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Operating
Instructions
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© MacGregor Welding Systems 2001
Contents
Preparation and Product Warnings 2
Mains Connections 2
Installation Basic Connections 3
Basic Features 5
WARNING !!!
DO Use a properly rated Mains Input Supply
An identification plate on the rear panel specifies the IMPORTANT
input mains voltage requirement.
DO Provide Proper Ventilation The unit MUST be connected to the correct mains supply voltage. Refer
DO Use Lifting Gear to Move the Unit to the identification plate located on the rear panel.
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© MacGregor Welding Systems 2001
Preparation and Installation
Basic Connections Thank you for purchasing this MacGregor Welding
Systems DC resistance welding power source.
DC601P/DC1001P Rear Panel Diagram Before attempting to use the power source, check that power
and Weld Head Connection Details is OFF.
25 Way Connector 37 Way Connector - Multiple
RS232 / RS485 Triggers and PLC Interface
Fuses SKT A SKT A
FS1 = Reserved
FS2 = 1A (F) Anti surge +24V to User
15 Way Connector
Trigger, +24V,
Faults
Voltage Sensing SKT B
Connection
**Note** When jack plug is Fan Outlet
removed internal sensing is DO NOT COVER
active.
Output
Terminals
Mains Input
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© MacGregor Welding Systems 2001
Preparation and Installation
Basic Connections
DC601P / DC1001P Front panel
Layout
Fan Outlet
DO NOT COVER
Output
Terminals
15 Way Connector - Trigger,
+24V, Faults
SKT B
25 Way Connector –
RS232 / RS485
SKT C
Voltage Sensing
Connection
**Note** Links must be removed
if external Voltage Sensing is
connected.
Mains Input
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© MacGregor Welding Systems 2001
Preparation and Installation
Basic Features
DC601P / DC1001P Front Panel Layout
1 ABC 2 DEF
3 GHI
JKL
4 5 6 PQR
7 STU 8 VW
9 XYZ
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© MacGregor Welding Systems 2001
Preparation and Installation
Basic Features
DC1801P Front Panel
Layout
Mains Switch
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© MacGregor Welding Systems 2001
Getting Started
To perform a test weld and to verify that all external connections are correct, please follow the instructions
below.
From the Pulse 1 Operating Graph, press the “LOAD/SAVE” soft menu key. In the next screen (Load Menu),
press the “LOAD PROFILE” soft menu key. Select Profile 99 and press the “LOAD” soft menu key. To scroll to
profile 99, press the “MORE” or “BACK”soft menu keys until profile 99 is displayed. Profile 99 should be
labelled TESTMWS 99. Once TESTMWS 99 is loaded then the Pulse 1 Operating Graph should be displayed.
The settings for profile 99 should be T1: 10 ms, T2: 10 ms, T3: 10 ms, Peak 100 Amps.
To make a test weld, close the welding head or connect a load across the output bars of the machine. Release
the Inhibit by pressing the Inhibit button on the panel. The LED will turn off when the Inhibit is released.
To weld, press the weld button and ensure that there are no faults displayed and that there is a feedback trace
(green line on graph) displayed. If no feedback trace appears, ensure that “TRACE ON”is one of the soft menu
keys available. If “TRACE OFF”is displayed, then press the “TRACE OFF” soft menu key and retry This the
test weld. If the trace is displayed, this demonstrates that there is a valid feedback path and the connections to
the welding head or test load are correct and allow the unit to operate without fault.
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© MacGregor Welding Systems 2001
Getting Started
Power On and
Verification continued…
Performing a Test Weld (continued):
Basic Schematic of
Output Description D-type pin out optically isolated output
Fault High Limit Collector 28 Collector
Emitter 17
Fault Low Limit Collector 10
Emitter 35
BCD Value 4 Collector 29 1K
Emitter 36
Feedback Fault Collector 11
Emitter 13
BCD Value 1 Collector 12
Emitter 15
BCD Value 2 Collector 31 1N4148
Emitter 32
Busy Collector 33 Emitter
Emitter 34
Spare output Collector 14
Emitter 16
The BCD outputs are used to select channels when configured for distribution. These outputs turn ON the opto
transistor when selected. All fault outputs and the busy output turn OFF the opto-transistor when active.
Basic Schematic of
optically isolated input
Profile No. DESCRIPTION D-Type Pin No.
Recall Store 0 Anode 21 Anode
(display) Cathode 27
Recall Store 1 Anode 3
Cathode 8
Recall Store 2 Anode 1
4K7
Cathode 26
Recall Store 3 Anode 22
Cathode 7
Recall Store 4 Anode 4
Cathode 5
Recall Store 5 Anode 20 Cathode
Cathode 24
Recall Store 6 Anode 2
Cathode 6
Recall Store 7 Anode 23 Typically, the anode is connected
Cathode 25
directly to +24VDC (obtained on pin
Externally available +24 VDC 37
24V 37) while the cathode is connected
0V (24) 19 via a PLC or switch to 0V(24),
Remote reset Anode – must be Volt-free 18* obtained on pin 19. Passing
Cathode – internally hardwired to 0V pin current, activates the input.
19
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© MacGregor Welding Systems 2001
Control Connections
Basic Schematic of
Output Description D-type pin out optically isolated output
Fault BCD Code 0 Collector 28 Collector
Emitter 17
Inhibit Status Collector 10
Emitter 35
Fault BCD Code 3 Collector 29 1K
Emitter 36
Feedback Hardware Collector 11
Fault Emitter 13
Fault BCD Code 1 Collector 12
Emitter 15
Fault BCD Code 2 Collector 31 1N4148
Emitter 32
Ready (Busy) SCR gate Collector 33 Emitter
drive Emitter 34
Spare output Collector 14
Emitter 16
The BCD outputs are used to select channels when configured for distribution. These outputs turn ON the opto
transistor when selected. All fault outputs and the busy output turn OFF the opto-transistor when active.
Weld Pulse
Typically, the collector
Busy Signal - Off after connection is pulled up to
T1 or T5 - On with +24VDC and is used as the
Reset input to a PLC, while the
emitter is connected to the
Hi/Low Fault - Active +24V return (0V) connection
until reset
Hardware/Feedback Fault
Reset Active until reset
Profile No. DESCRIPTION D-Type Pin No.
Recall Store 0 Anode 21
(display) Cathode 27
Not Used Anode 3 Basic Schematic of
Cathode 8 optically isolated input
Reset (Stop Anode 1
Welder) Cathode 26
Trigger Anode 22
Cathode 7
Recall BCD0 Anode 4
Cathode 5 Anode
Recall BCD1 Anode 20 4K7
Cathode 24
Recall BCD2 Anode 2
Cathode 6
Recall BCD3 Anode 23
Cathode 25
Cathode
Externally available +24 VDC 37
24V
0V (24) 19
Remote reset Anode – must be Volt-free 18*
Cathode – internally hardwired to 0V pin
19
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© MacGregor Welding Systems 2001
Control Connections
Rear Panel Connections - Optional DS Isolated Interface
The following specifies the functionality for the Optional DS Isolated Interface
The software has been enhanced to provide up to 16 error codes which are output via the optically isolated output pins
in a BCD code format. These error codes are held at the output until the RESET signal is applied. The Fault Hardware
Interrupt signal is also cleared in this fashion using the RESET signal.
The READY signal timing has been modified to allow the signal to be used as an SCR gate drive. On a single pulse
weld, this normally high signal goes low at the end of T1 and returns high at the end of the weld pulse, hence latching
the SCR.
On a double pulse weld the READY signal goes low at the end of T5 and returns high at the end of the second weld
pulse.
If the Trigger signal is still applied when the READY signal is due to return high, the Ready signal will be held low until
the Trigger signal is removed. This feature thereby ensures that the controlling device has time to detect the READY
signal.
In addition to these outputs, 4 BCD coded signals are available to indicate various fault conditions.
