STN 21 English PDF

Welding Controller
SMART-TIMER
STN21 Series
Version 1.2
Ver. No.SM059
Ver. No.SP038
Ver. No.SD038
Ver. No.SO033
(or
(or
(or
(or
SPECIFICATIONS
WELDING CONTROLLER
STN21- Series
For the safety use, read the safety precautions of this

instruction manual thoroughly to have a proper under
standing of it before operating this equipment. Be
sure to keep this manual in a specified place after
reading.
2004.3.10
No.F-202-
later)
later)
later)
later)
Notes on safety and handling procedure
= Notes on safety and handling procedure =

Read this instruction manual thoroughly before using
in order to use the product properly.
Installation, maintenance inspection, and repairing service of this equipment must be provided by qualified
technicians or those who sufficiently understand welding machines for safety reasons.
For safety purposes, operation of this equipment must be made by skilled persons who understand what is
described in this manual and are able to provide necessary safety control.
For safety training, reference is made to various kinds of seminars and qualification tests for welding
technicians and engineers held under the auspices of Welding Academy, Welding Association, and related
organizations.
Be sure to keep this instruction manual at a specified place for everyone.
For further information, please contact any of our offices whose phone or fax numbers are listed below.
Manufacturer: OBARA Corporation
Head Office:
Phones:
4-2-37 Ogami, Ayase-shi, Kanagawa-ken
OBARA CORP. JAPAN
252-1104
JAPAN
TEL
+81-467-70-7688
FAX
+81-467-70-7699
TEL
+1-586-755-1250
FAX
+1-586-755-6790
CINCINNATI PLANT
TEL
+1-859-283-5490
FAX
+1-859-283-5498
CANADA OFFICE
TEL
+1-519-485-6277
FAX
+1-519-485-6277
OBARA CORP. DE
MEXICO
TEL
+52-49-71-1525
FAX
+52-49-71-1526
OBARA EUROPE LTD.
TEL
+44-118-9302464
FAX
+44-118-9323483
OBARA FRANCE
REPRESENTATIVE
OFFICE
TEL
+33-3-20-61-55-56
FAX
+33-3-20-61-55-54
OBARA (MALAYSIA)
SDN.BHD.
TEL
+60-3-5191-9688
FAX
+60-3-5191-9699
OBARA (NANJING)
MACHINERY & ELECTRIC,
LTD.
TEL
+86-25-2104304
FAX
+86-25-2104305
OBARA (SHANGHAI)
CO.,LTD
TEL
+86-21-58316177
FAX
+86-21-58209793
OBARA (THAILAND)
CO., LTD.
TEL
+66-2-7499595
FAX
+66-2-7499598
OBARA KOREA CORP.
TEL
+82-2-868-3366
FAX
+82-2-838-3365
OBARA AUSTRALIA
PTY.LTD
TEL
+61-3-9764-1388
FAX
+61-3-9764-1398
OBARA CORP. INDIA

BRANCH OFFICE
TEL
+91-44-6202489
FAX
+91-44-6217966
OBARA CORP. U.S.A.

HERCULES WELDING
PRODUCTS DIVISION
All rights reserved.
F-202
Ver1.2
Printed in Japan.
OBARA Corp.
.Specifications
Page - 2
Safety precautions
= Safety precautions =
Read this instruction manual thoroughly before use in order to and use the product properly.
The cautionary instructions in this users guide are for safer operation to prevent danger and damage that
may occur to you and other persons.
While adequate safety considerations were given to the design and manufacture of this welder, items in
the cautionary articles of this users manual must always be followed to ensure the safe usage. Using the
welder without following these instructions may cause bodily accidents such as death and severe injuries.
Varying degrees of damages and dangers may occur when the equipment is mishandled.
These
degrees are categorized into 2 levels in this instruction manual, and they are accompanied by symbols,
that should catch your attention, and signaling words as warning indicators.
These symbols and signal
words to induce your caution are used with exactly the same meanings on the equipments warning
labels.
Attention
Calling
Signal Word
Description
Symbol
Improper handling of the equipment may cause a
DANGER
dangerous situation that can lead to eventual death or

severe injuries.
Improper handling of the equipment may cause a
CAUTION
dangerous situation that can lead to intermediate level

injuries, light injuries, and/or material damage.
The attention catching symbols indicate general situations.

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

Grounding work
for example.
Conducts that must not be done.

The symbols indicate general situations.
F-202
Ver1.2
OBARA Corp.
.Specifications
Page - 3
Limitation on operator
Limitation on operator
In order to maintain the safety of the operations, do not allow the following people to engage in the
operations.
DANGER
Mentally disabled.
Those with disability in hands, legs, eyes, and ears.
Drug (including narcotics) abusers.
Intoxicated.
Anyone who uses a heart pacemaker.
Those who do not wear specified protection devices.
Those who are non-qualified, (Those who have not had sufficient training in the
operation of the equipment.)
Those with loose long hairs.
Safety training
Operators of the gun should have enough knowledge and skill of the followings.
CAUTION
To understand the contents of this instruction manual.
To understand the meaning of warning labels.
To acquire the method of heart massage and artificial respiration(CPR).
To check protective attire such as that of fire fighters.
To clarify places and personnel to contact in emergency.
To acquire/check how to treat burns and injuries, and the location of first aid kit.
To check the location of emergency stop switch and how to reset it.
To understand how to inspect the system.
To have enough knowledge on electricity to understand it.
To understand the system, wiring diagram, and voltage.
To have enough knowledge on resistance welding to understand it.
F-202
Ver1.2
OBARA Corp.
.Specifications
Page - 4
Items to follow as safety precautions

! DANGER
!
Always follow the instructions below in order to prevent bodily

injuries.
1. Although considerations for safety have been adequately incorporated into the design and
manufacture of this welder, make sure the cautionary instructions in this instruction manual are
strictly obeyed upon usage of this equipment.
Operating without following these cautionary instructions may cause or lead to eventual death,
severe wounds, or other bodily- injury-related accidents.
2. Make sure that works on the power source on the input side, selection of installation site, and
storage of products and handling of waste material after welding operations should comply
with related laws and ordinances as well as your companys internal rules.
3. Make sure that no one enters the area surrounding the welder as well as welding operation
site carelessly.
4. Do not let anyone on a heart pacemakers come near the area surrounding the welder or
welding operation site unless he or she is permitted to do so by a physician.
The welder
generates a magnetic field in the surrounding area while it is charged, and thus, poses
negative affects to the pacemakers operation.
!
5. In order to assure safety, make sure that the installation, maintenance and inspection, and
repairs of this welder should be conducted by personnel with appropriate qualifications or
someone who is well versed with welders.
6. In order to assure safe operation of this welder, make sure it is operated by personnel who has
a good understanding of the contents of this instruction manual, and have the knowledge and
skills to operate it safely.
7. Do not use this welder for any purposes other than welding.
F-202
Ver1.2
OBARA Corp.
.Specifications
Page - 5
! DANGER
Always follow the following instructions in order to avoid electrical

shocks.
Touching a charged part other than the secondary conductor may cause life
threatening electrical shocks and/or burns.

Touching both ends of the secondary conductor simultaneously may cause
electrical shocks.
1. Do not touch any charged part other than the secondary conductor.
!
2. Make sure that the welder is grounded by a certified electrician in accordance with the law
(electrical installation technology regulation).
3. Make sure that installation, maintenance, and inspection are conducted at least 5 minutes after
all of the input side power source are turned off by the switches on the switch box.
Since
capacitors may still be charged even after the input side power sources are turned off, make
sure that the operation is conducted after checking that there is no voltage charged.
4. Do not use cables that have capacities below the specified requirement, that are damaged, or
that are exposing their conductive parts.
!
5. Tighten the weld part of the cable securely and insulate it.
6. Do not use the welder with its case or cover removed.
7. Do not use torn or wet gloves.
8. Make periodical inspection and maintenance and use the equipment only after the damaged
Always wear dry and well insulated gloves during operations.
parts are repaired.

!
9. Use high grade cooling water with a resistance of 5000-cm or more, which contains no
precipitate or sediment.
! 10. When preparing cables, pneumatic hoses, water hoses and other tubing and wiring, use the
ones that can adequately withstand the specified load or pressure.

! 11. When the welder is not being used, make sure that the power source for all of its devices is
turned off.
! 12. Do not open any door of the devices in any case except when necessary such as in
maintenance. When using the devices, be sure to lock the doors with keys, which should be
securely managed by authorized personnel.
F-202
Ver1.2
OBARA Corp.
.Specifications
Page - 6
! DANGER
Do not insert fingers or hands between the electrodes.
Placing a body part, such as hands, fingers, arms, etc., between electrodes will
cause the body part to be squeezed by the electrodes which, in turn will lead to
bone fracture or other injuries.
1. Do not insert your hands, fingers, arms, or other body parts between the electrodes.
!
2. Check for safety around the welder upon turning on the power or supplying pressurized air.
! CAUTION
Use appropriate protective devices to protect yourself and others

from splashes, spatter, and noise that are generated during
welding operations.
Airborne splashes and spatter may hurt your eyes and/or cause
burns.
Noise may cause hearing disorders.
!
1. Wear protective glasses to shield your eyes from airborne splashes and spatter.
2. Wear protective attire such as protective gloves, long-sleeve clothes, and leather aprons.
3. Install a protective curtain around the area surrounding the welding work site so that splashes
and spatter are not projected towards other people.
4. Utilize sound proofing devices if the noise level is high.
! CAUTION
Always follow the following precautionary instructions in order to

prevent fire and explosion.
Splashes and spatter generated during a weld and a hot base
metal right after a weld may cause fire.

Cables with imperfect connections may cause fire due to the heat
generated when they are charged.

!
1. Remove inflammable objects so that airborne splashes and spatter are not projected towards
them.
If they cannot be removed, cover the inflammable objects with a nonflammable cover.
2. Do not weld near combustible and/or inflammable gases.

3. Do not let base metals that are hot immediately after a weld get near inflammable objects.
!
4. Tighten the weld part of the cable securely and insulate it.
5. Prepare for unexpected accidents by having a fire extinguisher placed near the welding site.
F-202
Ver1.2
OBARA Corp.
.Specifications
Page - 7
Type of warning labels
Indications of dangerous parts and precautions

Type of warning labels and place to be attached
DANGER
The shaded areas in the figures show the

high-voltage hazardous areas of the
equipment.
Warning labels
F-202
Ver1.2
OBARA Corp.
.Specifications
Page - 8
Table of contents
Table of contents
1.Related manual ..............................................................................................10

2.Featurs ...........................................................................................................10
3. Basic specifications .......................................................................................11
3.1 Model ........................................................................................................................................11
3.2 Control......................................................................................................................................11
3.3 Input / Output ...........................................................................................................................12
3.4 Dimensions and Weight..........................................................................................................13
3.5 Facility Specifications.............................................................................................................13
3.6 Accuracy ..................................................................................................................................14
3.7 Coating Color...........................................................................................................................14
3.8 SCR characteristics.................................................................................................................15
F-202
Ver1.2
OBARA Corp.
.Specifications
Page - 9
Related manual
1. Related manual
The instruction manual of this equipment consists of individual manuals shown below.
Instruction manual
. Specifications
. Installation manual
. Operating manual
. Maintenance manual
. Reference manual
. Supplemental manual
This manual contains specifications instructions for this equipment, Read this manual thoroughly
to have a proper understanding of the specifications before operating the equipment.
2. Featurs
1. For 240 welding conditions.
2. Improved gun controlling functions
Retract control is available in standard models
Up to 4 guns can be controlled.
(Combination of 2 guns and 2 retract guns can be controlled.)
Additional Valve-selector function
3. Improved welding sequence
3-step welding with tempering applicable to aluminum welding
Flexible setting of delay time
Step-up function of up to 16 steps and can be set to any value
4. Down sized main frame
5. Improved controllability
Easy data input with back-lighted 4-line indication
6. For Installing Plurality of Units
Input of welding condition is possible from one TP-Net toward several Timers.
F-202
Ver1.2
OBARA Corp.
.Specifications
Page - 10
Input
Model
/ Output
3. Basic specifications
3.1 Model
STN21-G (For Plurality of unit)
3.2 Control
Control Method
Full-digital control (synchronous)
Control Series
4 Series/15 Series/16 Groups, 240 series maximum

Up to 8 guns (counter/Step Up control), or Up to 4 guns (solenoid control)
(combination of 2 guns and 2 retract guns can be controlled.)
Setting Method
Remote setting
Time Control
Squeeze Delay Time
0 to 99 cycles (all series)
Squeeze Time
Slope Time
Weld-1 Time
Cool-1 Time
Weld-2 Time
Down Slope Time
Cool-2 Time
Weld-3 Time
Hold Time
Off Time
Pressure Rise Time, 1
Hold End Delay Time
0 to 99 cycles (Common to all series)
Number of Pulsation
1 to 9 (all series)
Number of Re-weld Sequence
1 (can be specified by a parameter.)
Cycle Control
Current Control
Constant-current control
Primary-current feedback by CT
Current voltage control
Direct setting from 2000 to 60000A (100A in step)
Primary- current range
50 to 1500A
Voltage Control
Note
Constant-voltage control
Percentage setting from 25 to 100%
Since control ranges applicable to the settings of the current and voltage
controls depend on the connected load, the maximum and minimum
control currents vary with the load.
For example The minimum current will flow during welding if the welding time is specified,
though setting a welding current to 2000A.
Step Control
F-202
Ver1.2
Step-up setting: Up to 16 steps

OBARA Corp.
.Specifications
Page - 11
Available number of weld spots: Up to 9999 spots/step

Alarm Messages
Thyristor shorted
Cable shorted
Weld-1,2,3 cycle num. few
Thyristor over temperature
D/N Fatal error
Current flow rate high
Transformer over temperature
No current
Start switch trouble (D/N)
Current frequency abnormal
Current low
Start switch trouble (115)
Illegal parameter
Compensation voltage low
Communication time-out error
CPU operation failure
Current high
Communication data error
Illegal data setting
Compensation voltage high
OP communication error
Illegal current setting
Peak current high
Weld off warning
AD error 1
Line voltage low
Continuous pressure warning
AD error 2
Current unbalance
3.3 Input / Output

Solenoid Valve Specifications
DC24V
Rated current: 0.5A or less
Note1: Be sure to use the total current of each valve output by 0.8A or less.
Note2: Be sure to provide a surge absorber to the solenoid valve.
Not use for DeviceNet Parameter : Remote I/O .OFF

[ Input ]
Starting Input
1 N.O. contact, 4 series

o 4 N.O. contact, 1 series
Group Input
Retract Starting Input
Step Selection Clear Input 1 N.O. contact, 1 series

Step Reset Input
Alarm Reset Input
internal : 24VDC
Input current : 20mA
Weld ON/OFF Switch Input 1 N.O. contact, 1 series

Safety Switch Input
[ Output ]
Hold End Output
Alarm Output
1 N.O/N.C. contact, 1 series
Step Last Stage Out. 1 N.O. contact, 1 series

( Current Signal Output )*
Step Up Finish Out.
Relay contact output

Max. voltage : 24VDC
Max. current : 0.5A
*The step last stage signal output works instead of current detection signal output when
the
parameter is effective.
Note3: N.O. shows the Normally Open. N.C. shows reverse to N.O.
F-202
Ver1.2
OBARA Corp.
.Specifications
Page - 12
Dimensions and Weight
Use for DeviceNet Parameter : Remote I/O .ON

[ Input ]
D/N Input 1-6
6 N.O.
Step Reset Input
Alarm Reset Input
internal : 24VDC
Input current : 20mA
Weld ON/OFF Switch Input 1 N.O. contact, 1 series

Safety Switch Input
[ Output ]
D/N Output 1-4
1 N.O. contact, 1 series (DC24V output Max.current 0.5A)
D/N Output 5-8
1 N.O. contact, 1 series (Relay contact output Max.current 0.5A)
3.4 Dimensions and Weight

Dimensions
320 (W)470 (H)195 (D)
Weight
18 kg
3.5 Facility Specifications

Rated Voltage
Single-phase 200/220/380/400/420/440Vac 50/60 Hz

(Selected by switching the range on the base voltage.)
Rated voltage regulation within 20% of rated voltage
Power Consumption
50 VA (not in weld)
Frequency
50/60 Hz (automatically selected on power-on)
Temperature
0 to 50
Humidity
90% or less (non-condensing)
Cooling Water
Inlet port:
30 or less
Flow rate:
6 liters/min.
Maximum water pressure:

