Timer Controller PDF

Changing The Setting Range of Up Slope for OBARA AC Timer controller
Because a minimum, set value of the improvement slope became "0cyc" from “1cyc", it
explains the change point.
（Available for Software Version TM 6.4（SM064）, TP 6.4（SP064）, DP 6.4（SD064） and their succeeding version）
１．Contents of Design Change ３．Date of enforcement

Minimum setting value of UP SLOPE was 1 cyc for old spec., but This applies to all the products that will be shipped after 1 July,
it is possible to set 0 cyc for the New spec. 2007.
Type Place of Destination （OBARA Model）
R
POWER
W-TC Japan STN21 -ECL-TY3JPN

C US
CAUTION
WARNING!
Teaching
F1 F2 F3 F4
F5 F6 F7 F8
F-Disp. TM#
Select Home ELECTRIC
HAZARD
AW-TC North America STN21 -ECL-TY3USA

SW. Last Step No- Conti.
Start Step End Alarm Weld Press Set Ready
Pendant
Shift Step
Reset 7 8 9 Danger/? ?
Reset D E F
4 5 6
A B C
Help 1 2 3
ON
0
OFF
UW-TC UK,TMMT,TMCA (CE Spec.) STN21 -ECL-TY3ENG

JAPAN
RESISTANCE WELDING
Hazardous voltage. CONTROLLER
STN21-ECL-TY3CSA
MODEL/ TYPE
Will cause severe POWER INPU T AC 460 V 5 0/60 Hz 1 PH ASE
injury or death. POWER OUTPU T AC 460 V 1 PHASE
Turn power off POWER RATING 480V 150 KVA at 50% duty cycle
before servicing. VALV E MAXIMUM OUTPUT CURRENT 0.5 A at DC24 V

SCR TYPE MTL500TY1-16 SIZE E
垿? ? ?
WORKAB LE TEMPERATURE 0∼50℃ WEIGHT 25 Kg
感電による火傷や死亡の恐れ有り。 DIAGRAM No. E3-1348* MFG.DATE 2007.01
メンテナンスの時は必ず電源を切って SER IAL No. 20000
から行って下さい。 MADE IN CHINA
ES4-7036
CHW-TC China STN21 -ECL-TY3CHN
Instantaneous RW-TC Russia (GOST-R Spec.) STN21 -ECL-TY3RUS

Set Value current tester
CW-TC Canada (CSA Approved) STN21 -ECL-TY3CSA
UP SLOPE WELDING TIME BRW-TC Brazil STN21 -ECL-TY3BRA

1cyc 3cyc Measurement Value W-TC1 Series All Model ( As of 1 July, 2007.)
４．Reason of Changes
UP SLOPE setting value of the old spec. was a minimum 1 cyc. (It was not
4cyc able to set 0 cyc.) So even if customer does not want to set UP SLOPE, it has
to be 1 cyc. In this case, the current tester detected total cyc that was
the welding time + 1 cyc of UP SLOPE. The 1 cyc difference which
occurred between the measurement value of the current tester and setting
Old spec.: Min. setting value of UP
value of welding time caused a misunderstanding for customer.
SLOPE was 1 cyc.
５． Compatibility
・ Connection from the conventional Teaching Pendant
UP WELDING TIME to New Spec Timer controller.
SLOPE: 0
4cyc After changing to new spec., in the New Spec. New Spec Conventional
case of zero setting of UP SLOPE,
Timer controller T/P T/P
setting value of welding time is the UPS UPS
same as measurement value.
F1 F2 F3 F4 F1 F2 F3 F4
F5 F6 F7 F8 F5 F6 F7 F8
F-Disp. TM# F-Disp. TM#

Select Home Select Home
R SW. Last Step No - Conti. SW. Last Step No - Conti.

POWER Start Step End Alarm Weld Press Set Ready Start Step End Alarm Weld Press Set Ready
C US
Shift Step
Reset 7 8 9 Shift Step
Reset 7 8 9
Reset D E F Reset D E F
UPS 4
A
5
B
6
C
4
A
5
B
6
C
1 1
CAUTION
WARNING! Help
ON
2 3 Help
ON
2 3
OK
0 0
OFF OFF
JAPAN JAPAN
UPS UPS
ELECTRIC
HAZARD
(Notice) If the setting values are UP SLOPE: Danger/? ?
0 cyc and WELDING TIME: 4cyc, both

setting value and the measurement value are RESISTANCE WELDING
In the case of not using UP SLOPE,

STN21-ECL-TY3CSA
MODEL/TYPE
Will cause severe
OK
POWER INPUT AC 460 V 50/60 Hz 1 PHASE
injury or death. POWER OUTPUT AC 460 V 1 PHASE
same. However, UP SLOPE of 1cyc is

before servicing. VALVE MAXIMUM OUTPUT CURRENT 0.5 A at DC24 V
垿? ? ?
WORKABLE TEMPERATURE 0∼50℃ WEIGHT 25 Kg
感電による火傷や死亡の恐れ有り。 DIAGRAM No. E3-1348* MFG.DATE2007.01
メンテナンスの時は必ず電源を切って 20000
SERIAL No.
から行って下さい。
it is possible to set 0 cyc.

MADE IN CHINA
ES4-7036
included in the first of welding time.

Therefore actual WELDING TIME is 3 cyc
except UP SLOPE.
New Spec Timer controller can be operated with the conventional Teaching
Pendant. However, if UP SLOPE is set to the conventional Teaching Pendant,
２． Identification setting value is minimum 1 cyc. That will be the only thing different from the
New spec Teaching Pendant.
・ For timer controller, Teaching Pendant, and reset box of the new
spec., a “UPS” label is attached to the front door as drawing ・ Connection from New Spec Teaching Pendant to the conventional
below shows. Timer controller.
Conventional Conventional New Spec
・ There is not any distinction for model names between the
conventional Timer controller and the New spec Timer controller. UPS
F1 F2 F3 F4 F1 F2 F3 F4
F5 F6 F7 F8 F5 F6 F7 F8
F-Disp. TM# F-Disp. TM#

Select Home Select Home
R SW. Last Step No - Conti. SW. Last Step No - Conti.

POWER Start Step End Alarm Weld Press Set Ready Start Step End Alarm Weld Press Set Ready
Identifying Mark
C US
Shift Step
Reset 7 8 9 Shift Step
Reset 7 8 9
Reset D E F Reset D E F
UPS 4
A
5
B
6
C
4
A
5
B
6
C
1 1
CAUTION
WARNING! Help
ON
2 3 Help
ON
2 3
OK
0 0
OFF OFF
JAPAN JAPAN
UPS UPS
ELECTRIC
HAZARD
UPS
Danger/? ?
RESISTANCE WELDING
STN21-ECL-TY3CSA
MODEL/TYPE
R
Will cause severe
POWER
OK
POWER INPUT AC 460 V 50/60 Hz 1 PHASE
injury or death. POWER OUTPUT AC 460 V 1 PHASE
C US before servicing. VALVE MAXIMUM OUTPUT CURRENT 0.5 A at DC24 V
垿? ? ?
メンテナンスの時は必ず電源を切って 20000
SERIAL No.
から行って下さい。 MADE IN CHINA
UPS
ES4-7036
CAUTION
WARNING!
ELECTRIC
HAZARD
Conventional Timer controller can be connected and operated with New

SW.
Start
Last
Step
Step
End Alarm
No-
Weld
Conti.
Press Set Ready
F1 F2 F3 F4
Danger/? ?
Spec Teaching Pendant. Setting value of UP SLOPE is a minimum of 1 cyc
F5 F6 F7 F8
F-Disp. TM#
Select Home
for both the conventional Teaching Pendant and the New spec Teaching
SW. Last Step No- Conti.
Pendant.
Shift Step
Reset 7 8 9
Reset D E F RESISTANCE WELDING
STN21-ECL-TY3CSA
MODEL/TYPE
Will cause severe
4 5 6 injury or death.
POWER INPUT
POWER OUTPUT AC
AC 460 V 50/60 Hz
460 V 1 PHASE
1 PHASE
A B C
・ Connection from Display Pendant to New Spec/Conventional Timer

JAPAN 0.5 A at DC24 V
1 before servicing. VALVE MAXIMUM OUTPUT CURRENT
UPS Help
ON
2 3 垿? ? ? SCR TYPE MTL500TY1-16 SIZE E
0 メンテナンスの時は必ず電源を切って
から行って下さい。
SERIAL No. 20000
MADE IN CHINA
OFF ES4-7036
UPS
JAPAN
controller.
It is possible to use both the New spec/conventional Display Pendant
for the New spec/conventional Timer controller. There is no change
of operation. Each combination has interchangeability.
Design Change of OBARA AC Timer controller
with Additional SOL Over-current Protector
Changes from Conventional Timer controller W-TC Series to New Specification Timer
controller W-TC1 Series are as follows.
（Available for Software Version TM 6.5（SM065）, TP 6.5（SP065）, DP 6.5（SD065） and their succeeding version）
１．Changes ３．New Specification Model

・ Circuit Protector (SP3) for the over-current was added as New Spec Timer controller can be distinguished from the
measures against short-circuiting of Solenoid-controlled valve conventional by adding “1” at the end of model No. This applies to
output, upgrading the main board. Also, the following Alarms the products that will be shipped after 21 Jan.2008.
were added; The conventional timer controller can be manufactured and
New Spec. Timer controller
supplied as spares.
W-TC1 Series
Type Place of Destination （OBARA Model）
Added
SP3 W-TC1
W-TC Japan STN21 -ECL-TY3JPN1
-ECL-TY3JPN
AW-TC1
AW-TC North America STN21 -ECL-TY3USA1
-ECL-TY3USA
U
V
SP3
PNP-MU NPN-MU PNP-PO NPN-PO
UW-TC1
UW-TC UK,TMMT,TMCA (CE Spec.) STN21 -ECL-TY3ENG1
-ECL-TY3ENG
PE
02 CHW-TC1
CHW-TC China STN21 -ECL-TY3CHN1
-ECL-TY3CHN
G1 K1
G2 K2
01
RW-TC1
RW-TC Russia (GOST-R Spec.) STN21 -ECL-TY3RUS1
-ECL-TY3RUS
T1 T2
01 0
200
220
1 2 03
240
0
180
CW-TC1
CW-TC Canada (CSA Approved) STN21 -ECL-TY3CSA1
-ECL-TY3CSA
G1 K1
220
240
K2 G2
BRW-TC1
BRW-TC Brazil STN21 -ECL-TY3BRA1
-ECL-TY3BRA
W-TC1 Series All Model （ As of 21 January, 2008）
・ Added Alarms ４．Reason of changes
SP3 Trip （021 SP3 Trip） With the conventional timer controller, when the wiring of Solenoid
Detection
Detect Circuit Protector(SP3) tripping and output the alarm. When the operated valve is short-circuited by wrong wiring , the main board
Circuit Protector is OFF, detect it as well as tripping.
may fail. If the circuit protector of I/O Power(SP1 on the main
Check if there is fault such as the incorrect wiring of the solenoid valve or board) is tripped, “031 SCR O. Heat” is abnormally shown.
Measures
short circuit between wires. After the correction, Turn Circuit Protector(SP3)
ON and the abnormal alarm can be reset.
Circuit Protector(SP3) is to protect the solenoid valve output against the ５．Compatibility
Descript.
over-current. The Circuit Protector(SP3) is tripped when the over-current

flows because of wrong wiring or short circuit between the wires. ・ Connection from the conventional Teaching Pendant
to New Spec Timer controller.
I/O Power Check（020 I/O Pwr CHK.）
New Spec. New Spec Conventional
Detect Circuit Protector for I/O Power （SP1 on the main board）tripping and T/P T/P
Detection
Timer controller
outputs the alarm. And detect it when the alarm “SCR O. Heat” and “ Tr. O. SP3
Heat” happen simultaneously.
F1 F2 F3 F4
F5 F6 F7 F8
During this alarm, if the power indicator lamp on the door is lit, Circuit
F-Disp. TM#
Select Home
SW. Last Step No - Conti.

POWER
Measures
Shift Step
Reset 7 8 9
Reset D E F
Protector for I/O Power is tripped. Press the button on SP1 to return. UPS
Help
4
1
A
ON
5
B
2
6
3
C
OK
寈崘 0
In case of power indicator lit, the SCR and the welding transformer may
OFF
JAPAN
UPS
simultaneously overheat. Check the coolant water. When checking, be 怗? 婋?

姶揹拲堄
sure to turn off power and be careful about burn injury. ? ? /? ?
Conventional timers detect wrongly the abnormality of “SCR O. Heat” and

OK
RESISTANCE WELDING CONTROLLER
Description
挙渼? ? MODEL /TYPE STN21-ECL-TY3CHN1

POWER INPUT AC 380 V 50/60 H Z 1 PHASE
? ? 氷? ? ? 淜? ? ? 湉? ? ? ? 0.5 A at DC24
VAL VE MAXI MUM OUT PUT CUR RENT V
? ? ? ? ? ? ? ? ? ? ? ? ? SCR T YPE MTL500TY1-16 SIZE E
6 L/min ? 0? 30亷
SCR M INIMUM WATER F LOWRAT E
垿? ? ?
“ Tr. O. Heat” when the circuit protector for I/O Power (SP1 on the main
0.5 MPa
SCR M AXIMUM WATER P RESSUR E
感電による火傷や死亡の恐れ有り。 WOR KABLE T EMPERAT URE 0? 50亷 WEIGH T
25 Kg
メンテナンスの時は必ず電源を切って DIAGR AM No. ES3-1017* MFG.DA TE
から行って下さい。 S ERIAL N o.
MA DE IN C HINA
ES4 -7089
board). Therefore, the prior alarm 031 SCR O. Heat is shown. The alarm
output of the new spec timer is changed in case that “SCR O. Heat” and
“ Tr. O. Heat” simultaneously happen.
New Spec Timer controller can be operated with the conventional
Teaching Pendant. However, the additional alarm cannot be shown
２．Identification correctly. This is the only difference from the New Spec TP.
・ New Spec Timer controller can be distinguished from the
conventional Timer controller by adding “1” at the end of model No. ・ Connection from New Spec Teaching Pendant to the
Conventional Timer controller ＝ □□W-TC conventional Timer controller.
New Spec Timer controller ＝ □□W-TC1 Conventional New Spec
Conventional
・ New Spec Timer controller are labeled with “Identifying mark” at SP3
the front of Teaching Pendant and Display Pendant (Reset Box). F1
F-Disp. TM#
Select Home
F5
F2
F6
F3
F7
F4
F8
（See below）
SW. Last Step No - Conti.
POWER
Shift Step
Reset 7 8 9
Reset D E F
UPS 4
A
5
B
6
C
Help 1 2 3
ON
寈崘
OK
0
OFF
JAPAN
UPS
怗? 婋?
姶揹拲堄
Identifying Mark Added 1 at the end of

? ? /? ?
the model code 挙渼? ?

MODEL/TYPE STN21-ECL-TY3CHN1
OK
POWER INPUT AC 380 V 50/60 HZ 1 PHASE
? ? 氷? ? ? 淜? ? ? 湉? ? ? ? VALVE MAXIMUM OUTPUT CURRENT 0.5 A at DC24 V
? ? ? ? ? ? ? ? ? ? ? ? ? SCR TYPE MTL500TY1-16 SIZE E
SP3
SCR MINIMUM WATER FLOWRATE 6 L/min? 0? 30亷
垿? ? ? SCR MAXIMUM WATER PRESSURE 0.5 MPa
感電による火傷や死亡の恐れ有り。 WORKABLE TEMPERATURE 0? 50亷 WEIGHT 25 Kg
メンテナンスの時は必ず電源を切って DIAGRAM No. ES3-1017* MFG.DATE
から行って下さい。 SERIAL No.
MADE IN CHINA
ES4-7089
POWER
UPS
Conventional Timer controller can be connected and operated with
寈崘
New Spec Teaching Pendant. However, the alarm “031 SCR O.
怗? 婋?
姶揹拲堄
Heat” is shown when the circuit protector of I/O Power(SP1 on the
? ? /? ?
main board) is tripped because it is detected as abnormal output
from the conventional Timer controller.
挙渼? ?
? ? 氷? ? ? 淜? ? ? 湉? ? ? ?
? ? ? ? ? ? ? ? ? ? ? ? ?
MODEL/TYPE
POWER INPUT
SCR TYPE
STN21-ECL-TY3CHN1
AC380 V
MTL500TY1-16
50/60 HZ
SIZE E
1 PHASE
0.5 A at DC24
VALVE MAXIMUM OUTPUT CURRENT V
・ Connection from Display Pendant to New Spec/Conventional Timer
controller.
6 L/min? 0? 30亷
SCR MINIMUM WATER FLOWRATE
垿? ? ? 0.5 MPa
SCR MAXIMUM WATER PRESSURE
感電による火傷や死亡の恐れ有り。 WORKABLE TEMPERATURE 0? 50亷 WEIGHT 25 Kg
メンテナンスの時は必ず電源を切って DIAGRAM No. ES3-1017* MFG.DATE
から行って下さい。 SERIAL No.
MADE IN CHINA
ES4-7089
Display Pendant can be connected as well as above.

The alarm is shown in the same manner as above.
Version 2.6
Ver. No.SM063 or later
Ver. No.SM064 or later（For UPS）
Ver. No.SM065 or later（For SP3）
Ver. No.SP043 or later
Ver. No.SP064 or later（For UPS）
Ver. No.SP065 or later（For SP3）
Ver. No.SD042 or later
Ⅰ．SPECIFICATIONS Ver. No.SD064
Ver. No.SD065
or
or
later（For
later（For
UPS）
SP3）
WELDING CONTROLLER
W-TC Series
（STN21-ECL-TY3 Series）
W-TC1 Series（With SOL over-current protection （SP3））
（STN21-ECL-TY3***1 Series）
For the safety use, read the safety precautions of

this instruction manual thoroughly to have a proper
understanding of it before operating this equipment.
Be sure to keep this manual in a specified place
after reading. 2008.05.27 No.0276EN-Ⅰ
Notes on safety and handling procedure
= Notes on safety and handling procedure =

Read this instruction manual thoroughly before using
in order to use the product properly.
• Installation, maintenance inspection, and repairing service of this equipment must be provided by qualified
technicians or those who sufficiently understand welding machines for safety reasons.
• For safety purposes, operation of this equipment must be made by skilled persons who understand what is
described in this manual and are able to provide necessary safety control.
• For safety training, reference is made to various kinds of seminars and qualification tests for welding
technicians and engineers held under the auspices of Welding Academy, Welding Association, and related
organizations.
• Be sure to keep this instruction manual at a specified place for everyone.
• For further information, please contact any of our offices whose phone or fax numbers are listed below.
Manufacturer: OBARA Corporation
Head Office: 4-2-37 Ogami, Ayase-shi, Kanagawa-ken 252-1104 JAPAN
OBARA CORP. JAPAN TEL +81-467-70-7688 FAX +81-467-70-7699
OBARA CORP. U.S.A.
HERCULES WELDING
TEL +1-586-755-1250 FAX +1-586-755-6790
PRODUCTS DIVISION
CINCINNATI PLANT TEL +1-859-283-5490 FAX +1-859-283-5498
CANADA OFFICE TEL +1-519-485-6277 FAX +1-519-485-6277
OBARA MEXICO, S. DE R.
TEL +52-449-971-1525 FAX +52-449-971-1526
L. DE C.V.
OBARA CORP. UK
TEL +44-1332-297-868 FAX +44-1332-341-600
BRANCH OFFICE
OBARA CORP. FRANCE
TEL +33-3-27-23-76-16 FAX +33-3-27-23-76-17
BRANCH OFFICE
OBARA (MALAYSIA)
TEL +60-3-5191-9688 FAX +60-3-5191-9699
SDN.BHD.
OBARA (NANJING)
MACHINERY & ELECTRIC, TEL +86-25-5210-4304 FAX +86-25-5210-4305
LTD.
OBARA (SHANGHAI)
TEL +86-21-50462668 FAX +86-21-50462558
CO.,LTD
OBARA (THAILAND)
TEL +66-38-571-894 FAX +66-38-571-912
CO., LTD.
OBARA KOREA CORP. TEL +82-2-868-3366 FAX +82-2-838-3365
OBARA AUSTRALIA
TEL +61-3-8795-0100 FAX +61-3-8795-0133
PTY.LTD
OBARA CORP. INDIA
TEL +91-20-30688551 FAX +91-20-30688550
BRANCH OFFICE
OBARA CORP. CZECH
TEL +420-469-318-202 FAX +420-469-318-223
BRANCH OFFICE
All rights reserved. Printed in Japan.
No.0341EN
No.0276EN OBARA Corp. Ⅰ.Specifications Page - 2
Safety precautions
= Safety precautions =
• Read this instruction manual thoroughly before use in order to and use the product properly.
• The cautionary instructions in this user’s guide are for safer operation to prevent danger and damage that
may occur to you and other persons.
• While adequate safety considerations were given to the design and manufacture of this welder, items in
the cautionary articles of this user’s manual must always be followed to ensure the safe usage. Using the
welder without following these instructions may cause bodily accidents such as death and severe injuries.
• Varying degrees of damages and dangers may occur when the equipment is mishandled. These
degrees are categorized into 2 levels in this instruction manual, and they are accompanied by symbols,
that should catch your attention, and signaling words as warning indicators. These symbols and signal
words to induce your caution are used with exactly the same meanings on the equipment’s warning
labels.
Attention
Calling Signal Word Description
Symbol
Improper handling of the equipment may cause a
! DANGER dangerous situation that can lead to eventual death or

severe injuries.
! CAUTION dangerous situation that can lead to intermediate level

injuries, light injuries, and/or material damage.
The attention catching symbols indicate general situations.
The severe injuries mentioned above include, but not limited to, wounds, burns (at high and low temperatures),
electrical shock, bone fracture, intoxication, and other injuries that leave after effects requiring hospitalization or
prolonged outpatient medical care.
On the other hand, intermediate level injuries and light injuries include, but not limited to, injuries such as
electrical shock and burns that do not require hospitalization or prolonged outpatient medical care, while
material damages include damages to property, and expanded damages related to equipment.
!
Conducts that must be done.
Mandated Grounding work for example.
Prohibited Conducts that must not be done.
The symbols indicate general situations.

Limitation on operator
In order to maintain the safety of the operations, do not allow the following people to engage in the
operations.
! DANGER
Mentally disabled.
Those with disability in hands, legs, eyes, and ears.
Drug (including narcotics) abusers.
Intoxicated.
Anyone who uses a heart pacemaker.
Those who do not wear specified protection devices.
Those who are non-qualified, (Those who have not had sufficient training in the
operation of the equipment.)
Those with loose long hairs.
Safety training
Operators of the gun should have enough knowledge and skill of the followings.
! CAUTION
! To understand the contents of this instruction manual.
! To understand the meaning of warning labels.
! To acquire the method of heart massage and artificial respiration(CPR).
! To check protective attire such as that of fire fighters.
! To clarify places and personnel to contact in emergency.
! To acquire/check how to treat burns and injuries, and the location of first aid kit.
! To check the location of emergency stop switch and how to reset it.
! To understand how to inspect the system.
! To have enough knowledge on electricity to understand it.
! To understand the system, wiring diagram, and voltage.
! To have enough knowledge on resistance welding to understand it.

Items to follow as safety precautions
! DANGER
Always follow the instructions below in order to prevent bodily
injuries.
! 1. Although considerations for safety have been adequately incorporated into the design and
manufacture of this welder, make sure the cautionary instructions in this instruction manual are
strictly obeyed upon usage of this equipment.
Operating without following these cautionary instructions may cause or lead to eventual death,
severe wounds, or other bodily- injury-related accidents.
! 2. Make sure that works on the power source on the input side, selection of installation site, and
storage of products and handling of waste material after welding operations should comply
with related laws and ordinances as well as your company’s internal rules.
3. Make sure that no one enters the area surrounding the welder as well as welding operation
site carelessly.
4. Do not let anyone on a heart pacemakers come near the area surrounding the welder or
welding operation site unless he or she is permitted to do so by a physician. The welder
generates a magnetic field in the surrounding area while it is charged, and thus, poses
negative affects to the pacemaker’s operation.
! 5. In order to assure safety, make sure that the installation, maintenance and inspection, and
repairs of this welder should be conducted by personnel with appropriate qualifications or
someone who is well versed with welders.
! 6. In order to assure safe operation of this welder, make sure it is operated by personnel who has
a good understanding of the contents of this instruction manual, and have the knowledge and
skills to operate it safely.
7. Do not use this welder for any purposes other than welding.

! DANGER
Always follow the following instructions in order to avoid electrical
shocks.
＊ Touching a charged part other than the secondary conductor may cause life
threatening electrical shocks and/or burns.
＊ Touching both ends of the secondary conductor simultaneously may cause
electrical shocks.
1. Do not touch any charged part other than the secondary conductor.
! 2. Make sure that the welder is grounded by a certified electrician in accordance with the law
(electrical installation technology regulation).
! 3. Make sure that installation, maintenance, and inspection are conducted at least 5 minutes after
all of the input side power source are turned off by the switches on the switch box. Since
capacitors may still be charged even after the input side power sources are turned off, make
sure that the operation is conducted after checking that there is no voltage charged.
4. Do not use cables that have capacities below the specified requirement, that are damaged, or
that are exposing their conductive parts.
! 5. Tighten the weld part of the cable securely and insulate it.
6. Do not use the welder with its case or cover removed.
! 7. Do not use torn or wet gloves. Always wear dry and well insulated gloves during operations.
! 8. Make periodical inspection and maintenance and use the equipment only after the damaged
parts are repaired.
! 9. Use high grade cooling water with a resistance of 5000Ω-cm or more, which contains no
precipitate or sediment.
! 10. Please turn off the welding power supply when stopping cooling water.
! 11. When preparing cables, pneumatic hoses, water hoses and other tubing and wiring, use the
ones that can adequately withstand the specified load or pressure.
! 12. When the welder is not being used, make sure that the power source for all of its devices is
turned off.
! 13. Do not open any door of the devices in any case except when necessary such as in
maintenance. When using the devices, be sure to lock the doors with keys, which should be
securely managed by authorized personnel.

