sequence “0”

(1) Push [SEQ] key and select sequence number “0”
F) REPEAT ON
0) REF VOLT 380 V Second line
(2) Push [◄ADRS►] key and select squeeze delay

F) REPEAT ON
0) SQUZ. DLY 0 CYC Second line
(3) Push [▼DATA▲] key and change data to what you need.
F) REPEAT ON
0) SQUZ. DLY  10 CYC Second line
You may see  mark blinking; this shows that data is in preset stage.
At this time, data is not stored to memory yet.
(4) Push [WR] key,  mark disappear and data is stored into memory.
F) REPEAT ON
0) SQUZ. DLY 10 CYC Second line
Likewise, program all items, which you need to change.
7) Programming of sequence “1 ∼ 15(1 ∼ 31)”

(1) Push [SEQ] key display sequence number 1.
0) SQUZ. DLY 10 CYC
1) SQUZE 40 CYC Second line
Operation of programming is same as those of Sequence “0”.

Remember that programming is required only for sequences which you use.

(2) You need to program some items, which have no direct relations to operation of timer.
For example, “Transformer turn ratio”, when using toroidal as current feedback device,
does not affect welding current. This item is used for, however, calculation of primary current.
Thus if this value is not correct, you will get wrong primary current value display.
8) Selection of sequence Monitor “M”

(1) Sequence monitor is used for monitoring of welding results. That is to say omission of
programming is accepted if you don't need.
(2) Push [SEQ] key, to change display to monitoring display.
1) SQUZE 40 CYC
CURRENT 9800 A second line
(3) Push [◄ADRS►] keys, to select monitoring item, for example “CURRENT (secondary)”.
(4) Since monitoring items are not for programmable, [▼DATA▲] key do not work in this
mode, and [WR] key just scrolls up display one line.
CURRENT 9800 A
PRIM CUR 213 A Second line
(5) Next, choose the second monitoring item using [◄ADRS►] keys.
Up to second (in case of remote type, fourth) monitoring items available on LCD at the
same time.
Monitoring values are automatically updated at end of every weld.

4. Setting of welding condition
1) Setting of sequence “F”
Function Selection
SEQUENCE Number of Sequences 4(5) 15(31)
SLFHOLD Self hold of run OFF WELD PULSE
REPEAT Weld of repeat OFF ON
EOH Output mode of end of hold 50ms 200ms HOLD
REWELD Reweld in case of fault OFF IF ERR
RESTART Restart in case of fault OFF ON
STEPPER Current stepper OFF STEP LINEAR AUTO
WELDER Welding machine AC DC1 DC2 DC3
CONTROL Control method constant current voltage compensation
SENSOR Current feedback type CT Toroidal coil
TIP STUCK Detection of tip stuck OFF ON
♣ Note) By default, “CT: Current Transformer” feedback device is installed.
(1) “SEQUENCE”
Relationship between input switch and sequences.
 In case of sequence “4(5)”: (Sequence “5” is only the “DECOMSTAR-79” type)
Inputs
SW-1 SW-2 SW-3 SW-4 SW-5 Remark
Seq. No.
1 ON
2 ON
3 ON
4 ON
5 ON D-79

 In case of sequence “15(31)”:
(Sequences from “16 to 31” is only the “DECOMSTAR-79” type)
Inputs
SW-1 SW-2 SW-3 SW-4 SW-5 Remark
Seq. No.
1 ON
2 ON
3 ON ON
4 ON
5 ON ON
7 ON ON
7 ON ON ON
8 ON
9 ON ON
10 ON ON
11 ON ON ON
12 ON ON
13 ON ON ON
14 ON ON ON
15 ON ON ON ON
16 ON D-79
17 ON ON D-79
18 ON ON D-79
19 ON ON ON D-79
20 ON ON D-79
21 ON ON ON D-79
22 ON ON ON D-79
23 ON ON ON ON D-79
24 ON ON D-79
25 ON ON ON D-79
26 ON ON ON D-79
27 ON ON ON ON D-79
28 ON ON ON D-79
29 ON ON ON ON D-79
30 ON ON ON ON D-79
31 ON ON ON ON ON D-79
(2) “SELF HOLD”:

“PULSE” : If on state have started input lasts for at least 30ms, welder starts welding.
“WELD” : If on state of start input lasts at least until squeeze time, welder starts welding.
“OFF” : To weld, on state of start input should be last until the end of welding.
(3) “REPEAT”:

If set “ON”, after “OFF” time welder repeats the same welding sequence from “SQUEZ”.
(4) “EOH”:
When welder finishes a welding sequence, it outputs “EOH” relay signals. It determines
period (how long “EOH” relay contacts persist) of “EOH” relay signal. “50ms”, “200ms”
means “50ms” and “200ms” respectively. “HOLD” means “EOH” relay signal persist until
the end of on state of starts input.
(5) “REWELD”:
It determines whether welder automatically re-welds in case of “UNDER CURRENT”,
“OVER % HEAT”, “WELD TIME MISSED”, “NO CURRENT” faults. If set “ON”, it
automatically re-welds.
(6) “RESTART”:
When fault (except memory fault) occurs, if this is set as “ON”, welder automatically reset
the fault and start welding upon reception of start input.
(7) “STEPPER”:
When welding sequence continues, diameter of electrode tip extends (mushrooming) and
accordingly, current density decreases. This function compensates bad welding caused by
mushrooming of electrode tips.
If set as “STEP”, you can program stepwise increase of welding current. If set as “LINEAR”,
you can program linear increase of welding current. If set as “AUTO”, welder determines
increase or decrease of current automatically. If you want disable this function, set as "OFF".
(8) “WELDER”:
Set type of welder.
“AC” : AC output from transformer
“DC1” : DC output from transformer with small size of secondary loop
“DC2” : DC output from transformer with medium size of secondary loop
“DC3” : DC output from transformer with large size of secondary loop
(9) “CONTROL”:
“CC (Constant Current)” continuously controls welding current for voltage and load
variations, “VC (Voltage Compensation)”control continuously controls welding current for
unduly voltage variations.
(10) “SENSOR”:
Select current sensor used. “CT” is standard. It is used to detect primary current,
“TOROIDAL” coil is option. It is used to detect secondary current.
In case of “DC1”, “DC1”, or “DC1” it should be set as “CT”.
(11) “TIP STUCK”:

To detect fastening between tips and workpieces, set this as “ON”. For details, refer to
Appendix A-1.
2) Setting of Sequence “0”

ITEM Setting range
SQUZ. DLY Squeeze delay 0 ~ 50 cycle
EOHD.DLY End of hold delay 0 ~ 50 cycle
CMP-TIME Compensation of welding time 0 ~ 50 cycle
TIME-LIM Lacking of welding cycle 0 ~ 50 cycle
MAX-TIME Exceeding of Welding time 10 ~ 999 cycle
REF-VOLT Reference of weld power source 100 ~ 600 V
MIN-VOLT Under limit or weld power source 5 ~ 40 %
MAX-VOLT Under limit or weld power source 5 ~ 40 %
COUNT A1 Counts of step A1 0 ~ 1000 count
COUNT B1 Counts of step B1 0 ~ 1000 count
TIP STIC TIME Detecting time of tip stuck 0 ~ 199 cycle
LO - FIX Minimum resistance value (fix side) 0 ~ 2000 μΩ
HI - FIX Maximum resistance value (fix side) 0 ~ 2000 μΩ
LO - MOV Minimum resistance value (move side) 0 ~ 2000 μΩ
HI - MOV Maximum resistance value (move side) 0 ~ 2000 μΩ
3) Setting of Sequence “1 ∼ 15(1 ∼ 31)”
Items Setting range Remark

CURR 1 Current of weld 1 20 ~ 500 kA CC mode
%HEAT 1 %heat of weld 1 20 ~ 100% VC mode
TRANS Turn ratio of weld transformer 1.0 ~ 200.0
HI-CURR Upper limit of current 5 ~ 90%
LOW-CURR Under limit of current 5 ~ 90%
MAX-HEAT Upper limit of %heat 20 ~ 200 %
MIN-HEAT Under limit of %heat 10 ~ 100 %
MONITOR Monitor of weld 1~3
INCR 2 Rate of increase of step 2 0 ~ 50 % step / linear
VALVE No No. of Solenoid valve A, B
PRESUR Electrode force 0 ~ 10.0 kgf/cm2
Senstivty Sensitivity 0 ~ 99 auto
Explsn CNT Expulsion counter 0 ~ 99 count auto
Normal CNT Non-expulsion counter 0 ~ 99 count auto
Incrs MAX Upper limit of current increasing 100 ~ 200 % auto
Decrs MIN Under limit of current decreasing 0 ~ 100 % auto
Blank TIM Blanking time 0 ~ 9 cycle auto
 CC: Constant current, VC: Voltage compensation
4) Setting of “STEPPER”(“STEP” and “LINEAR”)