Electric resistance:
0.3 Mpa or less
5000cm or higher
Thyristor
AE11-5S07U772 (Size: E, 1100A type)
Preservation Period of Set data
10 years
CAUTION
Handling the welding set data

The data stored in the timer memory is preserved for 10years after it is input given the
timer is in the normal operating condition. The data may be damaged when there is a
failure to the main PC board.
It is strongly recommended that the user write the important welding conditions down
separately just in case the data stored in the timer is lost.
F-202
Ver1.2
OBARA Corp.
.Specifications
Page - 13
Accuracy
3.6 Accuracy
Power-source Voltage Regulation Within 10%
Resistance Load Regulation
Within 10%
Setting Accuracy
3% (of full scale)
Repeatability
3% (of full scale)
3.7 Coating Color

Frame Paint Color:
Orange (color chip No.: E5-259)
Source:
Book of standard color samples for painting

(Issued in 1981 by Japan Painting Industry Association)
F-202
Ver1.2
OBARA Corp.
.Specifications
Page - 14
SCR characteristics
3.8 SCR characteristics

SCR Type AE11-5S07U772 (AE11)
AW13-5S07U772 (AW13)
Ratings and characteristics
Item
condition
Symbol
Model
AD90
Repetitive peak off-state voltage
VDRM
1600
Non-repetitive peak off-state reverse voltage
VDSM
1700
R.M.S.water temperature 30flow rate 6 L/min IT(RSM)

R.M.S. current at 10% duty cycle20 cycles
water temperature 30flow rate 6 L/min
ITSM
900
1200
2150
2400
10000
5000
10
PG(AV)
Peak gate current
IGM
Peak gate voltage
VGM
20
Peak reverse gate voltage
VRGM
Motion junction temperature
Tjw
40 125
Water temperature
Tw
0 30
Storage temperature range
Tstg
40 80
1 cycle-surge on-state current (50Hz non-repetitive)

15 cycle-surge on-state current (50Hz non-repetitive)
Maximum Peak gate power dissipation

Rating Average gate power dissipation
PGM
Mass
Maximum peak off-state current
IDM
(Tj=125,VDM=VDRM)
Maximum peak reverse current
IRM
(Tj=125,VDM=VDRM)
Maximum on-state voltage
VTM
(Tj=25,TM =1700A)
Maximum gate trigger current
IGT
(Tj=25,VD =6,IT =1A)
Characte-r Maximum gate trigger voltage
VGT
istics
(Tj=25,VD =6,IT =1A)
Minimum gate non-trigger current
IGD
(Tj=125,VD =2/3VDRM)
Minimum gate non-trigger voltage
VG
Minimum critical rate of rise of off-state voltage
dv/dt
Thermal resistance (between junction and cooling water,
Rth(j-w)
flow rate 6/min
F-202
Unit
AE12
Ver1.2
OBARA Corp.
2.5
Kg
30
mA
30
mA
1.69
150
mA
10
mA
0.25
500
V/s
0.120
/w
.Specifications
Page - 15
SCR characteristics
Duty cycle R.M.S. current rating

AD90-ST230C160
( 900A-Type )
Condition
4000
Frequency
50 Hz
Flow rate
6L/min
Cooling water temperature 30

n=3
n=5
3000
R.M.S. current A
n=10
n=20
n=40
2000
1000
0
1
10
Duty cycle
20
50
100
n
= N 100 (%)
F-202
Ver1.2
OBARA Corp.
.Specifications
Page - 16
SCR characteristics
Duty cycle R.M.S. current rating

AE12-ST330C160
( 1200A-Type )
Condition
4000
n=3
Frequency
50 Hz
Flow rate
6L/min
Cooling water temperature 30
n=5
n=10
3000
R.M.S. current A
n=20
n=40
2000
1000
0
1
F-202
Ver1.2
10
20
50
Duty cycle
OBARA Corp.
100
.Specifications
Page - 17
Version 1.5
Ver. No.SM059
Ver. No.SP038
Ver. No.SD038
Ver. No.SO033
(or
(or
(or
(or
later)
later)
later)
later)
INSTALLATION MANUAL
WELDING CONTROLLER
STN21- Series
For the safety use, read the safety precautions of

this instruction manual thoroughly to have a proper
understanding of it before operating this equipment.
Be sure to keep this manual in a specified place
after reading.
2004.03.10
No.F-201-
Table of contents
Table of contents
1. Related manual ...........................................................................................10
2. Installation ...................................................................................................11
2.1 Installation ................................................................................................................. 11
2.2 Connecting Power Cable and Welding Transformer.............................................. 12
2.3 Grounding.................................................................................................................. 12
2.4 Installing Cooling-water Hose.................................................................................. 13
2.5 Connecting TP-Net Cable ......................................................................................... 13
2.6 Connecting Controlling Lines .................................................................................. 14
2.7 TB1 Input / Output for Parameter setting Remote I/O : ON............................... 17
2.8 Inputting Start Signal and Instructions ................................................................... 18
2.9 Step Clear .................................................................................................................. 19
2.10 Step Select Clear....................................................................................................... 19
3. Precautions in Supplying Initial Power ........................................................19

3.1 Checking Items before Powering On....................................................................... 20
3.2 Checking Items in Powering On .............................................................................. 20
3.3 Emergency Stop........................................................................................................ 20
4. Storage Instructions ....................................................................................21
F-201
Ver1.5
OBARA Corp.
.Installation manual
Page - 9
Related manual
1. Related manual
Instruction manual
. Specifications
. Operating manual
. Reference manual
This manual contains installation details of this equipment, Read this manual thoroughly to have
a proper understanding of the installation before operating the equipment.
F-201
Ver1.5
OBARA Corp.
Page - 10
Installation
2. Installation
2.1 Installation
(1) Weight
STN21 Standard model
(2) Space Requirements
506 (W) x 507 (D) x 500 (H)

506 (W) x 532 (D) x 500 (H)
(3) Installation
18kg
Hose-nipple specifications
Install the equipment using 4 mounting holes at the bottom of

the mainframe.
Mounting hole diameter (11)
Precautions in Installation
! Install the controller in a place where ambient temperature is between 0 to 40 and out
of direct sunlight.
! Provide lightening protection to the controllers incoming power source according to

appropriate rules and regulations.
! Avoid locations subject to water or oil ingress, or dust containing metal.

Space RequirementsMainframe Bottom-side View
Bottom View
Mainframe Mounting hole Diagram
* The controller is the hose-nipple type.
F-201
Ver1.5
OBARA Corp.
Page - 11
Connecting Power Cable and Welding Transformer
2.2 Connecting Power Cable and Welding Transformer

Power Cable:
Connect it to "01-02" of the power connection terminal at the bottom

of the controller.
Welding Transformer: Connect it to "01-03" of the power connection terminal at the bottom
of the controller.
(Refer to the following diagram for connections.)
Wiring Instructions
! Connecting wire:
100mm2 or larger in size (Refer to the following diagram.)
! Withstand voltage:
AC600V or higher
! Voltage-drop in welding:
Less than 20% of the rated voltage
! Power source:
Install the fuse on the base of power source.
! No Fuse Breaker (NFB):
Install the NFB or ELB between the controller and the
welding power source before using the controller.
Welding Transformer Capacity
Welding Transformer Capacity NFB Rated Current (AC380 to 440V)
35kVA
Wire Size
55kVA
100A
38mm2 or larger
125kVA
225A
60mm2 or larger
180kVA
350A (400A frame)
100mm2 or larger
Note: Any NFB other than described above does not protect the circuit from
overload. (If you have any questions, please contact us.)
2.3 Grounding
! Grounding wire: Connect it to the "grounding connection terminal" in the lower part of the
controller. (Refer to the following diagram.)
Grounding Instructions
! Connecting wire: 50mm2 or larger in size (Larger than half the size of the power cable.)
Power Cable Grounding wire
Connect grounding wire here.

(M8 bolt)
Example of Connection
Connect power cable here.
01-02 (M10 bolt)
F-201
Ver1.5
OBARA Corp.
Connect welding transformer

cable here.
01-03 (M10 bolt)
Page - 12
Installing Cooling-water Hose
2.4 Installing Cooling-water Hose

Cooling-water Hose: To provide cooling water use 9.5mm (3/8 inch) bore hose . (Refer to the
following diagram.)
Cooling-water Requirements
! Temperature at the inlet port: 10 to 30
Maximum pressure: 0.3 MPa or less
! Flowrate: 6 L/min or higher
Resistance: 5000cm or higher
Cooling-water Instructions
Use clean water or industrial water for cooling . Do not use water characterized with
electrolyte such as saline.
! For circulating cooling water, renew the water entirely once in every six months or renew 5 to
10% of the entire water at all times (Since water will evaporate).
! If using the controller in a place where freezeing occurs, be sure to drain the water from the
controller when not in use.
! If using the low resistance cooling water, the hose length 2M or higher,
2.5 Connecting TP-Net Cable

Connect the TP-Net cable to the connector (CN4) on the right side of the main board located on
the upper side of the timer mainframe.
(Refer to the following diagram for the connecting
locations of the cables.)

Connecting Diagram of Cooling-water Hose and Pendant Cable
Connect pendant cable here.
Standard Model
Water OUTLET
Water INLET
Nipple-type Model
Water OUTLET
Water INLET
F-201
Ver1.5
OBARA Corp.
Page - 13
Connecting Controlling Lines
2.6 Connecting Controlling Lines

Connect the wires to the TB1 terminal block on the upper side of the controller. (Refer to the
instructions affixed to the block.)
Description of Connecting Item:
Item
Description
Input
Output
SOL1,2
Outputs a signal to each of the solenoid valves of GUN1 and GUN2.

Outputs a signal to the retract valve. It can be also used as an output
SOL7,8
signal to each of the solenoid valves of GUN3 and GUN4.
Outputs an alarm signal on occurrence of fatal or warning (caution)
alarm.
ALARM
Related Parameters:
Caution, Test W ALM, ALM Mode, and ALM Out
STEP UP FINISH Outputs a signal on completion of the specified steps in the Step-up
OUTPUT
function.
STEP LAST STAGE When the final step stage, this output signal is on.
OUTPUT
When the parameter Pr is on, the current detection signal output is
( CURRENT DETECTION
made effective.
SIGNAL OUTPUT )
Outputs a signal every weld spot. When an error has been detected,
the output depends on the error condition.
HOLD END
Related Parameters:
Hold Out , Hold A Dly
Binary input of GROUP 0,1,2,3 will select the welding condition group
GROUP 0 to 3
from 0 to 15.
1. An input to start operation. Up to 240 conditions can be selected by
the combination input of the Start switch, Group 0,1,2,3.
2. Inputting one of these signals and the STEP SELECT CLEAR
signal simultaneously will reset the value of Step preset to a
START SW1 to 4
specified gun.
Related Parameters:
AB Mode, Sw mode, and One Shoot
RETRACT START
An input to start the Retract function
SW7, 8
ALARM RESET
Short-circuiting this will reset a currently issued alarm.
A switch to externally operate/stop the welding. The terminals, A12
WELD ON/OFF
and B13, need to be short-circuited when not in use since these
terminals are N.C. (Welding is available when closed.)
STEP CLEAR
Clears the Step-up data of up to GUN8.
Inputting this signal and the Start switch simultaneously will specify a
STEP SELECT
gun number and clears its Step data. Refer to Section 2.9 for details of
CLEAR
the connection.
Connection of the thermostat wire of the welding transformer N.C.
TRANS. THERMO
(Closed in normal state).
A switch to stop the timer in case of emergency. N.C. (Activates when
SAFETY SW
closed.)
Parameter: The mode to select timer functions or carry out basic setups. Refer to
"V. Reference manual" for details.
F-201
Ver1.5
OBARA Corp.
Page - 14
Connection Example of Robot Control Board

Condition: B Mode (binary switch input) Step control is enable.
2
Refer to Section, 2.7 "Inputting Start Switch and Instructions".
The step last stage signal output works instead of current detection signal
output when the parameter is effective.

F-201
Ver1.5
OBARA Corp.
Page - 15
Connection Example of Portable Transformer

Condition: Selectable between A-Mode and 1 retracted gun
F-201
Ver1.5
OBARA Corp.
Page - 16
2.7 TB1 Input / Output for Parameter setting Remote I/O : ON

Each Input and Output item became DeviceNet I/O at the time of the Remote I/O : ON choice.
Refer to the bottom table for the details.
Parameter
Remote I/O : OFF
Parameter
Remote I/O : ON
Table of TB1 item

TB1
standard
D/N output 1 to 4
- common
DC24V output
D/N output 5 to 8
relay contact output
D/N input 1 to 6
relay contact input
Alarm reset
Short-circuiting this will reset a currently issued alarm.
Weld ON/OFF
A switch to externally operate/stop the welding.

N.C. (Closed in possible for welding)
Step clear
Clears the Step-up data of up to GUN8.
Transf. thermo
Connection of the thermostat wire of the welding transformer.

N.C. (Closed in normal state).
Safety SW
A switch to stop the timer in case of emergency.

N.C. (Activates when closed.)
F-201
Ver1.5
OBARA Corp.
Page - 17
Inputting Start Signal and Instructions
2.8 Inputting Start Signal and Instructions

Inputting Start Switch Signal :
Operation mode is selectable between A-Mode and B-Mode by setting the corresponding
parameter of the timer.
A-Mode:
Employs welding conditions of the Series corresponding to an activated Start
switch. Mainly used for systems to which portable guns are connected.
B-Mode:
Selects one of the Series from 1 to 15 by combination input of the Start
switch signal, assuming the switch number to be a binary code.
Group :
Group
Selection:
Series from 1 to 15 is called "Group". The binary input of the Group SW

allows one of the Groups from 1 to 3 to be selected. As shown in the
following table, no input selects Group 0.
Group
A Mode (4 series)
Series 1
Series 2
Series 3
Series 4
Start Switch 1
Start Switch 2
Start Switch 3
Start Switch 4
Group
B Mode (1 to F :15 series)
Series
Start SW1
Start SW2
Start SW3
Start SW4
Group
Group 0
Group 1
Group 2
Group 3
Group Selection
Maximum welding conditions = 15series
F-201
Ver1.5
OBARA Corp.
16groups = 240conditions
Page - 18
Inputting Start Signal and Instructions
Inputting Instructions of Start Signal

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

Example of Start Switch Input
At first, close the relays, CR18, and then close the contact, CR0, after CR0 short interval.
This method of closing the contact, CR0, after closing the six relays poses no problem if the
differences in closing timing of the relays are moderate.
Diagram of Starting Switch Input
Wiring Example
Common
CR0 : Input common
CR1 : Relay contact for SW 1
CR5 : Relay contact for Group 0
Terminal Block
2.9 Step Clear

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

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

Combination of the S.SW for Step clear
The inside treatment of step select clear:

Selected
to
step select clear
F-201
Ver1.5
GUN num. which shows a specified to
Reference to GUN num.
combination of the Start SW is looked
combination of Start SW
up from the welding condition table.
at selected to
OBARA Corp.
Page - 19
Precautions in Supplying Initial Power
(Note) When the parameter Ps and P8 are both enable, the action of step select clear changes to
the following.
1. The Step return" disappears from welding condition items.
2. The step state of step series2 is set to1, and the step count is reset by this input signal
(TB1-A14).
3. Step series2 only can be cleared by this input signal (TB1-A14).
3. Precautions in Supplying Initial Power

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

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

Opening the signal circuit of SAFETY SWITCH on the TB1 terminal block will immediately stop
the valves and the supply of welding current. System engineers must utilize this as occasion
demands.
F-201
Ver1.5
OBARA Corp.
Page - 20
4. Storage Instructions
To store the timer, observe the following instructions:
1. Drain the water off from SCR by air blowing.
2. Make sure that the inside of the mainframe is dust free.
3. Place the timer in its original plastic bag so as to prevent penetration of dust into the timer.
4. Store the timer in a place where temperature is between 0 and 60 with 70% or less
humidity and condensation of humidity will not occur. Avoid locations receive vibrations or
direct sunlight.
F-201
Ver1.5
OBARA Corp.
Page - 21
Version 1.5
Ver. No.SM059
Ver. No.SP038
Ver. No.SD038
Ver. No.SO033
(or
(or
(or
(or
later)
later)
later)
later)
OPERATING MANUAL
WELDING CONTROLLER
STN21- Series

after reading.
2004.03.10
No.F-201-
Table of contents
Table of contents
1. Related manual ...........................................................................................10
2. Precautions in Operation.............................................................................11
3. Products System Configuration...................................................................11
3.1 Connecting to Robot Gun.......................................................................................................11
4. Alarm Messages and Precautions ..............................................................12

