Aro Micro 2x16iiieng

MICRO 2X16 III
USER'S MANUAL
10T128P - CNOMO
TYPE 3D Revision 32
Rack Model
GB
T421GB
RECORD OF REVISIONS
DOCUMENT
DATE REFERENCE DESCRIPTION OF REVISIONS
06/02 T421GB Creation 3D31
01/04 Creation 3D32
We reserve the right to change the design and specifications of the products and equipment presented in this document. Any description provided cannot
be considered contractually binding.
The reproduction of this document, whether in whole or in part, using any process whatsoever, is forbidden without prior approval.
ARO 1, avenue de Tours - 72500 Château-du-Loir - France - Tél : 33 (0)2 43 44 74 00

SAFETY INSTRUCTIONS
PROGRAMMABLE WELDING CONTROL SYSTEMS

GENERAL SAFETY INSTRUCTIONS
ALWAYS READ THESE INSTRUCTIONS BEFORE
INSTALLING THE EQUIPMENT
Before powering up the unit, carefully read these instructions. Inform everyone who works with
the devices of these instructions and ensure that they are fully understood.
In addition to our recommendations, always ensure that the device is installed and used in
accordance with local laws and regulations (especially when the device is used outside of
France).
WARNING
This equipment is designed for use under the conditions defined in its instructions for use and for
maintenance. Any use that does not comply with the applications it was designed for or any
unqualified application may have the following consequences:
• Danger to persons.
• A risk of destruction to the equipment and to other property belonging to the user.
• Interfering with equipment or operator efficiency.
ARO cannot accept any liability should incidents or accidents arise as a result of, or
subsequently to the use of the equipment under the following conditions:
• With safety mechanisms neutralized or modified.

• Using the equipment without regard to the recommendations made by ARO.
• Replacing the welding sequence with one that was not supplied by ARO.
• Modifying the equipment without ARO's approval.
• Using accessories not supplied by ARO.
• Using equipment for purposes other than those for which it was intended.
182E ARO 1, avenue de Tours - 72500 CHATEAU-DU-LOIR - FRANCE - Tel. 33 02 43 44 74 00 I

SAFETY INSTRUCTIONS
1 – GENERAL
1.1 Comply with the equipment installation, use and maintenance procedures as defined in the
operating and maintenance manuals.
1.2 Ensure that the mounting base is a stable one that is solid enough and that the mounting used
meets the requirements set out in the installation manual.
1.3 The device must not be used in an explosive atmosphere.
1.4 Prior to starting work, always provide training on the type of work to be performed as well as
on the possible dangers faced.
1.5 The device must be protected against projections of water, shavings, dust, etc… Never
expose the device's components to radiation generated by arc welding or to any other source
of ultraviolet rays as these may destroy the contents of the EPROM's.
2 – ELECTRIC POWER HAZARDS

Always read this before powering up the equipment
2.1 The device complies with "low voltage" directive 73/23/CEE as modified by 93/68/CEE and
with the 89/336/CEE EMI directive as well as with the following uniform generic standards:
NF EN 50081-1 and NF EN 50081-2

NF EN 50082-1 and NF EN 50082-2
2.2 Ensure the compliance of the electrical installation and the protection measures: circuit
breaker, fuses, cross-section and condition of conductors, compliance and condition of mains
outlets, quality of grounding.
2.3 The device is designed to be supplied from a 24 volt AC supply. The maximum voltage
allowed over the two supply conductors must be less than an effective 30 volts.
2.4 The devices are supplied with a P.E. (electrical protection) terminal that must always be
grounded and never connected to the phase or neutral lines. Sub-D type connector sockets
are connected directly to the accessible metal elements. For MICRO 2x16 III welding
sequences, the electrical protection conductors (P.E.) must be connected to pin No. 19 on
connector X1 and to the sockets of the sub-D type connectors.
WARNING:
Any break in protection conductor continuity whether inside or outside of the device as well as
eliminating the ground connector may make using the device dangerous. Voluntarily isolating
the ground connection is forbidden.
2.5 Regarding accessories not supplied by ARO (auxiliary cables and socket, etc…), ensure that
they match the requirements stated for proper device operation.
2.6 The device must be disconnected and its used prevented if its operation does not appear to
ensure the required safety conditions, which may be the result of:
• Visible damage to the device,

• Certain parts becoming detached,
• Long term storage under harsh conditions (e.g. outside or in a damp environment),
• Transportation under harsh conditions (e.g. in unsuitable packaging).
182E ARO 1, avenue de Tours - 72500 CHATEAU-DU-LOIR - FRANCE - Tel. 33 02 43 44 74 00 II

SAFETY INSTRUCTIONS
3 – SERVICING
3.1 Before any servicing takes place, always ensure that the electrical power supply is cut off and
that it cannot be reconnected accidentally.
3.2 The device must not be powered up when its metal cover has been removed or replaced with
another cover. If measurement need to be taken or it the device requires re-calibration with the
device's covers open, then this must only be done by the authorized personnel who are duly
qualified and familiar with the above mentioned hazards.
3.3 The device must absolutely be subject to the periodic inspections called for in the operating
and maintenance manuals. Maintenance work must not lead to improvised repairs. Always
perform repairs that comply with requirements and replace faulty elements.
3.4 If a fuse requires replacement, replace it with a fuse of the same value: 3.15 Amps.
3.5 The welder control system has a low voltage supply (24 VAC) but this is often built-into a
cabinet that contains a power supply with voltages that may reach 440 volts (this is specified
on the rating plate), and this implies danger if the instructions for operating and maintaining
this cabinet are not complied with.
4 – INDIVIDUAL PROTECTION
4.1 For control systems built-into welding units, we should remind users that incandescent
particles may be projected. Persons working on these devices must always wear suitable
clothing: eye protection, caps, uninflammable clothes during the time they are present for
these tests on the welders.
4.2 Persons who work on control systems installed in welders must not wear any jewelry or any
other objects that may be current conductive for this could cause serious burning if they
become suddenly heated when resuming welding applications.
4.3 The magnetic field caused by operating the machine that hosts this device may affect the
operation of certain objects such as watches, and may even damage them. For this same
reason, users of "active implants" must not work on these machines nor remain close to them
during their operation.
5 – WORKSTATION
5.1 While working on the welding control system, ensure that the workstation and especially the
movement area around it as well as the area required for accessing emergency stop
mechanisms is obstacle free and kept clear.
5.2 Become familiar with the equipment prior to using it.
5.3 When a machine fitted with a welding control system is not operating, shut off all power
sources.
5.4 The adhesive labels that may be fitted to the machines and cabinets where this device is
installed and that indicate a possible danger or provide instructions for use must be kept in
place. It is up to the user to affix new labels when this is necessary.
182E ARO 1, avenue de Tours - 72500 CHATEAU-DU-LOIR - FRANCE - Tel. 33 02 43 44 74 00 III

CONTENTS
1 PRESENTATION
1.1 Reference/Designation 1
1.2 Description 4
2 FAMILIARIZATION
2.1 Software Organization 8
2.2 Basic Programming 12
2.3 Explanations on Basic Programming 24
3 SETTING INTO SERVICE

3.1 Software Configuration
3.1.1 Calling up Configuration Windows 55
3.1.2 Special Functions 68
3.2 Hardware Configuration 69
3.3 Electrical Connection 70
4 OPERATION
4.1 Calling up the RUN Mode 85
4.2 Explanations on Run Windows 86
5 MAINTENANCE
5.1 Acknowledging Faults
5.1.1 Explanations and Acknowledgement 93
5.1.2 Fault Screen Explanations 97
5.2 Assembling/Disassembling the Main Component Parts 106
6 PC COMMUNICATION 116
SET UP SEQUENCE FOR A
MICRO 2X16 III UNIT
This manual covers all of the data required to set up a Micro 2X16 III and use it optimally. A
step by step description of the basic data required in order to be able to run a welding cycle with a Micro
2X16 III is provided.
First step
Micro unit presentation:

- Menu browsing
- Key functions
- Software organization • Basic function:
- Etc…
Essential steps for ensuring
Second step the proper operation of the
Micro 2X16 III.
Programming window settings:
- Basic programming:
- Spot by spot welding PRG MODE:
- Compensation time (PROGRAMMING)
- Welding time
- Type of regulation
- Etc…
- Pressure programming
- Wear compensation programming
- Etc…
Third step
Configuration window settings:

- Determining the type of operation
(assigning the programs allowed in the
programming)
- Language
- Password
- Etc..
Fourth step
• Performing a
Using the data entered in the welding cycle:
configuration and programming
windows:
- Displaying programming parameters Using the data entered by
while performing a welding cycle the user to perform custom
- Measuring the intensity level (and welding work.
measuring the voltage level depending
on the software) RUN MODE:
- Status WCC inputs and outputs (EXECUTION)
- Displaying wear compensation for
electrodes
- Displaying fault conditions
- Etc..
1. PRESENTATION
1.1. Reference/Designation
The device reference along with other information are shown on the rating plate affixed to the
outer protection panels.
Device type Supply frequency

Serial number Reference
Supply voltage Year of manufacture
The reference code is explained below:
ab: PRESENTATION
AA Presentation of 2X16 III rack version
SA Presentation of 2X16 III case version
cd: HARDWARE VERSION

0A Basic rack and case standard Rack in case with front panel SubD output
0B Adapted for second SubD-RS485 2E Adapted for pressure control
0C Adapted for 60Hz 2G Adapted for 8 Input + 8Output + 2 analog out.
0D Adapted for Medium Frequency operation Rack in P case
0E Adapted for pressure control 3A Rack 0A in P case
0F Adapted for three-phase operation 3E Rack 0E in P case
Adapted for pressure control +daughter board with Rack with field bus
0G
8 inputs + 8 outputs + 2 analog outputs 4I FIPIO
0H Adapted for pressure control + 60Hz operation 4J Profibus DP 50 Hz
0I Adapted for pressure control + second SubD-RS485 4K Interbus-S 50 Hz
0J Adapted for MF + 8I + 8O + 2 ana. output d.board 4L Profibus DP MF
0K Soldered jumpers and 60Hz operation 4M Interbus-S MF
0L Medium frequency 60Hz operation 6J Device Net
Rack in case with cable output
1A Standard
1E Adapted for pressure control
1G Adapted for pressure control + 8I + 8O + 2 ana. out
T421GB ARO 1, avenue de Tours - 72500 CHATEAU-DU-LOIR - FRANCE - Tel. 33 02 43 44 74 00 1

1. PRESENTATION
SOFTWARE VERSION
e f A B C D E F G H I J K L M N
German market, no KSR 1 - X X - - - - - - - - - - -
German market, with KSR 2 X X X - - - - - - - - - - -
French automotive market 3 X - - X - - - - - X - - - -
French automotive market 4 X X X X X - - - X X X X X X
Export automotive market 5 X X X X X X - X - - X - - -
ARO standard 6 X X - - - - - - - - - - - -
ARO standard 7 X X X X X X X X X - - - - -
Special machine
executions 8 X X X X X X - - - - - - -
Open 9 - - - - - - - - - - - - - -
g: WCC supply voltage

h: Thyristor control
7 24 VDC supply
A Long pulse - ARO standard m.processor type ZR…
8 110 VAC supply
B 1.3 ms pulse (specific to competing m.processors)
9 24 VAC supply
C Single 500 µs short pulse - CNOMO (RNUR)
D Four 100 µs pulses CNOMO - ARO m.proc. ZRA type
i: Type of WCC supply phase Servo valves Programmable outputs

Power circuit in phase with External 24 External 24
P
WCC supply j: 110 VAC
Internal 24 Internal 24
- 110 VAC
Internal 24
Power circuit out of phase VAC VDC VDC
Q 24 to 48VDC 24 - 48VDC
with WCC supply E X - - X -
G - - X - X
i - X - - X
Gate and servo valve H - - X X -
k: control association j - X - X -
s Control one gun k X - - - X
m Control two guns
MECHANICAL CHARACTERISTICS
DATA VALUES COMMENTS
Weight [kg] 3 rack version
Dimensions
(Height x width x depth) [mm] 297 x 182 x 130 rack version
Operating conditions
- Temperature [°C] 0 to 50 without forced ventilation
- Humidity [%] 20 to 80
Storage conditions
- Temperature [°C] -20 to 60
- Humidity [%] 80
MTBF
- Display [H] 200,000
- Front panel keys [actions] 2 x 10 6
- Key switch [actions] 10,000 at full load
Protection
- Front panel/display IP 65
16
Vibration resistance [Hz]
Impact resistance [g] 10

1. PRESENTATION
ELECTRICAL CHARACTERISTICS
DATA VALUES COMMENTS
Supply [V] 24 VAC +15%/-20% Specified on ordering

See rating plate
Frequency [Hz] 50/60 Specified on ordering
Power [VA] 50
Relay output
-General failure - Thyristor failure 2 x 10 7 VMAX 24 VAC IMAX 2A PMAX 50 VA
Transistorized outputs 2 x 10 7 External power supply:

-SV1-SV2 VMAX 24 VAC IMAX 1A PMAX 25 VA
Internal power supply:
VMAX 24 VAC IMAX 1A PMAX 25 VA
VMAX 24 VDC IMAX 0.25A PMAX 6 VA
- Other outputs 2 x 10 7 VMAX 24 VAC IMAX 0.1A PMAX 3 VA

Optically coupled inputs 15 mA
Common input voltage + 24 VDC
Protection devices
- Servo valve control 2A Fuse
- Supply 1A in 110 VAC Delayed action 5 x 20 fuse
3.15A in 24 VAC
Resistance
- to electro-magnetic interference Level IV To IEC 801-4
- to electro-static discharge Level IV To IEC 801-2

1. PRESENTATION
1.2. DESCRIPTION
The front panel of the device comprises a polyester membrane that allows local plain language
device programming and operating actions. An LCD is provided for reading programming settings
as well as displaying data during operation. A built-in RS485 link is used for downloading or
locally backing up programs to a PC. When in the "RUN" position, the key switch does not allow
changes to welding settings. Mounted behind the front panel, the CPU board comprises the
microprocessor and related peripherals, RAM, EPROM, etc... This board also handles the
input/output interface functions (optical coupling and protection systems). Connections are made
directly to the board or by using unpluggable connector blocks (X1A, X1B, X2, X3), or by using
Sub-D connectors for connecting to the M.F. converter (X15) and the secondary current
measurement channels (X16). On the front panel, an RS485 connector is provided for a point-to-
point PC connection for downloading and backing up setting parameters. The power supply is
slotted onto the CPU board. All of the electronic components are protected by a metal casing
against impact damage, projections of all kinds and radiated electromagnetic interference.
1. Front panel with programming key pad and control LEDs

2. Liquid Crystal Display
3. X7 connector (9p female Sub D): RS485 serial link
4. Programming/Run (PRG/RUN) key switch
5. CPU board
6. Power supply unit
7. Protective case
8. Connector - terminal block X1A and X1B: WCC inputs
9. Connector - terminal block X2: WCC outputs
10. Connector - terminal block X3: proportional valve control
11. Connector X4 (15p male Sub D): Not used

1. PRESENTATION
12. Connector X5 (9p male Sub D): Not used

13. Rating plate
14. Regulator/Interface board
15. Connector - terminal block X12: servo valves (option)
16. Connector - terminal block X13: inputs (not used)
17. Connector - terminal block X14: outputs (not used)
18. Connector X (9p female Sub D): RS485 serial link
19. Connector X16 (9p male Sub D): M.F. measurement
20. Connector X15 (25p female Sub D): connection to the M.F. converter
21. Connector X11 (9p male Sub D): RS232 serial link, M.F. board

1. PRESENTATION
Front panel

1. PRESENTATION
No. TYPE FUNCTION

1 Powered up
indicator
2 Welding current flow

indicator
3 SV1 output
indicator
4 SV2 output
indicator
5 Single spot welding mode

indicator
LEDs 5, 6, 7
blink if a failure
6 Series stop welding mode
indicator occurs
WITH/WITHOUT current mode (Lit if
7
indicator "WITH CURRENT"
8 Label Type and version
9 Display LCD, 4 lines of 20 characters
10 Access to the next lower program number or configuration pages

key
11 Access to the next higher program number or configuration pages
key
12 Access to the previous programming page

key
13 Access to the next programming page

key
14 Increments the value under the cursor

key
15 Decrements the value under the cursor

key
16 Moves to the next parameter on the same page. In "RUN" mode: Reset fault
key
Recalculates the reference currents (screens P6, P7, P8, P9)
17 [F1] key
Automatically recalculates the compensation factor (screen P20)
18 [F2] key Sets the measurement as a reference (screens P6, P7, P8, P9)
19 [F3] key Selects a specific program for editing
• "Redo Spot" function in the event of a type 4 inhibiting fault
20 [F4] key
• Move the cursor to prog. digit/digit
21 [F5] key "Next Spot" function in the event of a type 4 inhibiting fault
• Programming certain screens
22 [F6] key
• Configuring WCC
Acknowledge electrode replacement or dressing
23 [F7] key
Reset wear compensation
24 "MODE" is used to see the programming settings being executed

key
25 Connector 9p female Sub D connector for RS485 (depending on options)
26 Key switch Key switch for selecting the programming (PRG) or run (RUN) mode

2. FAMILIARIZATION
2.1. SOFTWARE ORGANIZATION

All of the programming for this device can be performed from the front panel built-into all models.
However, if the user wishes, it is also possible to perform programming on a PC (connected via
the 9p Sub D connector on the front panel) after first purchasing the software required for this
kind of programming from ARO and then downloading or retrieving the program files.
2.1.1. Program and Parameter Organization
• Accessing programming mode

The key switch located on the front panel must be set to PRG to change parameters
(see No. 4 in the figure on page 4).
• Accessing parameters
The memory used to store welding parameters is arranged like a spreadsheet. The
columns represent program numbers and the lines represent the different welding cycle
parameters. The special functions are located on the left of the configuration screens.
Parameter Config.
Window
Parameter
Window
Parameter
Window
Parameter
Window
Configuration screens 32 Basic programs
This window displays one or more parameter lines for a given program. To move the
display field, press the or key to access the next higher or the next lower
program and use the or key to access the previous or the next group of
parameters in a given program.

2. FAMILIARIZATION
Horizontal and vertical movements are continuous ones. This means that from the last
program access to configuration pages is gained by pressing and in the same way,
from the first program to the configuration pages by pressing . In the same way, to
move from the last group of parameters in a given program to the first group, press .
• Displaying parameters programmed in RUN mode

It is not possible to change welding parameters in RUN mode, it is however possible to
check their value by pressing the mode key .
The window will no longer display run parameters, clearing the way for the last
programming window that was displayed before switching from PRG → RUN. The
, , , , keys are used to access other parameters in other programs.
Pressing the MODE key once again will return you to the RUN parameters.
• Changing parameters while working

To change parameters, switch to the PRG mode, change the parameters, then switch
back to the RUN position to allow welding cycles to resume and to accept new
parameters.
Changing parameters while welding is possible for the WCC function continues to
manage welding cycles in PRG mode.
The new parameters are accepted:
- With the key switch in "Program" mode after pressing or , and when the next
START call is made.
- With the key switch returned to "Run", when START is next selected.
• Changing parameters
Typical programming window appearance.
1. Program number
2. Parameter labels (names are often abbreviated)
3. Parameter values
4. Cursor position under the parameter to change
5. Cursor position in the windows where parameters can only be accessed after
pressing [F6]. Refer to the description of special case No. 2 overleaf.
- The same window may comprise one or more parameters.

- When accessing a new window using one of the four , , , , keys, the
cursor automatically locates to the first parameter.
- This parameter value can be increased or reduced by pressing the or key.