13 reserved
14 reserved
15 reserved
16 reserved
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© MacGregor Welding Systems 2001
Control Connections
Typical Connections
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© MacGregor Welding Systems 2001
Control Connections
Rear Panel Connections
25W D Type RS232
TXD pin 2
RXD pin 3
0V pin 7
A PC uses either a 9-pin D-type serial connector or a 25-pin D-type. The table below shows how to interface the m3 to
either type of PC serial communication port. (Handshake lines CTS,RTS, DSR & DTR can usually be omitted)
A 15W D type socket is fitted on many machine variants to provide the following useful signals and indicators
FUNCTION Pins
Remote weld trigger (of store 0) 1 Pin 1 is hardwired to 0V (pin14) and pin 2 is the
by contact closure 2 cathode connection for store 0
Normally open contacts used to 4 The relay contacts rating is 24V at 0.5A
indicate a fault condition 5 The contacts close for a Feedback Fault.
Remote fault reset by contact 7 Pin 8 is hardwired to +24VDC (pin 15) and pin 7 is the
closure 8 anode connection for this input
Externally available 0V 14 Protected by fuse Fs2 in the rear panel rated at 1A
power supply 24VDC 15 anti-surge type T
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© MacGregor Welding Systems 2001
The User Interface
Keypad Layout and Functions
TFT Display
¼ VGA
Rotary Encoder
Weld
A full functional description for each of the labelled components is provided on
the following page. Soft Menu Keys
Programming instructions for the unit are located in the BASIC and ADVANCED
CONTROL sections of this manual. Inhibit
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© MacGregor Welding Systems 2001
The User Interface
Keypad Layout and Functions
Inhibit: When the LED is illuminated, this prevents welding. Press the button to toggle the inhibit status.
Soft keys: these are associated with screen instructions in RED text. The soft menu functions allow text
descriptions of the keys for each screen and make navigation more intuitive and friendly.
Alphanumeric keys: Use in edit mode to enter alphanumeric data. When entering text the keys behave in a
similar way to those on a cellular phone. Multiple key presses allow the character to cycle through the respecticve
number and letters for each key. To confirm a character, press the enter key. All passwords are alphanumeric and
the user must press the enter key between each digit of the password.
Rotary encoder: Used to edit / modify the settings and controls of the unit.
Rotate to highlight the variables (coloured green). The yellow box identifies the current variable
selected.
To select the variable depress the encoder once. The text changes to red and the box background
becomes yellow.
To change the variable EITHER rotate the encoder OR use the keypad.
Depress the encoder again, once, to finish modifying the variable. This function is duplicated
by the enter key on the keypad and returns the operator from Edit to Modify mode.
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© MacGregor Welding Systems 2001
Basic Control Options
Loading a Profile from Memory
**Note** Loading a profile will place the profile in the Display location.
This location can be triggered by setting any of the trigger inputs to
“Display”. This is accomplished in the “Distribution Configuration”
screen and outlined in the ADVANCED CONTROL OPTIONS section
of this manual.
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© MacGregor Welding Systems 2001
Basic Control Options
Saving a Profile to Memory To Save a Profile to Memory:
**Note** The profile data stored in that location will be overwritten by the
new profile data being saved. Profiles indexes (memory locations) that
have had data stored in them are labelled with the date the data was last
saved. Any profile index with Default under the DATE column is an
unused profile index.
**Note** When in Modify mode, pressing the “SAVE” soft menu key will
display the PROFILE MANU. From this screen, use the encoder to select
the desired memory location and press the “SAVE” soft menu key a
second time and the Profile will be saved and the screen will return to the
OPERATING GRAPH or OPERATING MENU screen.
Pulse 1 Operating Graph
The initial screen displays profiles 1-15. Further profiles (16-99) can be viewed by using the “BACK” or “MORE”
soft menu keys.
Use the rotary encoder to highlight the desired profile and then press the “SAVE” soft menu key. This will save
the profile to the highlighted memory location. To return to the normal operating screens, press the “EXIT” soft
menu key two times.
**Note** When saving a profile the first time after turning on the unit, the display
will prompt the user for a password. The factory password is 1234. This is set in
the System Configuration Menu under passwords. The setting of passwords is
outlined in the ADVANCED CONTROL OPTIONS section of this manual.
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© MacGregor Welding Systems 2001
Basic Control Options
Changing Profile Settings
Modifying and Editing Values:
Modify Mode: When the “MODIFY”soft menu key is Normal Mode - Pulse 1 Operating Graph
pressed, the unit changes into Modify mode. This mode is
characterised by the yellow outline box around one of the
values on the screen. The yellow box can be moved to any
value displayed in Green text and that value edited. To edit
the highlighted value, press the enter key or depress the
encoder to enter Edit mode.
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© MacGregor Welding Systems 2001
Basic Control Options
Changing Profile Settings
Continued…
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© MacGregor Welding Systems 2001
Basic Control Options
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© MacGregor Welding Systems 2001
Basic Control Options
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© MacGregor Welding Systems 2001
Basic Control Options
Changing Profile Settings
Continued…
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© MacGregor Welding Systems 2001
Basic Control Options
Changing Profile Settings
Continued…
The Hi Limit setting is a limit setting used to monitor the weld. The Hi Limit is active for the duration of the weld
pulse. The HI Limit is set in Amps if the Control Mode is either Voltage or Power, and in Volts if the control mode is
Current. The Hi Limit establishes a limit to the variable feedback. In current control, the Hi Limit is particularly useful
as it can detect poor connections, and oxidised parts due to the increase in voltage at a set current level. In voltage
and power mode, the Hi Limit will indicate a part with low resistance and therefore a higher monitored current at a
set voltage or power.
The best means of determining the optimum setting for the Hi Limit value is to make a number of welds on known
clean and correct parts and to record the peak reading from the weld monitor. This value is labelled MAX: on the
user interface. Once a number of values have been recorded, remove any readings from bad or poorly welded parts
and then set the limit just over the highest value recorded. As time goes on, parts that trip the Hi Limit can be
examined and the limit raised or lowered to ensure that all welded parts that are indicated as a fault are in fact bad
welds.
The Low Limit setting is a limit setting used in the weld monitoring circuit. The low limit is active during the peak time
of the pulse (T2, T6) and monitors the low point of the monitored value. If during the weld, the monitored value drops
below the Low Limit setting then the limit will trip and indicate a fault.
The Low Limit can be used in several ways. When welding in constant current control, a Low Limit fault would
indicate a lower than normal resistance or a short circuit condition. When welding in constant power or constant
voltage mode, a Low Limit fault would indicate a higher than normal resistance or an open circuit condition. The Low
Limit can also be used to ensure that a minimum amount of current flows through the parts when welding in voltage
or power control.
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© MacGregor Welding Systems 2001
Basic Control Options
Changing Profile Settings
Continued…
When the desired value is displayed, press the enter Changing the Low Limit (Lo Lim) Value:
key or depress the encoder to select that mode. The
solid yellow box should be replaced with an outline box To change the Lo Limit (Lo Lim) value, press the
around the new value. “MODIFY”soft menu key when viewing either the
Text or Graph profile screen. This action will
To select other values to edit, rotate the encoder to enable modify mode and a yellow outline box will
index from value to value. appear around the control mode value. Using the
rotary function of the encoder, move the yellow box
Press the “EXIT MODIFY” soft menu key to exit Modify until it is highlighting the Lo Lim value.
mode.
Press the enter key on the keypad or depress the
encoder to change into Edit mode and edit the Lo
Lim value. Once in Edit mode, the peak value will
be displayed in a Solid Yellow Box with red text.
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© MacGregor Welding Systems 2001
Basic Control Options
The user interface displays each pulse on a separate screen. When in Pulse 1 Operating Graph or Pulse 1
Operating Menu, press the “P2” soft menu key to view the second pulse of the weld profile. From the Pulse 2
screens, press the “P1”soft menu key to view Pulse 1 of the weld profile.
