Manual Fanuc Weld Control

Document No.
: IN-4972E
Electrical Engineering Dept.
INSTRUCTION MANUAL
Robot Integrated Weld Control
RWC-2000 Series
Timer Unit：RWCB-2000-※※※-※
(Single Phase AC)
Conform to UL / CE
Original instructions
The instruction manual must be carefully

read for proper machine operation.
No person is allowed to install, conduct test run of, operate, maintain, repair the
machine or do similar works, without having well understood what the manual refers to.
The improper operation with inadequate knowledge may cause serious accident.
Incidentally, the manual must be kept at a place accessible to any of the person
concerned.
Please inquire an uncertain point of our Sales Department/each office.
DENGENSHA MFG.CO.,LTD
1－23－1 Masugata, Tama-ku, Kawasaki-shi, Kanagawa-ken, JAPAN
TEL：+81-44-922-1121／FAX：+81-44-922-1100
Instruction manuals
 Robot Integrated Weld Control Timer unit instruction manual (this document)
This manual provides instructions regarding Timer unit of Robot Integrated Weld Control,
descriptions of the Timer unit functions, installation method, notices of troubleshooting
against errors and maintenance.
 Robot Integrated Weld Control Contactor unit instruction manual Each model type
This manual provides instructions regarding Contactor unit of Robot Integrated Weld Control,
descriptions of the contactor unit functions, installation method and maintenance.
 An instruction manual related to the robot controller.

Please refer to the instruction manual of the robot, about the setup, operation, and maintenance.
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Contents
1. SAFETY INSTRUCTIONS AND CONSIDERATIONS ...................................... 1

1 - 1. Product safety labels and symbols .................................................................................. 1
1 - 2. Application of the equipment and safety ........................................................................ 2
1 - 3. Safety considerations ...................................................................................................... 2
1 - 4. Safety during operation .................................................................................................. 2
1 - 5. Electrical safety .............................................................................................................. 3
1 - 6. Safety items on maintenance work ................................................................................. 4
1 - 7. Accident prevention ........................................................................................................ 5
2. WARRANTY and REPAIR-AVAILABLE PERIOD ............................................ 8
2 - 1. Warranty ......................................................................................................................... 8
2 - 2. Repair-Available period .................................................................................................. 9
3. Overview of Timer unit RWC-2000 series ............................................................ 10
4. Timer Unit ............................................................................................................. 12
4 - 1. Timer Unit Models.......................................................................................................... 12
4 - 2. How to check the timer unit type .................................................................................... 13
5. Timer Board ........................................................................................................... 14
5 - 1. Specification ................................................................................................................... 14
5 - 2. Parts Name...................................................................................................................... 15
5 - 3. Jumper and DIP SW on Timer board .............................................................................. 17
6. Installation ............................................................................................................. 18
6 - 1. Timer board in robot controller (PMU-0531/PMU-0547) .............................................. 18
7. Weld Schedule ....................................................................................................... 24
7 - 1. 3 impulse welding ........................................................................................................... 24
7 - 2. 5 impulse welding ........................................................................................................... 24
7 - 3. W-5 Multi Impulse (5 impulse welding)......................................................................... 25
7 - 4. 14 impulse (free wave-form) welding ............................................................................ 26
8. Weld Parameters .................................................................................................... 27
8 - 1. Programming items......................................................................................................... 27
8 - 2. Description of programming items (welding schedules and function setting) ............... 31
9. Hardware gain........................................................................................................ 39
10. Monitor function .................................................................................................. 39
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11. Functions.............................................................................................................. 41
11 - 1. Current Stepper ............................................................................................................. 41
11 - 2. Transformer short-circuit detection .............................................................................. 42
11 - 3. Current Control method ................................................................................................ 42
11 - 4. All impulse current monitor .......................................................................................... 44
11 - 5. 5 impulse welding ......................................................................................................... 44
11 - 6. W-5 Multi Impulse (5 impulse welding) ....................................................................... 45
11 - 7. 14 impulse (free wave-form) welding........................................................................... 46
11 - 8. Current linearity compensation ..................................................................................... 49
11 - 9. Electrode tip stuck (Option) .......................................................................................... 50
11 - 10. Primary cable resistance detecting (Option) ............................................................... 50
11 - 11. Secondary cable resistance detection (Option) ........................................................... 53
12. Fault code and troubleshoot................................................................................. 55
12 - 1. Fault code list ............................................................................................................... 55
12 - 2. Troubleshooting method ............................................................................................... 57
12 - 3. Fault items and counter measures ................................................................................. 58
13. Maintenance......................................................................................................... 71
13 - 1. Maintenance parts list ................................................................................................... 71
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1. SAFETY INSTRUCTIONS AND CONSIDERATIONS
IT IS IMPERATIVE THAT：
Any person involved with the installation, functional testing, operation, maintenance and repair of this
machine must start the work with complete understanding of the machine after reading this
INSTRUCTION MANUAL carefully, to help prevent personal injury or damage to the equipment.
DENGENSHA equipment has been designed and produced with due consideration to safety. Be sure
to observe the instructions in this instruction manual. Failure to comply with these instructions may
cause personal injury.
1 - 1. Product safety labels and symbols

In this manual and the machine, the following labels or symbols are used.
(1) General warning sign

This is the general warning sign. It is used to alert the user to potential
hazards. All safety messages that follow this sign shall be obeyed to avoid
possible harm.
(2) Hazard severity panels
Indicates a hazard with a high level of risk which, if not

DANGER avoided, will result in death or serious injury.
Indicates a hazard with a medium level of risk which, if

WARNING not avoided, could result in death or serious injury.
Indicates a hazard with a low level of risk which, if not

CAUTION avoided, could result in minor or moderate injury.
(3) Prohibition sign

A black graphical symbol inside a red circular band with a red diagonal bar
defines a safety sign that indicates that an action shall not be taken or shall be
stopped.
(4) Mandatory action
A white graphical symbol inside a blue circle defines a safety sign that
indicates that an action shall be taken to avoid a hazard.
1 DENGENSHA
1 - 2. Application of the equipment and safety
This equipment is intended for use, exclusively, for the purpose specified in associated
documentation (instruction manual, specification sheet). Employment of the equipment for any
other purpose is regarded as a deviation from the intended application.
Improper usage other than intended may cause：
(a) Serious injury or death,
(b) Damage to this and/or other equipment
DENGENSHA equipment uses the latest state of the art technology and is made to operate
safely and reliably. The equipment should be used only for the intended purpose. Dengensha
will not accept liability for misuse of the equipment.
1 - 3. Safety considerations
We emphasize that DENGENSHA MFG.CO., LTD. disclaims all liability for damage and
malfunctions resulting from non-compliance with the following instructions in particular：
(a) The instruction manual must be read and strictly understood. If there are any questions,
contact our business department and/or each office.
(b) Unauthorized conversion and/or modification affecting the safety of the equipment are not
allowed.
(c) The equipment may not be equipped or operated with products of other manufacturers
whose use is not expressly permitted in the associated manuals.
(d) For the items(b)and(c), consult with our business department/each office on safety.
1 - 4. Safety during operation
CAUTION
(1) Injury prevention from electrode or clamping force
Resistance welding machine generally uses electrode pressurizing force or clamping
force of several thousands Newtons or more.
Since this large force is dangerous, do not put hands, fingers, or any part of the body
between the electrodes, and between the clamps. Failure to observe this warning can
cause serious injury. The same warning applies to the electrodes when opening.
A guard is provided to protect against a pinch point when the upper electrode opens.
Do not put hands, fingers or any part of the body between the upper electrode and the
cylinder body. Operation should not occur unless the guard is in place.
CAUTION
(2) Wearing safety gear
Spark or spatter that is produced during welding operation may cause eye injury. Since
it is difficult to eliminate spark or spatter completely, it is necessary to put on
protective glasses, helmet, gloves and non-combustible working clothes to safeguard
against splash and spatter.
2 DENGENSHA
CAUTION
(3) Prevention from burns or fire
Spark or spatter produced during welding operation or hot parts just after being
welded cause burns. Observe the following precautions and install fire extinguishers
close to the weld working area in case of an emergency.
(a) Remove flammable substances so that Spark or spatter do not fall on them or drape
them with a non-combustible cover.
(b) Do not perform welding work near the flammable gas.
(c) Do not bring hot parts immediately after being welded, close to the flammable
materials.
(d) Do not touch the parts just after being welded with bare hands. Even if they are not
red, the temperature may be very high, causing a burn.
(e) Keep any personnel other than workers away from a place where spark or spatter is
produced.
(4) Noise protection

Measure noise level of this equipment and its surroundings area. If the level is in excess
of 85db, use appropriate hearing protection.
1 - 5. Electrical safety
DANGER
(1) In order to aroid electrical shock
In order to avoid electrical shock, be sure to observe the following items：
(a) Do not touch the parts bearing electrical charges other than secondary conductor.
Failure to observe this may result in a fatal electrical shock or severe burns.
(b) Do not touch both ends of secondary conductor simultaneously. Failure to observe
this may result in a slight electrical shock.
(2) Connection to the power supply

The equipment should be connected properly to the power supply as per the instruction
manual. The power supply work should be carried out according to local laws and your
in-house standards.
(3) Qualifications for electrical work
Voltage of approx. 440V is supplied to the equipment according to the specification
(Higher voltage may be used depending on models. Refer to the specification).
Educated, trained and qualified personnel1) with regard to the potential hazards arising
from these dangerous voltages should be assigned, especially, to electrical work for
installation, maintenance and repair works.
Notice : 1) For example, personnel who possess qualifications for electrical work or
authorized customer employee.
3 DENGENSHA
(4) Grounding work
An earth terminal is provided with the equipment for safety.
A person qualified for conducting the electrical work should carry out the grounding
work according to the local laws and in house standards
(5) Provision of properly sized conductors
The customer is responsible to provide properly sized conductors for the incoming
power feed to the welder. Do not use wire of insufficient capacity or damaged/exposed
wires. Failure to observe this may cause fire due to overheated electrical wire and
electrical shock or current leakage.
(6) Electric wire connection
The connection terminal of the electrical wire should firmly be tightened and insulated.
In case of loose connection, the connection may become overheated and cause fire, and
insufficient insulation may cause electrical shock or current leakage.
1 - 6. Safety items on maintenance work
DANGER
(1) Promotion of safe system start-up and shut-down
There is a possibility of causing extremely dangerous condition when the sources of
power supply, pneumatic and water are turned on without warning to a worker during
maintenance/repair work. Systems that promote safe system start-up and shutdown
should be provided for personnel safety.
(2) Before performing maintenance work
DANGER
Before performing any maintenance and/or repair work, including cleaning, it must be
ensured that：
(a) The equipment has been disconnected, using a lock-out/tag-out procedure, from all
power supplies for welding, control and power.
(b) Perform plant lock-out/tag-out procedures on power sources of the equipment.
CAUTION
(c) All sources of pneumatic pressure and cooling water have been
locked-out/tagged-out.
(d) Residual pressure of all pneumatic circuits and cooling water circuits have been
relieved.
(3) Perform maintenance work

Installation, maintenance/inspection, repair work should be performed by trained
qualified personnel2) according to the instruction manual for safety reasons.
Notice : 2) Qualified personnel, authorized by the customer, who have received
manufacturer’s or customer’s in-house training and have clear understanding of the
equipment in question.
4 DENGENSHA
(4) Perform periodic maintenance
It is necessary to perform periodic maintenance and inspection of the equipment as
described in the manual.
(5) Water or pneumatic hoses
When the customer prepares to install water, or pneumatic hoses to the welder, make
sure they will sufficiently bear the pressure.
Possibilities of danger occur when these hoses have insufficient resistance to pressure or
are deteriorated or damaged, periodically perform maintenance and inspection and repair
the deteriorated or damaged parts before using the equipment.
(a) When hoses bursts or disconnected, the hose may act violently or the equipment
may operate unexpectedly.
(b) When a water hose bursts developing a leak, there is a possibility of deteriorated
insulation of the electrical circuit or deterioration of the control equipment and/or
current leakage.
1 - 7. Accident prevention
(1) Cooling water used for welding machine
Be sure to observe the following items for safe operation, to prevent accident and
maintain proper functioning of the equipment.
(a) Use water of the following quality or equivalent：
i) Rate of electric resistance: More than 5,000Ω・cm for thyristor cooling water.
ii) Less deposit in water.
iii) Ammonium ion content must be less than 1ppm.
Smaller resistance of water may cause current leakage. The cooling water with large
deposits may clog a circuit to degrade the circuit function, lowering the cooling capacity
and causing the circuit to malfunction or fail.
Cooling water containing a large amount of ammonium ions may have the possibilities
of corroding copper or copper alloy components on the cooling circuit and create water
leaks, leading to current leakage and electrical shock or electrical breakdown of welding
transformer that can causes a fire on the equipment.
(b) When the cooling water is turned off, be sure to turn off the welding power supply.
Leakage current flowing for a long time may heat and damage thyristors,
depending on quality of cooling water.
(c) Amount of cooling water prescribed in the specification of the equipment should be
provided in the following manner. It is also important to keep water temperature
prescribed in the specification in order to maintain the cooling capacity as well as
water quantity：
i) Maintain a given water pressure prescribed in the specification.
ii) Check the water flow periodically to prevent clogging & overheation conditions.
iii) Perform maintenance of cooling water circuit as prescribed in the specification.
When cooling capacity is deteriorated, the equipment may generate faults or a fire may
generate due to overheated components such as welding transformers, conductors,
electrodes, thyristors.
5 DENGENSHA
CAUTION
(2) Upper electrode falls when air supply is stopped
In general, when air supply for welding machine is stopped, the upper electrode falls
spontaneously due to deadweight. Though its falling speed is not high, there is a
possibility of occurring problems： injury may occur if hands, fingers, a part of body
are caught, or work piece be deformed if it is between the electrodes.
(3) Proper pressurizing force must be established
Proper pressurizing force must be established before passing welding current through
the electrodes. If current is passed through the electrodes when the pressurizing force
is too low, a dangerous explosion of sparks and splatter will occur, causing serious
injury or burns.
EXAMPLES:
(a) When pressure of 0.1Mpa or less has been established causing uncontrolled drifting
down of the electrode.
(b) When the squeeze time is set too short and the electrode completes the weld circuit
under load.
(4) Magnetic field effect
The resistance welding machine generates high magnetic field around the secondary
circuit when energized. This magnetic field has an influence on operation of certain type
of sensors, watch, and magnetic cards. For the same reason, a person who uses a heart
pace maker is prohibited from coming up to the resistance welding machine during
operation.
(5) Equipment fall down prevention
Equipment may fall down depending on models when an earthquake occurred. Perform
installation work of the equipment according to the instruction manual.
(6) Safety information of peripheral devices
Information about possibilities of danger of peripheral devices of this equipment such as
conveyors, feeders, robots should also be provided to workers.
(7) To use within maximum input and allowable duty factor
The welding transformer has rated input, maximum input, allowable duty factor, and so
forth. This is the heat capacity of welding transformer prescribed under the cooling
conditions (temperature and quantity of water). This specification indicates the upper
limit of operation of the welding transformer. In excess of this limit, the welding
transformer may be overheated or burnt in some cases. Since the heat capacity of
welding transformer is based predicated on being cooled, the welding transformer may
be overheated under normal operation or burnt in some cases if the cooling condition is
insufficient.
The welding machine and welding transformer should be used within prescribed
maximum input and allowable duty factor without fail. (For details, refer to the
REFERENCE “Maximum Input of Welding Transformer, allowable duty factor”.)
6 DENGENSHA
◎ Reference 1： Maximum input and allowable duty factor of welding transformers
Rated input P50, maximum input Pmax, allowable duty factor max, etc. are prescribed for
welding transformers.
Rated input P50 indicates the input kVA of the welding machine when the duty factor is
assumed to be 50%.
The heat capacity of a welding transformer can be indicated with the following formula,
using the input and duty factor.
Heat capacity = P50  (0.5)1/2
The heat capacity is constant, regardless of how the transformer is to be used. Since
the heat capacity will be the same even when the transformer is used with maximum
input Pmax, it follows that the duty factor will be restricted by a certain value, and this
value will be called the "allowable duty factor" max. That is, they will have the
following relationship.
P50  (0.5)1/2 = Pmax  (max)1/2
In other words, the duty factor will have to be reduced when the welding machine or
welding transformer is to be used with a large input kVA, and when using it with the
duty factor increased, it will exceed the heat capacity of the welding transformer unless
the input kVA is lowered. This can easily be examined, if you apply values to
above-mentioned formula.
◎ Reference 2： Equivalent continuous current (continuous secondary current) of welding

