English
Created on 06.04
Medium Frequency Spot Welding Controller Product
1. Product Introduction & Core Advantages
- IDW series medium frequency resistance welding controller is a high-precision industrial welding control device designed for medium-frequency spot/projection welding equipment. Operating at 1kHz output frequency with millisecond-level timing accuracy, this controller adopts closed-loop secondary current feedback technology to realize precise welding output control, widely matched with medium frequency spot welding transformers, industrial robots and automated welding production lines.
1.1 Key Product Features
- Output frequency 1kHz, millisecond-level precise timing control; current control accuracy up to 5‰.
- Programmable storage for maximum 32 independent welding parameter schedules to satisfy multi-spec workpiece production.
- Three-section welding heating logic: Preheat → Weld → Temper; adjustable upslope/downslope and independent cycle times within welding segment.
- Customizable programmable I/O terminals (3 groups of output), easy connection with PLC, industrial robots and peripheral automation devices.
- Supporting industrial communication & BCD code signal control, realizing remote centralized automation management via external PC or PLC.
- Real-time secondary coil current feedback + closed-loop regulation to greatly improve welding current stability and finished welding quality consistency.
- Built-in historical fault alarm record storage function for fast troubleshooting and production data tracing.
2. Main Technical Specifications
2.1 Electrical Specification
Parameter | Details |
Input Power | 3-phase AC380V, tolerance +10%/-20%, 50Hz±1% |
PWM Output Voltage | Single-phase, peak 540V |
Rated Output Current | IDW-400T:400A / IDW-600T:600A / IDW-800T:800A / IDW-1000T:1000A / IDW-1200T:1200A |
Solenoid Valve Output | DC24V±10%, Max 0.15A per channel, total 3 groups air valve drive |
Input Power Cable | 50mm² |
Cooling Water Flow | 6L/min for IDW400/600; 8L/min for IDW800/1000;12L/min for IDW1200; Min pressure ≥0.15MPa, Max water temp ≤40℃ |
Working Ambient | Temp: -5℃~50℃ (water cooling); Humidity ≤80%; Max altitude ≤1000m |
Insulation Class | Class F |
Outer Dimension | IDW400/600/800/1000T:672×267×400mm; IDW1200T:750×265×460mm |
2.2 Welding Timing Parameter Range (Unit: ms unless specified)
- Pre-pressure:0~9999 | Squeeze Time:0~9999 | Upslope:0~99 | Preheat:0~999
- Cooling Time:0~9999 | Weld Time:0~999 | Downslope:0~99 | Temper Time:0~999
- Hold Time:0~9999 | Rest Time:0~9999
- Current Mode Option 1: Primary Constant Current CC1:0~9999A
- Current Mode Option 2: Secondary Constant Current CC2:0~99.99KA (per segment 1/2/3)
- Notes: Do NOT run no-load test; controller must connect matched welding transformer before startup. For multi-cycle welding, cooling time ≥2ms is mandatory.
3. HMI Panel Introduction
Equipped with industrial 7-inch touch screen for full operation: parameter setup, real-time monitoring of welding current, DC bus capacitor voltage, working cycle count and equipment running status.
- Main screen categories: Running Status Screen: Default boot screen for normal welding execution, displays total weld counts, capacitor voltage, 3-channel actual welding current.
- Parameter Setting Screen: Configure all timing values, primary/secondary constant current values and weld schedule copy function.
- Function Setting Screen: Switch spot/continuous/roll seam welding mode, pulse/level trigger, primary/secondary constant current, electrode dressing reminder, water flow & transformer temperature detection, motor delay and boost valve control parameters.
- Current Monitoring Screen: Independent upper/lower limit & allowable tolerance setup for Preheat/Weld/Temper current; over/under current alarm & continuous under-count protection.
- Current Step-up Screen: Max 10-step programmable current increment to compensate electrode wear by setting step percentage & corresponding weld quantity.
- Production Management Screen: Total production counter, workpiece & box counting, target production setup and data correction.
- Historical Data Screen: Store real-time curve of welding discharge current and bus voltage; support USB export of full production data for PC analysis.
- Fault Record Screen: Save all historical alarm codes and occurrence timestamp for maintenance check.
4. Core Functional Description
4.1 Welding Mode Selection
- Single Spot: One welding cycle per trigger signal regardless of sustained trigger input.
- Continuous Weld: Hold-type / Jog-type optional for automatic cyclic spot welding.
- Roll Seam Weld: Jog/Hold two trigger logic, compatible with continuous seam welding production.
4.2 Trigger Mode: Pulse Trigger or Level Trigger available
4.3 Constant Current Control
- Primary CC: Regulate input primary transformer current; secondary coil connection optional.
- Secondary CC: Closed-loop based on real secondary output current; secondary coil wiring is compulsory.
4.4 Extra Practical Functions
- Electrode Dressing Alert: Set fixed weld quantity to output pre-alarm and full dressing reminder signal when reaching preset count.
- Step-up Current Compensation: Gradually raise output current by preset percentage after specified welds to offset electrode abrasion.
- Multi-point Current Monitoring: Auto alarm when actual current exceeds upper limit or falls below allowed lower tolerance.
- 32 Schedule Selection: Switch welding program via front touch panel or external BCD terminal signal.
5. Common Fault Code & Troubleshooting
Fault Code | Alarm Content | Cause & Solution |
E01 | Overheat Transformer | High cooling water temp / insufficient water flow / over duty cycle; improve cooling condition, replace damaged thermal switch |
E02 | Abnormal Cooling Water | Low water pressure or faulty flow detection wiring; adjust water pressure & inspect wiring |
E03 | Emergency Stop Activated | External E-stop switch disconnected; reset after troubleshooting |
E04 | Electrode Dressing Full Count | Reach preset dressing point; dress electrode then reset via dedicated input terminal |
E05 | Step-up Max Count Reached | Full step-up weld quantity; reset counter |
E06 | No Welding Current Output | Broken secondary coil / loose sensor plug / damaged transformer; check wiring & replace defective parts |
E07 | Over Maximum Output Current | Short circuit / wrong current parameter; reduce setting value and inspect secondary loop |
E09 | Overheat IGBT Heatsink | Poor cooling; improve water flow and lower continuous working duty |
E10 | IGBT Module Abnormality | Damaged drive board/IGBT; check wiring or replace power module |
E13/E14/E15 | Capacitor Voltage Out of Range | Unstable input 380V grid / missing phase; check input power supply |
E16~E24 | Weld Current Over/Under Limit | Improper monitoring parameter / defective secondary loop; revise setpoints and inspect welding circuit |
E25 | Production Target Completed | Pre-set total output finished; disable production count function then reset |
- Other non-code faults: Solenoid valve malfunction(Check DC24V supply & wiring); Touchscreen black screen(Inspect 24V power supply or replace HMI).
6. Maintenance & After-sales Service
- Equipment maintenance must be operated by professional electrician and welding technician. Improper misuse voids free warranty.
- One-year free warranty from factory delivery date under normal working condition. Free repair for manufacturing defect within warranty period.
- Damage caused by wrong operation, unauthorized modification, transportation impact or improper installation will be charged for spare parts and maintenance service. Paid repair service is available for out-of-warranty products.
- Custom technical support and on-site guidance can be offered upon customer request. Product specification subject to physical product without prior notice if updated.
7. Application Range
- IDW medium frequency resistance welding controller is widely used in automotive parts, hardware, home appliance, new energy battery, sheet metal processing industries for spot welding, projection welding and seam welding matched with medium frequency inverter spot welders and automated robotic welding lines.
Leave your information and
we will contact you.
we will contact you.
WhatsApp