2. FAMILIARIZATION
- The key is used to move to the next parameter in the same window.
If a parameter value should not be changed, press without changing this value
to move to the next parameter.
- Parameters changed during programming are only stored and therefore validated
when the window changes (press the or key), or on returning to the RUN
mode.
When the parameter is a literal value (Y/N, WITH/WITHOUT), successively pressing
, will scroll the list of options placed under the cursor. When the desired
option appears, validate it by changing the window (press the or key) or by
changing to RUN mode.
SPECIAL CASE:
1) To simplify entering distant values, each digit can be incremented or decremented

individually.
Press the [F4] key to move the cursor under each digit, then use the or key
to adjust the value. Press to store the value or press , ; , , to access
another window.
E.g.: P1 - l 1 l 5 l"0"l 0 l
[F4]
P1 - l 1 l"5"l 0 l 0 l
2) Protected parameters
Given the risk that unintentional access and modification may represent to the
programming of some parameters, access to these parameters in only possible after
first pressing the [F6] key. The choices made are validated in the same way as
described previously.
This restriction applies for the "Mode" P0, P19, P20, P21, P23 and P24 or
configuration windows (for the latter, parameter setting will be described later).
Basic programs
A basic program is used to fill-in all of the automation system and welding settings
required for performing a spot weld. Depending on the options retained (wear
compensation, heat treatments, proportional valve settings, etc.), a program may
contain up to 70 parameters.
Accessing a specific program

Pressing the [F3] from any field will call up the program number field. The [-], [+] and
[F4] keys are used to change the number. Pressing the key allows direct access
to the program displayed, without the need to move through intermediate programs.
Exiting the screen without confirming, by pressing the key cancels the request:
the action is performed for the program displayed before the [F3] key is pressed.

2. FAMILIARIZATION
2.1.2. Configuration Screens
It is possible to access these screens from program 0 by pressing the key. To

program these windows (refer to sub-section 3.1.).

2. FAMILIARIZATION
2.2. Basic Programming
REFERENCE VALUES
WINDOW BY
No.
DISPLAY MIN MAX INCREMENT DEFAULT
■ E0 Pr
With current ■
no yes - yes
P0 Working program:
■
single spot series spot - single spot
❚: Requires pressing F6 : Text field #: Number field
Parameter definitions:
“With current” is used to choose between a cycle with or without current (refer to the
common steps in the Grafcet chart).
• The “yes” field selects a cycle with current.
• The “no” field selects a cycle without current.
“Working program” is used to choose between two working modes:

• The “single spot” field defines spot by spot welding.
• The “series spot” field defines continues series spot welding.
REFERENCE VALUES
DISPLAY BY
No.
WINDOW MIN MAX INCREMENT DEFAULT
Welding E1 Pr Current
% cyclic ratio - % cyclic ratio
Regulation/control regulation
P1 ■
■ Current
No control - No control
control
: Text field #: Number field
“Regulation/” of the current level lets you choose between different kinds of operation.
• The “% cyclic ratio” field defines operation without current regulation but with the welding
current programmed as a % of the cyclic ratio. A 100% cyclic ratio defines 500µs pulses.
• The “Regulation cur.” field defines operation with current regulation that is programmed in
amps or kilo-amps. (Note: the choice of amps or kilo-amps is made from configuration screen C1
and determines the value of the units used in the rest of the programming screens).
“/control” of the current level lets you choose between different kinds of operation.
(Note: the request values for regulation and control functions using a %, in amps or in kilo-amps
are entered in programming screens P6 to P9):
• The “No control” field defines operation without checking the current value against the
minimum and maximum thresholds.
• The “Current control” field defines operation that includes checking the current value against
the minimum and maximum thresholds. Current control operation is based on monitoring the
current level measurement which should remain between the minimum and maximum thresholds
defined by the tolerances set in programming screen P10.
• The “Control cur. and %” field defines operation with a check on the command % level as
well as the actual current level.

2. FAMILIARIZATION
REFERENCE VALUES
DISPLAY BY
No.
000,0 125 000,5 000,0
per. E2 Pr 000,0 125 000,5 000,0

P2 First squeeze ,
Squez Hold Off 000,1 125 000,5 001,0
, , ,
000,0 125 000,5 000,0

#: Number field
Parameter definitions: Programming the welding cycle

“First squeeze ###” sets the first squeeze time in periods.
“Squez ###” sets the squeeze time in periods.
“Hold ###” sets the hold time in periods.
“Off ###” sets the off interval in periods between two welding cycles.
REFERENCE VALUES
DISPLAY BY
No.
0 1000 1 0
E2b Pr
Welding time ms
P2B Number of Pulses 1 20 1 1
Interval ms
1 2000 1 10
Parameter definitions: Programming the welding cycle

“Welding time ####” defines the welding time in milliseconds.
“ Number of pulses ##” defines the number of pulses, determining the welding time or current
passage time (1: no pulses).
“Interval ####ms” defines the cold time in milliseconds (without any current passage) between
two welding pulses, in milliseconds.
REFERENCE VALUES
DISPLAY BY
No.
00 15 1 00
■Electr E3 Pr 000 999 1 000

P3 Alarm beforeFVE
Fault after FVE 00 99 1 00
New el.dressing■
yes no - no
█ : Requires pressing F6 : Text field #: Number field
“Electr ##” sets which electrode is used with this program.

2. FAMILIARIZATION
“Alarm ### beforeFVE”: the number of spots before the last step (or segment) in the wear
compensation cycle for triggering the alarm: number of spots between the alarm (request
electrode replacement or request electrode dressing) and the end of service life.
“Fault ## afterFVE” after the end of electrode service life. The wear compensation fault is
generated N spots after the end of electrode service life.
“New el.dressing” requests or does not request dressing for newly replaced electrodes:
• “yes” the WCC generates a dressing request when electrode replacement has just been
acknowledged. New electrode dressing acknowledgement does not increment the dressing
counter.
• “no” the WCC does not generate a dressing request for a new electrode.
REFERENCE VALUES
WINDOW BY
No.
Electr E4 Pr no yes - no
Interstep Dress■
Replacement:
P4 ■ limited extended - limited
③ yes no - yes
#: Number field : Text field
Elect ## shows the number of the electrode assigned to this program.
Interstep Dress
- No: dressing is only possible at the end of the wear compensation step.
- Yes: interstep dressing mode (dressing is performed at regular spot intervals).
Used to choose between two ways of resetting counters:
- Limited: only the current electrode's counters are reset when electrode replacement is
acknowledged.
- Extended: the counters for a number of electrodes are reset when electrode replacement is
acknowledged.
Replacement ③ (for the extended replacement mode):
- No: acknowledging electrode replacement only affects electrodes in extended replacement
mode.
- Yes: acknowledging electrode replacement affects all electrodes (even those in limited
replacement mode).
REFERENCE VALUES
WINDOW BY
No.
Electr E5 Pr 00 99 1 00
dressing at
P5 end of step
Offset
0000 65000 1 0000
#: Number field
“Dressing at end of step” defines the maximum number of electrode dressing action performed at
the end of each wear compensation cycle before an electrode replacement request is issued.
“Offset ####” is used to offset the number of spots shown on the spot counter after each dressing
action. The offset does not take into account new electrode dressing.

2. FAMILIARIZATION
REFERENCE VALUES
WINDOW BY
No.
Electr E5b Pr 1 9999 1 1

Dressing within step
P5B every spots
Dressing margin
00 99 1 30
#: Number field
The P5B screen is only accessible if interstep dressing was chosen from screen P4.
“Dressing within step every #### spots” defines the number of spot welds between each request for
interstep dressing.
“Dressing margin ##” defines the number of spots allowed after a dressing request.
REFERENCE VALUES
WINDOW BY
No.
Electr E6 Pr
01 % kA
02 % kA 00000 65000 1 00000
P6 03 % kA
Electr E7 Pr
04 % kA 20.0% 99.0% 0.1% 40.0%
05 % kA
P7 06 % kA
Electr E8 Pr
P8 07 % kA 0.50 KA 9.99 KA 0.01 KA 03.0 KA
08 % kA
09 % kA
Electr E9 Pr
10 % kA
P9 10.0 KA 99.9 KA 0.1 KA -
The “01 #####” number field defines the number of spots in each wear compensation step.
The “##,#%” number field defines the request value when operating with a % of the cyclic ratio
set or serves as the reference check value when using the current regulation control mode with a
current and % level check.
The “#,##KA” number field defines the request value when operating in current regulation
mode or serves as the reference check value when operating with a % of the cyclic ratio set and
a current level check.

2. FAMILIARIZATION
The accessibility of number fields and is set by the options chosen when programming
screen P1.
ACCESSIBILITY FUNCTION
F1 F2 F2
Regulation mode Check mode % A/KA
(i/%) (i ref) (% ref)
% cyclic ratio • ✶ - - -
No check
Current regulation ✶ • - - -
% cyclic ratio • • - X -
Current check
Current regulation ✶ • - - -
Curr. and %
Current regulation • • - - X
check
• : Accessible field ✶: Inaccessible field X: Accessible key
- Key F2 (i ref) is intended to copy to the cursor position on line 4, the last current
measurement made in current reference mode in the “#,##”A/KA number field for the
appropriate step.
- Key F2 (% ref) is intended to copy to the cursor position on line 4, the last current
measurement made in percentage reference mode in the “##,#”% number field for the
appropriate step.
REFERENCE VALUES
DISPLAY BY
No.
03 99 01 03
I.ToleranceE10 Pr 03 99 01 03
P10 Pos% + % Neg%- %
Recurrence - % 03 99 01 03
Nr. infringements
0 9 1 0
#: Number field
The P10 screen is only accessible if the “I.ToleranceEl0” or “I.Tolerance and %” modes are
selected in the P1 screen.
“Pos% +##%” defines the tolerance as a percentage for the positive welding current limit in
relation to the request value (fault 23 if generated if it is exceeded).
“Neg% -##%” defines the tolerance as a percentage for the negative welding current limit in
relation to the request value (fault 24 if generated if it is exceeded).
“Recurrence -##%” defines the tolerance as a percentage for the lower welding current limit that
can be crossed a number of times in succession before generating fault No. 25.
“Nr. infringements #” defines the number of times the lower limit can be crossed during the
current program before generating fault No. 25.

2. FAMILIARIZATION
REFERENCE VALUES
DISPLAY BY
No.
00 99 01 10
% ToleranceE11 Pr 00 99 01 10
P11 Pos% + % Neg%- %
Recurrence + % 00 99 01 10
Nr. infringements
01 99 1 1
#: Number field
The P11 screen is only accessible if the “ToleranceEll and %” modes are selected in the P1
screen.
“Pos% +##%” defines the tolerance as a percentage for the positive welding current limit as a
percentage measured in relation to the reference percentage (fault 8 is generated if it is
exceeded).
“Neg% -##%” defines the tolerance as a percentage for the negative welding current limit as a
percentage measured in relation to the reference percentage (fault 28 is generated if it is
exceeded).
“Recurrence -##%” defines the tolerance as a percentage for the positive measured welding
current percentage that can be crossed a number of times in succession before generating a fault
(fault 29 is generated if it is exceeded).
“Nr. infringements #” defines the number of times the lower limit can be crossed during the
current program before generating fault No. 29.
REFERENCE VALUES
DISPLAY BY
No.
000 500 1 000

Upslope E12 Pr 10.0 99.9 00.1 10
ms Beginning
Downslope
P12 ms End KA % - %
000 500 1 000
10.0 99.9 00.1 10

“Upslope ###” defines the duration in milliseconds of the of the progressive increase in current
(included in the first hot time is the pre-heating or welding).
“Beginning #,##” defines the current level at the beginning of the upslope.
“ ”: % if % of cyclic ratio mode.
kA: if current regulation mode.
“Downslope ###” defines the duration in milliseconds of the progressive reduction in current
(added to the welding time).
“End ####” defines the current level at the end of the downslope.

2. FAMILIARIZATION
REFERENCE VALUES
DISPLAY BY
No.
0 1000 1 0
KA 0.50KA 99KA 0.01-0.1 3.00KA
P13 ms E13 Pr % 10.0% 99.9% 0.1% 40.0%

Preheat.
Cooling
Annealing 0 2000 1 0
% kA - %
#: Number field
Parameter definitions: Programming the eight motion welding cycle

• “#### Preheat.” defines the duration of preheating in milliseconds.
• “#### Annealing” defines the duration of annealing (reheating after welding and cooling) in
milliseconds.
The “#.##” number fields define the current request level during the preheating and annealing
times.
“Cooling ###” defines a duration in milliseconds allowing a cold period (with no current) after
the welding time and prior to the annealing time.
Restates the unit used for the current request, based on the table below:
ACCESSIBILITY
Regulation mode Control mode KA %
Current regulation Regardless of • -
% of cyclic ratio control choice - •
•: Accessible field
ACCESSIBILITY REFERENCE VALUES

PRESSURE
PROGRAM
DCY1.SV1
DCY2.SV2
DEFAULT
SV1.SV2
WINDOW
SV2
No.
MAX
SV1
MIN
INC
BY
DISPLAY
-
Dcy2.SV2
Dcy1.SV1
■SV mode E14 Pr

■
X X - - - -
-
P14
■SV mode
■
E14 Pr * - - - - X 0 999 1 0
SV2 (per.)
Delay Leng.
* - - - - X 0 999 1 0
❚: Requires pressing F6 #: Number field
“SV mode” is used to choose between different servo valve operating profiles:

2. FAMILIARIZATION
• The “DCY1.SV1, DCY2.SV2” field controls the welding servo valves based on the corresponding
number of cycle starts (DCY1 SV1 or DCY2 SV2).
• The “SV1” field controls welding servo valve SV1, regardless of cycle start.
• The “SV2” field controls welding servo valve SV2, regardless of cycle start.
• The “SV1.SV2” field controls welding servo valves SV1 and SV2 at the same time, regardless
of the cycle start.
The “pressure program” field controls welding servo valves SV1 and SV2 based on the following
pressure program parameters:
* Parameter accessibility via the fields numbered and is determined by the choice of servo
valve operation in “pressure program” mode. The table above summarizes this accessibility.
“Delay ###” defines the delay before releasing SV2 in relation to the start of squeeze time.
“Leng. ###” defines, following the delay time, the time during which SV2 is powered down
during the cycle.
REFERENCE VALUES
DISPLAY BY
No.
Electr E15 Pr no yes - no

Duty cycle
monitoring■
P15 Therm. rating kA 0.00kA 9.99kA 0.01kA 00.0kA
10.0kA 30.0kA 00.1kA -
“Duty cycle monitoring” is used to choose between:
• The “yes” field that sets a duty cycle for each cycle.
• The “no” field that does not use duty cycle monitoring.
“ Therm. rating ####A” defines the maximum permanent current value allowed by the user for
a comparison with the maximum permanent current value calculated by duty cycle monitoring.
REFERENCE VALUES
WINDOW BY
No.
E16 Pr
Programmable output
P16 Number 0 2 1 0
#: Number field
This window only appears if “Output modes” = 0 in screen C8.
“Programmable output number #” defines the programmable output number ( 1 PO1, 2 PO2,
0 no programmed output). This is used to set the selected output to “1” depending on program
chosen; if no output number has been defined, the output is set to state “0”.

2. FAMILIARIZATION
REFERENCE VALUES
DISPLAY BY
No.
Electr E17 Pr
daN/V Servovalve
1 % daN 000 999 1 000
2 % daN
P17
Electr E17 Pr * 000 100 1 000
daN/V Servovalve
1 % daN
2 % daN
* 0000 9999 1 0
❚: Requires pressing F6 #: Number field ✶: Field cannot be accessed
“###daN/V” defines the relationship between the servo valve control voltage and the action on
the electrodes.
“Servovalve ###%” is used to program the desired pressure level value as a percentage, based
on the maximum pressure level allowed by the welder (representing 100% in this case).
* The pressure value setting can be programmed as a %, in field “Servovalve ###%”, or in
daN, in field “####daN”, but for the latter field “###daN/V” should always be filled in for safety
reasons by pressing F6.
“####daN” is used to program the desired pressure value in daN.
Remark: the second servo valve can only be accessed if DIP 4 is set to ON (two servo valves are
optional on the additional medium frequency regulator board).
REFERENCE VALUES
DISPLAY BY
No.
■Electr E19 Pr ✶✶✶ 180 - 056

Transformer ■ kVA
Measure■
Number of coils
P19 secondary primary - secondary
1 2 1 1
❚: Requires pressing F6 #: Number field : Text field
Field “Transformer ###kVA” is used to define the welding transformer used:

- 056 kVA
- 057 kVA
- 090 kVA
- 091 kVA
- 180 kVA
Field “Measure ” is used to define the measurement channel used for control
purposes:
- primary
- secondary

2. FAMILIARIZATION
Field “ Number of coils #” is used to define the number of coils, 1 or 2 (if two coils are
connected in series).
REFERENCE VALUES
DISPLAY BY
No.
■Electr E20 Pr 00.50 99.99 0.001

Reference kA Value
P20 WCC Measure kA measured by
Adjustment , the WCC
100.0 160.0 000.1
Reference: Displays the value read on a reference device in order to change the reference
value factor.
- Press [F6] the symbols disappear to display the two measurements (this value initially shows
"WCC Measure").
- Press [+] and [-] change the reference value.
- Press [F1] automatically calculates the reference factor (the ratio between the reference
measurement and the WCC measurement, after taking into account the former factor used).
WCC Measure: the last measurement made by the WCC using the edited program.
Adjustment: displays the reference factor (a fine adjustment, for each electrode, of the
measured current level).
REFERENCE VALUES
DISPLAY BY
No.
■Electr E21 Pr
001.0 255.0 001.0 001.0
Measurement:
P21 Beginning ms
End %
➁ 10 100 1 100
#: Number field
The “###,#” number field defines the time after which the second measurement is calculated.
➁The “###%”number field defines the threshold (as a % of stabilized current) below which the
second measurement is no longer assigned, after the end of welding.

2. FAMILIARIZATION
REFERENCE VALUES
DISPLAY BY
No.
00,00 99,99 00,01 00,00
■Electr E22 Pr 000,0 400,0 000,1 000,0

P22 Slope YL , kA
A , YA , kA 00,00 99,99 00,01 00,00
B , YB , kA
000,0 400,0 000,1 000,0

The P22 screen is only accessible if the type of welding transformer is not referenced (✶✶✶kVA)
and if primary measurement is selected from screen P19:
“YL” defines the limit between the lines: 0, line B not used.
“Slope” defines the slopes of lines A and B expressing the transformation ratio.
“YA” defines the initial ordinate of line A.
“YB” defines the initial ordinate of line B.
REFERENCE VALUES
DISPLAY BY
No.
yes no - yes
■Electr E23 Pr
Control diodes ■
P23 Water flow ■ l/min 4 8 2 4
Water temperat. °C
01 99 01 20
#: Number field : Text field
“Control diodes ”: if YES, test the diode thermal state prior to every weld (fault No. 5 with
a non-validity cause, No. 33 if diode capacity level exceeded).
“Water flow #l/min” defines the cooling water flow around the diodes (4, 6 or 8 liters per
minute).
“Water temperat. ##°C” defines the water temperature on the inlet into the welding
transformer.
REFERENCE VALUES
WINDOW BY
No.
■Electr E24 Pr 00000 65000 1 00000

Spot counter
Dressing counter
P24 Between step ➁ 000 999 1 000
③ 0000 9999 1 0000

2. FAMILIARIZATION
Resets the spot counters assigned to the specified electrode, to any value (especially 0).
Reinitialization is only possible if the configuration in screen C8 allows it (Reset counter = yes).
“Spot counter #,###” allows resetting the spot counter assigned to this electrode, to the
desired value, since the last dressing or electrode replacement action.
➁“Dressing counter #,###” allows resetting the dressing counter assigned to this electrode, to
the desired value, since the last electrode replacement action.
➂“Between step #,###” allows resetting the dressing spot counter assigned to this electrode, to
the desired value, since the last interstep dressing request.

2. FAMILIARIZATION
2.3.EXPLANATIONS ON BASIC PROGRAMMING
2.3.1. Welding Current Variation Principle
The welding current variation is achieved through a medium frequency converter.
• Electrical layout diagram
50/1000Hz Converter
ARO 1000Hz rectified transformer
400V, 50 or 60 Hz,
three-*phase
mains supply
Control electronics
Micro 2X16III
Welding Check
Controller
• Operation
The converter rectifies the three-phase voltage supply, smoothes it and chops it. The
transformer lowers the voltage (increasing the current) and the diodes rectify the signal.
The welding gun as an impedance coil smoothes the current.
Current regulation is achieved by the four IGBT units controlled by the converter.