machines
Welding current and duty factor are prescribed for welding transformers. Calculating
the following formula with these values will give you the equivalent continuous current
(continuous secondary current).
I2p = Equivalent continuous current = Welding current  duty factor (A)
This is the maximum continuous current that this transformer can allow to flow.
Example 1： calculation formula of the equivalent continuous current that uses the
specification
When the welding current is 11,000 A, and the duty factor is 10%：
Equivalent continuous current = 11,000  0.1 = 3,470 A
Example 2： calculation formula of the equivalent continuous current from the welding
condition
In the case of applying electrical current three times：
I1  WT1  I 2  WT2  I 3  WT 3
2 2 2
I2p = (A)
Production Cycle time (sec.)  frequency (Hz)
If a transformer is to be used in excess of this equivalent continuous current, generation
of heat by this transformer will cause damages and other accidents.
I1： First current to be applied (A)
I2： Second current to be applied (A)
I3： Third current to be applied (A)
WT1： Period of time of the first current to be applied (cycle)
WT2： Period of time of the second current to be applied (cycle)
WT3： Period of time of the third current to be applied (cycle)
7 DENGENSHA
2. WARRANTY and REPAIR-AVAILABLE PERIOD
2 - 1. Warranty
(1) Warranty Period
① Product for Japanese market
The warranty period shall be one (1) year from the date of the acceptance
inspection of the Product or within 2,000 hours after commencement of operation
of the Product, whichever comes first.
② Export Product
In the case where a specification sheet have an agreement on the warranty period,
that period shall be applied. In the case where a specification sheet have no
agreement on the warranty period, the period shall be one (1) year after the
acceptance inspection of the Product, or within 2,000 hours after the
commencement of operation, or for a period of fifteen months as from the date of
the last shipment of the Product, whichever comes first.
In addition, for a repaired part of the Product, warranty services shall be available
for six (6) months since the implementation of such repair, however, the warranty
period or the repair-available period for the entire Product shall not be extended.
(2) Warranty Conditions (applied to Product for Japanese market, Export Product)
In the event of any failure that is obviously attributed to the Company during proper
operation of the Product as provided in the instruction manual during the warranty
period as specified above, the Company shall repair the Product at no cost. Provided
that, even within the warranty period, this warranty shall not apply in cases such as the
ones specified below:
① Any defect or damage due to improper handling, operating, storing, and environment
in your premises;
② In the cases where the Product has been disassembled, modified, repaired by any
company other than the Company or those designated by the Company;
③ Any defect due to use of parts other than genuine parts of the Company;
④ In the case where the Customer failed to do maintenance as provided in the
instruction manual and replace consumable parts;
⑤ Any failure or damage caused by dropping, etc. at the time of installation or transfer;
⑥ Any failure or damage caused by natural disasters (fire, lightning, earthquake, flood
or the like) and abnormal voltage.
⑦ Any damage or loss caused by a failure of the Product;
⑧ In the case where the person requesting the repair is not the first end-user;
⑨ The following consumable parts,
The consumable parts mean those which shall have been worn out and not
worked properly by using the Product. Those parts need to be changed
periodically.
(For example: Electrode tip, Wheel electrode, guide pin, shunts, Bite cutter, Vinyl
tube, Capacitor bank) Including consumable parts listed in Parts list of Instruction
manual.
8 DENGENSHA
2 - 2. Repair-Available period
(1) Repair-available period shall mean a period during which the Product can be repaired by
using functional parts for repair even after expiration of the warranty period. The
period shall be ten (10) years from the acceptance inspection as a standard, but the actual
period may vary slightly.
(2) The Product for which the repair-available period has expired may be unacceptable for
repair.
(3) In the event that a repair of the Product is requested by a person other than the first
end-user of the Product, such repair may be unacceptable if the distribution channels of
the Product cannot be identified.
(4) In the event that the functional parts for repair are out of inventory, the repair period may
be longer because it takes time to obtain the correct functional parts for repair.
(5) In the event that the functional parts for repair turn out to be unobtainable, the Product
may be repaired by attaching alternative parts bearing equivalent performance. In such
case, the repair period may be longer due to performance evaluation of the alternative
parts and other such procedures.
9 DENGENSHA
3. Overview of Timer unit RWC-2000 series
(1) Robot Integrated Weld Control is configured with contactor unit and timer unit.
Timer unit is comprised of board and software. Contactor unit is composed of electrical
components such as housing and thyristor.
ロボット統合型抵抗溶接制御装置
Robot Integrated Weld Control
e.g.) RWC-2000
タイマユニットタイマ基板
Timer Unit Timer Board
e.g.) RWCB-2000-A00-* e.g.) PMU-0531
ソフトウェア
Software
e.g.) RWC2000 0101 0015 0000 0000
コンタクタユニット点弧基板
Contactor Unit Firing Board
e.g.) SRCR-N1DI-M1-E3
サイリスタ
Thyristor
ブレーカ
Circuit breaker
(2) Timer unit (RWCB-2000-***-*) is built into the robot controller (Fanuc R-J3i, R-30i) and
connected to the dual port RAM (DPR) via the PC/104 bus. Faster signal transfer realizes
shorter cycle time.
(3) Welding parameters are edited using the Robot Teaching-pendant. All data including robot
operation, welding conditions, monitoring and faults/errors is batch-managed on the robot
side.
(4) Special current control (Depending on the model type)

(Available with RWCB-2000-B02-*, RWCB-2000-B06-A, RWCB-2000-B08-* and
RWCB-2000-B11-*)
This is control for stabilizing the current the 2nd welding and reducing the abnormalities. In
welding by taking away the garbage adhering to a work etc. by the 1st welding. 1st welding
is Heat-control with a current limit, and constant current controls 2nd and 3rd welding.
(5) Electrode Tip stuck detection (Depending on the model type)

(Available with RWCB-2000-B02-*, RWCB-2000-B06-A, RWCB-2000-B08-* and
RWCB-2000-B11-* with the tip-stuck detecting board inside the contactor unit)
Monitoring the contact condition between gun and jig (or panel on jig).
(a) Preparation
Connecting 2 detection cables. One is between jig and contactor unit (specified
terminal). Another is between gun and contactor unit (another specified terminal).
(b) Detection
When contact between jig and gun is happened while NOT welding, tip stuck signal
turns ON (for stopping robot).
Precautions
The ground resistance of a welding machine must be not less than 100.
This function is not available when the secondary circuit is grounded.
10 DENGENSHA
(6) Example of installation
溶接トランス
DG標準ベース WELD TRANS.
ロボット制御盤
コンタクタユニット Robot controller
Contactor Unit R-J3i
SRCR/SRCN Robot control
タイマユニット
点弧基板 Timer Unit
Firing board RWCB-2000-A**-*
溶接電源 Weld control ロボット電源

PF-0532 PMU-0531
ロボット Robot
点弧ケーブル
Firing cable
溶接トランス
DG拡張標準ベース WELD TRANS.
コンタクタユニットロボット制御盤
Contactor Unit Robot controller
SRCR/SRCN R-J3i
Robot control
点弧基板タイマユニット
Timer Unit
PF-0532 溶着基板 RWCB-2000-B**-*
PTS-0548 Weld control

溶接電源ロボット電源
PMU-0547
ロボット Robot
溶着ケーブル
Tip stuck cable
点弧ケーブル
Firing cable
11 DENGENSHA
4. Timer Unit
4 - 1. Timer Unit Models
Model: RWC B – 2000 – A 00 – C

① ② ③ ④ ⑤ ⑥
① Base mark ----------- RWC : Single-phase AC type
RWI : Inverter type
② Identification mark-- B : Timer unit (Timer board)
③ Robot ----------------- 2000 : Fanuc R-J3i, R-30i (AC)
3200 : Nachi AX, FD controller
4200 : Yaskawa NX100, DX100, DX200 (PCI)
5200 : Kawasaki E controller (PCI)
6000 : ABB (PCI) (AC)
④ Board number ------- A : PMU-0531
B : PMU-0547
D : PMU-0541
E : PMU-0571
H : PMU-0531VMC
⑤ Software spec. ------ 00 : DG Standard (PMU-0531)
02 : DG Extension (PMU-0547)
05 : All impulse current monitor (PMU-0531)
06 : 5 impulse welding (PMU-0547)
11 : W-5 multi impulse (5 impulse welding) (PMU-0547)
⑥ Revision -------------- A : Up to PMU-0531-3
: Up to PMU-0547-1
B : From PMU-0531-5 first edition
: From PMU-0547-3 first edition
C : From PMU-0531-5 PLD update
: From PMU-0547-3 PLD update
※ all combinations is not possible. Please refer to the Model list.
 Model list
Timer Board number Specification
RWCB-2000-A00-* 3 impulse welding
RWCB-2000-A05-* PMU-0531-* 3 impulse welding ,All impulse current monitor
RWCB-2000-A07-* 5 impulse welding
RWCB-2000-B02-* 3 impulse welding, cable resistance check
RWCB-2000-B06-A 5 impulse welding, cable resistance check
PMU-0547-*
RWCB-2000-B08-* 14 impulse welding, cable resistance check
RWCB-2000-B11-* W-5 multi impulse (5 impulse welding), cable resistance check
12 DENGENSHA
4 - 2. How to check the timer unit type
For example
Model： RWC B – 2000 – B 06 – C

① ② ③ ④ ⑤
(1) Robot Teaching-pendant displays software version as following

ex) RWC 2000 0002 0011 0000 0006
① ③ ⑤
Notice： Combination of ④ and ⑤ are fixed
(2) The nameplate displays software version board number as following.
CPU1
1 CNCPU 7 1 3
CT
TR
F1 F0 T1 T0
4
SEL
3
2
ON
1
0
CNPLD
XTAL
1
PMU-0547-1
DENGENSHA
MADE IN JAPAN
5
JPGAIN
TR
CT
4
JPCUR
TR
1
CNRST
CNF CNMB
13 DENGENSHA
5. Timer Board
5 - 1. Specification
No. Item Specification
1 Cooling Natural air
2 Data setting unit By Robot Teaching-Pendant
3 Weld schedule 255 [schedules]
Stepper schedules 4 Guns (for Gun Changer)
Stepper type Linear up / step up
4 Stepper 10 [steps]
Increasing ratio 50 - 200[%] in each step (step 0 is fixed to 100%)
Step count 0 - 1000[welds] in each step
5 Timer node Depending on the robot specification
6 Data backup Robot memory stores weld parameters
Firing angle control range: 25 to 140 [°]
Primary current control range: 50 to 1,500 [A]
7 Controllable ranges (Limited by the thyristor size and Heat%)
Secondary current control range: 2.0 to 50.0 [kA]
Welding transformer turns ratio: 1.0 to 200
Constant current control
Loop control by current feedback
Repeatability:±2% of max. current.
( with 20% of disturbing influence)
Voltage compensation control
Open loop control by measuring the welding source voltage
8 Weld current control Repeatability:±2% of maximum current
( with 20% of welding source voltage fluctuation)
Special Current Control ※ Depending on the model
Voltage compensation control applies to the upslope,
heat control with current limits applies to weld1, and constant
current control to applies to weld2, weld3… and down-slope.
Fixed 1 [schedule] (at the 255th schedule)
Weld transformer leak A detection current value (primary) is a fix setup.
9
current check
※ Depending on the model
Connecting cable
10 3, 5 or 10 meters (50 meters max)
(Firing cable)
14 DENGENSHA
5 - 2. Parts Name
(1) Up to PMU-0531-3
1 2 3 4
T0 T1 F0 F1
0 ON TR
1 1 2 3 4 CT
SEL
1 CNCPU 7
CNPLD 1
PMU-0531-3
MADE IN JAPAN
A1
B1
5
PC104
XTAL
7 JPGAIN
TR
CT
JPCUR
13 CNF 1
8
(2) From PMU-0531-5
1 2 3 4
F1 F0 T1 T0
CNPLD 1 CT 4 3 2 1
1
ON
TR 0
ON
SEL
1 CNCPU 7
MADE IN JAPAN
A1
B1
5
PC104
XTAL
6 PMU-0531-5
JPGAIN
TR
CT
7
TR
CT
JPCUR
13 CNF 1
① Mounting hole： For mounting on robot controller rack. (M3, 5 places)

② CNCPU： CPU program writing port. (There is no need to use it.)
③ CNPLD： PLD writing port. (There is no need to use it.)
④ SEL： For board function setting
⑤ PC/104： Connector for connecting robot controller.
⑥ JPGAIN： Jumper for switching current detection mode.
⑦ JPCUR： Jumper for switching current detection mode.
⑧ CNF： Used for connecting to firing board in contactor unit.
15 DENGENSHA
(3) Up to PMU-0547-1
1
2
1 CNCPU 7
CT
TR
F1 F0 T1 T0
CPU
4
SEL
3
2
3
ON
1
0
1
CNPLD
XTAL
PMU-0547-1
DENGENSHA
MADE IN JAPAN
5
JPGAIN
TR
CT
6
JPCUR
TR
1
CNRST
7 CNF CNMB
8 9
(4) From PMU-0547-3
1
2
CNCPU
1 SEL 7
1 0
CPU
T0
ON
1
T1
2
F0
3
3
4
F1
CT TR
CNPLD
XTAL
5 PMU-0547-3
JPCUR
TR TR CT
JPGAIN
6
1
CNRST
7 CNF CNMB
8 9
① Mounting hole： For mounting on robot controller rack. (M3, 4 places)
② CNCPU： CPU program writing port. (There is no need to use it.)
③ SEL： For board function setting
④ CNPLD： PLD writing port. (There is no need to use it.)
⑤ PC/104： Connector for connecting robot controller.
⑥ JPGAIN： Jumper for switching current detection Mode.
⑦ JPCUR： Jumper for switching current detection mode.
⑧ CNF： Used for connecting to firing board in contactor unit.
⑨ CNMB： Used for connecting to tip stuck board in contactor unit.
⑩ CNRST： It is not used
16 DENGENSHA
5 - 3. Jumper and DIP SW on Timer board
(1) SEL
 4-bit Dipswitch.
※ Be careful with direction of SEL

Mounting direction is different for each board number and
revision number. Please check with silk well.
 factory default settings

Bit Item OFF (1) ON (0) Notice
1
Timer ID
2
3 Spare fixes to ON
4 Current detector CT TR Depending on the model
(a) Setting of Timer ID

Bit No.
Timer ID
1 2
1 0 (ON) 0 (ON)
2 1 (OFF) 0 (ON)
The robot controller rack can be mounted plurality of timer boards. In this case, the
welding controller number (Timer ID) is set. If mounted one timer board, should be
set to "00".
(b) Setting of current detection mode as follows:

CT side: Primary current detection (uses CT inside contactor unit)
TR side: Secondary current detection (by toroidal coil)
(2) JPCUR, JPGAIN