! DANGER Do not insert fingers or hands between the electrodes.
＊ Placing a body part, such as hands, fingers, arms, etc., between electrodes will
cause the body part to be squeezed by the electrodes which, in turn will lead to
bone fracture or other injuries.
1. Do not insert your hands, fingers, arms, or other body parts between the electrodes.
! 2. Check for safety around the welder upon turning on the power or supplying pressurized air.
! CAUTION
Use appropriate protective devices to protect yourself and others
from splashes, spatter, and noise that are generated during
welding operations.
＊ Airborne splashes and spatter may hurt your eyes and/or cause
burns.
＊ Noise may cause hearing disorders.
! 1. Wear protective glasses to shield your eyes from airborne splashes and spatter.
! 2. Wear protective attire such as protective gloves, long-sleeve clothes, and leather aprons.
! 3. Install a protective curtain around the area surrounding the welding work site so that splashes
and spatter are not projected towards other people.
! 4. Utilize sound proofing devices if the noise level is high.
Always follow the following precautionary instructions in order to

! CAUTION prevent fire and explosion.
＊ Splashes and spatter generated during a weld and a hot base

metal right after a weld may cause fire.
＊ Cables with imperfect connections may cause fire due to the heat
generated when they are charged.
! 1. Remove inflammable objects so that airborne splashes and spatter are not projected towards
them. If they cannot be removed, cover the inflammable objects with a nonflammable cover.
2. Do not weld near combustible and/or inflammable gases.
3. Do not let base metals that are hot immediately after a weld get near inflammable objects.
! 5. Prepare for unexpected accidents by having a fire extinguisher placed near the welding site.

Type of warning labels
＝ Indications of dangerous parts and precautions ＝

＝ Type of warning labels and place to be attached ＝
! DANGER
The shaded areas in the figures show the
high-voltage hazardous areas of the
equipment.
Warning labels

Table of contents
Table of contents
1.Related manual ..............................................................................................10

2.Featurs ...........................................................................................................10
3. Basic specifications .......................................................................................11
3.1 Model ........................................................................................................................................11
3.2 Control......................................................................................................................................12
3.3 Input / Output ...........................................................................................................................13
3.4 Dimensions and Weight..........................................................................................................14
3.5 Facility Specifications.............................................................................................................14
3.6 Accuracy ..................................................................................................................................14
3.7 Coating Color...........................................................................................................................14
3.8 Welding Power Source Indicator ..........................................................................................14
3.9 SCR characteristics.................................................................................................................15

Related manual
1. Related manual
The instruction manual of this equipment consists of individual manuals shown below.
Instruction manual Ⅰ. Specifications
Ⅱ. Installation manual
Ⅲ. Operating manual
Ⅳ. Maintenance manual
Ⅴ. Reference manual
Ⅵ. Supplemental manual
This manual contains specifications instructions for this equipment, Read this manual thoroughly
to have a proper understanding of the specifications before operating the equipment.
2. Featurs
1. Improved gun controlling functions
Retract control is available in standard models
Up to 4 guns can be controlled.(Division can be used for 2 Gun and 2 Retract)
4 Hold End signal (Output Hold End signal to each Gun)
2. Improved welding sequence
3-step welding with tempering applicable to aluminum welding
Flexible setting of delay time
Step-up function of up to 16 steps and can be set to any value
Liner-up function of up to 15 steps and can be set to any value
3. Improved controllability
Easy data input of TP-Net / DP-Net with back-light
4. Adoption of splashproof construction
Not only splashproof construction of the main body but also adoptions such as
splashproof connector and cable seal rocks.
5. Correspond to the diversification of the installation method.
The main body structure can correspond to various installations, for example,
TOYOTA specification rack installation, the wall installation, the postpone, and the
trans. all-in-one design.

Model
3. Basic specifications
3.1 Model
W-TC Series
(Example)
W-TC:Japan specification(OBARA model name:STN21-ECL-TY3JPN)
AW-TC:Texas specification(OBARA model name:STN21-ECL-TY3USA)
CW-TC:Canada specification(OBARA model name:STN21-ECL-TY3CSA)
CHW-TC:China Kuangchou specification(OBARA model name:STN21-ECL-TY3CHN)
RW-TC:RUSSIA specification(OBARA model name:STN21-ECL-TY3RUS)
UW-TC:Turkey (CE) specification(OBARA model name:STN21-ECL-TY3ENG)
BRW-TC: Brazil specification(OBARA model name:STN21-ECL-TY3BRA)
W-TC1 Series
(Example)
W-TC1:Japan specification(OBARA model name:STN21-ECL-TY3JPN1)
AW-TC1:Texas specification(OBARA model name:STN21-ECL-TY3USA1)
CW-TC1:Canada specification(OBARA model name:STN21-ECL-TY3CSA1)
CHW-TC1:China Kuangchou specification(OBARA model name:STN21-ECL-TY3CHN1)
RW-TC1:RUSSIA specification(OBARA model name:STN21-ECL-TY3RUS1)
UW-TC1:Turkey (CE) specification(OBARA model name:STN21-ECL-TY3ENG1)
BRW-TC1: Brazil specification(OBARA model name:STN21-ECL-TY3BRA1)
[Supplementation]
*W-TC, W-TC1: Model name * sign is assumed to be a destination.
* Destination
Nothing Japan
A North-America
C Canada
CH China
CZ TPCA
F TMMF
R TMMR
U UK,TMMT,TMCA
BR Brazil
General country
GE
(Excluding the above-mentioned country.)

Control
3.2 Control
Control Method Full-digital control (synchronous)
Control Series 4 Series (A Mode) /15 Series (B Mode) /16 Groups
240 series maximum
Up to 8 guns (The valve outputs are 4 solenoids, and division can be
used for 2 guns + 2 retracts.)
Setting Method Remote setting
Time Control Squeeze Delay Time 0 to 99 cycles (all series)
Squeeze Time 1 to 99 cycles (all series)
Slope Time 1 to 30 cycles (all series) (Note1)
Weld-1 Time 0 to 99 cycles (all series)
Cool-1 Time 0 to 99 cycles (all series)
Down Slope Time 0 to 99 cycles (all series)
Cool-2 Time 0 to 99 cycles (all series)
Hold Time 1 to 99 cycles (all series)
Off Time 4 to 99 cycles (all series)
Pressure Rise Time, 1 0 to 99 cycles (all series)
Hold End Delay Time 0 to 99 cycles (Common to all series)
Cycle Control Number of Pulsation 1 to 9 (all series)
Number of Re-weld Sequence 1 (can be specified by a parameter.)
Current Control Constant-current control : Primary-current feedback by CT
Current –voltage control
Direct setting from 2000 to 60000A (100A in step)
Primary- current range 50 to 1500A
Voltage Control Constant-voltage control Percentage setting from 25 to 100%
Note： Since control ranges applicable to the settings of the current and voltage
controls depend on the connected load, the maximum and minimum
control currents vary with the load.
For example： The minimum current will flow during welding if the welding time is
specified, though setting a welding current to 2000A.
Note1: The setting range of the shipment after July 1, 2007 becomes “0 to 30cycles".

Input / Output
Step Control Step-up setting: Up to 16 steps

Available number of weld spots: Up to 9999 spots/step
Liner-up setting: Up to 15 steps
Available number of weld spots: Up to 9999 spots/step
Alarm Messages
I/O Power supply check (Note2) AD error 2 Line voltage low
SP3 Trip (Note2) Cable shorted Current unbalance
Thyristor shorted D/N Fatal error Weld-1,2,3 cycle num. few
Thyristor over temperature Line voltage drop Current flow rate high
Transformer over temperature Line voltage over Start switch trouble (D/N)
Current frequency abnormal No current Start switch trouble (1∼15)
Illegal parameter Current low Communication time-out error
CPU operation failure Compensation voltage low Communication data error
Illegal data setting Current high OP communication error
Illegal current setting Compensation voltage high Weld off warning
AD error 1 Peak current high Continuous pressure warning
Note2: It is added from W-TC1 Series.
3.3 Input / Output
Solenoid Valve Specifications DC24V Rated current: 0.5A or less
Note1: Be sure to use the total current of each valve output by 0.8A or less.
Note2: Be sure to provide a surge absorber to the solenoid valve.
[ Input ]
Starting Input 1 N.O. contact, 4 series
oｒ 4 N.O. contact, 1 series
Group Input 4 N.O. contact, 1 series (No Connection)
Retract Starting Input 1 N.O. contact, 2 series
internal : 24VDC
Step Selection Clear Input 1 N.O. contact, 1 series
Max. current : 20mA
Step Reset Input 1 N.O. contact, 1 series
Alarm Reset Input 1 N.O. contact, 1 series
Weld ON/OFF Switch Input 1 N.O. contact, 1 series
Safety Switch Input 1 N.O. contact, 1 series
[ Output ]
Hold End Output 1 N.O. contact, 4 series
Relay contact output
Alarm Output 1 N.O/N.C. contact, 1 series
Max. voltage : 130VAC
Step Last Stage Out. 1 N.O. contact, 1 series
Max. current : 0.12A
( Current Ｄｅｔｅｃｔｉｏｎ Signal Output )*
Step Up Finish Out. 1 N.O. contact, 1 series
*The step last stage signal output works instead of current detection signal output when the
parameter is effective.
Note3: N.O. shows the Normally Open. N.C. shows reverse to N.O.
Dimensions and Weight
3.4 Dimensions and Weight

Dimensions 320 (W)×370 (H)×250 (D)
Max. Dimensions 380 (W)×475 (H)×260 (D)
Weight 25 kg
3.5 Facility Specifications
Rated Voltage Single-phase 220/380/400/420/440/460/480VAC
50/60 Hz
(Selected by switching the range on the base voltage.)
Rated voltage regulation within ± 20% of rated voltage
Power Consumption 50 VA (not in weld)
Frequency 50/60 Hz (automatically selected on power-on)
Temperature 0 to 50℃
Humidity 90% or less (non-condensing)
Cooling Water Inlet port: 30℃ or less
Flow rate: 6 liters/min or more.
Maximum water pressure: 0.5 Mpa or less
Electric resistance: 5000Ωcm or higher
Thyristor MTL500TY1-16 (Insulation structure)
Preservation Period of Set data 10 years
! CAUTION
Handling the welding set data
The data stored in the timer memory is preserved for 10years after it is input given the
timer is in the normal operating condition. The data may be damaged when there is a
failure to the main PC board.
It is strongly recommended that the user write the important welding conditions down
separately just in case the data stored in the timer is lost.
3.6 Accuracy
Power-source Voltage Regulation Within ±10%
Resistance Load Regulation Within ±10%
Setting Accuracy ±3% (of full scale)
Repeatability ±3% (of full scale)
3.7 Coating Color
Frame Paint Color: White (color chip No.: TMS-C17(10GY9/1))
Source: Book of standard color samples for painting
(Issued in 1981 by Japan Painting Industry Association)
3.8 Welding Power Source Indicator
Indicate Color Milk-white
Indicated Condition Welding power source-ON
(inside control power DC24V-ON)
SCR characteristics
3.9 SCR characteristics

SCR Type： MTL500TY1-16 (1000A Type)
Ratings and characteristics

Model
Item （condition） Symbol Unit
MTL500
Repetitive peak off-state voltage VDRM 1600 V
Non-repetitive peak off-state reverse voltage VDSM 1800 V
R.M.S.（water temperature 30℃，flow rate 6 L/min） IT(RSM) 1000 A

R.M.S. current at 10% duty cycle，20 cycles
2025 A
（water temperature 30℃，flow rate 6 L/min）
1 cycle-surge on-state current (50Hz non-repetitive) ITSM 10000 A
15 cycle-surge on-state current (50Hz non-repetitive) 2550 A
Maximum Peak gate power dissipation PGM 16 W

Rating Average gate power dissipation PG(AV) 4 W
Peak gate current IGM 4 A
Peak gate voltage VGM 16 V
Peak reverse gate voltage VRGM 5 V
Motion junction temperature Tjw −40 ∼ ＋125 ℃
Water temperature Tw 0 ∼ ＋30 ℃
Storage temperature range Tstg −40 ∼ ＋80 ℃
Mass 1.97 Kg
Maximum peak off-state current
IDM 60 mA
(Tj=125℃,VDM=VDRM)
Maximum peak reverse current
IRM 60 mA
(Tj=125℃,VDM=VDRM)
Maximum on-state voltage
VTM 1.8 V
(Tj=25℃,ＩTM =1700A)
Maximum gate trigger current
IGT 150 mA
(Tj=25℃,VD =6,IT =1A)
Characte-r Maximum gate trigger voltage
VGT 2 V
istics (Tj=25℃,VD =6,IT =1A)
Minimum gate non-trigger current
IGD 1.5 mA
(Tj=125℃,VD =2/3VDRM)
Minimum gate non-trigger voltage
VGD 0.2 V
(Tj=125℃,VD =2/3VDRM)
Minimum critical rate of rise of off-state voltage
dv/dt 200 V/μs
(Tj=125℃,VD =2/3VDRM)
Thermal resistance (between junction and cooling
Rth(j-w) 0.120 ℃/w
water, flow rate 6l/min）

SCR characteristics
Duty cycle … R.M.S. current rating

MTL500TY1-16 ( Insulation structure )
Condition
Frequency ： 50 Hz
Flow rate ： 6L/min
Cooling water temperature ： 30（℃）
n=3
3000 n=5
n=10
n=20
R.M.S. current （A）
n=40
2000
1000
0
1 2 5 10 20 50 100
Duty cycle α（％）
n
N α = ｎ／ N ×100 (%)

Version 2.6
Ⅱ．INSTALLATION MANUAL Ver. No.SD064
Ver. No.SD065
or
or
later（For
later（For
UPS）
SP3）
WELDING CONTROLLER
W-TC Series

after reading. 2008.05.27 No.0276EN-Ⅱ

organizations.
OBARA CORP. U.S.A.
HERCULES WELDING
TEL +1-586-755-1250 FAX +1-586-755-6790
PRODUCTS DIVISION
TEL +52-449-971-1525 FAX +52-449-971-1526
L. DE C.V.
OBARA CORP. UK
TEL +44-1332-297-868 FAX +44-1332-341-600
BRANCH OFFICE
OBARA CORP. FRANCE
TEL +33-3-27-23-76-16 FAX +33-3-27-23-76-17
BRANCH OFFICE
OBARA (MALAYSIA)
TEL +60-3-5191-9688 FAX +60-3-5191-9699
SDN.BHD.
OBARA (NANJING)
LTD.
OBARA (SHANGHAI)
TEL +86-21-50462668 FAX +86-21-50462558
CO.,LTD
OBARA (THAILAND)
TEL +66-38-571-894 FAX +66-38-571-912
CO., LTD.
OBARA AUSTRALIA
TEL +61-3-8795-0100 FAX +61-3-8795-0133
PTY.LTD
OBARA CORP. INDIA
TEL +91-20-30688551 FAX +91-20-30688550
BRANCH OFFICE
OBARA CORP. CZECH
TEL +420-469-318-202 FAX +420-469-318-223
BRANCH OFFICE
No.0341EN
No.0276EN OBARA Corp. Ⅱ.Installation manual Page - 2
Safety precautions
labels.
Attention
Symbol

severe injuries.

!

operations.
! DANGER
Mentally disabled.
Intoxicated.
Safety training
! CAUTION

! DANGER
injuries.
site carelessly.

! DANGER
shocks.
electrical shocks.
parts are repaired.
turned off.

! CAUTION
welding operations.
burns.




! DANGER
equipment.
Warning labels

Table of contents
Table of contents
1. Related manual ...........................................................................................10

2. Installation ...................................................................................................11
2.1 Installation...............................................................................................................................11
2.2 Moving the equipment..............................................................................................................12
2.3 Connecting Power Cable and Welding Transformer ...........................................................13
2.4 Grounding ...............................................................................................................................13
2.5 Installing Cooling-water Hose ...............................................................................................14
2.6 Connecting TP-Net Cable.......................................................................................................14
2.7 Connecting Controlling Lines................................................................................................15
2.8 Inputting Start Signal and Instructions.................................................................................22
2.9 Step Clear ................................................................................................................................23
2.10 Step Select Clear ....................................................................................................................23
3. Precautions in Supplying Initial Power ........................................................24
3.1 Checking Items before Powering On ....................................................................................24
3.2 Checking Items in Powering On ............................................................................................24
3.3 Emergency Stop......................................................................................................................24
4. Storage Instructions ....................................................................................25

Related manual
1. Related manual
This manual contains installation details of this equipment, Read this manual thoroughly to have
a proper understanding of the installation before operating the equipment.

Installation
2. Installation
2.1 Installation
(1) Weight W-TC Series (STN21-ECL-TY3 Series) 25kg
W-TC1 Series (STN21-ECL-TY3***1 Series)
(2) Space Requirements 580 (W) x 528.5 (D) x 460 (H)
635 (W) x 528.5 (D) x 460 (H) Hose-nipple specifications
(3) Installation Install the equipment using 4 mounting holes at the bottom of
the mainframe.
Mounting hole diameter (φ12)
―― Precautions in Installation ――
! ・ Install the controller in a place where ambient temperature is between 0 to 40℃ and out
of direct sunlight.
! ・ Provide lightening protection to the controllers incoming power source according to
appropriate rules and regulations.
! ・ Avoid locations subject to water or oil ingress, or dust containing metal.
Space Requirements・Mainframe Bottom-side View
Bottom View
Mainframe Mounting hole Diagram
* The controller is the hose-nipple type.
* Work at a low position has the possibility of hurting the waste etc. Please set it up so
that the height of the knob may become 600mm.

Moving the equipment
2.2 Moving the equipment

Lifting:
A lifting wire
1m or more
Load capacity
90Kg or more
! DANGER
Since the weight of the equipment is 20kg or more, moving or carrying the
equipment without using any tools may damage your back or arms.
Be sure to use carrying tools when moving it.

Connecting Power Cable and Welding Transformer
2.3 Connecting Power Cable and Welding Transformer

Power Cable: Connect it to "01-02" of the power connection terminal at the bottom
of the controller.
Welding Transformer: Connect it to "01-03" of the power connection terminal at the bottom
of the controller.
(Refer to the following diagram for connections.)
―― Wiring Instructions ――
! Connecting wire: 100mm2 or larger in size (Refer to the following diagram.)
! Withstand voltage: AC600V or higher
! Voltage-drop in welding: Less than 20% of the rated voltage
! Power source: Install the fuse on the base of power source.
! No Fuse Breaker (NFB): Install the NFB or ELB between the controller and the
welding power source before using the controller.
Welding Transformer Capacity
Welding Transformer Capacity NFB Rated Current (AC380 to 480V) Cable Size
2
35kVA - 55kVA 100A 38mm or larger（AWG2）
- 150kVA 250A（400A frame） 100mm2 or larger（AWG3/0）
Welding Transformer Capacity NFB Rated Current (AC240V) Cable Size

- 75kVA 250A（400A frame） 100mm2 or larger（AWG3/0）
Note: Any NFB other than described above does not protect the circuit from
overload. (If you have any questions, please contact us.)
2.4 Grounding
! Grounding wire: Connect it to the terminal at the center of the controller. (Refer to the
following diagram.)
―― Grounding Instructions ――
! Connecting wire: 50mm2 or larger in size (Larger than half the size of the power cable.)
Power cable, Ground wire
Connect grounding wire here.

（M10 bolt, Torque 15-20Nm）
Connect power cable here.

01- 02（M10 bolt, Torque 15-20Nm）
Connect welding trans. cable here.

01- 03（M10 bolt, Torque 15-20Nm）
Connect grounding wire here.

（M10 bolt, Torque 15-20Nm）
Note)The above figure is a CHW-TC(STN21-ECL-TY3CHN) specification.

Installing Cooling-water Hose
2.5 Installing Cooling-water Hose

Cooling-water Hose: To provide cooling water use 9.5mm (3/8 inch) bore hose . (Refer to the
following diagram.)
―― Cooling-water Requirements ――
! Temperature at the inlet port: 10 to 30℃ Maximum pressure: 0.5 MPa
! Flowrate: 6 L/min or higher Resistance: 5000Ω・cm or higher
―― Cooling-water Instructions ――
・ Use clean water or industrial water for cooling . Do not use water characterized with
electrolyte such as saline.
! ・ For circulating cooling water, renew the water entirely once in every six months or renew 5 to
10% of the entire water at all times (Since water will evaporate).
! ・ If using the controller in a place where freezeing occurs, be sure to drain the water from the
controller when not in use.
! ・ If using the low resistance cooling water, the hose length 2M or higher,
! ・ Please do not stop cooling water with the power supply of the main body turned on.
The SCR might generate heat because of the water quality etc.
2.6 Connecting TP-Net Cable

Connect the TP-Net cable to the connector (PENDANT CABLE) on the left side of the timer
mainframe. (Refer to the following diagram for the connecting locations of the cables.)
Connecting Diagram of Cooling-water Hose and Pendant Cable
Connect pendant cable here.
Nipple-type Model
Water OUTLET
Water INLET

Connecting Controlling Lines
2.7 Connecting Controlling Lines

Description of TB1 terminal block on the upper side of the controller.
(The connection becomes next paragraph “Connectison of HARTING connector”.)
Description of Connecting Item:
Item Description
SOL1,2 Outputs a signal to each of the solenoid valves of GUN1 and GUN2.
Outputs a signal to the retract valve. It can be also used as an output
SOL7,8
signal to each of the solenoid valves of GUN3 and GUN4.
Outputs an alarm signal on occurrence of fatal or warning (caution)
alarm.
ALARM
Related Parameters:
“ Caution”, “ Test W ALM”, “ ALM Mode”, and “ ALM Out”
Output
STEP UP FINISH Outputs a signal on completion of the specified steps in the Step-up
OUTPUT function.
STEP LAST STAGE When the final step stage, this output signal is on.
OUTPUT When the parameter “Pr” is on, the current detection signal output is
( CURRENT DETECTION
SIGNAL OUTPUT ) made effective.
Outputs a signal every weld spot. When an error has been detected,
the output depends on the error condition.
HOLD END
Related Parameters:
“ Hold Out “, “Hold A Dly”
Binary input of GROUP 0,1,2,3 will select the welding condition group
GROUP 0 to 3
from 0 to 15.
1. An input to start operation. Up to 240 conditions can be selected by
the combination input of the Start switch, Group 0,1,2,3.
2. Inputting one of these signals and the STEP SELECT CLEAR
START SW1 to 4 signal simultaneously will reset the value of Step preset to a
specified gun.
Related Parameters:
“ AB Mode”, “ Sw mode”, and “ One Shoot”
RETRACT START
An input to start the Retract function
SW7, 8
Input
ALARM RESET Short-circuiting this will reset a currently issued alarm.

A switch to externally operate/stop the welding. The terminals, A12
WELD ON/OFF and B13, need to be short-circuited when not in use since these
terminals are N.C. (Welding is available when closed.)
STEP CLEAR Clears the Step-up data of up to GUN8.
Inputting this signal and the Start switch simultaneously will specify a
STEP SELECT
gun number and clears its Step data. Refer to Section 2.9 for details of
CLEAR
the connection.
Connection of the thermostat wire of the welding transformer N.C.
TRANS. THERMO
(Closed in normal state).
A switch to stop the timer in case of emergency. N.C. (Activates when
SAFETY SW
closed.)
Parameter: The mode to select timer functions or carry out basic setups. Refer to
"V. Reference manual" for details.

Connection of HARTING connector
Connecting Diagram of HARTING connector
Connect HARTING connector

Here.
The signal input and output from HARTING connector is as follows.
24DD NAME 24DD NAME

1 COM./OUT(24V) 13 2ND VALVE POWR
2 HOLD END 14 SOL COMMON
3 ALARM (NOTE1) 15 SOL1
4 STEP UP FINISH 16 SOL2
5 COM./INPUT 17 STEP CLEAR
6 START SW1 18 EXT.DC24V
7 START SW2 19 SOL3
8 START SW3 20 SOL4
9 START SW4 21 HOLD END1
10 EXT.DC0V 22 HOLD END2
11 WELD / TEST 23 HOLD END3
12 ALARM RESET 24 HOLD END4
G GROUND
NOTE1) Select N.C. (Normal Close) for the alarm.

Connection of NPN/PNP
Switch with the connector of the jumper in the timer to switch the NPN/PNP connection of the
external power supply.
Switch of NPN/PNP
PNP-MU
NPN-MU
PNP-PO
NPN-PO
Note) The above figure is a CHW-TC(STN21-ECL-TY3CHN) specification.
Connector setting Usage

NPN-PO Portable / Station and NPN connection
PNP-PO Portable / Station and PNP connection
NPN-MU Multi / Robot and NPN connection
PNP-MU Multi / Robot and PNP connection
! caution
! Selection of connector at outside-purpose-position may cause the
damage of the cable and parts, etc. or fire, because of generation of
the short-circuit between cables.
! Factory setting is NPN-PO or PNP-PO.

Be sure to remove the jumper cable between A7 and B13 on the
terminal block TB1 on the main board when NPN-MU or PNP-MU is
used.

Connection Example of Portable transformer 1

Condition1: A Mode (Independent input mode) / 1 Gun + 2 step stroke
Interface power is contained inside.
Condition2: for Portable transformer, NPN connection. Connector setting inside the timer
is NPN-PO.
W-TC/W-TC1 (Timer side) TB1 (HAN1) Terminal box(Weld Trans. side)
COMMON / OUT A4 1
HOLD END A6 2
ALARM A5 3
STEP UP FINISH B5 4 J5
Gun side
COMMON / INPUT A7 5 5 1
A8 6 6 2
START SW1
A9 7 7
START SW2
A10 8 8
START SW3
A11 9 9
START SW4
10 J5
※1
B13 11 11
WELD / TEST
A13 12 13
ALARM RESET
CN2-9 13 72 + -
2ND VALVE POWER
A1 14 72 6
SOL COMMON
14 7
SP3 ※2
A2 15 14 3
SOL1
A3 16 71 4
SOL2
A14 17 71
STEP CLEAR
A12 18 15 - +
B2 19 ※1 16 Gun1 side
SOL3
B3 20 Solenoid Valve
SOL4
CN7-1 21 Refer to technical information
HOLD END1
CN7-2 22
HOLD END2 R-19-80-3 for details of Gun
CN7-3 23
HOLD END3 side connection.
CN7-4 24
HOLD END4
※1 Connected prohibition(For Multi/Robot only)

※2 SP3 was added to the W-TC1 series.
NOTE 1) Broken line in the timer: Input signal to the timer.

