Cooper Instruments WFC900-100-1 Installation Manual
WFC 900
WELD FORCE PROBE
USER’S GUIDE
www.cooperinstruments.com
PH: 540-349-4746 FAX: 540-347-4755
TABLE OF CONTENTS
1.0 INTRODUCTION ...................................................................................................................1
1.1 Overview.......................................................................................................................................... 1
1.2 Quick Operation Guide................................................................................................................... 1
1.3 Instrument Layout .......................................................................................................................... 1
1.3.1 LCD Display.............................................................................................................................. 1
1.3.2 Low Battery Indicator .............................................................................................................. 1
1.3.3 Decimal Point Position ............................................................................................................ 2
1.3.4 Incremental Display Step ........................................................................................................ 2
1.3.5 Load Cell................................................................................................................................... 2
1.4 Maximum Safe Overload ................................................................................................................ 2
1.5 Front and Side Views ..................................................................................................................... 2
1.6 Dimensions ..................................................................................................................................... 3
1.7 Specifications ................................................................................................................................. 3
2.0 OPERATION ..........................................................................................................................4
2.1 Battery Replacement...................................................................................................................... 4
2.2 Turning the Instrument On and Off............................................................................................... 4
2.3 Zeroing the Display ........................................................................................................................ 4
2.4 Restoring the Calibrated Zero ....................................................................................................... 4
2.5 Reading the High/Low Values ....................................................................................................... 5
2.6 Clearing the High/Low Values ....................................................................................................... 5
3.0 FIELD SELECTABLE FEATURES ........................................................................................5
3.1 Introduction..................................................................................................................................... 5
3.2 Setup Menu Operation ................................................................................................................... 5
3.3 Enable Options (“ ”) Description ............................................................................................... 6
3.3.1 Auto-off Feature ....................................................................................................................... 6
3.3.2 Always-On Feature .................................................................................................................. 6
3.3.3 [Zero] Button Disable Feature ................................................................................................ 7
3.3.4 [Hi/Lo] Button Disable Feature ............................................................................................... 7
3.3.5 [Clear] Button Disable Feature ............................................................................................... 7
3.4 Enable Options (“ ”) Menu Item ................................................................................................. 7
3.5 Engineering Units (“ ”) Menu Item ......................................................................................... 7
3.6 Auto-off time (“ “) Menu Item.................................................................................................. 8
3.7 Update Rate (“ ”) Menu Item .................................................................................................. 8
3.8 Internal Software Version (“ ”) Menu Item .............................................................................. 8
4.0 CALIBRATION.......................................................................................................................9
4.1 Calibration Considerations............................................................................................................ 9
4.2 Required Forces ............................................................................................................................. 9
4.3 Calibration Procedure .................................................................................................................... 9
4.3.1 Enter Forces to be Applied ..................................................................................................... 9
4.3.2 Apply Forces .......................................................................................................................... 11
4.4 Rear View of Front Face Panel .................................................................................................... 12
4.5 Calibration Error Messages ......................................................................................................... 12
5.0 TROUBLESHOOTING .........................................................................................................12
5.1 Introduction................................................................................................................................... 12
5.2 Help Message Codes.................................................................................................................... 13
5.3 Troubleshooting Hints ................................................................................................................. 13
WARRANTY REPAIR POLICY..................................................................................................13
WFC 900 ii Rev. D: 3/03
Limited Warranty On Products.......................................................................................................... 13
Obtaining Service Under Warranty ................................................................................................... 14
Repair Warranty.................................................................................................................................. 14
WFC 900 iii Rev. D: 3/03
1.0 INTRODUCTION
1.1 Overview
The WFC 900 is a rugged, hand-held instrument for accurately calibrating weld electrode force on resistance
welding machines. This device helps ensure compliance with ISO 9000 or QS 9000 quality requirements by taking
the guesswork out of setup. Measuring accurate force levels at the electrode tips helps eliminate inaccuracies of
the line-pressure readings, air cylinder friction, and mechanical wear.
The WFC 900 is designed for long life in the harsh welding environment by using Cooper’s standard fully-welded
load cell construction and NEMA 4 electronics packaging. The easy-to-use design includes a simple push-button
format and a large LCD display that provides both continuous and peak (maximum) force values in keypadselectable engineering units.
High-speed digital electronics sample readings during the squeeze-weld-hold sequence and capture the peak force
for display. A simple, one-button CLEAR prepares the instrument for the next reading. Two standard 9-volt alkaline
batteries provide 80 hours of continuous use. Battery life is maximized with a programmable power-off feature.