 Current detection mode is changed.
Current detection mode JPCUR JPGAIN F1 bit (SEL)
Primary current detection CT side Open CT side CT side
Secondary current detection TR side Short TR side TR side
※ Be careful with direction of Jumper
Mounting direction is different for each board number and revision number.
Please check with silk well.
CAUTION
If switch and jumper settings are carelessly changed, welding control may not only cease to
be executed correctly, but the equipment could be damaged as well. Set properly after
carefully reading the instructions manual.
CAUTION
Timer board is a printed circuit board consisting of high-density electronic circuits. Do not
directly touch the electronic components or pins of connectors on the board with your
hands. Before handling the board, make sure your body and clothes do not have an
electrostatic charge.
17 DENGENSHA
6. Installation
The procedure for mounting the DENGENSHA Timer unit in the FANUC robot controller is as
follows.
MANDATORY ITEM
Shut off the robot controller power source and welding power source before installing.
6 - 1. Timer board in robot controller (PMU-0531/PMU-0547)

 Timer board (PMU-0531/PMU-0547) is directly connected to the FANUC motherboard on
the card rack in the R-J3i / R-30i robot enclosure by a PC/104 bus connector.
 Up to 2 timer boards can be mounted on a single motherboard.
 Shut off the robot controller’s power source before mounting or removing Timer board
(PMU-0531/PMU-0547).
e.g.
FANUC
R-J3i
Motherboard on card rack
Connect to bus connector on motherboard on card rack
18 DENGENSHA
DANGER
Be sure to shut off the robot controller’s power source before attempting to access the inside
on the robot controller.
 Timer board is sometimes shipped together with the contactor unit and is sometimes
incorporated into the robot controller.
 TIMER CONTROL PCB is printed on the mother board panel so the mounting position can
be easily identified.
(1) Preparations and precautions

 The following items are required for mounting the timer board:
・Timer board
・Screws and poles (included with FANUC motherboard)
・Phillips screwdriver
・Conductive work mat (used for replacing the motherboard)
or
MANDATORY ITEM
If your body or clothing has an electrostatic charge, it could damage the electronic circuitry.
Before handling the circuitry, discharge the electrostatic charge by touching a grounded
metallic object.
MANDATORY ITEM
The timer board and mother board contain electronic components. Hold the panels and
printed circuit boards by the edges so as not to directly touch the components and terminals
on the board with your hands.
19 DENGENSHA
(2) Work procedure
① Removing the motherboard
The motherboard is located inside the robot controller near the bottom of the
controller.
Grip the tabs at the top and bottom on the front of the motherboard panel and pull
out toward yourself. The board is unlocked when the tabs are gripped.
Place the motherboard on a conductive work mat to ensure that it will not be
damaged by static electricity.
Motherboard
20 DENGENSHA
② Checking the timer board
Check the dipswitches and jumper on the timer board.
The switches are set in accordance with specifications and inspected at the factory
prior to shipment. You should however check the switches just to make sure they are
set correctly. (Refer to “Timer board”clause)
 WC (Weld Controller) number set by T0/T1 bit of Dip SW[SEL]

T0 T1 WC Number
0 0 Timer 1 Only using 1 timer board
1 0 Timer 2
F0 bit is set to 0 and cannot be changed.
 F1 bit of Dip SW[SEL] is used to switch detection signal in accordance with [JPCUR]
[JPGAIN]
Current detection mode JPCUR JPGAIN F1 bit (SEL)
Primary current detection CT side Open CT side CT side
Secondary current detection TR side Short TR side TR side
③ Mount the timer board on the PC/104 contactor on the motherboard.

Take note of the orientation of the timer board and make sure all pins are inserted
correctly. The motherboard should be placed on a conductive mat while performing
the work procedure.
Fastened with 4 screws
If using 1 timer board

If using 1 timer board, set WC number
to timer 1 ( 0 0 ) with Dip SW [SEL] .
[SEL] Dip SW setting example
0 TR
1 CT
Timer 1 (00)
Do not use the 4 poles

included with the
motherboard.
But fasten them inside the cabinet with tape, etc.,
to keep them from being lost.
※ The timer board PMU-0547 and PMU-0531-5 is larger than a standard timer
board, so mount the timer board after moving the post A together with the timer
board.
21 DENGENSHA
The board could be damaged if connector pins are bent or inserted incorrectly.
Carefully insert the connector pins and fasten in place the 4 screws that come with
the board. If the connector is not inserted correctly, the board cannot be fastened
with screws. If so, check if the connector is inserted incorrectly.
 Two timer boards may be mounted on a single motherboard, depending on

specifications.
This means a maximum of 2 timer boards may be used. In this case, WC numbers
must be set for each Timer board. Set the Dip SW [SEL] as described in item ②.
Be sure not to use the same WC number for another timer board.
 The equipment will not operate properly if the switches are set incorrectly.
Fastened with 4 screws
0 TR
1 CT
Timer 1 (00)
If using 2 timer boards

Fastened with 4 poles
If using 2 timer boards, included with the board
set a time No. for each timer board.
0 TR
1 CT
Timer 2 (10)
22 DENGENSHA
Insert pins into the sockets by matching Insert in the holes indicted by
the holes indicted by ※ in the figure. When the pins have been
※ in the figure with screws. inserted into the socket to a certain degree,
fasten with screws.
Socket Pole
Pin
④ Checking the timer board after mounting

Make sure the timer board is properly mounted on the motherboard.
 Visually inspect both ends of the contactor to make sure pins no pins are
protruding from either end of the contactor.
 Make sure all screws are tightened all the way. (Screws however cannot be
tightened all the way if the connector is not lined up correctly.)
⑤ Motherboard mounting
Mount the motherboard at its former position in the robot controller.
⑥ Checking work after completion

 Make sure the motherboard is inserted all the way.
 Unused poles (included with the motherboard) may be used in the future. Place
the unused poles back in the plastic bag they came in and fasten them with tape
inside the cabinet in a place where they can be seen. (Four poles are left over if
1 timer board is mounted on 1 motherboard.)
23 DENGENSHA
7. Weld Schedule
7 - 1. 3 impulse welding
 RWCB-2000-A00-*, RWCB-2000-A05-*, RWCB-2000-B02-*
起動(ロボット通信)
Start weld
(from Robot)
電極
Electrode
溶接電流電流1 電流2 電流3

Weld Current Current-1 Current-2 Current-3
スクイズｱｯﾌﾟｽﾛｰﾌﾟ通電1 クール1 通電2 クール2 通電3 ﾀﾞｳﾝｽﾛｰﾌﾟ保持

Squeeze Uslope Weld-1 Cool-1 Weld-2 Cool-2 Weld-3 Dslope Hold
パルセーション
Multi Impulse
モニタ/異常
Monitor/Fault
溶接完了(ロボット信号)
Weld comp.(to Robot)
CAUTION
The executive time of welding sequence may become short in weld off.
 RWCB-2000-B06-A, RWCB-2000-A07-*
Start weld
(from Robot)
電極
Electrode
溶接電流電流1 電流2 電流3 電流4 電流5

Weld Current Current-1 Current-2 Current-3 Current-4 Current-5
通電1 クール1 通電2 クール2 通電3 クール3 通電4 クール4 通電5 保持

Hold
モニタ/異常
Monitor/Fault
CAUTION
When No weld, was set to at least 2 of each multi-impulse 2, 3 and 4, only to run one
impulse of each set.
24 DENGENSHA
7 - 3. W-5 Multi Impulse (5 impulse welding)
 RWCB-2000-B11-*
Start weld
(from Robot)
電極
Electrode

通電1 クール1 通電2 クール2 通電3 クール3 通電4 クール4 通電5 クール5 保持
Hold
モニタ/異常
Monitor/Fault
CAUTION
Case of before Down-slope is Cool.
Run the down-slope sequentially to the weld of before. (Cool sequence does not run)
25 DENGENSHA
7 - 4. 14 impulse (free wave-form) welding
 RWCB-2000-B08-*
Start weld
(from Robot)
電極
Electrode
溶接電流
Weld Current
通電1 通電2 通電3 通電4 通電5 通電6 通電7 通電8 通電9 通電10 通電11 通電12 通電13 通電14 保持
Hold
自由通電区間（通電1～通電14）
Free waveform welding section (Weld-1 to Weld-14)
モニタ/異常
Monitor/Fault
 Refer to the clause of a "function" for the details of the 14 impulse (free wave-form) welding section.
26
DENGENSHA
8. Weld Parameters
Welding parameters are inputted by the robot teaching-pendant and can be managed by the robot
side.
8 - 1. Programming items
Symbol in the list shows each of 6 types of timer unit.
Symbol Timer unit Specification Board number
A00 RWCB-2000-A00-* 3 impulse welding PMU-0531-*
A05 RWCB-2000-A05-* 3 impulse welding ,All impulse current monitor PMU-0531-*
A07 RWCB-2000-A07-* 5 impulse welding PMU-0531-*
B02 RWCB-2000-B02-* 3 impulse welding, cable resistance check PMU-0547-*
B06 RWCB-2000-B06-A 5 impulse welding, cable resistance check PMU-0547-1
B08 RWCB-2000-B08-* 14 impulse welding, cable resistance check PMU-0547-*
W-5 Multi Impulse (5 impulse welding),
B11 RWCB-2000-B11-* PMU-0547-*
cable resistance check
(1). Schedule 1 - 255 (Weld Schedules) ※1

① RWCB-2000-A00,A05,A07,B02,B06,B11 (except for B08)
Item (item name used in “weld schedule”) Unit Initial Limits A00 A05 A07 B02 B06 B11
SQUEEZE CYC 50 0-100 ○ ○ ○ ○ ○ ○
A: 0-15
UP-SLOPE (Uslope) CYC 3 A A A A A B
B: 0-30
WELD 1 CYC 0 0-100 ○ ○ ○ ○ ○ ○
COOL 1 CYC 0 0-100 ○ ○ ○ ○ ○ ○
WELD 2 CYC 0 0-100 ○ ○ ○ ○ ○ ○
COOL 2 CYC 0 0-100 ○ ○ ○ ○ ○ ○
WELD 3 CYC 0 0-100 ○ ○ ○ ○ ○ ○
COOL 3 CYC 0 0-100 × × ○ × ○ ○
WELD 4 CYC 0 0-100 × × ○ × ○ ○
COOL 4 CYC 0 0-100 × × ○ × ○ ○
WELD 5 CYC 0 0-100 × × ○ × ○ ○
COOL 5 CYC 0 0-100 × × × × × ○
DOWN-SLOPE (Dslope) CYC 0 0-30 ○ ○ ○ ○ ○ ○
HOLD CYC 20 0-100 ○ ○ ○ ○ ○ ○
MULTI IMPULSE Time 1 1-10 ○ ○ × ○ × ×
WELD 2 MULTI IMPULSE
Time 1 1-10 × × ○ × ○ ○
(W-2 Multi impulse)
Time 1 1-10 × × ○ × ○ ○
(W-3 Multi impulse)
Time 1 1-10 × × ○ × ○ ○
(W-4 Multi impulse)
Time 1 1-10 × × × × × ○
(W-5 Multi impulse)
CURRENT 1 A 2000 2000-50000 ○ ○ ○ ○ ○ ○
CURRENT 2 A 2000 2000-50000 ○ ○ ○ ○ ○ ○
CURRENT 3 A 2000 2000-50000 ○ ○ ○ ○ ○ ○
CURRENT 4 A 2000 2000-50000 × × ○ × ○ ○
CURRENT 5 A 2000 2000-50000 × × ○ × ○ ○
HEAT 1 % 20 20-100 ○ ○ ○ ○ ○ ○
27 DENGENSHA
Item (item name used in “weld schedule”) Unit Initial Limits A00 A05 A07 B02 B06 B11
HEAT 2 % 20 20-100 ○ ○ ○ ○ ○ ○
HEAT 3 % 20 20-100 ○ ○ ○ ○ ○ ○
HEAT 4 % 20 20-100 × × ○ × ○ ○
HEAT 5 % 20 20-100 × × ○ × ○ ○
CURRENT HIGH LIMIT % 20 3-50 ○ ○ ○ ○ ○ ○
CURRENT LOW LIMIT % 20 3-50 ○ ○ ○ ○ ○ ○
HEAT HIGH LIMIT % 100 20-200 ○ ○ ○ ○ ○ ○
HEAT LOW LIMIT % 100 10-100 ○ ○ ○ ○ ○ ○
TRANS TURNS 200.0 1.0-200.0 ○ ○ ○ ○ ○ ○
CURRENT CTRL ※2
A: 0-1
A: V/C 1 A A A B B B
B: 0-2
B: V/C/S
MAX CURRENT A 20000 2000-60000 ○ ○ ○ ○ ○ ○
STEP 1 CURRENT % 100 50-200 ○ ○ － ○ －－
STEP 2 CURRENT % 100 50-200 ○ ○ － ○ －－
STEP 3 CURRENT % 100 50-200 ○ ○ － ○ －－
STEP 4 CURRENT % 100 50-200 ○ ○ － ○ －－
STEP 5 CURRENT % 100 50-200 ○ ○ － ○ －－
STEP 6 CURRENT % 100 50-200 ○ ○ － ○ －－
STEP 7 CURRENT % 100 50-200 ○ ○ － ○ －－
STEP 8 CURRENT % 100 50-200 ○ ○ － ○ －－
STEP 9 CURRENT % 100 50-200 ○ ○ － ○ －－
GUN No 1 1-4 ○ ○ ○ ○ ○ ○
A: 1-3
MONITOR IMPULSE 1 A A B A B B
B: 1-5
SC CURRENT LIMIT A 2000 2000-50000 × × × ○ ○ ○
※1： Schedule 255 of B02, B06, B08 and B11 setting is the fixed value for transformer
leak-current check function.
※2： V : Voltage Compensation, C : Constant current control, S : Special current control
－：Function is existing but setting area is replaced to other schedule.
② B08 (RWCB-2000-B08-*)
Please refer to “weld schedule” and "Function" clause “14 impulse welding" clause.
Item (item name used in “weld schedule”) Unit Initial Limits B08
SQUEEZE CYC 50 0-100 ○
UP-SLOPE (Uslope) CYC 3 0-15 ○
WELD 1 / COOL 1 (Weld-1) CYC 0 0-100 ○
WELD 4 / COOL 4 (Weld 4) CYC 0 0-100 ○
28 DENGENSHA
Item (item name used in “weld schedule”) Unit Initial Limits B08
DOWN-SLOPE (Dslope) CYC 0 0-30 ○
WELD 3-4 MULTI IMPULSE (Multi impulse) Time 1 1-10 ○
CURRENT 1 / SC LIMIT ※3 A 0 0-50000 ○
CURRENT 2 A 0 0-50000 ○
CURRENT 3 A 0 0-50000 ○
CURRENT 4 A 0 0-50000 ○
CURRENT 5 A 0 0-50000 ○
CURRENT 6 A 0 0-50000 ○
CURRENT 7 A 0 0-50000 ○
CURRENT 8 A 0 0-50000 ○
CURRENT 9 A 0 0-50000 ○
CURRENT 10 A 0 0-50000 ○
CURRENT 11 A 0 0-50000 ○
CURRENT 12 A 0 0-50000 ○
CURRENT 13 A 0 0-50000 ○
CURRENT 14 A 0 0-50000 ○
CURRENT HIGH LIMIT % 20 3-50 ○
CURRENT LOW LIMIT % 20 3-50 ○
TRANS TURNS 200.0 1.0-200.0 ○
CURRENT CTRL ※2
1 0-2 ○
V/C/S
MAX CURRENT A 60000 2000-60000 ○
GUN No 1 1-4 ○
MONITOR IMPULSE 1 1-14 ○
※2：V : Voltage Compensation, C : Constant current control, S : Special current control
※3：In case of "Special current control", setting data of this item becomes "special control
current limit (SC current limit)".
(2). Sequence C (Common sequence)