4.1 Precautions at Occurrence of Alarm .....................................................................................12
4.2 Alarm Messages on TP-Net/DP-Net .......................................................................................12
F-201 Ver1.5
OBARA Corp.
.Operating manual Page - 9
Related manual
1.
Related manual
Instruction manual
. Specifications
. Operating manual
. Reference manual
This manual contains operating instructions for this equipment. Read this manual thoroughly to
have a proper understanding of equipment operation before use.
F-201 Ver1.5
OBARA Corp.
Products System Configuration
2.
Precautions in Operation
!
CAUTION
! 1.
Before using the equipment, make sure that the cooling-water flowrate is at
the stated level (6 L/min).
2.
Only qualified engineers can change welding data. If any of the data requires
change, contact a manager and make sure that a qualified engineer changes
the data.
! 3.
If you find any abnormality or alarm messages during operation, immediately

stop the operation and contact a manager.
! 4.
This manual exclusively describes instructions for the controller. For other
products such as welding guns and so on, read the corresponding manual.
3.
Products System Configuration
3.1 Connecting to Robot Gun
F-201 Ver1.5
OBARA Corp.
Alarm Messages and Precautions
4.
4.1 Precautions at Occurrence of Alarm

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

Display of Alarm Message and List of Alarm Message
TP-Net
DP-Net
Alarm messages appear here.
Alarm indication lamp flickers.
F-201 Ver1.5
OBARA Corp.
Fatal Alarms:
Alarm Name
Alarm Message
Thyristor shorted
SCR Break
SCR Over Heat
Trans Over Heat
Illegal Freq.
Illegal parameter
Illegal Param
Illegal Data
Illegal Curr.
AD error 1
AD1 Error
AD error 2
AD2 Error
Cable shorted (Electrode sticking)
Cable Short
Warning Alarms:
No current
No Current
Current low
Current Low
% Voltage Low
Current high
Current High
%Voltage High
Peak Current high
PeakCurr High
Line voltage low
Line Volt. Low
Cautionary Alarms:
Current unbalance
Cur. Unbalance
Weld-1 cycle few
W1 Cycle Few
Weld-2 cycle few
W2 Cycle Few
Weld-3 cycle few
W3 Cycle Few
FlowRate Over
Indicative Alarms:
Start switch trouble ( 015)
Illegal Start ( 015)
Comi. Time Out
Comi. Data Err
OP TP Com. Err.
Weld off warning
No Weld Warn.
No Weld2 Warn.
Specific Alarm:
CPU Error
DeviceNet fatal error
DN-PCB Error
F-201 Ver1.5
OBARA Corp.
Version 1.5
Ver. No.SM059
Ver. No.SP038
Ver. No.SD038
Ver. No.SO033
(or
(or
(or
(or
later)
later)
later)
later)
MAINTENANCE MANUAL
WELDING CONTROLLER
STN21- Series

after reading.
2004.03.10
No.F-201-
Table of contents
Table of contents
1. Related manual ...........................................................................................10
2. Products Block Diagram..............................................................................10
3. Pre-operation Checks .................................................................................11
4. Maintenance and Inspection .......................................................................11
5. Maintenance................................................................................................12
5.1 Precautions in Maintenance ...................................................................................................12
6. Trouble Shooting.........................................................................................13
6.1 Faults Undetectable by Alarm Messages..............................................................................13
6.2 Alarm Descriptions and Remedies ........................................................................................15
7. Check I/O Information ...................................................................................22

7.1 I/O information list at the time of DeviceNet intact................................................................22
7.2 I/O information list at the time of DeviceNet use. ..................................................................24
F-201 Ver1.5
OBARA Corp.
.Maintenance manual Page - 9
Related manual
1.
Related manual
Instruction manual
. Specifications
. Operating manual
. Reference manual
This manual contains maintenance information for this equipment. Read this manual thoroughly
to have a proper understanding of the maintenance requirements before operating the equipment.
2.
Products Block Diagram
F-201 Ver1.5
OBARA Corp.
Pre-operation Checks
3.
Pre-operation Checks
Before starting welding, carry out the following checks in order to use the controller safely.
Requirements
SCR
There must be no water leakage.
Cooling Water
Flowrate must reach the stated level.
Power Lamp
The lamp will turn on/off by powering on/off.
Maintenance and Inspection

To use the controller safely, carry out the following servicing tasks at the stated running-time
intervals.
Check TP-Net to verify that the

required welding data have
been properly set.
Preset Data 1
Check TP-Net to verify that the
required parameters have been
properly set.
Verify that the flowrate of the
Welding-current Measurement welding current reaches the
required level.
Connection of the input/output
No loose connection
signal wires
Appearance of the
No visible damage nor
input/output signal wires
disconnection
Connection of the grounding
No loose connection
wire
Appearance of the grounding No visible damage nor
wire
disconnection
Connection of the cables to
the power source and the
No loose connection
welding transformer
Appearance of the cables to
No visible damage nor
the power source and the
disconnection
welding transformer
Inside of the controller must be
Internal state of the controller
kept clean.
Check by blowing air to verify
Cooling-water circuit (SCR)
that sufficient water can
circulate.
F-201 Ver1.5
OBARA Corp.
Occasionally
Annually
Requirements
Monthly
Checking Item
Weekly
Interval
Daily
4.
Checking Item
Maintenance
5.
Maintenance
! Before carrying out maintenance tasks, you must thoroughly read and understand V.
Reference manual.
5.1 Precautions in Maintenance

!
! 1.
! 2.
! 3.
! 4.
5.
! 6.
7.
DANGER
Before carrying out maintenance tasks, be sure to turn off the power source and
check with a voltmeter (AC 500V) to verify that the welding current has been shut
off.
The power indication lamp may not be lit because the bulb has burnt out, for
example, although power may still be present. When you check the presence of the
power using the power indication lamp always verify that the power indication lamp
goes out by turning off the main power source. (Verify the status of the lamp in both
situations.)
If a maintenance task needs to be carried out with the power source on do not touch
the following parts or cables as high voltage is present. To carry out the task
maintenance engineers must work on insulating rubber sheet and wear insulating
gloves. Touching the following parts may result in a serious accident or even death
from electric shock.
(1) TBO power terminal block: 01, 02, and 03
(2) SCR and its surrounding area
(3) The PC-1091 trigger circuit and its surrounding area (painted white)
(4) The RP1 and RP2 resistors
(5) The CP1 large capacitor
(6) The F1 input fuse
If you need to put your hands into the mainframe during maintenance always wear
insulating gloves. Do not carry out maintenance tasks with bare hands or you may
suffer an injury, for example, cutting your hands on a corner of a part.
Do not carry out maintenance tasks in poor lighting. Carrying out the maintenance
tasks in poor lighting may result in mistakes or contact with hazardous sections,
leading to a serious accident or even death.
When you perform a welding test during maintenance, always ensure that the
cooling-water flowrate reaches 6L/min. Carrying out a welding test with insufficient
cooling water may generate excessive heat in the cables or the hoses, and result in
hoses bursting.
Do not replace any parts on the PCB. Replace the PCB if necessary. The Obara
Corporation does not guarantee any malfunction or failure resulting from the
replacement of parts on the PCB.
F-201 Ver1.5
OBARA Corp.
Trouble Shooting
6.
Trouble Shooting
6.1 Faults Undetectable by Alarm Messages

The power indication lamp does not light.
Symptom
Cause
Welding power circuit breaker

trips.
Excessive heat from the
timers large resistor
Power cable is installed
properly.
Wrong wiring of 01-02 and

01-03
Welding power is connected to
01-03.
Imperfect contact of the CN2
connector in the timer
Faulty lamp
Remedy
See II. Installation manual,
and correct the wring.
See II. Installation manual,
and correct the wring.
Check the connector for
contact.
Replace the lamp.
The gun does not operate though the Start switch has been pressed.
Symptom
The power indication lamp is
on but no alarm message
appears.
The alarm message, No

Current, appears.
The alarm message, Start
switch trouble.
F-201 Ver1.5
Cause
Remedy
Disconnection of a D/N
communication cable or the
connector has separated.
The parameter Pq Remote
I/O is OFF setup.
Check the timer mode to see
that it is not set to Weld
disable or Continuous
pressurization mode.
D/N timer input information
Weld mode is not turned on.
Disconnection or wrong wiring
of the wire connected to
A16-B16, SAFETY SW, on the
TB1 terminal board.
A wiring check of after an error

check and a cable, or
exchange.
A parameter Pq Remote I/O
is turned ON.
Check TP-Net.
D/N timer input information

Starting series 1 to 8 is not
turned on.
OBARA Corp.
A check of the contents of

communication.
Check the wiring
See Section 6.2, and correct

the problem.
A check of the contents of
communication.
Trouble Shooting
No indication appears on TP-Net/DP-Net display

Symptom
Cause
The power indication lamp of Faulty cable.

the timer is on but the display
TP-Net/DP-Net is faulty.
is faulty.
Remedy
Replace the cable.
Replace TP-Net/DP-Net.
The target timer number is not displayed on TP-Net/DP-Net screen.

Symptom
Cause
Remedy
Change or check of a
The target timer number is not
Disconnection or failure of a
Timer-Timer connection
displayed on TP-Net screen.
Timer-Timer connection cable.
cable.
The power supply of Timer
An injection of a power supply.
which it is going to choose is
not turned on.
Change of parameter" timer
number."
There is a timer of the same

number setup.
Parameter : Po TM Number
TP-Net is alone connected to

timer which wants to change a
number.
Then, a power supply is
switched on, pushing Home
key in TP-Net.
The cable of TP-Net may be
taken out and inserted instead
of a power supply injection.
If it rises normally, it will be
made the edit mode of a
parameter and a number will
be changed.
F-201 Ver1.5
OBARA Corp.
Trouble Shooting
6.2 Alarm Descriptions and Remedies

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

SCR Over Heat
Fatal
Detecting
The controller issues the alarm when the thyristor thermostat switch has been
Method
activated, regardless of the state of the controller.
Cause/
1. Check duty cycle.
2. Insufficient cooling water
Remedy
3. Replace the thyristor with a larger one.
4. Replace the thyristor.
Alarm Name
Alarm Message
Category

Trans Over Heat
Fatal
Detecting
The controller issues this alarm when the transformer thermostat switch has
Method
been activated, regardless of the state of the controller.
2. Insufficient cooling water
1. Check duty cycle.
Cause/
4. Replace the transformer.
3. Replace the transformer with one having
Remedy
larger rated capacity.
Alarm Name
Alarm Message
Category

Illegal Freq.
Fatal
The controller checks frequency to select between 50 Hz and 60 Hz when it is
Detecting
turned on and issues this alarm if the frequency ranges outside the stated
Method
bandwidth.
Cause/
Check the controller power supply.
Remedy
Alarm Name
Alarm Message
Category
Illegal parameter
Illegal Param.
Fatal
Detecting
The controller issues this alarm when the parameter data has been lost.
Method
Cause/
1. Check and re-enter the parameters. 2. Replace the PCB.
Remedy
F-201 Ver1.5
OBARA Corp.
Trouble Shooting
Alarm Name
Alarm Message
Category

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

Illegal Curr.
Fatal
Detecting
The controller issues this alarm when the preset current of the activated Series
Method
is 0 but welding time is set to any value other than 0.
Cause/
Check and correct the welding condition data.
Remedy
Alarm Name
Alarm Message
Category
AD error 1
AD1 Error
Fatal
Detecting
Method
Cause/
Remedy
The controller issues this alarm when the measured current is abnormal.
1. Replace the timer. 2. Replace the CT.
Alarm Name
Alarm Message
Category
AD error 2
AD Error
Fatal
Detecting
Method
Cause/
Remedy
The controller issues this alarm when the measured current is abnormal.
1. Replace the timer.
Alarm Name
Alarm Message
Category
Cable shorted
Cable Short
Fatal
Detecting
The controller issues this alarm when the test current exceeds a specific level.
Method
Cause/
Replace the secondary cable.
Remedy
F-201 Ver1.5
OBARA Corp.
Trouble Shooting
Alarm Name
Alarm Message
Category
DeviceNet unusual detection

DN PCB Error
Fatal
Detecting
Timer is [ reception or ] a time of detecting about abnormalities.
Method
Automatic reset is performed after an unusual return.
Cause/
1. Failure of a substrate. change to UCS board
Remedy
2. The abnormalities in the exterior of Timer.
Warning Alarms
Alarm Name
Alarm Message
Category
No Current
No Current
Warning
Detecting
The controller issues this alarm when the measured current is 0 or the
Method
welding cycle is set to 0.
1. Secondary cable disconnection Re-fit / replace the cable.
2. The ignition circuit of the timer is at fault. Replace the timer.
Cause/
Remedy
3. Disconnection of the thyristor gate wire (G1, K1, G2, and K2) Re-fit
4. Thyristor Replace.
Alarm Name
Alarm Message
Category
Current low
Current Low
Warning
Detecting
The controller issues this alarm when the measured current falls short of the
Method
preset current.
1. Voltage variation is too large.
Replace the cable with a larger one. Check the power supply.
2. Deterioration of the secondary-cable Replace the cable.
Cause/
3. Incorrect welding parameters (welding current and lower current limit)
Remedy
Check welding conditions.
4. Significant error in transformer turn ratio parameter. Check welding
conditions.
F-201 Ver1.5
OBARA Corp.
Trouble Shooting
Alarm Name
Alarm Message
Category

% Voltage Low
Warning
Detecting
In constant current control, the controller issues this alarm when the measured
Method
voltage falls short of the preset voltage in %.
Replace the cable with a larger one. Check the incoming system.
Cause/
2. Check the constant voltage and the preset voltage in %.
Remedy
3. Deterioration of the secondary-cable Replace the cable.
4. Check the preset value of lower current limit.
Alarm Name
Alarm Message
Category
Current high
Current High
Warning
Detecting
The controller issues this alarm when the measured current exceeds the preset
Method
current.
1. In correct welding conditions (welding current and upper current limit)
Check welding conditions.
Cause/
2. Significant error in transformer turn ratio parameter. Check welding
Remedy
conditions.
3. Power voltage is unstable. Check the power supply.
Alarm Name
Alarm Message
Category

% Voltage High
Warning
Detecting
In constant current control, the controller issues this alarm when the measured
Method
voltage exceeds the preset voltage in %.
1. Check the constant voltage and the preset voltage in %.
Cause/
Remedy
2. Power voltage is unstable. Check the incoming system.
Alarm Name
Alarm Message
Category
Peak current high

PeakCurr High
Warning
Detecting
This controller issues this alarm when the current has a peak value, Its bigger
Method
than the setting value.
1. During GUN action : Check welding conditions squeeze time
2. In correct welding conditions Peak current Limit : Check welding conditions.
Cause/
3. Voltage variation is too large. : Check the incoming system.
Remedy
: Check the balance of power supply.
F-201 Ver1.5
OBARA Corp.
Trouble Shooting
Alarm Name
Alarm Message
Category
Line voltage low

Line Volt. Low
Cautionary
Detecting
The controller issues this alarm when the measured voltage falls short of V
Method
limit of welding condition.
Replace the cable with a larger one. Check the incoming system.
Cause/
Check the duty cycle.
Remedy
2. Check the setting of the power-voltage lower limit (V limit).
Cautionary Alarm Messages

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

W1(2 or 3) Cycle Few
Cautionary
Detecting
The controller issues this alarm when the welding current has not been supplied
Method
for the number of welding cycles specified (Weld 1 to 3).
1. Welding sequence has started before the gun has reached the required
Cause/
Remedy
pressure. Check the welding sequence.
Alarm Name
Alarm Message
Category

FlowRate Over
Cautionary
Detecting
The controller issues this alarm when the measured flow rate is greater than the
Method
preset value of C. Flow+ or FC Count.
1. Deterioration of the secondary cable. Replace the secondary cable.
2. The welding current is set to too high. Check the setting of welding current.
3. Illegal C. Flow+ value. Correct the setting.
Cause/
Remedy
Replace the cable with a larger one. Check the incoming power supply.
Check the duty cycle.
5. Illegal transformer turn ratio value. Correct the setting.
F-201 Ver1.5
OBARA Corp.
Trouble Shooting
Indicative Alarm
Alarm Name
Alarm Message
Category
Start-switch (SW 0 to 15)

Illegal Start (0~F)
Alarm Message
trouble
Detecting
The controller checks the Start switch status when the power is turned on and
Method
issues this alarm if any of the switches is ON.
Cause/
1. Wrong wiring of the Start switch. Check wiring.
Remedy
Alarm Name
Alarm Message
Category

Comi. Time Out
Alarm Message
Detecting
The controller issues this alarm when an error occurs during communication
Method
between TP-Net/DP-Net and the timer.
1.
Pendant cable faulty. Replace the cable.
Cause/
Remedy
2. TP-Net/DP-Net is faulty. Replace TP-Net/DP-Net.
Alarm Name
Alarm Message
Category

Comi. Data Err
Alarm Message
Detecting
The controller issues this alarm when the CRC errors (time-out) have been
Method
detected 10 times successively.
Cause/
1. TP-Net / DP-Net cable faulty
Remedy
Replace the cable.
Alarm Name
Alarm Message
Category
Cautionary /IndicativeAlarm
Message
The controller issues this alarm when receiving a input signal from the Start
switch if the timer is set to Weld disable & sol. Valve control.
F-201 Ver1.5
No Weld Warn.
1. Cancel Weld disable.
Alarm Name
Detecting
Method
Cause/
Remedy
Category
Cautionary /IndicativeAlarm
Message
The controller issues this alarm when receiving a input signal from the Start
switch if the timer is set to Weld disable.
Weld off warning

Detecting
Method
Cause/
Remedy
Alarm Message
No Weld2 Warn.
1. Cancel Weld disable & sol. Valve control.
OBARA Corp.
Trouble Shooting
Specific Alarm Message

Alarm Name
Cause/
Remedy
F-201 Ver1.5
Category
Alarm Message
(Message may not appear.)
The controller issues this alarm when detecting that the watch dog timer has
been activated. This alarm message may not appear but a pulse signal is
output.