Setting
Items Setting range Remark
sequence
Rate of increase of step 1 0% 1 ~ 31 This item is initial value
Rate of increase of step 2 0~50 % 1 ~ 31
Counts of step A1, B1 0~1000 count 0 Setting unit is 1 weld

This function is used to compensate poor welding caused by mushrooming of electrode tips.
The welding current is stepped up in five stages in proportion to increase of count of welds.
In linear stepper up mode, current is linearly increased by linear interpolation of rates of
increase.
In step up mode, no linear interpolation is carried out.
Current [A]
Rate of
Increase 5
Increase 4
Increase 3
Increase 2
Initial Value
Weld
count
Counts of Counts of Counts of Counts of Counts of
step 1 step 2 step 3 step 4 step 5
End of step
Step reset
 Notes
a) To use this step-up function, “STEPPER” of sequence “F” must be set to “LINEAR”
or “STEP”.
b) To reset stepper, push “STEP” key on program box or monitor box or front panel until
step 1 is displayed, or activates reset signal on external terminals.
c) Weld current is calculated as follows.

Final current = “Initial value” + “Initial value” x “Rate of Increase 2”
+ “Initial value” x “Rate of Increase 3”
5) Monitoring

Items Description
CURRENT Average secondary current(RMS) of during weld
PRIM-CUR Average primary current(RMS) of during weld
%HEAT Average %heat of during weld
W-TIME Weld time of during weld
LINE VOLT Average Line voltage of during weld
POWER FACT. Average power factor of during weld
STEP A,B Step number of STEP/LINEAR A, B
COUNT of A,B Count number of STEP/LINEAR A, B
SEQUENCE No Number of sequence
NETWORK No Timer ID
FIX SIDE Resistance value of secondary cable in fix side
MOVE SIDE Resistance value of secondary cable in move side
Senstivty ACT Actual sensitivity
Explsn ACT Actual expulsion counter
Normal ACT Actual non-expulsion counter
Total CNT Total weld counts
Curr RATIO Ratio of current increasing
5. Welding flowchart

Start input
(Pulse)
Start input
(Weld)
Valve
output
Weld
Current
up- off
slope
squeeze squeeze weld1 cool1 weld2 cool2 weld3 down hold hold
delay slope delay
Pulsation
Reweld
Repeat
At normal
end of hold output
fault output
At used end of hold delay

end of hold output
fault output
Note) If fault occurred, no end of hold output.
6. Fault warning

1) Fault code and fault message
Code Message
000 MEMORY ERROR
100 UNDER CURRENT
150 OVER CURRENT
200 UNDER % HEAT
250 OVER % HEAT
300 WELD TIME MISSED
350 WELD TIME LONG
400 UNDER LINE VOLTAGE
450 OVER LINE VOLTAGE
500 NO CURRENT
501 BEFORE TRANS
502 K-CABLE BROKEN
503 AFTER GUN
504 K-CABLE SHORT
550 THERMO SW - OPEN
600 SCR HALF CYC
650 SCR SHORTED
700 TIP STUCK
701 TIP WIRE BROKEN
750 OVER RESISTOR FIX
751 OVER RESISTOR MOV
760 WIRE BROKEN FIX
761 WIRE BROKEN MOV
800 COMMUNICATION ERROR
2) Setting of Fault limitation

(1) Under current and over current
On constant current control, if average welding current violates these limits,
“UNDER CURRENT” or “OVER CURRENT” fault occurs.
At this time, fault relay contact is closed.
Items Setting range Setting sequence Remark
LOW-CUR 5 % ~ 99 % 1~31
HI-CUR 5 % ~ 99 % 1~31
(2) Under %heat and over %heat

On constant current or voltage compensation control, if average percentage heat violates these
limits, “UNDER % HEAT” or “OVER % HEAT” fault occurs.

