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 UnitekDC25 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: (626) 303-5676
FAX: (626) 358-8048
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
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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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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

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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

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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
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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

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MODEL DC25 LINEAR DC RESISTANCE WELDING CONTROL
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MODEL DC25 LINEAR DC RESISTANCE WELDING CONTROL
xii 990-660
LIMITED WARRANTY
1. (a) Subject to the exceptions and upon the conditions set forth herein, Seller warrants to Buyer that
for a period of one (1) year from the date of shipment (“Warranty Period”), that such Goods will be free
from material defects in material and workmanship.
(b) Notwithstanding the foregoing and anything herein to the contrary, the warranty set forth in this
Section 1 shall be superseded and replaced in its entirety with the warranty set forth on Exhibit A
hereto if the Goods being purchased are specialty products, which include, without limitation, laser
products, fiber markers, custom systems, workstations, Seller-installed products, non-catalogue
products and other custom-made items (each a “Specialty Products.”
(c) EXCEPT FOR THE WARRANTY SET FORTH IN SECTION 1(A), SELLER MAKES NO
WARRANTY WHATSOEVER WITH RESPECT TO THE GOODS (INCLUDING ANY SOFTWARE) OR
SERVICES, INCLUDING ANY (a) WARRANTY OF MERCHANTABILITY; (b) WARRANTY OF
FITNESS FOR A PARTICULAR PURPOSE; (c) WARRANTY OF TITLE; OR (d) WARRANTY
AGAINST INFRINGEMENT OF INTELLECTUAL PROPERTY RIGHTS OF A THIRD PARTY;
WHETHER EXPRESS OR IMPLIED BY LAW, COURSE OF DEALING, COURSE OF
PERFORMANCE, USAGE OF TRADE OR OTHERWISE.
(d) Products manufactured by a third party and third party software (“Third Party Product”) may
constitute, contain, be contained in, incorporated into, attached to or packaged together with, the
Goods. Third Party Products are not covered by the warranty in Section 1(a). For the avoidance of
doubt, SELLER MAKES NO REPRESENTATIONS OR WARRANTIES WITH RESPECT TO ANY
THIRD PARTY PRODUCT, INCLUDING ANY (a) WARRANTY OF MERCHANTABILITY; (b)
WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE; (c) WARRANTY OF TITLE; OR (d)
WARRANTY AGAINST INFRINGEMENT OF INTELLECTUAL PROPERTY RIGHTS OF A THIRD
PARTY; WHETHER EXPRESS OR IMPLIED BY LAW, COURSE OF DEALING, COURSE OF
PERFORMANCE, USAGE OF TRADE OR OTHERWISE. Notwithstanding the foregoing, in the event
of the failure of any Third Party Product, Seller will assist (within reason) Buyer (at Buyer’s sole
expense) in obtaining, from the respective third party, any (if any) adjustment that is available under
such third party’s warranty.
(e) Seller shall not be liable for a breach of the warranty set forth in Section 1(a) unless: (i) Buyer gives
written notice of the defect, reasonably described, to Seller within five (5) days of the time when Buyer
discovers or ought to have discovered the defect and such notice is received by Seller during the
Warranty Period; (ii) Seller is given a reasonable opportunity after receiving the notice to examine such
Goods; (iii) Buyer (if requested to do so by Seller) returns such Goods (prepaid and insured to Seller at
1820 South Myrtle Avenue, Monrovia, CA 91016or to such other location as designated in writing by
Seller) to Seller pursuant to Seller’s RMA procedures and Buyer obtains a RMA number from Seller
prior to returning such Goods for the examination to take place; and (iii) Seller reasonably verifies
Buyer’s claim that the Goods are defective and that the defect developed under normal and proper use.
(f) Seller shall not be liable for a breach of the warranty set forth in Section 1(a) if: (i) Buyer makes any
further use of such Goods after giving such notice; (ii) the defect arises because Buyer failed to follow
Seller’s oral or written instructions as to the storage, installation, commissioning, use or maintenance of
the Goods; (iii) Buyer alters or repairs such Goods without the prior written consent of Seller; or (iv)
repairs or modifications are made by persons other than Seller’s own service personnel, or an
authorized representative’s personnel, unless such repairs are made with the written consent of Seller
in accordance with procedures outlined by Seller.