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© MacGregor Welding Systems 2001
Basic Control Options
Basic Profile and Monitor
Information
Weld Information Menu:
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© MacGregor Welding Systems 2001
Basic Control Options
Basic Profile and Monitor
Information
Distribution Monitor:
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© MacGregor Welding Systems 2001
Advanced Control Options
Unit Configuration Options:
System Options Menu
Unit Configuration:
To access the MAIN CONFIGURATION MENU go to the Normal Mode – Pulse1 Operating Menu
PULSE 1 or PULSE 2 OPERATING MENU (Text Screen).
From this screen, press the “CONFIG” soft menu key.
Unit Configuration
Options:
System Options Menu
Communications Menu:
To Exit the SET COMMUNICATIONS MENU, press the “EXIT” soft menu
key. It is only possible to exit the SET COMMUNICATIONS MENU from
Normal Mode. If the screen is in Modify or Edit mode, then the user must
return to Normal Mode before exiting.
Bar Code Wand Connected: This option allows the user to enable the bar code reader
interface. This option is not active on units without a Bar Code Wand or Bar Code Scanner
attached.
Baud Rate: This option allows the Baud Rate to be set for the RS232 output. When a bar
code wand is connected, the bar code baud rate is set in this field.
External RS232 System: This option allows the user to configure the SPC output string and
RS232 communication protocol for use with either the Windows® based Weld Comm
product family, or the MS Dos® based 8-bit.exe product family. The welding power supply is
supplied with a complimentary copy of Weld Comm Lt starting in Q1 2001.
To Set the Year, press the “MODIFY” soft menu key. Use
the encoder to highlight the Year value and press the
enter key or depress the encoder. The Year value will
now be indicated in red text in a solid yellow box. (e.g.
O1) Using the encoder or the keypad, enter the year.
When the correct year is entered, press the enter key or
depress the encoder to return to Modify mode.
Normal Mode – Set Time Menu To Exit the SET TIME MENU, return to Normal mode and
press the “EXIT” soft menu key.
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© MacGregor Welding Systems 2001
Advanced Control Options
Unit Configuration
Options: Screen Options Menu:
System Options Menu
Display Limits: Enables the display of Tolerance Limits
when in Graph mode. Set to Disable if no visual limits are
required.
**Note** Limits are always active when loaded and set to “LIMIT ON”
from the Operating Graph or Menu.
Time Format: This option allows the user to set the time
format to either European format (day/month/year) or to
American format (month/day/year).
A yellow outline box will appear around the Display Filtering: The Filtering option allows the user to set the
Limits value. Use the rotation function of the encoder software filter value for the displayed feedback trace.
to highlight the value to be changed.
**Note** This setting is for visual indication only and does not alter the
Press the enter key or depress the encoder to enter filter level of the system feedback loop. Settings entered do not effect the
Edit mode. The selected value will now be displayed performance of the unit.
**Note** The default setting for the filter is 0.
in red text in a solid yellow box. Use the encoder to
select the desired option or value. When the desired
Contrast: The contrast setting allows the user to set the
option or value is displayed, press the enter key or
screen contrast for easy viewing.
depress the encoder to return to Modify mode.
Screen Refresh: When enabled, the screen refresh
Use the same procedure to modify other values.
updates the Operating Graph or Menu screens after each
weld. When disabled, the screen will update the feedback
To exit from Modify mode, press the “EXIT MODIFY”
data only when the displayed Profile is triggered.
soft menu key to return to Normal Mode, and then
press the “EXIT” soft menu key to return to the **Note** For High Speed Welding Applications it is strongly
SYSTEM OPTIONS MENU screen. recommended that Screen Refresh be set to Disabled.
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© MacGregor Welding Systems 2001
Advanced Control Options
Unit Configuration Options:
System Options Menu
Password Configuration Menu:
Level 1
Level 2
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© MacGregor Welding Systems 2001
Advanced Control Options
Unit Configuration Options:
System Options Menu
Other System Options:
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© MacGregor Welding Systems 2001
Advanced Control Options
Unit Configuration Options:
Complex Options Menu
**Note** Calibration procedures are provided in the Service section Main Configuration Menu
of this manual.
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© MacGregor Welding Systems 2001
Advanced Control Options
Unit Configuration Options:
Complex Options Menu
Tolerance Limits:
Tolerance Limits are an additional weld monitoring function that uses a programmed average of the feedback data
for a particular Profile. Files are stored individually for Pulse 1 and Pulse 2.
Tolerance Limits allow the shape of the feedback data to be used to monitor the electrical characteristics during the
weld. Because each Limits file is Profile specific, the ability to monitor the behaviour of a specific weld profile with
limits based upon the actual weld feedback greatly increases the capability of the user to monitor a weld.
When active in a profile, the Tolerance Limits feature allows the user to set the Tolerance Limit boundaries (+/-) and
to select an active Window during which the Tolerance Limits are active. The following section outlines the
recording, amending, activation, setting of Tolerance values, and setting of Window values.
**Note** Only files which match Profile Index, Control Mode, and Pulse
Number are available. When no Limits files have been created for the
displayed profile, no files are displayed for selection.
**Note** In single pulse profiles, these soft menu keys are located in
the Pulse 1 Operating Graph when in Modify mode.
**Note** In dual pulse profiles, these soft menu keys are located in the
Pulse 2 Operating Graph when in Modify mode.
Active Window settings are displayed by the vertical Normal Mode (Tolerance Limits Active) –
dashed line Window markers. The represented time Pulse 1 Operating Graph
between the two markers is the active period for
Tolerance Limits.
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© MacGregor Welding Systems 2001
Advanced Control Options
Unit Configuration Options:
Complex Options Menu
Edit Mode (Positive Tolerance) – Pulse 1 Use the same procedure for the second TOL value.
Operating Graph
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© MacGregor Welding Systems 2001
Advanced Control Options
Unit Configuration Options:
Complex Options Menu
Feedback Trace
Lines follow both the tolerance and hard limits applied to the weld
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© MacGregor Welding Systems 2001
Advanced Control Options
Unit Configuration Options: Entering Tolerance Limits Menu
The Limits file will be configured for the pulse, profile and
control mode (e.g. Pulse 1, Profile 003) that was shown on
the display before entering into the Configuration Menu.
**Note** Because Limits files are based upon the feedback from the
welding pulse, it is critical that the setting of limits files be done with the
same settings, parts, and equipment configuration as is to be used in
Limit File(s) in Memory – Tolerance production. This will ensure that the data collected remains valid and
Limits Menu relevant to the weld being done in production.
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© MacGregor Welding Systems 2001
Advanced Control Options
Unit Configuration Options:
Complex Options Menu
Recording Average or Recording Peak Limit Information:
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© MacGregor Welding Systems 2001
Advanced Control Options
Warning: Tampering with the Calibration Settings will
Unit Configuration Options: effect the performance of the unit.
Complex Options Menu Calibration:
Before access is granted, the user must enter the factory set
password for the CALIBRATION screen. This password is
M007 and is entered by pressing the “5” key on the keypad
twice and then the enter key, then pressing the 0, enter, 0,
enter, 7, enter. When the password is entered, press the
“ENTER” soft menu key.
Enter Calibration Password – Password Menu
(Calibration Password: M007) Once in the calibration screen it is recommended that the
values be recorded in the event of an error in calibrating the
unit.
To Reset the Unit RAM, press the “RES RAM”soft menu key.
Resetting the RAM will clear any information that is left in the
Modify Mode – Calibration Screen RAM due to an error. Resetting the RAM will remove all
Profile and Limits data and should only be used if directed
by the Factory.
Read Only Calibration:
**Note** If INDEX 000 is selected, the Input will trigger the Profile shown on
the display at time of trigger.
