Amada MacGregor DC 13-T Series User manual

961-00060 rev9
DC Spot Welding Power Supply
DCxx13-T and M31xx-T
Resistance Welders
HARDWARE MANUAL

Operating Instructions DC-xx13 and M31xx
961-00060 rev9 2/25 2020-04-14
Annex:
- Safety regulations
- General references on resistance welding
- Contact addresses
Versions
Version Date Basis of Version
8 2019-01 Conversion to new layout
9 2020-04 Details Update
Copyright  2020: Amada Weld Tech UK Ltd
All rights reserved.
The products named in this manual are only used for identification purposes and may be trademarks
or registered trademarks of the respective companies.

Operating Instructions DC-xx13 and M31xx
Table of Contents
961-00060 rev9 3/25
Table of Contents
1 General Information ........................................................................................................... 4
2 Technical Description ........................................................................................................ 5
2.1 Introduction ........................................................................................................................ 5
2.2 Technical Specification ..................................................................................................... 5
3 Commissioning .................................................................................................................. 6
3.1 Electrical Connections ...................................................................................................... 6
4 Preparation and Installation .............................................................................................. 7
4.1 DCxx13 Front ...................................................................................................................... 7
4.2 M31 range Front ................................................................................................................. 8
4.3 DCxx13 Rear Connections ................................................................................................ 9
5 Rear Panel Connections ..................................................................................................13
5.1 Standard IO Isolated Interface ........................................................................................13
5.1.1 Standard Outputs .............................................................................................................13
5.1.2 Standard Inputs ................................................................................................................14
5.1.3 Default Configuration ......................................................................................................14
5.1.4 DS Option Configuration .................................................................................................15
5.1.5 BCD Option Configuration ..............................................................................................16
5.2 Optional IO Isolated Interface .........................................................................................16
5.2.1 Optional Outputs ..............................................................................................................16
5.2.2 Optional Inputs .................................................................................................................17
5.2.3 Default Configuration ......................................................................................................17
5.2.4 BCD Option Configuration ..............................................................................................18
5.2.5 Program Echo Configuration ..........................................................................................18
5.3 Isolated RS232..................................................................................................................19
5.4 Connecting a Typical PC Port .........................................................................................19
5.5 15 way Trigger/Fault D type ............................................................................................19
5.6 Voltage Sensing and Stop ...............................................................................................20
5.7 Isolated Analogue Outputs .............................................................................................20
5.8 Ethernet, USB and FS1 ....................................................................................................20
5.9 Quick Connection Strip ...................................................................................................21
6 Fault Codes and Warnings ..............................................................................................22
7 Trouble Shooting Guide ..................................................................................................23
8 Index ..................................................................................................................................25
8.1 Headword Index ...............................................................................................................25

Operating Instructions DC-xx13 and M31xx
961-00060 rev9 4/25
1 General Information
Information about safety regulations, symbols, copyrights, protection rights,
usage location conditions can be found in the back section of these operating
instructions.
Please read this information carefully before using these operating instructions.
These operating instructions should help you familiarize yourself with the system and
take advantage of its application possibilities when used as directed.
It contains important notes to help operate the unit safely, properly, and economically.
Observing the notes will help avoid risks, decrease repair costs and down times, and
enhance reliability and the service life of the unit.
It is a rule: Safety first!
Warning
Incorrect or inappropriate configuration, installation, settings, handling or use can cause
mechanical, electrical or thermal hazards, which may result in serious damage or injury.
Ensure the correct execution of these points and follow the respective notes in the
operating instructions.
Danger
Do not put the system into operation before you have read the operating instructions!
Danger Persons with cardiac pacemakers and metallic implants are prohibited from
approaching to within a radius of at least 5 m of welding equipment!
Crushing Hazard
There is a risk of crushing during the adjustment movement due to closing electrodes,
stops for limiting adjustment or stroke movement and the stop on the basic pincers unit
for limiting floating movement.
Warning
This Class A welding equipment is not supposed to be used in living quarters, where
the power supply is carried out by a public low voltage supply.
There it can be difficult to ensure electromagnetic compatibility because of conducted or
radiated disturbances.
Warning
Restrictions on use environment conditions
Use this equipment in an environment without conductive dust. If conductive dust
enters into equipment, it may cause failure, electric shock or ignition. If using
equipment in such environment, consult Amada Weld Tech.
Warning