MODEL DC25 LINEAR DC RESISTANCE WELDING CONTROL
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(g) All expendables such as electrodes are warranted only for defect in material and workmanship
which are apparent upon receipt by Buyer. The foregoing warranty is negated after the initial use.
(h) Subject to Section 1(e) and Section 1(f) above, with respect to any such Goods during the Warranty
Period, Seller shall, in its sole discretion, either: (i) repair or replace such Goods (or the defective part)
or (ii) credit or refund the price of such Goods at the pro rata contract rate, provided that, if Seller so
requests, Buyer shall, at Buyer’s expense, return such Goods to Seller.
(i) THE REMEDIES SET FORTH IN SECTION 1(H) SHALL BE BUYER’S SOLE AND EXCLUSIVE
REMEDY AND SELLER’S ENTIRE LIABILITY FOR ANY BREACH OF THE LIMITED WARRANTY
SET FORTH IN SECTION 1(A). Representations and warranties made by any person, including
representatives of Seller, which are inconsistent or in conflict with the terms of this warranty, as set
forth above, shall not be binding upon Seller.

MODEL DC25 LINEAR DC RESISTANCE WELDING CONTROL
xiv 990-660
Exhibit A
Warranty for “Specialty Products”
Limited Warranty
EXCEPT FOR THE WARRANTY SET FORTH BELOW IN THIS EXHIBIT A, SELLER MAKES NO
WARRANTY WHATSOEVER WITH RESPECT TO THE GOODS (INCLUDING ANY SOFTWARE) OR
SERVICES, INCLUDING ANY (a) WARRANTY OF MERCHANTABILITY; (b) WARRANTY OF
FITNESS FOR A PARTICULAR PURPOSE; (c) WARRANTY OF TITLE; OR (d) WARRANTY
AGAINST INFRINGEMENT OF INTELLECTUAL PROPERTY RIGHTS OF A THIRD PARTY;
WHETHER EXPRESS OR IMPLIED BY LAW, COURSE OF DEALING, COURSE OF
PERFORMANCE, USAGE OF TRADE OR OTHERWISE.
Warranty Period: The Warranty Period for Specialty Products is for one (1) year, and the Warranty
Period for laser welders and laser markers is two (2) years (unlimited hours), and the Warranty Period
for the laser pump diodes or modules is two (2) years or 10,000 clock hours, whichever occurs first (as
applicable, the “Warranty Period”). The Warranty Period begins as follows: (i) on orders for Goods
purchased directly by Buyer, upon installation at Buyer’s site or thirty (30) days after the date of
shipment, whichever occurs first; or (ii) on equipment purchased by a Buyer that is an OEM or systems
integrators, upon installation at the end user’s site or six (6) months after the date of shipment,
whichever occurs first.
Acceptance Tests: Acceptance Tests (when required) shall be conducted at Amada Miyachi
America, Inc., Monrovia, CA, USA (the “Testing Site”) unless otherwise mutually agreed in writing prior
to issuance or acceptance of the Acknowledgement. Acceptance Tests shall consist of a final visual
inspection and a functional test of all laser, workstation, enclosure, motion and accessory hardware.
Acceptance Tests shall include electrical, mechanical, optical, beam delivery, and software items
deliverable under the terms of the Acknowledgement. Terms and conditions for Additional Acceptance
Tests either at Seller’s or Buyer’s facility shall be mutually agreed in writing prior to issuance or
acceptance of the Acknowledgement.
Performance Warranty: The system is warranted to pass the identical performance criteria at Buyer’s
site as demonstrated during final Acceptance Testing at the Testing Site during the Warranty Period, as
provided in the Acknowledgement. Seller explicitly disclaims any responsibility for the process results
of the laser processing (welding, marking, drilling, cutting, etc.) operations.
Exclusions: Seller makes no warranty, express or implied, with respect to the design or operation of
any system in which any Seller’s product sold hereunder is a component.
Limitations: The limited warranty set forth on this Exhibit A does not cover loss, damage, or defects
resulting from transportation to Buyer’s facility, improper or inadequate maintenance by Buyer, Buyer-
supplied software or interfacing, unauthorized modification or misuse, operation outside of the
environmental specifications for the equipment, or improper site preparation and maintenance. This
warranty also does not cover damage from misuse, accident, fire or other casualties of failures caused
by modifications to any part of the equipment or unauthorized entry to those portions of the laser which
are stated. Furthermore, Seller shall not be liable for a breach of the warranty set forth in this Exhibit A
if: (i) Buyer makes any further use of such Goods after giving such notice; (ii) the defect arises because
Buyer failed to follow Seller’s oral or written instructions as to the storage, installation, commissioning,
use or maintenance of the Goods; (iii) Buyer alters or repairs such Goods without the prior written
consent of Seller; or (iv) repairs or modifications are made by persons other than Seller’s own service
personnel, or an authorized representative’s personnel, unless such repairs are made with the written
consent of Seller in accordance with procedures outlined by Seller.