Example: Using the screen shown on the left, if Input 002 is triggered, then
Profile 002 (Index 002) will be triggered and Distribution Unit Output 02
(Weld Head 2) will be selected.
The Distribution Configuration Menu allows the user to configure the unit to trigger specific profiles when specific
trigger inputs are selected. This feature allows the user to access any of the 99 profile locations from the 8 inputs
available.
To Enter the DISTRIBUTION CONFIGURATION Screen, press the “DISTRIBUTION” soft menu key from the
COMPLEX OPTIONS MENU.
To Modify and Edit the Selected Profiles press the “MODIFY” soft menu key and select and edit the Profile Index
numbers using the normal selection and editing procedure. When all the Index values are set to the desired setting,
return to Modify mode and press the “EXIT MODIFY”soft menu key.
To Exit the DISTRIBUTION CONFIGURATION Screen, press the “EXIT” soft menu key from Normal mode.
Press the “MODIFY” soft menu key and use the encoder to
highlight the WELD HEAD value. Press the enter key or
depress the encoder to Edit the WELD HEAD value.
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© MacGregor Welding Systems 2001
Advanced Control Options
Unit Configuration Options:
Complex Options Menu
Fault Options Menu:
Pulse 2 Low Limit: Same a Pulse 1 Low Limit but for To Exit the FAULT OPTIONS MENU, press the
Pulse 2 in Dual Pulse Welds “EXIT” soft menu key from Normal Mode.
Low Limit Cutout: The low limit cut out setting allows
the operator to program the machine reaction to a low
limit fault. In normal configuration (Disabled), when a low
limit fault occurs, the weld is completed and the fault
indicated as set in this menu and at the rear panel.
**Note** A similar function exists for the Hi Limit reaction. The Low
Limit Cutout is a global setting and will be applied to all welds made. To Edit a Fault Options Setting:
The Hi Limit Cutout setting is made for individual profiles and allows the
user to set a high limit in applications requiring the parts to be
conditioned to a set resistance. Press the “MODIFY” soft menu key. Use the
encoder to highlight the value to be edited and
The Hi Limit Cutout can be programmed in the Pulse 1 Operating Menu press the enter key or depress the encoder to
(Text screen) in any dual pulse profile. The value is located at the
bottom of the screen and can be changed using the standard editing select the value. Use the encoder to toggle the
procedure. value from Enable to Disable and when the
desired setting is displayed, press the enter key
The value is not displayed in a single pulse weld profile or depress the encoder to return to Modify mode.
To return to Normal mode, press the “EXIT
MODIFY”soft menu key.
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Advanced Control Options
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© MacGregor Welding Systems 2001
Advanced Control Options
To Enable Fast Mode, press the “ON / OFF” soft In fast mode, the unit is capable of making 1 weld
menu key. every 32.6 + X mS. (X = total weld time: Includes
upslope, downslope, peak time)
To Disable Fast Mode, press the “ON / OFF”soft
menu key. Double Pulse, 80mS, normal mode. Total DEAD
time = 58.3mS
Initial Signal Received +- - - -
To Exit the Fast Mode Screen, press the “EXIT” soft ¦ 1.0mS
menu key. Input Accepted +- - - -
¦ 300uS
Start Pre-Weld Calculations +- - - -
¦ 8.6mS
End Pre-Weld Calculations / Start Weld +- - - -
Fast Mode ¦ 80mS
Disabled – End Weld / Start Post-Weld Calculations +- - - -
Fast Mode ¦ 48.4mS
End Post-Weld Calculations +- - - -
Screen
Double Pulse, 80mS, fast mode. Total DEAD
time = 31.9mS
Initial Signal Received +- - - -
¦ 1.0mS
Input Accepted +- - - -
¦ 300uS
Fast Mode Start Pre-Weld Calculations +- - - -
Enabled – ¦ 8.6mS
Fast Mode End Pre-Weld Calculations / Start Weld +- - - -
¦ 80mS
Screen End Weld / Start Post-Weld Calculations +- - - -
¦ 22.0mS
End Post-Weld Calculations +- - - -
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© MacGregor Welding Systems 2001
Advanced Control Options
Unit Configuration Options:
Special Features Menu
Auto Cycle:
To View the AUTO CYCLE SCREEN press the “AUTO CYCLE” soft menu key from the SPECIAL FEATURES
MENU.
To Program the Cycle Count press the “MODIFY”soft menu key. A yellow outline box will appear around the Cycle
Count value. To Edit the Cycle Count value, press the enter key or depress the encoder.
**Note** The rotary encoder function is only active in Modify mode in this screen and cannot be used to adjust the values when in Edit mode.
When the desired number of Cycles is displayed, press the enter key or depress the encoder to return to Modify
mode.
To program the Time Interval value, press the “MODIFY” soft menu key. A yellow outline box will appear around
the Cycle Count value. Use the encoder to move the box to the Time Interval value. To Edit the Time Interval value,
press the enter key or depress the encoder.
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Advanced Control Options
Operator Mode:
Unit Configuration Options:
Special Features Menu Operator Mode is a special operating mode that limits the
changes that can be made by an operator to profiles, and
allows a supervisor to limit the profiles available for use.
Operator Programmable Variables (Single To Modify a Variable in Operator Mode, press the
Pulse Profile – Operator Mode): “MODIFY”soft menu key from the Operator Mode Profile
screen.
Profile: See following pages for details on
selecting profiles and loading authorised Use the encoder to select the variable to be modified and
profiles. press the enter key or depress the encoder to Edit the
selected value.
Pulse 1 Peak Value: The user is able to modify
the Pulse 1 Peak value set for the profile. Use the encoder or the keypad to enter the desired value.
When the desired value is displayed, press the enter key
Pulse 1 High Limit: The user can modify the or depress the encoder to return to Modify Mode.
Pulse 1 High Limit value
To Save Changes made to the profile, press the “SAVE”
Pulse 1 Low Limit: The user can modify the soft menu key and follow standard profile saving steps.
Pulse 1 Low Limit value.
To Return to Normal Mode, press the “EXIT MODIFY”
**Note** Changes made can be saved using the “SAVE” soft menu key.
feature on the screen. If Write Protect is enabled in
Password Options Screen, the user will be required to enter
the password each time data is saved.
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© MacGregor Welding Systems 2001
Advanced Control Options
Unit Configuration Options:
Special Features Menu
Pulse 2 High Limit: The user is able to modify the Edit Mode – Operator Screen - (Dual Pulse
Pulse 2 High Limit Value. Profile)
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© MacGregor Welding Systems 2001
Advanced Control Options
Unit Configuration Options:
Special Features Menu
Loading a Selected Profile (Operator Mode):
Use the encoder to scroll through the available profiles. Edit Mode (Change Profile) – Operator Screen
When the desired profile is displayed, press the enter
key or depress the encoder to select the profile.
**Note** The system will not allow the user to remove all profiles
from the OPERATOR SETUP MODE SCREEN. If all are
removed, then the system will default to showing Profile001.
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© MacGregor Welding Systems 2001
Advanced Control Options
Pattern Welding Options
Pattern Welding Option:
**Note** When inserting a profile, the new profile will appear above the
highlighted profile. When building new patterns, it is advised to insert the
proper number of profiles and then return and select the profile names in the
proper order.
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© MacGregor Welding Systems 2001
Advanced Control Options
Pattern Welding Options
Loading a Pattern File:
To Load a Pattern File, press the “LOAD/SAVE” soft menu key from the
Operating Graph (Graph Screen) or the Operating Menu (Text Screen).
From the LOAD MENU, press the “LOAD PATTERN” soft menu key.
Select the desired pattern in the same way a Profile is selected. Once
the desired Pattern is highlighted, press the “LOAD” soft menu key.
This will Load the Pattern and return the operator to the Graph or Text
screen.
Load Menu
Once a pattern is loaded, each trigger input to Input 00 will cause the
pattern to step through the programmed profiles in a loop configuration.
