MacGregor Welding Systems Operation Manual - DC601P DC1001P DC1801P

MacGregor Welding Systems, Ltd.
DC601P, DC1001P, DC1801P
Operating
Instructions
MWS Part Number 961-00017
-1-
© MacGregor Welding Systems 2001
Contents
Preparation and Product Warnings 2
Mains Connections 2
Installation Basic Connections 3
Basic Features 5
Getting Started Guide Power On and Verification 7
I/O Listings and Signal Diagrams 9

Control Connections External Cable Drawings 12
The User Interface Keypad Layout and Function 14
Basic Control Options Loading a Profile from Memory 16

Saving a Profile to Memory 17
Changing Profile Settings 18
Basic Profile and Monitor Information 26
Advanced Control Unit Configuration – System Options Menu 28

Unit Configuration – Complex Options Menu 33
Options Unit Configuration – Special Features Menu 42
Pattern Welding Options 48
Conditioning Pulse (Automatic Part Conditioning) Options 52
Trouble Shooting Guide Basic Trouble Shooting Procedures 53

Fault Finding Guide 53
Machine Specifications DC601P, DC1001P, DC1801P 56
Service Information PCB Diagrams with Primary Components Labelled 59

Changing EPROM’s 59
Diagnostic LED’s 59
PCB Test Points and Functions 59
Calibration Procedures 61
Principles of Resistance Basic Resistance Welding Theory 68

Welding
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.
DO NOT Operate Machine Without Covers

Connecting the Input Cable to Mains Supply
Single-Phase
DO NOT Operate With Suspected Failures Cable Colour: Brown Live
DO NOT Operate in an Explosive Atmosphere Blue Neutral
Yellow/Green Safety Earth / Ground
DO NOT Operate in Wet/Damp Conditions 3-Phase
Cable Colour: Black Line 1
IF IN DOUBT, CONTACT YOUR DISTRIBUTOR Black
Black
Line 2
Line 3
Yellow/Green Safety Earth / Ground
IMPORTANT Ensure a good earth / ground connection is provided for operator safety. The internal electrical circuits
Inspect the unit for any shipping damage prior to are floating, so an additional earth / ground connection should be made to one output lug or on one
connecting to the mains supply. side of the weld head. The unit will not operate with both the positive and negative outputs grounded.
-2-
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
Customer Specific Options:

Isolated Voltage, Current
and Power
Output is 0V to 10V = 0 to
full scale of range
Mains Input
-3-
Basic Connections
DC601P / DC1001P Front panel
Layout
37 Way Connector - Multiple Fuses

FS1 = Reserved
Triggers and PLC Interface FS2 = 1A (F) Anti surge +24V to User
SKT A
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
-4-
Basic Features
DC601P / DC1001P Front Panel Layout
Power On / +24V Status Indicator Mains Switch
1 ABC 2 DEF
3 GHI
JKL
4 5 6 PQR
7 STU 8 VW
9 XYZ
-5-
Basic Features
DC1801P Front Panel
Layout
Power On / +24V Status Indicator
Mains Switch
-6-
Getting Started
Power On and Verification
Turning the Power On:
When the unit is connected to a suitable mains

lead and all the cables are properly connected
to the welding head or test load, then the unit is
ready for an initial power up and verification.
To turn on the unit, the mains switch must be

set to the on position. The mains switch is
located on either the front of the unit (DC601P,
DC1001P, DC1801P, DC2003) or on the rear of
the unit (m3 series).
Once in the on position, the display should turn

on and the data in the Control PCB and the
Display PCB should synchronise. If there is a Synchronising Screen
problem synchronising, the unit will ask whether
the operator wants to upload or download data.
When first commissioning a unit, the best choice
is “UPLOAD”. This will copy the memory from
the control PCB to the display.
When the display and control PCB have

synchronised, the unit will display the Pulse 1
Operating Graph screen.
Performing a Test Weld: Pulse 1 Operating Graph at Start Up
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.
-7-
Getting Started
Power On and
Verification continued…
Performing a Test Weld (continued):
If a fault screen is displayed after the test weld is made then

there is either a problem with the load, welding circuit, or
there is a broken or improperly connected lead. If no problem
is found with the cabling or external connections, verify the
settings are the same as those pictured to the right.
If a Feedback fault is indicated, then the cables and

connections must be reviewed to ensure there is not an open
circuit. This fault might also occur if the welding head was
not closed when the test weld was made.
If a High Limit Fault was indicated, then there is a problem

with the test load or the resistance of the circuit is too high.
There can either be a poor connection or a missing lead. All
cables, sensing leads, and connections should be reviewed.
After successfully completing a test weld, the unit can be

programmed for the application it is intended for. The Test Weld Screen with Feedback
programming of a profile is outlined in the BASIC CONTROL Trace Display Shown
OPTIONS section. The advanced configuration of the unit
and the programming of the user selectable features is
outlined in the ADVANCED CONTROL OPTIONS section of
this manual.
Notation of Factory Calibration Values
It is recommended that the factory calibration

settings be recorded to ensure that they are able to
be re-entered in the event of an accidental memory
loss or reset of the calibration values.
To read the calibration values set in the unit, follow

the following instructions from Pulse 1 Operating
Graph.
Press the “TEXT” soft menu key to display the Pulse

1 Operating Menu.
Press the “CONFIG” soft menu key to display the
Main Configuration Menu.
Read Only Calibration Press the “COMPLEX” soft menu key to display the
Complex Options Menu.
DAC 1 X:_______ DAC 2 Y:_________ Press the “READ ONLY CALIB” soft menu key to
DAC 3 Z:_______ DAC 4 L:_________ display the Read Only Calibration screen.
VGain: ________ VOffs: ________

IGain:_________ IOffs: ________ The recording of the calibration values is highly
PGain: ________ POffs: ________ recommended by MacGregor Welding Systems Ltd
for any customers who are not familiar with the
Ref1 V _______ I _______ P _______ calibration of the unit. Detailed calibration
Ref2 V _______ I _______ P _______ instructions are provided in the SERVICE
INFORMATION section of this manual.
AD Gain: _______ Unit Serial Number M______
-8-
Control Connections
Rear Panel Connections - Standard Isolated
Interface
The following tables show the standard outputs and inputs available at the 37W D type PLC interface socket.
24V 20mA nominal rating - - Inputs and Outputs ARE fully protected against short circuit and overload.
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.
Weld Pulse Typically, the collector

connection is pulled up to
Busy Signal - Active +24VDC and is used as the
during weld + 30mS
input to a PLC, while the
Hi/Low Fault - 20mS emitter is connected to the
Hardware/Feedback Fault
+24V return (0V) connection
Active until reset
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
4K7
Cathode 26
Cathode 7
Cathode 5
Recall Store 5 Anode 20 Cathode
Cathode 24
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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Control Connections
Rear Panel Connections - Optional DS Isolated Interface

The following tables shows the optional output and input configuration available at the 37W - Inputs & Faults are BCD coded
24V 20mA nominal rating - Inputs and Outputs ARE fully protected against short circuit and overload
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.
(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
- 10 -
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.
These are summarised below.
Output Code Fault Description
1 Pulse 1 High Limit
2 Pulse 1 Low Limit
3 Pulse 2 High Limit
4 Pulse 2 Low Limit
5 Low Limit Pulse 1 and High Limit Pulse 2
6 Low Limit Pulse 1 and Low Limit Pulse 2
7 High Limit Pulse 1 and Low Limit Pulse 2
8 High Limit Pulse 1 and High Limit Pulse 2
9 Output Stage Temperature Error
10 24 VDC Error (Missing 24 VDC)
11 Missing Input Phase(s) (Only Active on DC1001P / DC1801P)
12 Missing Voltage Sensing Lead
13 reserved
14 reserved
15 reserved
16 reserved
- 11 -
Control Connections
Typical Connections
- 12 -
Control Connections
Rear Panel Connections
25W D Type RS232
The m3 25 Way D type connector

provides an optically isolated RS232
communications port.
Connections are as follows;
TXD pin 2
RXD pin 3
0V pin 7
Connecting a typical PC to the M3 Welding Power Supply
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)
Comms signal 25-pin 9-pin Connection 25-pin connector ‘b’

description comms port comms port required (m3)
Protective ground pin 1 pin 5
Tx pin 2 pin 3 pin 3 (Rx)
Rx pin 3 pin 2 Pin 2 (Tx)
RTS pin 4 pin 7
CTS pin 5 pin 8
DSR pin 6 pin 6
Logical Ground pin 7 pin 5 pin 7 (isolated 0V)
DTR pin 20 pin 4
15W D Type (Skt 'B')

(DC2003P Only)
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
- 13 -
The User Interface
Keypad Layout and Functions
The user interface is based upon

a dual control concept and
features alpha numeric keypad
and soft menu keys as well as a
push button rotary encoder.
This allows the operator to
navigate the menus and screens
in the method most convenient
for the operator. The information
about the weld, configuration, or 1 ABC 2 DEF 3 GHI
feedback data is presented on a JKL
¼ VGA full colour display. This
4 5 6 PQR
display is bright and easily read 7 STU 8 VW 9 XYZ
from a distance. The data is
colour coded to indicate which 0
values can be edited and which
are fixed. Both graphical and text
based menus are available.
The display and keypad are available in two formats.

