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HF27 Technical Manual - AMADA MIYACHI AMERICA

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1. S 0 99 ms DOSA NR 0 99 ms s Y e 0 99 ms IB q 0 99 ms MERO Suse dU EI UMEN MM 0 99 ms Dov a 0 0 Ln Y X I 0 99 ms D 0 999 ms Weld Energy Limits Monitoring Energy Limit Mode Terminate weld energy upon reaching the programmed current voltage power or resistance alarm level Weld Pre Check Mode Inhibit second weld pulse when first test pulse exceeds programmed limits Measurement Parameters Current voltage and power Measurement Selection Peak or average HF27 DC RESISTANCE WELDING SYSTEM A 2 990 3 0 APPENDIX A TECHNICAL SPECIFICATIONS Measurement Range and Accuracy 1 24 KA E 2 of scing 92A 0 2 9 999 V 2 of setting 0 02V 0 05 9 999 kW 5 of setting 10W Limit Ranges Same as the measurement ranges Alarms Display alert and four programmable AC DC relay contact outputs Force Specifications Force Set Output Range 0 5 VDC and 0 10 VDC Force Set Output Accuracy 3 0 0 1 Ib Force Read Input Range 0 5 VDC and 0 10 VDC Force Read Input Accuracy 3 0 0 1 Ib LVDT Specifications Stroke 1 0 25 4mm maximum Absolute Accuracy see Following G
2. 5 5 Dust Pulse Weld ________ UR 5 7 HF27 DC RESISTANCE WELDING SYSTEM vi 990 3 0 LE Uem iie Weld Montor 5 9 Seccion Morena Part Conditioning 5 13 Decbon IV DE PETI METIRI MINE 5 15 becton VL _____ PERPE 5 17 Section Weld To 5 19 __________ _ _ 5 21 Section IX Energy Monitor 5 19 Pee Ree um ER 5 24 ______ 5 24 PTS AC CHC 5 24 PVT UM 5 24 Betote You Start Set New Electrodes t Zero 5 25 Changing from Inc Be S to Miliimeters MM E E 5 25 High and Low Limits for Initial Thickness 5 26 Fite hiram Low Limits tor Displacement 5 27 STOP ENERGY AT Weld to a Specific Displacement 2 2 042 22 5 27 DeGHODn XT 5 28 DECBOB TE Pire E E a EE E E NIMM NE 5 29 Become 5 30 Secun XIV Probsrtaininthe 5 31 Chapter 6 Maintenance 6 1 General ICS or Proble HIS _______ _____ _____ 6 1 NIMM MM IF 6 1 becHon mto NIME 6 2
3. C a ScREENUPDATES AREORF 2 HF27 LINEAR DC RESISTANCE WELDING CONTROL 990 370 EO APPENDIX E COMMUNICATIONS Command Control State Description Command Control State Description 28 SCHEDULE schedule number crl l1f Any Returns the current schedule number to the host schedule number may be any number from 0 to 99 SCHEDULE FEEDBACKI FEEDBACK2 SQUEEZE UPI WELDI DOWNI COOL UP2 WELD2 DOWN2 HOLD ENGI ENG2 RINDEXI RINDEX2 EINDEXI EINDEX2 lt schedule number lt crlf gt KW lt crlf gt KW lt crlf gt squeeze time lt crlf gt weld time lt crlf gt weld time lt crlf gt weld time lt crlf gt weld time lt crlf gt weld time lt crlf gt weld time lt crlf gt weld time lt crlf gt hold time lt crlf gt weld energy lt gt weld energy lt gt resistance index crlf resistance index crlf energy index crlf energy index crlf Reports the settings of the currently loaded Control schedule parameters The schedule number variable identifies which schedule is currently loaded and may be any value from 0 to 99 squeeze time and hold time the parameter that defines the time for the given period in 1 msec Valid range 15 from 0 to 999 weld time is equivalent to 0 01 for Increments from 0 1 to 0 99 msec and increments of 0 1 msec for 1 0 to 9 9 msec and inc
4. 1 Welding Current DELAY 502 WELD bown HOLD E t 2 4 Delay time from Remote Schedule Select Signal ON to the start of the weld sequence that is start of SQZ DELAY time is 23 ms Squeeze time Selectable range 15 0 to 999 ms Up slope time Selectable range 15 0 0 to 99 0 ms Weld time Selectable range 15 0 0 to 99 0 ms Down slope time Selectable range 15 0 0 to 99 0 ms Cool time Selectable range 15 0 0 to 99 0 ms Hold time Selectable range is 0 to 999 ms HF27 DC RESISTANCE WELDING SYSTEM APPENDIX D SYSTEM TIMING Basic Weld Operation Air Head System with Two Level Foot Switch and Proportional Valve Definitions T1 T2 D1 D2 SQZ UP WELD DOWN COOL HOLD D 4 T1 24VAC or 24 VDC FOOT SWITCH WELD PRESSURE LEVEL1 0 7 SOFT TOUCH TIME WELD FORCE R SOFT TOUCH PRESSURE FOOT SWITCH LEVEL 2 FIRING L SWITCH WELDING 301 CURRENT 01 02 squeeze uP wero pow cooL uP WELD powN HOLD Pulse 1 Pulse 2 Delay time from Foot Switch Level 1 closure to Weld Force start Maximum delay time is 1 ms plus switch debounce time Switch debounce time can be set to none 10 20 or 30 ms with the SETUP 1 menu screen Soft touch time Delay time from Foot Switch Level 2 to Firing Switch closure Maximum D1 time is 10 seconds Ifthe firing switch does not
5. 2 6 EZ AIR Weld Head Connections 2 7 None Z ATK Weld Head Connections c tua opas ROS a aded etude ae uas 2 10 Chapter 3 System Configuration econ L STATIC 3 ______________ _____ __ __ __ 3 1 3 1 3 3 3 3 Eu E 3 3 INO D PT 3 3 1 NV M T mm 3 4 3 COP 3 5 2 Prop Valve Proporiional 3 5 Li M 3 5 PEUX NR UU ___ ____ 3 5 Ie 3 5 Lo ooa 3 5 3 6 RT ees 3 6 2 3 6 CECI FERRE 3 6 HF27 DC RESISTANCE WELDING SYSTEM IV 990 3 0 NR 3 7 l Communication S RR 3 7 2 3 8 3 TR 9 7777 72222222 3 8 d LD IN MM 3 8 3 9 D 3 10 Para tCs 3 11 25 5 e Se EIER 3 11 3 Resell Schedule 3 12 Cham Schedules 3 12 E E 3 14 1 Footswitch Weld Abort 3
6. 4 1 a esce 4 2 Voltage Mod 4 1 Weld Monitoring 4 3 Current Voltage Power amp Resistance Limits 4 4 Distance DUIS on sector ern redes 4 4 Epere y 4 5 Prnv lope 4 5 Force LIIS 4 4 IG FO QU OB 4 3 PEAK amp AVERAGE MONITORING 4 3 4 5 Active Part Conditioner APC 4 5 Pre Weld Bee E 4 8 4 7 4 10 Weld To A 4 9 4 4 2 1 8 1 7 a 31 cm 1 8 1 9 L 3 17 Ey DTC en 1 11 LVDT M in Screen 5 24 M E 3 3 hs TRIMESTRE gt RN 6 1 Introduce MOLD o ostii deter qp 6 1 Alarm Messages 6 1 General Kinds of Problems 6 1 Maintenance rc 6 12 Electrode Maintenance 6 12 Par s Replacement 6 12 6 13 Troubleshooting 6 2 Alarm 2 6 3 Troubleshooting emite 6 2 sen 1 4 Material Properties
7. 3 16 Display Contrast terae 3 16 End Of Cycle quein 3 16 Tx 3 17 Update Graph After Weld 3 16 3 17 Do Test Vell 3 17 uro J 3 17 S RR 3 17 Weld Functions 3 22 Welding Applications 3 22 3 25 Dual Pulse Weld Profile 3 26 Single Pulse Weld Profile 3 25 Upslope Downslope Weld Profile 3 26 Weld Head Applicability 3 23 Weld Schedule Definition 3 24 Weld Sequence Timing 3 24 When To Use Functions 3 23 DUBIE DS 3 6 HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 Index 5 INDEX S Continued By CCUG 3 6 D 1 T Technical Specifications 1 3 18 TIME 1 10 BET ML NORTE 4 4 5 29 Time bnergy Selector Keys iu cete hr nta 1 6 Troubleshooting 6 2 Uap knn 2 1 Update Graph After Weld 3 16 Upslope Downslope Weld Profile 3 26 Upslope Downslope Weld Schedule 5 5 Using the Weld 5 9 2 2 V Lac MEM 1 8 2 E E E VEE EEE 1 9 baud qe i 4 1 W un
8. 1 UPPER 3 201V LOWER 2 100V inone 4 RAISE OR LOWER LIMIT VALUES ___ PRESS COOL FOR ACTION UP FOR TIMING LOWER LIMIT 1 UPPER 3 201 none LOWER EZ 600 As you can see by the LCD screens above you can shorten the length of the time of the LOWER LIMIT so it will not cross the weld waveform This allows you to raise or lower the LOWER LIMIT closer to the peak of the actual waveform without crossing the weld waveform For some welds it may be very important to get up to the peak voltage or current to get the right melting and get there at the right time during the pulse Every millisecond could be very important HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 95 CHAPTER 5 OPERATING INSTRUCTIONS UR Press the SCHEDULE key then select a Weld Schedule using either the arrows or the numeric keypad Fire the welder and view the output waveform shaded graph on the display LE key to view the desired waveform Note that the other monitor keys do not have graphical waveforms Toggle the Pulse 1 weld time energy selector key to select the upper limit field for the weld period Use the numeric keypad or the arrows to enter the upper limit value for the Pulse 1 weld period 4 Perform one of the following to program the Pulse 1 monitor limit mode Press the kA key to program current as the limit mode Press the V key to progra
9. the VIDA aite ness C 4 Before YOU C 4 Recommended Gauge Thickness 4 Force 9 Force aliOrat 9 9 Set Force tate to Lero C 10 eti oett te dies C 5 Quick Calibration Quick Cal C 6 Set New Electrodes to Zero C 7 Calibration Equipment Required C I Chain Schedules Boetius 3 12 Changing from Inches to MM 5 25 COMBO 1 8 Combo Mode 4 2 Common Problems 5 9 3 7 Communication Role 3 7 1 Compatibility and Comparison H 1 Compressed IE NEM Ua 5 Compressed Air amp Cooling Water 2 2 5 3 ONS 5 1 Connections to External Equipment 2 3 ono gu CT ix Control Features RR TE 1 1 1 7 Control Mode Selection Keys 1 8 Copy MUNI 3 5 Criteria for SUCCESS osse redo testas G 10 G 11 UI CONS EE 4 1 Current Voltage Power amp Resistance Limits 4 4 D Declaration OT Conformity euesess Xi prep dT 1 1 liccc
10. d E restat breed 5 24 Distance Monitor 5 24 THESE Wy 3 17 Dual Pulse Weld Profile 3 26 Dual Pulse Weld Schedule 5 7 E Electrical amp Thermal Conductivity G 3 Electrical and Data Connections B 1 Electrode Maintenance rtr ere 6 12 Electrode 5 Electrode Selection imeni F 2 Emergency Stop Switch Operation 1 10 Pad Orc vele BUZZOE oiii trito ennn ni e 3 16 ENER 1 10 LINIS 4 5 Delo Monitor 5 19 PNVYELOPE TEY 1 9 4 5 IUE 5 30 EZ AIR Weld Head Connections 2 7 Factorial b DIUI G 11 25254 1 1 SWIC S 3 15 Foot Pedal Actuated Weld Head Connection 2 6 Footswitch Weld Abort 3 14 Force Calibration 9 Force 9 TORCE 1 9 OT CS dE 4 4 Force Monitor 5 28 POC em 3 5 lyon dbi Mc 3 5 Front Panel Data Entry and Mode Keys 1 7 Front Panel Display amp Display Controls 1 4 Calibrati
11. 2 Steel Nichrome 2 Cold 2 Platinum Platinum 2 Steel Nickel 2 Cold Rolled 2 Silver 11 14 Cadmium 13 Steel Nickel 2 Stainless Steel 2 Cold Rolled 2 Cold 2 Steel Steel Nickel 2 Tantalum 2 Cold Rolled Stainless Steel 2 Steel Nickel 2 Tungsten 2 Cold Tantalum 2 Steel Nickel Alloy 2 Nickel Alloy Stainless Steel Stainless Steel Nickel Alloy 2 Beryllium 2 Tantalum Tantalum 2 Copper Nickel Alloy 2 Cold Rolled Steel Electrode Maintenance Depending on use periodic tip resurfacing 1s required to remove oxides and welding debris from electrodes Cleaning of electrodes on production line should be limited to use of 2400 600 grit electrode polishing disks For less critical applications a file can be used to clean a badly damaged tip However after filing polishing disks should then be used to ensure that the electrode faces are smooth If this 15 not done the rough surface of the electrode face will have a tendency to stick to the work piece HF27 DC RESISTANCE WELDING SYSTEM F 4 990 3 0 APPENDIX F THE BASICS OF RESISTANCE WELDING Weld Schedule Development Developing a weld schedule 15 a methodical procedure which consists of making sample welds and evaluating the results The first weld should be made at low energy settings Adjustments are then made to each of the welding parameters at a time until a successful weld 16 made Install the co
12. 3 10 Resistance Set aseo ette sedet onu 4 7 5 15 Resistance Welding aisi ie dies G I Resistance Welding Parameters F 1 Resistive G 4 Revision conseua 11 HF27 DC RESISTANCE WELDING SYSTEM Index 4 990 370 INDEX R Continued RS232 485 Select redeunte 3 8 1 7 3 19 5 vire Reife X eV 1 6 Schedule LOCK 3 6 Soreeninb DOE S G 10 Sef Force tare TO ZETO 10 Set New Electrodes to Zero 5 25 Set New Electrodes to Zero C 7 cT 2 3 vis 171 o 3 3 SUPL R 3 14 3 16 3 17 omele Pulse Weld Profile a ri 3 25 single Pulse Weld Schedule 5 3 Soit Touch Pressure 3 5 Bolt Dess i 3 5 S lder ot Braze OD G 2 Solid Stat Joint Reo eio tds 5 2 Space te sedan 2 3 1 STOP ENERGY 5 27 Switch Debounce Time 3 15 System Configuration 3 1 Geng 3 1 Before You 3 1 ys 3 1 hof 3 3 Mam Ment ERR 3 3
13. HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 5 21 CHAPTER 5 OPERATING INSTRUCTIONS 12 Make several more welds and verify that under normal circumstances the limits are not reached and the welds are not aborted If the limits are reached under normal welding conditions adjust the levels and times of the upper and lower voltage limits accordingly 13 Return to the RUN screen and make several welds Observe that under normal conditions the welds are not aborted and that consistent strong welds can be produced 14 Try making welds with only one part present Also try making welds with misaligned parts Observe that the power supply terminates the weld as soon as the voltage limits are reached If the voltage limits are not being reached with these conditions present return to the voltage monitor screen and adjust the limits accordingly 15 Return to the RUN screen and WELD STOP LIMIT REACHED 20000955 make several welds Verify that 1 the Weld Stop function detects missing and misaligned parts 400 2 400 002 05 50 0010 00 0 0 06 0 001 ms Weld Stop Waveform NOTE When using the Weld Stop function always select a monitor mode that 15 different from the feedback mode For example e If you are welding in constant current put limits on voltage e If you are welding in constant voltage put limits on current e If you are welding in constant power put limits on current or voltage HF27 DC RESISTANCE
