Amada DC25 User manual

990-660 REV G
LINEAR DC RESISTANCE WELDING CONTROL
DC25
OPERATION MANUAL

MODEL DC25 LINEAR DC RESISTANCE WELDING CONTROL
ii 990-660
Copyright © 2001, 2013 - 2017 Amada Miyachi America
The engineering designs, drawings and data contained herein are the proprietary
work of Amada Miyachi America and may not be reproduced, copied, exhibited
or otherwise used without the written authorization of Amada Miyachi America.
Printed in the United States of America.
REVISION RECORD
Revision EO Date Basis of Revision
A 18122 12/01 Original Release
B 19166 12/01 Energy Capacity % Limit change.
C 21594 10/07 Updated Technical Specifications.
D 42840 10/13 Updated to Miyachi America name and logo.
E 43480 11/14 Updated to Amada Miyachi America name and logo.
F 43838 08/15 Updated to Amada Miyachi America format.
G 44640 05/17 Removed Reference to Weldstat Software

MODEL DC25 LINEAR DC RESISTANCE WELDING CONTROL
990-660 iii
FOREWORD
Thank you for purchasing a Miyachi UnitekDC25 Linear DC Welding Control.
Upon receipt of your equipment, please thoroughly inspect it for shipping damage prior to its
installation. Should there be any damage, please immediately contact the shipping company to file a
claim, and notify us at:
Amada Miyachi America
1820 South Myrtle Avenue
P. O. Box 5033
Monrovia, California 91016
Phone: [phone]
FAX: [phone]
E-mail: [email protected]
The purpose of this manual is to supply operating, maintenance and service personnel with the
information needed to properly and safely operate, maintain and service the DC25 Linear DC Welding
Control.
We have made every effort to ensure that the information in this manual is accurate and adequate.
Should questions arise, or if you have suggestions for improvement of this manual, please contact us at
the above location/numbers.
Amada Miyachi America is not responsible for any loss due to improper use of this product.

MODEL DC25 LINEAR DC RESISTANCE WELDING CONTROL
iv 990-660
SAFETY NOTES
This instruction manual describes how to operate and maintain the DC25 Linear DC Welding Control
and provides instructions relating to its SAFE use. Procedures described herein MUST be performed,
as detailed, by QUALIFIED and TRAINED personnel.
For SAFETY, and to effectively take advantage of the full capabilities of the workstation, please read
this instruction manual before attempting to use the DC25 Linear DC Welding Control.
Procedures other than those described in this manual, or not performed as prescribed in it, may expose
personnel to electrical hazards.
After reading this manual, retain it for future reference when any questions arise regarding the proper
and SAFE operation of the unit.
Please note the following conventions used in this manual:
WARNING: Comments marked this way warn the reader of actions which, if not followed, might
result in immediate death or serious injury.
CAUTION: Comments marked this way warn the reader of actions which, if not followed, might result
in either damage to the equipment, or injury to the individual if subject to long-term exposure to the
indicated hazard.

MODEL DC25 LINEAR DC RESISTANCE WELDING CONTROL
990-660 v
Table of Contents Page
Chapter 1: Description ................................................................................................................1-1
Section I: Introduction ................................................................................................................1-1
Features .....................................................................................................................................1-1
Applications ..............................................................................................................................1-2
Section II: Description .................................................................................................................1-3
Section III: Overview ....................................................................................................................1-4
Introduction ..............................................................................................................................1-4
LCD Screens .............................................................................................................................1-4
Menu Screens .................................................................................................................................1-5
Data Screens ...................................................................................................................................1-5
Alphanumeric Data ...................................................................................................................1-5
Operational States .....................................................................................................................1-5
Graphed Data ............................................................................................................................1-7
Section IV: Controls And Indicators ............................................................................................. 1-8
Introduction ..............................................................................................................................1-8
Liquid Crystal Display (LCD) And Weld Selector Keys ......................................................... 1-8
Numeric Keypad And Operational Controls ..........................................................................1-10
Section V: Emergency Stop Switch And 24V Jumpers .............................................................1-13
Section VI: Related Publications ................................................................................................. 1-14
Chapter 2: Getting Started .........................................................................................................2-1
Section I: Planning For Installation ............................................................................................ 2-1
Space Requirements .................................................................................................................2-1
Utilities .....................................................................................................................................2-1
Section II: Unpacking ..................................................................................................................2-2
Section III: Electrical And Data Connections ...............................................................................2-3
Section IV: Setup ...........................................................................................................................2-5
Manual Weld Head Connections ..............................................................................................2-5
Air-Actuated Weld Head Connections......................................................................................2-7
Relay, Data, And Communication Connections ....................................................................... 2-8
Chapter 3: Using DC25 Welding And Monitoring Functions .................................................3-1
Section I: Introduction ................................................................................................................3-1
Section II: Weld Schedules ..........................................................................................................3-2
Definition ..................................................................................................................................3-2
Weld Sequence Timing ............................................................................................................3-2
Welding Applications ...............................................................................................................3-3
Weld Head Applicability ..........................................................................................................3-3
Single-Pulse Weld Profile ........................................................................................................3-4
Applications ......................................................................................................................3-4
Description ........................................................................................................................3-4