1.2 Quick Operation Guide
1. Depress the [On/Off] button to power up the instrument. Wait about 5 seconds for the instrument to warm up.
2. If a non-zero value appears on the display, press and hold the [Zero] button until the display reads “
takes about three seconds).
3. Insert probe, initiate welder, and take reading.
4. Press and hold the [Hi/Lo] button until the display reads “
5. Press [Clear] to clear the maximum value in preparation for the next reading.
6. As shipped from the factory, the instrument will automatically shut itself off if no buttons have been pressed in
four minutes.
Note: The WFC 900 is a force calibration device designed to measure the force between electrodes on resistance
welders. It can withstand passing current through the force transducer.
It is recommended for the safety of the operator and the WFC 900 to disable current before
operation. Many repeated current firings may damage the weld force indicator.
” to read the maximum (or peak) force value.
” (this
1.3 Instrument Layout
1.3.1 LCD Display
The 4½-digit liquid crystal display (LCD) readout displays the load applied to the instrument, interacts with the user
when the instrument is being set up or calibrated, and indicates if there is a problem with the instrument.
When a WFC 900 instrument is turned on, it illuminates all LCD segments. Then, the engineering units the gauge
will be using appears on the display. Most WFC 900 instruments are calibrated in pounds (“
instrument has conversion factors for many standard engineering units built in. However, if the instrument displays
(special) it has been specially calibrated to another engineering unit at the factory. In that case, the serial
number tag on the top of the instrument will indicate the engineering units being used and the capability to select
other engineering units should not be used.
After the display of the engineering units, the force applied to the load cell is shown on the display. If the load
applied to the load cell is above the instrument's ability to measure, the display will indicate this overrange condition
by showing a "
" on the far left hand side of the display. The display will read " " if the instrument is underranged.
”) and the
1.3.2 Low Battery Indicator
On the left side of the display, just above the minus sign, is the low battery indicator (in the shape of an arrow).
When the battery voltage is less than 5 volts, the display will be blanked and the low battery indicator will illuminate
to indicate that the batteries should be replaced. The low battery indicator can be seen when the instrument is
turned on and all segments of the display are momentarily lighted.
WFC 900 1 Rev. D: 3/03
When the low battery indicator is illuminated, change the batteries as soon as possible. The instrument will not
function if the battery voltage falls below approximately 4 volts.
1.3.3 Decimal Point Position
The decimal point position automatically changes depending upon:
• the user selected engineering units
• the load range of the instrument.
The decimal point position cannot be changed manually.
1.3.4 Incremental Display Step
The incremental display step is the value by which the last digit of the display will change. This value will be 1, 2, or
5 display counts. It automatically changes depending upon:
• the user selected engineering units
• the load range of the instrument
The incremental display step cannot be changed manually.
1.3.5 Load Cell
The WFC 900 instrument can be ordered with one of two types of load cells: those with a load sensing button, and
those with a load sensing indentation. The load sensing button is useful when the unit is used with projection
welders. The load sensing indentation is useful for most spot welding applications.
1.4 Maximum Safe Overload
Maximum safe overload is the force that the instrument can experience occasionally without loss of accuracy or
permanent damage.
Force Range (lbs.)
0 - 500 = 500 750
0 - 1000 = 1K 1500
0 - 2000 = 2K 3000
0 - 5000 = 5K 7500
0 - 10000 = 10K 15000
Table 1: Maximum Safe Overload
Maximum Safe Overload
(lbs.)
1.5 Front and Side Views
Figure 1-1. Model WFC 900 Front View (2-handed version)
WFC 900 2 Rev. D: 3/03
Figure 1-2. Model WFC 900 Display Side View
1.6 Dimensions
Figure 1-4. Model WFC 900 Load Cell Dimensions (2000 lbs. Range with Sensing Indentation)
1.7 Specifications
Figure 1-3. Model WFC 900 Display Dimensions
Cooper continually improves its products, and thus these specifications are subject to change without notice.
Display Diameter: 3.7 inches
Accuracy: 0.5%
Operating Temperature: 30 to 180 ºF
Force Ranges 0 to: 1000, 2000, 5000, 10000 lbs.
Overload Capability: 150% of full-scale range
Calibration Engineering Units: lbs
Built-in Engineering Unit Conversion: lbs, Kg, kN, N, g (field selectable)
Sampling Rate: 19.2kHz internal; 24Hz display update
Power Requirements: two 9 Volt alkaline batteries provide approximately 80 hrs continuous life
Load Cell Material: BeCu
Housing Material: Stainless steel
High and Low Capture: Standard, same update rate as display
Zero and Span Adjustment: Standard
WFC 900 3 Rev. D: 3/03
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