Solid line in the timer: Output signal from the timer.
NOTE 2) Before shipping, a jumper cable is installed between A7 and B13 on the terminal
block TB1 on the main board of the timer.
Use the unit with the jumper cable between A7 and B13 if no switch is connected for
weld/test input.
NOTE3) Remove the jumper cable between A7 and B13 and install a selector switch between
J5 and 11 of the terminal box when switching weld/test input.
Connection Example of Portable transformer 2

Condition1:B Mode (Combination input mode) / 1 Gun + 2 step stroke
Interface power is contained inside.
Condition2: for Portable transformer, PNP connection. Connector setting inside the timer
is PNP-PO.
W-TC/W-TC1 (Timer side) TB1 (HAN1) Terminal box(Weld Trans. side)
COMMON / OUT A4 1
HOLD END A6 2
ALARM A5 3
STEP UP FINISH B5 4 J5
Gun side
COMMON / INPUT A7 5 5 1
A8 6 6 2
START SW1
A9 7 7
START SW2
A10 8 8
START SW3
A11 9 9
START SW4
10 J5
※1
B13 11 11
WELD / TEST
A13 12 13
ALARM RESET
CN2-9 13 72 - +
2ND VALVE POWER
A1 14 72 6
SOL COMMON
14 7
SP3 ※2
A2 15 14 3
SOL1
A3 16 71 4
SOL2
A14 17 71
STEP CLEAR
A12 18 15 + -
B2 19 ※1 16 Gun1 side
SOL3
B3 20 Solenoid Valve
SOL4
CN7-1 21 Refer to technical information
HOLD END1
CN7-2 22
HOLD END2 R-19-80-3 for details of Gun
CN7-3 23
HOLD END3 side connection.
CN7-4 24
HOLD END4
※1 Connected prohibition(For Multi/Robot


NOTE 2) Before shipping, a jumper cable is installed between A7 and B13 on the terminal
block TB1 on the main board of the timer.
Use the unit with the jumper cable between A7 and B13 if no switch is connected for
weld/test input.
NOTE3) Remove the jumper cable between A7 and B13 and install a selector switch between
J5 and 11 of the terminal box when switching weld/test input.

Connection Example of Multi, Robot control board 1

Condition1: B Mode (Combination input mode), Outside interface power supply
Condition2: for Multi/Robot, NPN connection. Connector setting inside the timer is
NPN-MU.
W-TC/W-TC1 (Timer side) TB1 (HAN1) Multi, Robot control board
COMMON / OUT A4 1 1
HOLD END A6 2 2
ALARM A5 3 3
STEP UP FINISH B5 4 4
COMMON / INPUT A7 5 5
A8 6 6
START SW1
A9 7 7
START SW2
A10 8 8
START SW3
A11 9 9
START SW4
B4 NPN-MU 10 11
B13 11 10
WELD / TEST
A13 12
ALARM RESET
CN2-9 13
A1 14
SOL COMMON
SP3 ※2
A2 15
SOL1
A3 16
SOL2
A14 17
STEP CLEAR
A12 NPN-MU 18 18
B2 19
SOL3
B3 20
SOL4
CN7-1 21
HOLD END1
CN7-2 22
HOLD END2
CN7-3 23
HOLD END3
CN7-4 24
HOLD END4

NOTE2) Before shipping, a jumper cable is installed between A7 and B13 on the terminal
block TB1 on the main board of the timer. Be sure to remove the jumper cable
between A7 and B13 when NPN-MU or PNP-MU is set.
NOTE 3) With regard to switching of weld/test input, when DC24V is applied between the pin
No.5 (A7) and No.11 (B13) of the harting connector by external power source, the
weld is selected. In the case of NPN-MU, pin No.5 is DC24V and pin No.11 is 0V.
On this occasion, never short between A7 and B13. Doing this may cause peripheral
devices.
Connection Example of Multi, Robot control board 2

Condition 1: B Mode (Combination input mode), Outside interface power supply
Condition 2: for Multi/Robot, PNPconnection. Connector setting inside the timer is
PNP-MU.
W-TC/W-TC1 (Timer side) TB1 (HAN1) Multi, Robot control board
COMMON / OUT A4 1 1
HOLD END A6 2 2
ALARM A5 3 3
STEP UP FINISH B5 4 4
COMMON / INPUT A7 5 5
A8 6 6
START SW1
A9 7 7
START SW2
A10 8 8
START SW3
A11 9 9
START SW4
A12 PNP-MU 10 11
B13 11 10
WELD / TEST
A13 12
ALARM RESET
CN2-9 13
A1 14
SOL COMMON
SP3 ※2
A2 15
SOL1
A3 16
SOL2
A14 17
STEP CLEAR
B4 PNP-MU 18 18
B2 19
SOL3
B3 20
SOL4
CN7-1 21
HOLD END1
CN7-2 22
HOLD END2
CN7-3 23
HOLD END3
CN7-4 24
HOLD END4

NOTE2) Before shipping, a jumper cable is installed between A7 and B13 on the terminal block
TB1 on the main board of the timer. Be sure to remove the jumper cable between A7
and B13 when NPN-MU or PNP-MU is set.
NOTE 3) With regard to switching of weld/test input, when DC24V is applied between the pin
No.5 (A7) and No.11 (B13) of the harting connector) by external power source, the
weld is selected. In the case of PNP-MU, pin No.5 is 0V and pin No.11 is DC24V.
On this occasion, never short between A7 and B13. Doing this may cause peripheral
devices.
Inputting Start Signal and Instructions
2.8 Inputting Start Signal and Instructions

Inputting Start Switch Signal :
Operation mode is selectable between A-Mode and B-Mode by setting the corresponding
parameter of the timer.
Employs welding conditions of the Series corresponding to an activated Start
A-Mode:
switch. Mainly used for systems to which portable guns are connected.
Selects one of the Series from 1 to 15 by combination input of the Start
B-Mode:
switch signal, assuming the switch number to be a binary code.
Group :
Series from 1 to 15 is called "Group". The binary input of the Group SW
Group
allows one of the Groups from 1 to 3 to be selected. As shown in the
Selection:
following table, no input selects Group 0.
１Group
A Mode (4 series)
Series 1 Series 2 Series 3 Series 4
Start Switch 1 ○ × × ×
Start Switch 2 × ○ × ×
Start Switch 3 × × ○ ×
Start Switch 4 × × × ○
１Group
B Mode (1 to F :15 series)
Series 1 2 3 4 5 6 7 8 9 A B C D E F
Start SW1 ○ × ○ × ○ × ○ × ○ × ○ × ○ × ○
Start SW2 × ○ ○ × × ○ ○ × × ○ ○ × × ○ ○
Start SW3 × × × ○ ○ ○ ○ × × × × ○ ○ ○ ○
Start SW4 × × × × × × × ○ ○ ○ ○ ○ ○ ○ ○
Group Selection
Group 0 1 2 3 4 5 6 7 8 9 A B C D E F
Group 0 × ○ × ○ × ○ × ○ × ○ × ○ × ○ × ○
Group 1 × × ○ ○ × × ○ ○ × × ○ ○ × × ○ ○
Group 2 × × × × ○ ○ ○ ○ × × × × ○ ○ ○ ○
Group 3 × × × × × × × × ○ ○ ○ ○ ○ ○ ○ ○
Maximum welding conditions = 15series x 16groups = 240conditions

Inputting Start Signal and Instructions
Inputting Instructions of Start Signal

In B-Mode, a long interval between activation of each Start switches may select a wrong Series.
Keep the intervals between activation of each Start switch within 5ms. Alternatively, the
following method is available.
―― Example of Start Switch Input ――

At first, close the relays, CR1∼8, and then close the contact, CR0, after CR0 short interval.
This method of closing the contact, CR0, after closing the six relays poses no problem if the
differences in closing timing of the relays are moderate.
Diagram of Starting Switch Input
Wiring Example
Common
CR0 : Input common

CR1 : Relay contact for SW 1
CR5 : Relay contact for Group 0
Terminal Block CR8 : Relay contact for Group 3
2.9 Step Clear

If the step up function is being used, then inputting a step clear signal to the TB1
terminal block will clear the gun step conditions.
(Note) When the parameter “Ps” and ”P8” are both enable, step series1 only can be cleared by this
input signal (TB1-A14).
2.10 Step Select Clear

Inputting a signal to Step select clear and Start switch on the TB1 terminal block at the same
time allows a gun number to be specified and its step data to be reset. And Step select clear
follows the data established in Step return (Welding condition).
Specifying a Step select clear:
TB1 : B14 TB1 : A12 TB1 : Combination of the start SW

Step select clear
+ Input common
+ Combination of the S.SW for Step clear
The inside treatment of step select clear:
Selected to Reference to GUN num. GUN num. which shows a specified to

step select clear
→ at selected to → combination of the Start SW is looked
combination of Start SW up from the welding condition table.

Precautions in Supplying Initial Power
(Note) When the parameter “Ps” and ”P8” are both enable, the action of step select clear changes to
the following.
1. The “Step return" disappears from welding condition items.
2. The step state of step series2 is set to1, and the step count is reset by this input signal
(TB1-B14).
3. Step series2 only can be cleared by this input signal (TB1-B14).
3. Precautions in Supplying Initial Power

3.1 Checking Items before Powering On
Before powering on the controller, make sure that the wires are connected correctly and check
the following items:
1. Connection of the power cable
2. Connection to the welding transformer
3. Grounding
4. Connection of the control wires
5. Installation and flowrate, 6L/min, of the cooling water
3.2 Checking Items in Powering On

Before powering on the controller, carry out the following checks:
1. Make sure that you are protected with safety equipment such as safety goggles and
insulating gloves.
2. Immediately after turning on the power, check the controller for noise, smoke, and smell.
3. Make sure that TP-Net/DP-Net displays no alarm message. If any, correct the problem by
referring to “IV. Maintenance manual”.
4. 5 minutes after turning on the power, make sure that the controller does not generate noise,
smoke, and smell.
5. Set welding data and parameters according to the procedures instructed in “V. Reference
manual”.
6. Start welding by the Star switch, and verify that the gun corresponding to the selected
Series operates.
3.3 Emergency Stop

Opening the signal circuit of “SAFETY SWITCH” on the TB1 terminal block will immediately stop
the valves and the supply of welding current. System engineers must utilize this as occasion
demands.

4. Storage Instructions
To store the timer, observe the following instructions:
1. Drain the water off from SCR by air blowing.
2. Make sure that the inside of the mainframe is dust free.
3. Place the timer in its original plastic bag so as to prevent penetration of dust into the timer.
4. Store the timer in a place where temperature is between 0 and 60℃ with 70% or less
humidity and condensation of humidity will not occur. Avoid locations receive vibrations or
direct sunlight.

Version 2.6
Ⅲ．OPERATING MANUAL Ver. No.SD064
Ver. No.SD065
or
or
later（For
later（For
UPS）
SP3）
WELDING CONTROLLER
W-TC Series

after reading. 2008.05.27 No.0276EN-Ⅲ

organizations.
OBARA CORP. U.S.A.
HERCULES WELDING
TEL +1-586-755-1250 FAX +1-586-755-6790
PRODUCTS DIVISION
TEL +52-449-971-1525 FAX +52-449-971-1526
L. DE C.V.
OBARA CORP. UK
TEL +44-1332-297-868 FAX +44-1332-341-600
BRANCH OFFICE
OBARA CORP. FRANCE
TEL +33-3-27-23-76-16 FAX +33-3-27-23-76-17
BRANCH OFFICE
OBARA (MALAYSIA)
TEL +60-3-5191-9688 FAX +60-3-5191-9699
SDN.BHD.
OBARA (NANJING)
LTD.
OBARA (SHANGHAI)
TEL +86-21-50462668 FAX +86-21-50462558
CO.,LTD
OBARA (THAILAND)
TEL +66-38-571-894 FAX +66-38-571-912
CO., LTD.
OBARA AUSTRALIA
TEL +61-3-8795-0100 FAX +61-3-8795-0133
PTY.LTD
OBARA CORP. INDIA
TEL +91-20-30688551 FAX +91-20-30688550
BRANCH OFFICE
OBARA CORP. CZECH
TEL +420-469-318-202 FAX +420-469-318-223
BRANCH OFFICE
No.0341EN
No.0276EN OBARA Corp. Ⅲ.Operating manual Page - 2
Safety precautions
labels.
Attention
Symbol

severe injuries.

!

operations.
! DANGER
Mentally disabled.
Intoxicated.
Safety training
! CAUTION

! DANGER
injuries.
site carelessly.

! DANGER
shocks.
electrical shocks.
parts are repaired.
turned off.

! CAUTION
welding operations.
burns.




! DANGER
equipment.
Warning labels

Table of contents
Table of contents
1. Related manual ...........................................................................................10

2. Precautions in Operation.............................................................................11
3. Products System Configuration...................................................................12
3.1 Connecting to Robot Gun.......................................................................................................12
3.2 Connecting to Portable Gun...................................................................................................12
4. Alarm Messages and Precautions ..............................................................13

4.1 Precautions at Occurrence of Alarm .....................................................................................13
4.2 Alarm Messages on TP-Net/DP-Net .......................................................................................13

Related manual
1. Related manual
This manual contains operating instructions for this equipment. Read this manual thoroughly to
have a proper understanding of equipment operation before use.

Precautions in Operation
2. Precautions in Operation
! CAUTION
! 1. Before using the equipment, make sure that the cooling-water flowrate is at
the stated level (6 L/min).
2. Only qualified engineers can change welding data. If any of the data requires
change, contact a manager and make sure that a qualified engineer changes
the data.
! 3. If you find any abnormality or alarm messages during operation, immediately

stop the operation and contact a manager.
! 4. This manual exclusively describes instructions for the controller. For other
products such as welding guns and so on, read the corresponding manual.

Products System Configuration
3. Products System Configuration

3.1 Connecting to Robot Gun
3.2 Connecting to Portable Gun

Alarm Messages and Precautions
4. Alarm Messages and Precautions

4.1 Precautions at Occurrence of Alarm
! CAUTION
! 1. If you discover any abnormality during operation, check TP-Net and DP-Net.
! 2. Operators must stop the operation immediately and contact a manager when
discovering any abnormality during operation.
3. Do not operate TP-Net when any of the alarm messages appear.
4.2 Alarm Messages on TP-Net/DP-Net

Display of Alarm Message and List of Alarm Message
TP-Net DP-Net
Alarm messages appear here.
Alarm indication lamp flickers.

Alarm Messages and Precautions
Fatal Alarms:
Alarm Name Alarm Message
I/O Power supply check (Note1) 020 I/O Pwr CHK.
SP3 Trip (Note1) 021 SP3 Trip
Thyristor shorted 030 SCR Break
Thyristor over temperature 031 SCR O.Heat
Transformer over temperature 032 Tr. O.Heat
Current frequency abnormal 033 illegal Frequen.
Illegal parameter 034 ill. Param.
Illegal data setting 036 ill. Data
Illegal current setting 037 ill. Current
AD error 1 038 AD1 Error
AD error 2 039 AD2 Error
Cable shorted (Electrode sticking) 040 Cable Short
Line voltage drop 046 LineV. Drop
Line voltage over 047 LineV. Over
Warning Alarms:
No current 050 No Current
Current low 051 CurrentLow
Compensation voltage low 052 %Volt. Low
Current high 053 CurrentHigh
Compensation voltage high 054 %Volt. High
Peak Current high 055 PeakCurHigh
Weld voltage low 056 Weld V. Low
Cautionary Alarms:
Current unbalance 060 Cur. Unbalance
Weld-1 cycle few 061 W1Cyc. Few
Current flow rate high 065 Flow%Over

Indicative Alarms:
Start switch trouble ( 1∼15) 080-095 ill. SW ( 1∼F)
Communication time-out error 100 CommT. Out
Communication data error 101 CommD. Error
OP communication error 102 OP-TP Error
Weld off warning 110 No Weld
Continuous pressure warning 111 No Weld2
Specific Alarm:
CPU operation failure 035 CPU Error
DeviceNet fatal error 041 DNPcb Error

Version 2.6
Ⅳ．MAINTENANCE MANUAL Ver. No.SD064
Ver. No.SD065
or
or
later（For
later（For
UPS）
SP3）
WELDING CONTROLLER
W-TC Series

after reading. 2008.05.27 No.0276EN-Ⅳ

organizations.
OBARA CORP. U.S.A.
HERCULES WELDING
TEL +1-586-755-1250 FAX +1-586-755-6790
PRODUCTS DIVISION
TEL +52-449-971-1525 FAX +52-449-971-1526
L. DE C.V.
OBARA CORP. UK
TEL +44-1332-297-868 FAX +44-1332-341-600
BRANCH OFFICE
OBARA CORP. FRANCE
TEL +33-3-27-23-76-16 FAX +33-3-27-23-76-17
BRANCH OFFICE
OBARA (MALAYSIA)
TEL +60-3-5191-9688 FAX +60-3-5191-9699
SDN.BHD.
OBARA (NANJING)
LTD.
OBARA (SHANGHAI)
TEL +86-21-50462668 FAX +86-21-50462558
CO.,LTD
OBARA (THAILAND)
TEL +66-38-571-894 FAX +66-38-571-912
CO., LTD.
OBARA AUSTRALIA
TEL +61-3-8795-0100 FAX +61-3-8795-0133
PTY.LTD
OBARA CORP. INDIA
TEL +91-20-30688551 FAX +91-20-30688550
BRANCH OFFICE
OBARA CORP. CZECH
TEL +420-469-318-202 FAX +420-469-318-223
BRANCH OFFICE
No.0341EN
No.0276EN OBARA Corp. Ⅳ.Maintenance manual Page - 2
Safety precautions
labels.
Attention
Symbol

severe injuries.

!

operations.
! DANGER
Mentally disabled.
Intoxicated.
Safety training
! CAUTION

! DANGER
injuries.
site carelessly.

! DANGER
shocks.
electrical shocks.
parts are repaired.
turned off.

! CAUTION
welding operations.
burns.




! DANGER
equipment.
Warning labels

Table of contents
Table of contents
1. Related manual ...........................................................................................10

2. Products Block Diagram..............................................................................10
3. Pre-operation Checks .................................................................................11
4. Maintenance and Inspection .......................................................................11
5. Maintenance................................................................................................12
5.1 Precautions in Maintenance ...................................................................................................12
6. Trouble Shooting.........................................................................................13
6.1 Abnormality from power supply ON to welding ...................................................................14
6.2 Layout of PCB parts ................................................................................................................17
6.3 Layout of PCB & Fuse .............................................................................................................17
6.4 Fatal Alarm Descriptions and Remedies...............................................................................18
6.5 Warning Alarm Descriptions and Remedies.........................................................................22
6.6 Cautionary Alarm Descriptions and Remedies ....................................................................24
6.7 Indicative Alarm Descriptions and Remedies.......................................................................24
7. Check I/O Information ...................................................................................26

Related manual
1. Related manual
This manual contains maintenance information for this equipment. Read this manual thoroughly
to have a proper understanding of the maintenance requirements before operating the equipment.
2. Products Block Diagram

Pre-operation Checks
3. Pre-operation Checks
Before starting welding, carry out the following checks in order to use the controller safely.
Checking Item Requirements

SCR There must be no water leakage.
Cooling Water Flowrate must reach the stated level.
Power Lamp The lamp will turn on/off by powering on/off.
4. Maintenance and Inspection

To use the controller safely, carry out the following servicing tasks at the stated running-time
intervals.
Interval
Occasionally
Annually
Monthly
Weekly
Checking Item Requirements
Daily
Check TP-Net to verify that the
required welding data have ○
been properly set.
Preset Data 1
Check TP-Net to verify that the
required parameters have been ○
properly set.
Verify that the flowrate of the
Welding-current Measurement welding current reaches the ○
required level.
Connection of the input/output
No loose connection ○
signal wires
Appearance of the No visible damage nor
○
input/output signal wires disconnection
Connection of the grounding
No loose connection ○
wire
Appearance of the grounding No visible damage nor
○
wire disconnection
Connection of the cables to
the power source and the No loose connection ○
welding transformer
Appearance of the cables to
No visible damage nor
the power source and the ○
disconnection
welding transformer
Inside of the controller must be
Internal state of the controller ○
kept clean.
Check by blowing air to verify
Cooling-water circuit (SCR) that sufficient water can ○
circulate.

Maintenance
5. Maintenance
! Before carrying out maintenance tasks, you must thoroughly read and understand “V.
Reference manual”.
5.1 Precautions in Maintenance
! DANGER
! 1. Before carrying out maintenance tasks, be sure to turn off the power source and
check with a voltmeter (AC 500V) to verify that the welding current has been shut
off.
! 2. The power indication lamp may not be lit because the bulb has burnt out, for
example, although power may still be present. When you check the presence of the
power using the power indication lamp always verify that the power indication lamp
goes out by turning off the main power source. (Verify the status of the lamp in both
situations.)
! 3. If a maintenance task needs to be carried out with the power source on do not touch
the following parts or cables as high voltage is present. To carry out the task
maintenance engineers must work on insulating rubber sheet and wear insulating
gloves. Touching the following parts may result in a serious accident or even death
from electric shock.
(1) TBO power terminal block: 01, 02, and 03
(2) SCR and its surrounding area
(3) PC-1107x trigger circuit and its surrounding area
(painted white inside)
(4) The RP1 and RP2 resistors
(5) The CP1 large capacitor
(6) The F1-F4 input fuse
! 4. If you need to put your hands into the mainframe during maintenance always wear
insulating gloves. Do not carry out maintenance tasks with bare hands or you may
suffer an injury, for example, cutting your hands on a corner of a part.
5. Do not carry out maintenance tasks in poor lighting. Carrying out the maintenance
tasks in poor lighting may result in mistakes or contact with hazardous sections,
leading to a serious accident or even death.
! 6. When you perform a welding test during maintenance, always ensure that the
cooling-water flowrate reaches 6L/min. Carrying out a welding test with insufficient
cooling water may generate excessive heat in the cables or the hoses, and result in
hoses bursting.
7. Do not replace any parts on the PCB. Replace the PCB if necessary. The Obara
Corporation does not guarantee any malfunction or failure resulting from the
replacement of parts on the PCB.

Trouble Shooting
6. Trouble Shooting
Abnormal detection flow
IF Is the alarm displayed in TP-Net・DP-Net?

No
6.1 Abnormality from power supply ON to welding
6.1.1 The power indication lamp does not Light P.14
6.1.2 The gun does not operate though the Start switch has been pressed P.15
6.1.3 No indication appears on TP-Net / DP-Net display P.16
6.1.4 The target timer number is not displayed on TP-Net / DP-Net screen P.16
6.1.5 The screen of TP-Net・DP-Net stops like ”Please wait…” P.16
6.7 Indicative Alarm Descriptions and Remedies
6.7.6 CPU operation failure 035 CPU Error P.25
Yes
6.4 Fatal Alarm Descriptions and Remedies
6.4.1 Thyristor shorted 030 SCR Break P.18
6.4.2 Thyristor over temperature 031 SCR O.Heat P.18
6.4.3 Transformer over temperature 032 Tr. O.Heat P.18
6.4.4 Current frequency abnormal 033 illegal Frequen. P.18
6.4.5 Illegal parameter 034 ill. Param. P.19
6.4.6 Illegal data setting 036 ill. Data P.19
6.4.7 Illegal current setting 037 ill. Current P.19
6.4.8 AD error 1 038 AD1 Error P.19
6.4.9 AD error 2 039 AD2 Error P.19
6.4.10 Cable shorted 040 Cable Short P.19
6.4.11 DeviceNet unusual detection 041 DNPcb Error P.20
6.4.12 Line voltage drop 046 LineV. Drop P.20
6.4.13 Line voltage over 047 LineV. Over P.20
6.4.14 I/O power supply check (Note1) 020 I/O Pwr CHK. P.20
6.4.15 SP3 Trip (Note1) 021 SP3 Trip P.21
Note1) It is added from W-TC1 Series.
6.5 Warning Alarm Descriptions and Remedies

6.5.1 No Current 050 No Current P.22
6.5.2 Current low 051 CurrentLow P.22
6.5.3 Compensation voltage low 052 %Volt. Low P.22
6.5.4 Current high 053 CurrentHigh P.22
6.5.5 Compensation voltage high 054 %Volt. High P.23
6.5.6 Peak current high 055 PeakCurHigh P.23
6.5.7 Weld voltage low 056 Weld V. Low P.23
6.5.8 2C. Wire break (Note2) 058 2C.WireBreak P.23
Note2) “2nd Current Select” function is due to add.
6.6 Cautionary Alarm Descriptions and Remedies

6.6.1 Current unbalance 060 Cur. Unbalance P.24
6.6.2 Weld 1-3 cycle few 06* W* Cyc. Few P.24
6.6.3 Current flow rate high 065 Flow%Over P.24

Abnormality from power supply ON to welding

6.7.1 Start-switch trouble 0** ill. SW* P.24
6.7.2 Communication time-out error 100 CommT. Out P.25
6.7.3 Communication data error 101 CommD. Error P.25
6.7.4 Weld off warning 110 No Weld P.25
6.7.5 Continuous pressure warning 111 No Weld2 P.25
6.7.6 CPU operation failure 035 CPU Error P.25
6.1 Abnormality from power supply ON to welding
6.1.1 The power indication lamp does not light.

Symptom Cause Remedy
Welding power circuit Wrong wiring of 01-02 and 01-03 See “II. Installation manual”,
breaker trips. and correct the wring.
Excessive heat from the Welding power is connected to See “II. Installation manual”,
timers large resistor 01-03. and correct the wring.
Power cable is installed Imperfect contact of the CN2 Check the connector for
properly. connector in the timer contact.
Lamp failure Replace the lamp.
The screen of TP-Net or Fuse(F3,F4) off. Replace the fuse(F3,F4).
DP-Net is not displayed.
Fuse off of PC-1108 fuse PCB LED confirmation of PC-1108
fuse PCB. Replace of fuse
PCB when even one LED has
been turned off.
The alarm message, “SCR O. Circuit protector (SP1) of Timer The return button in the part
Heat “, appears. PCB does trip. in circuit protector (SP1) is
(For W-TC Series.) pushed. (See “6.2 Layout of
PCB parts)
Fuse off of PC-1108 fuse PCB LED confirmation of PC-1108
been turned off.
The alarm message, “I/O Pwr Circuit protector (SP1) of Timer The return button in the part
CHK. “, appears. PCB does trip. in circuit protector (SP1) is
(For W-TC1 Series.) pushed. (See c6.2 Layout of
PCB parts)
Fuse off of PC-1108 fuse PCB. LED confirmation of PC-1108
been turned off.
There is an allophone or a Possibility of failure of a Replace the Timer.
nasty smell. step-down transformer.
Except the above Failure of a main PCB. Replace the main PCB.
Failure of a step-down Replace the Timer.
transformer.