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vi 990-660
Table of Contents (Continued)
Page
Upslope/Downslope Weld Profile Applications ......................................................................3-4
Applications ......................................................................................................................3-4
Description ........................................................................................................................3-4
Dual-Pulse Weld Profile ...........................................................................................................3-5
Applications ......................................................................................................................3-5
Description ........................................................................................................................3-5
Section III: Programmable Feedback Modes ................................................................................3-7
Introduction ..............................................................................................................................3-7
Current Mode ............................................................................................................................3-7
Applications ......................................................................................................................3-7
Description ........................................................................................................................3-7
Voltage Mode ...........................................................................................................................3-7
Applications ......................................................................................................................3-7
Description ........................................................................................................................3-7
Power Mode ..............................................................................................................................3-7
Applications ......................................................................................................................3-7
Description ........................................................................................................................3-7
Section IV: Weld Monitor .............................................................................................................3-8
Introduction ..............................................................................................................................3-8
Active Part Conditioner (APC) ................................................................................................3-8
Applications ......................................................................................................................3-8
Description ........................................................................................................................3-8
How It Works ....................................................................................................................3-9
Instructions .............................................................................................................................3-10
Energy Limits ................................................................................................................................3-10
Applications ....................................................................................................................3-10
Description ......................................................................................................................3-10
Pre-Weld Check .............................................................................................................................3-11
Application ......................................................................................................................3-11
Function ...........................................................................................................................3-11
Chapter 4: Operating Instructions ............................................................................................4-1
Section I: Introduction ................................................................................................................4-1
Section II: Initial Setup ................................................................................................................4-2
Pre-Operational Checks ............................................................................................................4-2
Connections .......................................................................................................................4-2
Power .................................................................................................................................4-2
Compressed Air .................................................................................................................4-2
Initial Setup Instructions ...........................................................................................................4-2

MODEL DC25 LINEAR DC RESISTANCE WELDING CONTROL
990-660 vii
Page
Section III: Programming Weld Schedules ................................................................................... 4-3
Introduction ..............................................................................................................................4-3
Select A Weld Schedule ....................................................................................................4-3
Enter New Values .............................................................................................................. 4-3
Single-Pulse Weld Schedule .....................................................................................................4-4
Upslope/Downslope Weld Schedule ........................................................................................4-5
Dual-Pulse Weld Schedule .......................................................................................................4-6
Section IV: Programming The Weld Monitor ...............................................................................4-7
Section V: Programming For Active Part Conditioning ............................................................4-10
Section VI: Operation .................................................................................................................. 4-12
General Operator Safety .........................................................................................................4-12
Manual Welding .....................................................................................................................4-12
Operation .........................................................................................................................4-12
Normal Stop ....................................................................................................................4-12
Automated Welding ................................................................................................................4-12
Operation .........................................................................................................................4-12
Normal Stop ....................................................................................................................4-13
Emergency Stop ..............................................................................................................4-13
Re-Set After Emergency Stop .........................................................................................4-13
Chapter 5: Setup Software ..........................................................................................................5-1
Section I: Introduction ................................................................................................................5-1
Overview ..................................................................................................................................5-1
Section II: How To Use Menu Screens .......................................................................................5-2
Main Menu ...............................................................................................................................5-2
Setup Menus .............................................................................................................................5-2
Section III: Operator Preferences ..................................................................................................5-4
Display Contrast .......................................................................................................................5-4
Buzzer Loudness ......................................................................................................................5-4
End Of Cycle Buzzer ................................................................................................................5-4
Update Graph After Weld ........................................................................................................ 5-5
Buzzer On Weld Stop ...............................................................................................................5-5
Section IV: System Settings ..........................................................................................................5-6
Waveform Check And Weld Fire Lockout ..............................................................................5-6
Waveform Check ON/OFF ...............................................................................................5-6
Stability Check % Limit Setting ........................................................................................5-6
Stability Check Delay Setting ...........................................................................................5-7
Energy Capacity % Limit Setting ......................................................................................5-7
Weld Fire Lockout Charge % Setting ............................................................................... 5-8
Footswitch Weld Abort ............................................................................................................5-8
Switch Debounce Time ............................................................................................................5-9
Firing Switch ............................................................................................................................5-9