MIN-HEAT 10 ~ 100 % 1~31
MAX-HEAT 20 ~ 200 % 1~31
(3) Lack of welding time

If difference between actual welding time and programmed one exceeds this limit,
“WELD TIME MISSED” fault occurs. At this time, fault relay contact is closed.
TIME-LIM 0 ~ 50 cycle 0
(4) Welding time compensation

This function compensates welding time difference caused by poor contact of workpieces and
electrode tips.
For example, If “TIM-CMP” programmed 3cycle, compensate less then 3cycle even if
deficiency had exceeded “TIM-CMP” programmed 3cycle.
TIME-CMP 0 ~ 50 cycle 0
(5) Over welding time

If total welding time for a welding sequence is longer than this limit, “WELD TIME LONG”
fault occurs. At this time, fault relay contact is closed.
MAX-TIME 10 ~ 999 cycle 0
(6) Under line voltage and over line voltage

If difference between average line voltage and programmed reference voltage violates these
limits, “UNDER LINE VOLTAGE” or “OVER LINE VOLTAGE” fault occurs.
REF-VOLT 100 ~ 600 V 0
MIN-VOLT 5 ~ 40 % 0
MAX-VOLT 5 ~ 40 % 0
(7) Watching impulse

Choose an impulse from three impulses (“WELD 1”, “WELD 2”, “WELD 3”) to monitor

faults. Note that must be chosen only one impulse.

1 = weld 1
MONITOR. PLS 1~3 0 2 = weld 2
3 = weld 3
3) Fault output and reset

When a fault is detected, fault relay contact is closed and fault message is displayed on the
LCD (panel and program box) or faults No. is blinked on LCD (monitor box).
If any fault happened, End of hold contact does not output.
4) Fault reset
Push “RST” key on monitor box or program box.
Turn on switch connected No. “153”, “154” of external terminal.
Re-initiate starts switch. This operation requires that re-start mode (by software switch) is
programmed on
5) Architectures of fault ruling

(1) “NO CURRENT”
When you set monitor as “WELD 1”, “WELD 2”, or “WELD 3”, and corresponding welding
current does not flow, this fault occurs. Thus, for example, if you use only “WELD 2”, then
set monitor as “2”.
(2) “THERMO SW OPEN”

When transformer-thermostat or SCR-thermostat or safety switches are opened, welding
operation stops immediately and fault message is displayed.
This message is disappeared when fault is reset by start input or fault reset input.
(3) “SCR HALF CYC”

If half cycle welding continues 3 or more cycles in a row, this fault occurs.
When this fault occur, welding sequence stops immediately, solenoid valve opens, and fault
relay contact outputs.
(4) “SCR SHORTED”

If welding current, which is greater than or equal to one cycle, is detected during squeeze
time, this fault occurs.
If this fault occurs, welding operation stops immediately, all solenoid valves are opened, a
fault message is displayed and relay-contact is output fault signal.

7. Trouble shooting method
1) Defect without output fault signal
(1) Does not squeeze
Check 1 :
Does Run-Lamp light up in the timer panel when timer starts?
If it does not light up, check wiring of starts inputs.
Confirm start inputs are correctly wired at external terminal.
Check 2 :
Check if valve designation in the corresponding sequence is right.
Check 3 :
When it started, does AC 100V appear at external terminal?
(“valve common”  “valve A”, “valve common”  “valve B”)
If it is about 0V, since timer is problem, exchange it.
If it is about 80-90V even before start, valve is of no good or wiring to valve is cut.
(2) Holding while valve squeezed

If valve is squeezed at the same time as power on, SSR of valve driver in timer PCB is bad.
Please exchange timer.
Note): Before timer exchange, get rid of wires up to valve and check if wires are not
shorted.
If they are shorted circuit, even after exchange of timer, problem still remains.
(3) No current (Without no weld fault output)

Check 1:
Is welding time programmed properly?
Check 2:
Are welding standby lamps light up on timer panel or program box?
If left lamp is not on, “WELD/NO WELD” (9,10) at external terminal is not connected,
thus please connect it.
If right lamp is not on, push weld “WELD/NO WELD” key on panel to light it up.
(4) Actual current is different to setting current.

At Constant Current mode:
Check if transformer turns ratio is properly set up.
If turn ratio is smaller than actual secondary current becomes bigger.
If turn ratio is larger than actual secondary current becomes smaller.
At Voltage Compensation mode:
Try welding with minimum % heat (20%).
If programmed current is significantly different to the monitor value, Please adjust the
difference with variable resistor, “VLT (VR3)” on PCB.
If difference still present, it is normal one caused by voltage compensation function. While
monitoring value does not exceed 100%, it is of no problem. If it is over 100%,
transformer capacity or capacity of power line should be increased.
(5) End of hold signal does not output

Check 1:
Check which signals are currently output?
Except secondary cable resistance fault and communion fault, End of hold signal does not
output.