These are landscape and portrait. The landscape version
is used in all m3 models, and any horizontal models of the
DC601P, DC1001P, DC1801P, and DC2003P. All remote
keypad assemblies also use the landscape version of the
display.
The portrait version of the display is used in the vertical

models of the DC601P, DC1001P, DC1801P, and
DC2003P. Both feature the same menus and interface
capability.
TFT Display
¼ VGA
Alpha Numeric Keypad
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
- 14 -
The User Interface
Keypad Layout and Functions
User Interface Component Descriptions

Weld: Trigger weld (for trials). This key will trigger the weld schedule displayed on the screen of the unit. This key
is used primarily in testing the unit. Normal operation utilises the trigger inputs located on the rear panel of the
machine.
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.
- 15 -
Basic Control Options
Loading a Profile from Memory
To Load a Profile from Memory:
From the Pulse 1 Operating Graph or the Pulse 1

Operating Menu, press the ”LOAD/SAVE”soft
menu key. This will display the Load Menu screen.
From this menu, press the “LOAD PROFILE” soft

menu key. This will display the Profile Menu.
Select a profile to load. 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 “LOAD”soft menu key.
This will load the profile and display the profile data
Pulse 1 Operating Graph
in either Text or Graph mode, depending on the
screen started in.
Load Menu Profile Menu (Load)
**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.
- 16 -
Saving a Profile to Memory To Save a Profile to Memory:
From the Pulse 1 Operating Graph or the Pulse 1

Operating Menu, press the ”LOAD/SAVE”soft menu key.
This will display the Load Menu screen.
From this menu, press the “SAVE PROFILE” soft menu

key. This will display the Profile Menu.
Select a memory location to save the profile to.
**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.
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.
Profile Menu (Save)

Load Menu
**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.
- 17 -
Changing Profile Settings
Modifying and Editing Values:
The user interface has 3 basic modes in relation to the

editing and modifying of profile settings. The three modes
are Normal, Modify, and Edit. These are described below.
These rules apply when modifying any value in the user
interface including those related to calibration,
configuration, and operation of the unit.
Normal Mode: This is the operating mode and indicates

that there are no modifications being made. When a profile
is loaded, it will be in this mode. When in normal mode, the
“MODIFY”soft menu key will be displayed. The values in
Green are those that can be changed.
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.
Edit Mode: Edit mode allows a single value to be changed

or entered. This mode is characterised by the presence of a
solid YELLOW box with the value indicated in Red text.
Once the desired value is shown, press the Enter key or
depress the encoder to return to Modify Mode.
To return to Normal Mode from Modify mode, press the

“EXIT MODIFY”soft menu key.
Changing the Control Mode (Current, Voltage, Power):
To change the control mode, press the “MODIFY”soft

Modify Mode – Pulse 1 Operating Graph
menu key from either the Operating Graph or the
Operating Menu screen (Graph or Text). A small yellow
box will appear around the green Control value. To select
Edit mode, press the enter key or depress the rotary
encoder once.
The highlighted value should now appear in red text in a

solid yellow box.
Using the rotary encoder, select the desired mode of

operation. Modes available are Current, Voltage, and
Power.
When the desired mode is displayed, press the enter key

or depress the encoder to select that mode. The solid
yellow box should be replaced with an outline box around
the new value.
To select other values to edit, rotate the encoder and

indexing from value to value, or press the “EXIT MODIFY” Edit Mode – Pulse 1 Operating Graph
soft menu key to exit Modify mode.
- 18 -
Continued…
Changing the Peak Value:
The Peak value is the Current, Voltage or Power setting

for the weld. It is the peak value set and maintained
during the Peak Time or T2. This value is defined by the
control mode set for the pulse. The setting of the control
mode is outlined on the previous page of this manual.
The values set will be in Amps when in Current Control
mode, Volts when in Voltage Control mode and Watts
when in Power Control mode.
To change the peak value, press the “MODIFY” soft

menu key when viewing either the Text or Graph profile
screen. This action will enable modify mode and a
yellow outline box will appear around the control mode
value. Using the rotary function of the encoder, move
the yellow box until it is highlighting the Peak value.
Press the enter key on the keypad or depress the

encoder to change into Edit mode and edit the peak Edit Mode – Pulse 1 Operating Graph
value. Once in Edit mode, the peak value will be (Editing Peak Value)
displayed in a Solid Yellow Box with red text.
To change the set value, either rotate the encoder or

use the keypad to enter the desired value. If a mistake
is made, pressing the Undo key will return the value to
the previous setting and the display will return to Modify
mode.
When the desired value is displayed, press the enter key

yellow box should be replaced with an outline box
around the new value.
To select other values to edit, rotate the encoder to

index from value to value.
Press the “EXIT MODIFY” soft menu key to exit Modify

mode.
- 19 -

Continued…
Changing the Upslope (T1) Value:

Weld Profile Time Settings:
The Upslope time in a weld is the time that is set for the Upslope (T1)
output to rise from 0 to the programmed peak demand. amplitude
Upslope is commonly used to reduce splash and to allow
the parts being welded to settle as the current is gradually
increased until it is at a level high enough to create a weld
joint.
To change the Upslope (T1) value, press the “MODIFY”

soft menu key when viewing either the Text or Graph
profile screen. This action will enable modify mode and a
value. Using the rotary function of the encoder, move the
yellow box until it is highlighting the T1 value.
time
Press the enter key on the keypad or depress the encoder
to change into Edit mode and edit the T1 value. Once in Upslope (T1)
Edit mode, the upslope (T1) value will be displayed in a
Solid Yellow Box with red text.
To change the set value, either rotate the encoder or use

the keypad to enter the desired value. If a mistake is
made, pressing the “UNDO” soft menu key will return the
value to the previous setting and the display will return to
Modify mode.

the new value.
To select other values to edit, rotate the encoder to index

from value to value.

mode.
Edit Mode (T1) – Pulse 1 Operating Graph
- 20 -

Continued…
Changing the Peak (T2) Value:

The Peak time in a weld is the time that is set for the Peak (T2)
output to remain at the output setting. For example, if the
amplitude
programmed peak level is 250 Amps as shown below,
then the programmed peak time of 15.0mS is the time that
the current level will be maintained at 250 Amps. The
longer the peak time, the longer the parts will be at a
welding temperature. The peak time will have the most
effect on the heat input to the joint of the 3 time settings
(T1, T2, T3).
To change the Peak (T2) value, press the “MODIFY”soft

menu key when viewing either the Text or Graph profile
screen. This action will enable modify mode and a yellow
outline box will appear around the control mode value. time
Using the rotary function of the encoder, move the yellow
box until it is highlighting the T2 value.
Peak (T2)
to change into Edit mode and edit the T2 value. Once in
Edit mode, the peak value will be displayed in a Solid
Yellow Box with red text.

Modify mode..

the new value.


mode. Edit Mode (T2) – Pulse 1 Operating
Graph
- 21 -
Continued…
Changing the Downslope (T3) Value:

Downslope (T3)
The Downslope time in a weld profile is the time
programmed for the output to decline from the peak setting amplitude
to 0. The downslope time is typically kept short because
the weld typically occurs during the peak time period and
the reduction of the Downslope time helps to minimise the
heat input to the parts. The use of a longer Downslope
time is typical when welding materials that require a form
of tempering. Materials that become brittle when cooled
rapidly will sometimes benefit from a controlled cooling
through use of the Downslope time setting.
To change the Downslope (T3) value, press the “MODIFY”

soft menu key when viewing either the Text or Graph time
profile screen. This action will enable modify mode and a
value. Using the rotary function of the encoder, move the Downslope (T3)
yellow box until it is highlighting the T3 value.

to change into Edit mode and edit the T3 value. Once in
Edit mode, the peak value will be displayed in a Solid
Yellow Box with red text.

Modify mode.

the new value.

Edit Mode (T3) – Pulse 1 Operating
Press the “EXIT MODIFY” soft menu key to exit Modify Graph
mode.
- 22 -
Continued…
Hi Limit Function and Setting:
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.
Low Limit Function and Setting:
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.
HUL = Hard Upper Limit (Hi Limit)

HLL = Hard Lower Limit (Low Limit)
- 23 -
Continued…
Changing the Hi Limit (Hi Lim) Value:
To change the Hi Limit (Hi Lim) value, press the

“MODIFY”soft menu key when viewing either the Text
or Graph profile screen. This action will enable modify
mode and a yellow outline box will appear around the
control mode value. Using the rotary function of the
encoder, move the yellow box until it is highlighting the
HI Lim value.

encoder to change into Edit mode and edit the HI Lim
value. Once in Edit mode, the HI Lim value will be
displayed in a Solid Yellow Box with red text.
To change the set value, either rotate the encoder or

use the keypad to enter the desired value. If a mistake Edit Mode (HI Limit) – Pulse 1
is made, pressing the “UNDO” soft menu key will return Operating Graph
the value to the previous setting and the display will
return to Modify mode.
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.
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.
To change the set value, either rotate the encoder

or use the keypad to enter the desired value. If a
mistake is made, pressing the “UNDO” soft menu
key will return the value to the previous setting and
the display will return to Modify mode.
When the desired value is displayed, press the

enter key or depress the encoder to select that
mode. The solid yellow box should be replaced with
an outline box around the new value.
To select other values to edit, rotate the encoder to

index from value to value.
Edit Mode (Low Limit) – Pulse 1 Operating
Graph Press the “EXIT MODIFY” soft menu key to exit
Modify mode.
- 24 -