14. 5 5 rowmummuwr 2 o 2 e smmurssummsr SOS HF27 LINEAR DC RESISTANCE WELDING CONTROL 990 3 0 E 25 APPENDIX E COMMUNICATIONS WELD STATUS CODES Wm SmusMemxe 0 7 6 SSTEMPARAMETERSARERESET 2 e mewosraowmuwr 2 wero Te TOOSWALL 0 SYSTEM ERROR SOFTWARE INTERRUPT s SYSTEM ERROR ILLEGAL INSTRUCTION System enon Diven py ZERO SYSTEM ERROR SPURIOUS INTERRUPT Lm 0000 TEST WELD MENU NO RUN YES 7 4 OOOO _ mosa 0 9 9 HF27 LINEAR DC RESISTANCE WELDING CONTROL E 26 990 370 APPENDIX E COMMUNICATIONS WELD STATUS CODES Wm satus message O O 2 we o roro nve zven OOOO OOO O ws SHECIEDSCHEDULEUMTS ANERESET O ws ws we we NEDTOSETMONTORUMI 2 no ACCESS DENIED CALIBRATIONLOCRON m gt OOOO wm macmwviwERUME _ a ms me we we __ 2 m 2 m mvoncemviwERUME 2 m
15. O 424kA 0000315 on the front panel press the kA prec 2 key to program an upper current limit on the MONITOR screen UPPER 37 ka 2 LOWER none STOP P1 STOP NOTE You can toggle between PEAK and AVERAGE readings by pressing the PEAK AVERAGE key 8 Press the COOL weld period PULSE 1 OUT OF LIMITS ACTION key This will bring up the PULSE 1 OUT OF LIMITS ACTION screen INHIBIT PULSE2 PART CONDITIONER Stop Pulse1 9 Select 4 PART CONDITIONER Stop 5 1 NUMBER Select MENU Previous menu NOTE For more details on this process see Active Part Conditioner in Chapter 4 Using Feedback Modes and Weld Monitoring 10 My Since different levels of oxide require different amounts of time to reach the current limit return to the RUN screen and extend the programmed weld time usually double the time works This will ensure that there will be enough time for the current to rise and reach the limit even with heavily oxidized parts HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 9 13 CHAPTER 5 OPERATING INSTRUCTIONS 11 12 5 14 Try welds with varying oxide clean and dirty The power supply terminates the first pulse when your programmed current is reached A clean part will reach the current limit sooner and the pulse will terminate early A dirty part will require more time before the oxide is broken down and current can flow Program your second welding pulse as O0
16. G 3 Material Variables G 7 POT G 3 MENU KEY M 1 7 T I 3 18 A NT 3 3 do E 1 7 Monitor 1 8 MONOT 3 20 INO Weld SEO 3 18 Non EZ AIR Weld Head Connections 2 0 OP 1 9 Operating Instructions 5 1 Active Part Conditioning 5 13 Distance 5 24 Displacement 5 24 Sree s 5 24 Before You Start Set New Electrodes to Zero 5 25 Changing from Inches to MM 5 25 Bienen t 5 24 5 28 High amp Low Limits for Initial Thickness 5 26 High amp Low Limits for DISDIaCemielil titia 5 27 HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 Index 3 INDEX O Continued STOP ENERGY AT Weld to a Specific Displacement 5 27 Energy 5 19 Envelope 5 30 0 5 1 Before You Start 5 1 5 2 Pre Operational Checks 5 Compressed 5 1 5 1 POW 5 5 3 Dual Pulse Weld Schedule 5 7 single Pul
17. SYNC lt crlf gt lt lf gt Any The Control return SYNC command back to the host computer when the SYNC command is received from the host computer gt 1 KA lt crlf gt TYPE2 KA lt crlf gt ENGI weld energy lt gt ENG2 weld energy lt gt lt gt RUN state Returns the Combo energy limits set for the current schedule HF27 LINEAR DC RESISTANCE WELDING CONTROL E 19 APPENDIX E COMMUNICATIONS Command Control State Description Command Control State Description Command Control State Description Command Control State E 20 TIME lt crlf gt UPPERI limit value lt crlf gt LOWERI limit_value lt UPPER2 limit_value lt crlf gt LOWER2 limit_value lt lt RUN state Returns the time limits set for the current schedule FORCE lt crlf gt UPPER limit_value lt LOWER limit_value lt crlf FIRE limit_value lt ACTION STOP lt crlf gt lt gt RUN state Returns the force limits VALVE lt crlf gt SOFT value lt crlf gt TIME time lt crlf gt FINAL value lt crlf gt lt RUN state Returns the pressure limits SYSTEM lt crlf gt LIGHT Light value lt gt BUZZER OFF ON lt crlf gt LOUDNESS loudness_value lt crlf gt DISPLAY PEAK AVG lt crlf gt SWSTATE switch state lt gt FIRES W AUTO REMOTE NONE lt crlf gt CTSTATE
18. gt lt gt Requests the Control to report the stored envelope When used with the READ keyword the current stored envelope waveform 15 returned see WAVEFORM under Control ORIGINATED COMMANDS When the SET keyword 15 used the host may set change the stored envelope waveform The following 15 a list of valid literal substitutions for the parameter name and value variables number of data points Total count of data points in this waveform pulse number P1 data for pulse 1 to follow P2 data for pulse 2 to follow type KA V IKW Envelope Type for pulse NOTE At least one space should be placed between each field in the title before the first lt crlf gt RELAY READ SET lt crlf gt parameter name value lt crif gt ss Any except while welding Provides control over the Control schedule parameters for relay settings When used with the READ keyword the relay settings of the currently loaded schedule are returned see RELAY under Control ORIGINATED COMMANDS When the SET keyword is used the host may set change the value of one or more of the relay settings of the currently loaded schedule The following is a list of valid literal substitutions for the parameter name and value variables ACTIVEI HIGH LOW Relay 1 Active High or Active Low CONDITIONI condition value Relay 1 Active Conditions SUBCONDI extended condition value Relay 1 Extended Conditions ACTIVE2 HIGH LOW Relay
19. 11 Make several more welds and inspect them for consistency of weld quality and or weld strength NOTE When using the Weld to a Limit function always select a monitor mode that 15 different from the feedback mode For example e If you are welding in constant current put limits on voltage e If you are welding in constant voltage put limits on current e If you are welding in constant power put limits on current or voltage HF27 DC RESISTANCE WELDING SYSTEM 5 20 990 370 CHAPTER 5 OPERATING INSTRUCTIONS Section VIII Weld Stop Note The Weld Stop function is similar to the Pre Weld Check function as both are used to detect missing or misaligned parts Both functions are used to stop the weld when a specific current voltage or power level is reached The Weld Stop function stops the weld in the actual welding pulse the Pre Weld Check uses a small pre pulse to stop the weld The Weld Stop function should only be programmed after a welding schedule which produces acceptable results has been developed The welding schedule includes the time and energy settings as well as the electrode force setting In the following steps a Constant Current weld is used as an example to show how the Weld Stop function 15 programmed 1 Press the SCHEDULE key then select a Weld Schedule using either the arrows or the numeric keypad 2 Program a single pulse for Constant Current operation as required to make strong consistent wel
20. DOON ___ _ 6 6_6_ 6 6 6______ _ _ _ _ 6 2 Ete VIO Sd ___ 6 3 6 12 Mn CS pt se is ap siesta ne ca 6 12 Ie PULS NETTE T 6 12 TV __ MEPE 6 13 HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 vii Appendix Appendix B Appendix C Appendix D Appendix E Appendix F Appendix G Appendix H viii CONTENTS Continued Page Technical Specifications 2 0 0 00 00 00000000000 1 Electrical and Data Connections 2 2 2222222222000 0 1 ellc m 1 e D 1 Communications 1 22 2 41 41 94 42 9 0 2 0 00 0 00000 0000 0200000004 1 The Basics of Resistance Welding 22 2002 22 22 1 1 Quality Resistance Welding Solutions Defining the Optimum Process 5 1 Compatibility and Comparison 22 2 x 8 EHE 1 27 DC RESISTANCE WELDING SYSTEM 990 370 05 Thank you for purchasing Miyachi Unitek Resistance Welding System Control Upon receipt of your equipment please thoroughly inspect it for shipping
21. For safety and to effectively take advantage of the full capabilities of the weld head and power supply please read these instruction manuals before attempting to use them Procedures other than those described in these manuals or not performed as prescribed in them may expose personnel to electrical burn or crushing hazards After reading these manuals retain them for future reference when any questions arise regarding the proper and safe operation of the power supply Please note the following conventions used in this manual WARNING Comments marked this way warn the reader of actions which if not followed might result in immediate death or serious injury CAUTION Comments marked this way warn the reader of actions which if not followed might result in either damage to the equipment or injury to the individual if subject to long term exposure to the indicated hazard HF27 DC RESISTANCE WELDING SYSTEM X 990 3 0 Engineering 5969 Robinson Ave Riverside 92503 851 637 2630 EN61010 1 2001 DECLARATION OF CONFORMITY Application of Council Directive 72 23 EEC Standards to which conformity is declared Manufacturer s Name Manufacturer 5 Address Equipment Description Equipment Class Model Number EN 61010 1 2001 Miyachi Unitek 1820 S Myrtle Ave Monrovia CA 91016 Welding Station 25 27 the undersigned hereby declare that the equipment specified above conforms to t
22. G 7 Quality G 7 Weld Head amp Mechanical Variables G 7 G 4 Common Problems ios remi arua G 9 Criteria for Success G 10 G 11 Factorial DOE G 11 Initial Welding Trials G 8 Application Perspective G 8 Process J erSpecll G 8 Introd uc G I Material Properties G 3 Conductive Metals etta G 3 Electrical amp Thermal Conductivity G 3 NN T G 3 Melting Point G 3 Refractory Metals G 4 gt G 4 Welding G I Fasion d oio aE ERR UNE G 2 OF Bra e Join acer G 2 Solid State Joint nci etis G 2 Serceninge DOE S G 10 Weld Proleg G 6 Quick Calibration Quick Cal C 6 R Rear Panel Components and Connectors 2 3 Recommended Gauge Thickness C 4 Isefraetory Metals G 4 3 9 3 15 6 13 Reset All Schedgles 3 11 Reset Schedule LIS 3 12 Reset System Parameters 3 11 Reset
23. WELD COUNTERS 7 RELAY MMC Dy COPY ASCHEDULE 8 RESET DEFAULTS pressing the MENU key on the front panel of the PROP VALVE 9 CHAIN SCHEDULES Control SYSTEM SECURITY of the menu screens have similar prompts that tell you how to go to a function on the menu and or get to the next menu Number Select an item e the NUMBER Select an item prompt use the numeric keypad to select one of the functions on the menu e Press the down AV keys to go to the next or previous menu Each additional menu gives you choices for additional functions e Press the MENU key to return to the main menu Main Menu 1 SETUP From the MAIN MENU screen press 1 to go to the SETUP page 1 of 3 SETUP 1 screen 1 FOOTSWITCH WELD ABORT 2 SWITCH DEBOUNCE TIME The SETUP 1 screen is shown on the right with 3 FIRING SWITCH typical settings Number Select V Page RUN or MENU From the SETUP 1 screen press the V key SETUP page 2 of 3 The SETUP 2 screen 15 shown on the right with 2 typical settings END OF CYCLE BUZZER OFF UPDATE GRAPH AFTER WELD LANGUAGE ENGLISH Number Select AW Page RUN or MENU From the SETUP 2 screen press the V key SETUP page 3 of 3 The SETUP 3 screen is shown on the right with 1 DO TEST WELD ALWAYS typical settings Number Select Page RUN or MENU HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 3 3 CHAPTER 3 SYSTEM CONFIGU
24. lt gt Returns the reference envelope waveform HF27 LINEAR DC RESISTANCE WELDING CONTROL E 21 APPENDIX E COMMUNICATIONS Command REPORT type of report number of reports lt crlf gt report crlf report crlf report lt gt lt gt Control State Any Returns the requested number of weld reports First field 1s the type of reports to be sent The second field 1s the number of reports sent Then follows the packets of report One report pack holds the information about the weld requested Each report packet 1s separated by crlf and this Command ends with lt crlf gt lt If gt Description Type of report This field defines the type of report that was requested by the host computer ALL This defines that a returned report will contain all fields of weld data The fields in the report packet are separated with a comma and all fields are in integer format There are always 37 fields in this report packet Report unit number schedule number weld status average current 1 average voltage 1 peak current voltage 1 average power 1 peak power l average resistance 1 peak resistance 1 time 1 null 1l average current 2 average voltage 2 peak current 2 peak voltage 2 average power 2 power 2 average resistance 2 peak resistance 2 time 2 null 2 disp units disp initial disp final disp displacement monitor limit disp SEA flag disp SEA time
25. 2 System Lock This function prevents unauthorized users from changing any of the options on the main menu It also prevents unauthorized users from changing weld energy time parameters within weld schedules 1 99 Note that schedule 0 15 a scratchpad and can still be edited when the System Lock is ON This security level allows you to select different schedules from the front panel 3 Calibration This function prevents unauthorized users from modifying any of the calibration settings NOTE All security options use the same procedure to enter a security code and to turn the security code OFF 1 Press the 1 key to select SCHEDULE lt STATUS LOCK This will bring up the CHANGE STATUS screen as shown at the right PASSWORD 2 Entera 7 digit number from 0000001 to 9999999 the code field and then NUMBERS for code followed by enter a period This will bring up the SYSTEM SECURITY menu screen this time with SCHEDULE LOCK ON With ON selected all other weld schedules are locked out and cannot be modified or used for welding 3 Tounlock the Control from security protection return to the CHANGE STATUS screen and enter the code that you entered in Step 2 This will bring up the SYSTEM SECURITY menu screen this time with SCHEDULE LOCK OFF 4 Ifyou forget the security code and wish to unlock the Control from security protection e Return to the CHANGE STATUS screen e Enter a security code of 280 HF2