Item Unit Initial Limits A00 A05 A07 B02 B06 B08 B11
WELD TIME COMP CYC 0 0-50 ○ ○ ○ ○ ○ ○ ○
WELD TIME SHORT CYC 0 0-50 ○ ○ ○ ○ ○ ○ ○
WELD TIME LIMIT CYC 1000 10-1000 ○ ○ ○ ○ ○ ○ ○
REF LINE VOLT V 400 100-1000 ○ ○ ○ ○ ○ ○ ○
LINE VOLT HIGH LIMIT % 20 5-50 ○ ○ ○ ○ ○ ○ ○
LINE VOLT LOW LIMIT % 20 5-50 ○ ○ ○ ○ ○ ○ ○
W-CUR FAULT LIMIT % 30 10-50 ○ ○ ○ ○ ○ ○ ○
OVER CURRENT LIMIT % - 100-150 △ △ △ △ △ △ △
LOW LIMIT. FIX μΩ 0 0-2000 × × × ○ ○ ○ ○
HIGH LIMIT. FIX μΩ 0 0-2000 × × × ○ ○ ○ ○
LOW LIMIT. MOV μΩ 0 0-2000 × × × ○ ○ ○ ○
HIGH LIMIT. MOV μΩ 0 0-2000 × × × ○ ○ ○ ○
LOW LIMIT. 01 μΩ 0 0-20000 × × × ○ ○ ○ ○
29 DENGENSHA
HIGH LIMIT. 01 μΩ 0 0-20000 × × × ○ ○ ○ ○
LOW LIMIT. 03 μΩ 0 0-20000 × × × ○ ○ ○ ○
HIGH LIMIT. 03 μΩ 0 0-20000 × × × ○ ○ ○ ○
△：There is a configuration item, but cannot use because not supported.
(3). Sequence S (Special Function)

Item Initial Limits A00 A05 A07 B02 B06 B08 B11
REWELD OFF OFF/ON ○ ○ ○ ○ ○ ○ ○
FAULT RESET BY PILOT OFF OFF/ON ○ ○ ○ ○ ○ ○ ○
A:ALARM ALARM
ALARM LEVEL A A A A A F F
F:FAULT /FAULT
OFF/STEP
STEPPER OFF ○ ○ ○ ○ ○ ○ ○
/LINEAR
TOROID SENSITIVITY ※4 STD STD/ISO ○ ○ ○ ○ ○ ○ ○
NO USE - - △ △ △ △ △ △ △
NO USE - - △ △ △ △ △ △ △
FIX CABLE RESISTANCE OFF OFF/ON × × × ○ ○ ○ ○
MOV CABLE RESISTANCE OFF OFF/ON × × × ○ ○ ○ ○
ELECTRODE TIP STUCK OFF OFF/ON × × × ○ ○ ○ ○
CABLE RESISTANCE SELECT PRI PRI/SEC × × × ○ ○ ○ ○
01 CABLE RESISTANCE OFF OFF/ON × × × ○ ○ ○ ○
03 CABLE RESISTANCE OFF OFF/ON × × × ○ ○ ○ ○
CURRENT AREA MONITOR OFF OFF/ON × × × × × ※5 ×
※4：Toroidal sensitivity selection applies to toroidal detection (optional) only.
※5：Please refer to the "Function" chapter "14 impulse (free wave-form) welding" clause.
(4). Sequence G1 - 4 (Number of welds for Gun 1 - 4 independently)

TIP DRESS COUNT 0 0-50000 ○ ○ ○ ○ ○ ○ ○
TIP CHANGE COUNT 0 0-50000 ○ ○ ○ ○ ○ ○ ○
STEPPER STEP 0 COUNT 0 0-1000 ○ ○ ○ ○ ○ ○ ○
STEP 1 CURRENT % 100 50-200 －－ ○ － ○ ○ ○
STEP 2 CURRENT % 100 50-200 －－ ○ － ○ ○ ○
STEP 3 CURRENT % 100 50-200 －－ ○ － ○ ○ ○
STEP 4 CURRENT % 100 50-200 －－ ○ － ○ ○ ○
STEP 5 CURRENT % 100 50-200 －－ ○ － ○ ○ ○
STEP 6 CURRENT % 100 50-200 －－ ○ － ○ ○ ○
30 DENGENSHA
STEP 7 CURRENT % 100 50-200 －－ ○ － ○ ○ ○
STEP 8 CURRENT % 100 50-200 －－ ○ － ○ ○ ○
STEP 9 CURRENT % 100 50-200 －－ ○ － ○ ○ ○
REV HI CUR LIM SETTING A 5000 2000-50000 × × × × × ※5 ×
REV LO CUR LIM SETTING A 5000 2000-50000 × × × × × ※5 ×
REV HI CUR LIM MEASURE A 5000 2000-50000 × × × × × ※5 ×
REV LO CUR LIM MEASURE A 5000 2000-50000 × × × × × ※5 ×
AREA MON-A HI CUR BORDER A 50000 2000-50000 × × × × × ※5 ×
AREA MON-A LO CUR BORDER A 2000 2000-50000 × × × × × ※5 ×
AREA MON-A CUR HI LIMIT % 20 3-50 × × × × × ※5 ×
AREA MON-A CUR LO LIMIT % 20 3-50 × × × × × ※5 ×
AREA MON-B HI CUR BORDER A 50000 2000-50000 × × × × × ※5 ×
AREA MON-B LO CUR BORDER A 2000 2000-50000 × × × × × ※5 ×
AREA MON-B CUR HI LIMIT % 20 3-50 × × × × × ※5 ×
AREA MON-B CUR LO LIMIT % 20 3-50 × × × × × ※5 ×
AREA MON-C HI CUR BORDER A 50000 2000-50000 × × × × × ※5 ×
AREA MON-C LO CUR BORDER A 2000 2000-50000 × × × × × ※5 ×
AREA MON-C CUR HI LIMIT % 20 3-50 × × × × × ※5 ×
AREA MON-C CUR LO LIMIT % 20 3-50 × × × × × ※5 ×
HEAT HIGH LIMIT % 100 20-200 －－－－－ ○ －
HEAT LOW LIMIT % 10 10-100 －－－－－ ○ －
※5：Please refer to the "Function" chapter "14 impulse (free wave-form) welding" clause.
－：Set in other schedule. (Functionality is same.)
8 - 2. Description of programming items (welding schedules and function setting)

 Programming is accomplished using the robot teaching-pendant.
(1) Schedule 1～255 (Weld Schedules)
Set for each weld schedule of 1-255. Please refer to the charts in “Weld schedule” clause.
Time control
① SQUEEZE ：0 - 100 [cyc]
② UP-SLOPE (Uslope) A ：0 - 15 [cyc]
B ：0 - 30 [cyc]
③ WELD TIME
WELD 1 ：0 - 100 [cyc]
WELD 2 ：0 - 100 [cyc]
WELD 3 ：0 - 100 [cyc]
WELD 4 ：0 - 100 [cyc] *5 impulse welding only
WELD 5 ：0 - 100 [cyc] *5 impulse welding only
④ COOL TIME
COOL 1 ：0 - 100 [cyc]
COOL 2 ：0 - 100 [cyc]
COOL 3 ：0 - 100 [cyc]
COOL 4 ：0 - 100 [cyc] * 5 impulse welding only
COOL 5 ：0 - 100 [cyc] * W-5 multi impulse only
31 DENGENSHA
⑤ WELD/ COOL
It is available only in 14 impulse welding specification.
WELD n / COOL n becomes welding when CURRENT n setting value is “1” or more,
and also becomes cool when CURRENT n setting value is "0".
WELD 1 / COOL 1(Weld-1) ：0 - 100 [cyc]
⑥ DOWN-SLOPE (Dslope) ：0 - 30 [cyc]

⑦ HOLD ：0 - 100 [cyc]
⑧ MULTI IMPULSE
MULTI IMPULSE ：1 - 10 [Time]
Multi impulse repeats WELD 2 and COOL 2 by setting times.
WELD 2 MULTI IMPULSE ：1 - 10 [Time]

Multi impulse repeats each of WELD and COOL by setting times.

It is available only in W-5 Multi impulse (5 impulse welding) specification.
Multi impulse repeats each of WELD and COOL by setting times.
WELD 3-4 MULTI IMPULSE ：1 - 10 [Time]

Multi impulse repeats WELD 3/COOL 3 and WELD 4/COOL 4 by setting
times.
Weld current and others

⑨ CURRENT/HEAT CURRET/HEAT-4,5 are available in 5 impulse welding
Please set CURRENT (A) when current control method is "constant current".
Please set Heat (%) when current control method is "voltage compensation".
CURRENT 1 ：2000 - 50000 [A] (for Constant current)
32 DENGENSHA
HEAT 1 ：20 - 100 [%] (for Voltage Compensation)
⑩ CURRENT
WELD n/COOL n becomes welding when CURRENT n setting value is "1" or more,
and also becomes cool when CURRENT n setting value is "0".
Please input current value even if current control method is "voltage compensation".
Current value is automatically divided by "Maximum current" and converted to heat%
value.
CURRENT 1 becomes current limit value when current control method is "2 (Special
current control)".
CURRENT 1 / SC LIMIT ：0 - 50000 [A]
CURRENT 2 ：0 - 50000 [A]
CURRENT 3 ：0 - 50000 [A]
CURRENT 4 ：0 - 50000 [A]
CURRENT 5 ：0 - 50000 [A]
CURRENT 6 ：0 - 50000 [A]
CURRENT 7 ：0 - 50000 [A]
CURRENT 8 ：0 - 50000 [A]
CURRENT 9 ：0 - 50000 [A]
CURRENT 10 ：0 - 50000 [A]
CURRENT 11 ：0 - 50000 [A]
CURRENT 12 ：0 - 50000 [A]
CURRENT 13 ：0 - 50000 [A]
CURRENT 14 ：0 - 50000 [A]
⑪ CURRENT HIGH LIMIT ：3 - 50 [%]

Please set fault detection level of “CURRENT HIGH” (150) fault.
⑫ CURRENT LOW LIMIT ：3 - 50 [%]
Please set fault detection level of “CURRENT LOW” (100) fault.
⑬ HEAT HIGH LIMIT ：20 - 200 [%]

Please set fault detection level of “HEAT% HIGH” (250) fault.
⑭ HEAT LOW LIMIT ：10 - 100 [%]
Please set fault detection level of “HEAT% LOW” (200) fault.
⑮ TRANS TURNS ：1.0 - 200.0

Please set the turn number of the welding transformer.
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⑯ CUR CTRL V/C/S A ：0 / 1
B ：0 / 1 / 2
Please choose current control method.
0 (V) : Voltage Compensation control
1 (C) : Constant Current control
2 (S) : Special Current control
⑰ MAX CURRENT ：2000 - 60000 [A]

Please set the measured actual maximum short current value of the welding gun.
⑱ STEP n CURRENT n=1 thru 9 ：50 - 200 [%]

Please set current increase ratio of “Current stepper” function.
Current stepper function increases weld current by this setting ratio.
When setting value is 100%, current stepper function does not increase weld current
anymore and keeps the setting current of weld schedule.
Current increase ratio of step 0 is fixed to 100%.
⑲ GUN No ：1 - 4
Please choose one of sequence G1-4.
Each weld schedule is available to choose one of sequence G1-4 for gun change.
Sequence G1-4 includes settings of stepper function, current monitor and current
linearity compensation individually.
⑳ MONITOR IMPULSE A ：1 - 3
B ：1 - 5
C ：1 - 14
Please set impulse number (WELD n) which should be checked by WELD
CURRENT HIGH, WELD CURRENT LOW, HEAT% HIGH, HEAT% LOW and
TIME FAULT. (Only specified number of impulse is checked)
When only Weld1 is available but setting was 2 (WELD 2), WELD 1 is checked
automatically.
EXCEPTIONS:
A05: All of 3 impulse are monitored (checked).
B08: Current band monitor is also available.
※ Please refer to “Functions” clause for details
◯
21 SC CURRENT LIMIT ：2000 - 50000 [A]
Please set the current limit value of WELD1 when current control method is "2
(Special current control). SC CURRENT LIMIT and SC LIMIT is the same item.
※ Please refer to “Functions” clause for details
(2) Sequence C (Common sequence)

Those setting items are common item for all welding schedules.
① WELD TIME COMP ：0 - 50 [cyc]
Please set compensation limit time.
Timer compensates actual lack of weld time up to this setting time.
When setting value was 3 cycle and actual weld time lack is more than 4 cycle, timer
extends 3 cycle of weld time.
34 DENGENSHA
② WELD TIME SHORT ：0 - 50 [cyc]
Please set TIME FAULT (520) detection time.
Timer unit detects this fault when total time of weld lack is larger than this setting
value. Timer does not count upslope and down slope time neither lack nor weld time.
③ WELD TIME LIMIT ：10 - 1000 [cyc]

Please set TOTAL W-TIME LONG (370) fault detection time.
Timer unit detects this fault when total welding time setting including up-slope and
down-slope is longer than this setting value.
④ REF LINE VOLT ：100 - 1000 [V]

Please set rated line voltage. Mismatch data causes wrong voltage monitor.
⑤ LINE VOLT HIGH LIMIT ：5 -50 [%]

Please set LINE VOLTAGE HIGH (410) fault detection volt.
⑥ LINE VOLT LOW LIMIT ：5 - 50 [%]
Please set LINE VOLTAGE LOW (400) fault detection volt.
⑦ W-CUR FAULT LIMIT ：10 - 50 [%]

Please set LINE CURRENT FAULT (510) fault detection ratio.
Timer unit detects this fault when actual current of monitor impulse is lower than
setting current and its current difference ratio is larger than this setting value.
It is recommendable this setting value is larger than CURRENT LOW LIMIT of each
weld schedule.
⑧ OVER CURRENT LIMIT ：100 - 150 [%]

It is not available now.
Cable resistance check

⑨ LOW LIMIT FIX ：0 - 2000 [μΩ]
Please set WIRE BROKEN 01/FIX (780) fault detection resistance.
Timer unit detects this fault when actual resistance of secondary fix side cable is lower
than this setting value.
⑩ HIGH LIMIT FIX ：0 - 2000 [μΩ]
Please set OVER RESISTANCE 01/FIX (790) fault detection resistance.
Timer unit detects this fault when actual resistance of secondary fix side cable is larger
than this setting value.
⑪ LOW LIMIT MOV ：0 - 2000 [μΩ]
Please set WIRE BROKEN 03/MOV (781) fault detection resistance.
Timer unit detects this fault when actual resistance of secondary movable side cable is
lower than this setting value.
⑫ HIGH LIMIT MOV ：0 - 2000 [μΩ]
Please set OVER RESISTANCE 03/MOV (791) fault detection resistance.
Timer unit detects this fault when actual resistance of secondary movable side cable is
larger than this setting value.
35 DENGENSHA
⑬ LOW LIMIT 01 ：0 - 20000 [μΩ]
Please set WIRE BROKEN 01/FIX (780) fault detection resistance.
Timer unit detects this fault when actual resistance of primary 01 cable is lower than
this setting value.
⑭ HIGH LIMIT 01 ：0 - 20000 [μΩ]
Please set OVER RESISTANCE 01/FIX (790) fault detection resistance.
Timer unit detects this fault when actual resistance of primary 01 cable is larger than
this setting value.
⑮ LOW LIMIT 03 ：0 - 20000 [μΩ]
Please set WIRE BROKEN 03/MOV (781) fault detection resistance.
Timer unit detects this fault when actual resistance of primary 03 cable is lower than
this setting value.
⑯ HIGH LIMIT 03 ：0 - 20000 [μΩ]
Please set OVER RESISTANCE 03/MOV (791) fault detection resistance.
Timer unit detects this fault when actual resistance of primary 03 cable is larger than
this setting value.
(3) Sequence S (Special Functions)

Those setting items are common to all welding schedules.
① REWELD ：OFF/ON
When this setting is ON, and in case of following error, timer waits 50cycle and then
starts welding once again automatically and error output is kept OFF.
ON : Welding is repeated.
OFF : Welding is not repeated.
 Applicable faults
CURRENT LOW, HEAT% HIGH, TIME FAULT, NO CURRENT,
CURRENT FAULT
② FAULT RESET BY PILOT ：OFF/ON