When using the Pattern Welding Option, the Screen Refresh Option determines whether or not the Operating Graph
or Menu updates with each Profile or only updates the feedback data when the displayed profile is triggered.
**Note** When welding at high frequency, it is recommended that Screen Refresh be Disabled to minimise the amount of Communications traffic
between the Control PCB and the Display PCB.
To Enable the Screen Refresh Option, go to the Operating Menu (Text Screen) and press the “CONFIG” soft
menu key. From the MAIN CONFIGURATION MENU, press the “SYSTEM” soft menu key. From the SYSTEMS
OPTIONS MENU, press the “SCREEN” soft menu key. Press the “MODIFY” soft menu key and use the encoder to
highlight the SCREEN REFRESH value. Press the enter key or depress the encoder to Edit the SCREEN REFRESH
value. When ENABLED is displayed, press the enter key or depress the encoder to return to Modify Mode. Press the
“EXIT MODIFY “ soft menu key to return to Normal Mode.
To Disable the Screen Refresh Option, go to the Operating Menu (Text Screen) and press the “CONFIG” soft
menu key. From the MAIN CONFIGURATION MENU, press the “SYSTEM” soft menu key. From the SYSTEMS
OPTIONS MENU, press the “SCREEN” soft menu key. Press the “MODIFY” soft menu key and use the encoder to
highlight the SCREEN REFRESH value. Press the enter key or depress the encoder to Edit the SCREEN REFRESH
value. When DISABLED is displayed, press the enter key or depress the encoder to return to Modify Mode. Press
the “EXIT MODIFY “ soft menu key to return to Normal Mode.
To Return to the Profile Operating Graph or Menu, press the “EXIT” soft menu key. From the SYSTEM OPTIONS
MENU press the “EXIT” soft menu key. From the MAIN CONFIGURATION MENU, press the “EXIT” soft menu key.
From the Profile Operating Menu, press the “GRAPH”soft menu key to return to the Operating Graph.
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Advanced Control Options
Pattern Welding Options
To set the Index Location, scroll through the profiles to PATTERN001 Loaded – Pulse 1
the desired Index Location (Screen should display the Operating Menu
next profile to be welded). When the desired profile is
displayed, press the “SET INDEX” soft menu key. The
display will return to Modify mode.
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Advanced Control Options
Pattern Welding Options
Pattern Monitor:
**Note** The Pattern Monitor soft menu key (“PATT MON”) is only
available when a Pattern is loaded. To Load a pattern, follow the
instructions on the previous pages in the Loading a Pattern section.
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Advanced Control Options
Conditioning Pulse:
Automatic Part
Conditioning (APC)
To be released in Q2 2001
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© MacGregor Welding Systems 2001
Trouble Shooting Guide
Basic Trouble Shooting and
Fault Finding
7. TROUBLE-SHOOTING GUIDE
The following section has been prepared as a basic checklist to use in the event of the system problem. The design
and reliability of the DCXXXXP product is such that power supply failure itself is extremely rare.
More often than not, a system problem will be caused by a change in the overall process in which the power supply is
used. It is therefore VERY IMPORTANT to consider the variables that may effect the welding process and to be sure
that these are under control, before suspecting a problem with the power supply.
If these aspects have been considered, then the following checklist should be worked through. All 16-bit systems (m3
series, DC601P, DC1001P, DC1801, DC2003P) offer several fault-reporting methods that are designed to assist in fault
diagnosis.
Initial Checks
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© MacGregor Welding Systems 2001
Trouble Shooting Guide
Basic Trouble Shooting and
Fault Finding
Machine starts, but displays This occurs if the incompatible Fit correct software
UNABLE TO ESTABLISH software is fitted
COMMS
Machine will not trigger Most often caused by loss of Check fuse and wiring
+24VDC
Alternatively, suspect wiring
The machine will also produce a FAULT CODE and brief description for various types of fault. These are listed
as follows
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© MacGregor Welding Systems 2001
Trouble Shooting Guide
Basic Trouble Shooting and
Fault Finding
Screen Warnings
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© MacGregor Welding Systems 2001
Machine Specifications
DC601P
Accuracy within 1%
Dimensions
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© MacGregor Welding Systems 2001
Machine Specifications
DC1001P
Accuracy within 1%
Dimensions
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© MacGregor Welding Systems 2001
Machine Specifications
DC1801P
Accuracy within 1%
Dimensions
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© MacGregor Welding Systems 2001
Service Information
MacGregor Welding Systems Ltd power supplies contain NO USER SERVICEABLE PARTS. In the unlikely event of a
failure, please contact your MacGregor Welding Systems representative.
The control PCB has two LED’s which flash alternately at 2Hz to indicate the circuit is functioning correctly. This PCB
connects to the display via a ribbon cable.
Advanced Detail
Occasionally it is useful for the user to be aware of the machine internal layout. This maybe of particular benefit
when, for example, the user wishes to perform an on site upgrade.
Within the machine there is one main control PCB. Key items are identified as follows:
LINKS
Within the machine there is one display PCB. Key items are identified as follows :-
SOFTWARE UPGRADES
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© MacGregor Welding Systems 2001
Service Information
Advanced Detail
Power Supply Board
TP1: +15v
TP2: 0v
TP3: -15v
TP4: +15v unregulated
TP5: 0v (+15v unregulated)
TP6: +24v unregulated
TP7: 0v (+24v unregulated)
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© MacGregor Welding Systems 2001
Service Information
Auto Calibration Procedure
AIM
The aim of this document is to specify the test procedure for automatically calibrating a 16 bit Main controller PCB (Pt
No’s 623-76073-x). The document assumes prior knowledge of the equipment under test and an understanding of
calibration.
PURPOSE
The purpose of this document is to provide a concise definition of the main requirements for automatic calibration and
the means by which this may be effected.
SCOPE
The scope of this document extends only to the calibration of 16 bit Main Controller PCB.
DEFINITIONS
GUI Graphical User Interface
Autocal Automatic calibration
INTRODUCTION
The MWS 16-bit controller PCBs are designed to ease the process of machine calibration by virtue of enhanced
software control. This reduces the use of manual potentiometer adjustment and makes it possible to entirely calibrate a
machine against an external standard, without having to remove the covers.
In any calibration method, calibrated equipment is required. For the purpose of DC machine calibration, this
necessitates the use of a calibrated oscilloscope or digital voltmeter, together with a calibrated or “known” DC load.
The software calibration method assumes the machine user is able to gain access to the calibration menu. This menu
provides the means of modifying the output characteristics of the machine. Through internal and external
measurement, actual machine performance can be compared against pre-set machine performance and the differences
may then be calculated and adjusted out using the internal software algorithms.
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Service Information
Auto Calibration Procedure
CALIBRATION METHOD
To perform a calibration, it is recommended that the operator use a calibrated DVM or oscilloscope and a calibrated
shunt.
CALIBRATION
Lines (1) and (2) provide DC offset adjustments. These are factory set and should not normally require adjustment.
Nominal start up values for these settings are:-
DAC1 = 150
DAC2 = 150
DAC3 = 150
DAC4 = 115
Lines (3) to (5) provide direct adjustment to the output levels as set by the user. These effectively give software control
over the amplitude of the reference signal specified by the user in determining the weld profile.
Lines (6) and (7) provide adjustment for six of the seven values used in the automatic calibration procedure. Line (6)
has the three low values (V, I, P) used in the AutoCal, while line (7) has the three high values (V, I, P) used in the
AutoCal. These will be explained further later.
Lines(8) to (10) provide adjustment to measured values displayed to the user. The ADGAIN variable in line (10)
provides a scaling value to the actual measurements made by the welder.
Pre-Autocal
The calibration software allows the user to perform a 10:20:10 weld by pressing weld when in the calibration menu.
When doing so the weld performed will use the demand and control set by PK_VAL and PK_CONT and the feedback
control set by MESCONT.