26. 7 4 eMRKCONWOLSGNASINHUTSTATOS OOOO 3 3 FHWNGSWICHBEORPFOUTSWOH SIFONCONROLSGNMISINMT _ Power TRANSISTOROVERHEATED EMERGENCY STOP OPERATORACTIVATED o WELD TRANSFORMER OVERHEATED s e VOUAGESHECHONFLUGRMSSNG MBTCONOLSUNAISACIVATID m m NocuRRENTREADNG SSS 7 4 NOVOLTAGEREADNG 2 e LoapresistanceToomGH 22 NOWERDTRANTORMERDETKCHED CHECK VOLTAGE CABLE amp SECONDARY ORCO 19 eALIDRATIONRESETTODEFAULT O C a LOWER LIMIT GREATER THANUPPERUNT O m ADDED FOR DIFFERENT FEEDBACK SETTNGTOOSMALE 2 36 SWEENRGYUMTREACHED 2 ri verer omr verays apioso O O 39 rower umr DELAYS anwso 2 3 rure om peras aous 2 x momom OOS HF27 LINEAR DC RESISTANCE WELDING CONTROL E 24 990 370 APPENDIX E COMMUNICATIONS WELD STATUS CODES Wm satus messag 0 x OOOO ACCESS DENIEDISYSTENSECURTVON e ILLEGAL CODEENTERED OOOO Oa Ce foso mmwomewssmar OOOO 5 s s osaami s psmacwewrHGH WHDSOPDSRRENHED 2 5
27. Maximum D2 time is 2 ms plus switch debounce time 507 Squeeze time Selectable range 1 0 to 999 ms UP Up slope time Selectable range 15 0 0 to 99 0 ms WELD Weld time Selectable range 15 0 0 to 99 0 ms DOWN Down slope time Selectable range 15 0 0 to 99 0 ms COOL Cool time Selectable range 15 0 0 to 99 0 ms HOLD Hold time Selectable range 15 0 to 999 ms HF27 DC RESISTANCE WELDING SYSTEM 990 370 D 1 APPENDIX D SYSTEM TIMING Basic Weld Operation Manual Head System with Firing Switch Operation Remote Firing Switch Welding Current DELAY 502 UP WELD HOLD T Pulse 12 2 4 Definitions DELAY Delay time from firing switch closure to the start of the weld sequence that 15 start of SQZ Maximum DELAY time 15 2 ms plus switch debounce time 507 Squeeze time Selectable range is 0 to 999 ms UP Up slope time Selectable range 1 0 0 to 99 0 ms WELD Weld time Selectable range 15 0 0 to 99 0 ms DOWN Down slope time Selectable range 15 0 0 to 99 0 ms COOL Cool time Selectable range 15 0 0 to 99 0 ms HOLD Hold time Selectable range 15 0 to 999 ms HF27 DC RESISTANCE WELDING SYSTEM D 2 990 3 0 APPENDIX D SYSTEM TIMING Basic Weld Operation System with Remote Firing Switch NOTE The firing switch mode 15 selected under the Setup 1 menu Definitions DELAY SQZ UP WELD DOWN COOL HOLD 990 3 0 On Firing Switch
28. Of these only metals can be resistance welded because they are electrically conductive soften on heating and can be forged together without breaking HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 G 1 APPENDIX G DEFINING THE OPTIMUM PROCESS Alloys are a mixture of two or more metals An alloy is normally harder less conductive and more Alloy brittle than the parent metal which has bearing on the type of joint one can expect when resistance welding a combination of different metals UN Metals atoms are naturally attracted to other metal atoms even in different parent materials Metal B Metals and alloys will bond together once surface contaminants such as dirt grease and oxides removed Resistance welding generates heat at the material interface which decomposes the dirt and grease and helps to break up the oxide film The resultant heat softens or melts the metal and the applied force brings the atoms on either side into close contact to form the bond The strength of the joint develops as it cools and a new structure 1s formed There are three main types of bonds that can be formed using the resistance welding process Solder or Braze Joint A filler material such as a solder or braze compound 15 either added during the process or present as a plating or coating Soldered joints are typically achieved at temperatures less than 4009 and brazed joints such as Sil Phos materials melt at temperatures above 400 C So
29. Squeeze gt 20 Is 1 BCD Welding Schedule Selection Scheme Weld Bit 2 Bit 2 Bit 2 Bit 29 iti Pin 1 Pin 4 Pin 12 Pin 14 BCD progression from 5 to 98 HF27 DC RESISTANCE WELDING SYSTEM 990 370 B 15 APPENDIX ELECTRICAL AND DATA CONNECTIONS Relay Outputs Function Four mechanical relays on the control board can be independently programmed to supply alarm or weld status contact signal outputs You can access the programming function through the main menu as described Chapter 3 The events that you can program for each relay and their timing diagrams are as follows Relay contacts closed or open in the energized state Relays are energized when 1 Weld cycle starts 2 Weld cycle ends Time Relay Weld Cycle Energized Time 50 ms Relay Energized Relay will stay energized until 50 ms after weld cycle is complete 0 ms Relay will stay energized for 200 ms 3 Alarm state 15 detected 4 Weld is out of programmed limits Time Relay Out of Limits Energized Alarm Is Cleared Relay will stay energized until out of limits alarm is cleared Time Relay Alarm State Energized Is Cleared Relay will stay energized until alarm state is cleared HF27 DC RESISTANCE WELDING SYSTEM B 16 990 370 APPENDIX C Calibration Section l Calibrating the Control Overview The Control is calibrat
30. e Combo The pulse starts in either Voltage or Power using the above limits and has a current limit as shown above E20 6 Perform one of the following to program the Pulse 1 feedback mode From the CONTROL keys section on the front panel press the kA key to program current as the feedback mode From the CONTROL keys section on the front panel press the V key to program voltage as the feedback mode From the CONTROL keys section on the front panel press the kW key to program power as the feedback mode From the CONTROL keys section on the front panel press the COMBO key to program combo as the feedback mode 7 Press the PULSE 1 DOWNSLOPE key to enter the amount of time for the Weld Pulse 1 downslope Use the numeric keypad to enter the time or use the AV arrows Enter time between 0 and 99 milliseconds Note that in combo mode when the unit reaches a constant current any time programmed in this segment will be added to the weld at the constant current level HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 5 CHAPTER 5 OPERATING INSTRUCTIONS 8 10 5 8 Press the COOL key to enter the amount of time between Pulse 1 and Pulse 2 Use the numeric keypad to enter the time or use the AV arrows Enter a time between 0 and 99 milliseconds We recommend at least 2 milliseconds Program Pulse 2 by repeating Steps 3 through 7 above using the keys for Pulse 2 entering appropriate values for Pulse
31. e The time in any element of the schedule changes e Ifthe weld energy field is highlighted and the V key is pressed HF27 DC RESISTANCE WELDING SYSTEM 990 370 3 17 CHAPTER 3 SYSTEM CONFIGURATION Section Ill Operational States The Control has seven operational states NO WELD WELD MENU MONITOR TEST ALARM RUN You go to the NO WELD MENU TEST RUN and MONITOR states through the control panel The WELD and ALARM states are functions of the force firing switch and foot switch input states No Weld State setting the WELD NO WELD switch on the control panel to the NO WELD position inhibits the delivery of weld energy if a weld is initiated and will display a WELD SWITCH IN NO WELD POSITION alarm on the screen But the Control will still go through its electronic weld cycles as programmed into the selected weld schedule Use the no weld state when adjusting the air regulators on air actuated weld heads Menu State Pressing the MENU key puts the Control in the MAIN MENU gt menu state It brings up menu screens that SETUP 6 COMMUNICATIONS WELD COUNTERS 7 RELAY enable you to select various options common to SCHEDULE B PE ET DEFAULTS all weld schedules such as how the Control PROP VALUE 9 CHAIN SCHEDULES interfaces with the force firing switch foot SYSTEM SECURITY switch and weld head Number Select item g 300V 2 900 Test State Programming a schedule for a voltage feedback OOOOA24 welding
32. 2 o feedback on the actual current voltage or PME 2 power used to make each weld It permits 7 you to program adjustable limits for both Tun UPPER 37 ka 0 500 weld pulses LOWER none STOP P1 none _ STOP Monitor Screen HF27 DC RESISTANCE WELDING SYSTEM 1 2 990 3 0 CHAPTER 1 DESCRIPTION Rear mounted RS 232 and RS 485 connectors allow for remote programming weld schedule selection and data logging for SPC purposes The Control has communication and data options that allow you to connect a single Control or multiple Controls to a printer or a computer in order to Compile store view and print weld history data for detailed analysis Remotely program weld schedules on the Control s Remotely program menu items on the Control s Appendix E Communications in this manual lists all of the commands that the Control will respond to and instructions on how to format commands sent to the Control so it will respond properly These commands have been implemented in Amada Miyachi America s Weld Stat program that provides PC based communication and control of the HF27 e The Control has a Linear Variable Differential Transformer LVDT function that allows the user to Measure Initial Part Thickness Measure Final Part Thickness Measure displacement during welding Stop the weld energy after a programmable displacement is reached Programm
33. 96 P1 JOULES lt LOWER LIMIT 6 8 Actual weld current is less than the user set Lower Limit value for Weld at the Current Monitor screen Actual weld voltage is greater than the user set Upper Limit value for Weld2 at the Voltage Monitor screen Actual weld voltage current is less than the user set Lower Limit value for Weld2 at the Voltage Monitor screen Actual weld power 15 greater than the user set Upper Limit value for Weld2 at the Power Monitor screen Actual weld power 15 less than the user set Lower Limit value for Weld2 at the Power Monitor screen The user set Upper Limit value has been exceeded and automatically terminated the weld energy During LVDT gauge calibration the thin value is greater than or equal to the thick value During LVDT gauge calibration the LVDT calibration thickness minimum delta Pulse 1 energy in Joules exceeded the upper limit Pulse 1 energy in Joules did not reach the lower limit Weld splash can cause the actual weld current to drop below the user set Lower Limit for Weld2 Add upslope to reduce weld splash Reset the lower Limit for Weld2 to a smaller value Weld splash can cause the actual weld voltage to exceed the user set Upper Limit for Weld2 Add upslope to reduce weld splash Reset the Upper Limit for Weld2 to a larger value Reduce the weld cable length or increase the diameter of the weld cables Reset the Lower Limit for Weld2 to a smaller
34. LOWER LIMIT 6 10 System security has locked out calibration changes Squeeze time increased for the MG3 The MG3 must have a squeeze time of at least 50ms If programmed squeeze time is less than this it 1s forced to that value Pulse 1 current exceeded the envelope upper limit Pulse 1 current did not reach the envelope lower limit Pulse 1 voltage exceeded the envelope upper limit Pulse 1 voltage did not reach the envelope lower limit Pulse 1 power exceeded the envelope upper limit Pulse 1 power did not reach the envelope lower limit Pulse 1 LVDT displacement exceeded the envelope upper limit Pulse 2 LVDT displacement did not reach the envelope lower limit Pulse 2 current exceeded the envelope upper limit Pulse 2 current did not reach the envelope lower limit Pulse 2 voltage exceeded the envelope upper limit Pulse 2 voltage did not reach the envelope lower limit Unlock calibration changes at the system security screen If welds are good and message consistently happens set envelope limits broader or remove them altogether If welds are good and message consistently happens set envelope limits broader or remove them altogether If welds are good and message consistently happens set envelope limits broader or remove them altogether If welds are good and message consistently happens set envelope limits broader or remove them altogether If welds are good and message consist
35. Press MENU to return to the MAIN MENU 2 Baud Rate The baud rate at which the data 1s sent must match the baud rate of the host computer To enter the baud rate proceed as follows l 2 From the COMMUNICATION menu lt BAUD gt press the 2 key to get the BAUD RATE 1200 6 19 2 face 2400 7 28 8 selection screen A800 8 384K Use the numeric keypad to select the e baud rate of the receiving device The ai display automatically returns to the Number Select Page or MENU COMMUNICATION menu which shows the new baud rate Press MENU to return to the MAIN MENU 3 RS232 485 SELECT Pressing the 3 key will alternately select either RS232 or 5485 communications The default selection is RS232 4 1 0 Number The host computer may be used to talk with multiple Controls using a single 5 485 communications line Each Control sharing that line must have a unique identification number To enter an identification number for the Control proceed as follows l 3 8 From the MAIN MENU press the 6 key lt 1 0 NUMBER to go to the COMMUNICATIONS MENU I D NUMBER 01 From the COMMUNICATIONS MENU screen press the 3 key to get the 1 0 NUMBER entry screen Number Select Page or MENU Enter a two digit number from 01 to 30 in the 1 0 NUMBER field Press the MENU key to get the COMMUNICATION menu screen This time the 1 0 NUMBER line will display your I D number entry Pr