6.1.2 The gun does not operate though the Start switch has been pressed.

The power indication lamp is The parameter “Pq Remote I/O “is A parameter “Pq Remote I/O”
on but no alarm message ON setup. is turned OFF.
appears. Check the timer mode to see that Check TP-Net.
it is not set to “Weld disable” or
“Continuous pressurization
mode”.
Disconnection or wrong wiring of Check the wiring
the wire connected to A16-B16,
SAFETY SW, on the TB1 terminal
board.
A7 and B13 are not jumped on the （NPN-PO or PNP-PO）
terminal block TB1 on the main See “II. Installation manual”,
board with NPN-PO or PNP-PO and check the jumper cable.
set.
DC24V is not applied between the （NPN-MU or PNP-MU）
pin No.5 and No.11 of HAN1 with See “II. Installation manual”,
NPN-MU or PNP-MU set. and check the external power
voltage.
The solenoid valve doesn't Failure of a solenoid valve. Replace the solenoid valve.
work though the solenoid
Failure of a main PCB. Replace the main PCB.
valve wiring is normal.
When an solenoid valve The mistake in piping of an air Review of air circuit.
operates hose.
The alarm message, “SP3 Faulty wiring or short-circuit of After wiring is confirmed,
Trip “, appears. solenoid valve wiring. Circuit protector (SP3) is
(For W-TC1 Series.) turned ON. (See “6.3 Layout
of PCB & Fuse)
Failure of a solenoid valve. After solenoid valves are
replaced, Circuit protector
(SP3) is turned ON. (See “6.3
Layout of PCB & Fuse)
Circuit protector (SP3) is OFF. Circuit protector (SP3) is
turned ON. (See “6.3 Layout
of PCB & Fuse)
The alarm message, “No See Section 6.5, and correct
Current”, appears. the problem.

6.1.3 No indication appears on TP-Net/DP-Net display

The power indication lamp of Faulty cable. Replace the cable.
the timer is on but the display
is faulty. TP-Net/DP-Net is faulty. Replace TP-Net/DP-Net.
Circuit protector(SP2) of Timer After the cable is exchanged,
PCB does trip. Circuit protector (SP2) is reset
between the TP connection
cable is short-circuit.
(See “6.2 Layout of PCB parts)
6.1.4 The target timer number is not displayed on TP-Net/DP-Net screen.

The target timer number is not Disconnection or failure of a Change or check of a
displayed on TP-Net screen. Timer-Timer connection cable. Timer-Timer connection cable.
The power supply of Timer An injection of a power supply.
which it is going to choose is
not turned on.
There is a timer of the same Change of parameter" timer
number setup. number."
Parameter : “Po TM Number”
TP-Net is alone connected to
timer which wants to change a
number.
Then, a power supply is
switched on, pushing “Home”
key in TP-Net.
The cable of TP-Net may be

taken out and inserted instead
of a power supply injection.
If it rises normally, it will be
made the edit mode of a
parameter and a number will be
changed.
6.1.5 The screen of TP-Net・DP-Net stops like ”Please wait…”

The pendant connection cable The pendant cable has been Pendant cable exchange.
have external wound. damaged. By the situation, Timer and
(Breaking and the bend are TP-Net / DP-Net is exchanged
contained) at the same time.
The pendant connection cable Defect of TP-Net / DP-Net, TP-Net / DP-Net exchange,
have no external wound. Or defect of Timer. or Timer exchange.

Layout of PCB parts
6.2 Layout of PCB parts
Layout of PCB parts

CN2 CN4
SP1(Circuit protector)
CN7
SP2(Circuit protector)
CN1 CN3
HIGH VOLTAGE DANGER
TB1
CNN CN6
CNG
6.3 Layout of PCB & Fuse
Layout of PCB & Fuse

PCB
SP3
（W-TC1 Series）
Fuse
U
SP3 U
PNP−MU NPN−MU PNP−PO NPN−PO PNP−MU NPN−MU PNP−PO NPN−PO
V V
PE PE
02 02
G1 K1
G1 K1
PC-1108
G2 K2
G2 K2
01 01
T1 T2
T1 T2
01 0
Fuse PCB 01 0
200 200
220 220
240 240
1 2 03 0 1 2 03 0
180 180
G1 K1
G1 K1
220 220
240 240
K2 G2
K2 G2
CHW-TC1 (China) specification AW-TC (USA) specification

(STN21-ECL-TY3CHN1) (STN21-ECL-TY3USA)

Fatal Alarm Descriptions and Remedies
6.4 Fatal Alarm Descriptions and Remedies
Alarm Name Alarm Message Category

6.4.1 Thyristor shorted 030 SCR Break Fatal
Detecting Welding current is measured at the final cycle of the Hold-end time. If the
Method measured current is greater than the stated level, the controller issues the
“Thyristor shorted” alarm.
Cause/ 1. Faulty thyristor → Replace the thyristor.
Remedy 2. Faulty main board → Replace the main board.

6.4.2 Thyristor over temperature 031 SCR O.Heat Fatal
Detecting The controller issues the alarm when the thyristor thermostat switch has been
Method activated, regardless of the state of the controller.
For W-TC Series

"031 SCR O . Heat" displays, and the source pilot lamp doesn't light, the
short-circuit between the wiring for the solenoid valve is thought.
Please take a measure according to the following measure 5.
Cause/ 1. Check duty cycle. 2. Insufficient cooling water
Remedy 3. Replace the thyristor with a larger one. 4. Replace the thyristor.
5. Please examine whether to find abnormalities of the faulty wiring of the
solenoid valve and the short-circuit between electric wires, etc.
Please correct, when abnormalities are found.
Please push the return button of circuit protector (SP1) that exists in the
substrate after correcting abnormality.

6.4.3 Transformer over temperature 032 Tr. O.Heat Fatal
Detecting The controller issues this alarm when the transformer thermostat switch has
Method been activated, regardless of the state of the controller.
Cause/ 1. Check duty cycle. 2. Insufficient cooling water
Remedy 3. Replace the transformer with one having 4. Replace the transformer.
larger rated capacity.

6.4.4 Current frequency abnormal 033 illegal Frequen. Fatal
Detecting The controller checks frequency to select between 50 Hz and 60 Hz when it is
Method turned on and issues this alarm if the frequency ranges outside the stated
bandwidth.
Cause/ Check the controller power supply.
Remedy


6.4.5 Illegal parameter 034 ill. Param. Fatal
Detecting The controller issues this alarm when the parameter data has been lost.
Method
Cause/ 1. Check and re-enter the parameters. 2. Replace the PCB.
Remedy

6.4.6 Illegal data setting 036 ill. Data Fatal
Detecting The controller issues this alarm if the welding condition data of an activated
Method Series is outside the range, or the welding times, W1 to W3, are all set to 0.
Cause/ Check and correct the welding condition data.
Remedy

6.4.7 Illegal current setting 037 ill. Current Fatal
Detecting The controller issues this alarm when the preset current of the activated Series
Method is 0 but welding time is set to any value other than 0.
Cause/ Check and correct the welding condition data.
Remedy

6.4.8 AD error 1 038 AD1 Error Fatal
Detecting The controller issues this alarm when the measured current is abnormal.
Method
Cause/ 1. Replace the timer. 2. Replace the CT.
Remedy

6.4.9 AD error 2 039 AD2 Error Fatal
Detecting The controller issues this alarm when the measured current is abnormal.
Method
Cause/ 1. Replace the timer.
Remedy

6.4.10 Cable shorted 040 Cable Short Fatal
Detecting The controller issues this alarm when the test current exceeds a specific level.
Method
Cause/ Replace the secondary cable.
Remedy


6.4.11 DeviceNet unusual detection 041 DNPcb Error Fatal
Detecting Timer is [ reception or ] a time of detecting about abnormalities.
Method Automatic reset is performed after an unusual return.
Cause/ 1. Failure of a substrate. change to UCS board
Remedy 2. The abnormalities in the exterior of Timer.

6.4.12 Line voltage drop 046 LineV. Drop Fatal
Detecting The controller issues this alarm when Line-voltage under watch becomes 75%
Method or less of the reference-voltage.
Cause/ Power supply shortage of equipment : Review of power supply equipment.
Remedy

6.4.13 Line voltage over 047 LineV. Over Fatal
Detecting The controller issues this alarm when Line-voltage under watch becomes 125%
Method or more of the reference-voltage.
Cause/ Power supply shortage of equipment : Review of power supply equipment.
Remedy

6.4.14 I/O power supply check 020 I/O Pwr CHK. Fatal
Detecting It is added from W-TC1 Series.
Method "020 I/O Pwr CHK." displays, and the source pilot lamp doesn't light, the
short-circuit between the wiring for the solenoid valve is thought.
Please take a measure according to the following measure 1.
And detect it when the alarm 031 SCR O. Heat and 032 Tr. O. Heat happen
simultaneously.
Cause/ 1. Check if there is fault such as the incorrect wiring of the solenoid valve or
Remedy short circuit between wires. Please correct it when abnormality is found.
After the correction, circuit protector(SP1) is tripped. Press the button on SP1
to return. (See “6.2 Layout of PCB parts)
2. In case of power indicator lit, the SCR and the welding transformer may
simultaneously overheat. Check the coolant water.


6.4.15 SP3 Trip 021 SP3 Trip Fatal
Detecting It is added from W-TC1 Series.
Method Detect circuit protector (SP3) tripping and output the alarm by over-current by
the short-circuit between wiring for solenoid valve.
When the circuit protector (SP3) is OFF, detect it as well as tripping.
Cause/ Check if there is fault such as the incorrect wiring of the solenoid valve or
Remedy short-circuit between wires. Please correct it when abnormality is found.
After the correction, Turn Circuit Protector (SP3) ON and the abnormal alarm
can be reset.
However, please make it to turning ON because it is turning OFF even if
abnormality is not found. (See “6.3 Layout of PCB & Fuse)

Warning Alarm Descriptions and Remedies
6.5 Warning Alarm Descriptions and Remedies

6.5.1 No Current 050 No Current Warning
Detecting The controller issues this alarm when the measured current is 0 or the
Method welding cycle is set to 0.
Cause/ 1. Secondary cable disconnection → Re-fit / replace the cable.
Remedy 2. The ignition circuit of the timer is at fault. → Replace the timer.
3. Disconnection of the thyristor gate wire (G1, K1, G2, and K2) → Re-fit
4. Thyristor → Replace.

6.5.2 Current low 051 CurrentLow Warning
Detecting The controller issues this alarm when the measured current falls short of the
Method preset current.
Cause/ 1. Voltage variation is too large. →
Remedy Replace the cable with a larger one. Check the power supply.
2. Deterioration of the secondary-cable → Replace the cable.
3. Incorrect welding parameters (welding current and lower current limit) →
Check welding conditions.
4. Significant error in transformer turn ratio parameter. → Check welding
conditions.

6.5.3 Compensation voltage low 052 %Volt. Low Warning
Detecting In constant current control, the controller issues this alarm when the measured
Method voltage falls short of the preset voltage in %.
Cause/ 1. Voltage variation is too large. →
Remedy Replace the cable with a larger one. Check the incoming system.
2. Check the constant voltage and the preset voltage in %.
3. Deterioration of the secondary-cable → Replace the cable.
4. Check the preset value of lower current limit.

6.5.4 Current high 053 CurrentHigh Warning
Detecting The controller issues this alarm when the measured current exceeds the preset
Method current.
Cause/ 1. In correct welding conditions (welding current and upper current limit) →
Remedy Check welding conditions.
2. Significant error in transformer turn ratio parameter. → Check welding
conditions.
3. Power voltage is unstable. → Check the power supply.

Warning Alarm Descriptions and Remedies

6.5.5 Compensation voltage high 054 %Volt. High Warning
Detecting In constant current control, the controller issues this alarm when the measured
Method voltage exceeds the preset voltage in %.
Cause/ 1. Check the constant voltage and the preset voltage in %.
Remedy 2. Power voltage is unstable. → Check the incoming system.

6.5.6 Peak current high 055 PeakCurHigh Warning
Detecting This controller issues this alarm when the current has a peak value, It’s bigger
Method than the setting value.
Cause/ 1. During GUN action : Check welding conditions “squeeze time”
Remedy 2. In correct welding conditions ”Peak current Limit” : Check welding conditions.
3. Voltage variation is too large. : Check the incoming system.
: Check the balance of power supply.

6.5.7 Weld voltage low 056 Weld V. Low Warning
Detecting The controller issues this alarm when the measured voltage falls short of “V
Method limit” of welding condition.
Cause/ 1. Voltage variation is too large.
Remedy Replace the cable with a larger one. Check the incoming system.
Check the duty cycle.
2. Check the setting of the power-voltage lower limit (V limit).

6.5.8 2C. Wire break (Note) 058 2C. WireBreak Warning
Detecting The controller issues this alarm when the 2nd-feedback current cannot be
Method measured though the 1st- feedback current is measured.
Cause/ 2nd feedback current wire is broken : Change wire.
Remedy
Note) “2nd Current Select” function is due to add.
When Parameter “2nd Current Select” is turning on, this alarm is displayed.

Cautionary Alarm Descriptions and Remedies
6.6 Cautionary Alarm Descriptions and Remedies

6.6.1 Current unbalance 060 Cur. Unbalance Cautionary
Detecting The controller issues this alarm when the lower and upper limits of welding
Method current disagree.
Cause/ 1. Disconnection or imperfect contact of the thyristor gate wire. →
Remedy Check wiring, or replace the thyristor.
2. The ignition circuit of the main board is at fault. → Replace the board.
3. Check the squeeze time. This alarm may also appear when welding current is
applied while the gun moves.

061 to 063
6.6.2 Weld 1-3 cycle few Cautionary
W1 to 3 Cyc. Few
Detecting The controller issues this alarm when the welding current has not been supplied
Method for the number of welding cycles specified (Weld 1 to 3).
Cause/ 1. Welding sequence has started before the gun has reached the required
Remedy pressure. → Check the welding sequence.

6.6.3 Current flow rate high 065 Flow%Over Cautionary
Detecting The controller issues this alarm when the measured flow rate is greater than the
Method preset value of “C. Flow+ ” or “FC Count”.
Cause/ 1. Deterioration of the secondary cable. → Replace the secondary cable.
Remedy 2. The welding current is set to too high. → Check the setting of welding current.
3. Illegal “C. Flow+” value. → Correct the setting.
4. Voltage variation is too large.
Replace the cable with a larger one. Check the incoming power supply.
Check the duty cycle.
5. Illegal transformer turn ratio value. → Correct the setting.

6.7.1 080-095
Alarm Message
Start-switch (SW 0 to 15) trouble ill. SW ( 0 to15,A to F)
Detecting The controller checks the Start switch status when the power is turned on and
Method issues this alarm if any of the switches is ON.
Cause/ 1. Wrong wiring of the Start switch. → Check wiring.
Remedy

Indicative Alarm Descriptions and Remedies

6.7.2 Communication time-out error 100 CommT. Out Alarm Message
Detecting The controller issues this alarm when an error occurs during communication
Method between TP-Net/DP-Net and the timer.
Cause/ 1. Pendant cable faulty. → Replace the cable.
Remedy 2. TP-Net/DP-Net is faulty. → Replace TP-Net/DP-Net.

6.7.3 Communication data error 101 CommD. Error Alarm Message
Detecting The controller issues this alarm when the CRC errors (time-out) have been
Method detected 10 times successively.
Cause/ 1. TP-Net / DP-Net cable faulty → Replace the cable.
Remedy

Cautionary /Indicative・
6.7.4 Weld off warning 110 No Weld
Alarm Message
Detecting The controller issues this alarm when receiving a input signal from the Start
Method switch if the timer is set to “Weld disable”.
Cause/ 1. Cancel “Weld disable”.
Remedy

Cautionary /Indicative・
6.7.5 Continuous pressure warning 111 No Weld2
Alarm Message
Detecting The controller issues this alarm when receiving a input signal from the Start
Method switch if the timer is set to “Weld disable & sol. Valve control”.
Cause/ 1. Cancel “Weld disable & sol. Valve control”.
Remedy

Alarm Message
6.7.6 CPU operation failure 035 CPU Error
(Message may not appear.)
Detecting The controller issues this alarm when detecting that the watch dog timer has
Method been activated. This alarm message may not appear but a pulse signal is
output.
Cause/ 1. The main board is faulty. → Replace the board.
Remedy

Check I/O Information
7. Check I/O Information

Checked by TP-Net on the present information.
Please confirm in V. Reference manual.
I/O information display

Binary code Hexadecimal code
N1 0000 0000 00 ０： off １：on ００ ∼ FF
N2 0011 0001 31
N3 0000 0000 00
N4 0000 0000 00 N2 0011 0001 31
N5 0000 0000 00
N6 0000 0000 00
Bit 7 Bit 0
N7 0000 0000 00
N8 0000 0000 00 1 shows ON, 0 shows OFF
Input / output table ( Note: Other ports uses to this date. )

Display # Terminal block TB1 output information
N 1 0 0 0 0 0 0 0 0 0 0
N10 ＳＯＬ１
N11 ＳＯＬ２
N12 ＳＯＬ３（Retract SOL７）
N13 ＳＯＬ４（Retract SOL8）
N14 Alarm
N15 Hold end
N16 Final step
N17 Last step
※１ ( Current dｅｔｅｃｔｉｏｎ signal )
Display # Terminal block TB1 Display # Terminal block TB1
N2 Input information N3 Input information
N20 Start SW１ N30 ―――
N21 Start SW2 N31 ―――
N24 Group ０ N34 ―――
N25 Group １ N35 ―――
N26 Retract start SW７ N36 Weld On / OFF SW
N27 Retract start SW８ N37 Alarm reset

※１：The step last stage signal output works instead of current detection signal output
when the parameter is effective.
Check I/O Information
( Note: Other ports uses to this date.)

Display # Terminal block TB1 Display # Terminal block TB1
N4 Input information N5 Input information
N40 ――― N50 ―――
N41 ――― N51 ―――
N42 Step clear N52 ―――
N43 Step select clear N53 ―――
N44 TRANSF. Thermostat N54 Group3
N45 SCR thermostat N55 ―――
N46 ――― N56 ―――
N47 ――― N57 ―――
Display # Terminal block TB1
N6 Input information
N60 SW start (LED)
N61 ―――
N62 ―――
N63 ―――
N64 Group2
N65 ―――
N66 ―――
N67 ―――

Product guarantee
Product guarantee
A free guarantee of this product becomes two years or less. This product is excluded
even the breakdown of this device by a human disaster and the natural damage or
within two years.
Examples of human disaster : 1 Cooling water forgetting, Volume of water shortage,

High temperature water, etc.
2 Faulty wiring
3 The short-circuit between lines and cutting of
connected cable by external power
4 When putting it on to the device by draining water off
5 Fall by incomplete installation
6 When it commits an act of vandalism by intention
and the device is destroyed
Example of natural disaster : 1 Damage due to thunder and earthquake

2 A fire and damage by a flood

Version 2.6
Ⅴ．REFERENCE MANUAL Ver. No.SD064
Ver. No.SD065
or
or
later（For
later（For
UPS）
SP3）
WELDING CONTROLLER
W-TC Series

after reading. 2008.05.27 No.0276EN-Ⅴ

organizations.
OBARA CORP. U.S.A.
HERCULES WELDING
TEL +1-586-755-1250 FAX +1-586-755-6790
PRODUCTS DIVISION
TEL +52-449-971-1525 FAX +52-449-971-1526
L. DE C.V.
OBARA CORP. UK
TEL +44-1332-297-868 FAX +44-1332-341-600
BRANCH OFFICE
OBARA CORP. FRANCE
TEL +33-3-27-23-76-16 FAX +33-3-27-23-76-17
BRANCH OFFICE
OBARA (MALAYSIA)
TEL +60-3-5191-9688 FAX +60-3-5191-9699
SDN.BHD.
OBARA (NANJING)
LTD.
OBARA (SHANGHAI)
TEL +86-21-50462668 FAX +86-21-50462558
CO.,LTD
OBARA (THAILAND)
TEL +66-38-571-894 FAX +66-38-571-912
CO., LTD.
OBARA AUSTRALIA
TEL +61-3-8795-0100 FAX +61-3-8795-0133
PTY.LTD
OBARA CORP. INDIA
TEL +91-20-30688551 FAX +91-20-30688550
BRANCH OFFICE
OBARA CORP. CZECH
TEL +420-469-318-202 FAX +420-469-318-223
BRANCH OFFICE
No.0341EN
No.0276EN OBARA Corp. Ⅴ.Reference Manual Page - 2
Safety precautions
labels.
Attention
Symbol

severe injuries.

!
No.0276EN OBARA Corp. Ⅴ.Reference manual Page - 3

operations.
! DANGER
Mentally disabled.
Intoxicated.
Safety training
! CAUTION

! DANGER
injuries.
site carelessly.

! DANGER
shocks.
electrical shocks.
parts are repaired.
turned off.

! CAUTION
welding operations.
burns.




! DANGER
equipment.
Warning labels

Table of contents
Table of contents
1. Related manual ...........................................................................................11
2. General Description ....................................................................................11
2.1 Products Overview ..................................................................................................................11
2.2 Flow Chart: From inputting welding condition to welding ..................................................12
2.3 Welding Data............................................................................................................................13
3. Operating DP-Net........................................................................................14
3.1 Display Pendant Operation Panel Keys and their Functions ..............................................14
3.2 Operation Flow Chart ..............................................................................................................14
4. Operating TP-Net ........................................................................................15

4.1 Teaching Pendant Operation Panel Layout ..........................................................................15
4.2 Functional Descriptions of Operation Panel Keys ...............................................................16
4.3 Descriptions of Function Keys...............................................................................................17
4.4 Copy Functions .......................................................................................................................18
4.5 Viewing Data by Scrolling.......................................................................................................19
5. Descriptions of Modes.................................................................................20
5.1 Changing Timer Mode.............................................................................................................20
5.2 Precautions of Set Mode.........................................................................................................21
6. Monitoring welding Sequence .....................................................................22

6.1 Weld Monitor Screen...............................................................................................................22
6.2 Resetting Gun Counter ...........................................................................................................23
6.3 Resetting Steps........................................................................................................................23
7. Setting Parameters .....................................................................................24

7.1 Descriptions of Parameter Functions....................................................................................24
7.2 Note on Changing Parameters ...............................................................................................29
8. Setting Welding Conditions .........................................................................30

8.1 Basic Sequence .......................................................................................................................30
8.2 Description of Welding Conditions........................................................................................32

9. Specific Welding Sequence ........................................................................35
10. Alarm Output ..............................................................................................39
10.1 Classifications of Alarms.......................................................................................................39
10.2 Settings Associated with Alarms ..........................................................................................40
10.3 Timing Charts of Sequences at Occurrence of Alarm ........................................................40
11. Step Up .......................................................................................................46

11.1 Step-up Control.......................................................................................................................46
11.2 Liner-up control ......................................................................................................................47
11.3 Setting Procedure to Use Step-up Function ........................................................................48
12. Pressure Adjustment (Option).....................................................................49

12.1 Setting pressure adjustment control ....................................................................................49
12.2 Setting Percentage setting method ......................................................................................49
12.3 Setting Direct setting method................................................................................................50
12.4 Pressure Adjustment Sequence............................................................................................51
13. Pressure Selector Function .........................................................................52

13.1 Procedure to Use Pressure Selector Function ....................................................................52
13.2 Pressure Selector Function Basic Sequence ......................................................................52
14. Weld Interlock Function...............................................................................53

14.1 Procedure to Use Weld Interlock Function ..........................................................................53
14.2 Weld Interlock Timing Chart ..................................................................................................53

Related manual
1. Related manual
This manual contains the reference section for this equipment, Read this manual thoroughly to
have a proper understanding before operating the equipment.
2. General Description
2.1 Products Overview
The system configuration of this equipment is as follows:
STN21・・・・・・・・・・Timer-Welding controller
TP-Net・・・・・・・・・・Edit welding condition data, parameter data, monitor welding result
and display alarm message.
DP-Net・・・・・・・・・・Monitor welding result and display alarm message, and welding
condition data.
PNCE(Pendant Cable)・・・For the network cable, connect between “STN21” and “TP-Net”
or ”DP-Net”.

Flow Chart: From inputting welding condition to welding
2.2 Flow Chart: From inputting welding condition to welding

To start welding, proceed as follows:
Verify that the controller has Before powering on the controller for the first time, carry out the following
been properly installed. pre-operation checks.
Check:
1. Installation of the power cable
After checking the 2. Wiring of the welding transformer
items listed right, 3. Wiring of the control wires on the TB1 terminal board
turn on the power 4. Verification of the rated power voltage on the timer nameplate
source. 5. Wiring of the DeviceNet
Refer to “II. Installation manual” for details of installation.
Input welding conditions.0 Input welding conditions with TP-Net. Refer to Section 4, “Operating TP-Net”.
To set welding conditions, enter Set Mode since the controller is in Monitor
Enter Set Mode.
Mode when turning on the power source.
F4 F4
F8 F8
The above key operation takes you to Set Mode. Verify that the
indication lamp is on.
Set functions and basic conditions according to your company standards.

Set parameters.
#TM F4 F1
Home F8 Shift ＋ F5
Refer to Section 7, “Setting Parameters”, for details.
Set welding conditions.

Set welding conditions.
#TM F2 Group F1
Home F6 Select F5
Refer to Section 8, “Setting Welding Conditions”, for details.
Verify that welding is correctly

Carry out a test welding to verify that the settings are correct.
performed.
NG You can monitor the welding sequence in Monitor Welding Sequence. Refer to
Section 6, “Monitoring welding”, for details.
OK If the test weld failed:
Check and correct the cause of the problem. Locate and correct the
parameters and the welding conditions. If the alarm lamp flickers correct the
problem by referring to “IV. Maintenance manual”.
Setting is complete.

Welding Data
2.3 Welding Data

The welding data available for STN21-ECL-TY3 Series fall into two main categories: Parameters
(to select functions) and Welding conditions. 15 Series (conditions) of welding condition data
make up one Group. 16 Groups and parameters make up one Unit. (Refer to the following figure.)
The timer can maintain and control the data of 240 kinds of welding conditions. TP-Net can
independently maintain 5 times as many as data that the timer can.
15 conditions x 16 groups
TIMER = 240 conditions
TM stored Data
Data Edit
Data Copy
Data Copy
TP-Net stored Data

TP-Net
5 unit
TM Data: The data stored in the timer. (Welding data)

TP Data: The data stored in the TP-Net as an external data.
Parameters: Enables timer functions to be selected or set. Refer to Section 6.1 for details.