Detecting
Method
Alarm Message
CPU Error
1. The main board is faulty. Replace the board.
OBARA Corp.
Check I/O Information
7. Check I/O Information

Checked by TP-Net on the present information.
Please confirm in V. Reference manual.
7.1 I/O information list at the time of DeviceNet intact.

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

Display #
N
Terminal block TB1 output information

0
N10
N11
N12
Retract SOL
N13
Retract SOL8
N14
Alarm
N15
Hold end
N16
Final step
N17
Last step
( Current d signal )
Display #
Terminal block TB1
Display #
Terminal block TB1
N2
Input information
N3
Input information
N20
Start SW
N30
N21
Start SW2
N31
N22
Start SW3
N32
N23
Start SW4
N33
N24
Group
N34
N25
Group
N35
N26
Retract start SW
N36
Weld On / OFF SW
N27
Retract start SW
N37
Alarm reset
The step last stage signal output works instead of current detection signal output
when the parameter is effective.
F-201 Ver1.5
OBARA Corp.
( Note: Other ports uses to this date.)

Display #
Terminal block TB1
Display #
Terminal block TB1
N4
Input information
N5
Input information
N40
N50
N41
N51
N42
Step clear
N52
N43
Step select clear
N53
N44
TRANSF. Thermostat
N54
Group3
N45
SCR thermostat
N55
N46
N56
N47
N57
Display #
Terminal block TB1
N6
Input information
N60
SW start (LED)
N61
N62
N63
N64
Group2
N65
N66
N67
F-201 Ver1.5
OBARA Corp.
7.2 I/O information list at the time of DeviceNet use.

Since the I/O specification of TB1 changes at the time of DeviceNet use, the contents of a display of
I/O information also change.
Input / output table (Note: Other ports uses to this date.)
Display #
Terminal block TB1
Display #
Terminal block TB1
N1
Input information
N2
Input information
N10
N20
N11
N21
N12
N22
D/N Input 1
N13
N23
D/N Input 2
N14
Alarm
N24
D/N Input 3
N15
Hold end
N25
D/N Input 4
N16
Final step
N26
D/N Input 5
N17
Last step
N27
D/N Input 6
Display #
Terminal block TB1
Display #
Terminal block TB1
N3
Input information
N4
Input information
N30
N40
N31
N41
N32
N42
Step clear
N33
N43
N34
N44
TRANSF. Thermostat
N35
N45
N36
Weld On / OFF SW
N46
N37
Alarm reset
N47
F-201 Ver1.5
OBARA Corp.
Version 1.5
Ver. No.SM059
Ver. No.SP038
Ver. No.SD038
Ver. No.SO033
(or
(or
(or
(or
later)
later)
later)
later)
REFERENCE MANUAL
WELDING CONTROLLER
STN21- Series

after reading.
2004.03.10
No.F-201-
Table of contents
Table of contents
1. Related manual ...........................................................................................11
2. General Description ....................................................................................11
2.1 Products Overview ..................................................................................................................11
2.2 Flow Chart: From inputting welding condition to welding ..................................................12
2.3 Welding Data............................................................................................................................13
3. Operating DP-Net........................................................................................14
3.1 Display Pendant Operation Panel Keys and their Functions ..............................................14
3.2 Operation Flow Chart ..............................................................................................................14
4. Operating TP-Net ........................................................................................15

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

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

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

8.1 Basic Sequence .......................................................................................................................30
8.2 Description of Welding Conditions........................................................................................31
F-201 Ver1.5
OBARA Corp.
.Reference manual Page - 9
9. Specific Welding Sequence ........................................................................34

10. Alarm Output ..............................................................................................38
10.1 Classifications of Alarms.......................................................................................................38
10.2 Settings Associated with Alarms ..........................................................................................38
10.3 Timing Charts of Sequences at Occurrence of Alarm ........................................................39
11. Step Up .......................................................................................................44

11.1 Step-up Control.......................................................................................................................44
11.2 Setting Procedure to Use Step-up Function ........................................................................45
12. Pressure Adjustment (Option).....................................................................46

12.1 Setting for proportional valve control ..................................................................................46
12.2 Pressure Adjustment Sequence............................................................................................46
12.2 Pressure Adjustment Sequence............................................................................................47
13. Pressure Selector Function .........................................................................47

13.1 Procedure to Use Pressure Selector Function ....................................................................47
13.2 Pressure Selector Function Basic Sequence ......................................................................47
14. Weld Interlock Function...............................................................................48

14.1 Procedure to Use Weld Interlock Function ..........................................................................48
14.2 Weld Interlock Timing Chart ..................................................................................................48
F-201 Ver1.5
OBARA Corp.
Related manual
1.
Related manual
Instruction manual
. Specifications
. Operating manual
. Reference manual
This manual contains the reference section for this equipment, Read this manual thoroughly to
have a proper understanding before operating the equipment.
2.
General Description
2.1 Products Overview

The system configuration of this equipment is as follows:
STN21Timer-Welding controller
TP-NetEdit welding condition data, parameter data, monitor welding result
and display alarm message.
DP-NetMonitor welding result and display alarm message, and welding
condition data.
PN/C(Pendant Cable)For the network cable, connect between STN21 and TP-Net
or DP-Net.
PJCFor the network cable, connect between STN21 and STN21.
(For multiple units connection with Optional function)
F-201 Ver1.5
OBARA Corp.
Flow Chart: From inputting welding condition to welding
2.2 Flow Chart: From inputting welding condition to welding

To start welding, proceed as follows:
Verify that the controller has
been properly installed.
After checking the

items listed right,
turn on the power
source.
Input welding conditions.0
Enter Set Mode.
Before powering on the controller for the first time, carry out the following
pre-operation checks.
Check:
1. Installation of the power cable
2. Wiring of the welding transformer
3. Wiring of the control wires on the TB1 terminal board
4. Verification of the rated power voltage on the timer nameplate
5. Wiring of the DeviceNet
Refer to II. Installation manual for details of installation.
Input welding conditions with TP-Net. Refer to Section 4, Operating TP-Net.
To set welding conditions, enter Set Mode since the controller is in Monitor
Mode when turning on the power source.
F4
F4
F8
F8
The above key operation takes you to Set Mode. Verify that the
indication lamp is on.
Set parameters.
Set functions and basic conditions according to your company standards.
#TM
Home
F4
F8
Shift
F1
F5
Refer to Section 7, Setting Parameters, for details.
Set welding conditions.
Set welding conditions.
#TM
Home
F2
F6
Group
Select
F1
F5
Refer to Section 8, Setting Welding Conditions, for details.
NG
Verify that welding is correctly

performed.
Carry out a test welding to verify that the settings are correct.
You can monitor the welding sequence in Monitor Welding Sequence. Refer to
Section 6, Monitoring welding, for details.
OK
If the test weld failed:

Check and correct the cause of the problem. Locate and correct the
parameters and the welding conditions. If the alarm lamp flickers correct the
problem by referring to IV. Maintenance manual.
Setting is complete.
F-201 Ver1.5
OBARA Corp.
Welding Data
2.3 Welding Data

The welding data available for STN21 Series fall into two main categories: Parameters (to select
functions) and Welding conditions. 15 Series (conditions) of welding condition data make up one
Group. 16 Groups and parameters make up one Unit. (Refer to the following figure.)
The timer can maintain and control the data of 240 kinds of welding conditions. TP-Net can
independently maintain 5 times as many as data that the timer can.
N
15 conditions x 16 groups
= 240 conditions
TM stored Data
Data Edit
Data Copy
Data Copy
TP-Net stored Data
TP-Net
5 unit
TM Data:
The data stored in the timer. (Welding data)
TP Data:
The data stored in the TP-Net as an external data.
Parameters: Enables timer functions to be selected or set. Refer to Section 6.1 for details.
F-201 Ver1.5
OBARA Corp.
Display Pendant Operation Panel Keys and their Functions
3.
Operating DP-Net
3.1 Display Pendant Operation Panel Keys and their Functions

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

Name
Description
Same as those
on TP-Net
Refer to the sections describing the

indication lamps on TP-Net.
3.2 Operation Flow Chart

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

Step
Reset
Monitor conditions
Reset step number
Display step count.
Change number
Shift
F-201 Ver1.5
Step
Reset
OBARA Corp.
To display the initial screen, press the

Home Home key.
Teaching Pendant Operation Panel Layout
4.
Operating TP-Net
4.1 Teaching Pendant Operation Panel Layout
TM#/Home
F-Disp,Select
Display
The forth line from the top
corresponding to function
keys.
Alarm
Step up finish
F1~F8
Step last stage
Ready
SW Start
Set
Shift
Step Reset
Conti. Press
Reset
No Weld
Help
0~F / on off
Scroll key
F-201 Ver1.5
Return
OBARA Corp.
Functional Descriptions of Operation Panel Keys
4.2 Functional Descriptions of Operation Panel Keys

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

Name
Ready
No Weld
Conti.Press
Set
Description
Lights when the controller is ready to receive welding data after TP has
completed initial processing and then received initial data through
communication.
Lights when the controller is in the Weld off mode.
Lights when the controller is in the Weld off mode and the gun-pressure
control is in continuous pressurization mode.
Lights when the controller is in data setting mode.
SW Start
Lights when the Start switch of the controller is turned on.
Step last
Lights when the controller has entered the final step.
stage
Step up finish Lights when the controller has entered the Step end phase.
Alarm
F-201 Ver1.5
Lights when the controller has detected trouble.
OBARA Corp.
Descriptions of Function Keys
4.3 Descriptions of Function Keys

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

Example : Copies the data of Heat 1 in Series 1 to all Series.
F3 Series Copy
Copies welding condition data between Series.

Example : Copies the data of Series 1 to Series 5.
F4 Group Copy
Copies data between groups specifying the unit-number.
F5 Group Verify
Compares data between groups specifying the unit-number.
F3 TP Data Edit
Enables the external memory data stored in TP-Net to be edited.
F1 Unit Edit
Selects Unit to edit.
1-5 unit select
Selects one of the units from 1 to 5.
F1 Edit, F5 Group Verify

Copies data between Units.
F2 Unit Copy
1-4 unit select
F1
Copies the data of a selected Unit from the timer to the pendant.
F2
Copies the data of a selected Unit from the pendant to the timer.
F3
Copies the data of a selected Unit to another Unit in the pendant.
F4
Compares the Unit data of the timer with that of the pendant.
F3 Parameter
Selects Unit and changes parameters in it.
1-5 unit select

F4 Para. Copy

Selects Unit and copies parameters in it.
1-5 unit select
F1 TM TP, F4 TM TP
F4 Mode Select
The same screens as described above.
Copies or compares parameters.
Changes a currently effective mode of the timer.
F1 Operation
Changes the current mode to the Weld mode.
F2 No Weld
Allows welding sequence to be performed with no current applied.
F3 C. Press
In addition to the actions of the No-weld mode, this mode enables the gun to be
pressurized continuously after the Hold End signal has been received.
F4 Set
Before editing any parameters or data, entering this mode is required.
F5 Parameter
Selects Parameters to be set.
F1 Edit
F-201 Ver1.5
Enables the selected parameters to be set.
OBARA Corp.
Copy Functions
4.4 Copy Functions

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

Group Copy
< Program Sheet >
Group 1
Display
Group 0
B
B
B
E
0
0
0
d
Combination of the triggered switch sig

1
Data Display
2 C o o l 1
0 c
2 W e l d 2
1 0 c
2 D . S l o p e
0 c
I t
F CP S CP GC
y
y
y
P
F2,3,4 Copy Functions
Function
Copy
Display
GunSel
PrSquez
Squeeze
Slope
Weld1
Cool1
Weld2
D.Slope
Cool2
Weld3
Hold
Off
Pulse
Heat1
1
2
1
GunSel
10
0
10
PrSquez
Combination
of the triggered
switch
sig
30
25
30
Squeeze
1 Slope
2
3
43
53
63
1
2
1
4
3
2
0
5
0
Weld1
10
0
10
0
0
0
0
0
0
Cool1
30
25
30
35
40
25
11
10
11
Weld2
3
3
3
3
3
3
3
0
3
D.Slope
0
5
0
10
0
5
0
0
0
Cool2
0
0
0
0
0
0
2
0
2
Weld3
11
10
11
10
10
10
5
5
5
Hold
3
0
3
5
0
0
0
0
0
Off
0
0
0
0
0
0
0
0
0
Pulse
2
0
2
10
0
0
0
8000
0
Heat1
5
0
Heat2
0
0
0
Heat3
8000
0
0
0
8000
0
6000
5000
0
12000
0
00
0
8000
0
6000
0
Heat2
8000
12000
8000
8000
13500
10000
Heat3
6000
6000
5000
35
40
25
10
10
10
10
10
0
5000
0
0
0
0
8000
13500
10000
5000
Series Copy
F-201 Ver1.5
OBARA Corp.
Viewing Data by Scrolling
4.5 Viewing Data by Scrolling

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

Display
Letter
Press the Scroll key.