36. from an operational standpoint it performs the same as older Miyachi Unitek Controls Older HF27 Models 1 287 01 1 287 01 01 1 287 01 02 require a different User s Manual Part Number 990 335 For information on getting that manual use the phone number or e mail address listed under Contact Us in the front of this manual Below 1s a Quick Look comparison showing the differences between old HF25A HF25DA HF27A Models 1 280 xx 1 285 xx 1 287 xx and new HF25 HF27 Models 1 315 xx 1 320 xx The HF25DA features have been incorporated into the HF27 HF25A NO HF25 NO LVDT connector HF25DA YES HF25D Not available HF27A YES 27 SAME YES new 8 pin connector incorporating Firing switch voltage sense and 24VDC valve output for new plug and play weld Weld Head connector heads used with new EZ AIR plug and play weld heads Emergency Stop cable SAME 60 pin Phoenix connectors Physically smaller size Appendix Electrical and Data Connections describes Software selection for YES polarity of input and mech opto type 10V to 10V HF27 ONLY Force output range 0 to 10V and 0 to 5V HF25DA and HF27 ONLY HF27 ONLY Force input range 10 to 10V 0 to 10V and 0 to 5V 24VDC output for customer YES limited to about 500mA with YES polyfused to 1 amp without voltage drop use voltage drop Upgrade from HF25 to HF27 YES at factory Eliminated no longer necessary S S S S HF27 DC RESISTANCE WELDING
37. number 3 Press 3 to access the next level menus which are shown on the next page Number Select Page RUN or MENU HF27 DC RESISTANCE WELDING SYSTEM 5 32 990 370 CHAPTER 5 OPERATING INSTRUCTIONS P1 amp P2 WHEN kA amp V WHEN OUT OF LIMITS 6 P2 HIGH kA LIMIT P2 kA LOW P1 OUT OF LIMITS 7 P2LOW V LIMIT P1 V HIGH P1 HIGH P1 kA HIGH P1 VLOW P1LOW P1 kA LOW P2 V HIGH P2 OUT OF LIMITS P2 kA HIGH P2 V LOW Number Select Page RUN MENU Number Select Page RUN or MENU Option 5 Option 6 lt kW amp R WHEN gt lt OTHER WHEN gt kW LIMIT P2 kW LOW FORCE LIMIT ENERGY LO R LIMIT P1 R HIGH START FORCE TIME LIMIT P1 kW HIGH P1 RLOW END FORCE TIME HIGH Pi kW LOW P2 R HIGH ENERGY LIMIT LOW P2 kW HIGH P2 R LOW ENERGY HI ENVELOPE LIMIT Number Select Page RUN or MENU Number Select Page RUN or MENU Option 7 Option 8 LVDT WHEN ANY DISPLLO INITIAL LO DISPL HI INITIAL HI INITIAL NG FINALLO DISPL NG FINAL HI STOP ENERGY AT Number Select Page RUN or MENU Option 9 HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 5 33 6 Maintenance Section l Introduction General Kinds of Problems It has been our experience that most resistance welding power supply problems are caused by lack of material control process control and electrode tip surface maintenance The proble
38. off time 1 off time 2 energy 1 energy 2 start force end force weld count P1 This defines that a returned report will contain only fields pertaining to Pulse 1 of the weld data The fields in the report packet are separated with a comma and all fields are in integer format There are always 17 fields in this report packet Report unit number schedule number weld status average current average voltage 1 peak current 1 peak voltage 1 average power 1 peak power 1 average resistance I peak resistance 1l time 1 off time 1 energy 1 start force end force weld count P2 This defines that a returned report will contain only fields pertaining to Pulse 2 of the weld data The fields in the report packet are separated with a comma and all fields are in integer format There are always 17 fields in this report packet Report unit number schedule number weld status average current 2 average voltage 2 peak current 2 peak voltage 2 average power 2 peak power 2 average resistance 2 peak resistance 2 time 2 off time 2 energy 2 start force end force weld count LVDT This defines that a returned report will contain only fields pertaining to displacement weld data The fields the report packet are separated with a comma and all fields are in integer format There are always 10 fields in this report packet Report unit number schedule number weld status disp units disp initial disp fi
39. plating 2 Wrong electrode material 2 Contaminated electrode surface Weld Piece Warping l Contaminated weld piece surface plating Wrong electrode material tip shape Insufficient weld head force Excessive current energy set at HF27 25 Excessive weld time set at HF27 25 Contaminated electrode surface Slow weld head follow up Metal Expulsion 1 Insufficient current energy set at HF27 25 Wrong electrode material tip shape Worn mushroomed electrodes Insufficient weld time set at HF27 25 Incorrect weld head polarity Contaminated weld piece surface plating 2 Excessive weld head force 3 Insufficient weld head force 3 Contaminated electrode surface 3 Incompatible weld piece projection design 3 Slow weld head follow up 4 Incompatible weld piece materials 4 No cover gas on weld piece Excessive current energy set at HF27 25 Insufficient weld head force Slow weld head follow up 1 1 1 1 Incompatible weld piece projection design 1 1 2 2 Contaminated weld piece surface plating Wrong electrode tip shape Wrong electrode material Contaminated electrode surface Excessive weld time set at HF27 25 Excessive weld head force Incompatible weld piece projection design 2 Incompatible weld piece materials 2 Wrong electrode tip shape 3 Excessive current energy set at HF27 25 Excessive current energy set at HF27 25 Insufficient weld head force Slow weld head follow up Incomp
40. to the appropriate graph to show the cupri programmed limits The screen on the right shows how the UPPER and LOWER UPPER and LOWER Limits and Alarm actions appear when Limits FOR PULSE 1 Limits FOR PULSEZ an actual weld trace 15 displayed on the Alarm Action Alarm Action for PULSE 1 for PULSE 2 LCD 11 After entering or changing monitor limits you must press either the appropriate MONITOR or RUN buttons to save the changes If this 15 not done the last input field will remain highlighted and the changes will not be saved to memory Any welds done in this condition will use the older unedited values still stored the memory HF27 DC RESISTANCE WELDING SYSTEM 990 370 5 11 CHAPTER 5 OPERATING INSTRUCTIONS 10 11 5 12 NOTE lower limits apply only to the Pulse 1 and Pulse 2 WELD periods Lower limits do not cover any upslope or downslope periods All upper limits apply to the entire Pulse 1 and Pulse 2 periods including their upslope and downslope periods Set an UPPER LIMIT and LOWER LIMIT using the procedures in Section III Programming the Weld Monitor Perform a weld to see how the limits dotted lines appear compared to the weld graph R aise or lower the UPPER LIMIT and LOWER LIMIT as necessary using the procedures in Section III Programming the Weld Monitor To lengthen or shorten the time periods go to the MONITOR screen Press the UPSLOPE key for PULSE 1 or PULSE 2 to get the MONITOR LIMITS
41. 2 Active High or Active Low CONDITION2 condition value Relay 2 Active Conditions SUBCOND2 extended condition value Relay 2 Extended Conditions ACTIVE3 HIGH LOW Relay 3 Active High or Active Low CONDITION3 condition_value Relay 3 Active Conditions SUBCOND3 extended condition value Relay 3 Extended Conditions 4 HIGH LOW Relay 4 Active High or Active Low CONDITION4 condition_value Relay 4 Active Conditions SUBCOND4 extended condition value Relay 4 Extended Conditions ALARM LIMITS WELD END P1 P2 KA V KW R OTHER MG3 DISP condition_value HF27 LINEAR DC RESISTANCE WELDING CONTROL APPENDIX E COMMUNICATIONS NOTE extended condition value not valid unless condition value 15 P1 P2 or KW R or OTHER DISP extended condition value for 2 LIMITS PIOUT P1HI PILOW P20UT P2HI P2LOW for KALIMIT VLIMIT PIKAHI PIKALOW 2 P2KALOW PIVHI PIVLOW P2VHI P2VLOW for KW R KWLIMIT RLIMIT PIKWHI PIKWLOW PZKWHI P2KWLOW PIRHI PIRLOW P2RHI P2ARLOW for OTHER FRLIMIT STFORCE EDFORCE EGLIMIT EGHI EGLOW TMLIMIT TMHI TMLOW ENVLIM for DISP ANY I IHI FLO FHI DLO DHI INII SEA NOTES P1 P2 condition value explanations LIMITS Pulse 1 or Pulse 2 out of limits P1OUT Pulse 1 out of limits PILOW Pulse 1 hi low limit reached P2OUT Pulse 2 out of
42. 300 447 0020031 2 2 36 8 220 O O 1 0 Q O 1 0 Q O 3 0 001 ms Pre Weld Check Waveform Example To detect misaligned parts use constant current and set upper and lower voltage limits for Pulse 1 If parts are misaligned the work piece resistance will be higher so the voltage will be higher If parts are missing voltage will be lower In either case the Pulse 1 upper or lower limits will be exceeded and Pulse 1 can be inhibited NOTE You must have upslope programmed into the pulse in order to set a lower limit In addition to inhibiting the weld the Control has four programmable relay outputs which can be used to trigger alarms to signal operators of weld faults or signal automation equipment to perform pre programmed actions such as stopping the assembly line so the faulty weld piece can be removed HF27 DC RESISTANCE WELDING SYSTEM 4 8 990 3 0 CHAPTER 4 INTRODUCTION TO FEEDBACK MODES AND MONITORING 4 Weld To A Limit Applications e Parts with narrow weld window e Part to part positioning problems e Electrode to part positioning problems Function To stop the weld when a sufficient current voltage or power level is reached Using limits in this way ensures a more consistent input of energy which produces consistently good welds Description This function terminates the weld energy during the welding process if pre set weld current voltage or power limits ar
43. 300kA peak 0 447 0020031 normal to achieve a strong weld 2 Constant voltage is recommended for round parts and constant current for flat MT T1 A lt 15mq 3 250V parts An upslope may be required to 020 50 08 20 30 10 00 OOO ms restrict the current flow early in the second pulse and avoid weld splash HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 CHAPTER 5 OPERATING INSTRUCTIONS Section V Resistance Set Note The Resistance Set tool is very similar to the Active Part Conditioning tool The difference 15 that the first pulse 15 programmed as all Upslope for Resistance Set where it is programmed as all Weld Time Square Wave for Active Part Conditioning The Resistance Set pulse 16 programmed as all Upslope to keep both the Voltage and Current low at the beginning of the pulse 1 Press the SCHEDULE key then select Weld Schedule using either the AV arrows or the numeric keypad 2 Program a single pulse for Constant Power operation but program the time in the Upslope portion of Pulse 1 Program the Weld Time and Downslope of Pulse 1 to 0 0 ms Program the power level and Upslope time to cause slight sticking between the two parts Make a few welds and pull them apart Increase or decrease the power setting until a light tack weld is achieved From the MONITOR keys section on the front panel press the voltage V key and observe gradual rise of the voltage waveform From the MONITOR keys section on the front p
44. BROWN TEN TO HF27 OY BLACK TO HF27 POWER r gt POWER CIRCUIT CIRCUIT QX BLUE CGND GREEN YELLOW 7 INSIDE THE HF27 EXTERNAL POWER CABLE NOTES 1 Measure building voltage from phase to phase not from phase to ground 2 The cable power leads are not phase dependent and may be connected to any of the 3 power connector pins Only the green yellow lead is dedicated to chassis ground CAUTIONS e Be sure that the shop source power is appropriate for your Control model e Ifthe blue phase wire 15 not connected no alarm will occur and the weld control will produce more than 20 ripple in the weld output waveform HF27 DC RESISTANCE WELDING SYSTEM 990 370 B 4 APPENDIX ELECTRICAL AND DATA CONNECTIONS Section ll Connectors Overview The control can be configured several different ways in order to match your welding needs Configuration 1s achieved by using the pre wired Configuration Plug and by fabricating your own I O cables using five un wired plugs of these connectors are supplied in the Ship Kit Complete connection information 15 in Section I O Configuration Before fabricating I O cables you should be familiar with the physical characteristics of the Control s I O connectors 60 Pin Connector REAR PANEL The 60 pin I O connector 15 located on the Control s rear panel as shown on the right This connector can accommodate six 10 pin plugs including the factory supplied Configurat