Display Pendant Operation Panel Keys and their Functions
3. Operating DP-Net
3.1 Display Pendant Operation Panel Keys and their Functions
Operation Panel Keys:

Name Description
Clears the step counts when the Step
Step Reset
function is enabled.
1. Resets alarms.
2. Clears the weld counter.
Reset
3. Clears the alarm history.
4. Suspends operations.
Displays the initial screen that appears
Home
upon turning on the power.
Each key scrolls the display in the direction
↑↓←→
indicated on it.
Selects functions such as I/O data and so
Shift on when another key is pressed while this
key is held down (e.g. Shift + Scroll key).
Indication Lamps (Indicate the state of the controller.):

Name Description
Same as those Refer to the sections describing the
on TP-Net indication lamps on TP-Net.
3.2 Operation Flow Chart

Power on
TM-No. Select
( For multiple units connection ＋ To select items,
with Optional function )
press the Return key.
Reset alarms
Monitor welding Reset Shift +
I/O status Alarm history Verify welding conditions Parameter monitor
Reset
Clear history Select Group Shift +

Reset
Display weld Reset gun counter

Step
count. Reset
Monitor conditions
Reset step number
Change number To display the initial screen, press the

Step Home Home key.
Shift + Reset

Teaching Pendant Operation Panel Layout
4. Operating TP-Net
4.1 Teaching Pendant Operation Panel Layout
TM#/Home
F-Disp,Select
Display
Alarm The forth line from the top
corresponding to function
keys.
Step up finish
F1~F8
Step last stage
SW Start Ready
Shift Set
Step Reset Conti. Press
Reset No Weld
Help 0~F / on off
Scroll key Return

Functional Descriptions of Operation Panel Keys
4.2 Functional Descriptions of Operation Panel Keys

Operation Panel Keys
Name Description
Function keys are used to select a menu.
F1~F4
To select F5 to F8, press Shift + a corresponding function key.
/ F5~F8
The F8 key is exclusively used to return to the previous menu.
F-Disp This key also allows you to select whether the function description is
Select displayed at the bottom of the display.
0~9 & “.” Keys for inputting data. To input A to F, press Shift + a key corresponding to
/ A~F a numerical value to be input.
/ ON & OFF ON and OFF keys operate regardless of the Shift key.
1. The button for returning to an initial screen.
2. A key to display and edit a currently connected TM#. A key to select a timer
TM#
number to be monitored.
/ Home
3. The selection mode of Timer number is expressed as “Shift”+“TM#/Home”
key.
Step Reset A key to reset the step counter when the Step function is enabled.
A key used to:
1. Reset currently issued alarms
Reset 2. Reset the spots count currently displayed on the weld counter
3. Clear the alarm history when it is displayed
4. Suspend operations
↑←→↓ Keys to scroll the screen to the direction indicated on them.
A key to display the screens help facility.
Help
The screen contains a detailed description of the function keys.
Shift An auxiliary key to select A to F and F5 to F8.
Indication Lamps (Indicate the state of the controller)

Name Description
Lights when the controller is ready to receive welding data after TP has
Ready completed initial processing and then received initial data through
communication.
No Weld Lights when the controller is in the Weld off mode.
Lights when the controller is in the Weld off mode and the gun-pressure
Conti.Press
control is in continuous pressurization mode.
Set Lights when the controller is in data setting mode.
SW Start Lights when the Start switch of the controller is turned on.
Step last
Lights when the controller has entered the final step.
stage
Step up finish Lights when the controller has entered the Step end phase.
Alarm Lights when the controller has detected trouble.

Descriptions of Function Keys
4.3 Descriptions of Function Keys

Pressing a function key (F1 to F8) will display a corresponding screen as shown below. Pressing
the Home key allows you to return to the Monitor screen.
F1 Monitor Displays the monitored data of the current welding and alarm history and so on.
F1 Step Change Enables the currently set step number to be changed when the Step-up function is
used.(Step Change)
F2 I/O Monitor Displays the I/O status. (Usually not used.)
F3 Alarm History Displays alarm history. (last 100 alarms)
F4 Monitor History Display of welding result data before last
F2 TM Data Set Displays the data stored in the timer.
0 to 15 Group Select Selects one of the Groups from 0 to 15.
F1 Edit Enables the welding data to be set.
F2 Function Copy Independently copies the data of a specific item of the welding conditions.
Example : Copies the data of Heat 1 in Series 1 to all Series.
F3 Series Copy Copies welding condition data between Series.

Example : Copies the data of Series 1 to Series 5.
F4 Group Copy Copies data between groups specifying the unit-number.
F5 Group Verify Compares data between groups specifying the unit-number.
F3 TP Data Edit Enables the external memory data stored in TP-Net to be edited.
F1 Unit Edit Selects Unit to edit.
1-5 unit select Selects one of the units from 1 to 5.
F1 Edit, … F5 Group Verify The same screens as described above.
F2 Unit Copy Copies data between Units.
F1 ＴＭ→ＴＰ Copies the data of a selected Unit from the timer to the pendant.
F2 ＴＰ→ＴＭ Copies the data of a selected Unit from the pendant to the timer.
F3 ＴＰ→ＴＰ Copies the data of a selected Unit to another Unit in the pendant.
F4 ＴＭ←→ＴＰ Compares the Unit data of the timer with that of the pendant.
F3 Parameter Selects Unit and changes parameters in it.
F4 Para. Copy Selects Unit and copies parameters in it.
F1 TM→ TP, … F4 TM ←→ TP Copies or compares parameters.
F4 Mode Select Changes a currently effective mode of the timer.
F1 Operation Changes the current mode to the Weld mode.
F2 No Weld Allows welding sequence to be performed with no current applied.
F3 C. Press In addition to the actions of the No-weld mode, this mode enables the gun to be
pressurized continuously after the Hold End signal has been received.
F4 Set Before editing any parameters or data, entering this mode is required.
F5 Parameter Selects Parameters to be set.
F1 Edit Enables the selected parameters to be set.

Copy Functions
4.4 Copy Functions

Using the copy functions save you from inputting and editing welding data.
For inputting the welding condition data (Refer to the diagram shown below.)
Function Copy: The data of a selected welding condition item to all Series.
Series Copy: Copies the welding data of a selected Series to another Series.
Group Copy: Copies the welding data of a selected Group to another Group.
Group Verify: Compares welding data between Groups. It is useful when used to verify that
Group Copy has been successfully completed.
Explanatory Drawing of Copy Functions:
Group Copy
Group 1 < Program Sheet >
Display Combination of the triggered switch sig

Data Display 1 2 3 4 5 6
Group 0 GunSel 1 2 1 4 3 2
B 0 2 C o o l 1 0 c y PrSquez 10 0 10 0 0 0
Display Combination
Squeezeof the triggered
30 switch
25 sig
30 35 40 25
B 0 2 W e l d 2 1 0 c y 1 Slope
2 3 43 53 63 3 3 3
B 0 2 D . S l o p e 0 c y GunSel 1 2 1 4 3 2
E d I t F CP S CP GC P Weld1 0 5 0 10 0 5
PrSquez 10 0
Cool1 10 0
0
0
0
0
0 0 0 0
Squeeze 30 25
Weld2 30 35
11
40
10
25
11 10 10 10
Slope 3 3
D.Slope 3 3
3
3
0
3
3 5 0 0
F2,3,4 Copy Functions Weld1 0 5 0 10 0 5
Cool2 0 0 0 0 0 0
Cool1 0 0
Weld3 0 0
2
0
0
0
2 10 0 0
Weld2 11 10
Hold 11 10
5
10
5
10
5 5 5 5
D.Slope 3
Off 0 3 5
0
0
0
0
0 0 0 0
Cool2 0 0
Pulse 0 0
0
0
0
0
0 0 0 0
Weld3 2 0
Heat1 2 10
0 0
8000 0
0 5000 0 0
Hold 5 5 5 5 5 5
Off 0 Heat2
0 0 0
8000 0
12000 0
8000 8000 13500 10000
Function Pulse 0 0 0 0 0 0
Copy Heat1 0 Heat3
8000 0 6000
5000 00 6000
0 5000 0 0
Heat2 8000 12000 8000 8000 13500 10000
Heat3 6000 0 6000 5000 0 0
Series Copy

Viewing Data by Scrolling
4.5 Viewing Data by Scrolling

Notes on Viewing Welding Data on TP-Net
Note that when you scroll the screen vertically to view the data of a specific starting Series, the
data of the gun number specified by “GunSel” will appear if they belong to the gun Series. As
shown in the figure below, when you display the data of the starting Series 2 by scrolling the screen,
the Series is changed to the gun Series 3 specified by “GunSel” when the data to be displayed
belong to the Step up rate.
Step Select: Gun Series Step Select: All Series

Display Combination of the triggered switch signal Combination of the triggered switch signal
Press the Scroll key.

Letter 1 2 3 4 5 6 1 2 3 4 5 6
GunSel 1 3 1 4 3 2 1 3 1 4 3 2
B 0 2 Gu n S e l 3
B 0 2 P r S q u e z 0 c y PrSquez 10 0 10 0 0 0 10 0 10 0 0 0
B 0 2 S q u I z 2 5 c y Squeeze 30 25 30 35 25 40 30 25 30 35 25 40
E d I t F CP S CP GCP ↓
PresV１ 50 50 50 50 50 50 50 50 50 50 50 50
PresＶ２ 80 90 65 50 90 85 80 90 65 50 90 85
PresV3 60 90 65 50 90 80 60 90 65 50 90 80
Step２ 102 104 104 102 − − 102 104 104 102 104 102
Step３ 104 106 104 104 − − 104 106 104 104 106 103
Step４ 106 106 106 104 − − 106 106 106 104 106 104
Step５ 108 108 106 106 − − 108 108 106 106 108 105
B 0 2 P r e s V 2 9 0 %
B 0 2 P r e s V 2 9 0 % ↓
B 0 3 S t e p 2 1 0 4 % Step１５ 122 116 118 120 − − 122 116 118 120 116 115
E d I t F CP S CP G C P Step１６ 124 116 120 120 − − 124 116 120 120 116 116
Gun Ｎｏ． Gun Ｎｏ．
1 2 3 4 1 2 3 4
Count1 100 120 200 180 100 120 200 180
Count2 150 160 250 230 150 160 250 230
Count3 180 180 250 250 180 180 250 250
B 0 Cu r r . Hi g 1 1 0% ↓
B 0 V. L i mi t 9 0% Count16 250 280 300 300 250 280 300 300
B 0 Ho l d De l y 1 5c y Curr.Low 90 90
E d I t F CP S CP GCP
Curr.Hig 110 110
V.Limit 90 90
HoldDely
Return to the to
15 15
Peak Curr 150 150
Pressing the Scroll key (up) after viewing the gun Series data with the scroll keys (right/left) allows
you to return to the data screen of the most recently displayed starting Series.
B 0 2 S t e p 1 4 1 1 4%
B 0 2 S t e p 1 5 1 1 6% To return to the most recently
B 0 2 S t e p 1 6 1 1 6% displayed screen of the starting
E d I t F CP S CP GCP Series, press the scroll (up) key.
B 0 3 Co u n t 1 2 0 0 B 0 4 Co u n t 1 1 8 0
B 0 3 Co u n t 2 2 5 0 B 0 4 Co u n t 2 2 3 0
B 0 3 Co u n t 3 2 5 0 B 0 4 Co u n t 3 2 5 0
E d I t F CP S CP G C P E d I t F CP S CP G C P

Descriptions of Modes
5. Descriptions of Modes
5.1 Changing Timer Mode
As described in Section 4.3, the function keys on TP-Net allows the timer mode to be changed.
F1
F5 Operation Mode
F2
#TM F4 F6 No-weld Mode
Home F8 F3
F7 C. Press Mode
F4
F8 Set Mode
F1 Parameter Mode
Shift ＋ F5
Brings the timer into Operation Mode. Welding data cannot be

Operation Mode
changed in this mode.
No-weld Mode Executes a welding sequence with no current applied.
Outputs a signal from the solenoid valve during the period the
C. Press Mode
Starting switch is held on.
Enables welding conditions or other preset values to be changed.
Set Mode
Also welding is enabled.
Parameter Mode It shifts to the parameter setting mode.
(1) No-weld Mode Sequence (Alarm output selection depends on the setting of the corresponding
parameter.)
Start SW →
Solenoid valve
Welding Current
Alarm Signal
Hold End Signal →

4cyc (min)
W. Sequence PS SQ USL W1 C1 W2 DSL C2 W3 HO HD OF
No-Weld
Indication Signal
Alarm Reset Input

Descriptions of Modes
(2) C. Press Mode Sequence

The controller applies pressure during the period that the Start switch is held on.
Start SW →
Solenoid valve →
Welding Current
Alarm Signal
Hold End Signal →
Conti. Press
Indication Lamp
Alarm Reset Input
5.2 Precautions of Set Mode
! CAUTION
! Before changing welding conditions or parameters always make sure that the “Set”
lamp on the TP-Net is turned on. Changing welding conditions or parameters without
entering Set Mode may cause an alarm.

Monitoring welding Sequence
6. Monitoring welding Sequence

This mode allows you to monitor welding sequences or manage Gun Counter or the Step data.
6.1 Weld Monitor Screen
Name Function
Gun Counter Displays the total number of weld
G u n 1 1 0 spots of each Gun 1-8.
G u n 2 1 5 8 0
G u n 3 2 3 0
Step Data The first number indicates a gun
G u n 4 7 0 0 0 number and the rest is the state of
G u n 5 1 0 the gun step, the number of weld
G u n 6 5 0 0 count and a weld state in the order
G u n 7 1 0 0 0 mentioned.
G u n 8 3 0 0 Operation Data BFF-8: Indicates the most recently
1 - S t e p 1 1 0 selected starting Series data.
2 - S t e p 1 2 1 8 0
3 - S t e p U p 2 3 0
(Example) B: Indicates B-Mode. (A or B)
4 - S t e p U p F i n i s h BFF-8 F: Indicates Group. (0∼F)
5 - S t e p 1 1 0 W.Cyc. 10cy F: Indicates starting Series (1∼F)
6 - S t e p 2 1 0 0 PF 68% -8: Indicates weld on Gun#8
7 - S t e p 8 2 0 0 C.Flow 78% W.Cycle 10 cy: The number of weld
8 - S t e p 1 3 0 0
cycles to be per-formed per sequence.
B F F - 8 Ｗ．Ｃｙｃ． 1 0 c y
ＰＦ 6 8 ％Ｃ．Ｆｌｏｗ 7 8 ％
PF68%: Power-factor
S e t V a l u e 8 . 7 k A C.Flow 78%: Flow rate
T o t a l C u r r 8 . 7 k A An average of the set-up heat 1-3 data
Set Value
H e a t 1 5 . 0 k A is displayed.
H e a t 2 1 0 . 0 k A Indicates the mean current value
H e a t 3 0 . 0 k A Total Current
applied to Heat 1-3.
P e a k Cu r r 1 0 . 5 k A
P r e s s ． N −V 1 3 5 0 0 N
Indicates the current values applied to
Current Value
1s t V o l t a g e 3 9 0V Heat 1-3.
L i n e V o l t ． 4 0 0V Peak Current The peak current during welding is
Note: displayed.
1. The gun number and the spot counts of
steps depend on the settings of the Pressure force Indicates the pressure force.
corresponding parameters. Indicates the primary voltage during
1st Voltage
welding.
2. The above example represents welding
Indicates the power voltage during idle
with 8 guns and the Step-up function Line Voltage
running.
! CAUTION
Set Value :
Set Value shows the result carried out on the basis of the value calculated from current step
and welding condition.
After welding, if the data with which the above is related is changed, the relation between set
current display value and the total current display ground is not in agreement.

Monitoring welding Sequence
6.2 Resetting Gun Counter

To reset the gun counter, proceed as follows:
1. Enter the Weld Monitor screen. #TM
Home
2. Scroll the screen to display the desired gun number on the top line.
Gu n 3 1 6 2 0 0
Gu n 4 1 7 0 0 0
1- S t e p 1 1 0
Mo n T MD T P D Mo d e
In case of reset to GUN No.3

3. Press the Reset key, and then press the Return key to complete the procedure.
Ｇｕｎ 3 1 6 2 0 0
ＣｏｕｎｔｅｒＣｌｅａｒ
ＯＫ？ Reset
ＯＫ：Ｒｅｔ．Ｑｕｉｔ：Ｆ −8
6.3 Resetting Steps

To reset the steps, proceed as follows:
1. Enter the Weld Monitor screen. #TM
Home
2. Scroll the screen to display the desired gun number on the top line.
4 - S t e p U p F i n i s h
B 3 F Ｗ．Ｃｙｃｌｅ 1 0 c y
ＰＦ 6 8 ％Ｃ．Ｆｌｏｗ 7 8 ％
T o t a l Cu r r 8. 7 k A
3. Press the Step reset key, and then press the Return key to complete the procedure.
4- S t e p Up F i n i s h Step
S t e p Up Cl e a r Reset
ＯＫ?
4 - S t e p 1 0
In case of step reset to GUN No.4
B 3 F Ｗ．Ｃｙｃｌｅ 1 0c y
ＰＦ 6 8 ％Ｃ．Ｆｌｏｗ 7 8％
T o t a l Cu r r 8. 7k A

Descriptions of Parameter Functions
7. Setting Parameters
7.1 Descriptions of Parameter Functions
Function Name Requirements/Function
ON: Enable
OFF: Disable
Pulsation Select
Action:
(P1 Pulse. Sel.) Cyclically repeats Cool-1 and Weld-2 the number of times specified by
the pulsation number.
ON: A Mode
OFF:B Mode
Action:
A or B Mode Select In A-Mode, turning on one of the four switches will select welding
(P2 AB Mode) conditions from Series 1 to 4. When turning on two or more start
switches at the same time, the least series will precede others.
In B-Mode, a combination input of the four Start switches selects the
welding conditions from Series 1 to 15.
ON: Normally Open
Alarm signal NO/NC OFF: Normally Closed
select Action:
(P3 ALM Out) Selects the alarm output method on occurrence of an alarm between
Normally Open and Normally Closed.
ON: Enable
OFF: Disable
Trigger start
Action:
(P4 One Shoot) Setting this to ON enables the controller to receive a pulse input from the
Start switches.
ON: Enable
OFF: Disable
Hold End Delay signal
Action:
select
Setting this to ON allows the Hold End signal to be output after (or at the
(P5 Hold Out) same time) as an alarm signal has been output. The alarm is classified
as a warning alarm (such as current alarm).
ON: Enable
Hold End Delay Job OFF: Disable
section at alarm signal Action:
(P6 HoldA Dly) Delays the output of Hold End Signal by 30 cycles after a warning alarm
(such as current alarm). (Hold Delay Management)
0: Alarm pulse output enable
1: Alarm constant output enable
2: Alarm constant output & weld stop
3: Skip alarm output
Alarm output signal
Action:
select
On the occurrence of warning alarms (such as current alarm) this
(P7 ALM Mode) function controls the output timing of alarms according to the preset
parameters. Setting this to 0 with the above-mentioned parameter
enabled will fix the alarm signal output timing to 30 cycles.
When setting this to OFF, the alarm output depends on the Start switch.
0: Disable
1: Max. gun series
2: 4/15 series
Max. Step Up series
Action:
select
Setting this to 0 will disable the Step-up function.
(P8 Step Type) Setting this to 1 will allow the gun number (1 - 4) specified by the
parameter for the Step-up series.
Setting this to 2 will fix the Step-up series to be 4 (A-Mode)/15 (B-Mode).


ON: Trigger SW priority select
OFF: Weld sequence priority select
Trigger SW priority
Action:
select
When turning off the Start switch during welding or cooling, the welding
(P9 Sw mode) sequence will stop at the currently performed cycle and skip to the Hold
state, ignoring the remaining welding and cooling processes.
ON: Japanese
Japanese or English
OFF: English
display select
Action:
(Pa Japanease) Switches the display language between English and Japanese.
0: Disable
1: Max. gun series
2: 4/15 series
Transformer turn ratio
Action:
series select
Setting this 0 will allow Series 1 for the transformer turn-ratio.
(Pb Trans Type) Setting this to 1 will allow the gun number (1- 4) specified by the
parameter for the transformer turn-ratio. Setting this to 2 will select 4(A
Mode)/15(B Mode) Series.
ON: Enable
OFF: Disable
Repeat action select Action:
(Pc RepeatSel.) Keeping the start switch turned on will repeat the sequence from
squeeze. Turning the start switch off will stop the sequence.
The output timing of Hold End signal at this time depends on Off Time.
ON: Enable
OFF: Disable
Re-weld action select Action:
when current low Executes re-welding when it has been detected that the current level is
detected too low. After re-welding, if the current level is still too low, then the
(Pd Reweld) "Current too low" alarm is issued. When Trigger SW priority select is set
to ON, whether re-welding is executed or not depends on the state of
the Start switch.
0: Disable
1: % Setting enable
2: Direct number setting enable
3: Direct number setting enable, and display only setting pressure “1”
Pressure Adjustment
select
Action:
Setting “1” : Percentage setting method of gun pressure
(Pe VP Mode)
Setting “2” : Direct (N:Newton) setting method of gun pressure
Setting “3” : Percentage setting method of gun pressure as well as
setting “2”, though only setting pressure value “1” is displayed in TP-Net
monitor.
0 : Control range 0-5V
Pressure Adjustment 1 : Control range 0-10 V
control voltage select Action:
(Pf VP Type) Confirm the rating control voltage of electro-pneumatic regulator used
before setting.
ON: Enable
OFF: Disable
Caution output select
Action:
(Pg Caution) Specifies whether the pulse output of cautionary alarms is enabled or
not. Setting this to ON will allow the pulse output of alarms.


ON: Enable
OFF: Disable
Transformer thermostat Action:
When the transformer thermostat is monitored at all times on the
check sequence
attached gun, changing a gun will temporarily open circuit the
(Ph Gun Chang.) transformer thermostat and cause an alarm at the controller, although it
is in normal state. Accordingly, the transformer thermostat is not
checked during idle running when this is set to ON.
ON: Alarm output signal enable
OFF: Alarm output signal disable
Alarm output signal
select on No-weld Action:
In no-weld sequence and continuous pressurization, the Hold End
sequence signal is output after pulse output of an alarm signal.
(Pi TestW ALM) Setting this to OFF will disable the pulse output of alarm signal and
display no alarm messages.
01 – 08: MAX. SOL valve select.
11 – 18: Retract enables
21 – 28: Reverse wires retract enable
31 – 38: Valve selector enable
41 – 48: Weld interlock enable
51 – 58: Retract enable & Retract interlock enable
61 – 68: Reverse wires retract enable & Retract interlock enable
Action: Upper digit sets up a selection of function. Moreover, Low digit

sets up the maximum number of GUN to use.
When the upper digit is 0, SOL3 and SOL4 can not be used as
SOL since they are used for different functions.
When use DeviceNet, Setting to 01-08 (Max. number of GUN )
Retract function:
SOL7 (B2) is output in response to the input from the retract
Max. Gun num. select start SW7 (B8 on the terminal board TB1), and SOL8 (B3) is
Retract select output in response to the input from the retract start SW8 (B9).
Valve selector select Valve selector during welding (Welding selector function):
Weld interlock select MV3 (B2 on the terminal board TB1) is output after setting the
(Pj Gun Sel.) welding conditions and Pressure rise time 1. Subsequently,
MV4 (B3) is output after completion of Pressure rise time 2.
Please see 13.1(.2) for details.
Weld interlock function
The Start Acknowledgement signal is output (B2 on the
terminal board TB1) in response to SW1 to SW4. Information
during welding is also output by the Weld signal (B3). The Weld
Ready input (B8) delays the squeezing time. Please see
14.1(.2) for details.
Retract function & Retract interlock function:
Retract SOL7(B2) output when retract SOL8(B3) is turned off to
retract start SW7(B8) input.
Retract SOL8(B3) output when retract SOL7(B2) is turned off to
retract start SW8(B9) input.
↓
Next Page detail diagram


Max. Gun num. select Diagram for Gun num select to TB1 output
Retract select
Valve selector select TB1 Out SOL1 SOL2 SOL7 SOL8
Weld interlock select Setting （SOL3）（SOL4）
(Pj Gun Sel.)
01 Valve Out
02 Valve Out Valve Out
03 Valve Out Valve Out Valve Out
04∼08 Valve Out Valve Out Valve Out Valve Out
11 Valve Out SW7 SW8
12∼18 Valve Out Valve Out Retract Out Retract Out
31 Valve Out Press T2 Press T3
32∼38 Valve Out Valve Out Valve Out Valve Out
Output for Welding
41 Valve Out received
welding firing status
42∼48 Valve Out Valve Out start output

※ The setting data can input within above the numbers.

Step Up Max. value 2~16: Step Up max. number select
select Action:
(Pk Max Step) Specifies the number of steps (max.) to be performed in the final step.
0: Display all function
Display level select 1: Display limited function
(PL DispLevel) Action:
Enables welding to be executed only with the minimum setting data.
0: 200V line voltage 1: 220V line voltage
2: 380V line voltage 3: 400V line voltage
Step-down transformer 4: 420V line voltage 5: 440V line voltage
(Pm Ref. Volt) 6: 460V line voltage 7: 480V line voltage
Action:
This parameter needs to be set according to the welding power source.
0:Weld enable (standard) 1: Weld disable 2: Continuous pressurization
3:Cable-short detection 4: Cable-short detection2
Action:
Weld enable / disable 1: “Weld disable" will allow only gun action.
2: “Continuous pressurization " will allow gun continuous pressurization
select
while the start switch is on.
(Pn Test Mode) 3: “Cable-short detection “ When SW.15 of 15 groups of the startup
system is selected, it is effective.
4: “Cable-short detection 2“ When SW.15 is selected regardless of the
group of the startup system, it is effective.


0~99: Timer Number set
Action:
Timer number select
Set this parameter when using a network system.
(Po TM Number) The numerical value of last two digit of the timer manufacturing number is
set (recommendation).
ON: Enable (Gun number is fixed to start series.)
OFF: Disable (Gun number can be selected every start series)
Action:
Enable: Start series of odd numbers (1,3,5…) assign SOL 1 to be used
Gun assignment select
and that of even numbers (2,4,6…) assign SOL 2. This is used
(Pp GunNumFix)
mainly in portable systems.
However, all series use SOL1 when the lower digit is set to
one in Pj Gun Sel. (the maximum number of guns is one).
Disable: Output SOL can be selected arbitrarily every start series.
ON: Enable ( For DeviceNet)
OFF: Disable
Remote I/O select
Action:
(Pq Remote I/O)
It becomes DeviceNet correspondence by ON. Uniting, terminal block
TB1 serves as DeviceNet I/O.
ON: Enable
OFF: Disable
Action:
Enable: When the current is detected normally flowing by weld ON, the
current detection signal is output from B6 of terminal block
TB1.
The output timing is the same as the hold end signal output.
Current detection signal The step last stage signal is not output when the parameter
(Ｐｒ CurDetect) "Pr" is enable. Only the TP is displayed.
Disable: The current detection signal is not output.
The step last stage signal is output from B6 of terminal block
TB1 without setting the parameter "P8" to 0.
Note) Terminal block TB1 is used as a terminal block for remote I/O when
remote I/O is effective. Therefore, the current detection signal is not
output to terminal block TB1.
ON: Enable (Parameter “Ps” and “P8” are both ON(1 or 2).)
OFF: Disable
Action:
Enable: When step series1 is complete, the step up finish signal of step
series1 is output from the terminal TB1-B5. When step series2
Step up Finish
is complete, the step up finish signal of step series2 is output
2 series output
from the terminal TB1-B6. The signal other than step series1
(Ps StepF2out) and step series2 isn’t output.
(The signal of only step series1 or step series2 is output
separately.)
Disable: The step up finish signal is output when any step series is
complete without setting the parameter "P8" to 0.