MODEL DC25 LINEAR DC RESISTANCE WELDING CONTROL
viii 990-660
Table of Contents (Continued)
Page
Input Switch Select .................................................................................................................5-10
Mechanical Selection ......................................................................................................5-10
OPTO Selection ...............................................................................................................5-11
PLC Selection .................................................................................................................5-11
Control Signals Select ............................................................................................................5-12
Weld Counter Functions .........................................................................................................5-12
System Security ......................................................................................................................5-13
Calibration ..............................................................................................................................5-14
Chain Schedules .....................................................................................................................5-14
Section V: PID Test Weld Setup ................................................................................................5-17
Overview ................................................................................................................................5-17
Do Test Weld Options ............................................................................................................5-17
Ignore First/Last .....................................................................................................................5-18
Section VI: Relay Settings ..........................................................................................................5-19
Function ..................................................................................................................................5-19
Programming Instructions ......................................................................................................5-19
Section VII: Special Functions .....................................................................................................5-21
Copy A Schedule ....................................................................................................................5-21
Reset Defaults .........................................................................................................................5-21
Reset System Parameters ................................................................................................ 5-23
Reset All Schedules .........................................................................................................5-23
Section VIII:Communication And Data ....................................................................................... 5-24
Requirements ..........................................................................................................................5-24
Communication ......................................................................................................................5-24
I.D. Number ............................................................................................................................5-25
Baud Rate ...............................................................................................................................5-25
Chapter 6: User Maintenance ....................................................................................................6-1
Section I: Precautions .................................................................................................................6-1
Section II: Operator Maintenance ................................................................................................6-1
Section III: Troubleshooting .........................................................................................................6-1
General Kinds of Problems ......................................................................................................6-1
Soft ....................................................................................................................................6-1
Hard ...................................................................................................................................6-2
Alarm Messages .......................................................................................................................6-2
Troubleshooting ........................................................................................................................6-2
Technical Assistance ................................................................................................................6-5
Electrode Maintenance .............................................................................................................6-5
Parts Replacement ....................................................................................................................6-6

MODEL DC25 LINEAR DC RESISTANCE WELDING CONTROL
990-660 ix
Page
Chapter 7: Calibration ................................................................................................................7-1
Section I: Introduction ................................................................................................................7-1
Overview ..................................................................................................................................7-1
Calibration Equipment Required .............................................................................................. 7-1
Calibration Points .....................................................................................................................7-2
Section II: Calibration Equipment Setup .....................................................................................7-3
Section III: Calibration Procedure ................................................................................................7-4
Appendix A: Technical Specifications ......................................................................................... A-1
Appendix B: Electrical And Data Connectors .............................................................................B-1
Appendix C: The Basics Of Resistance Welding .........................................................................C-1
Appendix D: Quality Resistance Welding Solutions Defining The Optimum Process ............ D-1
Appendix E: LCD Display Messages ............................................................................................E-1
Appendix F: Relay Timing Diagrams ...........................................................................................F-1
Appendix G: Repetition Rates ...................................................................................................... G-1

MODEL DC25 LINEAR DC RESISTANCE WELDING CONTROL
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