Amada WELD SENTRY User manual

990-291 REV E
RESISTANCE WELDING PROCESS CONTROL MONITOR
WELD SENTRY
OPERATION MANUAL

WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR
ii 990-291
Copyright © 1998 - 2021, AMADA WELD TECH INC.
The engineering designs, drawings and data contained herein are the proprietary work of AMADA
WELD TECH and may not be reproduced, copied, exhibited or otherwise used without the written
authorization of AMADA WELD TECH.
Printed in the United States of America
Revision Record
Revision
EO
Date
Basis of Revision
A None 03/98 Original manual
B 17463 05/98 Incorporate Baxter CVG changes.
C 19146 01/02
Change name to Unitek Peco™.
Reformat manual.
D 45804 04/20
Update Company Name (Amada
Weld Tech).
E 46311 04/21 See ECO for Details

WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR
990-291 iii
FOREWORD
Thank you for purchasing an AMADA WELD TECH, Weld Sentry Resistance Welding Process Control
Monitor.
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
AMADA WELD TECH INC. at:
1820 South Myrtle Avenue
Monrovia, CA 91016
Telephone: [phone]
FAX: [phone]
e-mail: [e-mail]
The purpose of this manual is to supply operating and maintenance personnel with the information needed
to properly and safely operate and maintain the Weld Sentry Resistance Welding Process Control Monitor.
We have made every effort to ensure that the information in this manual is accurate and adequate. The
contents of this manual are subject to change without notice.
Should questions arise, or if you have suggestions for improvement of this manual, please contact us at the
above location/numbers.
AMADA WELD TECH is not responsible for any loss due to improper use of this product.
The Weld Sentry Option is available on many different AMADA WELD TECH Power Supplies, both
current and obsolete. The obsolete models are included for reference:
Current Power Supply Models:
HF2S/230
1-265-xx
HF2S/380
1-265-0x-01
HF2S/460
1-265-0x-02
HF2S/208
1-265-0x-03
Obsolete Power Supply Models:
250DPS
1-254-xx
500DPS
1-255-xx
500HVS
1-256-xx
875DPS
1-257-xx
PM7S
1-241-xx

WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR
iv 990-291
SAFETY NOTES
This instruction manual describes how to operate, maintain and service the Weld Sentry Resistance Welding
Process Control Monitor, and provides instructions relating to its SAFE use. Procedures described in this
manual MUST be performed, as detailed, by QUALIFIED and TRAINED personnel.
For SAFETY, and to effectively take advantage of the full capabilities of the tester, please read these
instruction manuals before attempting to use the workstation.
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 tester.
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.
Disposal
Properly handle and dispose of used materials.
For the disposal of electronic waste please contact AMADA WELD TECH.

WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR
990-291 v
CONTENTS
CHAPTER 1: DESCRIPTION.......................................................................................... 1-1
Function of a Weld Monitor ...................................................................................... 1-1
CHAPTER 2: GETTING STARTED................................................................................ 2-1
Rear Panel Components............................................................................................. 2-1
Screen Format............................................................................................................ 2-2
CHAPTER 3: INSTALLATION........................................................................................ 3-1
Sentry Option............................................................................................................. 3-1
Current and Voltage Measurement Inputs........................................................... 3-1
Current Coil Installation ...................................................................................... 3-1
Current Shunt Installation – User Supplied......................................................... 3-2
Weld Voltage Cable Installation................................................................................ 3-3
Optional Printer/PC Installation................................................................................. 3-3
Configure Communications Protocol ........................................................................ 3-3
CHAPTER 4: OPERATING INSTRUCTIONS............................................................... 4-1
Weld Sentry Operation .............................................................................................. 4-1
Setup Weld Sentry System................................................................................... 4-1
Setup Weld Sentry Program................................................................................. 4-1
Modify an Existing Sentry Program .......................................................................... 4-2
CHAPTER 5: SERVICE..................................................................................................... 5-1
Section I. Calibration...................................................................................................... 5-1
Calibration Check ...................................................................................................... 5-1
Current and Voltage Input Adjustments.................................................................... 5-2
Voltage Measurement Check..................................................................................... 5-2
Required Equipment ............................................................................................ 5-2
Setup PM7S or 250DPS....................................................................................... 5-3
Test Procedure ..................................................................................................... 5-3
Technical Assistance.................................................................................................. 5-4
Telephone Service................................................................................................ 5-4
Factory Service Repair......................................................................................... 5-4
APPENDIX A: WELD SENTRY SPECIFICATIONS.................................................... A-1
Weld Sentry Input/Output Cables.............................................................................. A-1
Sentry Voltage Measurement............................................................................... A-1
Sentry Current Measurement............................................................................... A-1
Sentry Current Shunt Option ............................................................................... A-1

WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR
vi 990-291
Sentry Measurement Technique .......................................................................... A-2
Sentry Measurement Rate.................................................................................... A-2
Sentry Basic Measurement Units......................................................................... A-2
Voltage/Current Difference Measurement Mode ...................................................... A-2
Sentry Time Periods................................................................................................... A-3
Voltage Gain.............................................................................................................. A-3
Current Gain............................................................................................................... A-3
Sentry Trigger Inputs................................................................................................. A-3
Sentry Relay Outputs................................................................................................. A-3
Relay Signal Timing............................................................................................ A-4
Sentry Control of Power Supply................................................................................ A-4
Weld Sentry Menu..................................................................................................... A-4
Default System Configuration................................................................................... A-5
Weld Sentry Programs............................................................................................... A-5
Remote Program Selection ........................................................................................ A-5
Sentry, Communications Interface............................................................................. A-5
Sentry’s Configuration Shunts................................................................................... A-6
Sentry Data Output .................................................................................................... A-7
Print Utilities.............................................................................................................. A-7
Print Options.............................................................................................................. A-8
SPC, Statistical Process Control................................................................................ A-8
SPC Memory........................................................................................................ A-8
Memory Management.......................................................................................... A-9
SPC Program History........................................................................................... A-9
Calculations.......................................................................................................... A-9
Time and Date...................................................................................................... A-10
Microprocessor CPU............................................................................................ A-10
Battery Backup..................................................................................................... A-10
Control Charts and Summaries............................................................................ A-10
Accessories Sentry Option................................................................................... A-11
ILLUSTRATIONS
Figure Title Page
1-1 250DP/Sentry Main Menu................................................................................... 1-2
2-1 Rear Panel of PM7S with Sentry Option Installed. ............................................. 2-1
2-2 Flow Chart for Sentry SPC Menu........................................................................ 2-4
3-1 Current Coil Placed Over a Single Welding Cable.............................................. 3-1
3-2 Current Shunt Installation.................................................................................... 3-2
3-3 Voltage Measurement Clip Attachment............................................................... 3-3
A-1 Proper Method for Wiring Inputs and Outputs to the Sentry’s Relay ................. A-4

WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR
990-291 vii
LIMITED WARRANTY
GENERAL TERMS AND CONDITIONS FOR THE SALE OF GOODS
1. Applicability.
(a) These terms and conditions of sale (these “Terms”) are the only terms which govern the sale of the goods (“Goods”) by Amada Weld Tech Inc. (“Seller”) to
the buyer identified in the Sales Quotation and/or Acknowledgment (as each defined below) to which these Terms are attached or incorporated by reference
(“Buyer”). Notwithstanding anything herein to the contrary, if a written contract signed by authorized representatives of both parties is in existence covering
the sale of the Goods covered hereby, the terms and conditions of said contract shall prevail to the extent they are inconsistent with these Terms.
(b) The accompanying quotation of sale (the “Sales Quotation”) provided to Buyer, and/or sales order acknowledgement (“Acknowledgement”) and these
Terms (collectively, this “Agreement”) comprise the entire agreement between the parties, and supersede all prior or contemporaneous understandings,
agreements, negotiations, representations and warranties, and communications, both written and oral. For clarification, after the Acknowledgement is received
by Buyer, the order for Goods is binding and cannot be cancelled by Buyer for any reason and the full purchase price amount set forth in the Acknowledgement
shall be due and payable by Buyer to Seller pursuant to the payment schedule set forth in the Acknowledgement unless otherwise agreed to in writing by Seller.
All terms and conditions contained in any prior or contemporaneous oral or written communication which are different from, or in addition to, the terms and
conditions in this Agreement are hereby rejected and shall not be binding on Seller, whether or not they would materially alter this Agreement. These Terms
prevail over any of Buyer’s terms and conditions of purchase regardless whether or when Buyer has submitted its purchase order or such terms. Fulfillment of
Buyer’s order does not constitute acceptance of any of Buyer’s terms and conditions and does not serve to modify or amend these Terms. Notwithstanding
anything herein to the contrary, all orders for Goods must be for a minimum purchase price of $100 or such orders will be rejected by Seller.
2. Delivery.
(a) The Goods will be delivered within a reasonable time after Seller provides Buyer the Acknowledgment, subject to availability of finished Goods. Seller will
endeavor to meet delivery schedules requested by Buyer, but in no event shall Seller incur any liability, consequential or otherwise, for any delays or failure to
deliver as a result of ceasing to manufacture any product or any Force Majeure Event. Delivery schedules set forth in the Acknowledgment are Seller’s good
faith estimate on the basis of current schedules. In no event shall Seller be liable for special or consequential damages resulting from failure to meet requested
delivery schedules.
(b) Unless otherwise agreed in writing by the parties in the Acknowledgement, Seller shall deliver the Goods to Seller’s plant in Monrovia, CA, USA (the
“Shipping Point”) using Seller’s standard methods for packaging and shipping such Goods. Buyer shall take delivery of the Goods within three (3) days of Seller’s
written notice that the Goods have been delivered to the Shipping Point. Buyer shall be responsible for all loading costs (including freight and insurance costs)
and provide equipment and labor reasonably suited for receipt of the Goods at the Shipping Point. Seller shall not be liable for any delays, loss or damage in
transit.
(c) Seller may, in its sole discretion, without liability or penalty, make partial shipments of Goods to Buyer, if applicable. Each shipment will constitute a
separate sale, and Buyer shall pay for the units shipped whether such shipment is in whole or partial fulfillment of Buyer’s purchase order.
(d) If for any reason Buyer fails to accept delivery of any of the Goods on the date fixed pursuant to Seller’s notice that the Goods have been delivered at the
Shipping Point, or if Seller is unable to deliver the Goods at the Shipping Point on such date because Buyer has not provided appropriate instructions,
documents, licenses or authorizations: (i) risk of loss to the Goods shall pass to Buyer; (ii) the Goods shall be deemed to have been delivered; and (iii) Seller, at
its option, may store the Goods until Buyer picks them up, whereupon Buyer shall be liable for all related costs and expenses (including, without limitation,
storage and insurance).
3. Non-delivery.
(a) The quantity of any installment of Goods as recorded by Seller on dispatch from Seller’s place of business is conclusive evidence of the quantity received by
Buyer on delivery unless Buyer can provide conclusive evidence proving the contrary.
(b) Seller shall not be liable for any non-delivery of Goods (even if caused by Seller’s negligence) unless Buyer gives written notice to Seller of the non-delivery
within three (3) days of the date when the Goods would in the ordinary course of events have been received.
(c) Any liability of Seller for non-delivery of the Goods shall be limited to (in Seller’s sole discretion) replacing the Goods within a reasonable time or adjusting
the invoice respecting such Goods to reflect the actual quantity delivered.
4. Shipping Terms. Unless indicated otherwise in the Acknowledgment, Delivery shall be made EXW (Incoterms 2010), Shipping Point, including without
limitation, freight and insurance costs. If no delivery terms are specified on the Acknowledgement, the method of shipping will be in the sole discretion of
Seller. Unless directed in writing otherwise by Buyer, full invoice value will be declared for all shipments.
5. Title and Risk of Loss. Title and risk of loss passes to Buyer upon delivery of the Goods at the Shipping Point. As collateral security for the payment of the
purchase price of the Goods, Buyer hereby grants to Seller a lien on and security interest in and to all of the right, title and interest of Buyer in, to and under the
Goods, wherever located, and whether now existing or hereafter arising or acquired from time to time, and in all accessions thereto and replacements or
modifications thereof, as well as all proceeds (including insurance proceeds) of the foregoing. The security interest granted under this provision constitutes a
purchase money security interest under the California Commercial Code.
6. Amendment and Modification. These Terms may only be amended or modified in a writing which specifically states that it amends these Terms and is signed
by an authorized representative of each party.

WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR
viii 990-291
7. Inspection and Rejection of Nonconforming Goods.
(a) Buyer shall inspect the Goods within two (2) days of receipt (“Inspection Period”). Buyer will be deemed to have accepted the Goods unless it notifies Seller
in writing of any Nonconforming Goods during the Inspection Period and furnishes such written evidence or other documentation as required by Seller.
“Nonconforming Goods” means only the following: (i) product shipped is different than identified in Buyer’s Acknowledgement; or (ii) product’s label or
packaging incorrectly identifies its contents. Notwithstanding the foregoing, for shipped Goods that require field installation, the “re-verification” terms in the
Acknowledgement shall apply and for custom installations, the inspection and verification shall take place at Buyer’s site immediately after the installation is
completed.
(b) Seller will only accept Nonconforming Goods that are returned under Seller’s Return Material Authorization procedures then in effect (“RMA”). Buyer shall
obtain a RMA number from Seller prior to returning any Nonconforming Goods and return the Nonconforming Goods prepaid and insured to Seller at 1820
South Myrtle Avenue, Monrovia, CA 91016 or to such other location as designated in writing by Seller for the examination to take place there. If Seller
reasonably verifies Buyer’s claim that the Goods are Nonconforming Goods and that the nonconformance did not developed by use from Buyer, Seller shall, in
its sole discretion, (i) replace such Nonconforming Goods with conforming Goods, or (ii) credit or refund the Price for such Nonconforming Goods pursuant to
the terms set forth herein. Notwithstanding the foregoing, the only remedy for Nonconforming Goods that are custom systems is repair (not refund or
replacement). No returns for Nonconforming Goods are allowed after thirty (30) days from the original shipping date.
(c) Buyer acknowledges and agrees that the remedies set forth in Section 7(a) are Buyer’s exclusive remedies for the delivery of Nonconforming Goods. Except
as provided under Section 7(a) and Section 14, all sales of Goods to Buyer are made on a one-way basis and Buyer has no right to return Goods purchased under
this Agreement to Seller.
8. Price.
(a) Buyer shall purchase the Goods from Seller at the prices (the “Prices”) set forth in Seller’s published catalogue literature in force as of the date of the Sales
Quotation. However, the Prices shown in such catalogue literature or any other publication are subject to change without notice. Unless specifically stated to
the contrary in the Sales Quotation, quoted Prices and discounts are firm for thirty (30) days from the date of the Sales Quotation. Unless otherwise stated,
prices are quoted EXW (Incoterms 2010), Shipping Point. Unless otherwise stated in the Acknowledgement, if the Prices should be increased by Seller before
delivery of the Goods to a carrier for shipment to Buyer, then these Terms shall be construed as if the increased prices were originally inserted herein, and
Buyer shall be billed by Seller on the basis of such increased prices.
(b) All Prices are exclusive of all sales, use and excise taxes, and any other similar taxes, duties and charges of any kind imposed by any governmental authority
on any amounts payable by Buyer. Buyer shall be responsible for all such charges, costs and taxes (present or future); provided, that, Buyer shall not be
responsible for any taxes imposed on, or with respect to, Seller’s income, revenues, gross receipts, personnel or real or personal property or other assets.
9. Payment Terms.
(a) Unless otherwise provided in the Acknowledgement, if Buyer has approved credit with Seller, Buyer shall pay all invoiced amounts due to Seller within thirty
(30) days from the date of Seller’s invoice. If Seller does not have Buyer’s financial information and has not provided pre-approved credit terms for Buyer, the
payment must be made in cash with order or C.O.D. in US dollars. If Buyer has approved credit terms, the payment may be made by cash with order, wire
transfer of immediately available funds, or check in US dollars. Certain products require a down payment. Any payment terms other than set forth above will
be identified in the Acknowledgement. Notwithstanding anything herein to the contrary, all prepaid deposits and down payments are non-refundable. If a
deposit is not received when due, Seller reserves the right to postpone manufacturing of Goods until payment is received. Seller will not be responsible for
shipment delays due to deposit payment delays.
(b) In Seller’s sole discretion, Seller may access Buyer interest on all late payments at the lesser of the rate of 1.5% per month or the highest rate permissible
under applicable law, calculated daily and compounded monthly. Buyer shall reimburse Seller for all costs incurred in collecting any late payments, including,
without limitation, attorneys’ fees. In addition to all other remedies available under these Terms or at law (which Seller does not waive by the exercise of any
rights hereunder), Seller shall be entitled to suspend the delivery of any Goods if Buyer fails to pay any amounts when due hereunder and such failure continues
for ten (10) days following written notice thereof.
(c) Buyer shall not withhold payment of any amounts due and payable by reason of any set-off of any claim or dispute with Seller, whether relating to Seller’s
breach, bankruptcy or otherwise.
10. Intellectual Property; Software License.
(a) To the extent that any Goods provided under this Agreement contains software, whether pre-installed, embedded, in read only memory, or found on any
other media or other form (“Software”), such Software and accompanying documentation are licensed to Buyer, not sold and shall remain the sole and
exclusive property of Seller or third party licensors of Seller. Seller grants Buyer a non-exclusive license to use the Software solely as provided in and in
connection with the use of the Goods in which such Software is contained and in accordance with any applicable user documentation provided with such Goods
and subject to the provisions of this Agreement. Certain of Seller’s Goods may include third party software such as computer operating systems. Licenses to
such third party software are subject to the terms and conditions of any applicable third party software license agreements. Unless identified in the
Acknowledgement, no license is granted by Seller with respect to such third party software products that may be provided with the Goods (if any). Seller makes
no warranties regarding any third party software that may accompany the Goods or otherwise and such software is explicitly included in the definition of Third
Party Products below.
(b) Buyer shall not copy, modify, or disassemble, or permit others to copy, modify, or disassemble, the Software, nor may Buyer modify, adapt, translate,
reverse assemble, decompile, or otherwise attempt to derive source code from the Software. Buyer shall not transfer possession of the Software except as part
of, or with, the Goods, and each such transfer shall be subject to the restrictions contained herein. Buyer may not sublicense, rent, loan, assign or otherwise
transfer the Software or documentation, and Buyer shall retain on all copies of the Software and documentation all copyright and other proprietary notices or
legends appearing therein or thereon. Seller may terminate this license upon written notice for any violation of any of the terms of this license or any material
breach of any provision of this Agreement. Buyer shall immediately discontinue use of the Software upon any termination of this license or Agreement. This
license shall terminate upon any termination of the Agreement.

WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR
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(c) All patents, trademarks, copyrights or other intellectual property rights embodied in the Goods, including without limitation the Software, are owned by
Seller and its licensors. Seller and its licensors retain all right, title and interest in such intellectual property rights. Except as expressly set forth herein, no
license rights or ownership in or to any of the foregoing is granted or transferred hereunder, either directly or by implication. ALL RIGHTS RESERVED.
(d) If Buyer is the United States Government or any agency thereof, each of the components of the Software and user documentation are a “commercial item,”
and “computer software” as those terms are defined at 48 C.F.R. 2.101, consisting of “commercial computer software” and “commercial computer software
documentation,” as such terms are used in 48 C.F.R. 12.212. Consistent with 48 C.F.R. 12.212 and 48 C.F.R. 227.7202-1 through 227.7202-4, all United States
government Buyers acquire only those rights in the Software and user documentation that are specified in this Agreement.
11. Installation and Other Services. Seller shall provide installation services (“Installation Services”) to Buyer if set forth in the Acknowledgment. If Installation
Services are provided for in the Acknowledgement, Buyer will prepare the location for the installation consistent with Buyer’s written specifications and Buyer
will install necessary system cable and assemble any necessary equipment or hardware not provided by Seller, unless agreed otherwise in writing by the parties.
For Goods that will be operated on or in connection with Buyer supplied hardware or software, Buyer is responsible for ensuring that its hardware and software
conform with Seller minimum hardware and software requirements as made available to Buyer. Seller shall provide other field services, such as maintenance
visits and field repairs (the “Other Services” and together with the Installation Services, the “Services”) if set forth in the Acknowledgement.
12. Limited Warranty.
(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 12 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 Product”).
(c) EXCEPT FOR THE WARRANTY SET FORTH IN SECTION 12(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 12(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 12(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 12(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.
(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 12(e) and Section 12(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 12(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 12(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.
13. Limitation of Liability.
(a) IN NO EVENT SHALL SELLER BE LIABLE FOR ANY CONSEQUENTIAL, INDIRECT, INCIDENTAL, SPECIAL, EXEMPLARY, OR PUNITIVE DAMAGES, LOST PROFITS
OR REVENUES OR DIMINUTION IN VALUE, LOSS OF INFORMATION OR DATA, OR PERSONAL INJURY OR DEATH ARISING IN ANY WAY OUT OF THE
MANUFACTURE, SALE, USE, OR INABILITY TO USE ANY GOODS, SOFTWARE OR SERVICE, ORARISING OUT OF OR RELATING TO ANY BREACH OF THESE TERMS,
WHETHER OR NOT THE POSSIBILITY OF SUCH DAMAGES HAS BEEN DISCLOSED IN ADVANCE BY BUYER OR COULD HAVE BEEN REASONABLY FORESEEN BY
BUYER, REGARDLESS OF THE LEGAL OR EQUITABLE THEORY (CONTRACT, TORT OR OTHERWISE) UPON WHICH THE CLAIM IS BASED, AND NOTWITHSTANDING
THE FAILURE OF ANY AGREED OR OTHER REMEDY OF ITS ESSENTIAL PURPOSE.
(b) IN NO EVENT SHALL SELLER’S AGGREGATE LIABILITY ARISING OUT OF OR RELATED TO THIS AGREEMENT, WHETHER ARISING OUT OF OR RELATED TO
BREACH OF CONTRACT, TORT (INCLUDING NEGLIGENCE) OR OTHERWISE, EXCEED THE TOTAL OF THE AMOUNTS PAID TO SELLER FOR THE GOODS SOLD
HEREUNDER.

WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR
x 990-291
(c) ALL WARRANTIES SET FORTH HEREIN, DIRECT OR IMPLIED, ARE VOIDED IF THE INITIAL INSTALLATION AND START-UP OF THE SUBJECT GOOD IS NOT
SUPERVISED BY AN AUTHORIZED REPRESENTATIVE OF SELLER. AFTER INSTALLATION, ANY RE-ALIGNMENT, RE-CLEANING, OR RE-CALIBRATION, PROVIDED
THEY ARE NOT RELATED TO A PROVEN DEFECT IN MATERIALS OR WORKMANSHIP, SHALL BE PERFORMED BY AN AUTHORIZED REPRESENTATIVE OF SELLERAT
THE CURRENT SERVICE RATES.
(d) WHERE GOODS ARE SUBJECT TO A MOVE TO ANOTHER LOCATION AFTER THE ORIGINAL INSTALLATION HAS BEEN MADE, THE WARRANTY MAY BE
MAINTAINED ONLY IF SUPERVISED BY AN AUTHORIZED REPRESENTATIVE OF SELLER. SELLER, FOR A SERVICE CHARGE, WILL ARRANGE FOR AND SUPERVISE
THE DISCONNECTION, TRANSPORTATION, REINSTALLATION AND START-UP OF THE EQUIPMENT. CLAIMS FOR DAMAGE IN SHIPMENT ARE THE
RESPONSIBILITY OF BUYER AND SHALL BE FILED PROMPTLY WITH THE TRANSPORTATION COMPANY.
14. Return Goods Policy. Seller’s products may be returned to Seller for credit within sixty (60) days of shipment subject to the following conditions.
(a) In order to return products for credit, Buyer must obtain a RMA number from Seller. Upon receipt, it must be executed by an authorized person and then
returned with the Goods. Goods returned to Seller without a RMA will be returned at Buyer’s expense.
(b) Goods are to be returned to Seller at 1820 South Myrtle Avenue, Monrovia, CA 91016 with Freight Prepaid. Seller will not accept collect shipments.
(c) Restocking fees will be assessed in accordance with the following schedules: (i) Goods returned within the first thirty (30) days from shipment date will be
restocked less twenty percent (20%) of the amount billed on the original invoice. (ii) Goods returned over thirty (30) days of shipment but less than sixty (60)
days will be restocked less thirty percent (30%) of the amount billed on the original invoice. (iii) No returns are allowed after sixty (60) days from the original
shipping date.
(d) The restocking fees set forth above are the minimum fees. If a returned Good requires rework to restore it to a saleable condition, further charges will be
assessed. Seller’s quality assurance department will document the condition of the Goods when received by Seller and report their findings to Buyer.
(e) Notwithstanding the foregoing provisions of this Section 14, the following Goods cannot be returned, are not eligible for any credit and cannot be
restocked: (i) custom or modified products and (ii) any expendable product(s) that have been used.
15. Compliance with Law and Indemnification. Buyer shall comply with all applicable laws, regulations and ordinances. Buyer shall maintain in effect all the
licenses, permissions, authorizations, consents and permits that it needs to carry out its obligations under this Agreement. Buyer shall comply with all export
and import laws of all countries involved in the sale of the Goods under this Agreement or any resale of the Goods by Buyer. Goods, Services and technical data
delivered by Seller shall be subject to U.S. export controls. Buyer shall, and shall cause its customers to, obtain all licenses, permits and approvals required by
any government and shall comply with all applicable laws, rules, policies and procedures of the applicable government and other competent authorities. Buyer
will indemnify and hold Seller harmless for any violation or alleged violation by Buyer of such laws, rules, policies or procedures. Buyer shall not transmit,
export or re-export, directly or indirectly, separately or as part of any system, the Goods or any technical data (including processes and Services) received from
Seller, without first obtaining any license required by the applicable government, including without limitation, the U.S. government. Buyer also certifies that
none of the Goods or technical data supplied by Seller under this Agreement will be sold or otherwise transferred to, or made available for use by or for, any
entity that is engaged in the design, development, production or use of nuclear, biological or chemical weapons or missile technology. No Buyer information
will be deemed “technical data” unless Buyer specifically identifies it to Seller as such. Buyer assumes all responsibility for shipments of Goods requiring any
government import clearance. Seller may terminate this Agreement if any governmental authority imposes antidumping or countervailing duties or any other
penalties on Goods. For all international shipments, Seller requires that all required Export Control documentations, including Form BIS-711 Statement by
Ultimate Consignee and Purchases, are submitted by Buyer along with the purchase order. Seller reserves the right to postpone shipment until all
documentations are completed and submitted to Seller. Seller will not be responsible for shipment delays due to non-compliance by Buyer of the foregoing two
sentences.
16. Termination. In addition to any remedies that may be provided under these Terms, Seller may terminate this Agreement with immediate effect upon
written notice to Buyer, if Buyer: (i) fails to pay any amount when due under this Agreement and such failure continues for ten (10) days after Buyer’s receipt of
written notice of nonpayment; (ii) has not otherwise performed or complied with any of these Terms, in whole or in part; or (iii) becomes insolvent, files a
petition for bankruptcy or commences or has commenced against it proceedings relating to bankruptcy, receivership, reorganization or assignment for the
benefit of creditors.
17. Waiver. No waiver by Seller of any of the provisions of this Agreement is effective unless explicitly set forth in writing and signed by Seller. No failure to
exercise, or delay in exercising, any rights, remedy, power or privilege arising from this Agreement operates or may be construed as a waiver thereof. No single
or partial exercise of any right, remedy, power or privilege hereunder precludes any other or further exercise thereof or the exercise of any other right, remedy,
power or privilege.
18. Confidential Information. All non-public, confidential or proprietary information of Seller, including, but not limited to, specifications, samples, patterns,
designs, plans, drawings, documents, data, business operations, customer lists, pricing, discounts or rebates, disclosed by Seller to Buyer, whether disclosed
orally or disclosed or accessed in written, electronic or other form or media, and whether or not marked, designated or otherwise identified as “confidential,” in
connection with this Agreement is confidential, solely for the use of performing this Agreement and may not be disclosed or copied unless authorized in
advance by Seller in writing. Upon Seller’s request, Buyer shall promptly return all documents and other materials received from Seller. Seller shall be entitled
to injunctive relief for any violation of this Section 18. This Section 18 does not apply to information that is: (a) in the public domain through no fault of Buyer;
(b) known to Buyer at the time of disclosure without restriction as evidenced by its records; or (c) rightfully obtained by Buyer on a non-confidential basis from a
third party.
19. Force Majeure. Seller shall not be liable or responsible to Buyer, nor be deemed to have defaulted or breached this Agreement, for any failure or delay in
fulfilling or performing any term of this Agreement when and to the extent such failure or delay is caused by or results from acts or circumstances beyond the
reasonable control of Seller including, without limitation, acts of God, flood, fire, earthquake, explosion, governmental actions, war, invasion or hostilities
(whether war is declared or not), terrorist threats or acts, riot, or other civil unrest, national emergency, revolution, insurrection, epidemic, lock-outs, strikes or
other labor disputes (whether or not relating to either party’s workforce), or restraints or delays affecting carriers or inability or delay in obtaining supplies of

WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR
990-291 xi
adequate or suitable materials, materials or telecommunication breakdown or power outage (each a “Force Majeure Event”), provided that, if the event in
question continues for a continuous period in excess of thirty (30) days, Buyer shall be entitled to give notice in writing to Seller to terminate this Agreement.
20. Assignment. Buyer shall not assign any of its rights or delegate any of its obligations under this Agreement without the prior written consent of Seller. Any
purported assignment or delegation in violation of this Section 20 is null and void. No assignment or delegation relieves Buyer of any of its obligations under
this Agreement.
21. Relationship of the Parties. The relationship between the parties is that of independent contractors. Nothing contained in this Agreement shall be
construed as creating any agency, partnership, joint venture or other form of joint enterprise, employment or fiduciary relationship between the parties, and
neither party shall have authority to contract for or bind the other party in any manner whatsoever.
22. No Third-Party Beneficiaries. This Agreement is for the sole benefit of the parties hereto and their respective successors and permitted assigns and nothing
herein, express or implied, is intended to or shall confer upon any other person or entity any legal or equitable right, benefit or remedy of any nature
whatsoever under or by reason of these Terms.
23. Governing Law. All matters arising out of or relating to this Agreement is governed by and construed in accordance with the internal laws of the State of
California without giving effect to any choice or conflict of law provision or rule (whether of the State of California or any other jurisdiction) that would cause
the application of the laws of any jurisdiction other than those of the State of California.
24. Dispute Resolution.
(a) If Buyer is an entity formed under the laws of the United States of America, or any of its states, districts or territories (“U.S. Law”), then any dispute, legal
suit, action or proceeding arising out of or relating to this Agreement shall be adjudicated and decided in the federal courts of the United States of America or
the courts of the State of California in each case located in the City of Los Angeles and County of Los Angeles, California and each party irrevocably submits to
the exclusive and personal jurisdiction of such courts in any such dispute, suit, action or proceeding.
(b) If Buyer is an entity formed under the laws of any country, state, district or territory other than U.S. Law, then the parties irrevocably agree that any dispute,
legal suit, action or proceeding arising out of or relating to this Agreement shall be submitted to the International Court of Arbitration of the International
Chamber of Commerce (“ICC”) and shall be finally settled under the Rules of Arbitration of the ICC. The place and location of the arbitration shall be in Los
Angeles, California, pursuant to the ICC’s Rules of Arbitration and shall be finally settled in accordance with said rules. The arbitration shall be conducted before
a panel of three arbitrators. Each party shall select one arbitrator and the two arbitrators so selected shall select the third arbitrator, who shall act as presiding
arbitrator. Notwithstanding the foregoing, if the matter under dispute is $500,000 or less, there shall only be one arbitrator who shall be mutually selected by
both parties. If the party-selected arbitrators are unable to agree upon the third arbitrator, if either party fails to select an arbitrator, or in the case that only
one arbitrator is required and the parties are unable to agree, then the International Court of Arbitration shall choose the arbitrator. The language to be used in
the arbitral proceeding shall be English. The arbitrator(s) shall have no authority to issue an award that is contrary to the express terms of this Agreement or
the laws of the State of California or applicable US Federal Law, and the award may be vacated or corrected on appeal to a court of competent jurisdiction for
any such error. The arbitrator(s) shall be specifically empowered to allocate between the parties the costs of arbitration, as well as reasonable attorneys’ fees
and costs, in such equitable manner as the arbitrator(s) may determine. The arbitrator(s) shall have the authority to determine issues of arbitrability and to
award compensatory damages, but they shall not have authority to award punitive or exemplary damages. Judgment upon the award so rendered may be
entered in any court having jurisdiction or application may be made to such court for judicial acceptance of any award and an order of enforcement, as the case
may be. In no event shall a demand for arbitration be made after the date when institution of a legal or equitable proceeding based upon such claim, dispute or
other matter in question would be barred by the applicable statute of limitations. Notwithstanding the foregoing, either party shall have the right, without
waiving any right or remedy available to such party under this Agreement or otherwise, to seek and obtain from any court of competent jurisdiction any interim
or provisional relief that is necessary or desirable to protect the rights or property of such party, pending the selection of the arbitrator(s) hereunder or pending
the arbitrator(s)’ determination of any dispute, controversy or claim hereunder.
25. Notices. All notices, request, consents, claims, demands, waivers and other communications hereunder (each, a “Notice”) shall be in writing and addressed
to the parties at the addresses set forth on the face of the Acknowledgement or to such other address that may be designated by the receiving party in writing.
All Notices shall be delivered by personal delivery, nationally recognized overnight courier (with all fees pre-paid), facsimile (with confirmation of transmission)
or certified or registered mail (in each case, return receipt requested, postage prepaid). Except as otherwise provided in this Agreement, a Notice is effective
only (a) upon receipt of the receiving party, upon confirmation of delivery by nationally recognized overnight courier or upon forty-eight (48) hours after being
sent by certified or registered mail (as applicable), and (b) if the party giving the Notice has complied with the requirements of this Section 25.
26. Severability. If any term or provision of this Agreement is invalid, illegal or unenforceable in any jurisdiction, such invalidity, illegality or unenforceability
shall not affect any other term or provision of this Agreement or invalidate or render unenforceable such term or provision in any other jurisdiction.
27. Survival. Provisions of these Terms which by their nature should apply beyond their terms will remain in force after any termination or expiration of this
Order including, but not limited to, the following provisions: Compliance with Laws, Confidentiality, Governing Law, Dispute Resolution, Survival, and the
restrictions on Software in Sections 10(b), (c) and (d).



WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR
990-291 1-1
CHAPTER 1
DESCRIPTION
Function of a Weld Monitor
Two conditions must be met to produce a good weld. First, the oxide layer covering the metal surfaces must
be eliminated. Second, the irregular surface of the metals must be in intimate contact with each other.
All present day welding processes are just different ways of achieving these two goals by using various
combinations of heat, pressure and time. In the resistance welding process, the pressure is applied by the
electrodes which are mounted on a welding head. These electrodes carry a very high electrical current for a
fraction of a second. Heat, generated by the resistance of the workpieces to the flow of electricity, either
melts the workpieces at their interface or at least reduces their strength to a level where their surfaces
become plastic. When the flow of current stops, the electrode force is maintained, for another fraction of a
second, while the weld rapidly cools and solidifies. The size and shape of the weld is generally limited by
the size and contour of the faces of the electrodes.
General practice in resistance spot welding is to base quality control on weld properties as well as on the
uniformity and consistency of results. The quality of spot welds is usually checked by visual inspection and
by destructive testing. Nondestructive testing methods tend to be inconsistent and are not ordinarily used as
an inspection criteria except in the semiconductor industry. Quality standards should be based on the
requirements of the specific application. For example, it is rarely possible to obtain maximum joint strength
and minimum indentation using the same machine settings.
Weld monitors are devices which measure one or more specific electrical and/or mechanical parameters
which dynamically change during the welding process. Somewhat in order of popularity, these
measurements include weld current, the voltage drop across the electrodes, workpiece expansion /
deformation, the electrode force, the size of the electrode face, the acoustic energy emitted while the weld is
being formed, and the temperature of the workpieces. Variations in the thickness, tensile strength, hardness,
surface finish and cleanliness of the workpieces have a significant effect on weld quality. The shape of the
electrode face also affects weld quality. Modern measurement techniques make it possible to accurately
measure the energy and pressure used to make a resistance weld. Weld monitoring is effective to the extent
that the electrical and mechanical measurements made during the welding process reflect the variations in
the physical properties of the workpieces and the welding equipment.
The successful user of a weld monitor usually conducts extensive experiments in order to determine which
combination of measurement parameters correlates with the quality of their specific parts. Once correlation
is verified in a production environment over a reasonable time, the weld monitor becomes a vital
manufacturing tool. To date no weld monitor has been commercially available which simultaneously
monitors all parameters; nor has any monitor successfully predicted the quality of the parts.
AMADA WELD TECH’s - Weld Sentry accurately and consistently measures the voltage (AC/DC) and
current used during the weld process. This makes it superior to any other precision instrument of its type.
Production line testing has shown that the Weld Sentry makes precise measurements that accurately
evaluates the quality of a welding processes and can increase quality and reduce manufacturing costs.

CHAPTER 1: DESCRIPTION
WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR
1-2 990-291
Figure 1-1. Example showing the 250DP/Sentry Main Menu
1. BASIC SETUP 2. PRINT UTILITIES 3. PRINT OPTIONS 4. RELAY OUTPUT 5. SPC 6. SET TIME & DATE 7. SYSTEM SETUP 8. CALIBRATE SENTRY 9.COMMUNICATIONS 10. DISPLAY GRAPH
SENTRY MAIN MENU
This menu is accessed by selectingWeld Sentry from Main Menu.
PRINT RESULTS FOR : NONE/REJECT/ALL WHICH UNIT OFMEASURE : ALL/ONE PRINTGRAPHS : NO/YES/RAW DATA EXPANSION SCALE : X1/X2/X5/X10 PRINTSCHEDULE/PROGRAMS : ON/OFF
PRINT
OPTIONS
PRINT GRAPH LAST WELD PRINT SYSTEM DATA PRINTCURRENT SCHEDULE& PROGRAM PRINT ALL SCHEDULES & PROGRAMS CANCEL PRINTING
PRINT
UTILITIES
MONITOR WHICH PULSE:FIRST PULSE SECOND PULSE
BOTH PULSES
BASIC
SETUP
(SEE SPC MENU)
SPC
MENU
TODAY'S DATE : ## - ## - ## TIME : ## . ## : ##
SET
TIME & DATE
EXTENDED MODE : ON/OFF CURRENTPICKUPTYPE : COIL/SHUNT MULTIPLIER FOR COIL : 1X/10X RESISTANCE VALUE OF SHUNT : 10/1/.1/.01m
SYSTEM
SETUP
VOLTAGE INPUT : ### (*) CURRENTINPUT : ### (*) DISCONNECT THE VOLTAGE AND CURRENTINPUTS FROM THE REAR PANEL OF THE SENTRY. VALUE SHOULD BE LESS THAN 3.
CALIBRATE
SENTRY
ROLE : MASTER/SLAVE I. D. NUMBER : ## BAUD RATE : 1200/2400/4800/9600 PRINTER PROTOCOL : IBM/EPSON
COMMUNI-
CATIONS
ZOOM. 1/2/5/10 ms/div VIEW: 0/4/8. . ms ##A
DISPLAY
GRAPH
1. RELAY K1 2. RELAY K2 3. RELAY K3 4. RELAY K4 5. INHIBIT 250DP 6. RELAY SIGNAL
RELAY
OUTPUT
CHECK THE MEASUREMENT CABLES AND CONNECTIONS. MAKE A SAMPLE WELD SO THAT THE SENTRY CAN DETERMINE A MONITORING PROBLEM
SAMPLE
WELD
TEST
WELD
MAKE ANOTHER WELD. THE SENTRY WILL MONITOR THE TEST WELD AND DISPLAY THE GRAPHIC RESULTS.
PULSE 1: ###.# (*) PULSE 1: MEASUREMENT UNITS (SEE NOTE 1) PULSE 2: ###.# (*) PULSE 2: MEASUREMENT UNITS (SEE NOTE 1)
REVIEW
MEASUREMENTS
(SAVE) SAVE PROGRAM AS PERMANENT PROGRAM (RUN) COPY PROGRAM TO TEMPORARY PROGRAM 0 (MENU) DISCARD INFORMATION & EXIT
ENTER
REJECTHI : ON/OFF REJECT LO : ON/OFF ACCEPT : ON/OFF MARGINAL : ON/OFF NO WELD : ON/OFF OVER LOAD: ON/OFF
RELAY
STATUS
LOW RANGE : ### (*) HIGH RANGE : ### (*)
COIL
CALIBRATION
TOTAL NUMBER OF WELDS : ####### NUMBER OF REJECTS LOW : ##### NUMBER OFREJECTS HIGH : ##### NUMBER OF ACCEPT WELDS : #####
WELD
COUNTER
(WHEN THE SENTRY IS INSTALLED, THIS SCREEN REPLACES THE WELD COUNTER SCREEN IN THE 250DP MENU.)
MEASUREMENT UNIT : (SEE NOTE 1) LOWER LIMIT : ###.#  UPPER LIMIT : ###.#  WELD STATUS: REJECT HI/REJECT LOW/NO WELD /OFF/MARGINAL/OVER LOAD/ACCEPT PROGRAM NUMBER : A - E
RUN
SCREEN
MEASUREMENT UNIT : (SEE NOTE 1) LOWER LIMIT : ###.#  UPPER LIMIT : ###.#  SENTRY STATUS : ON/OFF PROGRAM NUMBER : A - E
PROGRAM
SCREEN
(BOTTOM TWO ROWS OF THE 2500DP PROGRAM SCREEN)
[PROG]
ACTIVATION DELAY : 0 > 500 ms REMAIN ON : 2 > 500 ms/
UNTIL NEXT WELD
RELAY
SIGNAL
CHAINING MODE : > /END/RPT PULSE TO MEASURE : 1ST PULSE/2ND PULSE VOLTAGE GAIN : 32/15/8/4/2/1/.5/.25/AUTO CURRENTGAIN : 32/16/8/4/2/1/.8/.4/.2/.1/AUTO DELAY TIME : 0.00 > ##.# ms (*) MEASUREMENT TIME : 0.00 > ##.# ms (*)
PROGRAM
OPTIONS
DELAY TIME : ###.# MEASUREMENT TIME: ###.# MEASUREMENT UNIT ## A
BASIC SETUP
GRAPH
DELAY TIME : ###.# MEASUREMENT TIME: ###.# MEASUREMENT UNIT ## A
BASIC SETUP
GRAPH
[CHNG], [NUMBER]
[PROG]
[SAVE] , [RUN]
[SAVE] , [RUN]
(BOTTOM TWO ROWS OF THE 2500DP PROGRAM SCREEN)
Note 1: Measurement unit
(1) When extended mode is off: (2) When extended mode is on:
Note 2: (*) = Display only; cannot change
AmpCSec/VoltCAmp-VoltCSec/OhmCSec /WattCSec/RMS Amp Amp2CSec/Volt2CSec/Peak Amps/
Peak Volts/Peak Watts/Ohms @ Peak
: HOST / CLIENT

WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR
990-291 2-1
CHAPTER 2
GETTING STARTED
Rear Panel Components
The Weld Sentry option is an available option for multiple AMADA WELD TECH Power Supplies. The
illustration below shows the input and output connections on the rear panel of the obsolete PM7S
(Phasemaster 7 with Sentry Option). The I/O Connections will be the same over the different product lines.
Weld
Sentry
Option
A VOLTAGE INPUT: 3-pin receptacle for the 7 foot (2.1 m) shielded cable assembly which is used to
measure Weld Voltage. The voltage measurement range is 0.10 to 40 volts peak. The clip terminals
permit easy attachment of this cable to the welding electrodes. Polarity is not important.
B CURRENT INPUT: 2-pin receptacle for the Current Coil or Current Input Cable for a user supplied
Shunt. Supplied with a snap-on 1x current Coil, Model WSPUC 150, with 9.8 feet (3 m) of cable
and a measurement range of 150 to 40,000 amps peak. The optional 10x Current Coil, Model
WSPUC 15, is available, with a measurement range of 15 to 4,000 amps peak. The measurement
range for user supplied Shunts is 10 to 40,000 amps.
1
2
OUTPUT
POWER
OFF
OFF
CB1
A
Figure 2-1. Rear Panel of PM7S with Sentry Option Installed
LCD
CONTRAST
MECHANICAL
FIRING
SWITCH
OPTICAL
FIRING
SWITCH
FOOTSWITCH
ACCESSORY
PORT
AIR VALVE
DRIVE
CONTROL
SIGNALS
VOLTAGE
INPUT
CURRENT
INPUT
COIL
SHUNT
START
SIGNAL
RS
-232
SERIAL
PORT
RELAY
OUTPUT

CHAPTER 2: GETTING STARTED
WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR
2-2 990-291
C COIL/SHUNT SWITCH: Selects whether a Current Coil or a Shunt is used to measure welding
current. The “OUT” position selects Shunt and the “IN” position selects Coil.
D EXT. TRIGGER: External Triggering is not used when the Sentry is installed in the power supply.
E RS-232 SERIAL PORT: DB-25 Connector is used to connect the Sentry’s RS-232 Communications
Interface. The Sentry can transmit data in ASCII or Binary Format. Transmit lines and
communications protocol can be configured by changing the position of 5 shunts, E1-E5, on the
Sentry’s control board.
F OUTPUT: 2 DC solid state relays, 3 to 60 volts, 1 amp. Relays can be programmed to activate
under any combination of six conditions: Accept; Marginal; Reject Low; No Weld; and Input
Overload. As an option, 2 additional DC or AC solid state relays can be added. AC solid state
relays are rated 12 to 280 volts, 1 amp.
Screen Format
In the screen examples below, both the 250DPS and PM7S are obsolete products, however the screen
displays are basically the same across all product lines:
a250DPS RUN STATE SCREEN,
bSENTRY MAIN MENU,
c250DPS PROGRAM STATE SCREEN,
dSENTRY PROGRAM SCREEN,
eSENTRY PROGRAM GRAPH and
fPM7S RUN STATE.
where “S” indicates the Sentry Status Line which shows: Sentry Program (A-E), Measurement Unit
(results of last weld), Upper/Lower Limits; and Sentry Status (ON/OFF).