45. Description Provides control over the basic weld monitor settings of the Control schedule When used with the READ keyword the basic weld monitor settings of the currently loaded schedule are returned see MONITOR under Control ORIGINATED COMMANDS When the SET keyword is used the host may set change the value of one or more of the parameters of the basic weld monitor settings pertaining to the currently loaded schedule The following is a list of valid literal substitutions for the parameter name and value variables 1 Monitor for pulse 1 ACTIONI STOP INHIBIT APC Out of Limit Action for pulse 1 limit value Upper Limit for pulse 1 LOWERI value Lower Limit for pulse 1 MONTYPE2 KAI VI KWIR j Monitor Type for pulse 2 ACTION2 STOP Out of Limit Action for pulse 2 UPPER2 limit_value Upper Limit for pulse 2 LOWER2 limit_value Lower Limit for pulse 2 PILDLY1 delay value Pulse 1 Lower Delay Start Time For Lower Limit PILDLY2 delay value Pulse 1 Lower Delay End Time For Lower Limit PIUDLY1 delay_value Pulse 1 Upper Delay Start Time For Upper Limit PIUDLY2 delay value Pulse 1 Upper Delay End Time For Upper Limit P2LDLY1 delay value Pulse 2 Lower Delay Start Time For Lower Limit P2LDLY2 delay value Pulse 2 Lower Delay End Time For Lower Limit P2UDLY1 delay_value Pulse 2 Upper Delay Start Time For Upper Limit
46. KA V KW R or OTHER or DISP extended condition value for PI P2 LIMITS P1IOUT P1HI PILOW P20UT P2HI P2LOW for KALIMIT VLIMIT PIKAHI PIKALOW P2KAHI 2 PIVHI PIVLOW P2VHI P2VLOW for KW R KWLIMIT RLIMIT PIKWHI PIKWLOW PZKWHI P2KWLOW PIRHI PIRLOW P2RHI P2ARLOW for OTHER FRLIMIT STFORCE EDFORCE EGLIMIT EGHI EGLOW TMLIMIT TMHI TMLOW ENVLIM for DISP ANY I ILOIIHI FLO FHI DLOIDHIIINI DSP SEA HF27 LINEAR DC RESISTANCE WELDING CONTROL 990 370 APPENDIX E COMMUNICATIONS NOTES P1 P2 condition value explanations LIMITS Pulse 1 or Pulse 2 out of limits P1O0UT Pulse 1 out of limits P1ILOW Pulse 1 low hi limit reached P20UT Pulse 2 out of limits P2HI P2LOW Pulse 2 low hi limit reached condition value explanations KALIMIT Current Limit Reached VLIMIT Voltage Limit Reached PIKALOW Pulse 1 Current low hi error P2KAHI P2KALOW Pulse 1 Current low hi error PIVLOW Pulse 2 Voltage low hi error P2VHI P2VLOW Pulse 2 Voltage low hi error KW R condition value explanations KWLIMIT Power Limit Reached RLIMIT Resistance Limit Reached PIKWHI PIKWLOW Pulse 1 Power low hi error P2KWHI P2KWLOW Pulse 1 Power low hi error P1RHI PIRLOW Pulse 2 Resistance low hi error P2RHI P2RLOW Pulse 2 Resistance low hi error OTHER condition value explanations FRLIMIT
47. LIMIT 990 3 0 Actual weld voltage is greater than the user set Upper Limit value for Weldl at the Voltage Monitor screen Actual weld voltage current is less than the user set Lower Limit value for Weldl at the Voltage Monitor screen Actual weld power 15 greater than the user set Upper Limit value for Weldl at the Power Monitor screen Actual weld power 15 less than the user set Lower Limit value for Weldl at the Power Monitor screen Actual weld resistance 15 greater than the user set Upper Limit value for Weldl at the Resistance Monitor screen Actual weld resistance 15 less than the user set Lower Limit value for Weldl at the Resistance Monitor screen User programmed the HF27 25 to automatically reset all 100 weld schedules to their factory set default values User programmed the HF27 25 to automatically reset all I O and other system parameters to their factory set default values The user has attempted to program zero for all upslope weld and downslope time periods Actual weld current is greater than the user set Upper Limit value for Weld2 at the Current Monitor screen Weld splash can cause the actual weld voltage to exceed the user set Upper Limit for Weld1 Add upslope to reduce weld splash Reset the Upper Limit for Weldl to a larger value Reduce the weld cable length or increase the diameter of the weld cables Reset the Lower Limit for Weldl to a smaller value Weld splash can cause
48. Mr 1 1 Control Features 1 1 Weld Quality Process Tools 1 1 Introd Ue 1 2 1 11 Major Components 1 4 CYS 1 7 Control Mode Selection Keys 1 8 KATOV 1 8 1 8 EN EET 1 8 1 8 e 1 8 21 1 9 1 9 DISTANCE 1 9 ENERGY 1 10 HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 Index 1 INDEX D Continued ENVELOPE Ky iin 1 9 FORCE 1 9 1 8 4 1 9 1 10 ba A 1 9 1 9 Front Panel Data Entry and Mode Keys 1 7 I VP iiie MIU ESO MEME 1 7 M de Keyi M ee ais 1 7 1 7 RUN 1 7 Front Panel Display amp Display Controls 1 4 ior A 1 5 Display Controls 1 6 SCHEDULE Key 205 1 6 Time Energy Selector Keys 1 6 Weld Period Selector Keys 1 6 Major Components 1 4 WELD NO WELD Switch 1 10 Emergency Stop Switch Operation 1 10 deed Hed Ute 5 24 ccm 1 5 Display Contrast 3 16 Display Gio na a dpt rA 1 6 DISTANCE c 1 9 Distance asninn 4 4 Distance Di illl
49. P1 amp P2 Number Select Page RUN or MENU RELAY 1 gt 1 SET RELAY TO N 2 WHEN OUT OF LIMITS Number Select Page RUN or MENU RELAY 1 gt 1 SET RELAY TO ON 2 WHEN OUT OF LIMITS 3 kW amp R WHEN kW LIMIT Number Select Page RUN or MENU 990 3 0 HF27 DC RESISTANCE WELDING SYSTEM 3 9 CHAPTER 3 SYSTEM CONFIGURATION P1 amp P2 WHEN OUT OF LIMITS P1 OUT OF LIMITS P1 HIGH P1LOW P2 OUT OF LIMITS 6 P2 HIGH 7 P2LOW kA amp V WHEN kA LIMIT P2 kA LOW V LIMIT P1 V HIGH P1 kA HIGH P1 V LOW LOW P2 V HIGH P2 kA HIGH P2VLOW Number Select Page RUN MENU Number Select Page RUN MENU Option 5 Option 6 kW amp R WHEN OTHER WHEN kW LIMIT P2 kW LOW FORCE LIMIT ENERGY LO R LIMIT P1 R HIGH START FORCE TIME LIMIT P1 kW HIGH P1 RLOW END FORCE TIME HIGH P1 kW LOW P2 R HIGH ENERGY LIMIT LOW P2 kW HIGH P2 R LOW ENERGY HI ENVELOPE LIMIT Number Select Page RUN or MENU Number Select Page RUN or MENU Option 7 Option 8 lt LVDT WHEN gt ANY DISPL LO INITIAL LO DISPL HI INITIAL HI INITIAL NG FINALLO DISPL NG FINAL HI STOP ENERGY AT Number Select Page RUN or MENU Option 9 8 RESET TO DEFAULTS From the MAIN MENU press the 8 key to go to RESET TO DEFAULTS the RESET TO DEFAULTS menu as shown at the 1 RESET SYST
50. P2UDLY2 delay value Pulse 2 Upper Delay End Time For Upper Limit HF27 LINEAR DC RESISTANCE WELDING CONTROL 990 370 9 APPENDIX E COMMUNICATIONS Command Control State Description E 10 limit value 15 the parameter that specifies the range of the valid readings If the reading was within the range of the imit value no alarm will occur If the reading was out of the valid range an alarm will occur If the monitor type is KA the imit value 15 in unit of 1A If the monitor type is V the imit value is in unit of ImV If the monitor type is kW the limit value is in unit of IW The valid number for limit value is 1 through 9999 and 0 is for none The delay value is the parameter that defines the time for the given period in 0 1ms Valid range is from 0 to 99 Lower delay value 15 only valid during WELD time Upper delay value is valid during UP time WELD time and DOWN time ENVLIMIT READ SET crlf parameter name value lt crlf gt lt gt Provides control over the basic welding envelope limit settings of the current schedule When used with the READ keyword the basic welding envelope limit settings for the currently loaded schedule are returned see ENVLIMIT under Control ORIGINATED COMMANDS When the SET keyword is used the host may set change the value of one or more of the parameters of the basic welding envelope limit settings pertaining to the currently loaded schedule The following is a lis
51. STFORCE Starting force limit reached EDFORCE Ending force limit reached EGLIMIT Energy limit reached EGHI EGLOW Energy low hi limit reached TMLIMIT Time limit reached TMHI TMLOW Time low hi limit reached DISP condition value explanations ANY Any displacement error ILO IHI Initial thickness low hi error FLO FHI Final thickness low hi error DLO DHI Final displacement low hi error INI Initial thickness error DSP Any final displacement error SEA Stop energy at error Control State Description Reports the relay settings HF27 LINEAR DC RESISTANCE WELDING CONTROL 990 370 3 APPENDIX E COMMUNICATIONS Command Control State Description Command Control State Description Command Control State Description E 32 SECURITY crlf SCHEDULE ON OFF lt crlf gt SYSTEM ON OFF lt gt CALIBRATION ON OFF lt crlf gt lt lf gt Any Returns the current status of the security settings DISP schedule number lt cr f gt INITLO Linitial thick lo lt crlf gt INITHI Linitial thick hi lt gt FINALLO final thick lo lt crlf gt FINALHI final hi lt crl gt DISPLO displacement lo gt DISPHI displacement hi lt gt DISPWT displacement lt crlf gt UNITS IN 1000 MM lt crlf gt INITERR CONT STOP lt crlf gt et Any except while welding Reports the current settings of the Control system displacem
52. SYSTEM 990 3 0 CHAPTER 5 OPERATING INSTRUCTIONS Section IV Active Part Conditioning 1 Press the SCHEDULE key then select Weld Schedule using either the arrows or the numeric keypad 2 Program a single pulse for Constant Power operation Program the power level and weld time to cause slight sticking between the two parts Make a few welds and pull them apart Increase or decrease the power setting until a light tack weld 15 achieved 3 w From the MONITOR keys section on the front panel press the voltage V key and observe the high peak of the voltage waveform 4 From the MONITOR keys section on the front panel press the resistance key and observe the resistance waveform This should appear to begin high then start to drop as a tack weld is made and oxides are removed 5 From the MONITOR keys section on the front panel press the kA current key and observe the current waveform starting to rise as the oxidization breaks down If the current waveform starts to flatten this 1s an indication that the resistance has stabilized and the parts have come into closer contact 6 Push RUN and optimize the energy and time setting of Pulse 1 constant power to provide an adequate tack weld and also a current waveform view in the monitor screen that has started to flatten out but 1s still rising This indicates that a full melt has not yet occurred ys From the MONITOR keys section MONITOR 0 373kA
53. Weld Head Connector The Weld Head Connector combines all the inputs and outputs necessary to connect a plug and play EZ AIR Miyachi Unitek weld head Using the supplied Configuration plug on Pins 11 20 allows the use of the Miyachi Unitek 2 level footswitch directly If PLC or other means of trigger is used refer to the I O Signal Interface General Description on page B 3 Weld Head Connector Description HEAD 1 switched 24V common for solenoid 24V OUT 24VDC for solenoid 24COM FIRE 1 PIN 6 PIN 5 PIN 8 VOLT IN VOLT COM AIRHEAD Not used HF27 DC RESISTANCE WELDING SYSTEM 12 990 370 UJ APPENDIX B ELECTRICAL AND DATA CONNECTIONS LVDT Connector The LVDT connector provides the inputs for the LVDT sensor LVDT Connector Description LVDTPRI 1 LVDTPRI 2 LVDTSEC 1 LVDT GND LVDT GND LVDTSEC 2 Force Firing Switch Cable Input Function The force firing switch input to the Control from the weld head signals that the selected pressure has been applied to the weld pieces Note that a mechanical firing switch 1s subject to contact bounce which can cause false weld starts The effects of switch bounce can be avoided at low weld speeds by using the switch debounce function on the Control main menu If welding speeds are to exceed 1 5 welds per second use an optical firing switch Connections The firing switch cable 15 5 feet long Type 2 C 600 volt cable containing two shielded twisted pair 22 AWG str
54. access to the Control alarm logic When used with the READ keyword the current error condition value is returned See Appendix A for list of alarm messages When the CLEAR keyword is used all alarm conditions are canceled When the SET keyword is used the host may invoke an error identified by error number When the DISPLAY keyword 15 used an error condition can be created with any message desired The length of the error message must be limited to 40 characters or less No help message will be available in connection with this created error message TIME READ SET lt crlf gt parameter name value lt crlf gt lt gt RUN state Provides control over the Control schedule parameters When used with the READ keyword all parameters pertaining to the currently loaded schedule are returned see SCHEDULE under Control ORIGINATED COMMANDS When the SET keyword 15 used the host may set change the value of one or more of the parameters pertaining to the currently loaded schedule The following is a list of valid literal substitutions for the parameter name and value variables UPPER1 limit value Upper Time Limit for pulse 1 LOWERI limit value Lower Time Limit for pulse 1 UPPER2 limit value Upper Time Limit for pulse 2 LOWER2 value Lower Time Limit for pulse 2 FORCE READ SET lt crlf gt parameter name value lt crlf gt lt gt RUN state Provides control over the Control schedule param