Continued…
Single and Dual Pulse Profiles
Changing to Single or Dual Pulse Mode:
From the Graph screen, press the “TEXT” soft menu

key to display the Pulse 1 Operating Graph. Press the
“MODIFY”soft menu key to enable Modify mode.
Rotate the encoder until the Mode value is highlighted
with a yellow outline box. Press the enter key or
depress the encoder to enter Edit mode. Using the
encoder, select either X1 PULSE or X2 PULSE. When
the desired mode is selected, press the enter key or
depress the encoder to return to Modify Mode. Press
the “EXIT MODIFY” soft menu key to return to normal Edit Mode (Single or Dual Pulse) – Pulse
mode. 1 Operating Menu
Programming the delay Time (T4):
The Delay time (T4) is the time between pulse 1 and

2. This value is set in the Pulse 2 Operating Graph or
Menu. It is programmed in the same manner as other
time settings.
Programming T5, T6, and T7:
T5, T6 and T7 represent the Upslope, Peak, and

Downslope times for Pulse 2 in a weld profile. These
are programmed in the same manner as T1, T2 and
T3 respectively.
Edit Mode (T4) – Pulse 2 Operating Graph
Viewing Dual Pulse Profiles:
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.

(Dual Pulse Navigation)

(Dual Pulse Navigation)
**Note** The “P1” and “P2” soft

menu keys are not available when
in Edit or Modify modes. Return to
Normal mode to enable the “P1”
and “P2” soft menu keys
- 25 -
Basic Profile and Monitor
Information
Weld Information Menu:
The Weld Information Menu provides statistical data for

the weld profile displayed.
The data displayed provides the profile, pattern, weld

head and limits information for the displayed profile. A
Weld and Fault Counter are displayed and record the
number of welds, the number of faults and the types of
faults recorded for each Profile.
The Distribution Monitor is accessible from the Weld

Information Menu by pressing the “DIST MON” soft
menu key.
The counter values can be reset to 0 by pressing the

“RESET COUNT” soft menu key. The user will be
prompted to confirm this action. If YES is selected, then
the counters for the weld and fault values will be reset to
0.
Weld Information Menu
The Pattern Monitor is accessible from the Weld
Information Menu by pressing the “PATT MON”soft
menu key. The Pattern monitor allows the user to
observe the location in the trigger sequence for the
loaded pattern.
**Note** The “PATT MON”soft menu key is only active

when a Pattern is loaded. When no pattern is loaded,
Main Configuration Menu: the soft menu key is displayed but not active.
The main configuration menu is the navigation

point for all configuration screens and functions.
The screen has three soft menu keys labelled
“SYSTEM”, “COMPLEX”, and “SPECIAL”. These
soft menu keys take the user to the individual
configuration menus.
The Main Configuration Menu displays the Date

and Time as set in the system.
The Output Stage temperature is displayed for

simple diagnostics.
The software version and specification data is

provided so that user can verify what software
version is running in the machine. This
information is also helpful when contacting the
factory for support of the unit.
Main Configuration Menu
To return to the Operating Graph or Menu, press
the “EXIT”soft menu key.
- 26 -
Basic Profile and Monitor
Information
Distribution Monitor:
The Distribution Monitor allows the feedback

values, weld counter, and fault counter to be
displayed and updated for any four weld profiles.
This feature is designed for use with multiple
output welding systems so that the process and
quality data is accessible for a number of weld
profiles in a single screen.
The Distribution monitor screen allows the viewed

profiles to be selected by the user using the
standard “MODIFY” soft menu key. When Modify Distribution Monitor
mode is selected, rotate the encoder to the profile
index value of any of the four display zones.
Press the enter key or depress the encoder to
enter Edit mode. Enter the desired profile index
using the alphanumeric keypad or the rotation
function of the encoder.
When the desired profile index is displayed, press

the enter key or depress the encoder to return to
Modify mode. To exit modify mode, press the
“EXIT MODIFY”soft menu key.
Edit Mode – Distribution Monitor

(Changing Viewed Profile Selection)
Resetting a Profile Counter:
To reset any of the four Profile Counters displayed on

the Distribution Monitor, press the “RESET” soft menu
key. This will enable Modify mode and a yellow outline
box will appear around the Total value for the first weld
profile. Use the rotary encoder to highlight the profile
counter that is to be reset.
Press the “RESET” soft menu key again to reset the

counter value.
To return to Normal mode, press the “EXIT” soft menu

key.
Reset Profile Counter – Distribution
Monitor
- 27 -
Advanced Control Options
Unit Configuration Options:
System Options Menu
Unit Configuration:
All user programmable options for the welding power

supply other than profile or pattern related options are
programmed and accessed through the MAIN
CONFIGURATION MENU. The configuration area allows
the user to configure the Display, Set Active Features,
Configure Limits, Access Calibration Data, View
Calibration Data, Set Fault Instructions, Configure the
Trigger Inputs, and Access Special Modes of Operation.
Special modes of operation include Fast Mode, Auto
Cycle, Operator Mode, and Operator Mode Setup.
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.
The MAIN CONFIGURATION MENU will be displayed.

This screen shows the set system time and date, the
Output Stage temperature, the Software versions for the
Control PCB and Display PCB, and the software
specification.
Pressing the desired soft menu key accesses the three

Primary Configuration Menus.
To return to the Pulse 1 or Pulse 2 OPERATING MENU,

press the “EXIT” soft menu key.
The specific functions and configurations options

accessible to the operator are listed in the following
pages.
System Options Menu: Main Configuration Menu
The Systems Option Menu provides access to the

setting and configuration of basic features.
Systems Options - Accessible Features:
Communication Options
Bar Code Reader
Baud Rate – RS232
SPC Data Format
Time Options
Date
Time
Screen Options
Display Limits
Time Format
Pattern / Profile / Limits Format
Language
Filtering
Contrast
Screen Refresh
Password Options
Other Options
Inhibit on Power Up
Voltage Sensing Detection
Systems Options Menu

- 28 -
Unit Configuration
Options:
System Options Menu
Communications Menu:
The Communications Menu allows the user to enable the

Bar Code option (Cost Option – Requires Bar Code Wand
or Bar Code Reader Option), Set the serial comms Baud
Rate, and set the desired SPC data format. The SPC
Data can be formatted for use with either the Weld Comm
software product group, or the 8-bit.exe software product
group.
Modify Mode – Set Communications Menu

Set Communications Menu:
To Access the SET COMMUNICATIONS MENU, press the

“COMMUNICATION”soft menu key from the SYSTEM OPTIONS MENU
screen.
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.
Edit Mode (RS232) Set Setting the Time and Date:

Communications Menu
To set the system clock in the welding power supply,
press the “TIME” soft menu key on the SYSTEM
OPTIONS MENU screen. This will display the SET TIME
MENU screen.
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.
To Edit the Other Values, use the same procedure for

each value.
Normal Mode – Set Time Menu To Exit the SET TIME MENU, return to Normal mode and
- 29 -
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).
Pattern Format: Allows user to set Pattern display format

to Name or Index location for recalling, saving, or viewing.
Profile Format: Allows user to set Profile display format to

Name or Index location for recalling, saving, or viewing.
Limits Format: Allows user to set Limits display format to

Normal Mode – Screen Options Menu
Name or Index location for recalling, saving, or viewing.
Editing Screen Options: Language: Allows user to select desired interface

language. Standard languages include English, French,
To edit any screen options, press the “MODIFY” soft and Dutch.
menu key on the SCREEN OPTIONS MENU to enter
**Note** Other languages can be added if needed. Consult Factory for
Modify mode. details.
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.
- 30 -
System Options Menu
Password Configuration Menu:
To Set the User Selectable Password press the

“PASSWORD”soft menu key on the SYSTEM OPTIONS
MENU screen. The user will be prompted for the system
password. The default password is 1234.
Passwords must be entered pressing the enter key

between each digit. To select a letter, press the
appropriate keypad key until the desired letter is displayed.
When the desired number or letter is displayed, press the
enter key to move to the next digit.
Enter Password – Password Menu
To Change the user set password, press the “MODIFY”
soft menu key to enter Modify mode. Use the encoder to
select the Password value and press the enter key or
depress the encoder to enter Edit mode. Use the encoder
or the keypad to enter the new password pressing the
enter key between each digit. When the new password is
entered and verified, press the “STORE”soft menu key.
The display will return to Modify mode.
To Enable / Disable Write Protect press the “MODIFY”

soft menu key. Use the encoder to highlight the Write
Protect value with the yellow outline box. Press the enter
key or depress the encoder to edit the Write Protect value.
Use the encoder to select LEVEL 1, LEVEL 2, or DISABLE
as required. When the appropriate value is displayed,
press the enter key or depress the encoder to select the
value and return to Modify mode.
Normal Mode – Password Configuration
To Return to Normal Mode and Exit the PASSWORD Menu
MENU screen press the “EXIT MODIFY” soft menu key
and then the “EXIT”soft menu key.
Password Protection Levels
Level 1
When Level 1 password protection is set, the unit will

require the operator to enter the user set password the first
time a profile is loaded or saved to memory after turning on
the unit. After the password is entered once, then only
calibration changes will require a password until the unit is
switched off.
Level 2
When Level 2 password protection is set, the unit will

require the operator to enter the user set password each
time a change is made to the profile or memory. This Enter New Password – Password
option is intended for use in areas where no changes are Configuration Menu
authorised or permitted.
- 31 -
System Options Menu
Other System Options:
The Other System Options Menu allow the user to

configure the unit to Power Up with the Inhibit Relay on or
off at start up.
In systems where a PLC or PC controls the unit, it is

recommended that the Inhibit On Power Up be set to
Disable to remove the requirement for the control system
to toggle the Inhibit status after boot up.
For manual operation, it is recommended that the Inhibit

on Power Up be set to Enable. The operator is required to
clear the Inhibit status after switching on the unit when
Inhibit on Power Up is set to Enable.
The Other System Options Menu allows the user to