When this setting is ON, start input resets fault instead of fault reset input and timer
starts next welding.
Exception faults are major errors and thermo error. These errors should reset from
program box or reset input.
ON : Reset start carried out.
OFF : Reset start not carried out.
 Applicable faults
Ordinary faults
Error of only a warning (ex. stepper completion, etc.)
③ ALARM LEVEL ：ALARM/FAULT

Timer fault stops robot, but timer alarm does not stop robot.
This setting is available to change timer alarm to fault.
Exception
STEP COMP., TIP DRESS COMP., and TIP CHANGE COMP are fixed to alarm.
36 DENGENSHA
④ STEPPER ：OFF/STEP/LINEAR
This setting is for choice of stepper type, step up or linear up.
When this setting is OFF, stepper function is not available.
OFF : Not used
STEP : Step up
LINEAR : Linear up
⑤ TOROIDAL SENSITIVITY ：STD/ISO

This setting is a choice of toroidal coil type.
STD : Set when using DG standard coil (230mV / 1,000A)
ISO : Set when using ISO standard coil (Not available for this unit)
※ Effective only toroidal detection model
Cable resistance check

⑥ FIX CABLE RESISTANCE ：OFF/ON
This setting is a choice of secondary fixed side cable resistance detection.
OFF : Not to be detected
ON : To be detected
⑦ MOV CABLE RESISTANCE ：OFF/ON
This setting is a choice of secondary movable side cable resistance detection.
ON : To be detected
⑧ ELECTRODE TIP STUCK ：OFF/ON
This setting is a choice of detecting tip adhesion.
ON : To be detected
⑨ CABLE RESISTANCE ：PRI/SEC
Please select of cable resistance detection of primary and secondary.
PRI : Primary side cable resistance detection
SEC : Secondary side cable resistance detection
⑩ 01 CABLE RESISTANCE ：OFF/ON
This setting is a choice of primary 01 cable resistance detection.
ON : To be detected
⑪ 03 CABLE RESISTANCE ：OFF/ON
This setting is a choice of primary 03 cable resistance detection.
ON : To be detected
Current band monitor

⑫ CURRENT AREA MONITOR ：OFF/ON
It is available only 14 impulse welding specification.
This setting is a choice of Current band monitor function.
OFF : Not use (MONITOR IMPULSE is available)
ON : Use (Current band monitor is available)
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(4) Sequence G1 - 4 (Gun 1 - 4 individual)
① TIP DRESS COUNT ：0 - 50000 [weld point]
② TIP CHANGE COUNT ：0 - 50000 [weld point]
③ STTEPER STEP n COUNT n=0 thru 9 ：0 - 1000 [weld point]

This setting is spot weld count for each step 0 thru 9.
④ STEP n CURRENT n=1 thru 9 ：50 - 200 [%]
When setting value is 100%, current stepper function does not increase weld current
anymore and keeps the setting current of weld schedule.
Current linearity compensation (2 points calibration)

⑤ REV HI CUR LIM SETTING (Calibration base high side) ：2000 - 50000 [A]
Input area of the weld schedule current setting value of high side.
⑥ REV LO CUR LIM SETTING (Calibration base low side) ：2000 - 50000 [A]
Input area of the weld schedule current setting value of low side.
⑦ REV HI CUR LIM MEASURE (Measuring current of high side)：2000 - 50000 [A]
Input area of the measuring current value of the high side.
⑧ REV LO CUR LIM MEASURE (Measuring current of low side)：2000 - 50000 [A]
Input area of the measuring current value of the low side.
Current band monitor

⑨ AREA MON-A HI CUR BORDER ：2000 - 50000 [A]
Please set upper border current of monitor area-A.
⑩ AREA MON-A LO CUR BORDER ：2000 - 50000 [A]
Please set lower border current of monitor area-A.
⑪ AREA MON-A CUR HI LIMIT ：3 - 50 [%]
Please set current high limit ratio of monitor area-A.
⑫ AREA MON-A CUR LO LIMIT ：3 - 50 [%]
Please set current low limit ratio of monitor area-A.
⑬ AREA MON-B HI CUR BORDER ：2000 - 50000 [A]
Please set upper border current of monitor area-B.
⑭ AREA MON-B LO CUR BORDER ：2000 - 50000 [A]
Please set lower border current of monitor area-B.
⑮ AREA MON-B CUR HI LIMIT ：3 - 50 [%]
Please set current high limit ratio of monitor area-B.
⑯ AREA MON-B CUR LO LIMIT ：3 - 50 [%]
Please set current low limit ratio of monitor area-B.
⑰ AREA MON-C HI CUR BORDER ：2000 - 50000 [A]
Please set upper border current of monitor area-C.
⑱ AREA MON-C LO CUR BORDER ：2000 - 50000 [A]
Please set lower border current of monitor area-C.
⑲ AREA MON-C CUR HI LIMIT ：3 - 50 [%]
Please set current high limit ratio of monitor area-C.
⑳ AREA MON-C CUR LO LIMIT ：3 - 50 [%]
Please set current low limit ratio of monitor area-C.
38 DENGENSHA
Other items
◯
21 HEAT HIGH LIMIT ：20- 200 [%]
Please set HEAT % HIGH (250) fault detection ratio.
Timer unit detects this fault when any of actual heat % in welding is higher than this
setting value.
◯
22 Heat lower limit (HEAT LOW LIMIT) ：10 - 100 [%]
Please set HEAT % LOW (200) fault detection ratio.
Timer unit detects this fault when any of actual heat % in welding is lower than this
setting value.
9. Hardware gain
Hardware gain is the adjustment setting of each timer unit, and stored in the flash memory on the
timer board (PMU-0531/PMU-0547).
(1) Sequence H (Hardware Gain)

Item Unit Initial※6 Limits A00 A05 A07 B02 B06 B08 B11
PRIM-CT GAIN - 10000 7500-12500 ○ ○ ○ ○ ○ ○ ○
2 ND-TOROID GAIN - 10000 7500-12500 ○ ○ ○ ○ ○ ○ ○
LINE VOLT GAIN - 10000 7500-12500 ○ ○ ○ ○ ○ ○ ○
CURRENT BALANCE - 10000 7500-12500 × × × × × × ○
TIP RESISTANCE GAIN - 10000 7500-12500 △ △ △ ○ ○ ○ ○
FIX RESISTANCE GAIN - 10000 7500-12500 △ △ △ ○ ○ ○ ○
MOV RESISTANCE GAIN - 10000 7500-12500△ △ △ ○ ○ ○ ○
※6：Adjusted at factory, and described the adjustment value on the timer unit.
10. Monitor function

 Contents of monitoring can be displayed on the robot teaching-pendant and can be managed
altogether by the robot.
 FAULT 1 - 4 displayed faults of the last weld that occurred at the same time.
(1) Sequence M (Monitor function)
Item Unit A00 A05 A07 B02 B06 B08 B11
PART ID - ○ ○ ○ ○ ○ ○ ○
WELD ID - ○ ○ ○ ○ ○ ○ ○
SCHEDULE No. - ○ ○ ○ ○ ○ ○ ○
WELD CURRENT A ○ ○ ○ ○ ○ ※7 ※7
WELD TIME CYC ○ ○ ○ ○ ○ ※7 ※7
HEAT % ○ ○ ○ ○ ○ ○ ○
POWER FACTOR % ○ ○ ○ ○ ○ ○ ○
LINE VOLT V ○ ○ ○ ○ ○ ○ ○
GUN No. - ○ ○ ○ ○ ○ ○ ○
39 DENGENSHA
Item Unit A00 A05 A07 B02 B06 B08 B11
TIP DRESS COUNT - ○ ○ ○ ○ ○ ○ ○
TIP CHANGE COUNT - ○ ○ ○ ○ ○ ○ ○
STEP No - ○ ○ ○ ○ ○ ○ ○
WELDS COUNT - ○ ○ ○ ○ ○ ○ ○
FIX RESISTANCE μΩ △ △ △ ○ ○ ○ ○
MOV RESISTANCE μΩ △ △ △ ○ ○ ○ ○
TIP RESISTANCE μΩ △ △ △ △ △ △ △
EXPANSION - △ △ △ △ △ △ ×
01 RESISTANCE μΩ × × × ○ ○ ○ ○
03 RESISTANCE μΩ × × × ○ ○ ○ ○
WELD 1 CURRENT A × × × × × ○ ※8
WELD 2 CURRENT A × × × × × ○ ※8
WELD 3 CURRENT A × × × × × ○ ※8
WELD 4 CURRENT A × × × × × ○ ※8
WELD 5 CURRENT A × × × × × ○ ※8
WELD 6 CURRENT A × × × × × ○ ×
WELD 10 CURRENT A × × × × × ○ ×
WELD 11 CURRENT A × × × × × ○ ×
WELD 12 CURRENT A × × × × × ○ ×
WELD 13 CURRENT A × × × × × ○ ×
WELD 14 CURRENT A × × × × × ○ ×
WELD 1 TIME CYC × × × × × × ※8
WELD 2 TIME CYC × × × × × × ※8
WELD 3 TIME CYC × × × × × × ※8
WELD 4 TIME CYC × × × × × × ※8
WELD 5 TIME CYC × × × × × × ※8
FAULT 1 ○ ○ ○ ○ ○ ○ ○
FAULT 2 ○ ○ ○ ○ ○ ○ ○
FAULT 3 ○ ○ ○ ○ ○ ○ ○
FAULT 4 ○ ○ ○ ○ ○ ○ ○
※7：current of the weld number that number is specified by "MONITOR IMPULSE".
※8：The monitored value are display, but they are not judgment item of faults.
40 DENGENSHA
11. Functions
11 - 1. Current Stepper
This is a function that gradually increases current corresponding to weld count.
When weld count increases deformation and expansion of welding tip occurs. This causes weakening
of welding strength. Linear/Step-up function prevents weakening of welding strength.
Step-up increase is made step by step, and Linear-up change is made linearly towards set ratio of
increase as its target value.
(1) STEPPER ：OFF/STEP/LINEAR

Set in the sequence C (Common sequence)
This setting is for choice of stepper type, step up or linear up.
(2) STEP n CURRENT (1-9) ：50 - 200 [%]

Current increase ratio step 1 thru 9 setting is current increase ratio of each step.
 Stepper current (1-9) are available to set in each of 255 (254) schedules individually.
Except RWCB-2000-B06-A, RWCB-2000-B08-* and RWCB-2000-B11-*
Set the current rise rate of 1 to 9 steps at each welding conditions.
 Stepper current (1-9) are available to set in each of G1-4 individually.
RWCB-2000-B06-A, RWCB-2000-B08-* and RWCB-2000-B11-*
Sequence G1-4 includes Current rise rate (1-9), and each of 255 schedules is available
to choose one of gun No.1-4.
When setting value is 100%, current stepper function does not increase weld current anymore
and keeps the setting current of weld schedule.
(3) STTEPER STEP n COUNT (0-9) ：0 - 1000 [weld point]

Sequence G1-4 includes Stepper count (0-9) and each of 255 schedules is available to choose
one of gun No.1-4.
This setting is spot weld count for each step 0 thru 9.
41 DENGENSHA
11 - 2. Transformer short-circuit detection
It is available with RWCB-2000-B02-*, RWCB-2000-B06-A, RWCB-2000-B08-* and
RWCB-2000-B11-*
(1) Operation
Start the 255 schedule while gun open for inspection. This should be open circuit. Short
circuit causes current. Timer outputs LEAK DETECT(680) fault by detecting this current.
(2) Setting
Fix value has been set to the 255th schedule automatically.
Fix value setting for welding
Squeeze ：1 [cyc]
Weld1 ：1 [cyc]
Hold ：1 [cyc]
Current1 ：20 [%] (Voltage Compensation control)
Level of current detection cannot be changed. When current is detected, the fault is output.
11 - 3. Current Control method

Current control mode includes constant current control, voltage compensation control and constant
power control. Select a control mode suited to operational condition.
There is the control method that cannot be used depending on the model.
(1) Setting item

Schedule 1 - 255 (Weld Schedules)
CURRENT CTRL
A: 0-1
A: V/C - 1 A A A B B B B
B: 0-2
B: V/C/S
SC CURRENT LIMIT A 2000 2000-50000 × × × ○ ○ － ○
CURRENT-1/SC LIMIT A 0 0-50000 × × × －－ ○ －
V: Voltage Compensation, C: Constant current control, S: Special current control
(2) Constant current control

Current feedback is measured every half cycle, and the next cycle firing angle to apply current
close to designated current value is calculated based on this data. Therefore, high-speed
response to changes in line voltage and load becomes possible.
① Current setting：Directly set current value.
Setting unit ：100 [A]
Setting range ：2000 - 50000 [A]
② Trans turns ratio：Set the transformer turns ratio
③ Factors compensated：Line voltage and load change
(3) Voltage compensation control

When welding (applying current) with multiple guns such as multi-gun, select voltage
compensation.
① Current setting：Set by taking full current application value at rated voltage as 100%.
Setting range ：20 - 100 [%]
② Trans turns ratio：Not required
③ Factors compensated：Line voltage only
42 DENGENSHA
(4) Special Current Control
It is available with RWCB-2000-B02-*, RWCB-2000-B06-A, RWCB-2000-B08-* and
RWCB-2000-B11-*
This function is designed to remove dirt on the work piece or dust on the chip without
expulsion at weld-1 and stabilizing weld-2 and weld3.
In this control method, weld-1 is heat control mode with current limit to avoid expulsion,
weld-2 and weld-3 is constant current mode.
Current control mode setting as:

Set to “0” ：V(Voltage Compensation control)
→ Voltage compensation control applies to all welding.
Set to “1” ：C (Constant Current control)
→ Constant current control applies to all wattages.
Set to “2” ：S (Special Current control)
→ Voltage compensation control applies to the upslope, heat control with current
limits applies to weld1, and constant current control to applies to weld2 and weld3 and
the down-slope.
① Instructions
Please weld actual work-piece by only WELD 1 constant current mode with usual
current or more 10% and time to get actual HEAT% data. Please set this actual
HEAT% data to HEAT 1, and set CURRENT 1 data to SC CURRENT LIMIT (or
CURRENT 1/SC-LIMIT) and also set usual current to CURRENT 2.
It is a recommended that WELD 1 is short time, higher current, short COOL 1 time,
WELD 2 is usual time and current, monitor impulse setting is 2.
Please tune up setting data by test welding.
② Restrictions
If there is an up-slope, voltage compensation control applies to the up-slope, and heat
control with current limits applies to weld1. Constant current control applies to the
subsequent portions.
Up W1 W2 W3 Dw
V S C C C
When weld2 and weld3 are set to 0cyc, voltage compensation control applies to the
up-slope, weld1 and the down-slope.
Up W1 Dw
V V V
When weld1 is set to 0cyc, constant current control applies to the up-slope, weld2 and
weld3, and the down-slope.
Up W2 W3 Dw
C C C C
43 DENGENSHA
11 - 4. All impulse current monitor
It is available with RWCB-2000-A05-*
(1) Specification
Timer unit monitors all impulse, and checks WELD CURRENT HIGH, WELD CURRENT
LOW, HEAT% HIGH, HEAT% LOW and TIME FAULT.
(2) Monitor display value

WELD CURRENT value of monitor is the good actual value of the specified impulse while
all welding is good, it changes actual over limit current of the fault impulse while any of
impulse is no good.
e.g.) Setting MONITOR IMPULSE: 2
Actual current of weld-1 is under low limit, actual current of weld-2 is good.
WELD CURRENT value of Monitor: actual current of weld-1
It is available with RWCB-2000-B06-A and RWCB-2000-A07-*
Standard specification was extended, and the following item was added.
 5 pulse welding (weld pulse added)
 Multi impulse was weld 2,3 and 4.
(1) Weld Schedule of the 5 impulse welding
Start weld
(from Robot)
電極
Electrode

通電1 クール1 通電2 クール2 通電3 クール3 通電4 クール4 通電5 保持

Hold
モニタ/異常
Monitor/Fault
(2) Monitor value at MULTI IMPULSE

When specified monitor impulse repeats multi impulse, weld current and weld time of
monitor is an average current and time of multi impulse.
44 DENGENSHA
11 - 6. W-5 Multi Impulse (5 impulse welding)
It is available with RWCB-2000-B11*
Standard specification was extended, and the following item was added.
 5 pulse welding (weld pulse added)
 Multi impulse was weld 2,3,4 and 5.
 The number of setting cycles of up-slope was increased.
 Monitoring of the welding current and the weld time of all sequence are possible. (but
they are not judgment item of faults.)
(1) Weld Schedule of the W-5 Multi Impulse (5 impulse welding)
Start weld
(from Robot)
電極
Electrode

通電1 クール1 通電2 クール2 通電3 クール3 通電4 クール4 通電5 クール5 保持
Hold
モニタ/異常
Monitor/Fault
(2) Monitor value at MULTI IMPULSE

When specified monitor impulse repeats multi impulse, weld current and weld time of
monitor is an average current and time of multi impulse.
(3) Case of before Down-slope is Cool.