ON: Liner-up control
OFF: Step-up control
Step liner up
Action: When selection of control liner-up, the following current and the
(Pv Liner up) straight line are interpolated. UP is gradually done by the current
value of the ratio divided in the number of set welding runs batted in.
ON: Secondary- current feedback
OFF: Primary- current feedback
Action: Selection by the primary-current feedback or by the
2nd Current Select
secondary-current feedback to control a fixed current. The alarm is
(Pw 2ndCurSel.)
processed after switching automatically to the primary-current
(Note) feedback and welding when the primary-current feedback is not
detected though selected.
Note) Please use the troidal coil for the ISO standard.
Note) “2nd Current Select” function is due to add. Setting this parameter OFF when this timer use.
7.2 Note on Changing Parameters
! CAUTION
In order to assure system operation of the timer, Whenever changing the parameter,
!
always switch on the power of the again. If not, it can cause malfunctions of the timer.
Changing parameters also requires modification or review of the welding condition data
! associated with the parameters changed.
Example 1: When Pulsation Select has been changed from 0: Disable to 1: Enable,
Pulsation number of the welding conditions also needs modification.
Example 2: When Max. Step Up series select has been changed from 0: Disable to 1:
Max. gun series, Steps and Step count of the welding conditions also need
modification.
Example 3: When the parameter of Max. Gun num. Select has been changed, all
setting items including Max. Gun num. Select, Transformer turn-ratio, and
Step series of the welding conditions need modification.

Basic Sequence
8. Setting Welding Conditions

8.1 Basic Sequence
(1) Slope (USL) ≧ 1cyc setting
Start SW
MV/SOL
Heat1 Heat2 Heat3
Welding Current
Hold End Signal

(Note2) HES
Welding Sequence PS SQ USL W1 C1 W2 DSL C2 W3 HO HD OF
Min. Set Cycle 0 1 1 0 0 0 0 0 0 1 0 0
Note1:Since setting 0 to welding times (W1 to W3) simultaneously will cause a data error, at least
one must be set to a value other than 0.
Note2:”Hold End signal” (from 1 to 4) is output corresponding to from SOL1 to SOL4.

”Hold End signal” of the past is output at same time when the weld is completed.
Abbreviations:
MV/SOL: Retract-vale/solenoid-valve output signal
PS: Pre-squeeze time SQ: Squeeze time
USL: Up-slope time W1: Weld-1 time
C1: Cool-1 time W2: Weld-2 time
DSL: Down-slope time C2: Cool-2 time
W3: Weld-3 time HO: Hold time
OF: Off time HES: Hold End signal (4 cycles minimum)

Basic Sequence
(2) Slope (USL) = 0cyc setting (Note1)
Start SW
MV/SOL
Heat1 Heat2 Heat3
Welding Current
Hold End Signal

(Note2) HES
USL
Welding Sequence PS SQ W1 C1 W2 DSL C2 W3 HO HD OF
Min. Set Cycle 0 1 0 0 0 0 0 0 0 1 0 0
Note1:Since setting 0 to welding times (W1 to W3) simultaneously will cause a data error, at least
one must be set to a value other than 0.
Note2:”Hold End signal” (from 1 to 4) is output corresponding to from SOL1 to SOL4.

”Hold End signal” of the past is output at same time when the weld is completed.
Note3: When "Slope time (USL) = 0cyc" is setting, slope time 1cyc is included in the weld time.
For example, the case of "Slope time = 0cyc" and "Weld time = 10cyc".
It becomes Weld time 10cyc = Slope time 1cyc + Weld time 9cyc.

Description of Welding Conditions
8.2 Description of Welding Conditions
Name Indication Input Condition/Description/Relevant Data

Condition A gun number (MV/SOL) used in a specific Series is selected.
Gun Selection GunSel Description A function to output SOL/MV to the gun number set here.
Relevant
Parameter “Pj Gun Sel.”
parameter
Condition Setting range: 1 to 99 (cycles), Setting 0 will disable this item.
A function to wait for a period specified here after MV valve has
Pre-squeeze PrSquez Description been activated. This is the initial process in the welding
sequence, and ignored when welding is repeated.
Relevant
parameter
Setting Range: 1 to 99 (cycles), Needs to set a value other than
Condition
0.
Squeeze Tim Squeeze Description A function to wait for slope control (welding).
Relevant
parameter
Condition Setting Range: 1 to 30 (cycles) (Note1)
A function to gradually increase welding current from the
Slope Time Slope Description minimum-striking angle of arc to a required level. Slope time
before the next welding time is specified here.
Relevant
parameter
1 to 99 (cycles), Setting 0 will disable this item. Cannot set all
Condition Weld times to 0 simultaneously. At lest one Weld time must be
Weld-1 Time Weld1 set to a value other than 0.
Weld-2 Time Weld2
Weld-3 Time Weld3 Description Welding times are specified here.
Relevant
parameter
Setting Range: 2.0 to 60.0 (kA), or 25 to 100 (%),
Condition
(sw TurnRatio=0)
Welding Current, 1 Heat1
Welding Current, 2 Heat2 Welding current required for each Weld time is specified here.
Description
Welding Current, 3 Heat3 TP displays the set value in % when swTurnRatio=0.
Relevant
Welding Conditions “Transformer Turn Ratio”
parameter
Condition Setting Range: 1 to 99 (cycles), Setting 0 will disable this item.
Cool-1 Time Cool1 Description The interval between welding is specified here.
Cool-2 Time Cool2
Relevant
parameter
Condition Setting Range: 1 to 99 (cycles), Setting 0 will disable this item.
A function to interpolate welding current between Weld-2 Time
Down-slope Time D.Slope Description and Weld-3 Time. The current may increase according to the
setting.
Relevant
parameter
Setting Range: 1 to 99 (cycles), Always set this (0 cannot be
Condition
set).
Hold Time Hold The hold time before a gun is released after application of
Description
welding current has been completed.
Relevant
parameter

Setting Range : 0.1 to 200.0
Control voltage control : Set 0.0
Condition
The setting of Series 1, Gun Series, and All Series depends
on the condition of the "Transformer Turn Ratio" parameter.
Transformer Turn
TurnR. It is used as a coefficient when converting the primary
Ratio
Description current into the secondary current. Voltage compensation
control (% voltage) is available when setting this to 0.0.
Relevant
Parameter “Pb TransType”
parameter
Setting Range: 4 to 99 (cycles)
Condition No use by 0 cycles setting.
The parameter, "RepeatSel." must be ON.
Off Time Off
Description Holding the start switch ON will repeat cycle operation.
Relevant
Parameter “Pc RepeatSel.”
parameter
Setting Range: 1 to 9 (times), The "No. of Pulsation
Condition
Selection" parameter must be ON.
Pulsation will be repeated for a number of times specified
No. of Pulsation Pulse here. In addition to the basic cycle operation, whether
Description
operations will continue according to the Start switch
depends on the parameter.
Relevant
Parameter “P1 Pulse. Sel.”
parameter
Condition Setting Range: 30 to 100(%)
A reference value to compare the flowrate of current
welding with the flowrate assumed to be 100 % at full-wave,
the waveform with the maximum current controlled by SCR.
Maximum Current Description Since the flowrate will decrease with the increase of electric
C. Flow+
Flowrate resistance due to cable deterioration, the system
automatically shifts the trigger point to increase the
flowrate.
Relevant Welding Conditions “Error Count”
parameter Alarm Output ”Current flow rate high”
Setting Range: 1 to 99 (times), Setting 0 will disable this
Condition
item.
A criterion to judge current error when the applied flowrate
Error Count CF.Count Description
has repeatedly exceeded the maximum flowrate.
Relevant Welding Conditions “Maximum Current Flow-rate”
parameter Alarm Output ”Current flow rate high”
Setting Range: 0 to 9999 (N), This specifies the maximum
Condition
gun pressure shown on the gun drawing.
Maximum Pressure Max V. In conjunction with the air pressure explained below, it is
Description
used as a coefficient to calculate a setting pressures.
Relevant
Parameter “Pe Pressure Adjustment select”
parameter
Condition Setting Range: 50 to 150 (%)
In conjunction with the above set value of Maximum
Pressure Description Pressure, it is used as a coefficient to calculate the setting
P Adjust
Coefficient pressures.
Relevant
parameter


Condition Setting Range: 0 to 99 (cycles)
Pressure Rise
Time 1 The timings for changing pressure and switching the
PresT1 pressure selector are specified here. Specify the timing so
Pressure Rise Description
PresT2 as to change pressure within the period from the beginning
Time 2
PresT3 of the sequence operation to the end of welding.
Pressure Rise
Time 3 Relevant
parameter
Condition Setting range: 0 to 9999 (N) or 0 to 100 (%)
Set Pressure 1 PresV1
Set Pressure 2 PresV2 Description Required pressure can be set in N or %.
Set Pressure 3 PresV3 Relevant
parameter
Setting Range: 50 to 200 (%), The available setting range in
Condition Series 1, Gun Series, and All Series depend on the
Step 1 Step 1 parameter.
To To The welding current, Heat 1 to 3, will be adjusted according
Description
Step 16 Step16 to the current step.
Relevant Parameter “P8 Step Type ”
parameter “Pk Step Up Max. value select ”
Setting Range: 0 to 9999 (times), The available setting
Condition range in Series 1, Gun Series, and All Series depends on
the parameter.
Count, 1 Count 1
The maximum count in each step will be indicated when
To To
Description Step Control is in effective. Operation will proceed to the
Count, 16 Count16
next step when the current step reaches the full count.
Relevant Parameter ”P8 Step Type “
parameter “Pk Step Up Max. value select “
Setting Range: 50 to 100 (%), Setting 100 (%) will disable
Condition
this item.
A function to detect current error by comparing the actual
Current Low Limit Curr. Low Description welding current with the set current, including a step-up
current.
Relevant Welding Conditions “Welding Current1,2,3”
parameter Alarm Output “Current low”
Condition
this item.
A function to detect current error by comparing the actual
Current High Limit Curr. Hig Description welding current with the set current, including a step-up
current.
Relevant Welding Conditions “Welding Current1,2,3”
parameter Alarm Output “Current low”
Condition
this item.
Power Voltage Low A function to detect voltage error by comparing the
V. Limit Description measured voltage with the set voltage (Power voltage low
Limit
limit). Voltage is measured at the final cycle of weld.
Relevant
Alarm Output “Weld voltage low”
parameter
Condition Setting Range: 0 to 99 (cycles)
When this setting is in effective, the Hold End signal will not
Hold End Delay Description be output immediately after the elapse of HO (Hold Time)
Hold Dely
Time but delayed by the period specified here.
Relevant
parameter

Specific Welding Sequence

Setting Range: 100 to 200 (%), Setting 100(%) will disable
Condition
this item.
A function to detect peak current error by comparing the
Peak Current Limit PeakCurr Description actual welding current with the set current, including a step
up current.
Relevant
Alarm Output “Peak current high”
parameter
Condition Setting Range: 1 to Parameter ”Pk Max Step”-1,
If “Step select clear(TB1 or D/N)” is inputted, it will
Step return location StepReturn Description
return to the position set up here.
Relevant Parameter ”P8 Step Type”
parameter “Pk Step Up Max. value select”
9. Specific Welding Sequence
(1) Parameter: One Shoot (ON: Enable)
Start switch
MV/SOL
Welding Current
Hold End signal HES

4cyc
(2) When the Start switch is held on
Start switch →
MV/SOL
Welding Current
Hold End signal HES→

4cyc

（３） Parameter: P1 selection of Pulsation ………ON

Parameter: Pc selection of repeat………… When it is ON, start switch is retained
Input of OFF time for welding condition is available by selecting ON at repeat on parameter.
Start SW →
MV / SOL
Repeat
Welding Current
Hold End Signal Pulsation

(Repeat)
Hold End Signal 4cyc →
(Pulsation) min
（４） Parameter: P9 start switch in priority selection

Sequence (up side), Trigger switch priority select … ON
When start switch turns to OFF during the sequence, the sequence after the next cool down
time is skipped and transfers to HO (hold) process.
Sequence (down side), Trigger switch priority select…OFF
The sequence is not aborted even start switch turns OFF during the sequence.
Start SW
MV / SOL
Welding Current
（Para.P9 ：ON）
Welding Current
（Para.P9：OFF）
Hold End Signal

(5) Parameter: Re-weld (ON: Enable)

Setting this parameter to ON will execute re-welding at the occurrence of the following alarms:
the “Current too low” or “Compensation voltage too low”.
Start switch
MV/SOL
Welding Current
Hold End signal HES

4cyc
* The re-weld sequence can be executed only once.
(6) Sequence to discover short-circuited cable.

Parameter to discover short-circuited cable: Weld enable/disable select (3: Cable short check
enable)
Inputting “F” activates

Start switch the sequence. →
MV/SOL
Test Current
Alarm Signal 30 cycles min. or HD

preset time
Hold End signal →

4cyc
W. Sequence PS SQ HD

(7) Current ditection signal output function : Parameter Pr-CurDetect （Note１）

Current ditection signal sequence 1・・・・・ON: Enable
The current detection signal is output when parameter “Pr” is Enable.
The output condition：Detect the welding current. Without, "no Weld"
and "current error" etc.
The step last stage signal is not output in TB1 when the parameter "Pr"
is enable. Only the TP is displayed.
Current ditection signal sequence 2・・・・・OFF: Disable
When the parameter is Disable the current detection signal is not
output.
When “1” or “2” of the step types in the parameter have been selected,
the final step signal is output in TB1.
Start information
ＭＶ／ＳＯＬ
Heat1 Heat2 Heat3
Welding current
Hold end signal ＨＥＳ
（Note2）
current detection
signal 1 （Ｐｒ ON）
current detection
signal 2 （Ｐｒ OFF）
Welding sequence PS SQ USL W1 C1 W2 DSL C2 W3 HO HD OF
Minimum,set cycle ０１１００００００１００
（Note １）Terminal block TB1 is used as a terminal block for remote I/O when remote I/O is effective. Therefore,
the current detection signal is not output to terminal block TB1.
（Note 2）When the welding current is detected, and the welding sequence finished normally, the current
detection signal is output.
The current detection signal is not output with an current error or no weld.
The output timing is done later by the processing beginning about one cycle at the HOLD time.

Alarm Output
10. Alarm Output

10.1 Classifications of Alarms
The alarms are categorized into the classifications listed below according to their degree of risks.
Refer to “IV. Maintenance manual” for descriptions and troubleshooting the alarms.
Fatal Alarms:
I/O Power supply check (Note1) Line voltage drop
SP3 Trip (Note1) Illegal data setting
Thyristor shorted Illegal current setting
Thyristor over temperature AD error 1
Transformer over temperature AD error 2
Current frequency abnormal Cable shorted (Electrode sticking.)
Illegal parameter Line voltage over
Warning Alarms:
Current low Current high
Compensation voltage low Compensation voltage high
No current Peak current high
Weld voltage low
Cautionary Alarms:
Current unbalance Weld-2 cycle num. Few
Current flow rate high Weld-3 cycle num. Few
Weld-1 cycle num. Few
Indicative Alarms:
Start switch trouble Weld off warning
Communication time-out error Continuous pressure warning
Communication data error OP communication error
Specific Alarm:
CPU operation failure DeviceNet fetal error

Timing Charts of Sequences at Occurrence of Alarm
10.2 Settings Associated with Alarms

The parameters and welding conditions associated with the alarms are as follows:
Refer to the corresponding section for details.
Parameters Associated with Alarms Welding Conditions Associated with Alarms
Alarm output signal select Current flow rate high
Hold End signal select Error count
Hold End Delay Job selection at alarm signal Current low limit
Alarm signal NO/NC select Current high limit
Caution output select Power voltage low limit
Alarm output select on No-weld sequence Peak current limit
10.3 Timing Charts of Sequences at Occurrence of Alarm

The actions taken at the occurrence of alarm are as follows:
Fatal Alarms: Outputs the alarm signal and stops the whole sequence. Hold end signal will
not be output.
Warning Alarms: Outputs an alarm signal. The output sequence and whether the Hold End
signal is output or not depend on parameter settings.
Cautionary Alarms: After trouble has been detected, the corresponding alarm will be classified into
either Warning or Display according to parameter settings. The Output of the
Hold End signal depends on the parameter settings corresponding to the
alarm classified.
Indicative Alarms: Does not output an alarm signal but displays an alarm message on TP-Net.
The Hold End signal will be output.
Specific Alarm: Detects trouble that occurs in the CPU or the circuit. Contact output of alarm
with no message appearing on TP-Net indicates “CPU operation failure”.
With warning alarms, the output timings of the alarm signal and the Hold End signal depends on
the settings of parameters related to the alarms. Refer to the timing charts shown in the following
pages for the output timing.

Sequences at the Occurrence of a Warning Alarm

Refer to Section 8.1, “Welding Sequence”, for the abbreviations used in the following timing
charts.
(1) Parameters: TestW ALM— ON

Hold Out — ON
ALM Mode — 0 (Alarm pulse output enable)
Start Switch
MV/SOL
Welding Current
Alarm Signal 30cyc

(min)
Hold End signal 4cyc

(min)
Alarm Message
Alarm Reset
Alarm output: 30 cycles min. or HD time.

Hold End signal: 4 cycles min., the OF time, or the Start switch hold time.

(2) Parameters: HoldA Dly—ON

Hold Out — ON
ALM Mode — 1 (Alarm constant output enable)
Start Switch
MV/SOL
Welding Current
Alarm Signal
30cyc
Hold End signal (min)

4cyc
(min)
Alarm Message
Alarm Reset
The Start switch input for the next sequence is acceptable even if there is no alarm reset input.

Hold Out — ON
ALM Mode — 2 (Alarm constant output & weld stop)
Start Switch
MV/SOL
Welding Current
Alarm Signal
30cyc
Hold End signal (min)

4cyc
(min)
Alarm Message
Alarm Reset
The Start switch input for the next sequence is unacceptable if there is no alarm reset input.
The controller waits for the alarm to be reset.

(4) Parameters: HoldA Dly—OFF

Hold Out — ON
ALM Mode — 3 (Skip alarm output)
Start Switch
MV/SOL
Welding Current
Alarm Signal

(min)
Alarm Message
Alarm Reset

Hold Out — OFF
Start Switch
MV/SOL
Welding Current
Alarm Signal 30cyc

(min)
Hold End signal
Alarm Message
Alarm Reset


Hold Out — ON
ALM Mode — 0 (Skip alarm output)
Start Switch →
MV/SOL
Welding Current
Alarm Signal →
Hold End signal 4cyc→

(min)
Alarm Message
Alarm Reset

Hold Out — OFF
Start Switch →
MV/SOL
Welding Current
Alarm Signal →
Hold End signal
Alarm Message
Alarm Reset

Sequence with the occurrence of Indicative Alarm:

Alarm messages will appear on TP-Net when the Hold End time passes.
Start Switch →
MV/SOL
Welding Current
Alarm Signal
→
(min)
Alarm Message
Alarm Reset

Step-up Control
11. Step Up
11.1 Step-up Control
The Step-up control function is used to compensate for decreased current density due to electrode
wear. Step end signal
is output here
Current value Step last stage signal
is output here
130%
102%
Step 1
Step 2
Step 3
Step 4
Step max-1
Step max
100%
Spot count
S Count 1
S Count 2
S Count (16)
! CAUTION
Actions at the end of Steps: At the beginning of the final Step, the “Step last stage” signal will be
output from the terminal TB1-B6. The “Step up Finish” signal will be
output from the terminal TB1-B5 at the completion of the final step.
(Note1) When the parameter "Pr Current detection signal" is effective, the
“Step last stage” signal isn’t output due to the “Current detection”
signal is output from the terminal TB1-B6.
(Note2) When the parameter "Ps Step up Finish 2 series output" is effective,
the “Step last stage” signal isn’t output due to the “Step up finish”
signal output of step series2 from the terminal TB1-B6.
(Note3) When the parameter "Ps Step up Finish 2 series output" is effective,
the “Step up finish” signal of another step series isn’t output due to
the “Step up finish” signal output of step series1 from the terminal
TB1-B5.
(Note4) The parameter "Pr Current detection signal" and “Ps Step up Finish
2 series output” can’t be set to ON at the same time.
Please be careful in setting the parameter.

Liner-up control
11.2 Liner-up control

The linear-up control is a function to interpolate the following current and the straight line when the
step is controlled.
Step end signal is output here.

Initial set current X Step0 improvement rate
Step last stage signal is output here.
Step7 set value
Current value I11

Step1
Step2
Step3
Step4
Step5
Step6
Step7
Step8
Step9
Step10
Step11
Step12
Step13
Step14
Step15
Weld current 1
Weld current 2
Weld current 3
Weld current 4
Weld current 5
Weld current 6
Weld current 7
Weld current 8
Weld current 9
Weld current 10
Weld current 11
Weld current 12
Weld current 13
Weld current 14
Weld current 15
NOTE1) Liner-up function of up to 15 steps and can be set to any value.

NOTE2) The improvement rate is set to step0 wh

Setting Procedure to Use Step-up Function
11.3 Setting Procedure to Use Step-up Function

(1) Parameter: Step Type
Specify a step-up method to be used.
0: Disable
1: Max. gun series
2: 4/15 series
(2) Parameter: Max Step
Specify a maximum step number to be applied. Up to 16 steps are available.
(3) Parameter: Gun Sel.
Specify a maximum number of guns to be used.
(4) Welding Condition: GunSel
Assign gun numbers to be used in each Series to set welding conditions according to the
following procedures.
(5) Welding conditions: Step 1 to 16
Specify a step-up rate to each gun or to the gun selected in the starting Series according
to the parameter, “Step Type”. (Refer to the setting example shown below.)
(6) Welding conditions: Count 1 to 16
Specify spot count to be performed between each step up.
Setting examples of Selecting Step-up rate Series
Setting Example: Gun Series Setting Example: All Series

Item / Function Combination of the triggered switch signal Item / Function Combination of the triggered switch signal
1 2 3 4 5 → F 1 2 3 4 5 → F
Gun Sel 1 2 2 2 4 4 Gun Sel 1 3 2 2 4 4
PrSquez 0 0 0 0 0 0 PrSquez 0 0 0 0 0 0
Squeeze 20 30 30 30 35 35 Squeeze 20 26 30 30 35 35
Slope 3 3 3 3 3 3 Slope 3 3 3 3 3 3
Weld1 0 5 0 0 10 5 Weld1 0 5 0 0 10 5
Cool1 0 0 0 0 0 0 Cool1 0 0 0 0 0 0
Weld2 5 5 10 10 10 5 Weld2 5 5 10 10 10 5
↓ ↓
0 0 0 0 0 0 0 0 0 0 0 0
PressV3 0 0 0 0 0 0
PressV3 0 0 0 0 0 0
Step2 102 102 103 103 Step2 102 105 103 103 102 102
Step3 104 104 106 106 Step3 104 106 106 106 104 104
Step4 106 106 109 109 Step4 106 110 109 109 106 106
↓ ↓
Step16 120 120 130 130 Step16 120 140 130 130 130 130
Gun select Number Gun select Number
1 2 3 4 1 2 3 4
Count1 300 200 150 200 Count1 300 200 150 200
Count2 350 250 200 300 Count2 350 250 200 300
Count3 350 250 200 300 Count3 350 250 200 300
↓ ↓
Count16 300 300 200 300 Count16 300 300 200 300
Note: Where 4 guns

are used.
The values indicate the step-up Specify the step-up rate of
rate of Gun 1 to 4 from the left. Gun 3 selected in the
Specify step-up rate to each gun. starting Series.