Check 2:
If end of hold relay (“CR1”) is on, problem is not within PCB, thus please check wiring.
(6) End of hold signal is on and does not turn off

Check 1:
Check if start signal is off.
Get rid of start input connection to external terminal.
Check 2:
Check if it is not AC type sequence input.
In this case, R, C connected with contacts can cause problem.
Check 3:
Check if End of hold outputs from several timers are connected with parallel.
In this case, this phenomenon can occur and it is normal.
Check 4:
Check if end of hold contacts is stuck together.
If contacts itself is problem, even after power is turned off, contacts are still stuck together.
Please exchange PCB.
Check 5:
Check if time from start signal off to next on is not extremely short?
Try longer.
(7) DATA is not changed.

Check 1:
Check if DIP switch No. 8 on PCB is “OFF”. If it is “ON”, data can not be changed.
Check 2:
After programmed data change, does “WR” key pushed?
To update as new data, please push “WR” key.
2) Defect with fault output

(1) “MEMORY ERROR”.
Check if it is past over 30 days after last power down.
Since backup duration can not over 30 days, after reset please re-input program data once
again. Within 30 days, if this fault occur, please exchange PCB.
(2) “UNDER CURRENT”.

Check 1:
Do not set value of low current limit too small?
Generally, 20% is appropriate.
Check 2:
Check if welding current, which exceeds capacity of welder, is not commanded.
Set %heat such that it does not exceed 100%.
Check 3:
Does this fault occur at final stage of current stepper?
Since increase ratio is too big, please lower increase ratio such that even at final stage,
current command does not exceed capacity of welder.
Check 4:
Is welding time not too short?
Accuracy of constant current function becomes poor with short welding time.
Please increase lower limit value.

Check 5:
Dirtiness of tip, tightness of clamp of workpieces, secondary cable wear caused by heat
etc. can cause this fault. Even though this is basically mechanical problem, slightly
increasing up slope time or doing welding twice can cure it.
Check 6: Check if wiring of current feedback sensor (“CT”).
(3) “OVER CURRENT”

Check 1:
Do not set value of high current limit too small? Generally, 10% is appropriate.
Check 2:
Check if limit is below 20% of max. capacity of welder.
Controllable lower limit is max. 20%.
Check 3:
Check if external “WELD/NO WELD” signal changes state during welding is in progress.
It should not be changed.
Check 4:
Check if current command is over max. capacity of welder.
If you try somewhat lower current command and this fault does not occur, this is cause of
fault.
(4) “UNDER %HEAT”

Check 1:
Is set value realistic?
If you have a particular reason to use this set value, please try 20% heat.
Check 2:
Check if there is any short circuit in secondary loop, especially kickless cable.
(5) “OVER %HEAT”

Check 1:
Is set value realistic?
We recommend set value of 20% plus that of monitoring value.
Check 2:
Check if line voltage abnormally drooped during welding.
If set value was 100% and this fault occurred, this means current which exceeded capacity
of welder was commanded.
Check 3:
(6) “WELD TIME MISSED”

Check 1:
Check if squeeze time is not too short.
Confirm that after actual squeeze is finished, welding starts.
Check 2:
Is set value of time limit, “TIME-LIM” is not too short?
Check 3:

(7) “WELD TIME LONG”
Check if set value of “MAX-TIME” is not shorter than actual welding time.
For example, when “WELD 1” is 20 cyc, cool is 0 cyc, “WELD 2” is 30 cyc, actual
welding time becomes 50 cyc and if “MAX-TIME” is set less than or equal to 50, this
fault occurs.
(8) “UNDER LINE VOLTAGE” and “OVER LINE VOLTAGE”

Check if set value of min. and max. voltage is appropriate.
If several welders are simultaneously welding at the same, large voltage drop can occur.
(9) “NO CURRENT”

Check 1:
Check if firing signal lamps are on during welding.
If lamps do not light up, please exchange timer PCB.
If lamps does light up but brightness is too low, it is due to poor contacts of gate circuit of
SCR. Please check connector wiring of contactor.
Check 2:
When firing lamps on/off normally
 A tip of gun is not completely clamped  Adjust clamp pressure.
 Cable is open  Exchange cable.
 Bad SCR  Exchange the SCR.
 Wrong connection of gate signals of SCR  Confirm wiring
 Squeeze time is short  Use longer squeeze time.
 Dirtiness of workpieces  Clean it.
 Dirtiness of tips  Exchange tip.
Check 3:
If this fault occurred even when large current is commanded, check if wiring of “CT” is
correct.
(10) “THERMO SW -OPEN”