Operating Instructions DC-xx13 and M31xx
961-00060 rev9 5/25
2 Technical Description
2.1 Introduction
Thank you for purchasing this MacGregor resistance welding power source.
This manual is designed to help the new user to understand and operate the equipment quickly and
safely. Please take a few moments to become familiar with the equipment and this manual before
attempting to use the equipment.
The following information covers the model you have purchased and others in the range and should
be kept for reference. This will also help you identify model specific features mentioned in this
manual.
All DC-xx13-Ts are comprised of a linear DC power unit controlled by a microprocessor and colour
touch screen interface.
It is the user's responsibility to ensure that their installation is safe both electrically and
mechanically.
The DC-xx13-T allows you to program the delivery of electrical energy into a weld by allowing
adjustment of time and amplitude. Typically, energy into the weld is gradually ramped up, held at a
peak and then reduced. The amount of energy will depend on the length of these times together with
the value of the peak amplitude achieved. In some cases it is beneficial to use 2 pulses in a weld,
usually with the first pulse acting as a means of pre-conditioning the parts.
A weld profile that is used to make a satisfactory weld can be saved as a PROFILE in the unit's
memory.
2.2 Technical Specification
For operation of the welder, please see the latest version of the associated hardware manual (961-
00061).

Operating Instructions DC-xx13 and M31xx
961-00060 rev9 6/25
3 Commissioning
3.1 Electrical Connections
DO Use a properly rated Mains Service Supply
An identification plate on the rear panel specifies the input mains voltage
requirement.
DO Provide Proper Ventilation
DO Use Lifting Gear to Move the Unit
DO NOT Operate Machine Without Covers
DO NOT Operate With Suspected Failures
DO NOT Operate in an Explosive Atmosphere
DO NOT Operate in Wet/Damp Conditions
IF IN DOUBT, CONTACT YOUR DISTRIBUTOR
Inspect the unit for any shipping damage prior to connecting to the mains supply.
Caution
This product MUST be connected to the correct mains supply voltage. Refer to the identification plate
located on the rear panel.
Single-Phase
Cable Colour:
Brown Live
Blue Neutral
Yellow/Green Safety Earth / Ground
3-Phase
Cable Colour:
Black Line 1
Black Line 2
Black Line 3
Yellow/Green Safety Earth / Ground
Ensure a good earth / ground connection is provided for operator safety. The internal electrical circuits
are floating, so an additional earth / ground connection can be made to one output lug or on one side
of the weld head. The unit will not operate with both the positive and negative outputs grounded.

Operating Instructions DC-xx13 and M31xx
961-00060 rev9 7/25
4 Preparation and Installation
4.1 DCxx13 Front
Four Tactile User
Keys
7” 800x480 Touch Panel
Scre
en
Two USB ports
memory sticks, mice
etc…
Mains On/Off
Remote Variants

Operating Instructions DC-xx13 and M31xx
961-00060 rev9 8/25
4.2 M31 range Front
Two USB ports + Ethernet :
memory sticks, mice etc…
7” 800x480 Touch Panel Screen
Four Tactile User Keys
Output bars
Voltage sensing
jack socket
Inhibit button
Power
Indicator