2. FAMILIARIZATION
2.3.2. Welding Cycle Operating Mode (Window P0)

A) Selecting the operating mode:
• Automatic welding cycle Grafcet (Main sequence: single spot and

continuous modes)
1 Waiting
DCY. Blocking faults
First Cmd Arm

2 approach
DCY DCY.End step 2
Cmd Arm
3 Squeeze
workpiece
DCY DCY.End step 3

Request
Cmd Arm
4 Welding
Workpiece
Authorization
DCY.Authorize welding cycle DCY..Authorize welding

DCY
Without current cycle
11 TIMER Cmd Arm

5 PREHEATING
Workpiece
Request
Cmd Arm
Workpiece
Welding Converter Cmd
Authorization
End timer End step 5
Cmd Arm
6 WELDING
Breakdown with different pulse

Workpiece
Request
Welding Converter Cmd
End step 6 Authorization
Request new pulse End step 6
Request
Pulse Cmd Arm
7 8 Welding
Workpiece
Authorization
Cmd Arm Cmd Converter
Request
Welding End step 8
Cmd Arm
End step 7 9 COOLING * Workpiece
Request
Welding
Welding with different Authorization
End step 9
Cmd Arm
10 ANNEALING
Workpiece
Request
End timer Welding Converter Cmd
Authorization
Cmd Arm
12 Hold* Workpiece
End step 12 .Type 2/3/4 blocking faults End step 12 .Type 2/3/4 blocking faults
General Cmd Reseale General Cmd Arm

13 Interval Workpiece 14 Interval Workpiece
End step 14 .Type 2/3/4 blocking faults
.End step 13 .End step 13

.Type 2/3/4 blocking faults .End step 13
.Type 2/3/4 blocking faults .Type 2/3/4 blocking faults
.DCY .DCY
End of the main sequnce for automatic single spot and continuous welding - continued
* cold time during which the thyristors are not controlled (no current)

2. FAMILIARIZATION
• Single spot welding mode:

- Grafcet - continued
Main sequence Grafcet for automatic single spot and continuous welding - continued
(1) (2) (3) (4) (5) (6)
15 FAULT 16 FAULT
SV Cmd SV Cmd
Realease workpiece
Reset . DCY
Reset . DCY Reset . DCY Reset . DCY Reset . DCY
. Type
.Type 2 fault .Type 3 fault .Type 4 fault . Type 1 fault
2/3/4 faults
Repeat
19
18 FCY 17 FCY
DCY DCY DCY DCY
. NO(F5) . NO(F5) .Yes(F4) . Yes(F4)
200 ms
DCY End Timer DCY
- A start cycle command is required to trigger each welding cycle. The start of cycle
command is opened at the end of the cycle, then closed again to start a new cycle.
The start cycle command must remain closed at least until the start of the first heating
period (preheating or welding). In this mode, the first squeeze time is taken into
account as part of each cycle and allowance is made for the general interval time
before allowing a new DCY.
START T
1S S 1S S W H 1S S W H 1S S W H T
Cycle
SV T
Current T
• Continuous welding mode:

A start cycle command can be held permanently and the welding cycles follow in
succession. They are timed by the general interval time during which the welding
distributor is powered down so that the welder can open and the workpiece or the
welder can be moved. The squeeze time is deducted from each welding cycle, while the
first squeeze time is deducted from the first cycle only.
The sequence stops as soon as DCY is released (once the current cycle has been
completed in full) or after a blocking fault.

2. FAMILIARIZATION
Main sequence Grafcet for automatic continuous welding - continued
(1) (2)(3) (4) (5) (6)
SV Cmd
15 FAULT
Release workpiece
Reset fault . DCY
Grafcet - continued
T
START
1S S W H I S W H I S W H I S W H T
Cycle
SV T
Current T
• B)
This function allows running a normal cycle without controlling the thyristors during the
hot periods. Applications : debugging: tooling, cycle time, etc., electrode dressing.
• IMPORTANT: Choosing the no current mode does not ensure safety when working
on the welder's power supply circuit.

2. FAMILIARIZATION
2.3.3. Choosing the Current Controller Mode
Operation:
WCC
X16
X15
MF Converter
L1 MF Transformer
Three-phase mains supply
L2
L3
• Operating with a constant conduction ratio (or % of cyclic ratio)

This control principle sets the time when the IGBTs are conductive during a half-control
period (control period = 1 ms). The conductive time may vary between 50 µs (10%
request) and 499 µs (99.8% request).
• Operating with a constant current level (or current regulation)

This control principle sets the time when the IGBT are conductive to obtain and
maintain a current level programmed by the user, to ensure consistent welding quality
whatever the fluctuations in the mains supply or in welder impedance (electrode fouling,
circuit heating, differing workpiece insertion, workpiece surface conditions and
conditions of secondary circuit parts: wire, flexible jumpers, contacts etc.).

2. FAMILIARIZATION
• Advantages and limits to current regulation

Current regulation allows maintaining a constant current level regardless of any
variations in the primary voltage and impedance levels affecting the machine.
Primary voltage variations: These can reach +15%, -20% in relation to the rated
supply level.
These variations are the result of load variations within plants and shops and cause
varying degrees of line voltage drops.
Impedance variations, main causes:
- Circuit heating: the resistance of copper increases with temperature.
- Degrading of flexible wires: braids or bands become broken.
- Increased contact resistance levels in the secondary circuits (oxidation, loosening).
Oxidation or pollution of electrodes.
- Magnetic losses dues to the presence of steel panels close to or within the
secondary loops.
Intensity regulation considerably increases the consistency of resistance welding
quality, but it cannot however eliminate every problem. In particular, it cannot
resolve the following phenomena:
- Jumper effect: Part of the current is drawn off by a neighboring spot weld.
Cure: choose welding programs with current values that vary between the first spot
and successive spots.

2. FAMILIARIZATION
Id (soudage
Dérivé)
- Widening electrode gap: As current dispersion increases, more current is

required to ensure the same welding quality.
Cure: progressively increase the current level according to the number of spots
performed.
- Double or multiple spot welding:
The overall current level I can be regulated, but it is impossible to know the split
between I1 and I2.

2. FAMILIARIZATION
2.3.4 Programming Basic Welding Cycle Steps (Screens P2 and P2B)
• Five step welding cycle:

The cold periods are programmed as a number of 50 Hz or 60 Hz AC periods and the
hot periods are programmed in milliseconds.
1 period = 20 ms (50 Hz) or 16.66 ms (60 Hz).
I and F
Pressure
Welding
current
Periods
t
1st Sq Pu Pu Pu Ho Int
sq ee ls en lse lse ldin erv
ee ze o1 Int no g al
ze er v 2
a l
Welding
1) First squeeze
This period of time corresponds to welder closure. This time is added to the squeeze
time. In continuous mode welding, the first squeeze time is only counted for the first
spot that follows pressing DCY (start cycle). For successive spots, only the squeeze
time is counted.
1S S W H I S W H I S W H I
START
In practice the first squeeze time is only used for continuous mode welding.
2) Squeezing
The estimated time that is required to obtain the welding pressure after DCY action.
This time must be programmed so that at least 90% of the pressure required is
achieved.
3) Welding
- Without pulses
The welding time corresponds to the total time during which the programmed
current flows.
- With pulses (this applies if screen P11 is filled in).
The welding time corresponds to a programmed pulse duration. This time is
considered as repeated as many times as there are pulses programmed, with a
cold period between each pulse, called the pulse interval.
- Pulse interval
The cold time between two pulses.

2. FAMILIARIZATION
4) Holding
Time during which the welding pressure is maintained whereas the current has
stopped flowing. This time period allows the melted core to cool under pressure.
5) General interval
In spot welding, this time is a cold period between two basic welding cycles. In
continuous welding mode, this time automatically sets the welder's welding rate. It
corresponds to the time during which the welder's servo valve is not supplied,
allowing the welder to open and move onto the next spot.
6) Programming the cycle times

The cycle's "cold" times (first squeeze, Squeezing, Holding, Interval) are
programmed as a number of periods (one period = 20ms for 50Hz and 16.66ms for
60Hz), and they can be adjusted to within a half period.
The cycle's "hot" times (Preheating, Upslope, Welding, Interval, Downslope, Cooling,
Annealing) are programmed in ms.
However, the full welding cycle time, regardless of the total duration of hot periods
programmed in ms, is an integer number of half periods, i.e. the total time is rounded
up to the next half period.
Example:
If the sum of programmed time periods is 250ms, the true cycle time is 250ms.
However, if the sum of programmed time periods is 253ms, the true cycle time is
260ms. The 7 ms are added to the holding time.
Furthermore, the full cycle time must take into account the 10 ms added prior to
squeezing. When continuous welding is used, these 10 ms are only present during
the first cycle.
Example:
If the sum of programmed time periods is 250 ms (hot times + cold times), the true
cycle time is 250 ms + 10 ms.
However, the sum of programmed time periods is 253 ms, so the true cycle time will
be 260 ms (rounded) + 10 ms.

2. FAMILIARIZATION
• Configuring the measurement
Welding without an upslope

Squeeze WELDING HOLDING
Tm = 20ms
100%
Start
meas.
Stabilized welding current
0%
Set welding current
Welding an upslope
WELDING HOLDING
Upslope Tm = 20ms
Start
meas.
Stabilized welding current
Set welding current
Two current level measurements taken over the welding duration are provided:
One measurement, identified as the "Stabilized welding current", including the
full welding time less the first 20 ms. This measurement is the result shown on
screen X1 (or the third line in screen X9) and it serves as the reference for current
control purposes. If the welding time is less than 20 ms, the current level shown is
that of the last ms of welding time.
A second measurement is shown in screen X9 (the "XX,XXkA fields in line 4):
the "Set welding current" is calculated on the basis of the parameters taken from
screen P21.
This is the screen used to configure the "Start meas." time, in ms, the "Stop meas."
threshold in %. "Start meas." indicates the ms point after which the current level is
calculated. The "Stop meas." point is used to include the natural current downslope
into the calculation. It determines, as a % of the welding current level value, the
threshold after which the measurement stops. 0 is displayed if the "Start meas." time
is higher than the total welding time.
These various calculations are only performed on the welding time, i.e. if any upslope is
included in the welding, this upslope time is not taken into account.
2.3.5 New Electrode Dressing (Screen P3)

• New electrode dressing
No: no dressing request is present for this electrode after its replacement.
Yes: a dressing request is generated for this electrode after its replacement.
2.3.6 Choosing the Type of Compensation (Screen P4)
• Interstep dress: Interstep dressing:

No: dressing is only possible at the end of the wear compensation steps.

2. FAMILIARIZATION
Yes: operates in interstep dressing mode (dressing is performed at regular

intervals between spots).
• Types of replacement:
1) Limited: Limited electrode replacement: Only the counters for the current
electrode are reset when electrode replacement is acknowledged.
2) Extended: Extended electrode replacement: The counters for a number of

electrodes are reset when electrode replacement is acknowledged.
• All electrodes: (for the extended electrode replacement mode)

No: electrode replacement acknowledgement only affects electrodes in extended
electrode replacement mode.
Yes: electrode replacement acknowledgement affects all electrodes (even those in
limited electrode replacement mode).
2.3.7 Dressing at the end of a Wear Compensation Sequence (Screen P5)

This page is only accessible if dressing between steps (P4) is set to “no”.
• The number of dressing actions at the end of a sequence

Field is used to program the number of dressing actions to perform before an
electrode replacement request is triggered. If no dressing is programmed, the WCC will
request electrode replacement as soon as the first wear compensation sequence is
completed.
• Offset
- Under Offset, enter the initial value of the spot counter after dressing.
2.3.8 Interstep Dressing (Screen P5B)

This screen is only accessible if interstep dressing was selected from screen P4.
• Interstep dressing every #### spots

This field is used to program the number of spots between each dressing request.
• Dressing not performed

This field defines the number of spots allowed between the time when the WCC
requests dressing in interstep mode and the time when the dressing performed reset
information has to reach the WCC. Any delay in performing dressing will not affect the
next dressing deadlines. If the interstep counter reaches this value without a dressing
performed reset being received, then fault No. 12 is triggered.
2.3.9 Configuring Wear Compensation (Screens P6/P7/P8/P9)
Each step comprises three headings: HEADINGS
01 ##### ##,# %#,## A Step No. 01

02 ##### ##,# %#,## A
• Step based wear compensation is characterized by the value on the spot counter at the
end of the step (Field ) and the welding current expressed as a percentage of %Imax
(Field ), or in kiloamps (Field ) during the step.

2. FAMILIARIZATION
Consequently each program comprises 10 steps or 9 segments. Segment based wear

compensation is defined by the spots that separate the segments. Each spot is
characterized by the value on the counter and the welding current.
• Heading :
The “01 #####” field defines the value of the spot counter at the end of the step or the
segment
- If the heading for step No. 01 is programmed for zero, then no wear compensation is
configured.
- If no incrementing rule is provided: identical welding current level throughout the life of
the electrodes, only step No. 01 need be filled in.
- If segment based wear compensation is configured, heading in the last step p must
be set so that Np = Np1+l for in this case, the last step includes only one spot. The
last step is necessarily horizontal (constant current intensity).
When N number of spots is reached, move onto the next step.
The last step is the one that precedes a step with a 00 000 value in heading or a
value that is lower than that of the previous step.
• Heading :
The “##,#%” field defines the current request in percentage of %Imax mode.
• Heading :
The “#,##kA” field defines the current request in kA.
- An incrementing rule may decrease: reducing the current values according to the
number of weld spots completed. On the other hand, the number of spots can only
increase. Any number of spots that is equal to or less than the previous setting is
taken as the end of an incrementing rule.
2.3.10 Electrode Wear Compensation and Dressing Principles
A) Purpose of wear compensation:

When electrodes are used, their characteristics deteriorate due to the effects of two
main processes:
- changes in geometry.
- changes in the characteristics of electrode materials.
• Changes in geometry
The impact effect caused by repeated pressure, clamping the workpieces as well as
electrode - workpiece contact heating combine to produce a superficial compression of
the electrode which consequently increases the heating area.
As the heating area increases, more current is required to melt the weld core, simply
maintaining a constant current level is not enough. The requested current level must be

2. FAMILIARIZATION
increased in the MICRO 2X16_III current control mode or as a % of the request in

M.F. converter current control mode depending on the number of spots performed.
This is done by line segments. This is what is called a wear compensation step.
• Changes in the characteristics of electrode materials

Under the effect of the heat, pressure and electric fields, the coating metal is
progressively diffused into the electrode material forming an alloy that does not retain
the same electrical conductivity as the original material.
All of these changes mean that the contact resistance becomes modified; the current
required for performing spot welds must therefore change accordingly.
B) Wear compensation steps and dressing:

The MICRO 2X16 allows programming and managing both a progressive increase in
the current according to the number of spot welds performed by the electrode (the wear
compensation steps or segments), as well as electrode dressing, where the electrode is
superficially cleaned after a certain number of spot welds have been performed.
Dressing may be requested at the end of a wear compensation step or during it.
Consequently it will be referred to as dressing between steps or between segments.
The wear compensation process may be a non continuous one, leading to a step
based process or a continuous one, which is segment based. The choice of the
approach used is made in configuration screen C5 and it is valid for all WCC programs.
• Advantages of dressing between steps

This approach is used in the event of severe electrode pollution by the (zinc) coating
metal. In this case, the zinc deposit must be eliminated very often (≈500 spots), but as
the electrode has not been geometrically modified during such short intervals there is
no need to increase the current level.
Discontinuous or step based CUPP type wear Continuous or segment based CUPS type wear
compensation (4 steps) compensation (3 segments with a rising current level
and one with a constant current level)
Each step is characterized by: Each spot along the curve is characterized by:
- the welding current as a % or in kA depending on the - the welding current as a % or in kA depending on the
setting made in configuration screen C16. setting made in configuration screen C16.
- the value of the spot counter that indicates the end of - the spot counter value.
the step (moving onto the next step or the end of the
current wear compensation process).

2. FAMILIARIZATION
Explanations on the parameters entered in screens P6 to P9, depending on the choice of wear
Note: compensation made (steps or segments).
Steps Screens P6 to P9 Segments
Step No. 01 01 N1 ✳✳,✳% I1 kA Spot No. 01
Segment No. 01
Step No. 02 02 N2 ✳✳,✳% I2 kA Spot No. 02
Segment No. 02
Step No. 03 03 N3 ✳✳,✳% I3 kA Spot No. 03
Segment No. 03
Step No. 04 04 N4 ✳✳,✳% I4 kA Spot No. 04
Segment No. 04
• Note:
When segment based wear compensation is chosen, the last segment (N3-N4) does
not have a rising current level. Therefore to create a rising current segment, a start and
end spot must be defined in programming screens P6 to P9, so that they can generate
a slope; in this case, there is no end spot.
Segments Start spot End spot

Segment No. 01 Spot No. 01 Spot No. 02
Segment No. 04 Spot No. 04 -
A wear compensation sequence comprises a maximum of 10 steps or 9 segments (for

10 spots).

2. FAMILIARIZATION
C) Wear compensation examples:
Example 1
Current
% or kA
Programmed
alarm trigger
Number of spots
Electrode alarm End of

=request electrode
electrode life
replacement
• Step based wear compensation comprising four steps and no

dressing
The end of electrode service life condition is generated at the end of the step based
wear compensation with a prior alarm signal (= electrode replacement request).
Current
% or kA
Programmed
alarm trigger
Number of spots
Electrode alarm End of

=request electrode
electrode life
replacement

2. FAMILIARIZATION
• Segment based wear compensation comprising four segments with a rising current
level and one segment with a constant current level and no dressing
- In this case, like in example 1, the aim is to have four segments for four rising current
level steps. Consequently, to generate a rising current level segment for each of the
four steps, five spots must be defined, but the fifth and last segment (N4-N5) does not
have a rising current level. Therefore to retain a rising current level approach for each
step, the last segment must be as short as possible and therefore comprises as few
welding spots as possible
(N4-N5=1 spot). This results in: N5=N4+1.
- The electrode end of service life condition is generated at the end of the wear
compensation process with a prior alarm signal (= electrode replacement request).
Example 2
• Step based wear compensation comprising four steps and two end of wear
compensation process dressing actions
Electrode N Electrode N+1
WC step 1 WC step 2 WC step3 WC step 1
Request
Dressing Dressing Dressing
electrode
request 0 request 1 request 2
replacement
(optional)
End of electrode life End of electrode life End of electrode life
- After running each of the first two wear compensation steps, the WCC generates an
electrode end of service life condition with a prior alarm X spots before the end of the
step (= dressing request).
- After each dressing action, the spot counter can be "advanced" so that the N’1 spot
number in the first increment during WC steps 2 and 3 is lower than when the
electrode is new (WC step 1), therefore N’1 < N 1. This programmable offset is
applied to all of the WC steps except the one that uses a new electrode (WC 1). This
ensures that allowance is made for the fact that an electrode, even after dressing, will
never recover the inherent characteristics of its as new condition. This offset is set in
screen P5.
- When the electrode is new, it may be necessary to run the dressing tool to make its
geometry look more like what it will be after future dressing actions. This operation is
a programmable one and if this choice is made, then each time the electrode is
replaced, the WCC will generate a dressing request before performing the first weld
spot.
• Note: Dressing without an alarm condition

- The alarm that is triggered before the end of service life (X) programmed in screen P3
is only taken into account after the end of the last wear compensation step. X = 0 for
all dressing phases and X resumes its number of weld spots value between the alarm
condition and the end of electrode service life for the last wear compensation step.
- An unacknowledged dressing request causes the WCC to lock up when the spot
counter value reaches the POST-FDVE value set in screen P3.