B
B
B
E
B
B
B
E
0
0
0
d
0
0
0
d
GunSel
PrSquez
Squeeze
2 Gu n S e l
3
2 P r S q u e z
0 c y
2 S q u I z
2 5 c y
I t
F CP S CP GCP
2 P r e s V 2
9
2 P r e s V 2
9
3 S t e p
2
1 0
I t
F CP S CP G
0
0
4
C
PresV
Pres
PresV3
Step
Step
Step
Step
Step
Step
%
%
%
P
Step Select: All Series
Combination of the triggered switch signal
10
10
10
10
30
25
30
35
25
40
30
25
30
35
25
40
50
80
60
102
104
106
108
50
90
90
104
106
106
108
50
65
65
104
104
106
106
50
50
50
102
104
104
106
50
90
90
50
85
80
50
80
60
102
104
106
108
50
90
90
104
106
106
108
50
65
65
104
104
106
106
50
50
50
102
104
104
106
50
90
90
104
106
106
108
50
85
80
102
103
104
105
122
116
118
120
122
116
118
120
116
115
124
116
120
120
124
116
120
120
116
116
Gun
B
B
B
E
0
0
0
d I
Count1
Count2
Count3
Count16
Cu r r . Hi g
1 1 0%
V. L i mi t
9 0%
Ho l d De l y
1 5c y
t
F CP S CP GCP
Gun
100
120
200
180
100
120
200
180
150
160
250
230
150
160
250
230
180
180
250
250
180
180
250
250
250
280
300
300
250
280
300
300
Curr.Low
Curr.Hig
V.Limit
HoldDely
Return to the top.
Peak Curr
90
90
110
110
90
90
15
15
150
150
Pressing the Scroll key (up) after viewing the gun Series data with the scroll keys (right/left) allows
you to return to the data screen of the most recently displayed starting Series.
F-201 Ver1.5
B
B
B
E
0
0
0
d
2 S t e p
2 S t e p
2 S t e p
I t
F CP
1
1
1
S
4
1 1 4%
5
1 1 6%
6
1 1 6%
CP GCP
B
B
B
E
0
0
0
d
3 Co u n t 1
3 Co u n t 2
3 Co u n t 3
I t
F CP S CP
2
2
2
G
0
5
5
C
0
0
0
P
OBARA Corp.
To return to the most recently

displayed screen of the starting
Series, press the scroll (up) key.
B
B
B
E
0
0
0
d
4 Co u n t 1
4 Co u n t 2
4 Co u n t 3
I t
F CP S CP
1
2
2
G
8
3
5
C
0
0
0
P
Descriptions of Modes
5.
5.1 Changing Timer Mode

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

changed in this mode.
Executes a welding sequence with no current applied.
Outputs a signal from the solenoid valve during the period the
Starting switch is held on.
Enables welding conditions or other preset values to be changed.
Also welding is enabled.
It shifts to the parameter setting mode.
Operation Mode
No-weld Mode
C. Press Mode
Set Mode
Parameter Mode
(1) No-weld Mode Sequence (Alarm output selection depends on the setting of the corresponding
parameter.)
Start SW
Solenoid valve
Welding Current
Alarm Signal
Hold End Signal
4cyc
W. Sequence
PS
SQ
USL
W1
C1
W2
DSL
C2
W3
HO
HD
(min)
OF
No-Weld
Indication Signal
Alarm Reset Input
F-201 Ver1.5
OBARA Corp.
(2) C. Press Mode Sequence

The controller applies pressure during the period that the Start switch is held on.
Start SW
Solenoid valve
Welding Current
Alarm Signal
Hold End Signal
W. Sequence
PS
SQ
USL
W1
C1
W2
DSL
C2
W3
HO
HD
OF
Conti. Press
Indication Lamp
Alarm Reset Input
5.2 Precautions of Set Mode

! CAUTION
Before changing welding conditions or parameters always make sure that the Set
lamp on the TP-Net is turned on. Changing welding conditions or parameters without
entering Set Mode may cause an alarm.
F-201 Ver1.5
OBARA Corp.
Monitoring welding Sequence
6.

This mode allows you to monitor welding sequences or manage Gun Counter or the Step data.
6.1 Weld Monitor Screen

Name
G
G
G
G
G
G
G
G
1
2
3
4
5
6
7
8
B
u
u
u
u
u
u
u
u
F
n
n
n
n
n
n
n
n
S
S
S
S
S
S
S
S
F
6
1
2
3
4
5
6
7
8
t
t
t
t
t
t
t
t
8
S e t
T
H
H
H
o
e
e
e
t
a
a
a
1 5
2
7 0
5
1 0
3
e p
e p
1
e p
U
e p
U
e p
e p
e p
e p
8
V
a
t
t
t
l
1
2
3
P e a k
P r e s s
1s t V o
L i n e
1
2
p
p
F i
1
2
8
1

8
a l u e
C u r r
8
5
1 0
0
1 0
Cu r r
N V 1
3
l t a g e
3
V o l t
4
1
2
n i
1
2
3
1
.
.
.
.
.
.
1
8
3
0
1
0
0
0
1
8
3
1
0
0
0
0
7
7
7
0
0
0
5
0
0
0
0
0
0
0
0
0
0
0
s
0
0
0
0
c
8
k
k
k
k
k
k
Function
Gun Counter
A
A
A
A
A
A
5 0 0 N
9 0V
0 0V
Note:
1. The gun number and the spot counts of
steps depend on the settings of the
corresponding parameters.
2. The above example represents welding
with 8 guns and the Step-up function
Displays the total number of weld

spots of each Gun 1-4.
Step Data
The first number indicates a gun
number and the rest is the state of
the gun step, the number of weld
count and a weld state in the order
mentioned.
Operation Data BFF-8: Indicates the most recently
selected starting Series data.
B: Indicates B-Mode. (A or B)
(Example)
BFF-8
F: Indicates Group. (0F)
W.Cyc. 10cy
F: Indicates starting Series (1F)
PF 68%
-8: Indicates weld on Gun#8
C.Flow 78%
W.Cycle 10 cy: The number of weld
cycles to be per-formed per sequence.
PF68%: Power-factor
C.Flow 78%: Flow rate
An average of the set-up heat 1-3 data
Set Value
is displayed.
Indicates the mean current value
Total Current
applied to Heat 1-3.
Indicates the current values applied to
Current Value
Heat 1-3.
Peak Current
The peak current during welding is
displayed.
Pressure force Indicates the pressure force.
Indicates the primary voltage during
1st Voltage
welding.
Indicates the power voltage during idle
Line Voltage
running.
! CAUTION
Set Value :
Set Value shows the result carried out on the basis of the value calculated from current step
and welding condition.
After welding, if the data with which the above is related is changed, the relation between set
current display value and the total current display ground is not in agreement.
F-201 Ver1.5
OBARA Corp.
6.2 Resetting Gun Counter

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

3.
Press the Reset key, and then press the Return key to complete the procedure.
3

1 6 2 0 0

Reset
6.3 Resetting Steps

To reset the steps, proceed as follows:
#TM
Home
1. Enter the Weld Monitor screen.
2. Scroll the screen to display the desired gun number on the top line.
4
B
S t e p
U

F
6 8
t a l Cu r
p
F i n

1

r
8.
i
0
7
7
s
c
8
k
h
y
3. Press the Step reset key, and then press the Return key to complete the procedure.
4- S t e p
Up
F i n i s h
S t e p
Up
Cl e a r
?
8
4
B
F-201 Ver1.5
S t e p

F
6 8
t a l Cu r
1
0

1 0c y
7 8
r
8. 7k A
OBARA Corp.
Step
Reset
In case of step reset to GUN No.4
Descriptions of Parameter Functions
7.
Setting Parameters
7.1 Descriptions of Parameter Functions

Function Name
Pulsation Select
(P1 Pulse. Sel.)
A or B Mode Select
(P2 AB Mode)
Alarm signal NO/NC

select
(P3 ALM Out)
Trigger start
(P4 One Shoot)
Hold End Delay signal

select
(P5 Hold Out)
Hold End Delay Job

section at alarm signal
(P6 HoldA Dly)
Alarm output signal

select
(P7 ALM Mode)
Max. Step Up series

select
(P8 Step Type)
F-201 Ver1.5
Requirements/Function
ON: Enable
OFF: Disable
Action:
Cyclically repeats Cool-1 and Weld-2 the number of times specified by
the pulsation number.
ON: A Mode
OFF:B Mode
Action:
In A-Mode, turning on one of the four switches will select welding
conditions from Series 1 to 4. When turning on two or more start
switches at the same time, the least series will precede others.
In B-Mode, a combination input of the four Start switches selects the
welding conditions from Series 1 to 15.
ON: Normally Open
OFF: Normally Closed
Action:
Selects the alarm output method on occurrence of an alarm between
Normally Open and Normally Closed.
ON: Enable
OFF: Disable
Action:
Setting this to ON enables the controller to receive a pulse input from the
Start switches.
ON: Enable
OFF: Disable
Action:
Setting this to ON allows the Hold End signal to be output after (or at the
same time) as an alarm signal has been output. The alarm is classified
as a warning alarm (such as current alarm).
ON: Enable
OFF: Disable
Action:
Delays the output of Hold End Signal by 30 cycles after a warning alarm
(such as current alarm). (Hold Delay Management)
0: Alarm pulse output enable
1: Alarm constant output enable
2: Alarm constant output & weld stop
3: Skip alarm output
Action:
On the occurrence of warning alarms (such as current alarm) this
function controls the output timing of alarms according to the preset
parameters. Setting this to 0 with the above-mentioned parameter
enabled will fix the alarm signal output timing to 30 cycles.
When setting this to OFF, the alarm output depends on the Start switch.
0: Disable
1: Max. gun series
2: 4/15 series
Action:
Setting this to 0 will disable the Step-up function.
Setting this to 1 will allow the gun number (1 - 4) specified by the
parameter for the Step-up series.
Setting this to 2 will fix the Step-up series to be 4 (A-Mode)/15 (B-Mode).
OBARA Corp.
Function Name
Trigger SW priority
select
(P9 Sw mode)
Japanese or English
display select
(Pa Japanease)
Transformer turn ratio

series select
(Pb Trans Type)
Repeat action select

(Pc RepeatSel.)
Re-weld action select

when current low
detected
(Pd Reweld)
Pressure Adjustment
select
(Pe VP Mode)
Pressure Adjustment
control voltage select
(Pf VP Type)
Caution output select

(Pg Caution)
F-201 Ver1.5
ON: Trigger SW priority select
OFF: Weld sequence priority select
Action:
When turning off the Start switch during welding or cooling, the welding
sequence will stop at the currently performed cycle and skip to the Hold
state, ignoring the remaining welding and cooling processes.
ON: Japanese
OFF: English
Action:
Switches the display language between English and Japanese.
0: Disable
1: Max. gun series
2: 4/15 series
Action:
Setting this 0 will allow Series 1 for the transformer turn-ratio.
Setting this to 1 will allow the gun number (1- 4) specified by the
parameter for the transformer turn-ratio. Setting this to 2 will select 4(A
Mode)/15(B Mode) Series.
ON: Enable
OFF: Disable
Action:
Keeping the start switch turned on will repeat the sequence from
squeeze. Turning the start switch off will stop the sequence.
The output timing of Hold End signal at this time depends on Off Time.
ON: Enable
OFF: Disable
Action:
Executes re-welding when it has been detected that the current level is
too low. After re-welding, if the current level is still too low, then the
"Current too low" alarm is issued. When Trigger SW priority select is set
to ON, whether re-welding is executed or not depends on the state of
the Start switch.
0: Disable
1: % Setting enable
2: Direct number setting enable
Action:
Selects the setting method of gun pressure between percentage setting
and direct (N: Newton) setting. Maximum gun pressure and air pressure
need to be set accurately in the direct setting.
0 : Control range 0-5V
1 : Control range 0-10 V
Action:
Setting 0 , When using a SMC proportional valve controller.
Setting 1 , When using a CKD proportional valve controller.
When using Air pressure regulator, Please select it for specification by
the voltage.
ON: Enable
OFF: Disable
Action:
Specifies whether the pulse output of cautionary alarms is enabled or
not. Setting this to ON will allow the pulse output of alarms.
OBARA Corp.
Function Name
ON: Enable
OFF: Disable
Transformer thermostat Action:
When the transformer thermostat is monitored at all times on the
check sequence
attached gun, changing a gun will temporarily open circuit the
(Ph Gun Chang.)
transformer thermostat and cause an alarm at the controller, although it
is in normal state. Accordingly, the transformer thermostat is not
checked during idle running when this is set to ON.
ON: Alarm output signal enable
OFF: Alarm output signal disable
Alarm output signal
Action:
select on No-weld
In no-weld sequence and continuous pressurization, the Hold End
sequence
signal is output after pulse output of an alarm signal.
(Pi TestW ALM)
Setting this to OFF will disable the pulse output of alarm signal and
display no alarm messages.
01 08: MAX. SOL valve select.

11 18: Retract enables
21 28: Reverse wires retract enable
31 38: Valve selector enable
41 48: Weld interlock enable
51 58: Retract enable & Retract interlock enable
61 68: Reverse wires retract enable & Retract interlock enable
Action:
Max. Gun num. select

Retract select
Valve selector select
Weld interlock select
(Pj Gun Sel.)
Upper digit sets up a selection of function. Moreover, Low

digit sets up the maximum number of GUN to use.
When the upper digit is 0, SOL3 and SOL4 can not be
used as SOL since they are used for different functions.
When use DeviceNet, Setting to 01-08 (Max. number of
GUN )
Retract function:
SOL7 (B2) is output in response to the input from the
retract start SW7 (B8 on the terminal board TB1), and
SOL8 (B3) is output in response to the input from the
retract start SW8 (B9).
Valve selector during welding (Welding selector function):
MV3 (B2 on the terminal board TB1) is output after setting
the welding conditions and Pressure rise time 1.
Subsequently, MV4 (B3) is output after completion of
Pressure rise time 2. Please see 13.1(.2) for details.
Weld interlock function
The Start Acknowledgement signal is output (B2 on the
terminal board TB1) in response to SW1 to SW4.
Information during welding is also output by the Weld
signal (B3). The Weld Ready input (B8) delays the
squeezing time. Please see 14.1(.2) for details.
Retract function & Retract interlock function:
Retract SOL7(B2) output when retract SOL8(B3) is turned
off to retract start SW7(B8) input.
Retract SOL8(B2) output when retract SOL7(B2) is turned
off to retract start SW8(B9) input.
Next Page detail diagram
F-201 Ver1.5
OBARA Corp.
Function Name
Max. Gun num. select

Retract select
Valve selector select
Weld interlock select
(Pj Gun Sel.)
Diagram for Gun num select to TB1 output
TB1 Out
SOL1
SOL2
Setting
SOL7
SOL8
SOL3
SOL4
01
Valve Out
02
Valve Out
Valve Out
03
Valve Out
Valve Out
Valve Out
0408
Valve Out
Valve Out
Valve Out
Valve Out
11
Valve Out
SW7
SW8
1218
Valve Out
Retract Out
Retract Out
21
Valve Out
SW7
SW8
2228
Valve Out
Retract Out
Retract Out
31
Valve Out
Press T2
Press T3
3238
Valve Out
41
Valve Out
4248
Valve Out
Valve Out
Output for
received
welding
start
Valve Out
Welding
firing status
output
51
Valve Out
SW7
SW8
5258
Valve Out
Retract Out
Retract Out
61
Valve Out
SW8
SW7
6268
Valve Out
Retract Out
Retract Out
Valve Out
Valve Out
Valve Out
Valve Out
Valve Out
Valve Out
The setting data can input within above the numbers.