Enable / Disable the Voltage Sensing Detect Circuit. Normal Mode – Other System Options
Menu
The Voltage Sensing Detect circuit checks the integrity of
the voltage sensing circuit for a particular weld head at the
beginning of each weld. In the event of a broken voltage
sensing lead, the unit will display an error message
alerting the operator to check the voltage sensing Other System Options Menu:
connections.
To Modify the Inhibit on Power Up setting, press
the “OTHER OPTIONS” soft menu key on the
SYSTEM OPTIONS MENU screen.
To Enable / Disable Inhibit on Power Up, press

the “MODIFY” soft menu key to enter Modify mode.
Use the encoder to select the Inhibit on Power Up
value and press the enter key or depress the
encoder to enter Edit mode. Use the encoder to
toggle the setting from Enable to Disable. When the
desired value is displayed, press the enter key or
depress the encoder to return to Modify Mode.
To Enable / Disable Voltage Sensing Detect,

press the “MODIFY”soft menu key. Use the encoder
to highlight the Voltage Sensing value with the
yellow outline box. Press the enter key or depress
the encoder to edit the Voltage Sensing value. Use
the encoder to select Enable or Disable as required.
When the appropriate value is displayed, press the
enter key or depress the encoder to accept the value
Edit Mode – Other System Options Menu and return to Modify mode.
To Return to Normal Mode and Exit the Other

Options screen press the “EXIT MODIFY”soft
menu key and then the “EXIT”soft menu key.
- 32 -
Complex Options Menu
Complex Options Menu:
Limits: This option allows the user to program, view,

amend, and clear Limits files for use with Tolerance
Limits.
**Note** Programming Limits Procedure is outlined in the Tolerance

Limits section of this manual.
Calibration: This option allows the user to set the

Calibration values using either a manual calibration
procedure or the Auto Calibration function.
**Note** Calibration procedures are provided in the Service section Main Configuration Menu
of this manual.
**Note** To enter Calibration screen, Calibration Password (M007)

must be entered.
Complex Options:
Read Only Calibration: Allows user to view
Calibration values with no ability to modify settings. The Complex Options Menu allows the user to
configure Tolerance Limits, Calibrate the Unit, View
**Note** No password is required to view Read Only Calibration Calibration Values, Configure Trigger I/O Inputs, and
Screen.
to Set Fault Actions.
Distribution: Allows user to set trigger inputs to select
This menu is designed to allow the user to optimise
specified Profiles.
the unit configuration for use in a particular
application.
Faults: Allows user to set actions for individual fault
types for simplified integration with control system.
When using a distribution unit, set-up of the
**Note** Faults are always indicated at rear panel I/O even if set to
Distribution Options is required to select the
Display Fault Disable. appropriate Profile for each trigger input. The Weld
Head (Distribution Unit Output) is set in the individual
profile menu in the Operating Menu (Text Screen).
The Navigation, Programming, and Functions of

each Complex Option is provided in the following
pages of this manual.
Please Contact MacGregor Welding Systems Ltd

with any questions about the use and setting of the
Complex Options Menu.
To View and Edit the Complex Options Menu

press the “COMPLEX” soft menu key from the MAIN
CONFIGURATION MENU screen. Use the soft
menu keys to select the appropriate option.
To Exit the Complex Options Menu and Return to

the MAIN CONFIGURATION MENU screen press
- 33 -
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.
Selecting and Loading Tolerance Limits Files:
In the Graph or Text screen, press the “MODIFY” soft

menu key. Use the encoder to highlight the LIMITS
value (Default: NONE) with the yellow outline box.
Press the enter key or depress the encoder to Edit the

LIMITS value. Use the encoder to scroll through
available Limits files.
**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.
When the desired Limits file is displayed, press the enter

key or depress the encoder to select the Limits file and
return to Modify mode.
To exit Modify mode and return to Normal mode, press

the “EXIT MODIFY” soft menu key. Edit Mode (Select Limit File) – Pulse 1
Operating Graph
To save the Limit file into the Profile data, press the
“LOAD/SAVE”soft menu key and follow the procedure
for saving a profile to memory.
Limits can be Enabled / Disabled by selecting the

“LIMITS OFF”or “LIMITS ON” soft menu keys.
**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.
The Limit Boundaries are displayed in Magenta lines.

When Limits are on, any time the green feedback trace
moves out of the Limit boundaries between the set
Active Window, a high or low limit fault will be indicated
as appropriate.
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.
- 34 -
Changing the Tolerance Percentage Values for

Active Limits:
To increase or decrease the percentage setting of the

Positive and Negative Tolerance values, press the
“MODIFY”soft menu key.
In Modify mode, use the encoder to highlight the upper

or lower TOL value. Press the enter key or depress the
encoder to edit the selected value.
Use the encoder or the keypad to enter the desired

percentage setting. When the correct value is
displayed, press the enter key or depress the encoder
to accept the value and return to Modify mode.
Edit Mode (Positive Tolerance) – Pulse 1 Use the same procedure for the second TOL value.
Operating Graph
Changing the Active Window Values for Active

Limits:
To increase or decrease the Active Window

percentage values, press the “MODIFY” soft menu
key.
In Modify mode, use the encoder to highlight the

upper or lower WIN value. Press the enter key or
depress the encoder to edit the selected value.
Use the encoder or the keypad to enter the desired

percentage setting. When the correct value is
displayed, press the enter key or depress the encoder
to select the value and return to Modify mode.
Use the same procedure for the second WIN value.

Edit Mode (Window Setting) – Pulse 1
Operating Graph
**Note** The Upper WIN value can not be set

at a lower setting than the Lower WIN value.
- 35 -
Tolerance Graphs (examples)
Rise Peak Fall
Upper Tolerance Limit
Feedback Trace
Lower Tolerance Limit
Hard Upper Limit (Hi Lim)
Hard Lower Limit (Lo Lim)
Indicates peak period outside of the tolerance window
Indicates the tolerance window
Lines follow both the tolerance and hard limits applied to the weld
- 36 -
Unit Configuration Options: Entering Tolerance Limits Menu
Complex Options Menu To ensure that no unauthorised operators are able to

modify or clear the Limits files in the power supply, the
TOLERANCE LIMITS MENU is password protected.
To Enter the TOLERANCE LIMITS MENU, go to the Text

screen and press the “CONFIG” soft menu key. This will
display the MAIN CONFIGURATION MENU. From this
menu, press the “COMPLEX” soft menu key. Then press
the “LIMITS” soft menu key. The password menu will be
displayed and the User set password must be entered.
(Factory Default 1234)
Recording Tolerance Limits:
Once in the TOLERANCE LIMITS MENU, the user can

select any unused memory location and record new Limits
Data. If a location is used by another file, the memory for
that location can be cleared by highlighting the location
Enter User Set Password- Password Menu and pressing the “CLEAR” soft menu key.
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.
The procedure for recording Tolerance Limits data is

shown on the following pages of this manual.
Amending Tolerance Limits:
If a memory location already contains Tolerance Limits

data, then this information can be amended with out
clearing the previously stored information. This feature
also makes it possible to add to the averages in a limits
file over time, allowing for a greater number of welds to be
included in the average and therefore a more statistically
reliable data set.
Unallocated Memory Location – Tolerance Limits
Menu To Amend a File, highlight the Limits Name to be
amended. The file must be a current Limits file, which is
valid for use with the loaded profile. (All files with Green
text in the Associated Profile Index field are current where
all files with Red Text in the same field are no longer
valid.) When the appropriate file is highlighted, press the
“AMMEND”soft menu key. This will take to operator to the
RECORD TOLERANCE LIMITS GRAPH screen and allow
further feedback traces to be added to the average used
in setting limits on the weld feedback.
**Note** The Associated Profile Index value is displayed with the

following information for each Limits file. Profile Index Number, Pulse
Number, and Control Mode. On the screen to the left, the ASSOC. PROF
INDEX – value 001-1-I means that the Limits File LIMIT001 is configured
for Profile Index 001, Pulse 1, Current Control.
**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.
- 37 -
Recording Average or Recording Peak Limit Information:
When entering the RECORD TOLERANCE LIMITS GRAPH,

the operator will be prompted to select “RECORD
AVERAGE” or “RECORD PEAK”. The normal selection is the
“RECORD AVERAGE”function and this function should be
used when the operator is not sure which choice to select.
Record Average: This function records the feedback trace