2. FAMILIARIZATION
- The end of electrode service life output is only activated at the end of the last wear
compensation step.
- Segment based wear compensation comprising four segments (three constant current
segments + constant current segment) and three end of wear compensation type
dressing actions.
Electrode N Electrode N+1
WC step 1 WC step 2 WC step3 WC step 1
Request
Dressing Dressing Dressing
electrode
request 0 request 1 request 2
replacement
(optional)
End of electrode life End of electrode life End of electrode life
- This process is handled the same was as shown in example 3, except that the steps
are replaced by segments. The initial I’1 value of the first segment in wear
compensation step 2 is automatically calculated by the WCC which takes into account
the programmed N'1 offset. Calculating current I’1 is necessary in this non constant
working environment (rising current level) unlike when step based wear compensation
is used.
- X is used to define the number of spots between the alarm and the end of electrode
life.
Note: The dressing without alarm condition function remains identical to

the step based wear compensation one.

2. FAMILIARIZATION
Example 3
Alarm=Request
electrode replacement
End of electrode life
• Step based wear compensation comprising three steps and "between step" type
dressing.
- The wear compensation process is the same as the one defined in example 1: at the
end of third step, the WCC generates an electrode end of service life state preceded
by a programmable alarm X spots before the end (= electrode replacement request).
- With a programmable and constant periodicity called Y, the WCC regularly issues
dressing requests asynchronously in relation to the wear compensation process. After
dressing, the WCC continues to check welding using the parameters for the current
step, and the spot counter is only reset after dressing.
- A tolerance of ∆Y is configured so that dressing is performed after the request is made
by the WCC. If dressing has still not been acknowledged ∆Y spots after the dressing
request, the WCC generates a fault (No. 12). Performing dressing ∆Y spots after the
WCC request does not shift the subsequent dressing rate.

2. FAMILIARIZATION
• Segment based wear compensation comprising three segments

and between step dressing
- This process is managed the same way as step based wear compensation where the
steps are replaced by segments.
D) Dressing with or without an alarm output:
DRESSING WITH ALARM:
Alarm Alarm
Post-fdve Post-Fdve
DRO ALE
DRO ALE
FVE DRO FVE
ALE
FVE FVE
Fault 10 Fault 10

2. FAMILIARIZATION
DRESSING WITHOUT ALARM:

Alarm
Post-fdve Post-Fdve
ALE
DRO ALE
DRO FVEALE
Fault 12 FVE
Fault 10
ALE Electrode replacement request output 10 Fault No. 10 (end of electrode life)
DRO Electrode dressing request output 12 Fault No. 12 (dressing not performed)
FVE End of electrode life output
E) Electrode management:
• Assigning electrodes to each program

Often, the same WCC controls a number of welders: two guns that work alternatively, a
number of machines controlled in cascade, a robot that uses a tool changer, a machine
that uses a number of tools. In every case, different program numbers are assigned to
the different welders.
To separately manage the incrementing rules that apply to the different welders, the
WCC requires the electrode number (or welder number) assigned to each program.
This number is chosen between 00 and 15.
If the WCC works with just one welder, No. 00 can be programmed everywhere.
The CPS will create as many counters in memory as there are electrode numbers
programmed. Each counter is incremented every time a spot weld is performed in one
of the programs where this electrode number (or counter number) can be found.
• Alarm before the end of electrode life

The user needs to be informed ahead of time when it is nearing time to replace the
electrodes (end of electrode life), to allow their replacement during downtime. This
especially applies to long cycle automated systems.
The alarm heading defines the number of spots before the end of the last wear
compensation step or segment where the alarm is triggered as activating an output.
If a number of sets of electrodes are used, the alarm threshold is valid for all of the
programs that use the same set of electrodes and the newly set value will be displayed
in all of these programs.
It is possible however to have as many alarm thresholds as there are electrode

numbers.
If the electrode number is changed, the alarm value is automatically alarmed with that
of the programs using the same electrode number.
If the new electrode number does not exist in other programs, the alarm value is reset
to 000 by default.

2. FAMILIARIZATION
Current
(%)
Alarm=500
Number of spot
Electrode alarm after

3500 spots completed
2.3.11 Welding servo valve/pressure program control command

(Screen P14)
• Assigning SV control outputs

- The WCC has two start of cycle commands, DCY1, DCY2, used to trigger a welding
cycle.
- In parallel, the WCC has two welding servo valve control outputs SV1 and SV2. The
WCC allows assigning SV1 and SV2 independently, depending on the start of cycle
command that is triggered.
The following options are available:

MODE SELECTION OPERATION APPLICATIONS
If DCY1 is triggered, the WCC enables
A WCC controls two welders each
DCY1.SV1 output SV 1.
0 with a start of cycle command and a
DCY2.SV2 If DCY2 is triggered, the WCC enables
welding servo valve.
output SV2.
General case: Gun equipped as
Whichever start of cycle is triggered, only standard with a two program handle
1 SV1 with a start of cycle command and a
one servo valve is enabled (SV1). choice of programs. Hand operated
ARO S series guns.
As above but SV2 is enabled in place of
2 SV2 As above.
SV1.
Cylinders are supplied by two
SV1 and SV2 enabled simultaneously and
welding servo valves (NO, NC), to,
synchronously (without a pressure
3 SVl.SV2 for example, obtain different
program), regardless of the start of cycle
pressure levels when closing and
that is triggered.
opening.
SV1 and SV2 are controlled at the same Projection welding, aluminum
time, but SV2 is released during the welding, etc.
Pressure welding cycle; the SV2 release delay time
4
program after the start of squeezing as well as the
duration of the SV2 low step are all
programmable.
WARNING: Connecting the SV control outputs.

2. FAMILIARIZATION
• Defining a pressure program

This function is used to vary the pressure on the electrodes during the holding welding
phase. It is for example possible to ensure a high pressure level at the end of
squeezing and then reduce this during welding before increasing it once again during
holding (cycle A). It is also possible to increase pressure during welding and reduce it
during holding (cycle B).
Pressure Pressure
Time Time
Squeeze Welding Holding Squeeze Welding Holding
Sv1
Time Time
Sv2
Time Time
• Practical implementation
Time Time
Time Time

2. FAMILIARIZATION
• Applications
- Welding aluminum alloys to ensure good squeezing and then reduce pressure to
improve welding.
- Projection welding: reduce the squeeze pressure to preserve the shaping and then
increase it to improve follow up.
- Profiled welding, hollow assemblies, sensitive parts.
• Programming the pressure program

Pressure
Time
Sv1
1st squeeze Squeeze Welding Holding Time
Sv2
Delay Duration Time
SV1 and SV2 are controlled in parallel as soon as DCY is triggered. SV1 is held
throughout the welding cycle. SV1 and SV2 then fall back together after holding is
finished, regardless of the tR and tD values.
Two parameters are used to set the operation of the second servo valve SV2.
tR: DELAY: delay before SV2 is released in relation to the start of squeeze time.
tD: DURATION: the time during which SV2 is not triggered during the cycle (duration).
• Special cases
No. 1: High pressure holding (increasing the pressure level during holding)
Tps
Tps

2. FAMILIARIZATION
No. 2: Permanent contrary pressure.
Tps
Tps
No. 3: Start of welding is differed in relation to the end of squeezing time. This is the
case for example when the welding authorization function uses an external input.
Time
S W H Programmed
Cycle
Sequence
S W H Actual
Case a) Actual
Sv2 Time
Case b) Actual
Sv2
Time
Whatever the delay time X, the anticipations (a) or delays (b) in the action of SV2, the
SV2 action in relation to the start of welding is complied with.

2. FAMILIARIZATION
2.3.12 Checking the Duty Factor, Programming Heat Intensity
• Definitions
Sum of hot periods (current passing)
Duty factor =
Total cycle time
Hot time: the welding time during which current passes through the part.
Cycle time: the time base to be chosen to match the manufacturing process:
- For a machine that handles a long running regular production run (1,000 parts per
hour for example) cycle time = 1' = 60" = 3,000 periods
- For a machine that handles non continuous production with working periods as well as
idle periods for transporting parts. E.g. a gun mounted on a robot.
Cycle time = the time between two component production "start of cycle" commands.
A duty factor check comprises checking that the maximum permanent current level
that the welder can accept is not exceeded.
This check may be carried out if a measurement coil that allows measuring the
welding current level is connected and if the welder's heat limit level is set.
• Permanent (or heating) current level calculation principle
After each spot weld, the WCC calculates a duty factor based on the welder's last 60
seconds of operation, by applying the following formula:
2 2 2
Is1 .t s1 + Is2 .t s2 + ....... + Is2 .t s2
Ip =
60 000
I S1 , IS2. …….I Sn are the effective average current levels measured during the n spots
performed during the last 60 seconds (in kA).
tS1, t S2 ……t Sn are the welding times carried out for each of the n spots performed
during the last 60 seconds (in ms).
Then the WCC will compare the calculated value with the programmed heat limit and
generate a fault (No. 17) if this level is exceeded.
• Programming
If the Duty factor control: yes choice is made, the next heading asks for the machine
or the installation's max. heat intensity value.
The value stated must be expressed in kA:
Range 0.00 to 9.99 kA and 10.0 to 30.0 kA
The limit used will generally be that of the transformer's permanent current level.
• WARNING:
ARO cannot ever be held liable should any damage occur affecting installations that
operate under the control of a duty factor. The thermal intensity values stated by the
user remain their full and complete liability.
2.3.13 Assigning Two Programmable Outputs
• Individual Use for Automation System Control

The MICRO 2XI6 has two discrete outputs numbered 1 and 2. Each time a program is
run, it is possible to assign one of these outputs. The programmed output will change

2. FAMILIARIZATION
state from 0 to 1 as soon as the program is called up and it will return to 0 as soon as a
program is called up where another output number is programmed.
Program
Sequence
Programmed outputs
State S1 Time
State S2 Time
Typical values:
tm = 1.5 ms
td = 1.5 ms
If a 0 value is programmed under the output heading number, no output will be

activated when this program is called up.
• Applications
- Selecting the logical pressure (as opposed to selecting the electronic pressure).
EV1: welding servo valves

ED 1,2: Electro-distributors for selecting the pressure, controlled by WCC outputs S1 and S2.
MR1,2: Pressure regulators for manually adjusting the pressure
• Operation
The system shown above allows setting two different pressure levels on pressure
regulators MR1 and MR2.
Each welding program can be assigned one of the discrete outputs, S1 or S2. As soon
as the program is called up, the electro-distributor that corresponds to the programmed
output is activated and allows the pressure level that is regulated upstream to reach the
welding distributor. When the start cycle command (DCY) is triggered, the welding
distributor allows the selected pressure into the cylinder.

2. FAMILIARIZATION
PROG No
OUTPUT No
PRESSURE Time
SELECTED
Time
PRESSURE
WELDING
Time
CYCLE
• NOTE:
It is necessary to estimate the time required to establish pressure in order to correctly
manage the program choice cycle - DCY - squeezing - welding - holding interval...
• Other applications
Controlling automation systems based on the programs chosen:
- starting up a dressing unit
- lighting indicators or markers
- selecting welders
• Programming
Using the Programmable output No. heading, program the number of the output (1 or
2) that is to be activated (contact closed) when this program is called up. If 0, no output
is activated.
2.3.14 Using Electronic Pressure Selection (Screen P17)
• Definition
Pressure selection is used to assign each program a different pressure level and
therefore a different welding pressure.
The MICRO 2X16 has two 0-10 Volt analog outputs that can control a proportional
pressure regulator valve that provides a pressure that is between 0 and the rated
circuit pressure level (generally 10 bar), for a control signal of between 0 and 10 Volts.
The MICRO 2X16 can program the pressure request as a % (000 to 100) or a value in
daN (00 to 9999), depending on how screen P 17 is programmed.

2. FAMILIARIZATION

2. FAMILIARIZATION
• Pressure selection diagram

The pressure variation from one program to another.
As soon as a program is called up, the corresponding proportional action valve
control voltage is generated by the MICRO 2X16 III.
Programm
selection
Control
voltage
supplied by
the MICRO 2X16
START
Welding cycle
distributor command S W H S W H S W H S W H
Pressure supplied
by the proportionnal
action valve
Pressure in the
cylinder
Time
t1, t2: proportional action valve reaction time depending on the characteristics of the valve used, the pressure scale
required and the pneumatic circuit used.
• Programming
Programming can be done using a percentage value or directly in daN.
Programming as a % allows displaying the desired pressure level as a percentage of
the valve's rated pressure level (generally 10 bar).
Programming in daN will directly programmer the welding pressure in daN on
condition of course that you know the relationship between pressure on the electrodes
and the pressure in the cylinder. To find out this relationship, first perform a number of
spot welds to measure the pressure level achieved (using a dynamometer) for a given
pressure setting.
• Special cases
If the circuit pressure level does not reach the rated valve pressure level, the accessible
pressure level will be restricted to the circuit pressure level, even if the request value is
higher.
E.g. with a 0-10 bar valve; a 6 bar circuit; a 100 daN/bar welder.
Between 60% and 100% of the request value, the actual pressure will peak at 6 bar.
Even with a request value that exceeds 600 daN, the true pressure level will still be
limited to 600 daN.
• Programming in %
Calculate the pressure level required in the cylinder, depending on the welding pressure
required (based on the tables provided by the machine's manufacturer).

2. FAMILIARIZATION
Calculate the VP value as a percentage to be programmed in the % heading for the

proportional action valve:
P
VP = .100
Po
P: requested pressure.
Po: rated pressure given for the valve at 10 Volts (generally 10 bar).
Enter the VP value in the % heading for the proportional action valve.
• Programming in daN
Based on the tables provided by the machine's manufacturer, determine the following
ratio
Pressure on electrodes
r1 =
Pressure in cylinder
Pressure on electrodes
Calculate the ratio r2 =
Cylinder control voltage
PO
r 2 = r1. in daN
10 Volt
A measurement should confirm the precision of the ratio calculated.
Po = rated pressure given for the valve at 10 Volts (generally 10 bar).

Program the r2 value in the daN/V heading for the proportional action valve.
Program the required welding pressure value (in daN) in the corresponding heading.
2.3.15 Primary/Secondary Measurement

Screen P19 can be used to configure the measurement taken from the transformer's
primary or secondary winding. When the primary measurement is used, the sensor that
is used is built into the inverter, for a secondary winding measurement a secondary coil
is required.
When the measurement is taken from the primary winding, the welding current on the
secondary winding is calculated based on which transformer is used (set in screen
P19).
If the transformer is not referenced, then to regulate from the primary winding, the
secondary current transformation trend must first be set up based on the primary
current level (screen P22).
2.3.16 Primary/Secondary Current Ratio Trend

Procedure
You require the means to measure the secondary current, using:
An outside calibration device (Myachi…). Check that the measurement reading on this
device corresponds to the measurement made by the 2x16 (i.e. without the first
20 milliseconds and without the downslope phase), or
A secondary measurement coil that you have temporarily connected to the 2x16.
Reading the characteristic
Configure a program in "% cyclic ratio" mode.
Choose a relatively long welding time (>=150 ms).
Set the welding request value to 10%.

2. FAMILIARIZATION
Run the cycle, then record the secondary current value measured (from the calibration
device or the 2x16 in screen X1) as well as the primary intensity level from the 2x16
(screen X9).
Repeat this, changing the welding request value until your system's current limit is
reached. Around ten spots are enough, covering the system's entire operating range.
Calculating the trend
Slope A
Is Is2
Is1
YL
YA
Slope B
YB
Ip1 Ip2
Ip
The trend may be a single line or the association of two lines, as shown above.
With a single line:

Set YL = 0, YB = 0 and B = 0.
For YA take the intersection between the Is axis and t the continuation of the line.
Is 2 − Is1
For A take the guideline factor for line A =
Ip 2 − Ip1
With two lines:

To be more precise, this characteristic can be entered as an association of two lines.
Determine YL taking the Is value at the intersection between the two lines. For any
current request that exceeds YL, take line A to calculate the equivalent primary current,
and for lesser requests, take line B.
Determine YA and A in the same way as above, taking the line segment that
corresponds to the higher currents.
Determine YB as the secondary current at the intersection between axis Is and the line
that corresponds to the low current levels and B the guideline factor for this line.
2.3.17 Diode Control Function

The diode control function is used to provide a continual, theoretical, monitoring of
transformer diode heating.
Depending on the type of transformers used, on the water flow and on the water
temperatures set in screen P23, the 2x16 system performs a calculation before every
spot, to determine the temperature that the transformer diodes could reach before the
end of the programmed cycle. If this temperature is likely to damage the diodes, and if
the "Diode control" function is set to "yes" (in screen P23), the cycle is forbidden (fault
No. 5 with non validity cause No. 33).

2. FAMILIARIZATION
Thermal cycle of a
41 852 790 -6.3V - 4 diodes
20 390 298 spots before failure Thermal excursion between 2 spots: F(N)=39°
Thermal excursion between 2 robot cycles : F(N)=54°
Cycle thermal level

4330A<6300A
Hot periods : 0,20

Diode temperature [°C]
Cold periods : 1,20 s
Number of spots: 5
15 kA
10 kA Cycle time : 8,0 s
Junction
Temperature
Max. Junction
temperature
Time [Seconde]
Below is an example of how diode temperature evolves (the blue trend) when
successive spot welds are performed.
2.3.18 Resetting Counters (Screen P24)
• Spot counter
Any of the electrode counters (there are as many counters as there are electrode
numbers programmed) can be reset to any value and especially to 00000.
Advantage: Repositioning in the wear compensation process at any time. For example,
if the WCC is swapped without swapping the electrode, then the one or more counters
in the new WCC can be reset to allow for existing electrode wear.
The same applies when an Electrode nr. is coming due for replacement, it may be
preferable to replace all of the electrodes and to reset all of the counters.
• Dressing counter
Just like the spot counter, it is possible to reset the dressing counter such as at the end
of wear compensation to any value, and especially to 00. In the between steps mode,
there is no need to change this counter as it does not influence how wear compensation
is performed.
• Between steps
This counter shows the number of spots performed since the last time dressing was
requested in the between steps mode (without taking into account any possible offset
between requesting dressing and actually performing it). This value can be reset to any
value in order to advance or delay the next dressing request.

3. SETTING INTO SERVICE
3.1. Software configuration
3.1.1. Access to configuration screens:
The configuration screens can be accessed in programming mode using the key from program 0.
REFERENCE VALUES
WINDOW BY
No.
C0
C0 Password 0000 9999 1 0000
#: Number field
“Password ####” is used to secure the configuration by allowing access to the most sensitive
windows or to the individual user via the or keys.
• Note:
- The default password value after clearing the memory is 0000.
- The password value is changed from screen C12, naturally after first validating the old
password from screen C0.
REFERENCE VALUES
WINDOW BY
No.
■ Configuration C1
parity program
C1 ■ none even - none
❚: Requires pressing F6 : Text field
The “ parity ….program…. ” field uses the parity bit to test for proper connection of the
bits that encode the program number value. The way the parity bit works allows various choices:
• The “none” field defines no parity operation and therefore no test.
• The “odd” field defines a test where the parity bit value must be such that the number of bits
at 1 is odd.
• The “even” field defines a test where the parity bit value must be such that the number of bits
at 1 is even.

REFERENCE VALUES
WINDOW BY
No.
■ Configuration C2 0 1 1 0
Relation program/DCY
C2 DCY1 mode Prog
DCY2 mode Prog
00 127 1 00
❚: Requires pressing F6 : Text field #: Number field ✶: Field not accessible
This screen is used to select programs according to the DCY triggered. The programs originate
remotely or by the program number set in field using this screen.
Field “DCY1 mode #” or field “DCY2 mode #” take state:
• State = 0:
- Then the program that is run is the remotely selected program.
- Except if the remotely selected program is 0, then the program number entered in field is run.
• State =1:
Whatever the remote selection, the program to be run is run with the DCY setting on the same
line.
Field “Prog###” is used to enter the number of the program to be run with the DCY found on
the same line.
REFERENCE VALUES
WINDOW BY
No.
00 127 1 00
Authorized programs
C3 with DCY1 :
with DCY2 :
00 127 1 127
This screen is used to define control over a set of programs based on the DCY used.
The fields are used to define the program number values that set the limit values for the
corresponding DCY control function.
Warning, for each DCY, the program number range must include the program number assigned
to it in screen C2.