Check 1:
Check cooling water of SCR and transformer.
Clean inside of water hose using compressed air.
Check 2:
Check if excess % heat is used.
Check 3:
Check if AC 100V is applied to external terminals correctly.
Check 4:
Check if terminals for safety switch are not open.
(11) “SCR HALF CYC”

Check if two lamps light up during welding.
If only one lamplight up, check gate wiring of SCR.
If gate wiring is O.K., exchange SCR.

(12) “SCR SHORTED”
Check 1:
Check if there are no wrong connections in power source cable.
Check 2:
If SCR is bad, replace the SCR.
(13) “TIP WIRE BROKEN”

Check if tip stick item is set as “ON” in “F” sequence.
If you do not use tip detection and/or if there is no detection wire installed, please turn
“OFF” tip stick item in “F” sequence.
(14) There is fault display but there is not fault code, warning lamp, and fault output
Contacts.
Check if fault reset signal is not shorted at external terminal.
In case when fault reset signal is open, exchange PCB.

Resistance Welding Controller Instruction Manual: Nawootec Co., LTD

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Resistance Welding Controller

 Separation of fault messages output

NAWOOTEC CO., LTD.

NAWOOTEC CO., LTD. 0 Sep. 2001

Type DECOMSTAR SERIES

Separation of fault messages output     

Detection of electrode tip stuck      

Control of electrode force      

Detection of break of secondary cable     

Detection of short of secondary cable 

Max. number of weld sequences 15 15 15 15 15 15 15 15 31

: Auto stepper (Automatic Current Density Control)

NAWOOTEC CO., LTD. i Sep. 2001

RISK OF ELECTRIC SHOCK

NAWOOTEC CO., LTD. ii Sep. 2001

Special features of Decomstar - 70 Series.................................................0

NAWOOTEC CO., LTD. Sep. 2001

From welding To welding I/O signal

NAWOOTEC CO., LTD. 1 Sep. 2001

2) Explanation of DIP Switch

Switch No. 5~6: Not used

Switch No. 8: Off; Able to change programming data. (In networking)

NAWOOTEC CO., LTD. 2 Sep. 2001

NAWOOTEC CO., LTD. 3 Sep. 2001

SEL STEP STEP

MONITOR BOX MB-70

NAWOOTEC CO., LTD. 4 Sep. 2001

SEQ ◀ADRS▶ ▼DATA▲ WR RST STEP WELD NAWOOTEC CO., LTD.

SCR Firing signal

NAWOOTEC CO., LTD. 6 Sep. 2001

 Sequence “15(31)” Mode:

(2) [◄ADRS►] Key:

When ADRS ► key is pushed, display advances in the direction marked as .

NAWOOTEC CO., LTD. 7 Sep. 2001

(4) [WR] Key:

(5) [NO WELD] Key:

(6) [STEP] Key:

(7) [RST] Key:

5) Programming of sequence “F”

0) REF VOLT 380V

(2) Push [◄ADRS►] key and select SEQUENCE No.

NAWOOTEC CO., LTD. 8 Sep. 2001

Likewise, program all items, which you need to change.

6) Programming of sequence “0”

(2) Push [◄ADRS►] key and select squeeze delay

Likewise, program all items, which you need to change.

7) Programming of sequence “1 ∼ 15(1 ∼ 31)”

Operation of programming is same as those of Sequence “0”.

NAWOOTEC CO., LTD. 9 Sep. 2001

8) Selection of sequence Monitor “M”

(2) Push [SEQ] key, to change display to monitoring display.

NAWOOTEC CO., LTD. 10 Sep. 2001

SEQUENCE Number of Sequences 4(5) 15(31)

SLFHOLD Self hold of run OFF WELD PULSE

REPEAT Weld of repeat OFF ON

EOH Output mode of end of hold 50ms 200ms HOLD

REWELD Reweld in case of fault OFF IF ERR

RESTART Restart in case of fault OFF ON

STEPPER Current stepper OFF STEP LINEAR AUTO

WELDER Welding machine AC DC1 DC2 DC3

CONTROL Control method constant current voltage compensation

SENSOR Current feedback type CT Toroidal coil