Operating Instructions DC-xx13 and M31xx
961-00060 rev9 9/25
4.3 DCxx13 Rear Connections
The photo below shows the rear panel connections of a DC2013T
Internal +24V 1amp DC
supply fuse. This is provided
as a protection for the
+24VDC available at the
various D type connectors for
external interfacing
USB port - 0V reference is
taken from the positive output
bar of the machine which is
isolated and floating
Ethernet port - 0V reference is
taken from the positive output bar
of the machine which is isolated
and floating
Isolated RS232
TxD = 2, RxD = 3, GND = 7
Basic digital weld trigger and fault
indication port.
Trigger contact across 1 & 2
Positive Output bar. This is
isolated from earth
Standard optically isolated I/O
PLC Interface for program recalls
and fault indications
Isolated Analogue Channels for
Voltage, Current and Power
0 – 10VDC
Optional optically isolated I/O
PLC Interface for displacement
information and extended I/O
operations
Negative Output bar. This is
isolated from earth
Machine Stop. When this link is
opened, the machine shunt trip
will active, switching off power to
the machine. N.B. Test monthly
Additional Earthing stud
Mains Input Gland
Serial Number Plate
Variable speed cooling fan
Single Channel LVDT input
MWS Use only.
This is a CAN connection for
MWS peripherals
Voltag
e sensing
connections

Operating Instructions DC-xx13 and M31xx
961-00060 rev9 10/25
The photo below shows the rear panel connections of a DC6013T or DC1013T
Internal +24V 1amp DC
supply fuse. This is provided
as a protection for the
+24VDC available at the
various D type connectors for
external interfacing
USB port - 0V reference is
taken from the positive output
bar of the machine which is
isolated and floating
Ethernet port - 0V reference is
taken from the positive output bar
of the machine which is isolated
and floating
Isolated RS232
TxD = 2, RxD = 3, GND = 7
Basic digital weld trigger and fault
indication port.
Trigger contact across 1 & 2
Positive Output bar. This is
isolated from earth
Standard optically isolated I/O
PLC Interface for program recalls
and fault indications
Isolated Analogue Channels for
Voltage, Current and Power
0 – 10VDC
Optional optically isolated I/O
PLC Interface for displacement
information and extended I/O
operations
Negative Output bar. This is
isolated from earth
Machine Stop. When this link is
opened, the machine shunt trip
will active, switching off power to
the machine. N.B. Test monthly
M
ains Input Gland
Serial Number Plate
MWS Use only.
This is a CAN connection for
MWS peripherals
Voltage sensing jack socket input

Operating Instructions DC-xx13 and M31xx
961-00060 rev9 11/25
The photo below shows the rear panel connections of a M31 range welder

Operating Instructions DC-xx13 and M31xx
961-00060 rev9 12/25
Before attempting to use this power supply ensure the mains is OFF and the welder is connected
correctly.

Operating Instructions DC-xx13 and M31xx
961-00060 rev9 13/25
5 Rear Panel Connections
5.1 Standard IO 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.
Also shown are the available initial IO configurations. Note that it is now possible to modify these
configurations if desired. This includes changing whether outputs are asserted high/low on activation
and on whether inputs are triggered on high-low or low-high transitions. For more details, see the
software manual IO Configuration section.
5.1.1 Standard Outputs
Output Description D-type Pin Number
Standard Output #1 Collector 28
Emitter 17
Standard Output #2 Collector 10
Emitter 35
Standard Output #3 Collector 29
Emitter 36
Standard Output #4 Collector 11
Emitter 13
Standard Output #5 Collector 12
Emitter 15
Standard Output #6 Collector 31
Emitter 32
Standard Output #7 Collector 33
Emitter 34
Standard Output #8 Collector 14
Emitter 16
Typically, the collector connection is pulled up to +24VDC (obtained on pin 37) and is used as the
input to a PLC, while the emitter is connected to 0V(+24RTN), obtained on pin 19.
Passing current activates the output.