REFERENCE VALUES
WINDOW BY
No.
Configuration C4
Fault ■ 00 90 1 00
■
C4
Not blocking Blocking - Blocking
This window is used to hierarchically arrange faults into blocking and non blocking type faults.
The “Fault ## ” field defines the fault number to configure, on condition that the fault number
is followed by the “✱” symbol, then field is accessed by pressing F6.
The “# ” field is used to classify a fault using a choice of five types of fault:
- “0 Not blocking” allows the welding cycle to continue.
- “1 Blocking… ACQ/start=0” allows the current welding cycle to continue to completion but
blocks the next cycle from starting. To acknowledge this, the previous DCY must be disabled.
- “2 Blocking… End of cycle” generates an End of cycle condition as soon as the fault is
acknowledged.
- “3 Blocking… Repeat spot” will, after acknowledgement, cause the creation of a new spot if the
DCY signal remains maintained.
- “4 Blocking… Repeat spot?” provides a choice between two options after acknowledgement.
Repeating the spot by pressing F4 and End of cycle by pressing F5.
REFERENCE VALUES
WINDOW BY
No.
steps segments - steps

W.C. type■
Reset WC■
Dressing request
C5 with warning ■ with warning permanent - with warning
no yes - yes
This window is used to configure the various wear compensation components.
The “ W.C. type ” field is used to define step related wear compensation
(incrementing the non continuous current level) or segment related wear compensation
(incrementing the continuous or linear current level).
The “Reset WC ” field is used to acknowledge (Reset therefore), the dressing warning
generated by the dressing counter and it offers two choices:
-“with warning”: this can only be acknowledged during the wear compensation warning
condition.
-“Permanent”: this can be acknowledged at any time during wear compensation.
“Dressing request with warning”:
- Yes: the dressing request is shown at the end of the step rule, less the warning value, the end
of electrode service life output is actuated at the end of the step rule and fault No. 10 is
generated at the end of the step rule, plus the post-dressing warning value.

- No: the dressing request is shown at the end of the step rule and fault No. 12 is generated at
the end of the step rule, plus the post-dressing warning value (the end of electrode service life
output is not triggered).
REFERENCE VALUES
WINDOW BY
No.
no yes - no
■ Linked spots■
Linked requests■
no yes - no
C6 Keep out closed■
Prog. on alarm ■
no yes - no
no yes - no
This screen is used to configure the various wear compensation settings.
The “Linked spots ” field is used for setting in screens P6 to P9:
- “no”: allows incrementing, decrementing of the step spot number.
- “yes”: requests automatic incrementation of the number of spots in successive steps.
The “Linked requests ” field is used for setting in screens P6 to P9:
- “no”: allows incrementing, decrementing of the selected step's current level.
- “yes”: request automatic incrementation of the current level in successive steps.
The “Keep out closed ” field defines whether or not to hold the wear compensation
outputs based on two choices:
-“no”: retains control over the FVE, ALE, DRO outputs depending on the program being run.
-“yes”: retains control over the FVE, ALE, DRO outputs depending on all programs.
The “Prog. on alarm ” field is used to select the program with two choices:
-“no”: allows running the program specified in “ Prog ### ” in screen C2 (if remote selection = 0
and DCY1 = 0).
- “yes”: allows running the program with the electrode end of service life alarm (FDVE), or with
the replace electrode alarm (ALE), or with the request electrode dressing alarm (DRO) (if remote
selection = 0 and DCY1 = 0).
REFERENCE VALUES
WINDOW BY
No.
no yes - no
■ Release with key
on PRG position
C7 F4:■ F5:■ no yes - no
F7:■
no yes - no

This screen is used to control the acknowledgement of certain faults using the F4, F5 and F7
buttons in Run mode, or in Program mode for enhanced safety. (The fault is acknowledged by
persons who have the key required to switch to Program mode).
The “F4”: ” field defines F4 button operation:
- “no”: allows acknowledging faults in Run mode.
- “yes”: only allows acknowledgement in Program mode for fault No. 11.
- “yes”: only allows acknowledgement in Program mode for fault No. 11.
- “yes”: only allows acknowledgement in Program mode for X11 screen faults (electrode dressing
warning), X12 screen faults (electrode replacement warning), D10 screen faults (end of electrode
service life) and D12 screen faults (dressing not done).
REFERENCE VALUES
WINDOW BY
No.
■ Configuration C8 yes no - no
Counter reset ■
Out. contactor■
Outputs mode
C8 ② yes no - no
③ 0 1 1 0
① This screen is used to allow or inhibit changes to the counters in screen P24:
- yes: allow changes to the counters.
- no: inhibit changes to the counters.
② Out. contactor:
- yes: second phase control management: output X2.14/15 (PH2) is triggered at the start of a
cycle and held for 15 seconds (12.5 seconds in 60 Hertz operation) after the start of the cycle.
③ Choice of control modes for programmable outputs X2.18 and X2.19:
- 0: control as set in screen P16;
- 1: type 1 or 4 fault presence indication: X2.18 = type 1
X2.19 = type 4

REFERENCE VALUES
WINDOW BY
No.
0 3 1 1
0 3 1 1
■Outputs type C9 0 1 1 0
DGN DFA DAS
FVE ALE DRO
PO1 PO2 ④ 0 3 1 0
C9
⑤ 0 3 1 0
⑥ 0 3 1 0
⑦ 0 3 1 0
⑧ 0 3 1 0
This screen is used to change the idle and active states of the specified outputs:
0 = output open when idle, closed when active.
1 = output closed when idle, open when active.
2 = output open when idle, blinking when active.
3 = output closed when idle, blinking when active.
Field “DGN #” defines the general failure output.
Field “DFA #” defines the type A fault output.
Field “DAS #” defines the request welding authorization output.
④ Field “FVE #” defines the electrode end of service life failure output.
⑤ Field “ALE #” defines the electrode alarm fault output.
⑥ Field “DRO #” defines the dressing request fault output.
⑦ Field “PO1 #” defines programmable output 1.
⑧ Field “PO2 #” defines programmable output 2.
The type set for outputs PO1 and PO2 is only taken into account if “outputs mode” is set to 1 in
screen C8.
REFERENCE VALUES
WINDOW BY
No.
Date / / C10
: :
01/01/00 31/12/ 20 99 - -
C10 F6 Modify/display
F5 agree modif.
00: 00: 00 23: 59: 59 - -
This window is used to configure the date and time.
F6 is used to modify or update the display and F5 to agree to the modification (Pressing F6 a
second time once again allows refreshing without taking into account the modifications made).

REFERENCE VALUES
WINDOW BY
No.
Configuration C11 P0 X10 - P0

C11 screen ■
authorized
NO YES - YES
This window is used to authorize screens in run or program mode.
The “screen P## ” field defines the number of the screen to configure, on condition that the
screen number is followed by the “✱” symbol. Pressing F6 makes it accessible, or not, in field
“authorized ”. (no = screen not accessible).
REFERENCE VALUES
WINDOW BY
No.
C12 0000 9999 1 0000

New password:
This screen is used to change the password value for the configuration screens.
The “ New password: ####” field as defined here is set to 0000 by default.
REFERENCE VALUES
WINDOW BY
No.
0 9
WCC name:
C13 A Z - -
a z
The “ ” field is used to enter a text that customizes the next WCC and this
text will be displayed in the cover screen.
Text entry rules:
Text entry is performed from left to right. It is possible to shift it (or enter a space), to do this,
press F4. To obtain alphanumeric characters, press the or keys until the desired character
appears.
F6 is used to return to the start of the line.

REFERENCE VALUES
WINDOW BY
No.
■ Type C14 ➀ 00 06 1 00
of serial line:
C14 Baudrate ■ ➁ 300 38400 x2 9600
Report type
➂ 0 3 1 3
This screen is used to set the communication speed for the RS485 serial link (X7 connector) and
the format of messages sent in signature transmission mode.
① This field is used to set the type of communication (PC or printer).

- printer trace 00: Network communication with a PC running the ARODMS or ARONET
applications with a communication protocol.
- printer trace 01, 02, 03, 04, 05, 06: write spot signatures to a PC using the corresponding
format or network communication with a PC without a protocol (no ARO software).
② Baudrate.
➂ Report type: This field is valid if field is set to 01 to 06; then one of three types can be
defined:
- type 0: no signature.
- type 1: signature for spot welds with faults.
- type 2: signature for spot welds with no faults.
- type 3: signature for all spot welds.
The latter choice also determines the kind of signatures that are visible in the X7 screen.
The signature header is set after changing the trace, to the printer and when the WCC is
powered up.
Configuring the RS485 serial link:

- Speed: 9600 baud
- 8 data bits
- 1 stop bit
- no parity bit
- RS485 output (see section 6)
- X7 connector pin 2 – TX output
- X7 connector pin 7 + TX output
Data is sent in "DUMMY" via the RS485 output without transmission checking, to the printer.
Examples of printer traces:
• Printer trace key:
"Cps": WCC number

"Pr": Program number
"Point": Spot counter in the current wear compensation process
"Rod": Dressing counter
"Pa": Step number
"El": Electrode number
"Intens.": Measured current level
"%Imax": Equivalent% (in "current regulation", "voltage compensation" or "% of linear Imax"
modes)
"Tens.": Measured voltage level (for programs with voltage measurement)
"Effort": Measured pressure (for programs with pressure measurement)

Type 01 printer trace
Date Time Cps Pr Point Rod Pa El Intens. %Imax Tens.

97/10/24 16:29:11 00 00 00006 000 00 00 000000 A 00,0 % 0000 daN
0000
97/10/24 16:29:30 00 00 00007 000 01 00 010530 A 00,0 %
daN
0000
97/10/24 16:29:51 00 00 00008 000 01 00 010550 A 00,0 %
daN
0000
97/10/24 16:30:00 00 00 00009 000 01 00 010060 A 00,0 %
daN
0000
97/10/24 16:30:09 00 00 00010 000 01 00 010060 A 00,0%
daN
- - - - - - - - - - -
0000
97/10/24 16:30:20 00 00 00011 000 01 00 010540 A 00,0%
daN
0000
97/10/24 16:30:56 00 00 00012 000 01 00 010540 A 00,0 %
daN
Date Time Cps Pr Point Rod Pa El Intens. %Imax Tens.
97/10/24 16:31:33 00 00 00012 000 01 00 010470 A 00,0 % 00,1 %
97/10/24 16:31:37 00 00 00013 000 01 00 010490 A 00,0 % 00,1 %
97/10/24 16:31:43 00 00 00014 000 01 00 010490 A 00,0 % 00,1 %
97/10/24 16:31:56 00 00 00015 000 01 00 009980 A 00,0 % 00,1 %
- - - - - - - - - - -
- - - - - - - - - - -
97/10/24 16:32:04 00 00 00020 000 01 00 010440 A 00,0 % 00,1 %
97/10/24 16:32:06 00 00 00021 000 01 00 010480 A 00,0 % 00,1 %

Date Time Cps Pr Point Rod Pa El Intens. % Imax
97/10/24 16:32:20 00 00 00018 000 01 00 010440 A 00,0 %
97/10/24 16:32:22 00 00 00019 000 01 00 010450 A 00,0 %
97/10/24 16:32:45 00 00 00020 000 01 00 010010 A 00,0 %
- - - - - - - - - -
- - - - - - - - - -
97/10/24 16:32:52 00 00 00028 000 01 00 010470 A 00,0 %
97/10/24 16:32:53 00 00 00029 000 01 00 010460 A 00,0 %
Type 04 printer trace (welding time/pressure/current):
010/0000/100490
010/0000/100470
010/0000/100480
Date Time Cps Pr Point Pa Acc Sou Pu Int For Demande Intens. Effort
99/01/19 13:22:35 00 00 00118 01 010 006 02 003 005 015000A 015010A 0000daN
99/01/19 13:22:46 00 00 00119 01 010 000 02 003 005 015000A 015010A 0000daN
- - - - - - - - - - - - - -
97/10/24 16:32:45 00 00 00120 010 006 02 003 005 015000A 015010A 0000daN

Date Time Cps Pr Point Pa Intens. %Imax Default

99/01/19 13 :23 :05 00 00 02140 01 015010A 90,3%
I+ I- PHI+ PHI- PHIE U- PSI+ PSI- %I U+ CONS %Z
1494 0000 3266 0000 3372 3913 0000 0000 0000 0000 1500 0000
1245 1509 3060 3279 3304 4515 3913 9394 0832 0902 1511 1126
1508 1584 3237 3350 3301 3680 3680 9435 0912 0921 1511 1029
1527 1595 3269 3369 3328 3660 3660 9318 0918 0928 1505 1027
1529 1584 3287 3372 3355 3720 3720 9151 0917 0919 1498 1034
1525 1560 3297 3360 3379 3813 3813 8953 0910 0912 1490 1044
1507 1529 3292 3342 3390 3912 3912 8842 0903 0903 1485 1053
1461 1488 3222 3277 3340 3972 3972 9017 0897 0899 1487 1060
1500 1536 3262 3329 3357 3879 3879 8922 0904 0904 1481 1051
1500 1524 3277 3329 3380 3932 3932 8745 0896 0905 1468 1055
1481 1497 3270 3313 3395 4025 4025 8611 0895 0896 1456 1066
1467 1477 3265 3301 3403 4085 4085 8466 0888 0887 1438 1072
99/01/19 13 :23 :15 00 00 02140 01 015010A 90,3% 05

I+ I- PHI+ PHI- PHIE U- PSI+ PSI- %I U+ CONS %Z
0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
- - - - - - - - - - - -
- - - - - - - - - - - -
- - - - - - - - - - - -
0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000
REFERENCE VALUES
WINDOW BY
No.
0 Français 10 English - 0 Français

■Language C15
Repetition
C15 WCC number 0 9 1 0
000 254 1 000

The “Language # ” field is used to define the WCC operating language:
“00 Français” “02 deutsch” “04 English” “06 English” “08 English” “10 English”
“01 English” “03 Español” “05 English” “07 English” “09 English”
The “Repetition ##” field is used to define the number of automatic spot weld repetitions
should type 3 and 4 faults occur.
The “WCC number ### ” field is used to define a WCC number for identification purposes on a
communications network.
REFERENCE VALUES
WINDOW BY
No.
■ Configuration C17 MFDC300 MFDC1200 - MFDC300
C17 Inverter: ■
Mains Voltage 0V
② 100 990 10 400
The “ ” field is used to determine the model of medium frequency inverter used from
among the following choices:
- MFDC350
- MFDC350A
- MFDC350A ventilated
- MFDC560
- MFDC560A
- MFDC560A ventilated
- MFDC800
- MFDC1200
② “Mains Voltage ###” lets you determine the welding voltage limit values. Enter the inverter's
mains voltage here. Power down and power up once again for the change to be taken into
account.
REFERENCE VALUES
WINDOW BY
No.
■ Configuration C18 no yes - no

Learning ■
Requests % %
C18 ② 20 40 1 30
③ 40 99 1 50
❚ : Requires pressing F6 # : C Number field : Text field
Learning:
Before it is possible to weld using the current regulation mode, a learning sequence must first be
completed. Learning serves to determine the electrical characteristics of the gun or the machine
connected to the inverter. This must therefore be performed on all of the guns (or machines)
controlled by the inverter. The quality of the learning process will determine the quality of the
regulation (rise time).

Learning comprises completing a specific cycle. This cycle uses as its approach and holding
parameters, the parameters set in the selected program and the results of the learning process
correspond to the electrode used in this same program.
Procedure:
Learning is performed on the gun used for welding. The cycle will be run in short circuit mode, i.e.
without any metal sheet present.
For learning purposes, program two request values expressed as a % (refer to screen C18),
chosen as a function of the application. If an MFDC300 inverter is used, it may be used over the
0.5kA to 20kA range. For learning request values, look for % values that are equivalent to 5kA
and 18kA for example.
From screen C18, configure these two request values, then set a "yes" opposite the "learning"
heading (or close the corresponding discrete input). Select a program that corresponds to the
electrode used and then activate the cycle by closing the DCY input.
Once learning is completed, return the "learning" heading to "no" in order to again work in
normal mode.
This procedure must be performed for each of the electrodes used.
REFERENCE VALUES
WINDOW BY
No.
■ Configuration C19 000 250 1 000

ELCB test:
C19 days periodicity
hours time limit
② 000 250 1 024
❚ : Requires pressing F6 # : Number field
“ ### days periodicity” lets you determine how often the electronic circuit breaker is tested (in
days) (0: no test): Ndays after the last test, at 00:00 hours, the WCC will trigger the differential
circuit breaker test alarm (screen X14).
“②### hours time limit” lets you determine a time limit, in hours, from when the alarm is
triggered, for performing the test. If this time limit expires without the test taking place, the WCC
triggers blocking fault No. 33.

3.1.2.Special Functions
Copying programs:
A window that is accessed by pressing the key from the configuration pages is
used to duplicate all of a welding program's parameters.
Description of the special functions window: FS1
REFERENCE VALUES
DISPLAY
No. BY
WINDOW MIN MAX INCREMENT
DEFAULT
000 127 OR RESET 1 000

Parameters copy
FS1 From program ■ 000 127 1 000
To program
F5 make copy
- - - -
#: Number field
“From program” = Used to enter the number of the source program whose parameters
are to be copied. If "RESET" is selected, the target program's parameters will be reset
to the default values.
➁ “To program” = Used to enter the number of the target program where the parameters
will be duplicated.
➂ The [F5] key is used to make a copy without exiting the screen.
REFERENCE VALUES
DISPLAY
No. BY
WINDOW MIN MAX INCREMENT
DEFAULT
1 15 OR RESET 1 000
Parameters copy
FS2 From electrode ■ 1 15 1 00
To electrode
F5 make copy
- - - -
#: Number field
“From electrode” = Used to enter the number of the source electrode whose parameters
are to be copied. If "RESET" is selected, the target electrode's parameters will be reset
to the default values.
➁ “To electrode” = Used to enter the number of the target electrode where the parameters
will be duplicated.
➂ The [F5] key is used to make a copy without exiting the screen.

3.2 HARDWARE CONFIGURATION

• Localization
WCC configuration
DIP switches
Motherboard
• DIP switch setting table
DIP SW
OPTIONS DEFINITION OF THE OPTION
No STATE
OFF 50 Hz mains.
Mains frequency 1
ON 60 Hz mains.
2 Not used
Handling and Hold servo valves if hold duration <> 0, if a type 2, 3 or 4 inhibiting fault
OFF
holding servo occurs until faults are acknowledged.
3
valves in case of Release servo valves after holding (opening electrodes) if a type 2, 3 or 4
failure ON
inhibiting fault occurs.
Handling servo OFF Only the X3 connector servo valve.
4
valves ON In addition, use the servo valves on the Medium Frequency controller board.
5 Not used
6 Not used
OFF
Handling
7 Voltage measurement on power synchronization is used to detect a lack of
interlocking ON
power.
Controlling a gun:
DCY1 and DCY2 activate the servo valves based on how screen P14 is
OFF programmed:
- input X1-A.12 = tightening without welding
- input X1-B.7 = welding authorization
Gun mode 8
Controlling two guns:
- Screen P14 is not accepted and cannot be accessed:
ON DCY1 active SV1: welding authorization via input X1-A.12.
DCY2 active SV2: welding authorization via input X1-B.7.
- No clamping function without welding.