0: Disable
Step Up Max. value
1~16: Step Up max. number select
select
Action:
(Pk Max Step)
Specifies the number of steps (max.) to be performed in the final step.
0: Display all function
1: Display limited function
Display level select
Action:
(PL DispLevel)
Enables welding to be executed only with the minimum setting data.
0: 200V line voltage
Step-down transformer 4: 420V line voltage
(Pm Ref. Volt)
Action:
This parameter needs to be set according to the welding power source.
0:Weld enable (standard) 1: Weld disable 2: Continuous pressurization
3:Cable-short detection 4: Cable-short detection2
Action:
1: Weld disable" will allow only gun action.
Weld enable / disable
2: Continuous pressurization " will allow gun continuous pressurization
select
while the start switch is on.
(Pn Test Mode)
3: Cable-short detection When SW.15 of 15 groups of the startup
system is selected, it is effective.
4: Cable-short detection 2 When SW.15 is selected regardless of the
group of the startup system, it is effective.
F-201 Ver1.5
OBARA Corp.
Function Name
0~99: Timer Number set

Action:
Timer number select
Set this parameter when using a network system.
(Po TM Number)
The numerical value of last two digit of the timer manufacturing
number is set (recommendation).
ON: Enable (Gun number is fixed to start series.)
OFF: Disable (Gun number can be selected every start series)
Action:
Enable: Start series of odd numbers (1,3,5) assign SOL 1 to be
Gun assignment select
used and that of even numbers (2,4,6) assign SOL 2.
(Pp GunNumFix)
This is used mainly in portable systems.
However, all series use SOL1 when the lower digit is set to
one in Pj Gun Sel. (the maximum number of guns is one).
Disable: Output SOL can be selected arbitrarily every start series.
ON: Enable ( For DeviceNet)
OFF: Disable
Remote I/O select
Action:
(Pq Remote I/O)
It becomes DeviceNet correspondence by ON. Uniting, terminal
block TB1 serves as DeviceNet I/O.
ON: Enable
OFF: Disable
Action:
Enable: When the current is detected normally flowing by weld ON,
the current detection signal is output from B6 of terminal
block TB1.
The output timing is the same as the hold end signal output.
Current detection signal
The step last stage signal is not output when the
( CurDetect)
parameter "Pr" is enable. Only the TP is displayed.
Disable: The current detection signal is not output.
The step last stage signal is output from B6 of terminal
block TB1 without setting the parameter "P8" to 0.
Step up Finish
2 series output
(Ps StepF2out)
F-201 Ver1.5
Note) Terminal block TB1 is used as a terminal block for remote I/O
when remote I/O is effective. Therefore, the current detection
signal is not output to terminal block TB1.
ON: Enable (Parameter Ps and P8 are both ON(1 or 2).)
OFF: Disable
Action:
Enable: When step series1 is complete, the step up finish signal of
step series1 is output from the terminal TB1-B5. When step
series2 is complete, the step up finish signal of step series2
is output from the terminal TB1-B6. The signal other than
step series1 and step series2 isnt output.
(The signal of only step series1 or step series2 is output
separately.)
Disable: The step up finish signal is output when any step series is
complete without setting the parameter "P8" to 0.
OBARA Corp.
7.2 Note on Changing Parameters
CAUTION
In order to assure system operation of the timer, Whenever changing the parameter,
always switch on the power of the again. If not, it can cause malfunctions of the timer.
Changing parameters also requires modification or review of the welding condition data
associated with the parameters changed.
Example 1: When Pulsation Select has been changed from 0: Disable to 1: Enable,
Pulsation number of the welding conditions also needs modification.
Example 2: When Max. Step Up series select has been changed from 0: Disable to 1:
Max. gun series, Steps and Step count of the welding conditions also need
modification.
Example 3: When the parameter of Max. Gun num. Select has been changed, all
setting items including Max. Gun num. Select, Transformer turn-ratio, and
Step series of the welding conditions need modification.
F-201 Ver1.5
OBARA Corp.
Basic Sequence
8.
Setting Welding Conditions
8.1 Basic Sequence
Start SW
MV/SOL
Heat2
Heat1
Heat3
Welding Current
Hold End Signal
Welding Sequence
Min. Set Cycle
HES
PS
SQ
USL
W1
C1
W2
DSL
C2
W3
HO
HD
OF
Note: Since setting 0 to welding times (W1 to W3) simultaneously will cause a data error, at least
one must be set to a value other than 0.
Abbreviations:
MV/SOL: Retract-vale/solenoid-valve output signal
PS:
Pre-squeeze time
SQ:
Squeeze time
USL:
Up-slope time
W1:
Weld-1 time
C1:
Cool-1 time
W2:
Weld-2 time
DSL:
Down-slope time
C2:
Cool-2 time
W3:
Weld-3 time
HO:
Hold time
OF:
Off time
HES:
Hold End signal (4 cycles minimum)
F-201 Ver1.5
OBARA Corp.
Description of Welding Conditions
8.2 Description of Welding Conditions

Name
Indication
Input Condition/Description/Relevant Data

Condition A gun number (MV/SOL) used in a specific Series is selected.
Gun Selection
GunSel
Description A function to output SOL/MV to the gun number set here.

Relevant
Parameter Pj Gun Sel.
parameter
Condition Setting range: 1 to 99 (cycles), Setting 0 will disable this item.
Pre-squeeze
PrSquez
Squeeze Tim
Squeeze
A function to wait for a period specified here after MV valve has

Description been activated. This is the initial process in the welding
sequence, and ignored when welding is repeated.
Relevant
parameter
Setting Range: 1 to 99 (cycles), Needs to set a value other than
Condition
0.
Description A function to wait for slope control (welding).
Relevant
parameter
Setting Range: 1 to 30 (cycles), Always set this (0 cannot be
set).
A function to gradually increase welding current from the
Description minimum-striking angle of arc to a required level. Slope time
before the next welding time is specified here.
Relevant
parameter
1 to 99 (cycles), Setting 0 will disable this item. Cannot set all
Condition Weld times to 0 simultaneously. At lest one Weld time must be
set to a value other than 0.
Condition
Slope Time
Slope
Weld-1 Time
Weld-2 Time
Weld-3 Time
Weld1
Weld2
Weld3
Description Welding times are specified here.

Relevant
parameter
Setting Range: 2.0 to 60.0 (kA), or 25 to 100 (%),
(sw TurnRatio=0)
Welding current required for each Weld time is specified here.
Description
TP displays the set value in % when swTurnRatio=0.
Relevant
Welding Conditions Transformer Turn Ratio
parameter
Condition
Welding Current, 1
Welding Current, 2
Welding Current, 3
Heat1
Heat2
Heat3
Cool-1 Time
Cool-2 Time
Cool1
Cool2
Condition Setting Range: 1 to 99 (cycles), Setting 0 will disable this item.

Description The interval between welding is specified here.
Relevant
parameter
Condition Setting Range: 1 to 99 (cycles), Setting 0 will disable this item.
Down-slope Time
D.Slope
Hold Time
Hold
F-201 Ver1.5
A function to interpolate welding current between Weld-2 Time

Description and Weld-3 Time. The current may increase according to the
setting.
Relevant
parameter
Setting Range: 1 to 99 (cycles), Always set this (0 cannot be
Condition
set).
The hold time before a gun is released after application of
Description
welding current has been completed.
Relevant
parameter
OBARA Corp.
Name
Transformer Turn
Ratio
Off Time
No. of Pulsation
Indication
TurnR.
Off
Pulse

Setting Range: 0.0 to 200.0, The setting of Series 1, Gun
Condition Series, and All Series depends on the condition of the
"Transformer Turn Ratio" parameter.
It is used as a coefficient when converting the primary
Description current into the secondary current. Voltage compensation
control (% voltage) is available when setting this to 0.0.
Relevant
Parameter Pb TransType
parameter
Setting Range: 4 to 99 (cycles), The parameter, "Reweld"
Condition
must be ON.
Description Holding the start switch ON will repeat cycle operation.
Relevant
Parameter Pd Reweld
parameter
Setting Range: 1 to 9 (times), The "No. of Pulsation
Condition
Selection" parameter must be ON.
Pulsation will be repeated for a number of times specified
here. In addition to the basic cycle operation, whether
Description
operations will continue according to the Start switch
depends on the parameter.
Relevant
Parameter P1 Pulse. Sel.
parameter
Condition Setting Range: 30 to 100(%)
Maximum Current
Flowrate
C. Flow+
Description
Relevant
parameter
Condition
Error Count
CF.Count
Description
Relevant
parameter
Condition
Maximum Pressure
Max V.
Description
A reference value to compare the flowrate of current

welding with the flowrate assumed to be 100 % at full-wave,
the waveform with the maximum current controlled by SCR.
Since the flowrate will decrease with the increase of electric
resistance due to cable deterioration, the system
automatically shifts the trigger point to increase the
flowrate.
Welding Conditions Error Count
Alarm Output Current flow rate high
Setting Range: 1 to 99 (times), Setting 0 will disable this
item.
A criterion to judge current error when the applied flowrate
has repeatedly exceeded the maximum flowrate.
Welding Conditions Maximum Current Flow-rate
Alarm Output Current flow rate high
Setting Range: 0 to 9999 (N), This specifies the maximum
gun pressure shown on the gun drawing.
In conjunction with the air pressure explained below, it is
used as a coefficient to calculate a setting pressures.
Relevant
Parameter Pe Pressure Adjustment select
parameter
Condition Setting Range: 50 to 150 (%)
Pressure
Coefficient
F-201 Ver1.5
P Adjust
In conjunction with the above set value of Maximum

Description Pressure, it is used as a coefficient to calculate the setting
pressures.
Relevant
parameter
OBARA Corp.
Name
Indication

Condition Setting Range: 0 to 99 (cycles)
Pressure Rise
Time 1
Pressure Rise
Time 2
Pressure Rise
Time 3
PresT1
PresT2
PresT3
Set Pressure 1
Set Pressure 2
Set Pressure 3
PresV1
PresV2
PresV3
Step 2
To
Step 16
Step 2
To
Step16
Count, 1
To
Count, 16
Count 1
To
Count16
Current Low Limit
Curr. Low
Current High Limit
Curr. Hig
Power Voltage Low

Limit
V. Limit
The timings for changing pressure and switching the

pressure selector are specified here. Specify the timing so
Description
as to change pressure within the period from the beginning
of the sequence operation to the end of welding.
Relevant
parameter
Condition Setting range: 0 to 9999 (N) or 0 to 100 (%)
Description Required pressure can be set in N or %.
Relevant
parameter
Setting Range: 50 to 200 (%), The available setting range in
Condition Series 1, Gun Series, and All Series depend on the
parameter.
The welding current, Heat 1 to 3, will be adjusted according
Description
to the current step.
Relevant Parameter P8 Step Type
parameter
Pk Step Up Max. value select
Setting Range: 0 to 9999 (times), The available setting
Condition range in Series 1, Gun Series, and All Series depends on
the parameter.
The maximum count in each step will be indicated when
Description Step Control is in effective. Operation will proceed to the
next step when the current step reaches the full count.
parameter
Setting Range: 50 to 150 (%), Setting 100 (%) will disable
Condition
this item.
A function to detect current error by comparing the actual
Description welding current with the set current, including a step-up
current.
Relevant Welding Conditions Welding Current1,2,3
parameter Alarm Output Current low
Condition
this item.
A function to detect current error by comparing the actual
Description welding current with the set current, including a step-up
current.
Relevant Welding Conditions Welding Current1,2,3
parameter Alarm Output Current low
Condition
this item.
A function to detect voltage error by comparing the
Description measured voltage with the set voltage (Power voltage low
limit). Voltage is measured at the final cycle of weld.
Relevant
Alarm Output Line voltage low
parameter
Condition Setting Range: 0 to 99 (cycles)
Hold End Delay

Time
F-201 Ver1.5
Hold Dely
When this setting is in effective, the Hold End signal will not
Description be output immediately after the elapse of HO (Hold Time)
but delayed by the period specified here.
Relevant
parameter
OBARA Corp.
Specific Welding Sequence
Name
Indication
PeakCurr
Setting Range: 100 to 200 (%), Setting 100(%) will disable

this item.
A function to detect peak current error by comparing the
Description actual welding current with the set current, including a step
up current.
Relevant
Alarm Output Peak current high
parameter
Condition
Peak Current Limit
Condition Setting Range: 1 to Parameter Pk Max Step-1,

Step return location
StepReturn
Description
If Step select clear(TB1 or D/N) is inputted, it will

return to the position set up here.

parameter
9.

(1) Parameter: One Shoot (ON: Enable)
Start switch
MV/SOL
Welding Current
Hold End signal
HES
4cyc
W. Sequence
PS
SQ
USL
W1
C1
W2
DSL
C2
W3
HO
HD
OF
(2) When the Start switch is held on
Start switch
MV/SOL
Welding Current
Hold End signal
HES
4cyc
W. Sequence
F-201 Ver1.5
PS
SQ
USL
W1
C1
W2
OBARA Corp.
DSL
C2
W3
HO
HD
OF
Parameter: P1 selection of Pulsation ON

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

(Repeat)
Hold End Signal
(Pulsation)
W. Sequence
4cyc
min
PS
SQ
USL
W1
C1
W2
DSL
C2
W3
HO
HD
OF
Parameter: P9 start switch in priority selection

Sequence (up side), Trigger switch priority select ON
When start switch turns to OFF during the sequence, the sequence after the next cool down
time is skipped and transfers to HO (hold) process.
Sequence (down side), Trigger switch priority selectOFF
The sequence is not aborted even start switch turns OFF during the sequence.
Start SW
MV / SOL
Welding Current
Para.P9 ON
Welding Current
Para.P9OFF
Hold End Signal
W. Sequence
F-201 Ver1.5
PS
SQ
USL
W1
C1
W2
OBARA Corp.
DSL
C2
W3
HO
HD
OF
(5) Parameter: Re-weld (ON: Enable)

Setting this parameter to ON will execute re-welding at the occurrence of the following alarms:
the Current too low or Compensation voltage too low.
Start switch
MV/SOL
Welding Current
Hold End signal
HES
4cyc
W. Sequence
PS
SQ
USL
W1
C1
W2
DSL
C2
W3
HO
HD
OF
* The re-weld sequence can be executed only once.
(6) Sequence to discover short-circuited cable.

Parameter to discover short-circuited cable: Weld enable/disable select (3: Cable short check
enable)
Inputting F activates
the sequence.
Start switch
MV/SOL
Test Current
30 cycles min. or HD
preset time
Alarm Signal
Hold End signal
4cyc
W. Sequence
F-201 Ver1.5
PS
SQ
HD
OBARA Corp.
(7) Current ditection signal output function : Parameter Pr-CurDetect Note

Current ditection signal sequence 1ON: Enable
The current detection signal is output when parameter Pr is Enable.
The output conditionDetect the welding current. Without, "no Weld"
and "current error" etc.
The step last stage signal is not output in TB1 when the parameter "Pr"
is enable. Only the TP is displayed.
Current ditection signal sequence 2OFF: Disable
When the parameter is Disable the current detection signal is not
output.
When 1 or 2 of the step types in the parameter have been selected,
the final step signal is output in TB1.
Start information
Heat1
Heat2
Heat3
Welding current
Hold end signal
Note2
current detection
signal 1 ON
current detection
signal 2 OFF
Welding sequence
Minimum,set cycle
PS
SQ
USL
W1
C1
W2
DSL
C2
W3
HO
HD
OF
Note Terminal block TB1 is used as a terminal block for remote I/O when remote I/O is effective. Therefore,
the current detection signal is not output to terminal block TB1.
Note 2When the welding current is detected, and the welding sequence finished normally, the current
detection signal is output.
The current detection signal is not output with an current error or no weld.
The output timing is done later by the processing beginning about one cycle at the HOLD time.
F-201 Ver1.5
OBARA Corp.
Alarm Output
10. Alarm Output

10.1 Classifications of Alarms
The alarms are categorized into the classifications listed below according to their degree of risks.
Refer to IV. Maintenance manual for descriptions and troubleshooting the alarms.
Fatal Alarms:
Thyristor shorted
AD error 1
AD error 2
Illegal parameter
Cable shorted (Electrode sticking.)
Warning Alarms:
Current low
Current high
No current
Peak current high
Cautionary Alarms:
Current unbalance
Weld-1 cycle num. Few
Line voltage low
Indicative Alarms:
Start switch trouble
Weld off warning
Specific Alarm:
DeviceNet fetal error
10.2 Settings Associated with Alarms

The parameters and welding conditions associated with the alarms are as follows:
Refer to the corresponding section for details.
Parameters Associated with Alarms
Welding Conditions Associated with Alarms
Alarm output signal select
Hold End signal select
Error count
Hold End Delay Job selection at alarm signal
Current low limit
Alarm signal NO/NC select
Current high limit
Caution output select
Power voltage low limit
Alarm output select on No-weld sequence
Peak current limit
F-201 Ver1.5
OBARA Corp.
Timing Charts of Sequences at Occurrence of Alarm
10.3 Timing Charts of Sequences at Occurrence of Alarm