CHAPTER 2: GETTING STARTED
WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR
990-291 2-3
(a) RUN STATE (b) SENTRY MAIN MENU
(c) 250DPS PROGRAM STATE (d) SENTRY PROGRAM SCREEN
(e) SENTRY PROGRAM GRAPH (f) PM7S RUN STATE
< SENTRY MAIN MENU >
■ BASIC SETUP ■ SET TIME & DATE
■ PRINT UTILITIES ■ SYSTEM SETUP
■ PRINT OPTIONS ■ CALIBRATE SENTRY
■ RELAY OUTPUT ■ COMMUNICATIONS
■ SPC ■ DISPLAY GRAPH
◄▼▲► Select then ENTER
SCHEDULE: 01
FUNCTION: BASIC WELD # : 00001
POLARITY: [ + ] WIDTH : SHORT
PULSE 1 PULSE 2
ENERGY :010% 030.0%
AMP SECONDS LOWER UPPER SENTRY PROG
0 63.00x 77.00x ON A
PROG Sentry Programs, ◄ ► A – E □PROGRAM □
PROGRAM : 01A → 01B END
PULSE TO MEASURE : FIRST SECOND
VOLTAGE GAIN : 4 4
CURRENT GAIN : 2 2
DELAY TIME : 00.00 ms 0.000 ms
MEASUREMENT TIME : 20.00 ms 15.00 ms
◄▲▼► SELECT, NUMBERS Change □ PROGRAM □
SCHEDULE: 9 UP / DOWNSLOPE
SYSTEM: AIR 2-LEVEL [ + ] WELD: 0000001
SQZ UP WELD DOWN HOLD
CYCLES: 10 12 10 0 0
CURRENT: 30 75 20
AMP SECONDS LOWER UPPER SENTRY
(A) 299.1µ 270.0µ 310.0µ READY
▲▼ Select Schedule □ RUN □
0ms DELAY TIME 0.600ms 1ms/div
Amp*Seconds
00A
1st
▲SELECT ▼, ◄MODIFY ►, CHNG, SAVE
SCHEDULE PULSE 1 PULSE 2
1 10.0% 35.0%
BASIC WELD POLARITY: (+)WIDTH: SHORT
AIR HEAD 2-L WELD#: 00001
AMP-SECONDS LOWER UPPER SENTRY
(A) 299.1µ 270.0µ 310.0µ READY
▲ ▼ Select Schedule RUN
S
SCHEDULE PULSE 1 PULSE 2
1 10.0% 35.0%
BASIC WELD POLARITY: (+)WIDTH: SHORT
AIR HEAD 2-L WELD#: 00001
AMP-SECONDS LOWER UPPER SENTRY
(A) 299.1µ 270.0µ 310.0µ READY
▲ ▼ Select Schedule RUN
S

CHAPTER 2: GETTING STARTED
WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR
2-4 990-291
Flow Chart for Sentry SPC Menu
1. STATISTICS, RUN CHART &HISTOGRAM 2. X &R CONTROL CHART AND SUMMARIES 3. SAMPLING MODE 4. REJECT REPORT 5. PRINT HISTORY & ERASE HISTORY
SENTRY SPC MENU
(This menu is selected from Sentry Main Menu) Note 1. (*) = Display only and cannot change.
MEASUREMENT UNIT : AMPCSEC (*) AVERAGE : # . #### (*) STANDARD DEVIATION : # . #### (*)
MAXIMUM VALUE : # . #### (*) MINIMUM VALUE : # . #### (*)
PROGRAM
STATISTICS
SAMPLING MODE : CONTINUOUS/PERIODIC SUB GROUP SAMPLE SIZE : ## SAMPLING PERIOD : ###
SAMPLING
MODE
1. PRINTHISTORY 2. ERASE HISTORY FOR LAST WELD 3. ERASE HISTORY FOR ONE SCHEDULE 4. ERASE HISTORY FOR ALL SECHEDULES
ERASE
HISTORY STATISTICS
DISPLAY SCHEDULE NUMBER : ## WELDS TO USE FOR CALCULATIONS : #### WELDS AVAILABLE FOR IN HISTORY : #### (*)
HISTOGRAM
DISPLAY CHART FOR SCHEDULE : ## (*)
WELDS TO USE FOR CALCULATIONS : #### (*) SUB GROUP SAMPLE SIZE : ## (*) WELDS AVAILABLE IN HISTORY : #### (*)
SAMPLING PERIOD (*) : CONTINUOUS
CONTROL
CHART
MEASUREMENT UNIT : AMPCSEC (*) SUBGROUPCOUNT : ##### (*)
AVERAGE X OR R : # . #### (*) UPPER CONTROL LIMIT : # . #### (*) LOWER CONTROL LIMIT : # . #### (*)
CONTROL
CHART
NEW SAMPLE SIZE OR INTERVAL IS NOTODIC COMPATIBLE WITH HISTORY ALL HISTORY WILL BE LOST PROCEED? YES/NO
ERASE
HISTORY
PROGRAM ##
REJECT REPORT
TOTAL WELDS : ###### (*) ACCEPTCOUNT : ###### ## . ##% (*)
REJECTHIGH : ###### ## . ##% (*)
REJECT LOW : ###### ## . ##% (*) TOTAL REJECT : ###### ## . ##% (*)
HISTORY FOR LAST WELD WILL BE LOST PROCEED? YES/NO
ERASE
HISTORY
ERASE HISTORY FOR SCHEDULE ##
ERASE
HISTORY
ALL HISTORY WILL BE LOST PROCEED? YES/NO
ERASE
HISTORY
ERASE HISTORY FOR SCHEDULE ## PROGRAM## A-E HISTORY WILL BE LOST PROCEED? YES/NO
ERASE
HISTORY
[CHNG] [CHNG] [CHNG] [CHNG] [CHNG]
ENTER SCHEDULE NUMBER ##
REJECT
REPORT
[ENTER] PRINT STATISTICS REPORT [ENTER] PRINTHISTOGRAM [ENTER] PRINT RUN CHART [ENTER] PRINT CONTROL CHART REPORT [ENTER] PRINT CONTROL CHART [ENTER] PRINTREPORT
PROGRAM
STATISTICS
# . #### # . #### # . ####
CONTROL
CHART
UCL X LCL

WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR
990-291 3-1
CHAPTER 3
INSTALLATION
Sentry Option
Current and Voltage Measurement Inputs
Input cables to pick up Weld Current and Weld Voltage must be connected at the rear panel of the
Sentry. To measure Weld Current the Sentry uses either a Current Coil or a user supplied Current
Shunt. Select the type of Current Input to be used by depressing the Coil/Shunt Switch on the rear panel
and by selecting the Shunt Size from the System Setup Menu. Weld Voltage is measured by attaching
the clips on the Voltage pickup cable to the welding electrodes.
Current Coil Installation
Snap open the Current Coil and slip the open coil over one welding cable or one electrode holder as
shwn in figure 3-1. The position of the Weldmatic current Coil is not critical. However, in some cases
changes of several percent in the Sentry measurement reading can be produced by moving the Current
Coil around. It is best to center the Current Coil and even better to orient the Current Coil in the same
positon each time it is removed and re-attached. Snap the coil completely closed.
Plug the Current Coil Connector into the matching receptacle on the Sentry rear panel. Depress the
COIL/SHUNT Switch to select COIL.
Figure 3-1. Current Coil Placed Over a Single Welding Cable

CHAPTER 3: INSTALLATION
WELD SENTRY RESISTANCE WELDING PROCESS CONTROL MONITOR
3-2 990-291
Current Shunt Installation – User Supplied
Current Shunts are 4 terminal precision resistors capable of handling very large currents. The maximum
recommended Current Shunt voltage drop should be limited to 0.5 volts in order to minimize weld
energy losses. Use the Current Coil, supplied with the Sentry Option, to determine the proper shunt.
Current Shunts can be obtained from meter manufacturers such as Simpson and Tripplet. The following
table provides a guide to Current Shunt selection.
Weld Current
(Max Amps)
Shunt Resistance
(milliohms)
50
10.0
500
1.0
5,000
0.1
50,000
0.01
To install the Current Shunt, disconnect the welding cable coming from one of the terminals on the weld
head as shown in figure 3-2. Place the Current Shunt betweed the open connections and then securely
re-attach all connections.
Figure 3-2. Current Shunt Installation