3.3 Electrical Connection
+24 VDC
+24 VDC
NP1 (program selection, bit 1)
NP64 (s program selection, bit 64)
NPP (program selection parity bit)

AUS (DIP 8=OFF) or AUS1 (DIP 8=ON)
ASO (cycle with welding)
DCY1 (Start cycle No. 1)
DCY2 (Start cycle No. 2)
0V24 (input 0 Volt level)
+24 VDC (input common line)

RDG (remote fault acknowledgement)
REE (electrode replacement ack.)
RRO (electrode dressing ack.)
Ms (stop welder or stop welding)
TH3 (welder thermostat)
SSS (DIP8=OFF) or AUS2 (DIP8=ON)
Input not used
0V24 connected to ground
Ground
DC (double travel)
SV1
SV2
External SV common line
MS: Safety micro switch

(connected to input X1-B.5)
DAS (Welding authorization request)
ALE (Replace electrode alarm)
FVE (End of electrode life)
FCY (End of cycle)
IGBT fault (NO contact)

IGBT fault (NC contact)
DGN General fault, type 1, 2, 3 or 4
DFA or PH2
DRO (Request electrode dressing alarm)

SP1 (Programmable output No.1) or TYP1
SP2 (Programmable output No.2) or TYP2
Programmable output common line
0 – 10V servo valve command

0V reference level (0V24)
Ground

1
2
DIP 3
1 2 43 4
LED
X11
0 VDC
(CTS)
Tx
(RTS)
Rx
X12 option
SVP1 (0-10 volt command)
0 volt servo valve
SVP2
0 volt servo valve
Ground (shield)
X14 not used

APPR (learning)
Input 2 (discrete)
Input 3 (discrete)
Input 4 (discrete)
Input 5 (discrete)
Input 6 (discrete) for 0-10 V instruction option
Analog input for 0-10 Volt instruction option
Input 7 (diff.) for I1 I2 input instruction option
X13 not used

Output 1 (discrete)
Output 2 (discrete)
Output 3 (discrete)
Output 4 (discrete)
0 VDC
Mains synchronization output for I1 I2
instruction option
Ground (shield)
Current measurement output signal for the
outside measurement option
1kohm S1
1 2 3
X16 X15
25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9
Link between the converter and

the controller board
(line to line)

A) Connecting discrete logic inputs (terminal block X1):
• General diagram
-A
16
• External program selection

- Connection
+24V
1 Ө
+24V
2 Ө
3 Ө Bit 1
4 Ө Bit 2
5 Ө Bit 4
6 Ө Bit 8
7 Ө Bit 16
8 Ө Bit 32
9 Ө Bit 64
10 Ө
11 Ө parity
External wiring

- Coding
PROG BINARY CODE PARITY PROG BINARY CODE PARITY

No.
No. 1 2 4 8 16 32 64 Even Odd 1 2 4 8 16 32 64 Even Odd
0 0 0 0 0 0 0 0 0 1 16 0 0 0 0 1 0 0 1 0
1 1 0 0 0 0 0 0 1 0 17 1 0 0 0 1 0 0 0 1
2 0 1 0 0 0 0 0 1 0 18 0 1 0 0 1 0 0 0 1
3 1 1 0 0 0 0 0 0 1 19 1 1 0 0 1 0 0 1 0
4 0 0 1 0 0 0 0 1 0 20 0 0 1 0 1 0 0 0 1
5 1 0 1 0 0 0 0 0 1 21 1 0 1 0 1 0 0 1 0
6 0 1 1 0 0 0 0 0 1 22 0 1 1 0 1 0 0 1 0
7 1 1 1 0 0 0 0 1 0 23 1 1 1 0 1 0 0 0 1
8 0 0 0 1 0 0 0 1 0 24 0 0 0 1 1 0 0 0 1
9 1 0 0 1 0 0 0 0 1 25 1 0 0 1 1 0 0 1 0
10 0 1 0 1 0 0 0 0 1 26 0 1 0 1 1 0 0 1 0
11 1 1 0 1 0 0 0 1 0 27 1 1 0 1 1 0 0 0 1
12 0 0 1 1 0 0 0 0 1 28 0 0 1 1 1 0 0 1 0
13 1 0 1 1 0 0 0 1 0 29 1 0 1 1 1 0 0 0 1
14 0 1 1 1 0 0 0 1 0 30 0 1 1 1 1 0 0 0 1
15 1 1 1 1 0 0 0 0 1 31 1 1 1 1 1 0 0 1 0
1: Contact closed 0: Contact open
No.
32 0 0 0 0 0 1 0 0 1 48 0 0 0 0 1 1 0 1 0
33 1 0 0 0 0 1 0 1 0 49 1 0 0 0 1 1 0 0 1
34 0 1 0 0 0 1 0 1 0 50 0 1 0 0 1 1 0 0 1
35 1 1 0 0 0 1 0 0 1 51 1 1 0 0 1 1 0 1 0
36 0 0 1 0 0 1 0 1 0 52 0 0 1 0 1 1 0 0 1
37 1 0 1 0 0 1 0 0 1 53 1 0 1 0 1 1 0 1 0
38 0 1 1 0 0 1 0 0 1 54 0 1 1 0 1 1 0 1 0
39 1 1 1 0 0 1 0 1 0 55 1 1 1 0 1 1 0 0 1
40 0 0 0 1 0 1 0 1 0 56 0 0 0 1 1 1 0 0 1
41 1 0 0 1 0 1 0 0 1 57 1 0 0 1 1 1 0 1 0
42 0 1 0 1 0 1 0 0 1 58 0 1 0 1 1 1 0 1 0
43 1 1 0 1 0 1 0 1 0 59 1 1 0 1 1 1 0 0 1
44 0 0 1 1 0 1 0 0 1 60 0 0 1 1 1 1 0 1 0
45 1 0 1 1 0 1 0 1 0 61 1 0 1 1 1 1 0 0 1
46 0 1 1 1 0 1 0 1 0 62 0 1 1 1 1 1 0 0 1
47 1 1 1 1 0 1 0 0 1 63 1 1 1 1 1 1 0 1 0


No.
64 0 0 0 0 0 0 1 0 1 80 0 0 0 0 1 0 1 1 0
65 1 0 0 0 0 0 1 1 0 81 1 0 0 0 1 0 1 0 1
66 0 1 0 0 0 0 1 1 0 82 0 1 0 0 1 0 1 0 1
67 1 1 0 0 0 0 1 0 1 83 1 1 0 0 1 0 1 1 0
68 0 0 1 0 0 0 1 1 0 84 0 0 1 0 1 0 1 0 1
69 1 0 1 0 0 0 1 0 1 85 1 0 1 0 1 0 1 1 0
70 0 1 1 0 0 0 1 0 1 86 0 1 1 0 1 0 1 1 0
71 1 1 1 0 0 0 1 1 0 87 1 1 1 0 1 0 1 0 1
72 0 0 0 1 0 0 1 1 0 88 0 0 0 1 1 0 1 0 1
73 1 0 0 1 0 0 1 0 1 89 1 0 0 1 1 0 1 1 0
74 0 1 0 1 0 0 1 0 1 90 0 1 0 1 1 0 1 1 0
75 1 1 0 1 0 0 1 1 0 91 1 1 0 1 1 0 1 0 1
76 0 0 1 1 0 0 1 0 1 92 0 0 1 1 1 0 1 1 0
77 1 0 1 1 0 0 1 1 0 93 1 0 1 1 1 0 1 0 1
78 0 1 1 1 0 0 1 1 0 94 0 1 1 1 1 0 1 0 1
79 1 1 1 1 0 0 1 0 1 95 1 1 1 1 1 0 1 1 0
No.
96 0 0 0 0 0 1 1 0 1 112 0 0 0 0 1 1 1 1 0
97 1 0 0 0 0 1 1 1 0 113 1 0 0 0 1 1 1 0 1
98 0 1 0 0 0 1 1 1 0 114 0 1 0 0 1 1 1 0 1
99 1 1 0 0 0 1 1 0 1 115 1 1 0 0 1 1 1 1 0
100 0 0 1 0 0 1 1 1 0 116 0 0 1 0 1 1 1 0 1
101 1 0 1 0 0 1 1 0 1 117 1 0 1 0 1 1 1 1 0
102 0 1 1 0 0 1 1 0 1 118 0 1 1 0 1 1 1 1 0
103 1 1 1 0 0 1 1 1 0 119 1 1 1 0 1 1 1 0 1
104 0 0 0 1 0 1 1 1 0 120 0 0 0 1 1 1 1 0 1
105 1 0 0 1 0 1 1 0 1 121 1 0 0 1 1 1 1 1 0
106 0 1 0 1 0 1 1 0 1 122 0 1 0 1 1 1 1 1 0
107 1 1 0 1 0 1 1 1 0 123 1 1 0 1 1 1 1 0 1
108 0 0 1 1 0 1 1 0 1 124 0 0 1 1 1 1 1 1 0
109 1 0 1 1 0 1 1 1 0 125 1 0 1 1 1 1 1 0 1
110 0 1 1 1 0 1 1 1 0 126 0 1 1 1 1 1 1 0 1
111 1 1 1 1 0 1 1 0 1 127 1 1 1 1 1 1 1 1 0
The even parity check defines the sum of the program selection bits set to 1. If this sum
of 1s is an odd number, then the parity bit must be set to 1. On the contrary, if the sum
is an even number, then the parity bit must be set to 0. The odd parity test works in the
same way but is used to obtain an odd sum of 1s.

When program selection by DCY or by programming is used (DCY mode = 0), all of the
contacts must stay open (select prog. 0). If DCY mode = 1, then no external program
selection is accepted, but parity is tested.
• Welder thermostat control
-B
Connect the one or more thermostats installed on the welder (for transformer
protection, secondary circuits, diodes, etc) in series on input X1.6. These must be
normally closed contacts. If no thermostat is to be used, short this input to the 24 VDC
line using a jumper.
- NOTE: Another thermostat input is provided for thyristor protection purposes. This
input is reserved in the X4 connector for connecting a thyristor type level
controller.
• Clamping without welding-welding authorization-cycle with current

functions
X1 -A X1 -B
24VDC
1 Ө 1 Ө
7 Ө Clamp without welding

12 Ө Welding authorization
With current control
13 Ө
- Clamping without welding:

If the contact is open, the cycle stops after the welder closes (end of squeeze time).
Even if the squeeze cycle duration has been exceeded prior to closing X1 -B.7. The
squeeze cycle is run before the welding cycle.
- If DCY is released before closing "SSS", the welder returns to the open position.
- If DIP8 = ON, the clamping without welding function is eliminated (input X1 –B7
becomes the weld authorization for DCY2).

- Welding authorization:
If the contact is open, the cycle stops after the welder closes (end of squeeze time).
- If DCY is released, the welder returns to the open position.
- If the squeeze cycle time is exceeded before closing the "welding authorization" input,
then the welding cycle runs as soon as X1-A 12 closes.
- If DIP 8 = OFF then the X1-A 12 input can be used to authorize thyristor activation
after closing DCY1 or DCY2.
- If DIP8 = ON then the X1-A 12 input can be used to authorize thyristor activation after
closing DCY1 (X1-A 14).
- If the contact is closed, the welding cycle continues normally. The X1-A 12 contact can
use a manually operated switch or a pressure or current level sensor or a PLC output.
- The input is active on closing or opening, depending on the configuration.
- Cycle with welding:
This input is tested at the end of the squeeze. If it is open at that time, then the cycle
runs normally but the thyristors are not controlled during welding time (no welding).
The spot counter is not incremented. This function can also be fulfilled by software
(refer to window P0). This function can be used to dress the electrodes. Under normal
operation, the two contacts must be closed. If the authorize welding and/or cycle with
welding functions are not used, the corresponding inputs must be jumpered to the
+24VDC line.
• Acknowledge fault - electrode replacement - dressing performed
X1-B
24VDC
1 Ө
2 Ө Acknowledge fault
3 Ө Acknowledge electrode replacement
Acknowledge electrode dressing
4 Ө
- Acknowledge fault
Close the outside X1-B 2 contact. The consequences of acknowledgement are
described in this sub-section. Acknowledgement can be performed from the WCC
front panel or from the central control station if the WCCs are connected over a
network.
- Acknowledge electrode replacement
Close the corresponding contact to reset the wear compensation function to zero once
new electrodes have been fitted. The electrode reset function is only active if the
electrode alarm signal is activated or at any time after configuring (refer to window
C3). Under some conditions, acknowledgement is also possible from the WCC front
panel or via the central control station if a network exists. If the wear compensation
process is complete, the "end of electrode life" alarm is activated. Simply close the
X1-B 3 acknowledge electrode replacement input to eliminate the fault condition and
trigger a new wear compensation process.
- Acknowledge electrode dressing
If the dressing function is used, closing the corresponding contact increments the
dressing counter and resets the wear compensation sequence under the conditions
defined. If the wear compensation process is complete, the "end of electrode life"
alarm is activated. Simply close the X1-B 4 acknowledge electrode replacement input
to eliminate the fault condition and trigger a new wear compensation process.

• Safety micro switch
-B
One or more safety contacts can be placed in series on this input. They may be
manually operated "emergency stop" type switches or temperature or water flow
surveillance type switches or ones using signals from the PLC or robot that controls the
welder. These contacts are "normally closed" ones. When these contacts open, they
stop the current welding cycle and shut down the servo valves controlled by the WCC.
WARNING: As this input does not cause the installation circuit breaker to trip, it cannot
be called an "emergency stop" but only a "welding stop" function. Any "emergency stop"
buttons used must be YELLOW in color and not RED.

• Start cycle
-A
14
15
Two cycle starts are supported by the WCC. The activated start cycle number may
affect the selected program number (refer to window C2) or the activated servo valve
number (refer to window P14).
B) Connecting servo valve control outputs:
• Connection diagram (internal AC/DC supply)
-B
10
11
12
13
14
- SV1.SV2: welding servo valves (refer to window P14) for SV1, SV2/DCY1, DCY2
assignments.
- SV3: auxiliary servo valve (approach stroke, etc.). Power supply provided by the
WCC but externally controlled by S3 (ON/OFF).
- JP2: jumper for selecting an external/internal servo valve power supply.
- JP1: jumper for selecting an internal 24 VDC or 24 VAC supply.
- F: 250V 2A protection fuse.
- SO: safety micro switch.
- T1.T2: transistorized SV1 and SV2 controls.
- X1-B: unpluggable terminal block for connecting servo valves. X1-B internal power
supply.

• Connection diagram (external AC/DC supply)
-B
10
11
12
13
14
- U1: external 24 to 110 VAC, 24 to 48 VDC power supply for servo valves.
- SV1.SV2: welding servo valves (refer to window P14) for SV1, SV2/DCY1, DCY2
assignments.
- SV3: auxiliary servo valve (approach stroke, etc.). Power supply provided by the
WCC but externally controlled by S3 (ON/OFF).
- JP2: jumper for selecting an external/internal servo valve power supply.
- JP1: jumper for selecting an internal 24 VDC or 24 VAC supply.
- F: 250V 2A protection fuse.
- SO: safety micro switch.
- T1.T2: transistorized SV1 and SV2 controls.
- X1-B: unpluggable terminal block for connecting servo valves. X1-B internal power
supply.
C) Connecting discrete logic outputs (terminal block X2):
• Request authorization to weld
- U1: external power supply for outputs, 24 VAC/DC to 48 VAC/DC.

- R: receiver: indicator light, coil, PLC input, etc.
The welding authorization request is triggered at the end of the approach period, the
cycle is locked until the X1-A 12 input contact opens.

• Electrode replacement alarm
The electrode alarm output is activated x spots before the end of electrode life and it
can be used to light an indicator light or activate a PLC or robot input.
• End of electrode life
The end of electrode life output is activated when the programmed number of spots is
reached in the wear compensation sequence. This output can be used to light an
indicator light or activate a PLC or robot input.
• End of cycle
The end of cycle output is activated at the end of the general interval time, on condition
that no type 1, 2, 3 or 4 blocking fault is present. It can be used to activate a PLC or a
robot input.

• General fault, type A fault
- General fault:
This output is activated every time a recognized welding fault is detected. When the
2X16 III is powered down, the relay is open. This output can be used to activate an
indicator light or a PLC or robot rack input. The output is disabled as soon as the fault
is reset.
- Type A fault:
This output is activated when an "awaiting event" type fault is present.
WCC in "operating without welding" condition.
The X2 (12,13) "general fault" and X2 (14,15) "type A fault" are normally closed, i.e. the
"general fault" relay is open (state 0), when a blocking fault occurs, if not, the relay is
kept closed (state 1). The "type A fault" (DFA) output is open if the WCC uses the no
current mode.
N.B.: By configuration, you have the option of reversing the idle states of these outputs.
• Dressing request
This output is active when the wear compensation with electrode dressing option is
used. It is triggered X spots before the end of the current wear compensation sequence
or periodically when interstep dressing is used.
- NOTE: When dressing is performed without an alarm
- The end of service life counter (X) programmed in screen P3 is only taken
into account at the end of the last wear compensation sequence. X = 0 for
all dressing phases, X returns to its number of spots value between the
alarm point and the end of electrode service life, for the last wear
compensation period.
- An unacknowledged dressing request causes the WCC to lockup, when the
spot counter reaches the POST-FDVE value. The end of electrode service
life output is not activated.

- The end of electrode service life output is only triggered at the end of the last
wear compensation sequence. It is released as soon as the "dressing
performed" input state changes to 1. In manual or semi-automatic welding
modes, this output can be used to light an indicator light. In automatic or
robot controlled welding modes, it can be used to trigger an input on the
PLC or the robot that controls the dressing tool.
• Programmable outputs
The programmable outputs can be configured so that they are activated on the basis of
the selected program number. Activation takes place as soon as the appropriate
program is called up. The common line is selected by jumper JP19 and may be the
+24VDC output provided by the WCC (JP19 on 2-3) or another outside 48 volt line:
(JP19 on 1-2).
D) Proportional servo valve control connection - terminal block X3:

This analog 0-10 volt output is used to control a proportional valve. This output is used
to supply the valve with its instruction level voltage used to adjust the output pressure
level. The 24 VDC supply to the valve is not provided by the WCC but by an auxiliary
24 VDC 2A power supply that must be installed in the welding cabinet. ARO ZRA range
thyristor equipped voltage level controllers may optionally be fitted to this auxiliary 24
VDC power supply.

E) WCC power supply/Converter/X15 socket connection:
X15
TI11
TI21
TI12
TI22
DEF
STOPS
TEMP
FCC ARO M.F.converter
CMD1
CMD2
DB25-F
DJ
CDEP
0VDC
GROUND
24VDC
L1
TDIF
L2
0VAC
24VAC
+15VP
0VP

F) Connecting the current measurement Connector X5:
• Connection for measuring- regulating the secondary current – one

coil
X16
MF converter
1
6
2
7
3
8
4
9
5
• Connection for measuring- regulating the secondary current – one

coil – two coils
X16
MF converter
1
6
2
7
3
8
4
9
5

4. OPERATION
4.1. Calling up the RUN Mode

The RUN mode is used to perform welding cycles. To use this mode, place the front panel key
switch in the "RUN" position: with the key located vertically.
Once in RUN mode, the cursor keys , , , , can be used to access a number of
windows, to display counter states, measured parameter values, input/output states and where
necessary, what kind of fault conditions appear (refer to sub-section 5.1 for the different kinds of
faults that are identified and for how to acknowledge them).
• Displaying "program" parameters in RUN

Pressing the mode key during a welding cycle (in RUN mode) will display the
programming and configuration windows for the program that is currently in use. This
function will however only display the programming and configuration windows, it does
not allow them to be changed. Pressing this key allows access to the programming and
configuration windows, pressing it once again will return the user to the RUN windows.
• Changing programmed parameter settings while running welding

cycles
The MICRO 2X16 unit can accept new parameters without interrupting the welding
function. Switch the key to the "Prg" position in order to change the programming or
configuration windows, then return the switch to the "RUN" position. The new
parameters will be used as soon as the current cycle comes to an end.