Pressure Adjustment (Option)
12. Pressure Adjustment (Option)

The Pressure Adjustment function allows the application pressure of the gun to be changed by
adjusting the pneumatic pressure with the electro-pneumatic proportional valve that can be
controlled by a pressure control output signal from the timer.
12.1 Setting pressure adjustment control

There are two kinds of pressure control adjustment methods to the timer.
(1) Percentage setting method : Method of setting the pressure with a percentage (%),
assuming the rating of the electro-pneumatic regulator
to be 100%.
(2) Direct setting method : Method of setting the pressure directly with Newton’s (N).
Set parameters and welding conditions as follows to select there.
12.2 Setting Percentage setting method

Setting related Parameters
Pressure adjustment 1: Uses percentage setting method
function select
Pressure adjustment Selects a rated control voltage of the Electro-pneumatic regulator
control-voltage select to be used.
0: Control voltage from 0 to 5V
Setting related Welding Conditions
Pressure Efficiency Enter 100 (%)
Pressure Rise Time Set Sequence referring to “12.4 Pressure Adjustment Sequence.”
1, 2, 3
Setting Pressure Set a percent value by assuming the rated air pressure of the
1, 2, 3 Electro-pneumatic regulator to be 100%.
*Confirm the ratings control voltage of the product used to “Pressure Adjustment control-voltage
select”.
Note) Relation between "Setting Pressure" and Control Air Pressure in Timer Welding
conditions(Source:ITV205-**:SMC)
Setting Value and Air Pressure

0.9
0.8
Control Air Pressure (MPa)
0.7
0.6
When a factory air
0.5
pressure is 0.5 MPa,
0.4
0.3 using no boost unit.
0.2
0.1
0
0 10 20 30 40 50 60 70 80 90 100
Welding Condition Setting Value (%)

Note) Air-pressure related Devices

When a boost valve unit is used:
Regulate the secondary pressure after increasing a pressure so as to be 0.9 to 1.0 MPa by
using the regulating valve of a boost valve unit.
When the boost valve unit is not used:
Obtaining an air pressure greater than that of supplied air is impossible even if setting a
corresponding parameter of the timer welding conditions to a value greater than the factory
air pressure.
12.3 Setting Direct setting method

Setting Parameters
Pressure adjustment 2: Uses direct setting method
function select
Pressure adjustment Selects a rated control voltage of the Electro-pneumatic regulator to
control-voltage select be used.
Setting Welding Conditions
Maximum Welding Set a pressure according to the rating of the GUN Electro pneumatic
Pressure regulator.
Pressure Efficiency After entering 100 (%), measure an actual value and then correct the
entered value.
Pressure Rise Time Set Sequence referring to “12.4 Pressure Adjustment Sequence.”
1, 2, 3
Setting Pressure Set a desired pressure by a numerical value (N).
1, 2, 3
*Confirm the ratings control voltage of the product used to “Pressure Adjustment control-voltage
select”.
Note) Setting a Maximum Welding Pressure
Confirm the applicable range of the rating of the Electro-pneumatic regulator, and then set a
maximum welding pressure according to the rating.
Example 1: When the applicable range of the rating of the Electro-pneumatic regulator is 0 to
0.5 MPa (SMC: ITV203 Series). In the case of 3000 N at 0.5 MPa (air pressure) of
a maximum welding pressure of the gun to be used,
→ Timer Welding Condition: Set 3000 (N) for the maximum welding pressure.
Example 2: When the applicable range of the rating of the Electro-pneumatic regulator is 0 to
0.9 MPa. (SMC: ITV205 Series). In the case of 3000 N at 0.5 MPa (air pressure)
of the maximum welding pressure of the gun to be used,
→ Timer Welding Condition: Set 5400 (N) for the maximum welding pressure.
0.9 MPa
Maximum Welding Pressure (N) × 3000 N =5400 N
0.5 MPa

! CAUTION
! 1. Do not set the pressure to a value greater than the maximum pressure applicable
to the gun; otherwise the gun may be damaged.
2. If your controller cannot distinguish between SMC and CKD specify SMC when
setting parameters. Wrong setting may cause damage to the controller.
3. Refer to “II. Installation manual”, for connection of the control wire for pressure
adjustment.
4. Obtaining a maximum pressure is impossible if the pneumatic pressure in your
facility does not meet the pressure required for the gun.
12.4 Pressure Adjustment Sequence

Pressure Adjustment Basic Sequence
PressV1 to V3: Pressure value V1 to V3
PressT1 to T3: Pressure rise time T1 to T3
The pressure values, V1 to V3 are controlled during the period specified by the pressure rise
times, T1 to T3, respectively. The pressure value, V1, is held when the sequence completes. If
welding sequence has been completed during the T2 pressure rise time, the sequence is given
priority and the sequence completes after the Hold End signal is output and the pressure value
is held to V1.
Start SW →
MV/SOL
Welding Current
PressV2
PressV3
Proportional PressV1 PressV1
valve ← PressT1 → ← PressT2 → ← PressT3 →
Hold End signal →

Pressure Selector Function
13. Pressure Selector Function

13.1 Procedure to Use Pressure Selector Function
Parameter: Gun Sel.
Set this parameter to “31” or “32”. In these two-digit numbers, the tens digit, 3, indicates that the
pressure selector function is available and the units digit, 1 or 2, indicates the output number of the
main solenoid valve to be used. Inputting 3 or 4 as the units digit does not assign the number to the
solenoid-valve output since the pressure selector function is given priority.
13.2 Pressure Selector Function Basic Sequence
Start SW →
MV/SOL
Welding Current
← Press T1 → ← Press T2 → ← Press T3 →
SOL3 output
SOL4 output
Hold End signal →

Welding Interlock Function
14. Weld Interlock Function

To obtain the input/output signals concerning the interlock from the terminal board TB1 in the unit,
set the parameters as shown in 14.1. See 14.2 for input/output and time chart.
14.1 Procedure to Use Weld Interlock Function
Parameter: Gun Sel.
Set this parameter to “41” or “42”. In these two-digit numbers, the tens digit, 4, indicates that the
weld interlock function is available and the units digit, 1 or 2, indicates the output number of the
main solenoid valve to be used. Inputting 3 or 4 as the units digit does not assign the number to
the solenoid-valve output since the welding interlock function is given priority.
14.2 Weld Interlock Timing Chart

Input/output of the Weld Interlock
Output for weld start : TB1 terminal block, Retract SOL common (B1) – Retract SOL7 (B2)
This signal is held on from when the start Switch signal is received until the hold action
completes.
Weld-wait input : TB1 terminal block, Retract switch common (A7) – Retract switch 7 (B8)
Welding is permitted when the input turns off. Squeeze time is extended when the input
turns on.
Weld on Signal : TB1 terminal block, Retract SOL common (B1) – Retract SOL8 (B3)
This signal is output during welding and is kept on from the beginning of the up-slope to W3.
Abbreviation used in the timing chart
WIL: Squeeze-time extension by welding interlock
Start SW →
MV/SOL
Welding current
Output for received start
Weld-wait input Wait
Weld Signal
Hold End signal →
W. Sequence PS SQ WIL USL W1 C1 W2 DSL C2 W3 HO HD OF

Parameter Sheet Timer No.
Display Parameter value
Item/Function Setting Range/Information (Shipping data)
Letter
ON :Enable
Pulsation Select P1 Pulse. Sel. OFF :Disable OFF
A or B Mode Select P2 AB Mode ON :A Mode OFF :B Mode A:(ON)
Alarm signal NO/NC select P3 ALM Out ON :Normal Open OFF :Normal Close N.C.:(OFF)
ON :Enable
Trigger start P4 One Shoot OFF :Disable OFF
ON :Enable
Hold End signal select P5 Hold Out OFF :Disable OFF
Hold End Delay Job section ON :Enable
at alarm signal
P6 HoldA Dly OFF :Disable OFF
0 :Alarm pulse output enable
1 :Alarm constant output enable
Alarm output signal select P7 ALM Mode 2 Alarm constant output & weld stop 2
3 :Skip alarm output
0 :Disable
Max. Step Up series select P8 Step Type 1 :Max. gun series 0
2 :4/15 series
ON :Trigger SW priority select
Trigger SW priority select P9 Sw mode OFF :Weld sequence priority select OFF
Japanese or English
display select
Pa Japanese ON :Japanese OFF :English OFF
0 :1 series
series select
Pb TransType 1 :Max. gun series 2
2 :4/15 series
ON :Enable
Repeat action select Pc RepeatSel. OFF :Disable OFF
Reweld action select ON :Enable
at current low detected
Pd Reweld OFF :Disable OFF
0 :Disable
Pressure adjustment 1 :%Setting enable
select
Pe VP Mode 2 :Direct number setting enable 0
3 :Direct number setting enable, and display only setting pressure "1"
Pressure adjustment 0 :control range 0-5V
control voltage select
Pf VP Type 1 :control range:0-10V 0
ON :Enable
caution output select Pg Caution OFF :Disable OFF
Transformer thermostat ON :Enable(Check at weld start)
check sequence
Ph Gun Chang. OFF :Disable(Always check) OFF
Alarm output signal select ON :Alarm output signal enable
on No-weld sequence
Pi TestW ALM OFF :Alarm output signal disable OFF
00∼08 :Max. SOL valve select
Max. Gun num. select 11∼18 :Retract enable
21∼28 :Reverse wire Retract enable
Retract select
Valve selector select
Pj Gun Sel. 31∼38 :Valve selector enable 12
41∼48 :Weld interlock enable
Weld interlock select 51∼58 :Retract & Retract interlock enable
61∼68 :Reverse wire Retract & Retract interlock enable
Step Up Max. value select Pk Max Step 2∼16 :Step Up max. number select 16
0 :Display all function
Display level select PL DispLevel 1 :Display limited function 0
0 :200V line voltage set
2 :380V line voltage set 2:(AC380V Turkey
3 :400V line voltage set /China/Russia)
Step-dawn transformer Pm Ref. Volt 4 :420V line voltage set 3:(AC400V JPN)
5 :440V line voltage set 6:(AC460V USA)
0 :Weld enable (standard)
1 :Weld disable
Weld enable/disable select Pn Test Mode 2 :Weld disable & sol. valve control 0
3 :Cable short check enable
4:Cable short check enable2
Timer number select Po TM Number 1∼99 :Timer Number set 1
OBARA Corp.
ON:
Fixed to GUN1 in odd-numbered series
Gun assignment select Pp GunNumFix Fixed to GUN2 in even-numberd series OFF
OFF:Can be set to any number.
ON :Enable(For DeviceNet)
RemortI/O select Pq RemortI/O OFF :Disable OFF
Current detection signal ON:Enable
output selection
Ｐｒ CurDetect OFF:Disable OFF
Step up Finish 2 series ON:Enable
output selection
Ｐs StepF2out OFF:Disable OFF
ON:Liner-up control
Step liner up Pv Liner up OFF:Step-up control OFF
ON:Secondary-current feedback
2nd Current select (Note) Pw 2ndCurSel. OFF:Primary-current feedback OFF
Note) "2nd Current select" function is due to add.
OBARA Corp.
Program sheet Timer No. Group No.
Display Combination of the triggered switch signal Note

Item/Function Setting Range
Letter 1 2 3 4 5 6 7 8 9 A B C D E F Num.
Gun Select GunSel 1∼8 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 1,8.11
PreSqueeze Time PrSquez 0∼99cyc 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Squeeze Time Squeeze 1∼99cyc 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 1
Slope Time Slope 0∼30cyc 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1,15
Weld1 Time Weld1 0∼99cyc 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5
Cool1 Time Cool1 0∼99cyc 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Weld2 Time Weld2 0∼99cyc 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1
Down Slope Time D.Slope 0∼99cyc 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Cool2 Time Cool2 0∼99cyc 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Weld3 Time Weld3 0∼99cyc 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Hold Time Hold 1∼99cyc 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Off Time Off 0 or 4∼99cy 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3
Pulse count Number Pulse 1∼9 times 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2
Heat1 Heat1 2.0∼60.0kA 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0
Heat2 Heat2 2.0∼60.0kA 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 1
Heat3 Heat3 2.0∼60.0kA 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0
Turn Ratio TurnR. 0. 0∼200.0 74 74 74 74 74 74 74 74 74 74 74 74 74 74 74 1
Current Flow Rate C.Flow+ 30∼100% 99 99 99 99 99 99 99 99 99 99 99 99 99 99 99 14
Current Flow Rate Count CF.Count 0 or 1∼99times 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 14
Max Press MaxV. 0∼9999N 4000 4000 4000 4000 4000 4000 4000 4000 4000 4000 4000 4000 4000 4000 4000 5
Press Adjust PAdjust 50∼150% 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 5
PressT1 PresT1 0∼99cyc 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 5
PressT2 PresT2 0∼99cyc 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 5
PressT3 PresT3 0∼99cyc 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 5
PressV1 PresV1 0∼9999N 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 5,7
PressV2 PresV2 0∼9999N 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 5,7
PressV3 PresV3 0∼9999N 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 5,7
Step Up 0 Step0 50∼200% 116 116 116 116 116 116 116 116 116 116 116 116 116 116 116 1,4,12
Step Up 1 Step1 50∼200% 101 101 101 101 101 101 101 101 101 101 101 101 101 101 101 1,4
Step Up 2 Step2 50∼200% 102 102 102 102 102 102 102 102 102 102 102 102 102 102 102 1,4
Step Up 3 Step3 50∼200% 103 103 103 103 103 103 103 103 103 103 103 103 103 103 103 1,4
Step Up 4 Step4 50∼200% 104 104 104 104 104 104 104 104 104 104 104 104 104 104 104 1,4
Step Up 5 Step5 50∼200% 105 105 105 105 105 105 105 105 105 105 105 105 105 105 105 1,4
Step Up 6 Step6 50∼200% 106 106 106 106 106 106 106 106 106 106 106 106 106 106 106 1,4
Step Up 7 Step7 50∼200% 107 107 107 107 107 107 107 107 107 107 107 107 107 107 107 1,4
Step Up 8 Step8 50∼200% 108 108 108 108 108 108 108 108 108 108 108 108 108 108 108 1,4
Step Up 9 Step9 50∼200% 109 109 109 109 109 109 109 109 109 109 109 109 109 109 109 1,4
Step Up 10 Step10 50∼200% 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 1,4
Step Up 11 Step11 50∼200% 111 111 111 111 111 111 111 111 111 111 111 111 111 111 111 1,4
Step Up 12 Step12 50∼200% 112 112 112 112 112 112 112 112 112 112 112 112 112 112 112 1,4
Step Up 13 Step13 50∼200% 113 113 113 113 113 113 113 113 113 113 113 113 113 113 113 1,4
Step Up 14 Step14 50∼200% 114 114 114 114 114 114 114 114 114 114 114 114 114 114 114 1,4
Step Up 15 Step15 50∼200% 115 115 115 115 115 115 115 115 115 115 115 115 115 115 115 1,4
Step Up 16 Step16 50∼200% 116 116 116 116 116 116 116 116 116 116 116 116 116 116 116 1,4,13
GUN No. 1 2 3 4 5 6 7 8
Step Count1 Count1 0∼9999 500 500 500 500 500 500 500 500 1,4,10
Step Count2 Count2 0∼9999 500 500 500 500 500 500 500 500 1,4,10
Step Count3 Count3 0∼9999 500 500 500 500 500 500 500 500 1,4,10
Step Count4 Count4 0∼9999 500 500 500 500 500 500 500 500 1,4,10
Step Count5 Count5 0∼9999 500 500 500 500 500 500 500 500 1,4,10
Step Count6 Count6 0∼9999 500 500 500 500 500 500 500 500 1,4,10
Step Count7 Count7 0∼9999 500 500 500 500 500 500 500 500 1,4,10
Step Count8 Count8 0∼9999 500 500 500 500 500 500 500 500 1,4,10
Step Count9 Count9 0∼9999 500 500 500 500 500 500 500 500 1,4,10
Step Count10 Count10 0∼9999 500 500 500 500 500 500 500 500 1,4,10
Step Count11 Count11 0∼9999 500 500 500 500 500 500 500 500 1,4,10
Step Count12 Count12 0∼9999 500 500 500 500 500 500 500 500 1,4,10
Step Count13 Count13 0∼9999 500 500 500 500 500 500 500 500 1,4,10
Step Count14 Count14 0∼9999 500 500 500 500 500 500 500 500 1,4,10
Step Count15 Count15 0∼9999 500 500 500 500 500 500 500 500 1,4,10
Step Count16 Count16 0∼9999 500 500 500 500 500 500 500 500 1,4,10,13
Common Data Default

Step return location StepReturn 1∼15(max.) 1 1,4
Current Low Limit Curr.Low 50∼100 % 90 1
Current High Limit Curr.Hig 100∼150 % 110 1
Voltage Limit V.Limit 50∼100 % 70 1
Hold Delay HoldDely 0∼99cyc 0 1
Peak Current Limit PeakCurr 100∼200% 100 1
Note1. Only 12 items are displayed when parameter DispLevel "1" is selected. Note8. The biggest number is to be same as the last digit of the parameter Gun Sel.
Note2. Not displayed when parameter Pulse Sel."OFF" is selected. Note9. % voltage to be set when parameter TurnR. is "0".
Note3. Not displayed when parameter RepeatSel."OFF" is selected. Note10. Only group num. "0" is available because only one group exists.
Note4. Not displayed when parameter Step Type "0" is selected. Note11. Not displayed when parameter Gun assignment select."OFF" is selected.
Note5. Not displayed when parameter VP Mode "0" is selected. Note12. Correspondence only in case of "Liner-up" controll.
Note6. % to be set when parameter VP Mode is "1". Note13. Correspondence only in case of "Step-up" controll.
Note7. To be set when parameter VP Mode is "2". Note14.When changing the data,Please refer to manual.
Note15. Setting range of Slope is changed from 1-30 to 0-30; setting value is changed from 1 to 0.
(The setting range of the shipment after July 1, 2007 becomes 0 to 30cycles". )
OBARA Corp.
Display Parameter
Item/Function Setting Range/Information
Letter value
ON :Enable
Pulsation Select P1 Pulse. Sel. OFF :Disable
A or B Mode Select P2 AB Mode ON :A Mode OFF :B Mode
Alarm signal NO/NC select P3 ALM Out ON :Normal Open OFF :Normal Close
ON :Enable
Trigger start P4 One Shoot OFF :Disable
ON :Enable
Hold End signal select P5 Hold Out OFF :Disable
Hold End Delay Job section ON :Enable
at alarm signal
P6 HoldA Dly OFF :Disable
0 :Alarm pulse output enable
1 :Alarm constant output enable
Alarm output signal select P7 ALM Mode 2 Alarm constant output & weld stop
3 :Skip alarm output
0 :Disable
Max. Step Up series select P8 Step Type 1 :Max. gun series
2 :4/15 series
ON :Trigger SW priority select
Trigger SW priority select P9 Sw mode OFF :Weld sequence priority select
Japanese or English
display select
Pa Japanese ON :Japanese OFF :English
0 :1 series
series select
Pb TransType 1 :Max. gun series
2 :4/15 series
ON :Enable
Repeat action select Pc RepeatSel. OFF :Disable
Reweld action select ON :Enable
at current low detected
Pd Reweld OFF :Disable
0 :Disable
Pressure adjustment 1 :%Setting enable
select
Pe VP Mode 2 :Direct number setting enable
3 :Direct number setting enable, and display only setting pressure "1"
Pressure adjustment 0 :control range 0-5V
control voltage select
Pf VP Type 1 :control range:0-10V
ON :Enable
caution output select Pg Caution OFF :Disable
Transformer thermostat ON :Enable(Check at weld start)
check sequence
Ph Gun Chang. OFF :Disable(Always check)
Alarm output signal select ON :Alarm output signal enable
on No-weld sequence
Pi TestW ALM OFF :Alarm output signal disable
00∼08 :Max. SOL valve select
Max. Gun num. select 11∼18 :Retract enable
21∼28 :Reverse wire Retract enable
Retract select
Valve selector select
Pj Gun Sel. 31∼38 :Valve selector enable
41∼48 :Weld interlock enable
Weld interlock select 51∼58 :Retract & Retract interlock enable
61∼68 :Reverse wire Retract & Retract interlock enable
Step Up Max. value select Pk Max Step 2∼16 :Step Up max. number select
0 :Display all function
Display level select PL DispLevel 1 :Display limited function
Step-dawn transformer Pm Ref. Volt 4 :420V line voltage set
0 :Weld enable (standard)
1 :Weld disable
Weld enable/disable select Pn Test Mode 2 :Weld disable & sol. valve control
3 :Cable short check enable
4:Cable short check enable2
Timer number select Po TM Number 1∼99 :Timer Number set
OBARA Corp.
ON:
Fixed to GUN1 in odd-numbered series
Gun assignment select Pp GunNumFix Fixed to GUN2 in even-numberd series
OFF:Can be set to any number.
ON :Enable(For DeviceNet)
RemortI/O select Pq RemortI/O OFF :Disable
Current detection signal ON:Enable
output selection
Ｐｒ CurDetect OFF:Disable
Step up Finish 2 series ON:Enable
output selection
Ｐs StepF2out OFF:Disable
ON:Liner-up control
Step liner up Pv Liner up OFF:Step-up control
ON:Secondary-current feedback
2nd Current select (Note) Pw 2ndCurSel. OFF:Primary-current feedback
Note) "2nd Current select" function is due to add.
OBARA Corp.
Program sheet Timer No. Group No.
Display Combination of the triggered switch signal Note

Item/Function Setting Range
Letter 1 2 3 4 5 6 7 8 9 A B C D E F Num.
Gun Select GunSel 1∼8 1,8.11
PreSqueeze Time PrSquez 0∼99cyc
Squeeze Time Squeeze 1∼99cyc 1
Slope Time Slope 0∼30cyc 1,15
Weld1 Time Weld1 0∼99cyc
Cool1 Time Cool1 0∼99cyc
Weld2 Time Weld2 0∼99cyc 1
Down Slope Time D.Slope 0∼99cyc
Cool2 Time Cool2 0∼99cyc
Weld3 Time Weld3 0∼99cyc
Hold Time Hold 1∼99cyc 1
Off Time Off 0 or 4∼99cy 3
Pulse count Number Pulse 1∼9 times 2
Heat1 Heat1 2.0∼60.0kA
Heat2 Heat2 2.0∼60.0kA 1
Heat3 Heat3 2.0∼60.0kA
Turn Ratio TurnR. 0. 0∼200.0 1
Current Flow Rate C.Flow+ 30∼100% 14
Current Flow Rate Count CF.Count 0 or 1∼99times 14
Max Press MaxV. 0∼9999N 5
Press Adjust PAdjust 50∼150% 5
PressT1 PresT1 0∼99cyc 5
PressV1 PresV1 0∼9999N 5,7
Step Up 0 Step0 50∼200% 1,4,12
Step Up 1 Step1 50∼200% 1,4
Step Up 2 Step2 50∼200% 1,4
Step Up 3 Step3 50∼200% 1,4
Step Up 4 Step4 50∼200% 1,4
Step Up 5 Step5 50∼200% 1,4
Step Up 6 Step6 50∼200% 1,4
Step Up 7 Step7 50∼200% 1,4
Step Up 8 Step8 50∼200% 1,4
Step Up 9 Step9 50∼200% 1,4
Step Up 10 Step10 50∼200% 1,4
Step Up 11 Step11 50∼200% 1,4
Step Up 12 Step12 50∼200% 1,4
Step Up 13 Step13 50∼200% 1,4
Step Up 14 Step14 50∼200% 1,4
Step Up 15 Step15 50∼200% 1,4
Step Up 16 Step16 50∼200% 1,4,13
GUN No. 1 2 3 4 5 6 7 8
Step Count1 Count1 0∼9999 1,4,10
Step Count16 Count16 0∼9999 1,4,10,13
Common Data
Step return location StepReturn 1∼15(max.) 1,4
Current Low Limit Curr.Low 50∼100 % 1
Current High Limit Curr.Hig 100∼150 % 1
Voltage Limit V.Limit 50∼100 % 1
Hold Delay HoldDely 0∼99cyc 1
Peak Current Limit PeakCurr 100∼200% 1
Note1. Only 12 items are displayed when parameter DispLevel "1" is selected. Note8. The biggest number is to be same as the last digit of the parameter Gun Sel.
Note2. Not displayed when parameter Pulse Sel."OFF" is selected. Note9. % voltage to be set when parameter TurnR. is "0".
Note3. Not displayed when parameter RepeatSel."OFF" is selected. Note10. Only group num. "0" is available because only one group exists.
Note4. Not displayed when parameter Step Type "0" is selected. Note11. Not displayed when parameter Gun assignment select."OFF" is selected.
Note5. Not displayed when parameter VP Mode "0" is selected. Note12. Correspondence only in case of "Liner-up" controll.
Note6. % to be set when parameter VP Mode is "1". Note13. Correspondence only in case of "Step-up" controll.
Note7. To be set when parameter VP Mode is "2". Note14.When changing the data,Please refer to manual.
Note15. Setting range of Slope is changed from 1-30 to 0-30; setting value is changed from 1 to 0.
(The setting range of the shipment after July 1, 2007 becomes 0 to 30cycles". )
OBARA Corp.
Version 2.6
Ⅵ．SUPPLEMENTAL Ver. No.SP065

Ver. No.SD042
or
or
later（For
later
SP3）
Ver. No.SD064 or later（For UPS）

MANUAL Ver. No.SD065 or later（For SP3）
WELDING CONTROLLER
W-TC Series

after reading. 2008.05.27 No.0276EN-Ⅵ
Contents
Supplemental Manual Introduction and Contents
This manual explains how to install the equipment, enter the welding condition data and perform
trial welding. When installing and starting up the equipment, follow the procedures given in this
manual.
Verifying Correct Installation
Setting Welding Condition
Powering on and Displaying Set Mode・・Ｐ８
Entering Parameters・・Ｐ９
Entering Welding Condition Data・・Ｐ１０
Trial Welding Sequence・・Ｐ１１
Trial Welding・・Ｐ１２
1. Related manual................................................................................................................ 3
2. Initial Operation .............................................................................................................. 4
3. TP Basic Operation.......................................................................................................... 5
4. Organization Chart of Function Keys ............................................................................. 6
5. Timer Data....................................................................................................................... 7
6. Displaying Set Mode........................................................................................................ 8
7. Entering Parameters ....................................................................................................... 9
8. Entering Welding Condition Data ................................................................................ 10
9. NoWeld Mode ................................................................................................................. 11
10. Weld Monitor ............................................................................................................... 12
11. Step Up......................................................................................................................... 13
12. Copying Data ............................................................................................................... 15
13. Procedure for Copying Data 1 ..................................................................................... 16
14. Procedure for Copying Data 2 ..................................................................................... 17
No.0276EN OBARA Corp. Ⅵ.Supplemental manual Page -2

Related manual
1. Related manual
The instruction manual of this equipment consists of individual manuals shown blow.
This manual gives the brief explanations of the equipment to supplement the instruction manual.
Before using the equipment, thoroughly read and understand the rest of the instruction manuals.

TP Basic Operation
2. Initial Operation
< TP-Net ⇔ Timer : When connection 1 to 1 >
It is not necessary to choose a Timer number. Please move on to the following
page.
< TP-Net ⇔ Timer : When connection 1 to n >

When a condition setup of two or more Timers is carried out by one TP-Net.
When power put on with TP-Net connected the following will be displayed in the sequence
indicated with arrow.
TP-Net Key operations :

Power put on
We l d . C o n t r o l l e r
T e a c h i n g P e n d a n t
T M* * . * T P * * . *
OP * * . * Wa i t . . .
After several sec ・・

ＴＭ number list
1 5 1 6 1 7
ＴＭ＃ N e x t ↓↑
The target timer No

Version input
We l d . C o n t r o l l e r
T e a c h i n g P e n d a n t
T M 6 . 3 T P 7 . 0
OP 7 . 0 Wa i t . . .
After several sec ・・

Initial screen
<Other Key Operations>
G u n 1 1 0
G u n 2 1 5 8 0
#TM
G u n 3 2 3 0 Shift ＋ Home
M o n T MD T P D Mo d e
Shift＋ＴＭ＃ key
Jump to TM number list
1 5 1 6 1 7
ＴＭ＃ N e x t ↓↑

TP Basic Operation
3. TP Basic Operation
When powering on TP-Net or connecting it to the equipment, the Initial screen appears on the
display. The fourth line on the screen indicates functions corresponding to the Function keys
selected. The Function keys let you chose to display the screen of any mode such as the welding
condition entry mode.
TP-Net Key operations :

TP-Net Display Initial Screen
G u n 1 1 0
G u n 2 1 5 8 0
G u n 3 2 3 0
F1 The fourth line indicates

F2 F3 F4 functions corresponding
F5 F6 F7 F8 to the Function keys
selected.
F1
F5 The items given in the fourth line change when
pressing any of the Function keys.
G u n 1 1 0
G u n 2 1 5 8 0
G u n 3 2 3 0
S t e p Ｉ／Ｏ A L H Mo H
Pressing and holding the Pressing and holding the Help

Shift Shift key display the items Help key display the descriptions of
corresponding to the F5 to the Function keys.
F8 key.
G u n 1 1 0 S t e p S t e p C h a n g e
G u n 2 1 5 8 0 I / O I / O I n f o r m.
G u n 3 2 3 0 AL H Al a r m H i s t .
P r e . Mo H Mo n i t . H i s t .
Reset Used for modifying data Shift ＋ F4 F8 Takes you back to the
cleared. previous screen.
#TM
Used for establishing or Takes you to the Initial Screen
Home
confirming data entered. from anywhere.