Run the down-slope sequentially to the weld of before. (Cool sequence does not run)
45 DENGENSHA
11 - 7. 14 impulse (free wave-form) welding
It is available with RWCB-2000-B08-*
Various welding patterns can be made.
(1) Weld Schedule of 14 impulse (free wave-form) welding
Start weld (from Robot)
電極
Electrode
溶接電流
Weld Current
通電1 通電2 通電3 通電4 通電5 通電6 通電7 通電8 通電9 通電10 通電11 通電12 通電13 通電14 保持
Hold
自由通電区間（通電1～14）
Free waveform welding section •iWeld-1 •`Weld-14•j
モニタ/異常
Monitor/Fault
(2) Choice of weld and cool

WELD n / COOL n becomes welding when CURRENT n setting value is “1” or more, and
also becomes cool when CURRENT n setting value is "0".
Operating Setting
When welding time is more than [1] cycle, and a current value is not [0]A
Weld
(Lowest welding current is heat% 20% even if current setting is less than that.)
Cool Welding time is [1] cycle or more, and welding current is [0]A.
skipped Welding time is [0] cycle
(3) Current setting

Input current value even if current control method is "voltage compensation". Current value is
automatically divided by "Maximum current" and converted to heat% value.
Target HEAT% ＝ Weld current value／Max current setting value×100 (%)
(4) Monitor method

There are two monitor methods. One is "MONITOR IMPULSE" another is "current band
monitor" (CURRENT AREA MONITOR).
Current band monitor includes 3 monitoring current band and each band has a high limit and
low limit individually.
(a) Selection of method

Sequence S (Special Function)
Item Initial Limits B08
CURRENT AREA MONITOR OFF OFF/ON ○
This setting is a choice of Current band monitor function.
OFF：Not use (MONITOR IMPULSE is available)
ON：Use (Current band monitor is available)
46 DENGENSHA
(b) MONITOR IMPULSE
Please set impulse number (WELD-n) which should be checked by WELD
CURRENT HIGH, WELD CURRENT LOW, HEAT% HIGH, HEAT% LOW and
TIME FAULT. (Only specified number of impulse is checked)
Item Initial Limits B08
MONITOR IMPULSE 1 C: 1-14 C
 Fault detection limit.

Voltage Compensation Control (0)：detected by heat%.
Constant Current Control (1)：detected by weld current and heat%.
Special Current Control (2)：
Detected by heat% when monitor impulse is 1
Detected by weld current and heat% when monitor impulse is 2 or more
Item Unit Initial Limits B08
CURRENT HIGH LIMIT % 20 3-50 ○
CURRENT LOW LIMIT % 20 3-50 ○
Sequence G1 - 4
HEAT HIGH LIMIT % 100 20-200 ○
HEAT LOW LIMIT % 10 10-100 ○
Sequence C
W-CUR FAULT LIMIT % 30 10-50 ○
(c) Current band monitor

Current band monitor includes 3 monitoring current band and each band has a high
limit and low limit individually.
Each impulse is monitored by the band that includes setting current of impulse.
And current is checked by the limit setting of the band.
When two or more bands are overlap, stricter limit setting is used for check.
Impulse that is included no band does not be monitored.
Sequence G1 - 4
AREA MON-A HI CUR BORDER A 50000 2000-50000 ○
AREA MON-A LO CUR BORDER A 2000 2000-50000 ○
AREA MON-A CUR HI LIMIT % 20 3-50 ○
AREA MON-A CUR LO LIMIT % 20 3-50 ○
AREA MON-B HI CUR BORDER A 50000 2000-50000 ○
AREA MON-B LO CUR BORDER A 2000 2000-50000 ○
AREA MON-B CUR HI LIMIT % 20 3-50 ○
AREA MON-B CUR LO LIMIT % 20 3-50 ○
AREA MON-C HI CUR BORDER A 50000 2000-50000 ○
AREA MON-C LO CUR BORDER A 2000 2000-50000 ○
AREA MON-C CUR HI LIMIT % 20 3-50 ○
AREA MON-C CUR LO LIMIT % 20 3-50 ○
47 DENGENSHA
AREA MON-A HI CUR BORDER：Please set upper border current of monitor area-A
AREA MON-A LO CUR BORDER：Please set lower border current of monitor area-A
AREA MON-A CUR HI LIMIT：Please set current high limit ratio of monitor area-A
AREA MON-A CUR LO LIMIT：Please set current low limit ratio of monitor area-A
AREA MON-B HI CUR BORDER：Please set upper border current of monitor area-B
AREA MON-B LO CUR BORDER：Please set lower border current of monitor area-B
AREA MON-B CUR HI LIMIT： Please set current high limit ratio of monitor area-B
AREA MON-B CUR LO LIMIT：Please set current low limit ratio of monitor area-B
AREA MON-C HI CUR BORDER：Please set upper border current of monitor area-C
AREA MON-C LO CUR BORDER：Please set lower border current of monitor area-C
AREA MON-C CUR HI LIMIT：Please set current high limit ratio of monitor area-C
AREA MON-C CUR LO LIMIT：Please set current low limit ratio of monitor area-C
e.g.) Actual welding：13000A、Pre-welding：20000A

Actual welding (Area-monitor A) is strict limit tolerance：±5%
Pre-welding (Area-monitor B) is comparatively strict limit tolerance：±10%
Other (Area-monitor C) is loose limit tolerance：±20%
[Settings] AREA MON-A HI CUR BORDER：15,000A
AREA MON-A LO CUR BORDER：10,000A
AREA MON-A CUR HI LIMIT, AREA MON-A CUR LO LIMIT：5%
AREA MON-B HI CUR BORDER：25,000A
AREA MON-B LO CUR BORDER：15,000A
AREA MON-B CUR HI LIMIT, AREA MON-B CUR LO LIMIT：10%
AREA MON-C HI CUR BORDER：35,000A
AREA MON-C LO CUR BORDER：2,000A
AREA MON-C CUR HI LIMIT, AREA MON-C CUR LO LIMIT：20%
50000A
判定外
40000A
35000A
25000A
モニタ領域B
20000A
モニタ領域C
モニタ領域A 15000A
10000A
5000A
2000A
溶接電流予備通電本通電
Weld Current Pre-welding Actual welding
通電クール通電
(d) Other
 SC (CURRENT) LIMIT
CURRENT-1 becomes current limit value when current control method is "2
(Special current control)".
 WELD 3-4 MULTI IMPULSE
Multi impulse repeats WELD-3/COOL-3 and WELD-4/COOL-4 by setting
times.
48 DENGENSHA
 Monitor item
All of 14 impulse actual current is stored in monitor area. ("WELD-n
CURRENT")
The actual current that impulse is specified by "MONITOR IMPULSE" is
stored in "WELD CURRENT".
11 - 8. Current linearity compensation

It is available with RWCB-2000-B08-*
(1) Specification
Timer improves current linearity with test welding data.
2 pattern of test welding and current measurement is required, one is higher current and
another is lower current.
(2) Setting item

Sequence G1 - 4 (Number of welds for Gun 1 - 4 independently)
REV HI CUR LIM SETTING A 5000 2000-50000 ○
REV LO CUR LIM SETTING A 5000 2000-50000 ○
REV HI CUR LIM MEASURE A 5000 2000-50000 ○
REV LO CUR LIM MEASURE A 5000 2000-50000 ○
REV HI CUR LIM SETTING (Calibration base high side)：

Please set the weld schedule current setting of higher weld.
REV LO CUR LIM SETTING (Calibration base low side)：
Please set the weld schedule current setting of lower weld.
REV HI CUR LIM MEASURE (Measuring current of high side)：
Please set the measurement current data of the high weld.
REV LO CUR LIM MEASURE (Measuring current of low side)：
Please set the measurement current data of the lower weld.
(3) Function
Measured value
Setting
Measured value
Measured value
(after calibration)
Setting
(4) Notices
This function is disable when 4 of setting item value are all initial value, or same value.
Please keep these value as initial till 2 pattern of test welding and current measurement is
complete.
49 DENGENSHA
11 - 9. Electrode tip stuck (Option)
It is available with RWCB-2000-B02-*, RWCB-2000-B06-A and RWCB-2000-B0-*, also need the
Tip stuck detection board in contactor unit.
(1) Connection of detection cable
Connect detection cable to the jig and to the secondary side of the welding transformer from
Connector (terminal block) in the contactor unit, as shown in the following figure.
(2) Principle of electrode tip stuck detection

Connect a small current to the electrode tip while the electrode tip is in contact with a work
piece and welding is not being done, and output the detected result as the adhesion signal.
Transmit this electrode tip stuck signal to the SDI of the robot.
Check the signal input in the SDI at a position where pressurization has been completed on
the robot side. If the adhesion signal indicates "CLOSED", output an alarm signal and stop the
robot.
In addition, prior to adhesion detection, before the start of welding and during squeeze time,
check whether the detection wire is broken. If the breaking of the cable is detected, inform
"DETECT WIRE BROKEN" to the robot.
(3) Setting item

Sequence S (Special Functions)
Item Initial Limits B02 B06 B08 B11
ELECTRODE TIP STUCK OFF OFF/ON ○ ○ ○ ○
(4) Precautions
 The ground resistance of a welding machine must be not less than 100.
If the secondary circuit is grounded, this function cannot be used.
 If the resistance of the adhesion detection circuit becomes 5 or more, mistaken
detection may occur.
If the jig and the work piece are insulated, this function cannot be used.
11 - 10. Primary cable resistance detecting (Option)

It is available with RWCB-2000-B02-*, RWCB-2000-B06-A and RWCB-2000-B08-*, also need the
relay box attached to contactor unit.
This function is used to detect the deterioration and breakage of the primary cable connecting the
timer with the welding transformer. Determination is made by information obtained from the
following hardware systems
50 DENGENSHA
Contactor
Unit Trans GUN
Terminal box
Insulation transformer
FUSE
FUSE
Reset Timer Board
Differential Integrating Full wave Voltage in cable 01

rectifier
(Analog input port)
Reset
Full wave Voltage in cable 03

Differential Integrating rectifier (Analog input port)
Terminal BOX Primary cable
Contactor unit
Trans gun
Schematic representation of installation
(1) Setting item

CABLE RESISTANCE PRI PRI/SEC ○ ○ ○ ○
01 CABLE RESISTANCE OFF OFF/ON ○ ○ ○ ○
03 CABLE RESISTANCE OFF OFF/ON ○ ○ ○ ○
51 DENGENSHA
(2) Setting range
Sequence C (Common sequence)
Item Unit Initial Limits B02 B06 B08 B11
LOW LIMIT 01 μΩ 0 0-20000 ○ ○ ○ ○
HIGH LIMIT 01 μΩ 0 0-20000 ○ ○ ○ ○
LOW LIMIT 03 μΩ 0 0-20000 ○ ○ ○ ○
HIGH LIMIT 03 μΩ 0 0-20000 ○ ○ ○ ○
(3) Detection
① Detection of deterioration in cable 01
This timer unit has the analog input port for monitoring voltage to be generated on
both ends of cable 01 when the power is turned on. Based on this voltage(V1) and
welding current(Iw), resistance(R1) of cable 01 can be calculated, where R1=V1/Iw.
If the value exceeds a set value for [HI LIMIT 01], I/O output of cable resistance alarm
“ON”, and fault code indicating “OVER RESIST 01/FIX (790)” is output.
② Detection of deterioration in cable 03

This timer unit has an analog input port for monitoring voltage to be generated on both
ends of cable 03 when the power is turned on. Based on this voltage(V2) and welding
current(Iw), resistance(R2) of cable 03 can be calculated, where R2=V2c/Iw.
If the result exceeds a set value for [HI LIMIT 03], I/O output of cable resistance alarm
“ON”, and fault code indicating “OVER RESIST 03/MOV (791)” is output.
③ Breakage of cable for detecting deterioration cable 01

Despite the normal output of welding current, if the result of calculation in ① is
below the set value for [LO LIMIT 01] on 01 side, it is considered that the detection
cable has broken.
In this case the I/O output of the cable resistance alarm “ON”, and fault code
indicating “WIRE BROKEN 01/FIX (780)” is output.
④ Breakage of the cable for detecting deterioration of cable 03

Despite the normal output of welding current, if the result of calculation in ② is
below the set value for [LO LIMIT 03] on 03 side, it is considered that the detection
cable has broken.
In this case, the I/O output of the cable resistance alarm “ON”, and fault code
indicating “WIRE BROKEN 03/MOV (781)” is output
(4) Precautions
Resistance of the primary cable is detected using the hardware on the same timer board as that
used for detection of the secondary cable resistance. Therefore, the software recognizes
voltage that has been detected by the wire using the same analog port as that for the secondary
cable. In "CABLE RESISTANCE" setting, please go to switch the primary cable detection
(PRI) / secondary cable detection (SEC).
If setting "PRI (primary)" by "CABLE RESISTANCE" item in a state in which the detection
line is connected to the secondary cable, it displays the resistance values of the wrong.
52 DENGENSHA
(5) Formula for calculating a theoretical value
When a voltage is input to the wire for detecting a cable in the full wave state
Input voltage × 3.14 ×Trans turn
= resistance value
√2 × 2 × full wave current
11 - 11. Secondary cable resistance detection (Option)

It is available with RWCB-2000-B02-*, RWCB-2000-B06-* and RWCB-2000-B08-*
(1) Connection of detection wire
Connect four detection wires to both ends of a pair of secondary cables from the CNRX
connector of the contactor unit.
(2) Setting
① Setting item
CABLE RESISTANCE PRI PRI/SEC ○ ○ ○ ○
FIX CABLE RESISTANCE OFF OFF/ON ○ ○ ○ ○
MOV CABLE RESISTANCE OFF OFF/ON ○ ○ ○ ○
② Setting range
Sequence C (Common sequence)
Item Unit Initial Limits B02 B06 B08 B11
LOW LIMIT.FIX μΩ 0 0-2000 ○ ○ ○ ○
HIGH LIMIT.FIX μΩ 0 0-2000 ○ ○ ○ ○
LOW LIMIT.MOV μΩ 0 0-2000 ○ ○ ○ ○
HIGH LIMIT.MOV μΩ 0 0-2000 ○ ○ ○ ○
③ Perform welding under the actual welding conditions.