The actions taken at the occurrence of alarm are as follows:
Fatal Alarms:
Outputs the alarm signal and stops the whole sequence. Hold end signal will
not be output.
Warning Alarms: Outputs an alarm signal. The output sequence and whether the Hold End
signal is output or not depend on parameter settings.
Cautionary Alarms: After trouble has been detected, the corresponding alarm will be classified into
either Warning or Display according to parameter settings. The Output of the
Hold End signal depends on the parameter settings corresponding to the
alarm classified.
Indicative Alarms: Does not output an alarm signal but displays an alarm message on TP-Net.
The Hold End signal will be output.
Specific Alarm:
Detects trouble that occurs in the CPU or the circuit. Contact output of alarm
with no message appearing on TP-Net indicates CPU operation failure.
With warning alarms, the output timings of the alarm signal and the Hold End signal depends on
the settings of parameters related to the alarms. Refer to the timing charts shown in the following
pages for the output timing.
Sequences at the Occurrence of a Warning Alarm
Refer to Section 7.1, Welding Sequence, for the abbreviations used in the following timing
charts.
(1) Parameters:
TestW ALM ON
Hold Out ON
ALM Mode 0 (Alarm pulse output enable)
Start Switch
MV/SOL
Welding Current
Alarm Signal
30cyc
(min)
Hold End signal
4cyc
(min)
W. Sequence
PS
SQ
USL
W1
C1
W2
DSL
C2
W3
HO
HD
OF
Alarm Message
Alarm Reset
Alarm output: 30 cycles min. or HD time.
Hold End signal: 4 cycles min., the OF time, or the Start switch hold time.
F-201 Ver1.5
OBARA Corp.
(2) Parameters:
HoldA DlyON
Hold Out ON
ALM Mode 1 (Alarm constant output enable)
Start Switch
MV/SOL
Welding Current
Alarm Signal
Hold End signal
4cyc
(min)
W. Sequence
PS
SQ
USL
W1
C1
W2
DSL
C2
W3
HO
HD
OF
Alarm Message
Alarm Reset
The Start switch input for the next sequence is acceptable even if there is no alarm reset input.
(3) Parameters:
HoldA DlyON
Hold Out ON
ALM Mode 2 (Alarm constant output & weld stop)
Start Switch
MV/SOL
Welding Current
Alarm Signal
Hold End signal
4cyc
(min)
W. Sequence
PS
SQ
USL
W1
C1
W2
DSL
C2
W3
HO
HD
OF
Alarm Message
Alarm Reset
The Start switch input for the next sequence is unacceptable if there is no alarm reset input.
The controller waits for the alarm to be reset.
F-201 Ver1.5
OBARA Corp.
(4) Parameters:
HoldA DlyOFF
Hold Out ON
ALM Mode 3 (Skip alarm output)
Start Switch
MV/SOL
Welding Current
Alarm Signal
Hold End signal
4cyc
(min)
W. Sequence
PS
SQ
USL
W1
C1
W2
DSL
C2
W3
HO
HD
OF
Alarm Message
Alarm Reset
(5) Parameters:
HoldA DlyON
Hold Out OFF
Start Switch
MV/SOL
Welding Current
Alarm Signal
30cyc
(min)
Hold End signal

W. Sequence
PS
SQ
USL
W1
C1
W2
DSL
C2
W3
HO
HD
OF
Alarm Message
Alarm Reset
F-201 Ver1.5
OBARA Corp.
(6) Parameters: HoldA DlyOFF

Hold Out ON
ALM Mode 0 (Skip alarm output)
Start Switch
MV/SOL
Welding Current
Alarm Signal
Hold End signal
4cyc
(min)
W. Sequence
PS
SQ
USL
W1
C1
W2
DSL
C2
W3
HO
HD
OF
Alarm Message
Alarm Reset
(7) Parameters:
HoldA DlyOFF
Hold Out OFF
Start Switch
MV/SOL
Welding Current
Alarm Signal
Hold End signal
W. Sequence
PS
SQ
USL
W1
C1
W2
DSL
C2
W3
HO
HD
OF
Alarm Message
Alarm Reset
F-201 Ver1.5
OBARA Corp.
Sequence with the occurrence of Indicative Alarm:

Alarm messages will appear on TP-Net when the Hold End time passes.
Start Switch
MV/SOL
Welding Current
Alarm Signal
Hold End signal
4cyc
(min)
W. Sequence
PS
SQ
USL
W1
C1
W2
DSL
C2
W3
HO
HD
OF
Alarm Message
Alarm Reset
F-201 Ver1.5
OBARA Corp.
Step-up Control
11. Step Up
11.1 Step-up Control
The Step-up control function is used to compensate for decreased current density due to electrode
Step end signal
is output here
wear.
Step last stage signal

is output here
Current value
130%
Step max
Step max-1
Step 4
Step 3
S Count (16)
S Count 2
S Count 1
Step 2
100%
Step 1
102%
Spot count
CAUTION
Actions at the end of Steps: At the beginning of the final Step, the Step last stage signal will be
output from the terminal TB1-B6. The Step up Finish signal will be
output from the terminal TB1-B5 at the completion of the final step.
(Note1) When the parameter "Pr Current detection signal" is effective, the
Step last stage signal isnt output due to the Current detection
signal is output from the terminal TB1-B6.
(Note2) When the parameter "Ps Step up Finish 2 series output" is effective,
the Step last stage signal isnt output due to the Step up finish
signal output of step series2 from the terminal TB1-B6.
(Note3) When the parameter "Ps Step up Finish 2 series output" is effective,
the Step up finish signal of another step series isnt output due to
the Step up finish signal output of step series1 from the terminal
TB1-B5.
(Note4) The parameter "Pr Current detection signal" and Ps Step up Finish
2 series output cant be set to ON at the same time.
Please be careful in setting the parameter.
F-201 Ver1.5
OBARA Corp.
Setting Procedure to Use Step-up Function
11.2 Setting Procedure to Use Step-up Function

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

Item / Function
Gun Sel
PrSquez
Squeeze
Slope
Weld1
Cool1
Weld2
PressV3
Step2
Step3
Step4
Step16
Setting Example: All Series

2
20
30
30
30
35
35
10
10
10
10
0
0
0
0
0
0
0
0
0
0
0
0
102
102
103
103
104
104
106
106
106
106
109
109
Step2
Step3
Step4
130
Step16
120
120
130
Item / Function
Gun Sel
PrSquez
Squeeze
Slope
Weld1
Cool1
Weld2
PressV3

1
20
26
30
30
35
35
10
10
10
10
0
0
0
0
0
0
0
0
0
0
0
0
102
105
103
103
102
102
104
106
106
106
104
104
106
110
109
109
106
106
120
140
130
130
130
130
Gun select Number
Count1
Count2
Count3
Count16
200
150
200
350
250
200
300
350
250
200
300
300
300
200
300
F-201 Ver1.5
F
4
Gun select Number
300
Note: Where 4 guns

are used.
Count1
Count2
Count3
Count16
The values indicate the step-up

rate of Gun 1 to 4 from the left.
Specify step-up rate to each gun.
OBARA Corp.
300
200
150
200
350
250
200
300
350
250
200
300
300
300
200
300
Specify the step-up rate of

Gun 3 selected in the
starting Series.
Setting for proportional valve control
12. Pressure Adjustment (Option)

12.1 Setting for proportional valve control
The Pressure Adjustment function allows the application pressure of the gun to be changed by
adjusting the pneumatic pressure with the electro-pneumatic proportional valve that can be
controlled by an output signal from the timer.
To Use Pressure Adjustment Function:
Parameters: VP Mode and VP Type
Welding condition: MaxP., PAdjust, PresT1 to T3, and PresV1 to V3
Setting Procedures:
Two kinds of setting methods are available. To set the pressure, you can input a direct value
expressed in Newtons. Otherwise you can set the pressure with a percentage, %, assuming
facility pneumatic pressure to be 100%.
Setting Direct Value:
(1) Set Maximum pressure
Input a maximum pressure applicable to the gun installed. (Check the drawing for the
pressure.)
(2) Set Pressure efficiency
Temporarily set this to 100%.
(3) Set Pressure rise time and Pressure value
Input values according to the welding sequence and applied pressure required.
(4) Adjust Pressure efficiency
Adjust the Preset efficiency value temporarily set in (2) by measuring actual pressure.
Setting with Percentage (%)
(1) Set Pressure efficiency
Basically, set this to 100%.
(2) Set Pressure rise time
Input a value according to the welding sequence to be performed.
(3) Set Pressure value
Input a percentage value (%) assuming the facility pneumatic pressure to be 100%.
CAUTION
1. If your controller cannot distinguish between SMC and CKD specify SMC when
setting parameters. Wrong setting may cause damage to the controller.
2. Refer to II. Installation manual, for connection of the control wire for pressure
adjustment.
3. Obtaining a maximum pressure is impossible if the pneumatic pressure in your
facility does not meet the pressure required for the gun.
F-201 Ver1.5
OBARA Corp.
Pressure Adjustment Sequence
12.2 Pressure Adjustment Sequence

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

W. Sequence
PS
SQ
USL
W1
C1
W2
DSL
C2
W3
HO
HD
OF
13. Pressure Selector Function

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

W. Sequence
F-201 Ver1.5
PS
SQ
USL
W1
C1
W2
OBARA Corp.
DSL
C2
W3
HO
HD
OF
Procedure to Use Welding Interlock Function
14. Weld Interlock Function

To obtain the input/output signals concerning the interlock from the terminal board TB1 in the unit,
set the parameters as shown in 14.1. See 14.2 for input/output and time chart.
14.1 Procedure to Use Weld Interlock Function

Parameter: Gun Sel.
Set this parameter to 41 or 42. In these two-digit numbers, the tens digit, 4, indicates that the
weld interlock function is available and the units digit, 1 or 2, indicates the output number of the
main solenoid valve to be used. Inputting 3 or 4 as the units digit does not assign the number to
the solenoid-valve output since the welding interlock function is given priority.
14.2 Weld Interlock Timing Chart

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

W. Sequence
F-201 Ver1.5
PS
SQ
WIL
USL
W1
C1
OBARA Corp.
W2
DSL
C2
W3
HO
HD
OF
Version 1.5
Ver. No.SM059
Ver. No.SP038
Ver. No.SD038
Ver. No.SO033
(or
(or
(or
(or
later)
later)
later)
later)
SUPPLEMENTAL MANUAL
WELDING CONTROLLER
STN21- Series

after reading.
2004.03.10
No.F-201-
Contents
Supplemental Manual
Introduction and Contents
This manual explains how to install the equipment, enter the welding condition data and perform
trial welding. When installing and starting up the equipment, follow the procedures given in this
manual.
Verifying Correct Installation
Setting Welding Condition

Powering on and Displaying Set Mode
Entering Parameters
Entering Welding Condition Data
Trial Welding Sequence
Trial Welding
1. Related manual .................................................................................................................. 3

2. Initial Operation ................................................................................................................. 4
3. TP Basic Operation ........................................................................................................... 5
4. Organization Chart of Function Keys .............................................................................. 6
5. Timer Data .......................................................................................................................... 7
6. Displaying Set Mode.......................................................................................................... 8
7. Entering Parameters ......................................................................................................... 9
8. Entering Welding Condition Data................................................................................... 10
9. NoWeld Mode................................................................................................................... 11
10. Weld Monitor.................................................................................................................. 12
11. Step Up ........................................................................................................................... 13
F-201
Ver1.5
OBARA Corp.
.Supplemental manual Page -2
Related manual
1. Related manual
The instruction manual of this equipment consists of individual manuals shown blow.
Instruction manual
. Specifications
. Operating manual
. Reference manual
This manual gives the brief explanations of the equipment to supplement the instruction manual.
Before using the equipment, thoroughly read and understand the rest of the instruction manuals
(from I through V).
F-201
Ver1.5
OBARA Corp.
TP Basic Operation
2. Initial Operation
< TP-Net Timer : When connection 1 to 1 >
It is not necessary to choose a Timer number. Please move on to the following

page.
< TP-Net Timer : When connection 1 to n >
When a condition setup of two or more Timers is carried out by one TP-Net.
When power put on with TP-Net connected the following will be displayed in the sequence
indicated with arrow.
TP-Net Key operations :

Power put on
W

After several sec
number list
1 5
1 6
1 7
N e x t
The target timer No

input
Version
W

3 3

3 3
3 3

After several sec

Initial screen
G
G
A
M
u
u
0
o
n 1
1
n 2
1 5 8
1

1 0
n
T M D
T P D
M o
<Other Key Operations>

0
0
c y
d e
Shift
#TM
Home
Shift key
Jump to TM number list
1 5
F-201
Ver1.5
OBARA Corp.
1 6
1 7
N e x t
TP Basic Operation
3. TP Basic Operation
When powering on TP-Net or connecting it to the equipment, the Initial screen appears on the
display. The fourth line on the screen indicates functions corresponding to the Function keys
selected. The Function keys let you chose to display the screen of any mode such as the welding
condition entry mode.
TP-Net Key operations :

Initial Screen
TP-Net Display
G
G
G
M
u
u
u
o
n 1
n 2
n 3
n
T MD
F1
F2
F5
F3
F6
F1
u
u
u
t
n
n
n
e
1
2
3
p
F4
F7
F8
1 0
1 5 8 0
2 3 0
A L H
Mo H
Pressing and holding the

Shift key display the items
corresponding to the F5 to
F8 key.
Shift
The fourth line indicates

functions corresponding
to the Function keys
selected.
The items given in the fourth line change when

pressing any of the Function keys.
F5
G
G
G
S
1 0
1 5 8 0
2 3 0
T P D
Mo d e
G u n 1
G u n 2
G u n 3
1
1 5 8
2 3
P r
Pressing and holding the Help

Help key display the descriptions of
the Function keys.
S t e p
0
0
0
e .
AL H
Mo H
S t e p
C
I n
Al a r m
Mo n I t .
h
f
H
H
a
o
i
i
n
r
s
s
g e
m.
t .
t .

Reset
Used for modifying data

cleared.
Used for establishing or
confirming data entered.
F-201
Ver1.5
OBARA Corp.
Shift
#TM
Home
F4 F8
Takes you back to the

previous screen.
Takes you to the Initial Screen

from anywhere.
Organization Chart of Function Keys
4. Organization Chart of Function Keys

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

Example : Copies the data of Heat 1 in Series 1 to all Series.
F3 Series Copy
Copies welding condition data between Series.

Example : Copies the data of Series 1 to Series 5.
F4 Group Copy
Copies data between groups specifying the unit-number.
F5 Group Verify
Compares data between groups specifying the unit-number.
F3 TP Data Edit
Enables the external memory data stored in TP-Net to be edited.
F1 Unit Edit
Selects Unit to edit.
1-5 unit select
F1 Edit, F5 Group Verify

Copies data between Units.
F2 Unit Copy
1-4 unit select
F1
Copies the data of a selected Unit from the timer to the pendant.
F2
Copies the data of a selected Unit from the pendant to the timer.
F3
Copies the data of a selected Unit to another Unit in the pendant.
F4
Compares the Unit data of the timer with that of the pendant.
F3 Parameter
Selects Unit and changes parameters in it.
1-5 unit select

F4 Para. Copy

Selects Unit and copies parameters in it.
1-5 unit select
F1 TM TP, F4 TM TP
F4 Mode Select
Copies or compares parameters.
Changes a currently effective mode of the timer.
F1 Operation
Changes the current mode to the Weld mode.
F2 No Weld
Allows welding sequence to be performed with no current applied.
F3 C. Press
In addition to the actions of the No-weld mode, this mode enables the gun to be
pressurized continuously after the Hold End signal has been received.
F4 Set
Before editing any parameters or data, entering this mode is required.
F5 Parameter
Selects Parameters to be set.
F1 Edit
F-201
The same screens as described above.
Ver1.5
Enables the selected parameters to be set.
OBARA Corp.
Timer Data
5. Timer Data
Two categories of data need to be set to the timer. These are as follows:
(1) Welding Condition Data Data associated with welding sequences and current values.
(2) Parameter Data Data associated with function settings such as Step On/Off.
ata stored in each timer are called Unit and consist of:
Welding Condition Data 240 conditions, 15 conditions 16 groups (Group 0 to 15)
Parameter Data
TP-Net can hold data for up to 5 timers (5 Units) as an external memory.
System Diagram of Data Settings

15 conditions x 16 groups
= 240 conditions
TM stored Data
PN/C
Cable
TP-Net stored Data
TP-Net
5 unit
F-201
Ver1.5
OBARA Corp.
Displaying Set Mode
6. Displaying Set Mode

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

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

TP-Net Display
Initial Screen
Select the screen mode you wan
G
G
A
M
u
u
0
o
n 1
1
n 2
1 5 8
1

1 0
n
T M D
T P D
M o
0
0
c y
d e
F4
G
G
A
O
u
u
0
p
n 1
1
n 2
1 5 8
1

1 0
e
N o w
N o w 2
S
0
0
c y
e t
F4
G
G
A
M
u
u
0
o
n 1
1
n 2
1 5 8
1

1 0
n
T M D
T P D
M o
0
0
c y
d e
#TM
Home
F8
to display.
F8
The Set mode appears.