Overview
The AutoCal is made up of two parts. The first is the feedback calibration and calibrates the AD_GAIN value. The
second is the reference calibration and calibrates the gain, offset and polarity settings for voltage, current and power.
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Service Information
Auto Calibration Procedure
The first weld performed will be the feedback calibration and will use the values set by PK_VAL and PK_CONT on line
(8).
Following on from that will be the reference calibration using the values set by REF1 (V, I, P) and REF2 (V, I, P) on lines
(6) and (7). Ten welds will be performed at each of the V, I, P low and high settings.
Stage 1
Connect a known shunt onto the output and connect suitable equipment for determining an accurate voltage
measurement through the shunt.
Stage 2
Stage 3
Stage 4
Stage 5
Set the PK_VAL value to the one used for REF2 (high) I.
Set PK_CONT to I for current control.
This value will be used for the feedback calibration.
Stage 6
Stage 7
Stage 8
The unit will now go on to perform the sixty welds needed to complete the reference calibration. Ten welds will first be
performed at the REF1 (low) voltage setting, followed by ten welds at the REF2 (high) voltage setting, followed by ten
welds at the REF1 (low) current setting, followed by ten welds at the REF2 (high) current setting, followed by ten welds
at the REF1 (low) power setting, followed finally by ten welds at the REF2 (high) power setting.
After each weld the feedback value will be displayed in MEAS_PK.
A counter is also displayed which shows the progress through the sixty welds.
NB. Should any of the welds cause a fault the AutoCal will have to be restarted. Work out which REF2 value was
set too high, reduce it, then restart the AutoCal.
Stage 9
When the AutoCal routine has completed the calibration screen will be 're-initialised' and the ADGAIN, GAIN, OFFS and
POL values should all now be set.
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© MacGregor Welding Systems 2001
Service Information
Manual Calibration Procedure
AIM
The aim of this document is to specify the test procedure for manually calibrating a 16 bit Main controller PCB (Pt No’s
623-76073-x). The document assumes prior knowledge of the equipment under test and an understanding of
calibration.
PURPOSE
The purpose of this document is to provide a concise definition of the main requirements for calibration and the means
by which this may be effected.
SCOPE
The scope of this document extends only to the calibration of 16 bit Main Controller PCB.
DEFINITIONS
GUI Graphical User Interface
INTRODUCTION
The MWS 16-bit controller PCBs are designed to ease the process of machine calibration by virtue of enhanced
software control. This reduces the use of manual potentiometer adjustment and makes it possible to entirely calibrate a
machine against an external standard, without having to remove covers.
In any calibration method, calibrated equipment is required. For the purpose of DC machine calibration, this
necessitates the use of a calibrated oscilloscope or digital voltmeter, together with a calibrated or “known” DC load.
The software calibration method assumes the machine user is able to gain access to the calibration menu. This menu
provides the means of modifying the output characteristics of the machine. Through external measurement, actual
machine performance can be compared against preset machine performance and the differences may then be
calculated and adjusted out using the calibration menu.
CALIBRATION METHOD
To perform a calibration, it is recommended that the operator uses a calibrated DVM or oscilloscope, a calibrated shunt.
In addition, a calculator and notepad will be required.
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© MacGregor Welding Systems 2001
Service Information
Manual Calibration Procedure
Lines (1) & (2) provide DC offset adjustments. These are factory set and should not normally require adjustment.
Nominal start up values for these settings are
DAC1 = 150
DAC2 = 150
DAC3 = 150
DAC4 = 115
Lines (3) to (8) provide direct adjustment to the output levels as set by the user. These effectively give software control
over the amplitude of the reference signal specified by the user in determining the weld profile.
Lines(9) to (11) provide adjustment to measured values displayed to the user. The ADGAIN variable in line (11)
provides a scaling value to the actual measurements made by the welder.
The method for calibration is identical for all three forms of output control i.e. Voltage current and power. For illustration,
the following narrative describes the procedure for calibrating current output.
The calibration software allows the user to perform a 10:20:10 weld by pressing weld when in the calibration menu.
Step 1
Connect a known shunt onto the output and connect suitable equipment for determining an accurate current
measurement through the shunt.
Step 2
The PKVAL variable in line (9) sets the peak output of the machine. In current control, this variable is in one amp
multiples, in voltage control, this number is in 10mV multiples and in power control, this number is in watt multiples.
The PKCONT variable sets the closed loop control parameter i.e. Current, voltage or power control. Since we want to
calibrate current, this should be set to I.
Step 3
The MESCONT variable in line (10) selects the parameter that is measured during the calibration weld and displayed in
the MEAS PK line (10). This is usually chosen to be the same as the PKCONT value. Therefore, set MESCONT = I.
Step 4
Perform five welds, and record the peak current measured by the external shunt and equipment. Then record the
average value.
Step 5
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Service Information
Manual Calibration Procedure
Step 6
Having now established two calibration points, the following mathematics must be performed to determine the optimum
values for IOFFS (Current Offset) and IGAIN (Current Gain). For illustration, we will assume the following
measurements have been made.
Take the lowest equation from the highest equation to get: 300 = (310*IGAIN)
These results should be entered at the IGAIN and IOFFS variables in lines (5) & (6).
Step 7
Repeat step 6 for measurements of voltage. Note the VOFFS variable is in 10mV increments. Note also that the
PKCONT and MESCONT variables should be changed to V.
Step 8
Repeat step 6 for measurements of power. Note power may be measured by multiplying the current and voltage
waveforms. Note also that the PKCONT and MESCONT variables should be changed to P.
Step 9
Having now calibrated the three forms of controlled output, it is necessary to calibrate the internal measurement system.
This can be done by setting a constant voltage as in step 7, say 1.00V. The actual voltage should be measured and
compared against the MEASPK value displayed. The ADGAIN variable in line (11) should then be adjusted according
to
ADGAIN = MEAS PK / EXTERNALLY MEASURED VALUE
**Note** Record all calibration values after calibration is complete. A page is provided in this manual for notation of the calibration values.
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© MacGregor Welding Systems 2001
Principles of Resistance Welding
Resistance welding involves the joining of one or more conductive materials by passing electrical current through the
assemblies. Heat is generated from the resistance of the materials and the interfaces to the flow of current. The
materials are held under a pre-set pressure to ensure the electrodes are in intimate contact. The conduction path and
pressure is applied through the electrodes of the weld head.
The basic principles of resistance welding establish that the heat generated is influenced by several variables. Heat is
generated by the passage of current and dependent on the current (I), time of application (t), and the resistance, and
may be expressed as I2Rt = Heat. Because any of these variables (I, R, t) can influence the amount of heat produced, it
is essential to control these parameters to the tightest tolerances possible. The use of state of the art electronics and
power control can help to stabilise the welding operation and be used to create consistency in the welding operation that
is not available without such control.
The primary process variables include any variable that is determined by the programmed weld schedule, the force
setting, the condition of the materials, and the shape and thickness of the materials. Each of these is related to the
process, and while they might determine the most suitable technology for the application, they can not be controlled by
the welding power supply or weld head.
a. Amplitude
The amplitude of the weld pulse is a function controlled by the welding power supply, but programmed by the user. Any
increase in the amplitude, whether in voltage, current, or power, will increase the amount of current in a particular weld.