MODEL DC25 LINEAR DC RESISTANCE WELDING CONTROL
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Seller further warrants that all Services performed by Seller’s employees will be performed in a good
and workmanlike manner. Seller’s sole liability under the foregoing warranty is limited to the obligation
to re-perform, at Seller’s cost, any such Services not so performed, within a reasonable amount of time
following receipt of written notice from Buyer of such breach, provided that Buyer must inform Seller of
any such breach within ten (10) days of the date of performance of such Services.
Seller shall not be liable for a breach of the warranty set forth in this Exhibit A unless: (i) Buyer gives
written notice of the defect or non-compliance covered by the warranty, reasonably described, to Seller
within five (5) days of the time when Buyer discovers or ought to have discovered the defect or non-
compliance and such notice is received by Seller during the Warranty Period; (ii) Seller is given a
reasonable opportunity after receiving the notice to examine such Goods and (a) Buyer returns such
Goods to Seller’s place of business at Buyer’s cost (prepaid and insured); or (b) in the case of custom
systems, Seller dispatches a field service provider to Buyer’s location at Buyer’s expense, for the
examination to take place there; and (iii) Seller reasonably verifies Buyer’s claim that the Goods are
defective or non-compliant and the defect or non-compliance developed under normal and proper use.
All consumable, optical fibers, and expendables such as electrodes are warranted only for defect in
material and workmanship which are apparent upon receipt by Buyer. The foregoing warranty is
negated after the initial use.
No warranty made hereunder shall extend to any product whose serial number is altered, defaced, or
removed.
Remedies: With respect to any such Goods during the Warranty Period, Seller shall, in its sole
discretion, either: repair such Goods (or the defective part). THE REMEDIES SET FORTH IN THE
FOREGOING SENTENCE SHALL BE BUYER’S SOLE AND EXCLUSIVE REMEDY AND SELLER’S
ENTIRE LIABILITY FOR ANY BREACH OF THE LIMITED WARRANTY SET FORTH IN THIS
EXHIBIT A. Representations and warranties made by any person, including representatives of Seller,
which are inconsistent or in conflict with the terms of this warranty, as set forth above, shall not be
binding upon Seller.
Products manufactured by a third party and third party software (“Third Party Product”) may
constitute, contain, be contained in, incorporated into, attached to or packaged together with, the
Goods. Third Party Products are not covered by the warranty in this Exhibit A. For the avoidance of
doubt, SELLER MAKES NO REPRESENTATIONS OR WARRANTIES WITH RESPECT TO ANY
THIRD PARTY PRODUCT, INCLUDING ANY (a) WARRANTY OF MERCHANTABILITY; (b)
WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE; (c) WARRANTY OF TITLE; OR (d)
WARRANTY AGAINST INFRINGEMENT OF INTELLECTUAL PROPERTY RIGHTS OF A THIRD
PARTY; WHETHER EXPRESS OR IMPLIED BY LAW, COURSE OF DEALING, COURSE OF
PERFORMANCE, USAGE OF TRADE OR OTHERWISE. Notwithstanding the foregoing, in the event
of the failure of any Third Party Product, Seller will assist (within reason) Buyer (at Buyer’s sole
expense) in obtaining, from the respective third party, any (if any) adjustment that is available under
such third party’s warranty.