55. among LBS pounds KG kilogram force or N Newtons 3 Soft touch pressure This function allows the user to program a lower pressure that 15 applied as the weldhead 15 closing This soft touch pressure which 15 maintained for the soft touch time see 4 below causes the weldhead to come down at a slower speed than if the full weld pressure were used This setting can be used to reduce deformation on round parts parts with projections or more delicate parts 4 Soft touch time This function allows the user to program the duration of lower pressure that 15 applied as the weldhead 15 closing This time starts as soon as the solenoid valve closes and runs for the user programmed time Note that squeeze time will not start until soft touch time 1s over and the firing switch if any is closed HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 3 5 CHAPTER 3 SYSTEM CONFIGURATION 5 SYSTEM SECURITY From the MAIN MENU press the 5 key to go to up SYSTEM SECURITY gt SYSTEM SECURITY screen With this screen 1 SCHEDULE LOCK OFF you can protect the weld schedules from 2 SYSTEM LOCK OFF 3 CALIBRATION OFF unauthorized changes by programming the Control with a user defined protection code NUMBERS Select an item RUN or MENU 1 Schedule Lock This function prevents unauthorized users from selecting any weld schedule other than the displayed schedule and from changing any weld energy time parameters within the weld schedule
56. and compares the measurements against the programmed limits NOTE When using the energy limits monitor always select a monitor mode that 15 different from the feedback mode For example e If you are welding in constant current monitor voltage e If you are welding in constant voltage monitor current e If you are welding in constant power monitor current or voltage HF27 DC RESISTANCE WELDING SYSTEM 4 10 990 370 CHAPTER 5 Operating Instructions Section Introduction Before You Start Before operating the Control you must be familiar with the following e The location and function of Controls and Indicators For more information see Chapter 1 of this manual e How to select and use the Control functions for your specific welding applications For more information see Chapter 3 System Configuration e The principles of resistance welding and the use of programmed weld schedules For more information see Appendix E The Basics of Resistance Welding For additional information on the welding process see Appendix F Quality Resistance Welding Solutions Defining the Optimum Process Pre Operational Checks Always perform these checks before attempting to operate the Control Connections Verify that the Control has been connected to a manual or air actuated weld head as described in Chapter 2 of this manual Verify that the Emergency Stop Switch shorting wires are connected or verify that an Emergency Stop Switch i
57. are as listed Verify that the Control shows signs of damage If it does please contact the carrier Also contact Amada Miyachi America Customer Service immediately at the postal or e mail address or telephone or FAX number shown in the Foreword of this manual 9 0 inches 229 mm Space Requirements e Allow ample workspace around the Control so that it will not be jostled or struck while welding e Allow sufficient clearance around both sides and back of the Control for power and signal cabling runs 12 8 inches e Install the Control in a well ventilated area 325mm that 1s free from excessive dust acids corrosive gases salt and moisture e Other installation considerations are The work surface must be level stable free from vibration and capable of supporting the combined weight of the total welding system The weight of the Control 15 62 165 28 kg The Control must be far enough from the weld head to avoid contact with weld splash There are sources of high frequency energy close by HF27 DC RESISTANCE WELDING SYSTEM 990 370 2 4 CHAPTER 2 INSTALLATION AND SETUP Utilities Power Because of the different electrical requirements for the countries in which the Control 15 used the Control 1s shipped without a power cable connector The required connections for your power cable connector are described in Appendix B Electrical and Data Connections Input power requirem
58. both complete input sections HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 5 APPENDIX ELECTRICAL AND DATA CONNECTIONS Signal Interface General Description m UNIT SIDE USER SIDE um CHASSIS GROUND 24COM HEAD 1 Not Active Not Active Not Active 24 VAC Not Active Not Active Not Active FIRE 1 24COM Not Active Not Active COMMON FOOT 1 FOOT 2 24COM 251 252 FIRE COM 24V OUT 24V OUT COMMON 2 M TK 24COM SCHEDULE 0 SCHEDULE 1 SCHEDULE 2 SCHEDULE 4 SCHEDULE 8 SCHEDULE 16 SCHEDULE 32 WELD INHIBIT CURRENT STOP 2 gt _ 5 2 0 3 alte J 1 J RELAY 1 JRELAY RELAY 4 Not Active Not Active FORCE SET 10 FORCE GROUND FORCE READ 10 INPUT Not Active Not Active FORCE READ 5 INPUT FORCE GROUND CHASSIS GROUND Not Active LVDT GROUND LVDTPRI 1 LVDTPRI 2 LVDTSEC 1 LVDTSEC 2 LVDT GROUND FORCE SET 5 FORCE GROUND CHASSIS GROUND HF27 DC RESISTANCE WELDING SYSTEM B 6 990 370 APPENDIX B ELECTRICAL AND DATA CONNECTIONS Input Output Signals CHASSIS GROUND Ground 24 NEGATIVE of internal 24 VDC power supply 3 HEAD 1 COMMON for air valve solenoid switched For 24VDC operation Connect other end of solenoid to 24 OUT For 24VAC operation Connect other end of solenoid to 24VAC ou ooe Binary Schedule inpu
59. close within 10 seconds the message FIRING SWITCH DIDN T CLOSE IN 10 SECONDS will be displayed Delay time from Firing Switch closure and Foot Switch Level 2 closure to squeeze time SQZ Maximum D2 time is 2 ms plus switch debounce time Squeeze time Selectable range is 0 to 999 ms Note that for 502 to start Foot Switch level 2 must be ON Soft touch time must be complete and the firing switch must be closed Up slope time Selectable range 15 0 0 to 99 0 ms Weld time Selectable range 15 0 0 to 99 0 ms Down slope time Selectable range 15 0 0 to 99 0 ms Cool time Selectable range 15 0 0 to 99 0 ms Hold time Selectable range 1s 0 to 999 ms HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 APPENDIX E Communications Overview The Control has the ability to communicate with a host computer or with automation control system The communications option uses either RS 232 to connect one control to one host or RS 485 multi drop architecture to connect up to 30 controls to one host on a single channel Amada Miyachi America s optional Weld Stat software will allow you to connect a single or multiple Controls to a computer in order to e Compile store view and print weld history data for detailed analysis e Check the status of the Control s e Remotely program weld schedules on the Control s e Remotely program menu items the Control s Remote Programming Most users will find the Weld Stat software functions sufficient
60. for collecting and using weld history information and remote schedule programming However advanced users may wish to perform additional programming for custom welding applications The codes needed to perform remote programming are listed in Section II Communications Protocol and Commands Using these codes users can write customized software for controlling all functions of the welding control and interfacing the unit to automation control systems For more information on the Weld Stat Kit Miyachi America Part Number 10 600 06 call or e mail us using the Contact Us information in the front of this manual RS 485 Connectors The unit has two DB 9 female connectors wired as follows 1 Not Used 6 Not Used 2 Not Used 7 Not Used 3 Not Used 8 Rx 4 9 5 HF27 LINEAR DC RESISTANCE WELDING CONTROL 990 370 E 4 APPENDIX E COMMUNICATIONS A terminating resistor assembly 15 supplied with the unit If only one unit is connected to the host the terminating resistor assembly must be installed in that unit If multiple units are connected to the host only one unit the unit furthest from the host must have the terminating resistor assembly installed RS 232 Serial Connector Information The serial port pin assignment 15 as follows 1 Not Used 6 Data Terminal Ready 7 CTS Clear to Send 8 RTS Request to Send 2 Transmi
61. force applied to the parts sufficient weld force 1s required to contain the molten material produced during the weld However as the force 15 increased the contact resistance decreases Lower contact resistance requires additional weld current voltage or power to produce the heat required to form a weld The higher the weld force the greater the weld current voltage power or time required to produce a given weld The formula for amount of heat generated is the square of the weld current times the workpiece resistance times the weld time T Welding Parameter Interaction HEAT TIME PROBLEM CAUSE PROBLEM CAUSE Parts Overheating Excessive Parts Overheating Excessive Weak Weld Weak Weld Insufficient Nugget Insufficient Nugget Metal Expulsion Metal Expulsion Warping Warping Discoloration Discoloration Electrode Damage Insufficient Electrode Damage Insufficient FORCE PROBLEM CAUSE Parts Overheating Excessive Weak Weld Insufficient Nugget Metal Expulsion Warping Discoloration Electrode Damage M Insufficient Interaction of Welding Parameters HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 F 1 APPENDIX F THE BASICS OF RESISTANCE WELDING Electrode Selection Correct electrode selection strongly influences how weld heat 1s generated in the weld area In general use conductive electrodes such as a RWMA 2 Copper alloy when welding electrically resistive parts such as nickel or
62. hain Schedules 3 12 Communication 3 7 Baud Rale 3 8 Communication Role 3 7 NUOCE RR RR 3 8 5232 Select 3 8 CODY A Schedule 3 5 Prop Valve Proportional Valve 3 5 Force COHPDIIE total eitis 3 5 3 5 Soft Touch Pressure 3 5 Solt Touch TI serere tet 3 5 NOD 3 9 Reset 3 10 Reset Schedules 3 11 Reset Schedule Limits 3 12 EE 3 3 System Sec rity mismo 3 6 Calibration 3 6 Schedule Lock 3 6 Systemi Lock 3 6 Weld 3 4 Reset System Parameters 3 11 Operational States 00 24 14 1 3 18 3 21 Menu State 3 18 Monitor State 3 20 No Weld 3 18 ISU 1 3 19 3 18 Weld 3 20 MUNERE 3 3 3 14 LU D TEA A 3 15 Firing 3 15 Footswitch Weld Abort 3 14 6 3 15 3 15 Switch Debounce Time 3 15 3 16 Buzzer Loudness
63. highlight the lower limit field for the Pulse 1 weld period Use the numeric keypad to enter a lower limit value with a voltage level that 1s slightly lower than the voltages observed in step 3 above Press the voltage V key to save the setting as a lower voltage limit 9 Make several more welds and verify that under normal circumstances the limits are not reached and the welds are not aborted If the limits are reached under normal welding conditions adjust the levels and times of the upper and lower voltage limits accordingly 10 Return to the RUN screen and make several welds Observe that under normal conditions the welds are not aborted and that consistent strong welds can be produced HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 5 17 11 12 CHAPTER 5 OPERATING INSTRUCTIONS Try making welds with only one part present Also try making welds with misaligned parts Observe that the power supply terminates the weld during the first pulse as soon as the voltage limits are reached If the voltage limits are not being reached with these conditions present return to the voltage monitor screen and adjust the limits accordingly You may also have to adjust the Pulse 1 current from the RUN screen if needed to optimize the Pre Weld Check settings The Pre Weld Check function can now JN 0 300 0 447 0020031 be used to detect misaligned or missing 2 parts before the Pulse 2 welding current is delivered to
64. in BETWEEN ELECTRODES CLOSE THE ELECTRODES 6 Manually adjust the weld head so the AROUND THE PIECE THEN PRESS electrodes are touching the part then press the W button on the front panel as shown on the screen on the right Press CAL to abort LVDT calibration HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 C 5 APPENDIX C CALIBRATION NOTE If your reference piece 15 too thin or not properly placed between the electrodes you will see the prompt at PUT THE GAUGE OF 0 100 in BETWEEN THE the bottom of the screen on the right ELECTRODES CLOSE THE ELECTRODES AROUND THE PIECE THEN PRESS V LVDT CALIBRATION PIECE MISSING OR TOO THIN Press CAL to abort LVDT calibration 7 When you have finished press the MENU key to return to the previous menu Quick Calibration Quick Cal The procedure sets a new zero position and recalibrates the LVDT For best accuracy the weldhead should be set to the force that will be used for welding 1 From the MONITOR keys section on the CALIBRATION gt front panel press the CAL key for the HF27 CALIBRATION LVDT GAUGE LVDT CALIBRATION LVDT QUICK CALIBRATION FORCE CALIBRATION Menu menu 2 Press 4 for QUICK CALIBRATION LVDT QUICK CAL Follow the instructions on these screens REMOVE ANY PIECE BETWEEN ELECTRODES PRESS TO CONTINUE CALIBRATION A ABORT CAL 3 A message will then flash to release the footswitch Do so and the screen on the r
65. move the highlighted cursor up down to the left and right in all screens Pressing SELECT allows editing of the highlighted field The A V keys allow you to increment up or decrement down numeric values on the display to change states such as OFF to ON up or ON to OFF down and to scroll the schedule number up and down while in the run mode To end the edit mode for that field press any key except SELECT V or the numeric keypad RUN Key Sets the Control to the operating mode Used to terminate program mode if already in the RUN screen MENU Key You access the menu screen with this key Menu items control system parameters such as setup and weld counter operation Refer to Menus in Chapter 3 Section II for details of the functions accessible through that screen Control Keys HF27 DC RESISTANCE WELDING SYSTEM 990 370 7 CHAPTER 1 DESCRIPTION Control Mode Selection Keys These keys allow you to select the control mode when programming with the WELD time energy selector keys Pressing the kA key selects current as the control mode for this schedule The control will output the current waveform shown on the LCD Pressing the V key selects voltage as the control mode for this schedule The control will output the voltage waveform shown on the LCD NOTE Selecting the voltage feedback mode requires you to make a test weld when the voltage or weld pulse time is changed The test weld optimizes the Control fee