(Just as Light set lamp)
Return to the Initial screen.
Status Indication of TP-Net

The Set lamp lights when the
timer is in the Set mode.
When an alarm is generated, clear the alarm by

pressing the Reset key.
F-201
Ver1.5
OBARA Corp.
Entering Parameters
7. Entering Parameters
Before entering welding condition data, you need to select the functions for the timer by setting
parameters. Select functions according to the welding system of your facility. For details about
the settings, refer to V. Reference Manual.
When modifying any of the parameters entered, you should thoroughly understand the
procedure.
To enter parameters, proceed as follows:

TP-Net Display
Initial Screen
G
G
A
M
u
u
0
o
n 1
1
n 2
1 5 8
1

1 0
n
T M D
T P D
M o
G
G
G
u
u
u
n 1
n 2
n 3
n
n
n
r
0
0
c y
d e
1 0
1 5 8 0
2 3 0
2

1
2
3
a
1 0
1 5 8 0
2 3 0
P r e .
P
P
P
E
1
P u l s e
S e l . O F F
2
A B
M o d e
3
A L M
O u t
N . O
d t
S e l
Select
F1
You can edit

the
data
displayed in the
F5
Parameter
F5
Select the parameter items you want

to edit using the Up/Dow Scroll keys,
and then select EDIT.
F1
Enter desired data, and then press

the Return key to establish them.
O F F
I n p u t
D a t a
0 1
Press and hold

the Shift key.
Point !
u
u
u
a
P u l s e
F8
Shift
G
G
G
P
P 1
Select Mode
F4

Reset
Used for modifying data

cleared.
Used for establishing or
confirming data entered.
F-201
Ver1.5
OBARA Corp.
Shift
#TM
Home
F4 F8
Takes you back to the

previous screen.
Takes you to the Initial Screen

from anywhere.
Entering Welding Condition Data
8. Entering Welding Condition Data

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

TP-Net Display
G
G
G
M
u
u
u
o
Initial Screen
n 1
n 2
n 3
n
T MD
S e t
F2
1 0
1 5 8 0
2 3 0
T P D
Mo d e
D a t a
Select TMD
F6
Input Group No.
Me n u
< Input 0 to 15 >

S e l e c t
G r o u p #
R a n g e 01 5
0
0
0
d
1
1
1
P r S q u e z
0 c
S
3 0 c
S
1 c
t
F C P
S C P
G C
y
y
y
P
Select a desired Series using the Left/Right Scroll keys.

Select a desired welding condition item using the
Up/Down Scroll keys.
Group 0
Select a desired Series.
0
0
0
d
2
2
2
P r S q u e z
0 c
S
3 0 c
S
1 c
t
F C P
S C P
G C
y
y
y
P
Series 2
0
0
0
d
1
1
1
P r S q u e z
0 c
S
3 0 c
S
1 c
t
F C P
S C P
G C
0 1
P r S q u e z
I n p u t
R a n g e :
0
0
0
d
D a t a
0 9 9
y
y
y
P
F1
F5
Select EDIT.
0 c y
1 0
Enter desired data by using

numerical keys.
1
1
1
P r S q u e z
1 0 c y
S
3 0 c y
S
1 c y
t
F C P
S C P
G C P
Press the Return key to establish

the data entered.
#TM
Home
Shift
F-201
Ver1.5
OBARA Corp.
Displays the Initial screen.
F4 F8
Displays the
previous screen.
NoWeld Mode
9. NoWeld Mode
After finishing the data settings, you need to verify the incoming sequence in the No-Weld mode
and take measurements of the application pressure in the C. Press mode.
NoWeld Mode
This mode is used for verifying the specified sequence or replacing electrode tips. The
welding sequence is performed as it is specified; however, welding current is not applied.
C. Press Mode
The welder keeps the pressurized state as long as the Start switch is on. It can be used for
measuring the application pressure. Welding current is not applied.
To display the No-Weld/C. Press mode screen, proceed as follows:

TP-Net Display
Initial Screen
G
G
A
M
u
u
0
o
n 1
1
n 2
1 5 8
1

1 0
n
T M D
T P D
M o
0
0
c y
d e
F4
G
G
A
O
u
u
0
p
n 1
1
n 2
1 5 8
1

1 0
e
N o w
N o w 2
S
0
0
c y
e t
F2
F8
F6
F3
F7
NoWeld
C. Press

.
8
Select a desired mode.
Select the NoWeld mode.

Select the C. Press mode.
Press the Return key to apply the mode selected.
Status Indication of TP-Net
The No-Weld lamp lights when

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

Press lamps light when the timer
is in the C. Press mode.
F-201
Ver1.5
OBARA Corp.
Weld Monitor
10. Weld Monitor

After verifying the welding sequence, you need to switch the screen mode from the NoWeld
mode to the Operation or Set mode in order to verify correct welding.
Check for Weld Monitor

The Initial screen of TP-Net displays the screen for the weld monitor.
When the Step Up function is enabled, the Step Up status is displayed in addition to the
number of total spot counts for each gun.
Otherwise, the welding condition of the previously selected Start Series is displayed.
When there is an error between the predetermined current value and a measured cur. value
The fine adjustment of the parameter, Transformer turn ratio, is required. The current value
is increased or decreased by increasing or reducing the turn ratio, respectively.
To confirm the monitoring items, proceed as follows:

Initial Screen
TP-Net Display
G
G
G
M
u
u
u
o
n 1
n 2
n 3
n
T MD
1 0
1 5 8 0
2 3 0
T P D
Mo d e
List of Monitoring
Confirm the items using the Up/Down

Scroll keys.
Name
Function
Displays the total number of weld spots

of each Gun 1-4.
Step Data
The first number indicates a gun
number and the rest is the state of the
gun step, the number of weld count
and a weld state in the order
mentioned.
Operation Data
B3F:
Indicates the most recently selected
(Example)
starting Series data.
B3F W.Cycle 10cy B: Indicates B-Mode. (A or B)
PF68%
3: Indicates Group 0. (03)
C.Flow78%
F: Indicates starting Series F (1F)
W.Cycle 10 cy:
The number of weld cycles to be
per-formed per sequence.
PF68%: Power-factor
C.Flow 78%: Flow rate
Gun Counter
G
G
G
G
G
G
G
G
1
2
3
4
5
6
7
8
B
u
u
u
u
u
u
u
u
3
n
n
n
n
n
n
n
n
S
S
S
S
S
S
S
S
F
6
1
2
3
4
5
6
7
8
t
t
t
t
t
t
t
t
e p
e p
1
e p
U
e p
U
e p
e p
e p
e p

8
S e t
T
H
H
H
o
e
e
e
t
a
a
a
1
2
p
p
F
1
2
8
1

Va l u e
a
t
t
t
l C u r r
1
2
3
1 0
1 5 8 0
2 3 0
7 0 0 0
1 0
5 0 0
1 0 0 0
3 0 0
1 0
1 8 0
2 3 0
i n i s
1 0
1 0 0
2 0 0
3 0 0
1 0c
7 8
8. 7k
8. 7k
5. 0k
0. 0k
0. 0k
0. 5k
A
A
A
A
A
A
Set Value
Total Current
1
P e a k
Cu r r
P r e s s . N V 1
3 5 0 0 N
Current Value
1s t V o l t a g e
L i n e
V o l t .
Peak Current
3 9 0V
4 0 0V
Pressure force
1st Voltage
Line Voltage
F-201
Ver1.5
OBARA Corp.
An average of the set-up heat 1-3

data is displayed.
Indicates the mean current value
applied to Heat 1-3.
Indicates the current values applied
to Heat 1-3.
The peak current under welding is
displayed.
Indicates the pressure force.
Indicates the primary voltage during
welding.
Indicates the power voltage during idle
running.
Weld Monitor
11. Step Up
The step up state can be confirmed on the TP-Net Monitor screen. The number of steps and the
spot quantity for each gun are indicated. A lamp comes on when the final step is reached and
completed.
The Final Step lamp comes on when
the final step has been reached.
TP-Net step related

lamp lighting timing
Current
value
Step max
Step max-1
Step 3
Step 2
Step 1
Spot count
The Final Step and Step End lamps come
on when all steps have been completed.
Step changing and

clearing procedure
TP-Net Display
Initial Screen
G
G
G
M
u
u
u
o
n 1
n 2
n 3
n
T MD
1
1 5 8
2 3
T P D
Mo
1
2
3
M
S t e p
U p
F i n i s h
S t e p
2
0
S t e p
1
0
n
T MD
T P D
Mo d e
Using the downward cursor key, allow the Step

Monitor screen for the Gun No. in question to appear
in the upper area. In this case, the screen is related to
GUN1.
0
0
0
d e
When the step is to

be changed :
When the step is

to be reset :
Step
Reset
1- S t e p
S t e p
U p
1
C l e a r
?
8
1
2
3
M
1
2
1
T P D
S t e p
S t e p
S t e p
n
T MD
0
0
0
Mo d e
Pressing the Return key after pressing the

Step Reset key completes the reset.
F-201
Ver1.5
OBARA Corp.
F1
F5
1
2
3
S
S
S
t e p
U p
F i n i s h
t e p
2
0
t e p
1
0
t e p
U p
F i n i s h

1
11 6
F1
F5
Pressing the F1 key causes the Monitor

mode to be entered, and then pressing the F1
key again causes the Step Change mode to
be entered. After entering the desired
number of the step to be reached, press the
Return key. The change is now complete.
Version 1.2
Ver. No.SM059
Ver. No.SP038
Ver. No.SD038
Ver. No.SO033
(or
(or
(or
(or
PLURALITY OF UNIT MANUAL

WELDING CONTROLLER
STN21-G Series
For the safety use, read the safety precautions of this

instruction manual thoroughly to have a proper under
standing of it before operating this equipment. Be
sure to keep this manual in a specified place after
reading.
2004.3.10
No.F-202-
later)
later)
later)
later)
Table of contents
Table of contents
1. Related Manuals ................................................................................................................ 3
2. Connection of Plurality of Units ....................................................................................... 4
2.1 General ........................................................................................................................................4
2.2 Installation of Plurality of Units.................................................................................................4
2.3 Parameter Data Setting on Plurality of Units Installed............................................................5
3. TP-Net Operation for Installation of Plurality of Units.................................................... 5

3.1 Selection of Timer Numbers ......................................................................................................5
4. Troubleshooting ................................................................................................................ 6
4.1 When Plurality of Units Are Connected ....................................................................................6
4.2 When There Are Identical Preset Timer Numbers ...................................................................6
F-202 Ver1.2
OBARA Corp.
.Plurality of unit manual
Page - 2
Related manuals
1. Related Manuals
The manuals for the equipment include the following:
Instruction manual
. Specifications
. Operating manual
. Reference manual
. DeviceNet manual
. Inputting plurality of Units manual
This document describes the optional functions of the equipment. To obtain optimum
performance from it, it is essential that the description be fully understood.
F-202 Ver1.2
OBARA Corp.
Page - 3
Connection of plurality of units
2. Connection of Plurality of Units

2.1 General
Welding conditions can be referred to and preset through TP-Net once the timer is connected to
this model using the PJC cable. Set the appropriate parameter number on each timer. When
calling the specific timer, select the number preset on it.
Wiring for Plurality of Units
Timer connection Max. 31 units

Length of total PJC cable 500m or less
In case of OBARA
2.2 Installation of Plurality of Units

Procedure:
Install the units referring to the II. Installation Manual.
Referring to the illustrations given above, connect the timers using the PJC cables.
The timer to be connected last must be terminated with resistors. Remove the PCB cover
from inside the timer main body and change the setting on the jumper located on the optional
board to RD11 (SET).
Termination with Resistors
F-202 Ver1.2
OBARA Corp.
Page - 4
Data Setting on Plurality of Units Installed
2.3 Parameter Data Setting on Plurality of Units Installed

When installing a plurality of units, the timer number must be set using the parameter data. The
timer number may be any of those ranging from 0 to 99. However, if the same number is selected
for two timers connected together, either of them cannot be called up.
Parameter designation
Timer number setting
Po TMNo.
Effective conditions/Operation
Any of 0 to 99 (Prior to shipment: 2 lower digits of the timer main
body serial No.)
Operation: This number is used to call up the desired timer when a
plurality of units are installed for effective operation.
3. TP-Net Operation for Installation of Plurality of Units

3.1 Selection of Timer Numbers
Upon connection to the timer with TP-Net connected, the initial screens appear in the following
order. After the list of TM numbers has been displayed, select the timer TM number to be edited.
Pressing SHIFT + TM# HOME keys changes the screen to the timer number list even when
other timer is being referred to.
TP-Net Screen
Screen appearing after power on
W

After several seconds
TM number list
1 5
1 6
1 7
N e x t
Indication of the
version number

Select the TM number

2

3 2

2
<Other related operations>

#TM
Home
Shift
Pressing the SHIFT + TM# HOME keys

Initial screen
G
G
G
M
u
u
u
o
n 1
n 2
n 3
n
T MD
F-202 Ver1.2
changes the screen to the TM number list.

After several seconds
1
1 5 8
2 3
T P D
Mo
0
0
0
d e
OBARA Corp.
1 5
1 6
1 7
N e x t
Page - 5
Troubleshooting
4. Troubleshooting
4.1 When Plurality of Units Are Connected
The timer number does not appear
Problem
Probable cause
Poor
connection
between the
Certain timer numbers
timer and the cable.
do not appear.
There are timers whose selected
parameter-preset
numbers
under TIMER No are identical.
No operation proceeds TP-Net used is not of the type
that suits the installation of a
from the initial screen.
plurality of units.
The timer in use is not of the
type that suits the installation of
a plurality of unites.
Remedial action
Check the PJC cable for
connection
Change
the
parameter-preset
numbers under TIMER No.
Check the version number preset
on the rear panel of TP-Net. It
must be of the SP03* type.
Check the nameplate of the timer.
It must be of the STN21-G* type.
4.2 When There Are Identical Preset Timer Numbers

When there are two timers whose selected numbers are identical are connected with the cable,
either of them cannot be referred to with TP-Net. These numbers must be changed by re-setting
the parameters.
Number re-setting procedure:
Disconnect the PJC cable that is connected to the timer whose preset number must be
changed.
Using the PN/C cable, connect TP-Net to the timer.
Change the parameter-preset Pp Timer No to a new number.
Re-connect the PJC cable.
! CAUTION
Do not confuse the PJC cable and the PN/C cable when connecting them. Use the PJC
cable (color: gray) between the timers, and use the PN/C cable (color: black) between
TP-Net and the specific timer.
F-202 Ver1.2
OBARA Corp.
Page - 6

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Welding Controller

For the safety use, read the safety precautions of this

Notes on safety and handling procedure

= Notes on safety and handling procedure =

4-2-37 Ogami, Ayase-shi, Kanagawa-ken

OBARA CORP. JAPAN

OBARA EUROPE LTD.

OBARA KOREA CORP.

OBARA CORP. INDIA

OBARA CORP. U.S.A.

All rights reserved.

These symbols and signal

Improper handling of the equipment may cause a

dangerous situation that can lead to eventual death or

Improper handling of the equipment may cause a

dangerous situation that can lead to intermediate level

The attention catching symbols indicate general situations.

Conducts that must be done.

Conducts that must not be done.

To understand the contents of this instruction manual.

To understand the meaning of warning labels.

To acquire the method of heart massage and artificial respiration(CPR).

To check protective attire such as that of fire fighters.

To clarify places and personnel to contact in emergency.

To understand how to inspect the system.

To have enough knowledge on electricity to understand it.

To understand the system, wiring diagram, and voltage.

To have enough knowledge on resistance welding to understand it.

Items to follow as safety precautions

Items to follow as safety precautions

Always follow the instructions below in order to prevent bodily

Items to follow as safety precautions

Always follow the following instructions in order to avoid electrical

threatening electrical shocks and/or burns.

7. Do not use torn or wet gloves.

Always wear dry and well insulated gloves during operations.

parts are repaired.

ones that can adequately withstand the specified load or pressure.

Items to follow as safety precautions

Do not insert fingers or hands between the electrodes.

Use appropriate protective devices to protect yourself and others

4. Utilize sound proofing devices if the noise level is high.

Always follow the following precautionary instructions in order to

metal right after a weld may cause fire.

generated when they are charged.

2. Do not weld near combustible and/or inflammable gases.

Type of warning labels

Indications of dangerous parts and precautions

The shaded areas in the figures show the

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

Full-digital control (synchronous)

4 Series/15 Series/16 Groups, 240 series maximum

Squeeze Delay Time

0 to 99 cycles (all series)

1 to 99 cycles (all series)

1 to 30 cycles (all series)

0 to 99 cycles (all series)

0 to 99 cycles (all series)

0 to 99 cycles (all series)

Down Slope Time

0 to 99 cycles (all series)

0 to 99 cycles (all series)