Operating Instructions DC-xx13 and M31xx
961-00060 rev9 14/25
5.1.2 Standard Inputs
Input Description D-type Pin Number
Standard Input #1 Anode 21
Cathode 27
Standard Input #2 Anode 3
Cathode 8
Standard Input #3 Anode 1
Cathode 26
Standard Input #4 Anode 22
Cathode 7
Standard Input #5 Anode 4
Cathode 5
Standard Input #6 Anode 20
Cathode 24
Standard Input #7 Anode 2
Cathode 6
Standard Input #8 Anode 23
Cathode 25
Externally available 24V +24VDC 37
0V (24 RTN) 19
Remote Reset
Anode (must be volt-free) 18*
Cathode (internally hardwired to 0V
pin 19)
Typically, the anode is connected directly to +24VDC (obtained on pin 37) while the cathode is
connected via a PLC or switch to 0V(+24RTN), obtained on pin 19.
Passing current activates the input.
5.1.3 Default Configuration
Output
Description
Pin
s
Standard Output #1 Fault High Limit 28, 17
Standard Output #2 Fault Low Limit 10, 35
Standard Output #3 BCD Value 4 29, 36
Standard Output #4 Feedback Fault 11, 13
Standard Output #5 BCD Value 1 12, 15
Standard Output #6 BCD Value 2 31, 32
Standard Output #7 Busy 33, 34
Standard Output #8 Inhibit Status 14, 16
The BCD outputs are used to select channels when configured for electrical distribution with
MacGregor distribution units. These outputs turn ON the opto transistor when selected. All fault
outputs and the busy output turn OFF the opto-transistor when active.
A typical timing diagram of selected outputs might look as follows:
Anode
Cathode
Basic Schematic of
optically isolated input
1K
3
Ohms

Operating Instructions DC-xx13 and M31xx
961-00060 rev9 15/25
Input
Description
Pins
Standard Input #1 Recall Store 0 (display) 21, 27
Standard Input #2 Recall Store 1 3, 8
Standard Input #3 Recall Store 2 1, 26
Standard Input #4 Recall Store 3 22, 7
Standard Input #5 Recall Store 4 4, 5
Standard Input #6 Recall Store 5 20, 24
Standard Input #7 Recall Store 6 2, 6
Standard Input #8 Recall Store 7 23, 25
5.1.4 DS Option Configuration
Output
Description
Pins
Standard Output #1 Fault BCD Code 0 28, 17
Standard Output #2 Inhibit Status 10, 35
Standard Output #3 Fault BCD Code 3 29, 36
Standard Output #4 Feedback Fault 11, 13
Standard Output #5 Fault BCD Code 1 12, 15
Standard Output #6 Fault BCD Code 2 31, 32
Standard Output #7 Busy 33, 34
Standard Output #8 Spare 14, 16
Input
Description
Pins
Standard Input #1 Recall Store 0 (display) 21, 27
Standard Input #2 Spare 3, 8
Standard Input #3 Reset (Stop Welder) 1, 26
Standard Input #4 Trigger 22, 7
Standard Input #5 Recall BCD 0 4, 5
Standard Input #6 Recall BCD 1 20, 24
Standard Input #7 Recall BCD 2 2, 6
Standard Input #8 Recall BCD 3 23, 25
The following specifies the functionality for the DS Isolated Interface:
The software has been enhanced to provide up to 15 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 fault conditions are summarised below.
Output Code
Fault
Description
0 No fault
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
Weld Pulse
Busy Signal - Active
during weld + 30mS
Hi/Low Fault – User
programmable time
Hardware/Feedback Fault
Active until reset