After the completion of welding, the resistance value of each cable is displayed in the
robot’s pendant; take note of the values.
Repeat this step several times and determine the mean value of the resistance value of
each side, and set each of upper and lower limit values.
Generally, set the upper and lower limit values at the following values
Upper value … Mean value of a new cable ×1.5～2
Lower value … Mean value of a new cable ×0.5
53 DENGENSHA
(3) Cable resistance alarm and detection wire breakage alarm
① Cable resistance
When the resistance of a cable exceeds a set upper limit value, the deterioration of the
secondary cable is informed to the robot.
("OVER RESIST FIX" or "OVER RESIST MOV")
② Detection wire breakage

When a detection wire is broken, the resistance of the broken cable becomes
abnormally low, below the lower limit value, and the breakage of the detection wire is
informed to the robot.
("WIRE BROKEN FIX" or " WIRE BROKEN MOV")
(4) Precautions
In case of "Voltage Compensation" is selected for current control, set trans turn ratio. Trans
turn ratio is not set, it erroneous detection may occur.
54 DENGENSHA
12. Fault code and troubleshoot
12 - 1. Fault code list
(1) Robot teaching-pendant displays fault name.
(2) The I/O ID can be output in 4-bit code from the robot I/O. Contents of monitor Fault 1.
(3) Reset can be input from outside to robot I/O.
(4) Alarm (warning) level does not stop the robot. The robot can be programmed to stop as fault
level. (ALARM level fixed: STEP COMP., TIP DRESS COMP., and TIP CHANGE COMP.)
(5) Fault level applies to faults and the robot stops.
(6) Error level applies to data errors and the timer does not start.
(7) There is Fault code that is not supported by the specification.
Item ID I/O ID Level When
WELD COMPLETE 000 0 After-W
CURRENT LOW 100 1 Alarm After-W
CURRENT HIGH 150 2 Alarm After-W
HEAT% LOW 200 3 Alarm After-W
HEAT% HIGH 250 4 Alarm After-W
LINE VOLT LOW 400 5 Alarm After-W
LINE VOLT HIGH 410 6 Alarm After-W
STEP COMPLETE 01x
TIP DRESS COMPLETE 05x 7 Alarm After-W
TIP CHANGE COMPLETE 06x
LINE CLOCK 450 8 Fault Imme
NO CURRENT 500 9 Fault After-W
CURRENT FAULT 510
TIME FAULT 520 10 Fault After-W
I/O FAULT 840
TRANS OVER TEMP 550
11 Fault Imme
SCR OVER TEMP 600
SCR SHORT 650
Fault Imme
SCR HALF CYCLE 660 12
LEAK DETECTED 680 Fault After-W
Reserved 13
DETECT WIRE BROKEN 710
WIRE BROKEN 01/FIX 780 Fault
WIRE BROKEN 03/MOV 781 14 After-W
OVER RESIST 01/FIX 790
Alarm
OVER RESIST 03/MOV 791
MEMORY ERROR 300
W-CUR PROGRAM LOW 350
W-CUR PROGRAM HIGH 360 15 Error Start-W
TOTAL W-TIME LONG 370
PARAMETER OUT LIMIT 380
When：Fault detection timing
After-W：After welding sequence ends Imme：Immediately when welding sequence is executed
Start-W：When welding sequence starts Imme*：Immediately when monitoring
Imme**：Immediately when power is turned on and data in
H series memory is replaced with new data
55 DENGENSHA
 Because the timer unit is built into the robot, when a welding-related fault occurs, the Timer
unit fault is displayed on the robot side.
 Welding controller (Timer unit) built in backplane board in robot controller while mounted on
FANUC PC104 I/F board, and has received the supply of control power. (Refer to Fanuc R-J3i,
R-30i maintenance manual)
Therefore, at the time of fault occurs, fuse (FA2) on PC104 I/F board may blowout.
Confirm the fuse, and please replace in refer to Fanuc R-J3i, R-30i maintenance manual when
fuse blowout.
 With the robot teaching-pendant, welding-related faults are displayed as follows:
SPOT-064 SCR OVER TEMP
Robot alarm code Character string that indicates the fault

(Timer unit fault item)
 If a welding-related fault occurs, the robot alarm code is roughly divided into 2.
SPOT-063・・・Stops temporarily
SPOT-064・・・Stops temporarily or becomes a warning
Notice: If fault level is FAULT or ERROR for fault with SPOT-064, operation stops
temporarily.
 ”Character strings that express faults” express faults output by DENGENSHA welding timer.
 Refer to the fault and countermeasures provided on the following pages and remove the cause
of the fault.
 Fault displays are as follows:
SPOT-063 SCR SHORT SPOT-064 CURRENT FAULT
SPOT-064 CURRENT LOW SPOT-064 TIME FAULT
SPOT-064 CURRENT HIGH SPOT-064 TRANS OVER TEMP
SPOT-064 HEAT% LOW SPOT-064 SCR OVER TEMP
SPOT-064 HEAT% HIGH SPOT-064 SCR SHORT
SPOT-064 LINE VOLT LOW SPOT-064 SCR HALF CYCLE
SPOT-064 LINE VOLT HIGH SPOT-064 MEMORY ERROR
SPOT-064 STEP END SPOT-064 W-CUR PROGRAM LOW
SPOT-064 TIP DRESS END SPOT-064 W-CUR PROGRAM HIGH
SPOT-064 TIP CHANGE END SPOT-064 TOTAL W-TIME LONG
SPOT-064 LINE CLOCK SPOT-064 PARAMETER OUT LIMIT
SPOT-064 NO CURRENT
56 DENGENSHA
12 - 2. Troubleshooting method
Please executed in the following steps.
Fault code output
Check the fault codes Displayed up to four codes

that occurred at the same time on Sequence M(Monitor).
Fault code No
with respect to
the current Find out following
Yes monitor value
・ SCHEDULE No.
Check the monitor value, ・LINE VOLT (V)
the measured value and the set value. ・ WELD CURRENT (A)
・ HEAT (%)
Wrong Line voltage 94% or more

Schedule No. High/low HEAT (%)
94%
Please check or less Possibility of external factors is high.
Please correct
the plant Please check the secondary side
set value.
equipment. of the Contactor unit.
(Primary/secondary welding cable,
welding transformer, Gun)
Please execute ”Fault items and counter measures”
Yes
Resolved
No
Please replace the timer unit (board)
Yes
Resolved
No
Possibility of failure in contactor unit is high. Timer unit failure.

OK Please replace the Contactor unit. Please replace or repair.
57 DENGENSHA
12 - 3. Fault items and counter measures
(1). 100 Excessively low current (CURRENT LOW) 4bit code “1”
(a) Description
This indicates that the lower current limit is lower than the set value.
It suggests that the application of current selected at the menu for monitor current application
was excessively low.
(b) Detection
It is inspected after the completion of welding current control at constant current control and
its notification is made after the sequence is completed. This will not function at voltage
compensation control.
(c) Check
① Check-1
Isn’t the lower allowable value too small?
It is generally set at approximately 10%.
② Check-2
Isn’t the current setting over the maximum capacity of the welding machine?
As the maximum current varies due to changes in power supply voltage and load,
consider the worst condition. Check heat ratio with the monitor display, and if it is
close to 94% it is its capacity limit.
③ Check-3
Does this error occur at the latter half of the current stepper?
It be exceeding the capacity of the welding machine as the increment ratio of each step
is large. Set current setting value for the final step so that there is some allowance for
the capacity.
④ Check-4
Isn’t the duration of current application too short?
The shorter the duration of current application is, the lower the constant current
accuracy against external disturbance. Set the allowable value slightly larger.
⑤ Check-5
Make sure there are no damage and soiling of the tip, distortion and soiling of work,
deterioration of secondary cable, loosening of each secondary parts, and insufficient
pressure.
Essentially, a mechanical improvement is required, but if the error is mild it may be
improved by making the up-slope time longer or conducting a preliminary current
application by applying current twice.
⑥ Check-6
The current feedback signal is transmitted to the timer board in the robot controller via
the CT in the contactor unit, firing board and firing cable.
Make sure there is no bad connection in between the two ends.
⑦ Check-7
Isn’t the up-slope setting 1 cycle?
Up-slope setting 1 cycle may generate a magnetic bias phenomenon in the welding
transformer to cause this error.
At the same time, it may cause excessively low voltage and insufficient current
application time errors. Change the up-slope setting to about 3 cycles. Moreover, if the
upper current limit in the setting items is set at a value appropriate for the capacity of
the welding machine, the initial up-slope current value becomes slightly larger to be
effective against the magnetic bias phenomenon.
58 DENGENSHA
(2). 150 Excessively high current (CURRENT HIGH) 4bit code “2”
(a) Description
This indicates that the welding current is larger than the set value for the upper current limit. It
suggests that the current application selected at the monitor current application was
excessively high.
(b) Detection
its notification is made after the sequence is completed. This will not function at voltage
compensation control.
(c) Check
① Check-1
Isn’t the upper allowable value too small?
It is generally set at approximately 10%.
② Check-2
Isn’t the current setting below 20% of the current control range of the welding
machine?
The lower controllable limit is 20%. Essentially it is necessary to lower the capacity of
the welding machine by another rank.
③ Check-3
Isn’t the welding machine used at its full capacity?
If the error can be avoided by lowering the current setting a little, this is the cause.
Lower the current setting or increase the welding machine capacity.
④ Check-4
the CT in the contactor unit, firing board and firing cable.
Make sure there is no bad connection in between the two ends.
(3). 200 Excessively low heat ratio (HEAT% LOW) 4bit code “3”
(a) Description
This indicates that the heat ratio is lower than the set heat ratio lower limit. It suggests that the
current application selected at the monitor current application items for heat ratio was too low.
(b) Detection
its notification is made after the sequence is completed. This will function both at constant
current control and voltage compensation control.
(c) Check
① Check-1
Isn’t this set value close to the actual heat ratio (check at the monitor Sequence M) of
the welding current?
If this alarm is not used, set it at 20%.
② Check-2
Isn’t the secondary circuit shorted somewhere?
Check, in particular, whether the kickless cable is shorted or not.
59 DENGENSHA
(4). 250 Excessively high heat ratio (HEAT% HIGH) 4bit code “4”
(a) Description
This indicates that the heat ratio is larger than the set heat ratio upper limit.
It indicates that the current application selected at the monitor current application items was
too high for the heat ratio.
(b) Detection
its notification is made after the sequence is completed.
This will function both at constant current control and voltage compensation control.
(c) Check
① Check-1
Isn’t this set value close to the actual heat ratio (check at the monitor display) of the
welding current?
Set the value so that it is about 20% higher than the value shown in the monitor.
② Check-2
Isn’t the welding power source voltage abnormally low during current application?
Check whether the line voltage is lowered due to simultaneous application of current
and whether the set current is appropriate.
③ Check-3
If this value is set at 100% it will be the same as the conventional full-heat (full-wave)
alarm. If this alarm still appears after this, it means that the welding condition is above
the capacity of the welding machine. Increase the capacity. It is considered that the
transformer allowance ratio is insufficient.
④ Check-4
pressure.
Essentially, a mechanical improvement is required, but if the error is mild it may be
improved by making the up-slope time longer or conducting a preliminary current
application by applying current twice.
(5). 400 Lowered power source voltage (LINE VOLT LOW) 4bit code “5”
(a) Description
This indicates that the welding power source voltage is lower than the set value for the power
source voltage lower limit.
(b) Detection
It is inspected during the welding current control and its notification is made after the
completion of the sequence.
(c) Check
① Check-1
Isn’t the set allowable value too small?
If current application overlaps (made simultaneously) with other welding machines,
the voltage may be lowered considerably. Check the operating voltage at the monitor
display and set the allowable value so that there will be some allowance above that
value.
60 DENGENSHA
② Check-2
transformer to cause this error. At the same time, it may cause excessively low voltage
and insufficient current application time errors.
Change the up-slope setting to about 3 cycles. Moreover, if the upper current limit in
the setting items is set at a value appropriate for the capacity of the welding machine,
the initial up-slope current value becomes slightly larger to be effective against the
magnetic bias phenomenon.
(6). 410 Increased power source voltage (LINE VOLT HIGH) 4bit code “6”
(a) Description
This indicates that the welding power source voltage is higher than the set value for the power
source voltage upper limit.
(b) Detection
It is inspected during the welding current control and its notification is made after the
(c) Check
① Check-1
Isn’t the set allowable value too small?
Check the operating voltage at the monitor display and set the allowable value so that
there will be some allowance above that value.
② Check-2
Is the value for the standard power source correctly set?
Set it so that it is the same value as the primary side tap voltage of the control
transformer in the contactor unit.
③ Check-3
Is the hardware gain “LINE VOLT GAIN” that makes circuit correction for the timer
board set correctly?
The adjustment value upon shipment is marked on the board. Set it to that value.
- Adjustment method when the value is unknown -
Measure the welding power source voltage with such instrument as a tester.
To minimize voltage drop upon current application, set the current setting to the
minimum current value (approximately 2,000A - 5,000A) and then apply current.
Adjust hardware gain “LINE VOLT GAIN” so that the value on the monitor will be
the same as the value obtained with the tester.
(7). Completion of 01x step (STEP COMPLETE) 4bit code “7”

(a) Description
This indicates completion of step-up of the gun series.
(b) Detection
It is notified after completion of the sequence. A number corresponding to gun series
counted-up will be entered into the x part. 011 (gun 1) to 014 (gun 4).
61 DENGENSHA
(8). 05x Dress completion (TIP DRESS COMPLETE) 4bit code “7”
(a) Description
This indicates count-up of the dress counter.
It is possible to execute such functions as the tip dress upon reception of signal of TIP DRESS
END (dress count completion).
(b) Detection
It is notified after the completion of the sequence. A number corresponding to gun series
counted-up will be entered into the x part. 051 (gun 1) to 054 (gun 4).
(9). 06x Tip replacement completion (TIP CHANGE COMPLETE) 4bit code “7”
(a) Description
This indicates count-up of the tip replacement counter. It is possible to execute such
operations as changing the tip upon reception of TIP CHANGE END (completion of tip
replacement counter).
(b) Detection
Its notification is made after completion of the sequence. A number corresponding to gun
series counted-up will be entered into the x part. 061 (gun 1) to 064 (gun 4).
(10). 450 Power source synchronization error (LINE CLOCK) 4bit code “8”
(a) Description
This is output when the power source frequency can not be identified.
The power source frequency signal is transmitted to the timer board in the robot controller
from control transformer in the contactor unit via the firing board and firing cable.
(b) Detection
It is inspected constantly during execution of welding sequence and when the power source
frequency is not identified, notification is made immediately and the welding sequence is
terminated.
(c) Check
① Check-1
Is the firing cable connected properly?
② Check-2
Check if the circuit breaker is ON
Check if the fuse (e.g. FU01, FU02) in the contactor unit blown out.
Check if the CNPWR connector in the firing board is not disconnected
③ Check-3
Defect in the firing board can be considered. Exchange it with a backup board.
④ Check-4
Measure voltage with a tester between 14-15 pins of the firing cable connected to the
timer board mounted on the robot controller.
If it is approximately AC 11V it can be deemed that normal signals are transmitted
from the contactor unit.
Defect in the timer unit (timer board) can be considered. Exchange it with a backup
board.
62 DENGENSHA
(11). 500 No current (NO CURRENT) 4bit code “9”
(a) Description
This indicates that the welding current is lower than 5% of the set value, or the thyristor firing
control failed.
(b) Detection
It is inspected during welding current control and its notification is made after the completion
of the sequence.
(c) Check
① Check-1
Check for dust in the work, soiling of the tip, and insufficiency in pressure application
time and power.
② Check-2
Check if the firing cable is connected properly.
③ Check-3
Is the LED1 and LED2 for checking firing on the firing board on during current
application?
 If not lit:
Check if the fuse (e.g. FU01, FU02) in the contactor unit blown out.
If not blown, defect in the firing board can be considered. Exchange it with a
backup board.
 If lit:
Is the output Isolation contactor (MC01) ON?
Measure welding current with a welding current meter.
If welding current of approximately 5,000A is running it can be deemed that the
current feedback circuit is defected and the firing circuit and thyristor are
sound.
Measure voltage at the welding transformer secondary side with such
instrument as a tester. If there is current of approximately AC 5V on the
transformer secondary side while LED1 and LED2 are lit, it can be deemed that
the firing circuit and the thyristort are sound.
If both of the above checks fail then defect in the thyristor is considered.
Replace the thyristor.
④ Check-4
the CT in the contactor unit, firing board and firing cable. Make sure there is no bad
connection in between the two ends.
⑤ Check-5
board.
(12). 510 Insufficient current (CURRENT FAULT) 4bit code “10”