and averages the data points after each weld providing an
average waveform over the number of recorded welds. This
will show the influence of lower and higher values in the
resulting value. Record Average / Record Peak – Tolerance
Limits
Record Peak: This function records the highest value
recorded for each point of the trace and when the test welds Making and Selecting Welds for Limits Files:
are completed will show a plot of each data point’s highest
recorded value. This option should be used when quality is The Limits file is intended to allow the operator to
primarily related to the High Limit value. determine the average waveform shape and amplitude of
the feedback information for a given weld. This means
that the unit will be able to distinguish between a weld
where there is variation in the shape of the waveform as
well as the amplitude governed by the Hi and Low Limits.
When in the RECORD TOLERANCE LIMITS GRAPH

screen, make a weld and then test the welded assembly
using the same standards that will apply to production
parts or assemblies. If the part is acceptable, then press
the “ADD TO AVERAGE”soft menu key. This will change
the feedback trace from Green to Magenta.
The Green trace represents the last weld made before it

is added to the average data. The Magenta trace
represents the average waveform as last calculated.
If a weld is not found to be acceptable, then simply make

an additional weld and then add the next good weld to the
Last Weld Feedback Trace – Record Tolerance average. If the “ADD TO AVERAGE” soft menu key is not
Limits Graph pressed, then the next weld will overwrite the previous
data.
If an error is made and a bad weld is added to the

average, then the “CLEAR AVERAGE”soft menu key can
be pressed and the data will be cleared. To avoid
accidental pressing of the “CLEAR AVERAGE”soft menu
key, the user will be prompted to confirm with a Yes or No
in a separate screen.
When the desired number of welds has been averaged,

press the “STORE” soft menu key to save the data to file.
To Exit the RECORD TOLERANCE LIMITS GRAPH,

press the “QUIT” soft menu key.
**Note** When the “RECORD PEAK” soft menu key is pressed, follow the
Average Waveform – Record Tolerance Limits procedure above substituting Peak for Average. All functions are the same
Graph in both the Record Average and the Record Peak Options.
- 38 -
Warning: Tampering with the Calibration Settings will
Unit Configuration Options: effect the performance of the unit.
Complex Options Menu Calibration:
All MacGregor units featuring the 16-bit control electronics offer

fully digital calibration. This feature removes the requirement for
the operator to open the unit and make adjustments on PCB’s.
Instead, the operator makes the adjustments in the
CALIBRATION screen.
To Enter the CALIBRATION Screen, the operator must go to

the Text profile screen and press the “CONFIG”soft menu key.
The user should then select the Complex option and press the
“CALIBRATION”soft menu key from the COMPLEX OPTIONS
MENU screen.
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 Modify an Individual Value, press the “MODIFY” soft menu

key and then select and edit the value in the normal fashion.
To Use the AutoCal Function, press the “AUTOCAL” soft

menu key and follow the procedure provided in the service
section of this manual.
To Reset the Calibration Data to default setting, press the

“RES CAL” soft menu key. This should only be done if the
previous values are recorded. The default settings are not the
calibrated settings.
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:
The READ ONLY CALIBRATION screen allows any

operator to access the calibration data without a
password. From this screen the values cannot be edited
or modified. This screen allows for a simple check of the
settings in the unit.
To View the READ ONLY CALIBRATION Screen, press

the “READ ONLY CAL”soft menu key from the
COMPLEX OPTIONS MENU.
To Exit the READ ONLY CALIBRATION Screen, press

Read Only Calibration Screen

- 39 -
Unit Configuration Options: Distribution Unit Configuration Glossary:
Complex Options Menu INPUT: Trigger Input as described in the Control
Connections section of this manual.
INDEX: User set profile for a given INPUT
PROFILE NAME: Profile name relating to selected INDEX

value.
**Note** If INDEX 000 is selected, the Input will trigger the Profile shown on
the display at time of trigger.
HEAD: Distribution Unit output (Weld Head Number) for

profile.
**Note** If HEAD 00 is selected, then no distribution output will be selected.
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.
**Note** if no distribution unit is connected, then HEAD # selection is not

Edit Mode – Distribution Configuration active.
Distribution Configuration Menu:
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.
Setting WELD HEAD Assignment for a Profile:
To set the Weld Head assignment for a profile to be used

by a Distribution Unit, go to the Pulse 1 Operating Menu for
the weld profile to be assigned to a Distribution Unit Output.
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.
Use the encoder to input the head / distribution unit

channel number desired. Press the enter key or depress
the encoder to return to Modify mode.
Be sure to save the profile with the new Weld head

information entered.
Normal Mode – Pulse1 Operating Menu
- 40 -
Fault Options Menu:
Fault Listings: The FAULT OPTIONS MENU allows the user to

program the machine actions for each type of
Pulse 1 Low Limit: This fault occurs when the monitored fault. The screen allows the user to set the
value drops below the programmed Low Limit or the machine to either Inhibit or Not Inhibit the unit
enabled Lower Tolerance Limit. The Low Limit is active after a fault and to either Display or Not Display
only during the Peak Time (T2, T6) of a weld pulse. The a fault notification screen after a fault has
Lower Tolerance Limit is active between the programmed occurred.
window settings.
The screen also allows the user to set the Low
Pulse 1 High Limit: This fault occurs when the Limit Cutout setting. This function is described
monitored variable exceeds the programmed High Limit in the Fault Listings to the left.
or the enabled Upper Tolerance Limit. The High Limit is
active for the duration of the weld pulse and the Upper To Enter the FAULT OPTIONS MENU, press
Tolerance Limit is active between the programmed the “FAULTS” soft menu key from the
window settings. COMPLEX 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.
Pulse 2 High Limit: Same as Pulse 1 High Limit but for

Pulse 2 in Dual Pulse Welds
Feedback Fault: The feedback fault occurs when the

unit is not able to output the programmed profile. This is
usually due a fault in the cabling or in the mains supply. If
a feedback fault occurs, please check all connections,
distribution configuration settings (if using distribution
unit) and the mains input.
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.
When set to Enable, the indication of a low limit fault will

terminate the weld output and then indicate the fault as
Edit Mode – Fault Options Menu
set in the 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.
- 41 -

Special Features Menu
Special Features Menu:
The Special Features Menu allows the user to access

special modes of operation or the configuration screens
for these modes of operation.
The Special Features Menu includes Fast Mode, Auto

Cycle, Operator Mode, and Operator Mode Setup.
Each of these functions is described in the following

pages including Programming and Enable / Disable
Settings for the features.
To Enter the SPECIAL FEATURES MENU, press the

“SPECIAL”soft menu key from the MAIN
CONFIGURATION MENU screen. Main Configuration Menu
To Select any of the Features Listed, press the
associated soft menu key.
To Exit the SPECIAL FEATURES MENU, press the

“EXIT” soft menu key.
- 42 -
Unit Configuration 16-bit Software Timing

Options: Single Pulse, 40mS, normal mode. Total DEAD time =
Special Features Menu 52.2mS
Initial Signal Received +- - - -
Fast Mode:
¦ 1.0mS
Input Accepted +- - - -
The Fast Mode feature is available for applications ¦ 400uS
where the trigger frequency is high. The use of Fast Start Pre-Weld Calculations +- - - -
Mode removes some of the calculation functions from ¦ 4.4mS
End Pre-Weld Calculations / Start Weld +- - - -
the welding protocol and allows the unit to weld at a ¦ 40mS (X)
higher trigger frequency. End Weld / Start Post-Weld Calculations +- - - -
¦ 46.4mS
When Enabled, the unit will not update the Display End Post-Weld Calculations +- - - -
screen and will not calculate the Energy value for the
weld. In normal mode, the unit is capable of making 1
weld every 56 + X mS. (X = total weld time:
When Disabled, the unit will perform all calculations Includes upslope, downslope, peak time)
and functions. Unless required, Fast Mode should be
Single Pulse, 40mS, fast mode. Total DEAD time =
set to OFF. 28.7mS
¦ 1.0mS
¦ 300uS
To Enable / Disable Fast Mode press the “FAST Start Pre-Weld Calculations +- - - -
MODE”soft menu key from the SPECIAL FEATURES ¦ 4.4mS
MENU screen. End Pre-Weld Calculations / Start Weld +- - - -
¦ 40mS (X)
End Weld / Start Post-Weld Calculations +- - - -
The FAST MODE SCREEN will be displayed and show ¦ 23mS
the Enabled / Disabled status. End Post-Weld Calculations +- - - -
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
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
¦ 1.0mS
¦ 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 +- - - -
- 43 -
Auto Cycle:
The Auto Cycle mode allows the user to set the

welding power supply to weld a set number of welds
at a set time interval.
**Note** This mode of operation is used to test the unit prior to

shipment. The units are run with a test load for 65,000 to 80,000
cycles to ensure the unit functions properly under load and at
operating temperature.
**Note** If 999999999 is set then the CYCLE COUNT value will

display INFINITY and will cycle until interrupted by a fault or by
pressing the Inhibit key.
Modify Mode – Auto Cycle Screen
To Initiate a Programmed Auto Cycle Sequence press

the Weld Key on the Keypad.
**Note** For normal operation, the Cycle Count
value must be set at 000000000. If a number is set,
the triggering of the weld profile will initiate the To Stop a Programmed Auto Cycle Sequence press the
Programmed Auto Cycle Sequence until the inhibit Inhibit Key on the Keypad.
key is pressed or the unit faults.
**Note** Once an Auto Cycle sequence has been initiated, the user can
scroll back to the Operating screens and observe the feedback data
generated.
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.
Enter the number of Cycles desired using the keypad.
**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.
Enter the desired Time Interval using the keypad.
**Note** The minimum recommended time interval setting is 10 mS.
- 44 -
Operator Mode:
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.
When Entering or Exiting Operator Mode, the user is

required to enter the user set password when prompted
unless Password Protection is set to DISABLE.
To Enable (Enter) Operator Mode, press the