66. on the LCD screen You can see the graph change as you enter new time and energy values Weld profiles may be programmed for single pulse upslope downslope or dual pulse operation Weld schedules may also use special monitoring features of the Control such as Energy Limit Active Part Conditioner and Pre Weld Check These features are described later in this chapter Weld Sequence Timing A weld schedule is a unique heat profile programmed in constant current voltage or power that is applied over a fixed time period to resistance weld different parts The entire weld can include all of the following time periods Squeeze Time Upslope 1 Weld Pulse 1 Downslope 1 Cool Time Upslope 2 Weld Pulse 2 Downslope 2 and Hold Time The sample dual pulse profile or waveform below shows the weld current and the corresponding position of the weld head The graph labeled WELD CURRENT is what displays on the LCD when you schedule a weld profile squeeze WELD OWN OGL E WELD DOWN HOLD RUN SLOPE SLOPE SLOPE RUN 5 TIME TIME TIME TIME srATE 0 989 msec 0 98 msec 0 98 msec 0 98 msec 0 999 msec 0 99 msec 0 99 msec 0 99 msec 0 99 msec B WELD POSITION WELD EE __ WELD PULSE 1 PULSE 2 Sample Weld Sequence Dual Pulse HF27 DC RESISTANCE WELDING SYSTEM 3 24 990 370 CHAPTER 3 SYSTEM CONFIGURATION Welding Applications Weld Pulse Profile Ty
67. parameters When used with the READ keyword all system parameters are returned see SYSTEM under CONTROL ORIGINATED COMMANDS When used with the SET keyword the host may set change the value of one or more of the system parameters The following 1 a list of valid literal substitutions for the parameter name and value variables LIGHT Light value LCD contrast LOUDNESS loudness_value Buzzer Loudness BUZZER OFF ON End of cycle buzzer DISPLAY PEAK AVG Display mode SWSTATE switch_state Input Switch Type FIRES W AUTO REMOTE NONE Firing Switch Type CTSTATE switch_state Control Signals Type GRAPH OFF ON Update Graph WELDABORT OFF ON Footswitch weld abort DEBOUNCE NONE 110120130 Switch debounce time in Msec These parameters pertain to the settings of the option menus available via the front panel user interface light_value is a number 0 to 100 for brightness of the LCD 0 is dark and 100 is the brightest loudness_value is a number 0 to 100 for buzzer loudness 0 is off and 100 is the loudest switch_state MECHOPEN MECHCLOSED OPTOOPEN OPTOCLOSED PLCOV PLC24V HF27 LINEAR DC RESISTANCE WELDING CONTROL E 19 APPENDIX E COMMUNICATIONS Command Control State Description Command Control State Description Command Control State Description ALARM READ I CLEAR SET error number DISPLAY alarm message string lt gt lt gt Any Provides
68. plug must be connected to pins 11 through 20 on the 60 pin connector For other configurations see Appendix Electrical and Data Connections HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 2 3 CHAPTER 2 INSTALLATION AND SETUP Weld Head Connections VOLTAGE SENSING CABLE 2 E Polarity Not Important EE n REAR PANEL WELD HEAD WELD TERMINALS ____ GARI ES ES my i Weld CAUTIONS Cable Washer 1 Install weld cable washers between the screw heads and cable terminals _ NOT between the cable terminals and Control terminals FE 2 Dress weld cables together with cable ties to minimize induction loss l Connect one end of a weld cable to the negative welding transformer terminal on the Control 2 Connect one end of the second weld cable to the positive welding transformer terminal on the Control 3 Connect the other end of the weld cables to the weld head 4 Attach the voltage sensing cable connector to the VOLTAGE SENSE INPUT connector 5 Install electrodes in the weld head electrode holders NOTE If you need additional information about the weld heads please refer to their user s manuals HF27 DC RESISTANCE WELDING SYSTEM 2 4 990 3 0 CHAPTER 2 INSTALLATION AND SETUP 6 Connectthe voltage sensing cable terminals to the electrode holders VOLTAGE SENSING LEADS 7 Attach a leads directly to each electrode
69. screen NOTE INGNORE 1st deletes time PULSE 1 MONITOR LIMITS gt from the beginning of the limit IGNORE LOWER LIMIT IGNORE 1ST 0 0ms LAST deletes time from the end of the LOWER LIMIT IGNORE LAST e UPPER LIMIT IGNORE 1ST 0 0 5 limit This will not only shorten the UPPER LIMIT IGNORE LAST 00 lt limit time but depending on the amount of time deleted on each end of the limit the limit will appear to move horizontally across the screen This allows you to fit the LOWER LIMIT precisely into the waveform graph NUMBER Select an item ENERGY Monitor screen Use the numerical keypad to select the number of the limit you want to change When the value is highlighted Example 2 5ms use the numerical keypad to type in a new value You must leave a minimum time of 0 5 ms in order for the changes to be saved in memory Press the RUN or monitor key when you have finished entering new values R aise or lower the UPPER LIMIT and LOWER LIMIT as necessary using the procedures in Section III Programming the Weld Monitor Return to the RUN screen and make a test weld in order to view the waveform to see where the new limits appear compared to the waveform graph Repeat steps 1 gt 10 until the limits are where you want them NOTE Lower limits apply to the programmed weld time only Programming a longer upslope extends the time before a lower limit applies in the monitoring screen HF27 DC RESISTANCE WELDING
70. switch_state lt gt GRAPH OFF ON lt crlf gt WELDABORT OFF ON lt crlf gt DEBOUNCE NONE 10120130 lt crlf gt e Any HF27 LINEAR DC RESISTANCE WELDING CONTROL 990 370 Description Command Control State Description Command Control State Description 990 3 0 APPENDIX E COMMUNICATIONS Reports the current settings of the Control system parameters light value is a number 0 to 99 for brightness of the LCD 0 is dark and 100 is the brightest loudness value is a number 0 to 99 for buzzer loudness 015 off and 100 1s the loudest switch state MECHOPEN MECHCLOSED OPTOOPEN OPTOCLOSED PLCOV PLC24V ENVLIMIT lt crlf gt 1 IV KW gt limit value lt limit value lt ACTIONI none STOP INHIBIT APC lt crlf gt TYPE2 KA V IKW gt UPPER2 limit_value lt LOWER2 limit_value lt crlf gt ACTION2 STOP lt crlf gt PILDLY1 delay value lt gt PILDLY2 delay value lt gt PIUDLY1 delay value lt crlf gt PIUDLY2 delay value lt crlf gt P2LDLY1 delay value lt crlf gt P2LDLY2 delay value lt crlf gt P2UDLY1 delay value lt gt P2UDLY2 delay value lt gt lt Returns envelope limits that are set for this schedule ENVWAVE number of data points P1 P2 lt gt data lt crlf gt data cerlt
71. the Control into the weld schedule selection mode Use the keypad to directly enter a desired weld schedule refer to Front Panel Data Entry and Mode Controls in this section then press the RUN key SCHEDULE Weld Period Selector Keys SQUEEZE UP WELD DOWN COOL UP WELD DOWN HOLD LL PULSE 1 PULSE 1 Select individual weld periods and weld energy fields in the weld schedule profile for programming see Front Panel Data Entry and Mode Controls Time Energy Selector Keys These two switches one for each of the PULSE 1 and PULSE 2 weld periods select either the bottom line of data or the second to bottom line of data on the screen to be programmed The bottom line of data is weld period time in milliseconds The second to bottom line 15 Weld Energy in the units selected by the energy units selection keys see Front Panel Data Entry and Mode Controls HF27 DC RESISTANCE WELDING SYSTEM 1 6 990 370 CHAPTER 1 DESCRIPTION Front Panel Data Entry and Mode Keys Key Pad The keypad consists of the numeric keys and the up down left right keys 3 Numeric Keys The numeric keys allow you to E 6 e Enter or modify weld period time and energy values m MU To use the numeric keypad you must first select a time energy weld period key or the schedule key e Enter or modify monitor and limit values e Directly recall a specific weld schedule The arrow keys
72. the Weld Head for specifications Example If the maximum force of the head is 20 pounds set the SOFT TOUCH to 5 pounds 7 Press the A key to accept the setting The screen will go to the previous page Press 4 to adjust the SOFT TOUCH TIME Use the numeric keypad to enter a time in milliseconds HF27 DC RESISTANCE WELDING SYSTEM 990 370 3 1 CHAPTER 3 SYSTEM CONFIGURATION 9 10 11 12 13 14 3 2 Press key to accept the setting The screen will go to the previous page NOTE After initial settings you can change the settings above as often as necessary Press the RUN key The screen will display SAVING CHANGES then go back to the RUN screen Press the FORCE key on the front panel to get the FORCE amp LIMITS menu Enter a value for PROP VALVE OUTPUT FORCE Push the FORCE key again to accept these values The screen will display SAVING CHANGES FORCE amp LIMITS gt PROP VALVE OUTPUT FORCE 010 0 LBS LO LIM 000 0LBS 000 0LBS HI LIM LAST 000 0LBS 000 0LBS 000 0LBS 000 0LBS WELD START WELD END ACTION CONTINUE Press the RUN key to go back to the RUN screen You may now use the foot switch to raise and lower the electrodes HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 CHAPTER 3 SYSTEM CONFIGURATION Section Menus Overview You program the system settings of the Control MAIN MENU through the MAIN MENU screen and its sub SETUP 6 COMMUNICATIONS
73. the front panel press the V key to program voltage as the feedback mode From the CONTROL keys section on the front panel press the kW key to program power as the feedback mode From the CONTROL keys section on the front panel press the COMBO key to program combo as the feedback mode Press the PULSE 1 DOWNSLOPE key to enter the amount of time for the Weld Pulse 1 downslope Use the numeric keypad or the arrows Enter 0 milliseconds Note that in combo mode when the unit reaches a constant current any time programmed in this segment will be added to the weld at the constant current level HF27 DC RESISTANCE WELDING SYSTEM 990 370 5 3 CHAPTER 5 OPERATING INSTRUCTIONS 8 Press the COOL key to enter the amount of time for the cool period after Pulse 1 Use the numeric keypad to enter the time or use the AV arrows Enter 0 5 milliseconds 9 Program Pulse 2 by repeating Steps 3 through 7 above using the keys for Pulse 2 entering the value O in each step 10 m Press the HOLD key to enter the amount of time for the hold period after the weld Use Ng the numeric keypad or the AW arrows Enter a time between 0 and 999 milliseconds We recommend at least 50 milliseconds as weld strength is formed in the hold time HF27 DC RESISTANCE WELDING SYSTEM 5 4 990 370 CHAPTER 5 OPERATING INSTRUCTIONS Upslope Downslope Weld Schedule NOTE If you are using the optional LVDT you must perform the procedures described
74. the hold time HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 CHAPTER 5 OPERATING INSTRUCTIONS Dual Pulse Weld Schedule NOTE If you are using the optional LVDT you must perform the procedures described in Appendix D LVDT Option Section 4 Operating Instructions in addition to the procedures below 1 Press the SCHEDULE key then select Weld Schedule using either the arrows or the numeric keypad Press the SQUEEZE key to enter the squeeze time before the weld Use the numeric keypad to enter the time or use the AV arrows Enter a time between 0 and 999 milliseconds If using the LVDT enter a time between 1 and 999 milliseconds If using a relay for MG3 synchronization enter a time between 50 and 999 milliseconds NOTE We recommend 150 milliseconds Press the PULSE 1 UPSLOPE key to enter the amount of time for the Weld Pulse 1 upslope Use the numeric keypad to enter the time or use the AV arrows Enter a time between 0 and 99 milliseconds Press the PULSE 1 WELD key to highlight the bottom line of the LCD to enter the weld time Use the numeric keypad to enter the time or use the AV arrows Enter a time between 0 and 99 milliseconds Press the PULSE 1 WELD key again to highlight the middle line of the LCD to enter weld energy Use the numeric keypad to enter the energy level or use the AV arrows The Control output ranges are e Current from 0 1 2 4 kA Voltage 0 2 gt 9 999 V e Power 0 05 gt 9 999 kW