Organization Chart of Function Keys
4. Organization Chart of Function Keys

The screen indication on TP-Net changes according to the Function key pressed. The following
chart gives the functional description of the Function keys. Pressing the TM#/Home key takes
you to the Initial screen from anywhere.
F1 Monitor Displays the monitored data of the current welding and alarm history and so on.
F1 Step Change Enables the currently set step number to be changed when the Step-up function is
used.(Step Change)
F2 I/O Monitor Displays the I/O status. (Usually not used.)
F3 Alarm History Displays alarm history. (last 100 alarms)
F4 Monitor History Display of welding result data before last
F2 TM Data Set Displays the data stored in the timer.
F1 Edit Enables the welding data to be set.
F2 Function Copy Independently copies the data of a specific item of the welding conditions.
Example : Copies the data of Heat 1 in Series 1 to all Series.
F3 Series Copy Copies welding condition data between Series.

Example : Copies the data of Series 1 to Series 5.
F4 Group Copy Copies data between groups specifying the unit-number.
F5 Group Verify Compares data between groups specifying the unit-number.
F3 TP Data Edit Enables the external memory data stored in TP-Net to be edited.
F1 Unit Edit Selects Unit to edit.
F1 Edit, … F5 Group Verify The same screens as described above.
F2 Unit Copy Copies data between Units.
F1 ＴＭ→ＴＰ Copies the data of a selected Unit from the timer to the pendant.
F2 ＴＰ→ＴＭ Copies the data of a selected Unit from the pendant to the timer.
F3 ＴＰ→ＴＰ Copies the data of a selected Unit to another Unit in the pendant.
F4 ＴＭ←→ＴＰ Compares the Unit data of the timer with that of the pendant.
F3 Parameter Selects Unit and changes parameters in it.
F4 Para. Copy Selects Unit and copies parameters in it.
F1 TM→ TP, … F4 TM ←→ TP Copies or compares parameters.
F4 Mode Select Changes a currently effective mode of the timer.
F1 Operation Changes the current mode to the Weld mode.
F2 No Weld Allows welding sequence to be performed with no current applied.
F3 C. Press In addition to the actions of the No-weld mode, this mode enables the gun to be
pressurized continuously after the Hold End signal has been received.
F4 Set Before editing any parameters or data, entering this mode is required.
F5 Parameter Selects Parameters to be set.
F1 Edit Enables the selected parameters to be set.

Timer Data
5. Timer Data
・ Two categories of data need to be set to the timer. These are as follows:
(1) Welding Condition Data ・・Data associated with welding sequences and current values.
(2) Parameter Data ・・Data associated with function settings such as Step On/Off.
・Ｄata stored in each timer are called “Unit” and consist of:
Welding Condition Data ・・ 240 conditions, 15 conditions × 16 groups (Group 0 to 15)
Parameter Data
・ TP-Net can hold data for up to 5 timers (5 Units) as an external memory.
System Diagram of Data Settings

15 conditions x 16 groups
= 240 conditions
Timer
TM stored Data
PN/C
Cable TP-Net stored Data
TP-Net
5 unit

Displaying Set Mode
6. Displaying Set Mode

To perform key entries by using TP-Net, you need to set the timer to the Set mode.
When powering on the equipment, the timer is in the Operation mode.
Notes on Modes： Operation Mode: Weld enabled + Data entry disabled

Set Mode: Weld enabled + Data entry enabled
If attempting to set data in the Operation mode, the error message, “MODE SET ERROR”,
appears. In this case, clear the error message by pressing the Reset key, and then switch the
screen mode to the Set mode.
To display the Set mode screen, proceed as follows:

G u n 1 1 0 Select the screen mode you wan
F4
G u n 2 1 5 8 0
F8 to display.
G u n 3 2 3 0
G u n 1 1 0
F4 The Set mode appears.
G u n 2 1 5 8 0
F8 (Just as Light “set” lamp)
G u n 3 2 3 0
ＯｐｅＮｏＷＮｏＷ2 Ｓｅｔ
G u n 1 1 0 #TM
G u n 2 1 5 8 0 Home Return to the Initial screen.
G u n 3 2 3 0
Status Indication of TP-Net
The Set lamp lights when the

timer is in the Set mode.
When an alarm is generated, clear the alarm by

pressing the Reset key.

Entering Parameters
7. Entering Parameters
Before entering welding condition data, you need to select the functions for the timer by setting
parameters. Select functions according to the welding system of your facility. For details about
the settings, refer to “V. Reference Manual”.
When modifying any of the parameters entered, you should thoroughly understand the
procedure.
To enter parameters, proceed as follows:

G u n 1 1 0
G u n 2 1 5 8 0 F4 Select Mode
G u n 3 2 3 0 F8
G u n 1 1 0 Press and hold

G u n 2 1 5 8 0 Shift the Shift key.
G u n 3 2 3 0
ＯｐｅＮｏＷＮｏＷ2 Ｓｅｔ Point !
You can edit
G u n 1 1 0 Select the data
F1 displayed in the
G u n 2 1 5 8 0 F5
G u n 3 2 3 0
Parameter
P a r a P r e .
Select the parameter items you want

P 1 P u l s e S e l . O F F F1 to edit using the Up/Dow Scroll keys,
P 2 A B M o d e Ａ F5 and then select EDIT.
P 3 A L M O u t N . O
E d ｉ t
P 1 P u l s e S e l O F F Enter desired data, and then press

the Return key to establish them.
I n p u t D a t a 1
Ｒａｎｇｅ： 0 − 1
Reset Used for modifying data Shift ＋ F4 F8 Takes you back to the
cleared. previous screen.
#TM
Used for establishing or Takes you to the Initial Screen
Home
confirming data entered. from anywhere.

Entering Welding Condition Data
8. Entering Welding Condition Data

After setting the parameters, you can enter the welding condition data. Before entering any of the
welding condition data, you need to fill in the program sheet with an intended sequence so that
you can refer to it when entering the data. For details about the welding conditions, refer to “V.
Reference Manual”.
To enter the welding condition data, proceed as follows:

G u n 1 1 0 F2 Select TMD
G u n 2 1 5 8 0 F6
G u n 3 2 3 0
Input Group No.

S e t D a t a Me n u
< Input “0” to “15” >
S e l e c t G r o u p #
R a n g e ： 0−1 5
B 0 1 Gu n S e l 1 Select a desired Series using the Left/Right Scroll keys.

B 0 1 P r S q u e z 0 c y
B 0 1 S q u e e z e 3 0 c y Select a desired welding condition item using the
E d i t F CP S CP GCP Up/Down Scroll keys.
Group 0
Select a desired Series. B 0 2 Gu n S e l 1

B 0 2 P r S q u e z 0 c y
B 0 2 S q u e e z e 3 0 c y
E d i t F CP S CP GCP
Series 2
B 0 1 Gu n S e l 1 F1
F5 Select EDIT.
I n p u t D a t a
R a n g e : 1 −8
B 0 1 Gu n S e l 1
Enter desired data by using
I n p u t D a t a 2 numerical keys.
R a n g e : 1 −8
B 0 1 Gu n S e l 2 Press the Return key to establish

the data entered.
I n p u t D a t a
R a n g e : 1 −8
#TM
Home Displays the Initial screen.
Shift ＋ F4 F8 Displays the

previous screen.

NoWeld Mode
9. NoWeld Mode
After finishing the data settings, you need to verify the incoming sequence in the “No-Weld” mode
and take measurements of the application pressure in the “C. Press” mode.
・ NoWeld Mode （ＮｏＷ）
This mode is used for verifying the specified sequence or replacing electrode tips. The
welding sequence is performed as it is specified; however, welding current is not applied.
・ C. Press Mode（ＮｏＷ２）
The welder keeps the pressurized state as long as the Start switch is on. It can be used for
measuring the application pressure. Welding current is not applied.
To display the No-Weld/C. Press mode screen, proceed as follows:

G u n 1 1 0 F4 Select a desired mode.
G u n 2 1 5 8 0 F8
G u n 3 2 3 0
G u n 1 1 0 F2
G u n 2 1 5 8 0 F6 Select the NoWeld mode.
G u n 3 2 3 0
ＯｐｅＮｏＷＮｏＷ2 Ｓｅｔ
F3 Select the C. Press mode.
F7
NoWeld C. Press
ＣｏｎｆｏｒｍＮｏＷｅｌｄ？ＣｏｎｆｏｒｍＮｏＷｅｌｄ 2 ？
ＮｏＷｅｌｄＥｎａｂｌｅＣｏｎｔｉｎｕｉｔｙ
ＯＫ？ＧｕｎＰｒｅｓｓｕｒｅＯＫ？
ＯＫ：Ｒｅｔ . Ｑｕｉｔ：Ｆ − 8 ＯＫ：Ｒｅｔ . Ｑｕｉｔ：Ｆ − 8
Press the Return key to apply the mode selected.
Status Indication of TP-Net
The “No-Weld” lamp lights when

the timer is in the NoWeld mode.
The “No-Weld” and “Conti.

Press” lamps light when the timer
is in the C. Press mode.

Weld Monitor
10. Weld Monitor

After verifying the welding sequence, you need to switch the screen mode from the “NoWeld”
mode to the “Operation” or “Set” mode in order to verify correct welding.
＜Check for Weld Monitor＞
The Initial screen of TP-Net displays the screen for the weld monitor.
・ When the Step Up function is enabled, the Step Up status is displayed in addition to the
number of total spot counts for each gun.
・ Otherwise, the welding condition of the previously selected Start Series is displayed.
＜When there is an error between the predetermined current value and a measured cur. value＞
The fine adjustment of the parameter, “Transformer turn ratio”, is required. The current value
is increased or decreased by increasing or reducing the turn ratio, respectively.
To confirm the monitoring items, proceed as follows:

G u n 1 1 0
G u n 2 1 5 8 0
Confirm the items using the Up/Down
G u n 3 2 3 0 Scroll keys.
Name Function
List of Monitoring
Gun Counter Displays the total number of weld spots
G u n 1 1 0 of each Gun 1-8.
G u n 2 1 5 8 0 Step Data The first number indicates a gun
G u n 3 2 3 0 number and the rest is the state of the
G u n 4 7 0 0 0 gun step, the number of weld count
G u n 5 1 0 and a weld state in the order
G u n 6 5 0 0 mentioned.
G u n 7 1 0 0 0 Operation Data BFF:
G u n 8 3 0 0 Indicates the most recently selected
1 - S t e p 1 1 0 (Example) starting Series data.
2 - S t e p 1 2 1 8 0 BFF-8 B: Indicates B-Mode. (A or B)
3 - S t e p U p 2 3 0 W.Cyc 10cy F: Indicates Group F. (0∼F)
4 - S t e p U p F i n i s h PF68% F: Indicates starting Series F (1∼F)
5 - S t e p 1 1 0 C.Flow78% -8:Indicates weld on Gun#8
6 - S t e p 2 1 0 0 W.Cyc 10 cy: The number of weld
7 - S t e p 8 2 0 0 cycles to be per-formed per sequence.
8 - S t e p 1 3 0 0 PF68%: Power-factor
B F F - 8 Ｗ．Ｃｙｃ 1 0 c y C.Flow 78%: Flow rate
ＰＦ 6 8 ％Ｃ．Ｆｌｏｗ 7 8 ％
S e t Va l u e 9 . 0 k A An average of the set-up heat 1-3
Set Value
T o t a l C u r r 9 . 0 k A data is displayed.
H e a t 1 5 . 0 k A Indicates the mean current value
Total Current
H e a t 2 1 0 . 0 k A applied to Heat 1-3.
H e a t 3 0 . 0 k A Indicates the current values applied
P e a k C u r r 1 0 . 5 k A Current Value
to Heat 1-3.
P r e s s . N - V 1 5 0 0 0 N
The peak current under welding is
1 s t V o l t a g e 3 9 0 V Peak Current
L i n e V o l t . 4 0 0 V displayed.
Pressure force Indicates the pressure force.
Indicates the primary voltage during
1st Voltage
welding.
Indicates the power voltage during idle
Line Voltage
running.

Weld Monitor
11. Step Up
The step up state can be confirmed on the TP-Net Monitor screen. The number of steps and the
spot quantity for each gun are indicated. A lamp comes on when the final step is reached and
completed.
The Final Step lamp comes on when
TP-Net step related the final step has been reached.
lamp lighting timing
Current
value
Step max
Step max-1
Step 1
Step 2
Step 3
Spot count
The Final Step and Step End lamps come
on when all steps have been completed.
TP-NET lights according to the following timing when liner-up control.
The Final Step lamp comes on when

TP-Net step related the final step has been reached.
lamp lighting timing
Current
Step max
Step max-1
value
Step 2
Step 3
Step 1
Step 0
Spot count
The Final Step and Step End lamps come
on when all steps have been completed.

Weld Monitor
Step changing and

clearing procedure
G u n 1 1 0
Using the downward cursor key, allow the Step
G u n 2 1 5 8 0 Monitor screen for the Gun No. in question to appear
G u n 3 2 3 0 in the upper area. In this case, the screen is related to
M o n T MD T P D Mo d e GUN1.
1 - S t e p U p F i n i s h F1
2 - S t e p 2 0 When the step is to F5
3 - S t e p 1 0 be changed :
When the step is 2 - S t e p 2 0 F1
to be reset : 3 - S t e p 1 0 F5
Step ＳｔｅｐＩ / ＯＡＬＨ
1- S t e p 1 0
S t e p U p C l e a r Reset
ＯＫ?
Ｓｔｅｐ C ｈａｎｇｅＭｏｄｅ
ＳｔｅｐＶａｌｕｅ 1
Ｒａｎｇｅ： 1−1 6
1 - S t e p 1 0
2 - S t e p 2 0
3 - S t e p 1 0 Pressing the F1 key causes the Monitor
M o n T MD T P D Mo d e mode to be entered, and then pressing the F1
key again causes the Step Change mode to
Pressing the Return key after pressing the be entered. After entering the desired
number of the step to be reached, press the
Step Reset key completes the reset.
Return key. The change is now complete.

Copying Data
12. Copying Data

You can copy the data set to a timer to another timer by using TP-Net. TP-Net can hold data for
up to 5 timers (5 Units) as an external memory temporarily. To perform the data copy, you need
to temporarily copy data to one of the external memory area in TP-Net and then re-copy them to
another timer.
Timer Data
Timer1
Data Copy TP-Net
Copy the data in a

selected timer to one
of the Units in TP-Net,
and then re-copy them
to another timer.
TP-Net can hold data for up to 5 timers.

Timer2
Data Copy
Timer Data

Procedure for Copying Data 1
13. Procedure for Copying Data 1

<Data is loaded into TP-Net>
TP-Net is made to the Set Mode according to the content shown in “6. Displaying Set Mode”.
Afterwards, data is copied from the Timer which wants to read the welding condition onto TP-Net.
To perform the data copy, proceed as follows:
Gu n 1 1 0 F3 Select “TPD”.
Gu n 2 1 5 8 0 F7
Gu n 3 2 3 0
Mo n T MD T P D Mo d e When you want to copy the
parameter.
G u n 1 1 0 F2 F4
G u n 2 1 5 8 0
Select “UCP”. Select “PCP”.
F6 F8
G u n 3 2 3 0
E d i t UCP P E d P CP
ＵｎｉｔＣｏｐｙＭｅｎｕ 1 If you want to copy the selected

ON data to Unit 1, enter 1.
ＳｅｌｅｃｔＵｎｉｔ＃1
Ｒａｎｇｅ： 1−5
Ｕｎｉｔ＃ 1 Ｓｅｌｅｃｔｅｄ F1 Select “T → P”.
ＣｏｐｙＭｅｎｕＳｅｌｅｃｔ F5
Ｔ：ＴｉｍｅｒＰ：Ｐｅｎｄａｎｔ
T →P P →T P →P T ←→P
T M → Ｕｎｉｔ＃1（ T P ） Press the Return key.

ＵｎｉｔＣｏｐｙ
O K
O K ：Ｒｅｔ . Ｑｕｉｔ： F ー 8
T M → U n i t ＃1 ( T P )
Return to the Initial screen.
Un i t Co p y
C o mp l e t e !
#TM
Home Return to the Initial screen.
! CAUTION
! The parameter can be copied. “Para.Copy” is selected in the copy selection part
of the above-mentioned procedure, and, besides, the same operation is repeated.

Procedure for Copying Data 2
14. Procedure for Copying Data 2

<Data is sent to TP-Net>
Disconnect TP-Net from the timer and reconnect it to the timer to which you want to copy the data in
TP-Net. Power on the equipment and copy the data from TP-Net to the desired timer.
To perform the data copy, proceed as follows:

Gu n 1 1 0 F3 Select “TPD”.
Gu n 2 1 5 8 0 F7
Gu n 3 2 3 0
Mo n T MD T P D Mo d e When you want to copy the
parameter.
G u n 1 1 0 F2 Select “UCP”. F4 Select “PCP”.

G u n 2 1 5 8 0 F6 F8
G u n 3 2 3 0
E d i t UCP P E d P CP
ＵｎｉｔＣｏｐｙＭｅｎｕ
1 If you want to copy the
ON
ＳｅｌｅｃｔＵｎｉｔ＃1 data in Unit 1, enter 1.
Ｒａｎｇｅ： 1−5
Ｕｎｉｔ＃ 1 Ｓｅｌｅｃｔｅｄ F2 Select “P →T”.
ＣｏｐｙＭｅｎｕＳｅｌｅｃｔ F6
Ｔ：ＴｉｍｅｒＰ：Ｐｅｎｄａｎｔ
T →P P →T P →P T ←→P
Ｕｎｉｔ＃ 1（ T P ） → T M Press the Return key.

ＵｎｉｔＣｏｐｙ
O K
O K ：Ｒｅｔ . Ｑｕｉｔ： F ー 8
U n i t ＃1 ( T P ) → T M
Un i t Co p y The data copy completed.
C o mp l e t e !
#TM
Home Return to the Initial screen.
! CAUTION
! The parameter can be copied. “Para.Copy” is selected in the copy selection part
of the above-mentioned procedure, and, besides, the same operation is repeated.

Revision history
Ver. No. Date of issue Reason for the change.

Ver.1.0 2005/04/15 New making.
Ver.1.1 2005/04/25 Change of part of the main body, and correct the error.
Ver.1.2 2005/05/11 Change of insertion chart according to change of part of the
main body.
Ver.1.3 2005/05/30 Adding the troubleshooting postscript (Adding the item
postscript of the fuse and circuit protector.)
Ver.1.4 2005/06/07 Upgrade of ROM, Adding the troubleshooting and the
connection example of control line postscript, correct the
error.
Ver.1.5 2005/10/06 Sharing with USA specification, correct the part of figure of
the connection example of Chapter 2, the attention
postscript.
Ver.1.6 2005/10/18 Correct the number of affiliated conditions of Chapter 1, and
the revision postscript.
Ver.1.7 2005/11/07 ・ Sharing of revision number with Japanese.
・ Replacement of drawing according to drawing revision.
・ Correct to each drawing by model name label change.
・ Ⅰ SPECIFICATION
｢3.2 Control｣:Correct to Control Series.
｢3.5 Facility Specification｣:Correct to voltage, change
to description of Flow rate.
・ Ⅱ INSTALLATION MANUAL
｢2.4 Grounding｣:Correct to figure.
｢2.6 Connecting TP-Net Cable｣:Correct to description.
｢2.7 Connecting Controlling Lines｣
:Correct to description, figure of from
17 page to 20 page.
・ Ⅳ MAINTENANCE MANUAL
｢5.1 Precautions in Maintenance｣:Add to TB4.
｢6.2 Layout of PCB parts｣:Correct to figure.
｢6.3 Layout of PCB & Fuse｣:Correct to figure.
・ REFERENCE MANUAL
｢7.1 Descriptions of Parameter Functions｣
:｢Pe VP Mode｣ & ｢Pk Max Step｣
Correct to Requirement/Function.
No.0276EN OBARA Corp. Revision history

Ver.1.8 2006/02/24 ・ Ⅰ Specification
Correct R.M.S. (P.15)
・ Ⅱ Installation manual
Add note about cooling water (P.13)
・ Ⅲ Operating manual
Correct warning alarm. (P.14)
・ Ⅳ Maintenance manual
Change expression of the troubleshooting.(P.13 - 24)
・ Ⅴ Reference manual
Correct Descriptions of Parameter Functions.
(Pe VP Mode, Pf VP Type, Pk Max Step,PV Liner up)
(P.25, 27, 28)
・ Ⅴ Reference manual
Correct Description of welding Conditions
(Transformer Turn Ratio, Off Time, Current Low Limit,
Power Voltage Low Limit) (P.32, 33)
Correct “Classifications of Alarms”, and “Setting Associated
with Alarms” (P.38)
Correct of “Sequence welding sequence” and
“Sequences at Occurrence of Alarm”. (P.34, 40, 42, 43)
Correct Pressure Adjustment. (P.46, 47, 48)
Ver.1.9 2006/03/03 ・ Ⅵ Supplemental manual
Correct the wrong. (P.8, 16, 17)
Ver.2.0 2006/10/10 ・ The correction with the Russian Specification addition (Ⅰ.P.11)
・ Correct the wrong description
(Ⅰ.P.14、Ⅱ.P.12、Ⅲ.P.15、Ⅴ. P.33、Ⅵ .P.6)
・ Adding the Shipment data of the Program sheet and Parameter
sheet. (Ⅴ Reference manual)
・ The addition and modification of drawing(Ⅰ、Ⅱ)
・ Change with code of manual (F276→0276EN)
Ver.2.1 2006/11/02 ・ Ⅵ Supplemental manual
Correct the wrong. (P.4,5,8,9,10,11,12,16,17)
Ver.2.2 2007/02/01 ・ Ⅱ Installation manual
Add note about jumper wire. (P.17,18,19,20,21)
Correct the wiring. (P.18,19,20,21)
・ Ⅳ Maintenance manual
Add expression of the troubleshooting. (P.14)

Ver.2.3 2007/02/05 ・ Ⅰ Specification
The destination of a form supplement is added. (P.11)
Notes addition and change at the time of connection of a
breaker. (P.13)
Torque addition with a bundle of a power supply line and an
earth wire. (P.13)
Ver.2.4 2007/03/07 ・ Ⅱ Installation manual
The wiring diagram between the timer and the transformer is
changed.
(It depends on the customer specification. File R-19-No.40-4)
Ver.2.5 2007/07/24 ・ Setting range change of slope time (0 to 30cyc). (Ⅰ.P.12、Ⅴ.P.31)
Ver.2.6 2008/05/27 ・ The supplementary explanation addition of setting range change of
slope time. (It adds to the beginning.)
・ Addition of supplementary explanation of circuit protector (SP3) for
over-current protection of solenoid output. (It adds to the beginning.)
・ Setting range change correction of slope time.
(Ⅰ.P.12、Ⅴ.P.30-32、shipping data)
・ Addition of circuit protector (SP3) for over-current protection of
solenoid output. (Each chapter cover、Ⅰ.P.11,13、Ⅲ.P.14、
Ⅳ.P.13-21、Ⅴ.P.39)
・ Circuit correction of connection example. (Ⅱ.P.18-21)

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Changing The Setting Range of Up Slope for OBARA AC Timer controller

１．Contents of Design Change ３．Date of enforcement

W-TC Japan STN21 -ECL-TY3JPN

AW-TC North America STN21 -ECL-TY3USA

UW-TC UK,TMMT,TMCA (CE Spec.) STN21 -ECL-TY3ENG

before servicing. VALV E MAXIMUM OUTPUT CURRENT 0.5 A at DC24 V

CHW-TC China STN21 -ECL-TY3CHN

Instantaneous RW-TC Russia (GOST-R Spec.) STN21 -ECL-TY3RUS

UP SLOPE WELDING TIME BRW-TC Brazil STN21 -ECL-TY3BRA

F-Disp. TM# F-Disp. TM#

R SW. Last Step No - Conti. SW. Last Step No - Conti.

(Notice) If the setting values are UP SLOPE: Danger/? ?

0 cyc and WELDING TIME: 4cyc, both

In the case of not using UP SLOPE,

same. However, UP SLOPE of 1cyc is

it is possible to set 0 cyc.

included in the first of welding time.

F-Disp. TM# F-Disp. TM#

R SW. Last Step No - Conti. SW. Last Step No - Conti.

Conventional Timer controller can be connected and operated with New

・ Connection from Display Pendant to New Spec/Conventional Timer

１．Changes ３．New Specification Model

over-current. The Circuit Protector(SP3) is tripped when the over-current

SW. Last Step No - Conti.

simultaneously overheat. Check the coolant water. When checking, be 怗? 婋?

sure to turn off power and be careful about burn injury. ? ? /? ?

Conventional timers detect wrongly the abnormality of “SCR O. Heat” and

挙渼? ? MODEL /TYPE STN21-ECL-TY3CHN1

Identifying Mark Added 1 at the end of

the model code 挙渼? ?

Display Pendant can be connected as well as above.

For the safety use, read the safety precautions of

= Notes on safety and handling procedure =

! DANGER dangerous situation that can lead to eventual death or

! CAUTION dangerous situation that can lead to intermediate level

Prohibited Conducts that must not be done.

The symbols indicate general situations.

No.0276EN OBARA Corp. Ⅰ.Specifications Page - 3

No.0276EN OBARA Corp. Ⅰ.Specifications Page - 4

Items to follow as safety precautions

No.0276EN OBARA Corp. Ⅰ.Specifications Page - 5

No.0276EN OBARA Corp. Ⅰ.Specifications Page - 6

! DANGER Do not insert fingers or hands between the electrodes.

Always follow the following precautionary instructions in order to

＊ Splashes and spatter generated during a weld and a hot base

No.0276EN OBARA Corp. Ⅰ.Specifications Page - 7

＝ Indications of dangerous parts and precautions ＝

No.0276EN OBARA Corp. Ⅰ.Specifications Page - 8

1.Related manual ..............................................................................................10

3.3 Input / Output ...........................................................................................................................13

3.4 Dimensions and Weight..........................................................................................................14

3.5 Facility Specifications.............................................................................................................14

3.6 Accuracy ..................................................................................................................................14

3.7 Coating Color...........................................................................................................................14

3.8 Welding Power Source Indicator ..........................................................................................14

3.9 SCR characteristics.................................................................................................................15

No.0276EN OBARA Corp. Ⅰ.Specifications Page - 9

Instruction manual Ⅰ. Specifications

No.0276EN OBARA Corp. Ⅰ.Specifications Page - 10

No.0276EN OBARA Corp. Ⅰ.Specifications Page - 11

No.0276EN OBARA Corp. Ⅰ.Specifications Page - 12

Step Control Step-up setting: Up to 16 steps