Operating Instructions DC-xx13 and M31xx
961-00060 rev9 16/25
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
5.1.5 BCD Option Configuration
Output
Description
Pins
Standard Output #1 BAD Weld 28, 17
Standard Output #2 Good Weld 10, 35
Standard Output #3 BCD Value 4 29, 36
Standard Output #4 Feedback Fault 11, 13
Standard Output #5 BCD Value 1 12, 15
Standard Output #6 BCD Value 2 31, 32
Standard Output #7 Busy 33, 34
Standard Output #8 Inhibit Status 14, 16
Input
Description
Pins
Standard Input #1 Recall Store 0 (display) 21, 27
Standard Input #2 Spare 3, 8
Standard Input #3 Reset (Stop Welder) 1, 26
Standard Input #4 Trigger 22, 7
Standard Input #5 Recall BCD 0 4, 5
Standard Input #6 Recall BCD 1 20, 24
Standard Input #7 Recall BCD 2 2, 6
Standard Input #8 Recall BCD 3 23, 25
Outputs are identical to the default configuration apart from the Good/Bad weld indicators. One of
these is activated after each weld. Inputs are identical to the DS option configuration.
5.2 Optional IO Isolated Interface
The following tables show the expanded outputs and inputs available at the optional extra 37W D type
PLC interface socket.
24V 20mA nominal rating - - Inputs and Outputs ARE fully protected against short circuit and overload.
Operation of the outputs and inputs is identical to the standard IO.
5.2.1 Optional Outputs
Output Description D-type Pin Number
Optional Output #1 Collector 1
Emitter 20
Optional Output #2 Collector 2
Emitter 21
Optional Output #3 Collector 3
Emitter 22
Optional Output #4 Collector 4
Emitter 23
Optional Output #5 Collector 5
Emitter 24
Optional Output #6 Collector 6
Emitter 25
Optional Output #7 Collector 7

Operating Instructions DC-xx13 and M31xx
961-00060 rev9 17/25
Emitter 26
Optional Output #8 Collector 8
Emitter 27
5.2.2 Optional Inputs
Input Description D-type Pin Number
Optional Input #1 Anode 9
Cathode 13
Optional Input #2 Anode 28
Cathode 32
Optional Input #3 Anode 10
Cathode 14
Optional Input #4 Anode 29
Cathode 33
Optional Input #5 Anode 11
Cathode 15
Optional Input #6 Anode 30
Cathode 34
Optional Input #7 Anode 12
Cathode 16
Optional Input #8 Anode 31
Cathode 35
5.2.3 Default Configuration
Output
Description
Pins
Optional Output #1 Spare 1, 20
Optional Output #2 Spare 2, 21
Optional Output #3 Remote Inhibit 3, 22
Optional Output #4 Displacement Max Fault 4, 23
Optional Output #5 Displacement Min Fault 5, 24
Optional Output #6 Displacement Condition Fault 6, 25
Optional Output #7 Displacement Oversize Fault (pre-weld) 7, 26
Optional Output #8 Displacement Undersize Fault (pre-weld) 8, 27
Note that all fault outputs turn OFF the opto-transistor.
Input
Description
Pins
Optional Input #1 New Electrode Input 1 9, 13
Optional Input #2 Reset HW 28, 32
Optional Input #3 Toggle Inhibit 10, 14
Optional Input #4 New Electrode Input 2 29, 33
Optional Input #5 New Electrode Input 3 11, 15
Optional Input #6 New Electrode Input 4 30, 34
Optional Input #7 New Electrode Input 5 12, 16
Optional Input #8 New Electrode Input 6 31, 35