DC25 LINEAR DC RESISTANCE WELDING CONTROL
990-660 1-1
CHAPTER 1
DESCRIPTION
Section I: Introduction
Features
The DC25 Linear DC Welding Control is a Resistance Welding Control. For the rest of this manual,
the DC25 will be referred to simply as the Control. The Control has the following features:
Programming of time in 10 µsec increments (minimum) provides shorter weld times, less part
deformation, longer electrode life, and greater weld strength with more part ductility.
Built-in Liquid Crystal Display (LCD) shows a graphical "trace" of weld current, voltage, power
and resistance, plus alphanumeric peak and average values.
Up to 99 individual Weld Schedules (sometimes referred to as weld profiles) can be programmed
and stored. Weld schedules can be used individually or in sequence with others using the "chain
schedules" function. You can also use schedule #00 as a "scratch pad" for developing schedules.
Easy-to-set limits establish process window for acceptable quality.
Weld limits and user programmable relays can be used in conjunction with visual and audible
signals for operators and automation interface.
Active Part Conditioning (APC) compensates for varying part conditions and oxide layers.
Rear-mounted RS-232 and RS-485 connectors allow for remote programming, weld schedule
selection, and data logging for SPC purposes.
Calibration traceable to NIST standards.
Optional DC25/DC25 Advanced Serial Datacom Communications Interface kit, commonly
called "the Datacom kit," available for process logging.
Password protection provides process security.

CHAPTER 1: DESCRIPTION
DC25 LINEAR DC RESISTANCE WELDING CONTROL
1-2 990-660
Applications
The Control is ideal for microjoining applications, which require exceptional control and highest quality
throughput. The Control has a closed-loop feedback circuit that allows the user to program constant
current, constant voltage, or constant power welding pulses. Chapter 3, Using DC25 Welding And
Monitor Functions, describes the Control's functions and how to use them for different welding
applications.
The Control requires only single-phase input power and can supply weld power up to 4,000 amps. The
advanced linear control circuit provides instantaneous update of the welding pulse in response to
changes in the resistance of the work piece during the weld. This level of control is essential to achieve
consistent welds in applications where the resistance changes dramatically.
The graphical display and intuitive weld monitor make understanding the weld and the weld
optimization process easy. Data output provides the necessary process documentation for critical
applications and permits data logging for SPC purposes.

CHAPTER 1: DESCRIPTION
DC25 LINEAR DC RESISTANCE WELDING CONTROL
990-660 1-3
Section II: Description
DC25 Front Panel
The front panel contains all the controls and indicators necessary to operate the Control. You can
program the Control using the data input keys and information appearing in the Liquid Crystal
Display (LCD). Descriptions for each button and display are in Section IV of this chapter, Controls
and Indicators.
All electrical connectors, data connectors, and the ON / OFF switch are located on the rear panel
of the Control. Connection instructions are described in Chapter 2, Getting Started.
Complete technical specifications for the Control are listed in Appendix A, Technical Specifications.
Connector pin identification and specifications are listed in Appendix B, Electrical And Data
Connectors.

CHAPTER 1: DESCRIPTION
DC25 LINEAR DC RESISTANCE WELDING CONTROL
1-4 990-660
Section III: Overview
Introduction
The front panel of the Control contains the Liquid Crystal Display (LCD), and pushbutton keys (Weld
Selector Keys, Numeric Keypad, and Operational Controls). Each is described in Section IV, Controls
And Indicators. The LCD and the front panel keys are used together when programming and operating
the Control. Instructions on how to do this are in Chapter 4, Operating Instructions.
The LCD displays all of the setup, programming, and operating information for the Control. The front
panel keys allow you to enter data for programming custom weld schedules, customizing the operating
parameters of the Control, and operating your welding equipment. The keys also allow you to program
the precise voltage, current, power, and time of each energy pulse into individual weld schedules, which
may contain one or two weld pulses. Weld schedules consist of:
Squeeze time before the weld pulse(s) [after the firing input is given]
The time and energy for each weld period
Cooling time between Pulse 1 and Pulse 2 [if two pulses are used]
Hold time after the welding pulse(s)
You can program and store up to 99 different weld schedules to meet a variety of welding applications.
LCD Screens
LCD Display Screens
The LCD displays two types of screens: Data screens and Menu screens.
NOTE: The purpose of this section is to describe the content of LCD screens. For clarity, LCD
screens are shown here without the Weld Selector keys located directly under the display.
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