4. OPERATION
4.2. Explanations on Run Windows
DISPLAY
N°
WINDOW
Wcc Prog
Measure , kA= , %
X1 Total spots
Fault IP
#: Number field
“Wcc###” is used to display the WCC number (configured in configuration screen C15).
“Prog ##” is used to display the number of the program that is running.
“Measure ##,##kA” is used to display the current value measured during the last spot weld
(average effective current level outside of the first 20 milliseconds). This value serves as the
reference for checking whether the current level is within the tolerances requested in the “check
current” or “check current and %” modes.
“= ##,#%” is used to display the equivalent % level that would yield the same current in the
“cyclic ratio %” mode.
“Total spots #####” is used to display the number of spots performed by the WCC since
the last change of electrode. This is different from the wear compensation counter value. It can
be used as a parts counter.
“ Fault ##” is used to display the number of the current fault. If no fault is present, “Fault
✶✶” is displayed. If a number of faults are active, the number of the first blocking fault that
appeared is displayed.
⑦“ IP ####” is used to display the number of interstep spots, and more exactly, the number of
spots performed since the last time the electrode was replaced or the last time an interstep
dressing request was made (if interstep mode is selected).
DISPLAY
N°
WINDOW
Electr Prog
Request , % kA
X2 Step Dress.
Spot Warn-
“Electr##” displays the number of the electrode assigned to the current program.
“Prog ##” displays the current program number.
“Request”: displays the choice of operating mode, the request value and possibly the reference
used for checking purposes:
- in %: % of cyclic ratio mode,
- in kA: current regulation mode.
“Step ## ” displays the current step or segment being run; if wear compensation is not used,
this value remains set to “01”.
“Spot #####” is used to display the number of spot welds performed during the current wear
compensation series; this value is reset to 0 when a change of electrode is acknowledged.
“Dress. ###” is used to display the number of electrode dressing operations performed since
the last change of electrode.
“Warn- #####” is used to display the countdown of the number of spot welds that can still be
performed before the change electrode alarm signal is triggered; this value is set to 0 if the alarm
level has been reached or if wear compensation is not used.

4. OPERATION
DISPLAY
N°
WINDOW
Inputs DIP
DCY1 AUS CEF
X4 DCY2 SSS PAR P
ASO RDG REE RRO
: Text field #: Number field ✶: Field not accessible
The X4 window provides a quick display of the DIP switches and the WCC inputs/outputs,
translating their states using the following code, except for the “PR##” field:
“0” state OFF “1” state ON
“ DIP # #######…
…87654321”: the state of the configuration DIP switches, to quickly determine the
hardware configuration linked to their state.
“DCY1#”: the status of the start cycle 1 input.
“AUS#”: the status of the weld authorization input.
“DCY2#”: the status of the start cycle 2 input..
“SSS# ”: the status of the squeeze time authorization input (0: squeeze without welding).
“PAR# ”: the status of the parity bit input.
“P###”: the number of the program that is selected from the remote inputs, but this program
number is not necessarily the one that will be run.
“ASO# ”: the status of the WITH/NO welding current input.
“RDG# ”: the status of the general fault reset input.
“REE# ”: the status of the electrode replaced reset input.
➉ “RRO# ”: the status of the electrode dressing reset input.
DISPLAY
No.
WINDOW
M.F. inputs 7654321

WS TH I
X4b Learn DIP
RPT PSV
: Test field #: Number field
The X4b window provides a quick display of the DIP switches and the inputs to the board,
translating their states using the following code:
“ WS#”: the status of the Welder Stop input.
“TH#”: the status of the M.F. converter thermostat.
“I####”: the status of inputs 7 to 4.
“Learn#”: the status of input 3 in learning mode.
“DIP####”: the status of DIP switches 4 to 1 on unit S2 (0 = OFF, 1 = ON).
“RPT#”: the status of input 1, acknowledge fault and repeat spot.
“PSV#”: the status of input 2, acknowledge faults and end cycle.

4. OPERATION
DISPLAY
N°
WINDOW
Outputs POW
SV1 SV2 PO1 PO2
X5 DGN DFA DAS FCY
IGBT FVE ALE DRO
#: Number field
The X5 window provides a quick display of the DIP switches and the WCC inputs/outputs,
translating their states using the following code:
“POW#”: indicates that power is present.

“SV1#”: command status for welding servo valve No. 1.
“SV2#”: command status for welding servo valve No. 2.
“PO1#”: programmable output No. 1.
“PO2#”: programmable output No. 2.
“DGN# ”: general fault output status.
“DFA# ”: program run choice WITH/NO welding current control (or PH2: 2nd. Phase command).
“DAS#”: weld authorization request.
“FCY# ”: end of cycle.
➉“IGBT# ”: M.F. converter IGBT fault output.
(11) “FVE# ”: electrode end of service life.
(12)“ALE# ”: electrode alarm.
(13)“DRO# ”: dressing request.
DISPLAY
No.
WINDOW
M.F. outputs Nr 4321

O
X5b LED
#: Number field
The X5b window provides a quick display of outputs and LEDs on the regulator board, translating
their states using the following code:
“O####” : the status of discrete outputs 4 to 1.

“LED####” : the status of LEDs 4 to 1.

4. OPERATION
DISPLAY
N°
WINDOW
Range Prog
/ / spot
X7
: : , kA
The X7 window displays the history of the last 250 spot welds or faults:
➀ “Range ##”: the range number displayed (0 = the most recent, 249 = the oldest), the display is
initially at 0 when the window appears. The and keys are used to change the record
displayed.
➁ “Prog ##”: the number of the current program when running the record (“**” if the record is
blank).
➂ “##/##/##”: record date (“**/**/**”if the record is blank).
➃ “##:##:##”: record time (“**:**:**”if the record is blank).
➄ “##### spot”: the spot counter value when the record is made (“*****”if the record is blank).
➅ “##,## kA”: the current level measured when the record is made (“***** **” if the record is
blank).
➆ “## ”: the fault number and abbreviation for a fault record.
DISPLAY
No.
WINDOW
X8
The X8 window displays the status of the 16 electrodes using a spot weld counter and three
kinds of messages relating to the service life and state of each electrode. Using the and
keys, you can move between electrodes.
“##”: electrode number.

“#####”: spot weld counter for each electrode.
“ ”: end of electrode service life for each electrode, displaying “FVE”.
“ ”: electrode alarm for each electrode, displaying “ALE”.
“ ”: dressing request for each electrode, displaying “DRO”.
DISPLAY
No.
WINDOW
Step Prog
Request , % kA
X9 Measure , % , kA
A , kA
#: Number field

4. OPERATION
The X9 window displays, for each program, the latest current level measurements and requests
(or references):
➀ “Step ##”: the step or segment number when the last spot was welded using the program
shown in field ➁.
➁ “Prog ##”: the number of the program displayed. When the window is first displayed, the
program is the one running. The and keys are then used to move from one program to
another.
“Request ##,#%: Request value as a % (or reference for checking) (0 if current regulation mode
is used without controlling the % level).
“#,##kA”: Request current value in kA (or reference for checking) (0 if the % of cyclic ratio
mode is used without control).
“Measure ##,#% ”: Equivalent average command level as a %.
“ ##,##kA”: measured secondary current level (without the first 20 milliseconds).
“ ####A”: measured primary current level (without the first 20 milliseconds).
“ ##,##kA”: The current level measured on the secondary winding, allowing for the parameters
set in window P21.
DISPLAY
No.
WINDOW
Micro 2X16-III 3N30

Wcc MA30
X10 Serial Nr
The X10 window displays the type and version level of the onboard software:
➀ “# ## ” Main processor software coding.
➁ “Wcc ###”: Slave number used for communications (RS485 serial link).
➂ “# ## ” Indication of the processor software on the additional board.
④ “Serial Nr ####141D### :
First and second characters: year of manufacture,
Third and fourth characters: week of assembly,
The last three characters: number
⑤“ ”: WCC identifier entered in window C13.
DISPLAY
No.
WINDOW
Prog
Dressing warning
X11
electrode Nr
F7 Release
#: Number field
The X11 window is an alarm that requests electrode dressing for the electrode specified in field
➁.
- Field ➀ shows the number of the current program.

- The alarm state can be acknowledged by closing the electrode dressing acknowledgement
input or if the fourth line is displayed, by pressing the [F7] button on the front panel: the electrode
dressing counter is incremented; if the interstep dressing mode is not used, then the spot counter
is reset to the offset value programmed in the P5 window.

4. OPERATION
- The fourth line is cleared if the key is in the RUN position and if acknowledgements using the
[F7] key are forbidden in the C7 window. In this case, the key switch must be moved to the PRG
position to see “F7 Release” displayed in order to use the [F7] button to acknowledge.
DISPLAY
No.
WINDOW
Prog
X12 Changing warning
electrode Nr
F7 Release
#: Number field
The X12 window is an alarm that requests electrode replacement for the electrode specified in
field ➁.
- Field ➀ shows the number of the current program.

- The alarm can be acknowledged by closing the change electrode acknowledgement input or by
pressing the [F7] button key on the front panel: the electrode counter is reset to 0.
DISPLAY
No.
WINDOW
ELCB Test Warning

X14
Periodicity elapsed since the last time the electronic circuit breaker's differential function was
tested: press the key outside of a welding cycle to perform the test.
DISPLAY
No.
WINDOW
DC Bus Loading
X15
#: Number field
This screen is displayed when the medium frequency converter is powered up and as long as the
DC bus voltage level is too low to perform a welding cycle. Starting a cycle despite this alarm will
trigger fault condition No. 35 (cycle with incorrect DC bus loading).

4. OPERATION
DISPLAY
No.
WINDOW
Fault ## type #
This screen is displayed during an active fault condition.

5. MAINTENANCE
5.1. ACKNOWLEDGING FAULTS

5.1.1 Explanations and Acknowledging Faults
• A) General:
There are two different families of programmable faults (window C4 in 3.1): "non blocking
faults" and "blocking faults".
Type 0 "non blocking faults" family

These faults alert the user to certain operating anomalies that are considered minor, without
actually blocking the running of the current cycle or any new cycles. These faults do not
trigger the general failure output.
Types 1, 2, 3, 4 "blocking faults" family

These faults interrupt the current welding cycle or forbid starting a new cycle. They trigger the
general failure output and can be split into four types.
- Type 1 blocking faults

Acknowledging a type 1 fault does not have any effect on the FCY (end of cycle) signal.
Acknowledgment is only possible if the DCY (start cycle) signal is disabled.

After acknowledging this type of fault, the FCY output is triggered.
If the DCY signal was still present when the fault was acknowledged, the FCY signal is held
until DCY is released.
If DCY was already released, the FCY signal is held for 10 periods (200 milliseconds at
50 hertz) or until DCY is activated once again if this occurs within 10 periods.
The one or more welding distributors remain set until the fault is acknowledged (if DIP 3 =
OFF) or are released at the end of holding (if DIP 3 = ON).
START 1S+S W H 1S+S W H 1S+S W H
Welding SV
(DIP 3=ON)
Welding SV
(DIP 3=OFF)
Type 2
blocking fault
Acknowlegement
End of cycle

Acknowledging a type 3 fault automatically triggers a new welding cycle, if DCY is held. If
the DCY signal was released, the FCY output is triggered for a maximum of 10 periods, just
like for a type 2 fault.
Holding or releasing welding distributors depends on how DIP 3 is set (refer to type 2).

5. MAINTENANCE
Welding SV
(DIP 3=OFF)
Welding SV
(DIP 3=ON)
Type 3
blocking faut
Acknowledgement
End of cycle

The acknowledgement of this type of fault is a combination of type 2 and 3 faults:
If DCY was released, the FCY output is held for a maximum of 10 periods.
If DCY was held, the Micro 2x16 displays fault screen window 11 which leaves the user to
option to either restart the spot, or move to the next spot.
The restart the spot (F4 key) choice is the same as acknowledging a type 3 fault (the cycle is
automatically repeated or the FCY command is held for a maximum of 10 periods).
The move to the next spot (F5 key) is equivalent to acknowledging a type 2 fault (FCY
command held until DCY is released or during a maximum of 10 periods).
Whether welding distributors are held or released depends on how DIP 3 is set (refer to type
2).
Welding SV
(DIP 3=OFF)
Welding SV
(DIP 3=ON)
Type 4
blocking fault
Acknowledgement
F4 key
F5 key
End of cycle

5. MAINTENANCE
Automatically repeating without acknowledging type 3 and 4 faults:

When a problem occurs that triggers a type 3 or 4 fault, it is possible to automatically repeat
the spot without indicating the fault condition. The number of automatic repeats allowed is set
in configuration window C8. If this number is set to 0 (the default value), then the fault is
indicated and must be acknowledged in the normal way (refer to types 3 or 4). If the number
of repeats allowed is not set to 0, repeats are performed and the fault does not actually
appear unless the problem remains after the number of repeats allowed is exhausted.
Example with a number of repeats allowed set to 1:

If the current level is too low, no fault condition and no end of cycle signal are generated, but
this can cause the welding distributors to be held on. If DCY was released, the Micro 2x16
again waits for a DCY signal. If DCY was held on, the cycle is repeated without delay. After
the second cycle, if the current level conforms, the Micro 2x16 ends the cycle normally
(releasing the welding distributors and triggering the FCY output), but if the current is once
again too weak, the Micro 2x16 blocks the cycle and triggers the fault conditions that must be
acknowledged.
• B) Displaying faults:
If a fault is detected by the welding command, the user is informed visually in two different
ways: by LEDs blinking on the welding controller's front panel and by displaying a fault
window (or displaying a fault condition number in window X1).
When a fault occurs, it automatically triggers the display of the fault window with a plain
language description of the fault. The key is used to access the fault window from the X1
window. When a number of faults are present, the and keys are used to move from
one fault window to another.
Furthermore, by closing the output contacts that correspond to the faults, the Micro 2x16
can inform the automated system that controls the welder or trigger light up or audible alarms.
RECOMMENDED
TYPE OF FAULT INDICATION
APPLICATION
Close contact X2-9,10
IGBT fault Power circuit breaker
Open contact X2-10,11
Welding cycle without current
Close contact X2-14,15 Light up or audible alarm
Type A faults (CNOMO)
Replace electrodes alarm Close contact X2-3,4 Light up or audible alarm
Electrode dressing alarm Close contact X2-16,17

Light up or audible alarm
End of electrode life alarm Close contact X2-5,6
Block automated system
Light up or audible alarm
General failure condition Close contact X2-12,13
Block automated system
• C) Fault acknowledgment:
Remote acknowledgement
All faults with causes that have ended (except for wear compensation fault numbers 10 and
12), are acknowledged by closing the X1-B2 input contact (connected to the +24 VDC
common line provided by X1-B1).

5. MAINTENANCE
Local acknowledgement: from the front panel

In window X1, the key is used to acknowledge the fault number displayed in the fourth line.
If the cause of the fault has ended, the fault number is cleared from window X1 if there is no
longer any fault ("**" display) or window X1 is automatically replaced by the next fault window.
In the fault windows, the key is used to acknowledge the fault shown. If the cause of the
fault has ended, the window is cleared and replaced by the next fault window or by window X1
if there are no more fault conditions.
If a number of faults are present, then as many acknowledgements are required as there are
faults present.
• D) Resetting a wear compensation rule:

Remote resetting
- After electrode replacement
The electrode replacement reset function works by closing the X1-B3 input contact and it
may take place at any time (regardless of the spot counter state) or only if the counter has
reached an alarm position (refer to window C5 in the software configuration, sub-section
3.1.1.). The electrode counter used by the program running is reset to zero, clearing fault
window no. 10 or the X12 window. If a number of counters need to be reset in limited
replacement mode, the corresponding programs must be selected successively and the X1-
B3 contact closed each time (refer to the P4 screen for more information).
- After electrode dressing

The electrode dressing reset function works by closing the X1-B4, input contact and it may
take place at any time (regardless of the spot counter state) or only if the counter has
reached an alarm position (refer to window C5 in the software configuration, sub-section
3.1.1.).
Resetting dressing is only possible during the last interstep rule. The electrode counter used
by the program running is reset to zero, clearing fault window no. 10 or 12, or the X11
window. If a number of electrodes need to be dressed, the corresponding programs must be
selected successively and the X1-B4 contact closed each time.
Resetting from the front panel key pad

This is done in the following cases:
- Counter resetting:
Call up the "PRG" and display window P24 from the desired program. Counters can be reset
to any value and especially zero, after pressing the [F6] key and only if authorization was
configured by the software: "Reset counter" = yes parameter (see window C8 in 3.1.1).
- Resetting after an "End of electrode life" fault:
From the fault No. 10 window (counter has reached the end of wear compensation),
pressing the [F7] key has the same effect as closing the X1-B3 contact: resetting the
electrode counter used by the running program. Fault No. 10 is automatically cleared.
- Resetting from screen X12:
When the electrode for the program running reaches the replacement alarm threshold, the
X12 screen is automatically displayed. Pressing the F7 key resets the specified electrode
counter. The X12 window is automatically cleared.
- Resetting from screen X11:
When the electrode in the program being run triggers a dressing alarm, the X11 screen is
automatically displayed. Pressing the key will acknowledge dressing.

5. MAINTENANCE
5.1.2. Fault Screen Explanations

DISPLAY
No. EXPLANATIONS
WINDOW
This field defines the number of the fault generated in this
instance.
Fault ## type #
This field defines the seriousness level based on the number.
D##
The lower the number, the more serious the fault.
Literal interpretation of the fault number assigned.
DISPLAY
No. SYMPTOMS CORRECTIVE ACTION
WINDOW
This fault appears if the safety Close the (one or more)
Fault 00 type 1 micro switch input (X1.B.5) is safety contact(s) after
open (+24 VDC supplied by ensuring that the causes that
WELDER STOP
D0 X1.A.1 or X1-A.2 or X1-B.1) triggered them have ended.
or if the "ASOUD" input (on
the 12 point M.F. converter
terminal block) is open.
DISPLAY
WINDOW
- IGBT shorting during - Contact ARO.
Fault 01 type 1 welding.
- Supply problem affecting
D1 IGBT fault
IGBT drivers.
DISPLAY
WINDOW
- The M.F. converter - Check water circulation.
thermostat is open (X15.4): - Check heat level.
one of the internal - Check connections.
Fault 02 type 2 thermostats is open or the HT
Inverter
input (on the 12 point M.F.
overtemperature converter terminal block) is
D2
open.
-Converter cooling failure
- Condenser overtemperature
- Faulty thermostat or
connection wires cut or
disconnected.

5. MAINTENANCE
DISPLAY
WINDOW
This fault appears if the Check and open, where
START input (DCY: start necessary, the Start cycle No.1
Fault 03 type
cycle) is actuated, on power (X1-A.14) and Start cycle No.2
D3 up or on acknowledging a (X1-A.15) contacts before
Start actuated
type 1 fault or a blocking fault acknowledging the fault.
in series spot mode.
#: Number field The type of fault can be reprogrammed.
DISPLAY
WINDOW
This fault appears if the parity Check that the program No.
bit value does not match the received by the WCC is indeed
number of the program the selected one (no cut or
Fault 04 type 1 selected, based on the disconnected wires).
configuration set in screen C1 Do the same for the parity bit.
D4 Program selection
invalid or if the program selection Select a program that is
does not match the authorized in the C3 screen or
configuration set in screen change the parameters set in
C3. the C3 to allow the selected
program.

5. MAINTENANCE
DISPLAY
WINDOW
Activating the start cycle input -Check that the selected
and selecting a program with program No. is the right one.
parameters that forbid the -Check that the way this
cycle; the cause of the program is programmed is
invalidity is shown in the correct.
second line:
01 : welding time 0
10 : holding time + general
interval 0
11 : general interval time 0 in
series spot mode
15 : servo valve instruction
daN > 10 x gain
16 : second servo valve
setting daN > 10 x second
servo valve gain
19 : learning en series spot Perform learning in single spot
mode mode.
20 : regulator mode without Perform learning before
learning regulating.
Fault 05 type 1
21 : transformer slope A = 0 Correctly set the non
D05 referenced transformer curve or
Welding program 22 : transformer slope B = 0 use the secondary current
invalid with low current limit ≠ 0 measurement.
23 : current setting too low
24 : current setting too high
25 : pre-heating setting too
low
26 : pre-heating setting too
high
27 : start of upslope setting
too high
28 : end of downslope setting
too high
29 : annealing setting too low
30 : annealing setting too high
33 : diode thermal level Review welding rate, setting or
exceeded duration. Do not trigger a start
35 : welding not allowed (fault of cycle until screen X14
appeared less than one ½ (current continuous bus
period before start of loading) is present.
cycle or continuous bus
loading not finished)
DISPLAY
WINDOW
- The welder thermostat - Check water circulation.
discrete input is open. - Check load factor value, heat
Fault 07 type 2 - Cooling fault. value.
D7 - Load factor exceeded. - Check connections, wiring.
Transformer - Faulty thermostat or - Check the thermostat.
overheating
connection leads cut or
disconnected.