This increase in current will also increase the amount of heat generated. The amplitude is the simplest and most widely
used means of increasing the temperature of the weld joint. When adjusting the welding amplitude, it is best to start at
a low level and increase the amplitude in moderate steps until a weld begins to form. At this point the steps should be
decreased in value until a passable weld is achieved. Once passable weld strengths are achieved, a number of parts
should be welded at that level, and at levels slightly higher. These batches of samples should then be examined and
tested for strength, consistency, and identification of any undesirable results such as weld splash, tempering, excessive
scaring, and discoloration. The setting that provides the most desirable and consistent weld quality should be selected.
b. Time
If desirable weld strengths can not be consistently achieved, then the time of the weld pulse can be lengthened in an
effort to create more heat without additional current amplitude. The time setting for a weld is used to determine the
duration of the weld pulse provided by the welding power supply. In a DC system, there are three primary time settings
for each pulse; upslope, peak, and downslope. The use of time and its relative effect on the weld joint and the materials
is dependent upon the weld pulse amplitude and the characteristics of the materials being welded. If the materials are
sensitive to heat and have a tendency to become brittle if heated, then the duration of the weld should be kept to a
minimum. This will allow the heat effected area around the weld to be minimised by reducing the time that heat is
generated and therefore reducing the time that the heat has to be transmitted into surrounding materials.
In normal process development, the time should be kept short to minimise the potential of heat damage. This can also
increase the systems ability to provide more welds in a set period of time as might be required in high-speed
applications.
The use of time and its effects on a certain application can be tested by the same means as the amplitude settings are
determined. When a welding time at a certain amplitude is established, then the time can be decreased slightly and
increased slightly for a set number of welds. The weld results can then be tested and the results examined to determine
the most desirable settings relative to the requirements and limitations of the product and application.
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© MacGregor Welding Systems 2001
Principles of Resistance Welding
c. Force
As with most variables associated with resistance welding, the pressure setting can impact the ideal or optimised level
of other settings or values. One that is typically closely related is the amplitude in relation to a given pressure.
The impact of increased or decreased pressure effects the electrical circuit by altering the contact resistance. The
higher the pressure, the lower contact resistance will be. The lower the pressure, the greater the contact resistance will
be. The contact resistance is a key value in the determination of the heat generated in the weld. The loss or reduction
of contact resistance from the circuit will lower the heat generated by a specific energy output. For this reason, when
the weld pressure is increased, the required amplitude of the output pulse is typically increased as well. Likewise, when
the weld pressure is decreased, the required amplitude of the output pulse is decreased. The change in amplitude
allows for the same amount of heat to be generated despite the change in the contact resistance.
The use of pressure in relation to weld amplitude can also be viewed from a weld stability perspective. High contact
resistances tend to cause unstable and rapidly collapsing joint resistance when the weld begins. The use of a higher
weld pressure can reduce the resistance levels prior to the initiation of the weld pulse and prevent the resistance from
causing excessive splash or volatile conditions. The control of the initial resistance can allow for a more stable weld.
The increase in pressure can also prevent excessive heating and wear on electrodes by decreasing the electrode to
material contact resistance. The lower resistance at these interfaces reduce the temperature that the electrodes are
introduced to and can prevent cosmetic scarring. The use of pressure in this way allows a higher amplitude pulse to be
used, and focuses the heat within the bulk of the materials to be welded. Inversely, if the amount of current required to
accomplish a given weld is too high, the pressure can be lowered to enhance the generation of heat in the weld area
while allowing a reduction of current. This can allow certain processes to function within guidelines that prohibit the
some settings and conditions for accomplishing the weld joint.
When experimenting with weld pressure and amplitude settings, it is recommended that the acceptable weld conditions
be established first. After the strongest joint possible is reached, then the alteration of the weld pressure and amplitude
can be effected to allow for consideration of other process constraints such as pressure sensitive components or high
cosmetic standards.
d. Electrode condition
The condition of the electrodes is a critical factor in the reliability of a welding process. If the electrode surface has
become scarred, misshapen, or contaminated, then the resistance of the weld joint will be effected. The maintenance of
the electrode surfaces is a simple procedure but costs production time while the electrodes are changed or dressed.
The proper cleaning interval is entirely dependent upon the application and is determined through proper monitoring of
the process. It is recommended that a conservative cleaning interval be adopted initially and slowly increased while the
process is being monitored. As the interval between the cleaning or changing of the electrodes is increased, the point
at which the process becomes unstable should be identified. Once this point is discovered, then the set interval for
electrode maintenance should be set below that level to ensure that there are no problems in the welds prior to the
maintenance operation. For example, if irregularities are consistently seen after 5000 welds, then the electrodes should
be dressed every 4750 welds.
The factors that contribute to the deterioration of the electrodes include the presence of contaminates, weld splash or
sparking, excessive heat at the electrode to weldment interface, and the effects of weld head force. In any process, the
causes of these problems should be identified and removed if possible. The lengthening of the electrode life can effect
cost savings in materials, rejects, and line utilisation.
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© MacGregor Welding Systems 2001
Principles of Resistance Welding
e. Part geometry
The part geometry is critical to the welding process because it will help to determine the consistency of the material
interface from weld to weld. If the material shape and thickness’are different from part to part, then the weld strengths
and the heat distribution in the weld will change from weld to weld. The geometry of the parts is not something that can
be controlled by the power supply or the weld head, but can be monitored. The DC series by MacGregor Welding
Systems can be configured to detect variations in the resistance of the joints as well as detect any physical differences
in the parts by monitoring the displacement at the weld head.
In any welding process, it is important that the part consistency be maintained as strictly as is cost effective. The use of
reliable and consistent parts will remove a large number of variables from the process and will enable the process to be
more reliable.
f. Part cleanliness
The cleanliness of the parts welded will impact the amount of heat generated and the possibility of weld splash from part
to part. Parts should always be presented to the welding process in the cleanest condition possible. The presence of
contaminates such as oils, oxidation, or dust can create a barrier to current flow that needs to be removed either prior to
the welding process or by the welding process. The welding process can be used to help in the removal of
contamination through use of upslope or a pre-pulse. Due to the influence of part contamination on the overall circuit
resistance, the weld monitor can detect the presence of contaminated parts in some applications.
g. Material composition
The material composition is critical to the welding process because the materials and the interaction of the materials
being welded will change when heated to a welding temperature. Because some materials become brittle if heated, the
process must allow for this characteristic to be compensated for. The affinity of certain materials for one another will
also play an important role in the proper selection of materials. If two materials are not easily joined, then those
materials will require a third interface material or will only be able to be welded in certain conditions. In the latter case,
there is very little room for the other variables that are in a welding process and the level of control over the various
variables will critical to the consistency of the process.
Material selection should always be made to allow for process tolerance. The more simply two materials can be joined,
the more variables can be present without having a detrimental effect on the quality of the weld.
Alloy additives should also be examined. In the case of Nickel, as the amount of impurities in the material increases,
the amount of cosmetic scarring also increases. The presence of impurities will also effect the weld quality because
they move towards the weld interface and create a brittle layer, lowering the weld strength. The presence of Zinc in an
alloy can cause pockets of gas to form in the weld nugget, due to the evaporation of the zinc at a lower temperature
than the other materials in the alloy. This can cause drastic irregularities in the joint resistance as the weld progresses
and cause weld splash.
The ability and ease with which each material can be joined to another can be found in metallurgy handbooks, or
provided by MacGregor Welding Systems upon request.
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© MacGregor Welding Systems 2001
Principles of Resistance Welding
Modes of operation for DC units
High Limit Pulse 2
High Limit Pulse 1 peak
time
peak Low Limit 2
time
Low Limit 1 downslope
upslope
downslope
upslope
delay
DC welding allows for the power supply to maintain a programmed output in current, voltage, or power. The various
modes or operation allow the user to select the mode that best suits the conditions of the specific weld joint. The units
have the capability to program different times, limits, and modes of operation for each pulse of the weld to allow for
maximum flexibility.
Because each mode of operation has its own benefits, the application should be reviewed and the mode best suited
should be selected.
Constant current control is commonly used in applications that utilise opposed electrode geometry. The use of current
control mode can also be used in series welding for initial development purposes and is typically reserved for clean
assemblies in a production environment due to the difficulties that arise if oxide or contamination layers exist.