Operating Instructions DC-xx13 and M31xx
961-00060 rev9 18/25
5.2.4 BCD Option Configuration
Output
Description
Pins
Optional Output #1 Remote Inhibit 1, 20
Optional Output #2 Head Retract Status (smart head systems only) 2, 21
Optional Output #3 Pre-Weld Fault (oversize/undersize) 3, 22
Optional Output #4 Good Weld 4, 23
Optional Output #5 BAD Weld 5, 24
Optional Output #6 Smart Weld Head Fault 6, 25
Optional Output #7 Smart Head System Fault 7, 26
Optional Output #8 Displacement Fault 8, 27
Input
Description
Pins
Optional Input #1 New Electrode Input 1 9, 13
Optional Input #2 Reset HW 28, 32
Optional Input #3 Toggle Inhibit 10, 14
Optional Input #4 New Electrode Input 2 29, 33
Optional Input #5 Retract Head (smart head systems only) 11, 15
Optional Input #6 New Electrode Input 4 30, 34
Optional Input #7 New Electrode Input 5 12, 16
Optional Input #8 New Electrode Input 6 31, 35
5.2.5 Program Echo Configuration
Output
Description
Pins
Optional Output #1 Remote Inhibit 1, 20
Optional Output #2 Weld Head 1 2, 21
Optional Output #3 Weld Head 2 3, 22
Optional Output #4 Program Echo Bit 0 4, 23
Optional Output #5 Program Echo Bit 0 5, 24
Optional Output #6 Program Echo Bit 0 6, 25
Optional Output #7 Program Echo Bit 0 7, 26
Optional Output #8 Spare 8, 27
The Program Echo lines form a BCD pattern which echoes back to the PLC the BCD input pattern,
indicating which profile was selected to weld with (1 to 15).
Input
Description
Pins
Optional Input #1 New Electrode Input 1 9, 13
Optional Input #2 Reset HW 28, 32
Optional Input #3 Toggle Inhibit 10, 14
Optional Input #4 New Electrode Input 2 29, 33
Optional Input #5 New Electrode Input 3 11, 15
Optional Input #6 New Electrode Input 4 30, 34
Optional Input #7 New Electrode Input 5 12, 16
Optional Input #8 New Electrode Input 6 31, 35

Operating Instructions DC-xx13 and M31xx
961-00060 rev9 19/25
5.3 Isolated RS232
5.4 Connecting a Typical PC Port
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
description
25
-
pin
comms port
9
-
pin
comms port
Connection
required
25
-
pin connector ‘b’
(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
5.5 15 way Trigger/Fault D type
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)
by contact closure
1 Pin 1 is hardwired to 0V (pin14) and pin 2 is the
cathode connection for store 0
** NB ** This is NOT isolated from the internal 24v
supply
2
Normally open contacts used to
indicate a fault condition
4 The relay contacts rating is 24V at 0.5A
The contacts close for a Feedback Fault.
5
Remote fault reset by contact
closure
7 Pin 8 is hardwired to +24VDC (pin 15) and pin 7 is the
anode connection for this input
8
Externally available
power supply
0V 14 Protected by fuse Fs2 in the rear panel rated at 1A
anti-surge type T
24VDC 15
The 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
.

Operating Instructions DC-xx13 and M31xx
961-00060 rev9 20/25
5.6 Voltage Sensing and Stop
5.7 Isolated Analogue Outputs
5.8 Ethernet, USB and FS1
The optional STOP link may be used to disengage the
mains switch trip to disconnect mains power inside the unit.
A contact closure across these terminals maintains the
power supply.
Some machines utilise a screw terminal strip for voltage
sensing. The two centre screws + & - are connected
internally to the output bars of the machine. Other machines
may use a jack socket for sensing.
The outer two screw connections are connected internally to
the voltage sensing electronics.
Thus, for internal voltage sensing, two links must be fitted as
shown.
For external voltage sensing, the inner two screw
connections are taken to the electrodes for voltage sensing
Optionally, some units are provided with 3 channels of optically isolated
analogue output monitoring. The three process parameters, voltage,
current and power are internally isolated and fed to rear panel BNC
connectors for direct connection to an oscilloscope.
FS1 is a 2 amp anti surge fuse that protects the internal +24V power
supply. Failure of this fuse will result in power supply malfunction.
Since +24VDC is distributed to the external rear connectors, be sure to
check and clear any faults before replacing this fuse.
There are 3 a non isolated USB connectors on the unit. Two at the
front and one on the rear panel. The USB connections are referenced
to the machine internal 0V, which is floating and is at the same potential
as the positive output bar. The shield/earth connections are also
floating. Thus keyboards, mice and memory sticks may be connected
into these points.