5. MAINTENANCE
DISPLAY
WINDOW
- The average IGBT level - Check mains voltage.
exceeds the upper tolerance - Check current measurement
limit allowed to ensure the sensor.
Fault 08 type
requested welding currant. - Check welder:
- Mains voltage too low. →secondary links
D8 - Welding impedance
Exceeding pos. % →secondary loop
(PWM) tolerance deterioration. →short circuits
- If necessary, review reference
% programming in screens P6
to P9.
#: Number field The fault type can be reprogrammed
DISPLAY
WINDOW
The primary current level has - Check transformer
Fault 09 type exceeded the level allowed by connections.
the M.F. converter. - Possibly check welding
D9 Primary current
settings.
Overload
DISPLAY
WINDOW
The number of spots set for Perform electrode dressing or
Fault 10 type the electrode wear replacement and validate by
compensation period (last step closing the:
Electr. end of life
F7 Release value) has been reached. - “Acknowledge electrode
Electrode dressing or dressing” or
electrode replacement is - “Acknowledge electrode
required. replacement” contact,
D10 Fault 10 type
- by pressing [F7].
Electr. end of life The F7 Release message F7 was configured to
will not be displayed. acknowledge faults in PRG
mode.
To see F7 Release,
displayed, turn the key to
PRG.
DISPLAY
WINDOW
This screen is displayed when - Repeat spot: press the F4 key
a type 4 blocking fault is if the third line is visible (if not,
Fault 11 type 4 indicated during welding. It turn the key to the PRG position
Press lets the operator repeat the to show it).
D11 F4 Repeat spot welding spot (of the third line - Next spot: press the F5 key if
F5 Next spot
is visible) or continue the the fourth line is visible (if not,
welding sequence by moving turn the key to the PRG position
onto the next spot (if the to show it).
fourth line is visible).

5. MAINTENANCE
DISPLAY
WINDOW
If the interstep (IP) or no - Perform dressing and validate
Fault 12 type alarm dressing modes are by closing the “Acknowledge
selected, exceeding the electrode dressing” window, or
D12 Dressing not perform
number of spots allowed after - Press [F7] (if the fourth line is
F7 Release
the WCC has requested visible).
dressing.
#: Number field The type of fault can be reprogrammed.
DISPLAY
WINDOW
The WCC is not receiving an - Check the power supply to the
image of the primary supply power device, then the electric
Fault 15 type
(24 VAC) or the mains line linking the WCC to the
No power frequency does not match the power supply cabinet (the
D15 position set by DIP1 (OFF = X15.9/10 power
50 Hz, ON = 60 Hz). synchronization input).
- Ensure that jumpers JP21 and
JP22 are set to 1-2 (power at
zero taken from the supply).
DISPLAY
WINDOW
- Welding voltage does not Configure the correct supply
Fault 16 type match the DC bus voltage voltage in screen C17. Switch
setting (screen C17), off and power up again so that
D16 DC Bus Voltage
- or phase disconnected, the change will be accepted.
out of limits
- or faulty rectifier module Check the power connections.
Contact ARO.
DISPLAY
WINDOW
The duty factor check option - Welding level or rate too high
was programmed and the in relation to machine capacity.
Fault 17 type WCC detected that the - Reduce the rate consequently
D17 permanent current level so that the permanent current
Duty factor exceeded exceeded the programmed level becomes acceptable.
maximum level. - Review max. temperature
level programming.

5. MAINTENANCE
DISPLAY
WINDOW
- No measurement signal - Check the coil using an
reaches the WCC. ohmmeter. It must show
Fault 18 type
- Coil failure or connection resistance of 20 to 30 Ohms for
Secondary wires cut or disconnected. a single winding unit and close
D18 measurement faulty - WCC input stage failure. to 50 Ohms for two winding
units.
- Check input X16 (1,2) or X16
(4,5).
DISPLAY
WINDOW
No primary measurement Contact ARO service.
signal is reaching the WCC.
Fault 19 type
The primary current sensor
D19 Primary has failed or the wires are cut
measurement faulty or disconnected.
The WCC input stage has
failed.
DISPLAY
WINDOW
This fault appears if the - Check the calibration factor.
“current regulation” option - Check whether the
Fault 20 type
was programmed. The programmed parameters are
Machine too powerful requested welding current correct.
D20
level is less than the minimum
level generated by the
machine.
DISPLAY
WINDOW
- This fault appears if the - Check the current level
“current regulation” option programming in relation to the
was programmed. The welder's capacity.
requested current value - If correct, check that the
exceeds the machine's welder is providing its full
D21 Fault 21 type capacity. performance: quality of
Machine too weak - This fault may also be secondary links, transformer
caused by a current overheating and secondary
measurement coil fault that links.
generates a value that is less - Check that the mains voltage
than the true one. level tolerance is acceptable.

5. MAINTENANCE
DISPLAY
WINDOW
- The average effective - Acknowledge the fault then
current level during the continue welding.
welding time exceeds the - If the fault continues, check
Fault 23 type maximum threshold allowed. that the requested parameter
Current too high
- A sudden mains voltage settings are compatible with the
D23 surge took place during machine's capacity.
welding. - Check the stability of the
mains supply.
- If there is an interaction
problem between different
welders, envisage interlocking.
DISPLAY
WINDOW
- The average effective - Acknowledge the fault.
current level during welding Repeat the welding spot.
time is below the minimum - If the fault happens regularly,
threshold allowed. check the stability of the mains
- Sudden drop in the mains voltage (see above), or the
Fault 24 type voltage during welding. quality of steel panel
D24
Current too low - Welding periods are missing squeezing.
due to faulty squeezing or bad - If surveillance mode is used,
follow up during indentation readjust the conduction rate in
(loss of contact). % terms, if necessary, to bring
it back within the required
current tolerances.
DISPLAY
WINDOW
- The average effective - Check the quality of
current level during the squeezing or the indent follow-
Fault 25 type welding time is below the up, as described above.
repeated threshold level - In surveillance mode, readjust
Low recurrence allowed. the programmed % level to re-
D25 current
- The threshold has been center the current level in
breached a number of times relation to the set tolerances.
in succession and more often
than the number of
acceptable repeats.

5. MAINTENANCE
DISPLAY
WINDOW
- The average IGBT - Check mains voltage.
command rate did not reach - Check the current
Fault 28 type the lower limit allowed to measurement sensor.
D28 ensure the requested welding - If necessary, review the
Exceeding Neg. current level. programming of the reference
% tolerance (PWM)
- Mains voltage too high. % set in screens P6 to P9.
- Change welder impedance.
DISPLAY
WINDOW
- The average IGBT - Check mains voltage.
command rate exceeded the - Check the current
Fault 29 type higher intermediate threshold measurement sensor.
allowed a number of - Check the welder:
Exceeding Pos. consecutive times making it →secondary links.
D29 recurrence % (PWM)
impossible to provide the →secondary loop.
requested welding current →short circuits.
level.
- mains voltage too low.
- welder impedance damage.
NAME AND TYPE

OF FAULT
Electronic differential circuit Acknowledging the fault should
Fault 33 type 1 breaker test not performed on trip the circuit breaker.
time or the test was faulty. If not, contact ARO.
D33 ELCB not tested
or faulty
NAME AND TYPE

OF FAULT
The WCC detected an Contact ARO service.
Fault 34 type ambient temperature level
that exceeds the maximum
D34 WCC temperature
allowed.
too high
NAME AND TYPE

OF FAULT
The main board's processor Acknowledge the fault.
Fault 35 type 1 no longer receives any If it recurs, power down then
response from the processor power up again.
D35 No response from
on the additional M.F. board. If the problem persists, contact
MF board
ARO service.

5. MAINTENANCE
DISPLAY
WINDOW
The non volatile memory is Pressing the button will
faulty. overwrite the specified field with
Line 3 indicates the faulty the initial parameters.
field: The fault ends when all of the
Fault 80 type 1 - Configuration, or erroneous fields have been
D80 Parameters loss - Electrode No.##, or cleared (powering down and
Erase ?
- Counter No.##, or then powering up again will not
- Program No.###, or make any difference).
- Learning routine No.## - If the problem persists,
contact ARO to replace the
faulty component.

5. MAINTENANCE
5.2. Assembling/Disassembling the Main Component Parts
WARNING: Before removing the connectors to allow removal of the rack, ensure that
all of the power supplies have been cut off: the main or auxiliary power
supplies to the WCC, where applicable.
The main disassembly operations that follow also shown how future re-assembly should
be performed in reverse order using the various component parts. Consequently, only the
disassembly actions are described.
• Bodywork preparation dimensions:
130

5. MAINTENANCE
• Swapping the CPU board

With the rack separated from the rest of the hardware environment:
1st. step: Remove the four case mounting screws.
2nd. step: Remove the nut that attaches the key switch to the front panel, taking care
to not loose the sealing washer.
3rd. step: Remove the two spacers that support the protection cover and the board,
as well as the four dedicated screws that hold the CPU board to the front
panel and release the CPU board.

5. MAINTENANCE
4th. step: Disconnect the key connection bus from the front panel to fully release the
CPU board from any other mounting.

5. MAINTENANCE
• Swapping the ALM4 power supply board

With the rack released from the rest of the hardware environment:
1st. step: Remove the unit's four mounting screws.
2nd. step: Remove the four M3 screws.

5. MAINTENANCE
3rd. step: Unplug the power supply board from the 12 pin connector on the CPU
board.

5. MAINTENANCE
• JUMPER POSITIONS:
Warning, be sure to comply with the precautions when swapping an electronic
circuit board.
The CPU board comprises jumpers (JP) used to configure certain functions.
1 2 3
1 2 3
JP2
JP23
1 2 3
1 2 3
JP1
JP24
1 1
2 2
3 3
JP21 JP22

5. MAINTENANCE
The regulator board must be fitted above the welding board and under the power supply
board.
1 2 3
S1

5. MAINTENANCE
If one of the boards is swapped, be sure to identify the position of the DIP switches on
the board that is removed so that the new board can be set to match the old one.
- Summary table showing jumper positions depending on the functions required:
Jumper
JP1 JP2 JP20 JP21 JP22 JP23 JP24 S1
Functions
3 2 1
Eternal SV 3 2 1
common line 3 or 2 1
- - - - -
Internal SV 24 VAC 3 2 1 3 2 1
common line - - - - -
Internal SV 24 VDC
3 2 1 3 2 1
common line - - - - -
Voltage 1 2 3
measurement by the - - - - - -
m.proceesor input
Voltage
measurement by the - - 1 2 3
- - - -
CTZ input
CTZ from the power 3 3
supply - - - 2
1
2
1
- -
CTZ from the I.L. 3 3
input - - - 2
1
2
1
- -
Int. measurement of
- - - - -
1 2 3 1 2 3
weld gain from 0 to
50 kA
Int. measurement of 1 2 3 1 2 3
weld gain from 50 - - - - -
kA to 130 kA
By default, add a
1 2 3
1kohm resistor
Measurement taken
1 2 3
without passing
through the resistor
Use this table to identify the position of jumpers on the removed board.
Note: For 4B and 4C software, JP25 should not be present.
• Software version
The CPU board comprises an EPROM to support WCC software.
The software version level is marked as shown below, on the label affixed to the
EPROM:

5. MAINTENANCE
Component Software Update

level version level
15 865 756 XX XXX

XX XX XXX
Year Week Serial number
Note: The software version level can be confirmed by pressing the key in RUN
mode until the following window is displayed:
Micro 2x16-III #X##X

WCC XXX XX##
SERIAL NO.####141D##
XXXXXXXXXXXXXXXXXXXX
• Help with troubleshooting failures and incidents

FAULTS POSSIBLE CORRECTIVE
OBSERVED CAUSES ACTIONS
Short-circuit before the power Check the two 24 V~ or 110 V~
Circuit breaker triggered
supply phases
Power supply short-circuit on the Check impedance on the +5 V, +24
Fuse
electronics side V lines then replace fuse
Control voltage short-circuit Check the SV fuse
Output failure
Optical coupler failure Check output impedance then
- SV control
Transistor BUX 86 HS replace components if necessary
- Transistorized controls
Direct output short to ground, hence Check the output control impedance,
- Relay controls (general fault)
excessive power consumption and then swap the affected relay if
- Control short-circuit on control
relay contact burn out necessary
voltage
Short-circuit or excessive power
consumption
Burn out affecting a diode, an input Check that the input voltage does not
Input failure resistor or the optical coupler. exceed 24 VDC or is < 0 V then
- Sel. prog/parity and other inputs replace the failed component or
replace the optical coupler
If front panel indicator on: Check control voltage and replace
- no control voltage the fuse if necessary
Does not control SV on START - protection fuse failure Contact ARO support
If front panel indicator off:
- electronic problem
No IGBT command, no AUS Check the AUS input on the
SV cmd present but does not weld
diagnostic screen
No input or 2X16 III programming Check inputs and 2X16 III
Performs its cycle without welding
without welding programming

5. MAINTENANCE
FAULTS POSSIBLE CORRECTIVE

OBSERVED CAUSES ACTIONS
No 24 VDC Check the +24 VDC supply
Welder shutdown Circuit breaker cut off Check circuit breaker setting Check
MS input failure optical input MS
Transistorized output failure Check the FCY output
End of cycle not issued
Welding fault during the cycle Reset the fault
Faulty NOV RAM CPU Replace the NOV RAM
Welding parameters lost Accidental pressing of F6 on power Reprogram WCC
up

6. PC COMMUNICATION
6. PC COMMUNICATION
The MICRO 2X16 III has a 9 point female Sub D connector on its front panel for the RS485 link.
- Software for editing, backing up and loading parameter settings from a PC is available on order
(ARODMS item code: HC0 01006).
- Supervision software called ARONET (item code: HC0 01003) is also available on order. The
ARONET centralized control software is used to display the counter, input and output data from
MICRO 2x16 III devices connected to the network. MICRO 2x16III device faults can be remotely
acknowledged from the PC.
From a PC, users can retrieve all of the program parameter settings and back them up to the
PC's hard drive or to a diskette. Parameter settings can be reloaded to another WCC or to the
current WCC if the parameter settings are lost.
• PC configuration required for ARODMS or ARONET
CONFIGURATION REFERENCE
Microprocessor Intel Pentium III
RAM 128 Mbytes or higher
Hard disk drive At least 200 Mbytes free space
CD-ROM
Serial port RS 232, 9 pin male
Display SVGA or compatible (800 x 600 minimum)
Operating system Windows 2000
• NOTE:
If the minimum configuration required is not provided, then this may affect software
performance levels and cause errors. For more information relating specifically to your
hardware environment, please contact ARO's sales department.

6. PC COMMUNICATION
• Hardware configuration required
Adapter
1) WCC
2) Connection cable and RS232/RS485 adapter

- Length: 1 to 2 meters
- Socket: WCC end: RS485 - 9 pin male
- Socket: PC end: RS232 - 9 point female
- Adapter for performing the conversion between the RS232 line and the RS485 line
There are two kinds of adapters:

- Standalone (RS232/RS485) adapter
This adapter allows connecting a single WCC to the PC.
(adapter and cable item code: AG853105).
- Mains supplied (230VAC) adapter (RS232/RS485) compatible with ARODMS and
ARONET software.
(adapter item code: 62490214).
(cable item code: BI291998).
3) PC compatible computer:
The PC must comply with the minimum configuration described above.
4) Communication software (ARODMS, ARONET).

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MICRO 2X16 III

06/02 T421GB Creation 3D31

01/04 Creation 3D32

ARO 1, avenue de Tours - 72500 Château-du-Loir - France - Tél : 33 (0)2 43 44 74 00

PROGRAMMABLE WELDING CONTROL SYSTEMS

• With safety mechanisms neutralized or modified.

182E ARO 1, avenue de Tours - 72500 CHATEAU-DU-LOIR - FRANCE - Tel. 33 02 43 44 74 00 I

1.3 The device must not be used in an explosive atmosphere.

2 – ELECTRIC POWER HAZARDS

NF EN 50081-1 and NF EN 50081-2

• Visible damage to the device,

182E ARO 1, avenue de Tours - 72500 CHATEAU-DU-LOIR - FRANCE - Tel. 33 02 43 44 74 00 II

5.2 Become familiar with the equipment prior to using it.

182E ARO 1, avenue de Tours - 72500 CHATEAU-DU-LOIR - FRANCE - Tel. 33 02 43 44 74 00 III

2.2 Basic Programming 12

2.3 Explanations on Basic Programming 24

3 SETTING INTO SERVICE

3.2 Hardware Configuration 69

3.3 Electrical Connection 70

4.2 Explanations on Run Windows 86

5.2 Assembling/Disassembling the Main Component Parts 106

Micro unit presentation:

Configuration window settings:

Device type Supply frequency

The reference code is explained below:

cd: HARDWARE VERSION

T421GB ARO 1, avenue de Tours - 72500 CHATEAU-DU-LOIR - FRANCE - Tel. 33 02 43 44 74 00 1

g: WCC supply voltage

i: Type of WCC supply phase Servo valves Programmable outputs

Weight [kg] 3 rack version

T421GB ARO 1, avenue de Tours - 72500 CHATEAU-DU-LOIR - FRANCE - Tel. 33 02 43 44 74 00 2

Supply [V] 24 VAC +15%/-20% Specified on ordering

Frequency [Hz] 50/60 Specified on ordering

Transistorized outputs 2 x 10 7 External power supply:

- Other outputs 2 x 10 7 VMAX 24 VAC IMAX 0.1A PMAX 3 VA

Common input voltage + 24 VDC

T421GB ARO 1, avenue de Tours - 72500 CHATEAU-DU-LOIR - FRANCE - Tel. 33 02 43 44 74 00 3

1. Front panel with programming key pad and control LEDs

T421GB ARO 1, avenue de Tours - 72500 CHATEAU-DU-LOIR - FRANCE - Tel. 33 02 43 44 74 00 4

12. Connector X5 (9p male Sub D): Not used

T421GB ARO 1, avenue de Tours - 72500 CHATEAU-DU-LOIR - FRANCE - Tel. 33 02 43 44 74 00 5

T421GB ARO 1, avenue de Tours - 72500 CHATEAU-DU-LOIR - FRANCE - Tel. 33 02 43 44 74 00 6

No. TYPE FUNCTION

2 Welding current flow

5 Single spot welding mode

10 Access to the next lower program number or configuration pages

12 Access to the previous programming page

13 Access to the next programming page

14 Increments the value under the cursor

15 Decrements the value under the cursor

24 "MODE" is used to see the programming settings being executed

T421GB ARO 1, avenue de Tours - 72500 CHATEAU-DU-LOIR - FRANCE - Tel. 33 02 43 44 74 00 7

2.1. SOFTWARE ORGANIZATION

2.1.1. Program and Parameter Organization

• Accessing programming mode

Configuration screens 32 Basic programs

T421GB ARO 1, avenue de Tours - 72500 CHATEAU-DU-LOIR - FRANCE - Tel. 33 02 43 44 74 00 8

• Displaying parameters programmed in RUN mode

• Changing parameters while working

- The same window may comprise one or more parameters.

- This parameter value can be increased or reduced by pressing the or key.

T421GB ARO 1, avenue de Tours - 72500 CHATEAU-DU-LOIR - FRANCE - Tel. 33 02 43 44 74 00 9

1) To simplify entering distant values, each digit can be incremented or decremented