“OPERATOR MODE” soft menu key from the SPECIAL
FEATURES MENU screen.
The user will be prompted to enter the user set password

and will be prompted to confirm the action by selecting
YES or NO as appropriate.
To Disable (Exit) Operator Mode, press the “EXIT” soft

menu key from the Operator Mode Profile screen. The
user will be prompted to enter the user set password.
Single Pulse Profile – Operator Mode Modifying Single Pulse Variables:
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.
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.
**Note** When entering Operator

Mode, the user is required to enter
the User Set Password.
**Note** When exiting Operator

Mode, the user is required to enter
the User Set Password. This
ensures that unauthorised operators
do not have access to the full menus
and profile options.
Are You Sure Screen Enter User Set Password –

Password Mode
- 45 -
Modifying Dual Pulse Variables:
To Modify a Variable in Operator Mode, press the

“MODIFY”soft menu key from the Operator Mode Profile
screen.
Use the encoder to select the variable to be modified and

press the enter key or depress the encoder to edit the
selected value.
Use the encoder or the keypad to enter the desired value.

or depress the encoder to return to Modify Mode.
To Save Changes made to the profile, press the “SAVE”

soft menu key and follow standard profile saving steps.
Weld Active Indicator flashes during
To Return to Normal Mode, press the “EXIT MODIFY” each weld.
soft menu key.
Operator Programmable Variables (Dual Pulse

Profile – Operator Mode):
Profile: See following pages for details on selecting

profiles and loading authorised profiles.
Pulse 1 Peak Value: The user is able to modify the

Pulse 1 Peak value set for the profile.
Pulse 2 Peak Value: The user is able to modify the

Pulse 2 Peak Value
Pulse 1 High Limit: The user is able to modify the

Pulse 1 High Limit value
Pulse 1 Low Limit: The user is able to modify the

Pulse 1 Low Limit Value.
Pulse 2 High Limit: The user is able to modify the Edit Mode – Operator Screen - (Dual Pulse
Pulse 2 High Limit Value. Profile)
Pulse 2 Low Limit: The user is able to modify the

Pulse 2 Low Limit Value.
**Note** Changes made can be saved using the “SAVE” feature on

the screen.
- 46 -
Loading a Selected Profile (Operator Mode):
When in Operator Mode, the user can only load profiles

selected for use in the Operating Mode Setup screen.
The procedure for selecting, and modifying profiles to
be made available for the operator is listed below.
To Load a Profile, press the “MODIFY”soft menu key

from the Operator Mode Profile screen. Use the
encoder to highlight the PROFILE variable and press
enter or depress the encoder to select a profile to load.
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.
Operator Mode Setup Screen:
The Operator Mode Setup Screen allows the user

(Supervisor Only – No access from Operator Mode)
to program which profiles are accessible when in
Operator Mode.
To view the OPERATOR MODE SETUP SCREEN,

press the “OPERATOR SETUP” soft menu key from
the SPECIAL FEATURES MENU screen.
To Insert a Profile, press the “INSERT” soft menu

key and a new profile will occur. Insert the number
of profiles that are to be made available to the
operator.
Operator Mode Setup Screen
To Program the Available Profiles, use the
encoder to highlight a Profile Name and press enter
or depress the encoder to edit the profile. Rotate the
encoder to select the desired profile. When the
desired profile is displayed on the screen, press the
enter key or depress the encoder to confirm the
selected profile.
To Remove a Profile, use the encoder to highlight

the unwanted Profile Name and press the
“REMOVE” soft menu key.
**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.
To Exit the OPERATOR MODE SETUP SCREEN,

Insert Profile – Operator Mode Setup Screen
- 47 -
Pattern Welding Options
Pattern Welding Option:
Pattern Welding allows the user to profile a number of

profiles in a set order and then set the unit to index through
the selected profiles when triggering. The feature is designed
for applications where a single head makes a number of
different welds in sequence. The use of the Pattern Welding
Option allows for individual profiles to be set for each weld.
Up to 99 Patterns can be configured and stored in the

welding power supply. This allows the user to configure a
number of products or welding sequences that can easily be
recalled and utilised.
Patterns Menu (Modify Patterns)
In standard systems, Patterns can only be loaded for use
with a single welding head.
Custom systems are available allowing individual operators

to load a pattern for each output of the distribution unit and
also provide individual
Operator Displays so
changes can be made
from each station.
To Modify a Pattern
File, go to the LOAD
menu and press the
“MODIFY PATTERN”soft
menu key.
Select a Pattern to Modify

using the encoder. When Load Menu Modify Pattern Profiles Menu
the desired Pattern is
highlighted, press the Modify Pattern Profiles Menu: Once in the MODIFY
“MODIFY”soft menu key. PATTERN PROFILES MENU, the user is able to insert,
remove, or edit the pattern file.
Follow the instruction for
inserting, removing, and To Build a New Pattern or Insert a Profile, press the
editing profiles in a “INSERT”soft menu key and a new profile will appear. Use
Pattern file. the rotary function of the encoder to select the desired profile
and press the enter key or depress the encoder to confirm
the selection.
**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.
To Remove a Profile, highlight the profile to be removed

using the encoder and press the “REMOVE” soft menu key.
This will remove the selected profile from the pattern.
Editing Profiles in Existing Patterns: Use the encoder to

highlight the Profile Name of a profile in the pattern and
press the enter key or depress the encoder to edit the profile
name. Using the encoder, scroll through the Profiles and
select the desired profile by pressing the enter key or
Insert Profile – Modify Pattern Profiles Menu depressing the encoder when the desired profile is displayed
- 48 -
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.
Viewing a Pattern File:
To View a Pattern before Loading, highlight the pattern to be viewed

and press the “VIEW” soft menu key. The selected pattern will then be
displayed. No changes can be made to the pattern from this screen. To
change pattern information, follow the instructions for Modifying a
Pattern found on the previous page.
When Viewing a Pattern, the PATTERN PROFILES MENU will be

displayed. To exit this screen and return to the PATTERNS MENU,
Load Pattern – Patterns Menu
Screen Refresh Option for Pattern Welding:
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.
- 49 -
Active Pattern Screens and Functions:
When a Pattern is loaded, the soft menu key functions

are changed to allow the user to navigate through the
profiles in the Pattern and to set the Index Location in
the Pattern to any given point in the Pattern.
Pattern Name Display:
The Pattern Name Display shows the name of the

Loaded Pattern. In the Operating Graph, the Pattern
name is shown in the PATTERN value. In the
Operating Menu, the Pattern name is shown in the PATTERN001 Loaded – Pulse 1
PATTERN FILE value. Operating Graph
Manual Pattern Indexing:
To Index through the profiles in a pattern while in the

Operating Graph or Menu, press the “MODIFY”soft
menu key. Use the encoder to highlight the PROFILE
or CURRENT PROFILE value and press the enter key
or depress the encoder to Edit the Index Location. Use
the encoder to scroll through the profiles in the loaded
pattern.
Set Index Location:
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.
Toggle Profile / Set Index – Pulse 1 Operating

Graph (PATTERN001 Loaded)
- 50 -
Pattern Monitor:
The Pattern Monitor is a screen that allows a user to view

the profiles in a pattern and monitor the progression
through the pattern while welding.
The current profile is indicated by the Pattern Location

Indicator.
**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.
To View the Pattern Monitor, go to the WELD

INFORMATION SCREEN when a Pattern is loaded. Press
the “PATT MON” soft menu key.
To Exit the Pattern Monitor, press the “EXIT” soft menu

key. The display will return to the WELD INFORMATION PATTERN001 Loaded – Weld Information Menu
MENU screen.
Pattern Location Indicator:
The Pattern Location Indicator is shown using a

yellow outline box. The box shows the next profile
to be used in the pattern. This feature allows the
user to monitor the progression through the pattern
while welding.
Manual Pattern Indexing:
In the Pattern Monitor, the user is able to set the index

location to any point in the pattern. The highlighted
profile is the next profile in the pattern when in Normal
mode.
Set Index Location:
To set the Index Location to a new point in the Pattern,

press the “MODIFY”soft menu key. Use the encoder
to move the yellow outline box to the desired profile.
Press the “SET INDEX” soft menu key.
When the Index Location is Set, the unit will return to

Normal Mode and the Pattern will continue from the
set point.
To Exit the Pattern Monitor, press the “EXIT” soft

menu key. The display will return to the WELD
INFORMATION SCREEN. PATTERN001 Loaded – Pattern Monitor
- 51 -
Conditioning Pulse:
Automatic Part
Conditioning (APC)
To be released in Q2 2001
- 52 -
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.
Typical process changes maybe
1. An electrode change; dirty or damaged electrodes