(a) Description
This indicates that the set current value is smaller than the set current error lower limit value.
(b) Detection
It is inspected after completion of welding current control and its notification is made after the
(c) Check
Check items are the same as 100 Excessively low current (CURRENT LOW).
63 DENGENSHA
(13). 520 Insufficient current application time (TIME FAULT) 4bit code “10”
(a) Description
This indicates that current application of the set cycle was not made. It is notified with
insufficient current application time of 0.5 cycle.
(b) Detection
It is inspected after the completion of welding current control and its notification is made after
the completion of the sequence.
(c) Check
① Check-1
pressure.
② Check-2
Check if the squeeze time is not insufficient.
③ Check-3
transformer to cause this error. At the same time, it may cause excessively low voltage
and insufficient current application time errors.
Change the up-slope setting to about 3 cycles. Moreover, if the upper current limit in
the setting items is set at a value appropriate for the capacity of the welding machine,
the initial up-slope current value becomes slightly larger to be effective against the
magnetic bias phenomenon.
(14). 840 I/O Error (I/O FAULT) 4bit code “10”

(a) Description
This indicates that current application has been cut off while current applied welding
sequence had been carried out.
(b) Detection
It is inspected after the completion of welding current control and its notification is made after
the completion of the sequence.
(c) Check
Check if the I/O signal on the robot side is normal.
(15). 550 Transformer over heating (TRANS OVER TEMP) 4bit code “11”
(a) Description
This indicates that the welding transformer is overheated. (External thermo. SW)
(b) Detection
It is inspected constantly during execution of welding sequence and when the error is detected
its notification is made immediately and the welding sequence is terminated.
(c) Check
① Check-1
Check frequency of use, cooling water temperature and water volume.
② Check-2
Check if the external thermo-sensor line is not broken.
③ Check-3
64 DENGENSHA
④ Check-4
Check if circuit breaker is ON.
Check if fuses (e.g. FU01, FU02) in the contactor unit are blown out.
Measure voltage between CNIO connector 7 and 8 or at both ends of D1 on the firing
board.
Check items Standard criterion range
CNIO connector 7 & 8
DC 5V ± 0.25V
At both ends of D1
If voltage is within standard criterion range, the firing board is defected. Exchange it
with a back-up board.
⑤ Check-5
The transformer thermo-signal is transmitted to the timer board in the robot controller
via firing board CNIO connector 7 and 8 pins >> firing cable.
Check for bad connection between the two ends.
⑥ Check-6
Defect in the timer board can be considered. Exchange it with a backup board.
(16). 600 SCR overheating (SCR OVER TEMP) 4bit code “11”
(a) Description
This indicates that the thyristor is overheated.
(b) Detection
(c) Check
① Check-1
Check frequency of use.
Water cooling type: Check cooling water temperature and water volume.
Forced air cooling type: Check a fan is running,
Are there obstructions and dust around the intake and exhaust ports？
② Check-2
③ Check-3
Check if power source display LED3 on the firing board is lit.
 If not lit:
Check if circuit breaker is ON.
 If lit:
Measure voltage between CNIO connector 5 and 6 pins (connector type firing
board) or at both ends of D3 on the firing board.
Check items Standard criterion range
CNIO connector 5 & 6
DC 5V ± 0.25V
At both ends of D3
If voltage is within standard criterion range, the firing board is defected. Exchange it
with a back-up board
④ Check-4
The thyristor thermo-signal is transmitted to the timer board in the robot controller via
firing board CNIO connector 5 and 6 pins >> firing cable.
65 DENGENSHA
⑤ Check-5
Isn’t the thermo-switch of the thyristor defective?
⑥ Check-6
board.
(17). 650 SCR shortage (SCR SHORT) 4bit code “12”

(a) Description
This indicates that the thyristor is shorted.
(b) Detection
It is inspected constantly while no current is applied and notification is made immediately.
(c) Check
① Check-1
Measure voltage at the welding transformer’s secondary side with such instrument as a
tester.
If voltage corresponding to welding transformer turn ratio (approximately AC 10V) is
measured while current is not applied, shorting in the thyristor can be considered.
Replace thyristor. Check if the welding current or frequency of use is not over the rated
value.
② Check-2
the CT in the contactor unit, firing board and firing cable. Make sure there is no bad
connection in between the two ends.
③ Check-3
Isn’t LED1 and 2 on the firing board lit constantly?
LED1 and 2 on the firing board light up only when current is applied.
Exchange it with a backup firing board.
④ Check-4
Defect in the timer unit (timer board) can also be considered. In that case, exchange it
with a backup board.
(18). 660 SCR half-cycle firing (SCR HALF CYCLE) 4bit code “12”
(a) Description
This indicates that either one of the two thyristor could not execute firing.
(b) Detection
(c) Check
① Check-1
Check for extreme voltage shift, deterioration of secondary coil, loosened parts in the
secondary circuit, and insufficient pressure application.
② Check-2
③ Check-3
Are firing check LED 1 and 2 on the firing board lit during current application?
66 DENGENSHA
 If only one side is lit:
If not blown out, defect in the firing board is considered. Exchange it with a
backup firing board. Defect in timer board is also considered. Exchange it with
a backup board.
 If both firing check LED 1 and 2 are lit:
Defect in the thyristor is considered. Replace the thyristor.
(19). 680 Leak detected (LEAK DETECTED) 4bit code “12”

(a) Description
This indicates that the welding transformer’s secondary side is shorted.
(b) Detection
It is monitored upon activation with the 255 series, and when current is detected it is notified
immediately.
(c) Check
① Check-1
Check if current application is made under condition while gun is open.
② Check-2
Check if the welding transformer’s secondary side is not shorted due to adhesion of
such substance as weld slags.
③ Check-3
Check welding current with a welding current meter.
In case proper welding current as set is not running, defect in the welding transformer
is considered. Replace the welding transformer.
(20). 710 Broken welding detection line (DETECT WIRE BROKEN) 4bit code “14”
(a) Description
This indicates that the tip stuck detection line is broken (condition under which detection is
impossible).
(b) Detection
It is inspected before welding current control and its notification is made after the sequence.
(c) Check
① Check -1
Check if fuses (e.g. FU07: 100VAC provide circuit) in the contactor are blown out?
② Check -2
Check connection and condition of the tip stuck detection line.
(21). 780 Broken fixed-side detection line (WIRE BROKEN 01/FIX) 4bit code “14”
(a) Description
This indicates that the resistance detection value of the fixed side is lower than the set lower
limit value.
(b) Detection
It is inspected during welding current control and its notification is made after the sequence.
(c) Check
Check connection and condition of the fixed-side resistance detection line and its set lower
limit value.
67 DENGENSHA
(22). 781 Broken movable-side detection line (WIRE BROKEN 03/MOV) 4bit code “14”
(a) Description
This indicates that the resistance detection value of the movable side is lower than the set
lower limit value.
(b) Detection
(c) Check
Check connection and condition of the movable-side resistance detection line and its set lower
limit value.
(23). 790 Deterioration of fixed-side cable (OVER RESIST 01/FIX) 4bit code “14”
(a) Description
This indicates that the resistance detection value of the fixed side is higher than the set upper
limit value.
(b) Detection
(c) Check
Check connection and condition of the fixed-side resistance detection line and its set upper
limit value.
(24). 791 Deterioration of movable-side cable (OVER RESIST 03/MOV) 4bit code “14”
(a) Description
This indicates that the resistance detection value of the movable side is higher than the set
upper limit value.
(b) Detection
(c) Check
Check connection and condition of the movable-side resistance detection line and its set upper
limit value.
(25). 300 Memory error (MEMORY ERROR) 4bit code “15”

(a) Description
After the robot controller’s power is turned on setting data is transmitted from the robot
controller. The timer verifies whether appropriate values are written. If inadequacy in data or
data domain should be found, the memory error notification is made immediately and the
initial (default) values will be written.
(b) Detection
It is inspected upon turning the robot controller’s power on.
(c) Check
① Check-1
Turn the robot controller’s power OFF/ON.
 If this error occurs:
Defect in the timer board can be considered. Exchange it with a backup timer
board.
68 DENGENSHA
 If this error is solved:
The set values have been initialized.
The circuit correction value hardware gain of each board has been initialized.
Resetting is necessary.
② Check-2
Turn the robot controller’s power OFF/ON.
If this error occurs again, defect in the system can be considered. Please contact
Dengensha Mfg. Co., Ltd. or the robot manufacturer.
(26). 350 Excessively low current setting (W-CUR PROGRAM LOW) 4bit code “15”
(a) Description
This indicates that the value exceeded the lower limit of the control range during computation
process of the constant current control.
(b) Detection
It is inspected upon start of the welding sequence and its notification is made immediately.
(c) Check
Check whether the set current value and turn ratio of the welding transformer are appropriate.
(27). 360 Excessively high current setting (W-CUR PROGRAM HIGH) 4bit code “15”
(a) Description
This indicates that the value exceeded the upper limit of the control range during computation
process of the constant current control.
(b) Detection
(c) Check
① Check-1
Check whether the set current value and turn ratio of the welding transformer are
appropriate.
② Check-2
Check and make sure the set current value is not over the maximum current setting
value.
(28). 370 Outside current application time range (TOTAL W-TIME LONG) 4bit code “15”
(a) Description
This indicates that the set current application time is longer than the set maximum current
application time.
(b) Detection
(c) Check
This error is caused if the set maximum current application time is not longer than the total of
the set time durations of all current application of the start-up system in use. Check whether it
is set correctly.
69 DENGENSHA
(29). 380 Outside setting value range (PARAMETER OUT LIMIT) 4bit code “15”
(a) Description
When inputting each parameter from the robot teaching-pendant it is designed so that data
outside the designated setting range cannot be input.
The welding parameter is checked and if inadequacy in data is found for some reasons, the
welding sequence will not be executed and the system will go into an error state.
(b) Detection
(c) Check
Check set data.
70 DENGENSHA
13. Maintenance
13 - 1. Maintenance parts list
TIMER UNIT
No. Symbol Parts name Q’ty MFR Description
1 - RWCB-2000-A00-* 1 DG PMU-0531
- RWCB-2000-A05-* 1 DG PMU-0531
- RWCB-2000-A07-* 1 DG PMU-0531
- RWCB-2000-B02-* 1 DG PMU-0547
PMU-0547-1
- RWCB-2000-B06-A 1 DG
no substitution (maintenance only)
- RWCB-2000-B08-* 1 DG PMU-0547
- RWCB-2000-B11-* 1 DG PMU-0547
71 DENGENSHA
Head Office & Plant 1-23-1 Masugata, Tama-ku,
Kawasaki-shi, Kanagawa-ken, Japan Tel: +81(44)922-1121
Toyama Plant 2-27-2 Ariiso, Imizu-shi, Toyama-ken, Japan Tel: +81(766)86-3113
Aichi Office 2-151-3 Onda-cho, Kariya-shi, Aichi-ken, Japan Tel: +81(566)63-5318

Kita-Kanto Office 216 Iida-cho, Ohta-shi, Gunma-ken, Japan Tel: +81(276)46-6621
Osaka Office 1-9-16 Yamabiko-Bldg. Oyodo-Minami, Tel: +81(6)6451-0521
Kita-ku, Osaka-shi, Osaka-hu, Japan
Hiroshima Office 15-10 Central-Bldg. Hachobori, Naka-ku, Tel: +81(82)225-2573
Hiroshima-shi, Hiroshima-ken, Japan
Kyusyu Office 1-9-1 Katanoshinmachi, Kokurakita-ku, Tel: +81(93)922-4442
Kitakyusyu-shi, Fukuoka-ken, Japan
Dengensha America 7647 First Place Drive Bedford, Ohio 44146, USA Tel: +1(440)439-8081
Dengensha Mexico Office Paseo del Moral #206 Int. 4 Col. Jardine del Moral, Tel: +52(477)717-8827
Leon G to C.P. 37160 MEXICO
Dengensha Europe Unit 8, Birchbrook Industrial Park Birchbrook Lane, Tel: +44-1543-481844
Shenstone, Staffs WS14 0DJ, ENGLAND
DENGENSHA

Manual Fanuc Weld Control

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Manual Fanuc Weld Control

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Document No.

The instruction manual must be carefully

Please inquire an uncertain point of our Sales Department/each office.

 An instruction manual related to the robot controller.

1. SAFETY INSTRUCTIONS AND CONSIDERATIONS ...................................... 1

1 - 1. Product safety labels and symbols

(1) General warning sign

(2) Hazard severity panels

Indicates a hazard with a high level of risk which, if not

Indicates a hazard with a medium level of risk which, if

Indicates a hazard with a low level of risk which, if not

(3) Prohibition sign

(4) Mandatory action

1 - 4. Safety during operation

(4) Noise protection

(2) Connection to the power supply

1 - 6. Safety items on maintenance work

(2) Before performing maintenance work

(3) Perform maintenance work

◎ Reference 2： Equivalent continuous current (continuous secondary current) of welding

(4) Special current control (Depending on the model type)

(5) Electrode Tip stuck detection (Depending on the model type)

溶接電源 Weld control ロボット電源

PTS-0548 Weld control

Model: RWC B – 2000 – A 00 – C

※ all combinations is not possible. Please refer to the Model list.

Model： RWC B – 2000 – B 06 – C

(1) Robot Teaching-pendant displays software version as following

(2) The nameplate displays software version board number as following.

① Mounting hole： For mounting on robot controller rack. (M3, 5 places)

※ Be careful with direction of SEL

 factory default settings

(a) Setting of Timer ID

(b) Setting of current detection mode as follows:

(2) JPCUR, JPGAIN

6 - 1. Timer board in robot controller (PMU-0531/PMU-0547)

Motherboard on card rack

Connect to bus connector on motherboard on card rack

(1) Preparations and precautions

 WC (Weld Controller) number set by T0/T1 bit of Dip SW[SEL]

③ Mount the timer board on the PC/104 contactor on the motherboard.

Fastened with 4 screws

If using 1 timer board

Do not use the 4 poles

 Two timer boards may be mounted on a single motherboard, depending on

Fastened with 4 screws

[SEL] Dip SW setting example

If using 2 timer boards

④ Checking the timer board after mounting

⑥ Checking work after completion

溶接電流 電流1 電流2 電流3

スクイズ ｱｯﾌﾟｽﾛｰﾌﾟ 通電1 クール1 通電2 クール2 通電3 ﾀﾞｳﾝｽﾛｰﾌﾟ 保持

溶接電流 電流1 電流2 電流3 電流4 電流5

通電1 クール1 通電2 クール2 通電3 クール3 通電4 クール4 通電5 保持

溶接電流 電流1 電流2 電流3 電流4 電流5

(1). Schedule 1 - 255 (Weld Schedules) ※1

(2). Sequence C (Common sequence)

(3). Sequence S (Special Function)

(4). Sequence G1 - 4 (Number of welds for Gun 1 - 4 independently)

8 - 2. Description of programming items (welding schedules and function setting)

⑥ DOWN-SLOPE (Dslope) ：0 - 30 [cyc]

WELD 2 MULTI IMPULSE ：1 - 10 [Time]

WELD 5 MULTI IMPULSE ：1 - 10 [Time]

WELD 3-4 MULTI IMPULSE ：1 - 10 [Time]

溶接電流電流1 電流2 電流3

スクイズｱｯﾌﾟｽﾛｰﾌﾟ通電1 クール1 通電2 クール2 通電3 ﾀﾞｳﾝｽﾛｰﾌﾟ保持

溶接電流電流1 電流2 電流3 電流4 電流5

溶接電流電流1 電流2 電流3 電流4 電流5

溶接電流電流1 電流2 電流3 電流4 電流5

溶接電流電流1 電流2 電流3 電流4 電流5