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© MacGregor Welding Systems 2001
Principles of Resistance Welding
2. Constant Voltage Control
Voltage control is best when used with clean materials, and can introduce a certain amount of process feedback due to
the ability to vary current with resistance. This is illustrated when the cross-sectional area increases during the weld. I.e.
when welding a joint with projections, as the projection(s) collapse and contact area increases, the current will increase
to maintain a certain current density within the joint. Constant voltage with a current limit in place can prevent excessive
current levels being reached under low resistance conditions.
The basis of power control mode is founded in multiplication and relational responses. Because power is the product of
voltage and current (I x V = W), the ability to harness and utilise a power control output relies on monitoring and
responding to changes in the dynamic weld properties. As with any weld, the resistance present in the weld joint will
effect the output of the machine in order to maintain the programmed output. The power output demand of the machine
is achieved through the monitoring and multiplication of the current and voltage output levels during the weld. The
implementation of a stable, responsive, and clean power pulse is achieved through a cascade of events and
relationships that are driven by potential current flow and the presence of resistance in the joint.
Just as a higher voltage level is desirable in the initial stages of a weld to break through resistance, a higher current
output is desirable in the mid and latter stages of the weld to create sufficient heat in the materials to create a desirable
weld joint. Following the notion mentioned above, that the use of power control in welding is based upon relational
responses, then two conclusions can be made:
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Principles of Resistance Welding
1. As the resistances present in a joint decreases, the amount of current that will be present in a particular power (W)
output amplitude will increase.
2. As the current level rises, the voltage level across the weld joint will decrease simultaneously in order to maintain a
set power output.
Based upon these two conclusions, the typical power output waveform will have an initial high voltage with a
corresponding low current level. As the weld progresses and the weldments settle into one another, the voltage
required to maintain the power level will begin to fall and the current level will increase. The basic functional definition of
the power control mode allows for broad and multifaceted applications into welding in actual conditions. The use of
power control mode can be seen as a means of creating process tolerance through welding technology.
In practical welding, the use of power control is applicable to several circumstances and conditions often found in
resistance welding applications. Any application performed outside of the realm of perfection will contain inconsistencies
in the parts, cleanliness, and tolerance of each of the assemblies. The goal in resistance welding is to develop a
process and technology base that allows for acceptable and reliable results to be attained in the realm of reality.
Reference
V
W
Current Output
I Limit I
I
The first of these benefits can be realised in the welding of heat and power sensitive materials where the amount of heat
and energy introduced to the assembly is critical to the material strength and the process stability. In these applications,
the use of power control mode can be employed to allow for the variability of initial resistances to drive the profile and
output characteristics of each weld. The use of a power profile allows for only the minimum amount of voltage needed
to be introduced to each part, as opposed to the amount required for the most demanding parts in the spectrum.
Typical use of this feature utilises a software configuration option in the monitor loop of the welding power supply
allowing the current profile to be monitored and to use of a programmed High Limit for the current level in the first weld
pulse. This addition will create what is termed a conditioning pulse or a pulse that is designed to clean or condition the
weldments and interfaces to a set resistance. This is accomplished by the administering of a constant power pulse with
a current level limitation.
This feature allows for the absolute minimum current and duration to be V
introduced to each assembly according to the assembly condition upon High Resistance
entry to the weld station. In simplified terms, a dirty part is subjected to Joint
a high voltage pulse that breaks down the resistances to a set point,
while a clean part is simply verified as a clean assembly. As shown to
the right, an oxidised or high resistance assembly will exhibit a high
initial resistance and will drive a high initial voltage level in order to I W
break down the resistance. Once the resistance level is broken and the
current level rises, the voltage will drop in accordance with the power
output requirements as defined by I x V =W. Once the current has Low Resistance
reached the programmed limit, the welding power supply will recognise V Joint
that the assembly is prepared for welding and will terminate the first
weld pulse and initiate a second pulse to effect the weld. Similarly, the
presence of a clean assembly will result in a lower initial resistance and
therefore a lower initial voltage will be generated. A higher current level I W
will accompany this lower voltage in order to maintain the power profile.
In this case, the current level will ramp up to the set limit level in a much more rapid time span and will terminate the first
weld pulse.
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Principles of Resistance Welding
In this case, the duration of the conditioning pulse is directly related to the individual part condition, not to a grouped
process which is designed to accommodate all the part to part inconsistencies.
The stability of process is achieved through the use of the power pulse to condition parts to a same resistance prior to
the second pulse where the weld is accomplished. The cleaning pulse amplitude can be adjusted to allow for removal
of oxidation and contamination in severe conditions or for use as a contact resistance preheating pulse. In this second
application, the pulse is simply employed to create a uniform settling of the part interfaces in order to increase weld to
weld consistency. The unique advantage offered when using multi-mode Linear DC or the m3 HFDC with near
instantaneous response time allows for the individual parts to drive the process. The use of the conditioning pulse can
be coupled with the most suitable method of joining (I, V, P) for the actual weld. Using an axial weld of a pin material to
a flat surface as an example, the use of the constant power pulse would allow for the projection on the end of the pin to
be adequately seated prior to the initiation of the final weld pulse. The weld will then likely be accomplished in either
voltage or current control mode.
The second use of power control mode in practical welding applications is found in welding applications similar to
battery tab attachment. The use of a series or step configuration lends itself to this mode of operation for several
reasons. In the case of battery tab attachment, the use of materials like steel and nickel make a power pulse an ideal
choice for cosmetic purposes. In other applications, introduction of excessive heat to the materials being welded can be
avoided by use of power control mode due to the same principles that decrease cosmetic scaring in a battery tab
application.
The use of the power control pulse feedback loop can help to contribute to the process stability in several ways when
looking at a step or series weld. If voltage control alone is being employed, then the set amplitude would have to be set
at a level sufficient to break through and weld the dirty assemblies. The use of the raised amplitude would yield
consistent results from the dirtiest of parts. If that weld schedule is used for all assemblies in order to avoid rejects
caused by corrosion, contamination, or oxidation, then the parts that were presented to welder without these initial
barriers to current flow would be subjected to an increased amplitude and duration of current flow. This increase can
result in reduced electrode life, excess heat deposited in the assembly and surrounding components, brittle material
formation as a result of the high heat, and discoloration due increased heat levels.
If current control is used, the same circumstances will continue to exist, but the reaction to the introduction of the current
controlled profile will differ from that of the voltage pulse. If there is an oxidation layer or geometric inconsistencies
present, the attempted application of current will cause a high voltage level to generated to facilitate the current flow set
by the profile. This results in a high temperature and possible damage to the parts and the electrodes. Where these
variables are present, the current pulse will likely cause weld splash and expulsion of material due to the sudden inrush
of current.
The use of power control allows for a rise in voltage that Voltage Profile with Oxide Film
will accommodate a gradual current inflow. In a clean
assembly, the use of a power control pulse will cause a
more gradual settling of the materials and has the
potential to significantly raise the electrode life. The
likelihood of electrode contact point deformation or Current Profile with Oxide Film
material deposit is also reduced and increased cleaning
intervals can be employed without detrimental quality side
affects.
The final practical benefit of constant power is realised in the cost reduction phase of process refinement. While part
consistencies and tolerance that are uniform and stringent are always recommended, the use of constant power control
can lower the acceptable level of stringency required to facilitate a tolerant and repeatable welding process. This
benefit can at times allow for cost reductions in component manufacturing due to the lower standards required. The
stringency or limitations of material selection can also be broadened for similar reasons. Oxidising materials are less of
a process liability and part handling and preparation can be abbreviated or refined to utilise this flexibility in the welding
process.
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© MacGregor Welding Systems 2001
Manufacturer’s Information
Manufacturer’s Contact
Information
Email:
General: enquiries@macgregor-systems.co.uk
Service: techsupport@macgregor-systems.co.uk
Sales: sales@macgregor-systems.co.uk
Email: treinders@macgregor-systems.co.uk
Web Site: www.macgregor-systems.co.uk
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© MacGregor Welding Systems 2001