2. Dimensional changes in product
3. Material quality, e.g. Oxide layer, substrate thickness etc..
4. Faulty weld heads
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
Check / Symptom Reasons Remedy

Is the power on indicator This LED illuminates to show the Check rear panel fuse (if fitted).
illuminated ? machine is ON and that the internal Disconnect ALL external connections.
+24VDC supply is functioning (It is quite common for external wiring
faults to cause the +24VDC supply to
be overloaded)
Check mains fuse
Check mains supply to machine
Is the Colour TFT display The machine display will illuminate Check rear panel fuses
illuminated? ONLY if the +15V internal supply is Check mains supply to machine
good Check mains fuse
Machine is on, but no output The machine output will be inhibited if Clear the fault & inhibit
the machine overheats or suffers a Allow machine to cool down and
feedback fault. investigate reasons for over heating
Check output connections.
Machine is on, but no output Loss of output maybe caused by either If using distribution, disconnect the
(using distribution electronics) the power supply or the distribution distribution electronics and connect a
electronics load across the welder directly. Try a
sample weld pulse.
Machine continually produces a This occurs when the machine loses the A quick check for voltage sensing
HARDWARE/FEEDBACK fault measurement feedback used for control feedback is to try a weld with internal
- The most common problem is broken sensing by disconnecting the leads
voltage feedback wires. and fitting links or by unplugging the
voltage sensing jack socket.
Similar faults also occur when
electrodes have been replaced or Check electrode contact
modified incorrectly.
Machine continually produces a The fault must be traced to either the If using distribution, disconnect the
HARDWARE/FEEDBACK fault power supply or the distribution distribution electronics and connect a
(using distribution electronics) electronics. load across the welder directly. Try a
sample weld pulse.
- 53 -
Fault Finding
Check / Symptom Reasons Remedy

No RS232 communication Problems generally occur with Check connections, particularly Tx &
incorrect wiring or incompatible Rx
software
Machine continually exceeds Often caused by variations in Run several trial welds and check
upper or lower limits electrode, particularly when new electrode alignment.
Operate machine in constant current

mode in order to rule out voltage
feedback problems.
Locate cause of voltage feedback

problem
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
Fault Description Remedy

ERROR 1 FEEDBACK FAULT. Check connections
FAULT 2 PULSE 1 UNDER LOW LIMIT Check Limit Settings
FAULT 3 PULSE 1 FAILED BOTH LIMITS Check Limit Settings
FAULT 4 PULSE 1 OVER HIGH LIMIT Check Limit Settings
FAULT 5 PULSE 2 UNDER LOW LIMIT Check Limit Settings
FAULT 6 PULSE 2 FAILED BOTH LIMITS Check Limit Settings
FAULT 7 PULSE 2 OVER HIGH LIMIT Check Limit Settings
FAULT 8 PULSE 1 UNDER LOW LIMIT AND PULSE 2 UNDER LOW LIMIT Check Limit Settings
FAULT 9 PULSE 1 UNDER LOW LIMIT AND PULSE 2 FAILED BOTH LIMITS Check Limit Settings
FAULT 10 PULSE 1 UNDER LOW LIMIT AND PULSE 2 OVER HIGH LIMIT Check Limit Settings
FAULT 30 PULSE 1 OVER HIGH LIMIT AND PULSE 2 OVER HIGH LIMIT Check Limit Settings
FAULT 31 PULSE 1 FAILED BOTH LIMITS AND PULSE 2 OVER HIGH LIMIT Check Limit Settings
FAULT 32 PULSE 1 FAILED BOTH LIMITS AND PULSE 2 UNDER LOW LIMIT Check Limit Settings
FAULT 33 PULSE 1 FAILED BOTH LIMITS AND PULSE 2 FAILED BOTH LIMITS Check Limit Settings
FAULT 34 PULSE 1 OVER HIGH LIMIT AND PULSE 2 UNDER LOW LIMIT Check Limit Settings
FAULT 35 PULSE 1 OVER HIGH LIMIT AND PULSE 2 FAILED BOTH LIMITS Check Limit Settings
FAULT 36 PRE WELD VOLTAGE SENSING TEST FAILED. CHECK Check VS leads
CONNECTION OF VOLTAGE SENSING LEADS.
- 54 -
Fault Finding
Screen Warnings
Fault Description Remedy

WARNING Be sure to check the
TOTAL PULSE TIME EXCEEDS 100MS. ENSURE PEAK power level is within
DEMAND IS SET TO A REASONABLE VALUE TO PREVENT the duty rating
ANY DAMAGE TO THE POWER SUPPLY
WARNING Check wiring/mains
THREE PHASE FAILURE DETECTED. CONTACT SERVICE
ENGINEER IMMEDIATELY
WARNING Check control cables
OUTPUT INHIBITED. and circuit breakers
WARNING Check that the fans
OUTPUT STAGE TEMPERATURE ERROR. are operating and that
the vents are not
obstructed
OUTPUT TRANSFORMER TEMPERATURE ERROR. are operating and the
(M3-40/M3-60 ONLY) vents are not
obstructed
OUTPUT STAGE AND OUTPUT TRANSFORMER are operating and the
TEMPERATURE ERRORS. vents are not
obstructed
MAIN TRANSISTOR TEMPERATURE ERROR. are operating and the
vents are not
obstructed
- 55 -
Machine Specifications
DC601P
Maximum output current 1% Duty (10 ms Pulse) 1000A

5% Duty (50 ms pulse) 600 A
Maximum output voltage at full supply 4 VDC
Maximum output power 4 kW
Duty Cycle 1000Amps 1% (10ms per second)

600 Amps 5% (50ms per second)
Output characteristics Constant current

(pulse 1 & pulse 2) Constant voltage
Constant power
RS232: baud rate 9600
Upslope time 0.1 – 999.9mS

Peak time 0.1 – 999.9mS
Downslope time 0.1 – 999.9mS
Accuracy within 1%
Output ripple less than 1%
Cooling Air-cooled with over

temperature protection
Data retention Memory backup

10-years
Dimensions
Vertical Width 190mm

Depth 400mm
Height 400mm
Horizontal Width 400mm

Depth 400mm
Height 190mm
Input voltage & frequency Refer to Identification

Plate on Rear of Machine
- 56 -
DC1001P
Maximum output current 1000 Amps
Maximum output power 4 kW
Duty Cycle 5% (50ms per second)

Constant power

Accuracy within 1%


10-years
Dimensions

Depth 400mm
Height 400mm

Depth 400mm
Height 190mm

for Details
- 57 -
DC1801P
Maximum output current 1800A
Maximum output power 10.8 kW
Duty Cycle 5% (50ms per second)

Constant power

Accuracy within 1%


10-years
Dimensions

Depth 560mm
Height 445mm

Depth 560mm
Height 220mm

for Details
- 58 -
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:
TEST POINT INFORMATION
TP1 Power Feedback

TP2 Voltage Feedback
TP3 Current Feedback
TP4 -15V
TP5 +12V
TP6 AGND
TP7 +15V
TP8 Reference
TP9 Error
TP10 Drive
TP11 Fault Status
TP12 Set Fault/Reset
TP13 AGND
TP14 -15V
TP15 +15V
LINKS
All links are factory set and

should not be tampered with
Within the machine there is one display PCB. Key items are identified as follows :-
SOFTWARE UPGRADES
Software upgrades involve

changing U11/U12 on the display
PCB and U4/U5 on the control
PCB.
Full details are provided if you

upgrade.
- 59 -
Service Information
Advanced Detail
Power Supply Board
Test Point Listing:
TP1: +15v
TP2: 0v
TP3: -15v
TP4: +15v unregulated
TP5: 0v (+15v unregulated)
TP6: +24v unregulated
TP7: 0v (+24v unregulated)
- 60 -
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.
- 61 -
Service Information
CALIBRATION METHOD
To perform a calibration, it is recommended that the operator use a calibrated DVM or oscilloscope and a calibrated
shunt.
The calibration menu appears as follows :-
CALIBRATION
DAC 1 X 000 DAC 2 Y 000 (1)

DAC 3 Z 000 DAC 4 L 000 (2)
VGAIN 0.0000 VOFFS 00.00 VPOL + (3)

IGAIN 0.0000 VOFFS 0000 VPOL + (4)
PGAIN 0.0000 VOFFS 0000 VPOL + (5)
REF1 V 00.00 I 00000 P 00000 (6)

REF2 V 00.00 I 00000 P 00000 (7)
PK VAL 00000 PK CONT I (8)

MEAS PK 00000.0 MESCONT I (9)
ADJ PK 00000.0 AD GAIN 1.0000 (1
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
It is assumed that these values are correct prior to calibration.
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.
- 62 -
Service Information
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
Set PK_CONT to V for voltage control.

Set PK_VAL to a low reasonable value.
Set MESCONT to I for current feedback.
Perform a weld.
If the feedback value MEAS_PK is within limits then increase the demand.
If the weld faults due to a feedback fault or high limit fault then reduce the demand.
Repeat this stage until you have a high value for voltage control that doesn't fault.
Set the REF2 (high) V value to this value.
Set the REF1 (low) V value to a small value that gives useable feedback.
Stage 3
Set PK_CONT to I for current control.

Set MESCONT to V for voltage feedback.
Perform a weld.
Repeat this stage until you have a high value for current control that doesn't fault.
Set the REF2 (high) I value to this value.
Set the REF1 (low) I value to a small value that gives useable feedback.
Stage 4
Set PK_CONT to P for power control.

Set MESCONT to I for current feedback.
Perform a weld.
Repeat this stage until you have a high value for power control that doesn't fault.
Set the REF2 (high) P value to this value.
Set the REF1 (low) P value to a small value that gives useable feedback.
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
Connect the calibrated oscilloscope across the known load.

Press 'AUTOCAL'.
- 63 -
Service Information
The button options on the left of the screen will change such that the only option is the exit from AutoCal. A text box will
appear with 'AUTOCAL' written in green on a magenta background. Another text box will appear with a red numerical
value written on a yellow background. This value is unimportant and should be ignored.
Stage 7
The feedback value in volts is now displayed in MEAS_PK.

It should be similar (or the same) as the value recorded on the oscilloscope.
If the oscilloscope did not capture the weld it can be repeated at this stage by simply pressing the weld button.
When a suitable trace is visible on the oscilloscope type in the voltage value using the numerical keys.
This value will appear in the red-on-yellow text box.
When the value is entered correctly press 'ENTER' to accept it.
The feedback calibration is now complete and the ADGAIN value will be calculated and set by the software.
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.
- 64 -
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.
The calibration menu appears as follows :-
DAC1 X 000 DAC2 Y 000 (1)

DAC3 Z 000 DAC4 L 000 (2)
VGAIN 1.0000 VOFFS 00.00 (3)
VPOL + (4)
IGAIN 1.0000 IOFFS 0000 (5)
IPOL + (6)
PGAIN 1.0000 POFFS 0000 (7)
PPOL + (8)
PkVAL 00000 PKCONT V (9)
MEAS PK 1.0000 MESCONT V (10)
ADJ PK 1.0000 ADGAIN 1.0000 (11)
- 65 -
Service Information
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
It is assumed that these values are correct prior to calibration.
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.
Set a 300A output peak by setting 00300.
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
Modify the PKVAL to 00600 to perform a 600A weld. Repeat step 4.
- 66 -
Service Information
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.
Current measured at 300A = 316A

Current measured at 600A = 626A
The calibration relies on solving the following two equations.
Demand(1) = [ (Current Out)(1) * IGAIN ] + IOFFS (a)

Demand(2) = [ (Current Out)(2) * IGAIN ] + IOFFS (b)
To solve the equation, first substitute the known values.
300 = (316*IGAIN) + IOFFS (c)

600 = (626*IGAIN) + IOFFS (d)
Take the lowest equation from the highest equation to get: 300 = (310*IGAIN)
Therefore IGAIN = (300 / 310) IGAIN = 0.9677
Now substitute the IGAIN value into (c)
300 = (316 * 0.9677 ) + IOFFS
Therefore IOFFS = 300 - (316 * 0.9677 ) IOFFS = -5.8
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.
- 67 -
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.
Basic Resistance Welding Guidelines
1. Primary process variables
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.
- 68 -
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.
- 69 -
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.
- 70 -
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
First Pulse Second Pulse
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.
1. Constant Current Control
Constant current control welding Voltage Profile with Clean Component

offers a controlled current profile to
be output by the MacGregor power
supply. The programmed current
demand waveform is maintained
through analogue monitoring of the
Current Profile with Clean Component
output using a current shunt and a
reference waveform. The signals
are fed into a fast response
comparison circuit and any
variation is corrected in near real
time. The voltage output of the
power supply is adjusted and remains dynamic in order to maintain the current output that was programmed. The use
of Linear DC or Hybrid HFDC control allows for a rapid detection and response to any process or load changes.
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.
- 71 -
2. Constant Voltage Control
Constant voltage control

Current Profile with Low Joint Resistance is used to maintain a set
voltage across the
electrodes during a weld.
Voltage Output Profile The benefit of constant
voltage is seen in the
ability of this control
Current Profile with High Joint Resistance
method to eliminate
large inrushes of current
when high resistance
conditions exist at the
onset of the weld.
Constant voltage is also
ideally suited for use in parallel gap applications, were the current flow must be controlled by the breakdown of the
resistance of the circuit as the weld is effected. Another benefit of constant voltage control is realised because the
sensing point is located at the electrodes. This effectively removes any inconsistencies in the weld cables and the
interconnections that occur outside of this area. The use of voltage control can overcome weld splash, but can yield
cold welds due to insufficient weld energy. In these cases, current is low due to the increased resistance. The set
voltage may be insufficient to break through oxide films.
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.
3. Constant Power Control
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.
In most welds, the initial resistance is high due to contact

interfaces in the joint. This high resistance typically requires a
higher voltage level to overcome these barriers than is
Voltage Profile necessary for accomplishing the weld joint itself. The primary
benefit of power control is realised as the voltage applied can
Power Output Profile be dictated by the state of the material interfaces. A common
problem seen when welding in constant voltage mode occurs
Current Profile
when the programmed voltage is not high enough to break
down the barriers fast enough to form a good weld joint. This
problem can be eliminated when power control is employed.
The use of a constant power pulse allows the voltage and current levels to be flexible. Due to this functionality, the
presence of a high initial contact resistance can be overcome by a higher amplitude voltage level from the onset while
the welding power supply is able to actively monitor and adjust to the changing conditions in the weld. This monitoring
ability allows for the MacGregor power supply to raise the current level and lower the voltage level being introduced to
the weld joint as the resistances break down.
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:
- 72 -
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.
- 73 -
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.
- 74 -
Manufacturer’s Information
Manufacturer’s Contact
Information
MacGregor Welding Systems Ltd
Main Office (United Kingdom):
69 Fred Dannatt Road

Mildenhall
Suffolk, IP28 7RD
United Kingdom
Phone: +44 (0)1638 510011
Fax: +44 (0)1638 510329
Email:
General: enquiries@macgregor-systems.co.uk
Service: techsupport@macgregor-systems.co.uk
Sales: sales@macgregor-systems.co.uk
Web Site: www.macgregor-systems.co.uk
Benelux Office (The Netherlands):

Phone: +31 492 538 597
Fax: +31 492 538 597
Email: treinders@macgregor-systems.co.uk
Web Site: www.macgregor-systems.co.uk
- 75 -

MacGregor Welding Systems Operation Manual - DC601P DC1001P DC1801P

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MacGregor Welding Systems, Ltd.

DC601P, DC1001P, DC1801P

MWS Part Number 961-00017

Getting Started Guide Power On and Verification 7

I/O Listings and Signal Diagrams 9

The User Interface Keypad Layout and Function 14

Basic Control Options Loading a Profile from Memory 16

Advanced Control Unit Configuration – System Options Menu 28

Trouble Shooting Guide Basic Trouble Shooting Procedures 53

Machine Specifications DC601P, DC1001P, DC1801P 56

Service Information PCB Diagrams with Primary Components Labelled 59

Principles of Resistance Basic Resistance Welding Theory 68

DO NOT Operate Machine Without Covers

Customer Specific Options:

37 Way Connector - Multiple Fuses

Power On / +24V Status Indicator Mains Switch

Power On / +24V Status Indicator

Power On and Verification

Turning the Power On:

When the unit is connected to a suitable mains

To turn on the unit, the mains switch must be

Once in the on position, the display should turn

When the display and control PCB have

Performing a Test Weld: Pulse 1 Operating Graph at Start Up

If a fault screen is displayed after the test weld is made then

If a Feedback fault is indicated, then the cables and

If a High Limit Fault was indicated, then there is a problem

After successfully completing a test weld, the unit can be

Notation of Factory Calibration Values

It is recommended that the factory calibration

To read the calibration values set in the unit, follow

Press the “TEXT” soft menu key to display the Pulse

VGain: ________ VOffs: ________

Weld Pulse Typically, the collector

Rear Panel Connections - Optional DS Isolated Interface

These are summarised below.

Output Code Fault Description

1 Pulse 1 High Limit

2 Pulse 1 Low Limit

3 Pulse 2 High Limit

4 Pulse 2 Low Limit

5 Low Limit Pulse 1 and High Limit Pulse 2

6 Low Limit Pulse 1 and Low Limit Pulse 2

7 High Limit Pulse 1 and Low Limit Pulse 2

8 High Limit Pulse 1 and High Limit Pulse 2

9 Output Stage Temperature Error

10 24 VDC Error (Missing 24 VDC)

11 Missing Input Phase(s) (Only Active on DC1001P / DC1801P)

12 Missing Voltage Sensing Lead

The m3 25 Way D type connector

Connections are as follows;

Connecting a typical PC to the M3 Welding Power Supply

Comms signal 25-pin 9-pin Connection 25-pin connector ‘b’

15W D Type (Skt 'B')

The user interface is based upon

The display and keypad are available in two formats.

The portrait version of the display is used in the vertical

Alpha Numeric Keypad

User Interface Component Descriptions

To Load a Profile from Memory:

From the Pulse 1 Operating Graph or the Pulse 1

From this menu, press the “LOAD PROFILE” soft

Select a profile to load. The initial screen displays

VGain: VOffs:

Note The “P1” and “P2” soft

Note The “PATT MON”soft menu key is only active