75. the welds are good set the time limits broader or remove them altogether This message usually signals a bad weld If it consistently happens and the welds are good set the time limits broader or remove them altogether Check force calibration If welds are good and message consistently happens set force limits broader or remove them altogether Check force calibration If welds are good and message consistently happens set force limits broader or remove them altogether Check force calibration If welds are good and message consistently happens set force limits broader or remove them altogether Check force calibration If welds are good and message consistently happens set force limits broader or remove them altogether Set a monitor limit Re do the action that failed HF27 DC RESISTANCE WELDING SYSTEM 6 9 6 110 ACCESS DENIED CALIBRATION LOCK ON 111 SQUEEZE TIME INCREASED 112 P1 gt ENV UPPER LIMIT 113 lt ENV LOWER LIMIT 114 VOL gt ENV UPPER LIMIT 115 VOL lt ENV LOWER LIMIT 116 Pl PWR gt ENV UPPER LIMIT 117 P1 PWR lt ENV LOWER LIMIT 118 DISP gt ENV UPPER LIMIT 119 DISP lt ENV LOWER LIMIT 120 P2 kA gt ENV UPPER LIMIT 121 2 lt LOWER LIMIT 122 P2 VOL gt UPPER LIMIT 123 P2 VOL lt
76. to the ON position The 1 default RUN screen will display lumus ZEIT 2 200 150 10 410 190 10 1010 10 Press the foot switch to actuate the first level The weld head upper electrode should descend smoothly to the DOWN position When it reaches the down position release the foot switch and proceed to Step 12 If it does not descend smoothly proceed to Step 11 11 Adjust the weld head down speed control knob and repeat Step 10 until the upper electrode descends smoothly 12 Press the foot switch all the way down to close both levels The weld head upper electrode should descend smoothly to the DOWN position and send the firing switch signal back to the Control when the preset electrode force 15 reached The upper electrode should then ascend smoothly back to the UP position HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 2 9 CHAPTER 2 INSTALLATION AND SETUP Non EZ AIR Weld Head Connections Non EZ AIR heads may be connected to the Control as shown below however you should refer to the manual provided with the weld head you are using for specific instructions UP SPEED CONTROL KNOB DOWN SPEED CONTROL KNOB FORCE ADJUSTMENT KNOB HNI SHOP AIR FORCE INDICATOR al Set to 5 A AIR INPUT WELD HEAD LOAD CELL ELECTRODE HOLDER FIRING SWITCH CABLE AIR DRIVER CABLE EMERGENCY STOP REAR PANEL SWITCH HF27 DC RESISTANCE WELDING SYST
77. transistors has exceeded the HF27 25 specified capability The Operator Emergency Stop switch has been activated All power to the HF27 25 1s immediately terminated The Firing Switch on a Miyachi Unitek air actuated weld head did not activate within 10 seconds after the Foot Switch was initially activated Weld Piece CHAPTER 6 MAINTENANCE Excessive weld time set at HF27 25 No cover gas on weld piece Excessive current energy set at HF27 25 Insufficient weld head force Contaminated weld piece surface plating Wrong electrode material tip shape Contaminated electrode surface Remove the I O input control signal condition preventing further HF27 25 operation NOTE The correct removal action depends on how the control signal select in the Setup 1 menu was programmed by the user Hardware problem Repeated displays of this message should be diagnosed and fixed by a technician Check the weld head for an improperly adjusted firing switch Automation Only Check the timing on the PLC control lines to the Firing Switch and Foot Switch inputs Remove the Process Stop activating signal from the CONTROL SIGNALS connector Reduce duty cycle Reduce weld time Remove any unsafe operating conditions at the welding electrodes Reset the Operator Emergency Stop switch Turn off power to the HF27 25 then turn it on again Press RUN and readjust the air pressure to the Miyachi Unitek air actuated
78. waveform is still rising at the end of the pulse the Weld to a Limit function may work well for the application If the current waveform quickly rises and flattens out early in the pulse the Weld to a Limit function 15 not appropriate for the application Di Observe the peak current reading on the current monitor screen Make several more welds and observe the range of peak current readings from weld to weld 6 Press the Pulse 1 weld key to highlight the upper limit field for the weld period Use the numeric keypad to enter the upper limit value for the Pulse 1 weld period Program a current level that is the same as the peak current readings observed in step 5 above ja Press the current kA key to save the setting as an upper current limit 8 Press the COOL weld period PULSE 1 OUT OF LIMITS ACTION key This will bring up the i mone PULSE 1 OUT OF LIMITS ACTION screen 3 INHIBIT PULSE2 4 PART CONDITIONER Stop Pulse1 9 Select 1 STOP WELD NUMBER Select MENU Previous menu HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 9 19 CHAPTER 5 OPERATING INSTRUCTIONS 10 B Return to the RUN screen and WELD STOP LIMIT REACHED 0000178 increase the weld time by 1 2 ms Make several welds and verify that the upper voltage l GMT re O 500V 2 300 limit 1s reached for every weld 150 3 90 3 0 00 20 20 00 00 050 ms and the weld pulse stops before the end of the programmed weld time Weld to a Limit Waveform
79. weld head HF27 DC RESISTANCE WELDING SYSTEM 6 3 6 08 Software detected that the welding Allow transformer to cool If repeated displays of WELD transformer is too hot this message allow more cool time between TRANSFORMER welds or if practical weld at a lower heat OVERHEATED setting 9 The voltage mode PID s will be adjusted None Test Weld when the next weld 15 done The Voltage Selection Plug on the Weld Verify the Voltage Selection Plug connection on VOLTAGE Transformer is missing or improperly the Weld Transformer SELECTION PLUG connected IS MISSING 11 Inhibit input control signal is Remove the Inhibit signal condition preventing INHIBIT CONTROL activated preventing the HF27 25 from further HF27 25 operation SIGNALS continuing to operate NOTE The correct removal action depends on ACTIVATED NOTE Activating the Inhibit input how the control signal I O logic was terminates only future operations It does programmed by the user NOT terminate any present HF27 25 operation 13 Previous weld current was below Check current pickup NO CURENT minimum value READING 14 Previous weld voltage was below Check voltage pickup NO VOLTAGE minimum value READING 15 The total electrical resistance comprised Reduce the total electrical resistance by reducing LOAD of the weld cables weld head and parts the weld cable length RESISTANCE TOO be welded
80. 0 3 0 5 29 CHAPTER 5 OPERATING INSTRUCTIONS Section Time Limits Time The function of the time screen 15 to allow the user to program limits around the Cut Off time The Cut Off time 15 defined as the time when the control system commands current to turn off because it reached a user programmed limit For both P1 and P2 this time is measured from the start of the first pulse Setting a value to zero turns off that limit In order for this function to accept limits a monitor limit must be set They can be based on current voltage power energy resistance envelope or displacement If multiple limits are set for weld to the time cut off limits will apply to the value that actually terminates the weld There are upper and lower limits for Cut Off time for and for P2 See Chapter 3 to program relay actions corresponding to these time limits TIME CUT OFF LO LIM HI LIM LAST P1 000 0 ms 000 0 ms 002 0 ms P2 000 0 ms 000 0 ms 008 ms 4 Arrows to select field RUN or MENU HF27 DC RESISTANCE WELDING SYSTEM 5 30 990 370 CHAPTER 5 OPERATING INSTRUCTIONS Section XIII Envelope Limits Operation of Envelope The user can program a limit around a reference waveform for current voltage or power for Pulse 1 and Pulse 2 Different modes can be selected for Pulse 1 and Pulse 2 1 Press the ENVELOPE button to call up ENVELOPE 0 000 0 000 0000511 the envelope screen 2 Push SEL
81. 00 value DISPLC 000 000 000 XX STOP ENERGY AT 000 XXXX IN 1000 3 Scroll to FINAL HI LIM Use the NEW ELECTRODE IS SET numerical keypad on the front of the Arrows to select field RUN or MENU Control to enter a numerical value HF27 DC RESISTANCE WELDING SYSTEM 990 370 5 27 CHAPTER 5 OPERATING INSTRUCTIONS High and Low Limits for Displacement DISPLACEMENT is the change or difference between the INITIAL and FINAL thickness You can put high and low limits around displacement The Control will give you an alarm on the screen which says out oflimits The percentage value shown on the right 15 for reference only See Section XIV Programming Relays for setting relay actions l Scroll to DISPLC LO LIM LVDT POSITION 092 0000000 2 Usethe numerical keypad on the front INITIAL 5 i x CONT of the Control to enter a numerical FINAL 000 000 000 value DISPLC 000 000 000 XX STOP ENERGY AT 000 XXXX 1IN 1000 3 Scroll to DISPLC HI LIM NEW ELECTRODE IS SET Arrows to select field RUN or MENU 4 Use the numerical keypad on the front of the Control to enter a numerical value STOP ENERGY AT Weld to a Specific Displacement You can program the LVDT to stop the current flow in the middle of the weld once it has reached a specific displacement 1 From the main LVDT screen press the SCHEDULE button to edit the screen 2 Scroll to WELD TO 3 Use the numerical keypad on the front of th
82. 000 000 000 XX96 STOP ENERGY AT 000 XXXX IN 1000 NEW ELECTRODE IS SET NOTES 4 Arrows to select field RUN or MENU e POSITION in the top row indicates the position of the top electrode relative to the bottom electrode This screen shows 092 which means that the top electrode 1s 0 092 away up from the bottom electrode The 7 digit number on the right side of the screen 3600277 in this example indicates the number of welds made e The xx number shows the displacement as a percentage of the initial thickness e The xxxx after the WELD TO limit shows the time at which the limit was reached e The large 1 indicates which weld schedule is currently selected e SCHEDULE in the bottom line indicates that you press the SCHEDULE or DISTANCE button in order to edit the LVDT screen In order to get accurate initial thickness readings squeeze time must be set to at least 1 msec e When you first press the SCHEDULE button the INITIAL LO LIM is highlighted and the bottom line changes as shown on the right e RUN in the bottom line indicates that you press the RUN button in order to leave the LVDT screen and return to the RUN screen e Ifyou wish to remain in the LVDT screen press the DISTANCE button instead of the RUN button This will remove highlighting but leave you in the LVDT screen HF27 DC RESISTANCE WELDING SYSTEM 5 24 990 370 CHAPTER 5 OPERATING INSTRUCTIONS Before You Start Set New Electrodes to Zero T
83. 14 2 Switch Debounce Time RTT 3 15 MT TT mmm 3 15 3 15 PM mE 3 15 SNB D Ru 3 15 A EA ___ __ _ ee 3 16 3 16 PNIS Dre ts 3 16 o PCO C 3 16 Z gt 3 16 3 MAMAS Sy Umm 3 17 3 17 JB NS sm 3 17 PI X 3 17 Del 3 17 Operon ___ nu aute 3 18 Weld State 3 18 T 3 18 3 18 ___ ____ _ 3 19 O 3 20 Monitor State 3 20 PS ESTER e e MR cem 3 21 Section IV Weld Functions 3 22 MEINE ey 0 1 ee __8_ _ __ 3 22 Weld Head Applicability M 3 23 When To Use Functions re eee 3 23 SCN SGU _________ 6__ ____8 3 24 Weld 3 24 HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 V CONTENTS Continued Page M eldiag pH BIDS PPP a ed euer Sp MEDII i 3 25 3 25 Upslop Downslope Weld Profile 3 26 3 26 Chapter 4 Introduction to
84. 2 Press the HOLD key to enter the amount of time for the hold period after the weld Use the numeric keypad to enter the time or use the AV arrows Enter a time between 0 and 999 milliseconds We recommend at least 50 milliseconds HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 CHAPTER 5 OPERATING INSTRUCTIONS Section Using the Weld Monitor Overview The Control allows you to adjust extremely precise limits for the amount of energy and weld time Like all welding processs development you ll need to make several test welds and view the waveforms and limits of actual welds in order to fine tune the limits to your needs The energy limits appear as horizontal dotted lines on the LCD screen The UPPER LIMIT line is longer than the lower limit line because it includes the UPSLOPE WELD and DOWNSLOPE portions of the actual weld waveform The LOWER LIMIT line is shorter because it only includes the WELD portion of the waveform If the line of either limit crosses the weld energy waveform the Control can trigger an alarm inhibit the second pulse or stop the weld energy See Chapter 4 Using Feedback Modes and Weld Monitoring for more details MONITOR LIMITS TIME MONTOR 30601 puoi 2000014 LOWER LIMIT 1 UPPER 3 201V LOWER 2 100V nbne SHORTEN LENGTHEN OR MOVE TIME VALUES MONITOR 3 060 peak 0 000 0000014
85. 27 LINEAR DC RESISTANCE WELDING CONTROL 990 370 APPENDIX E COMMUNICATIONS Control Originated Commands These are the commands sent from a Control to a host computer Command Control State Description Command Control State Description Command Control State Description Command Control State Description Command Control State Description Command Control State Description 990 3 0 STATUS ate name crl lf Any Identifies the current status of the weld data buffer May be in response with or OVERRUN means that the Control weld buffer did not over run since the last data collection and all the data are intact OVERRUN means that the Control weld buffer did over run since the last data collection and only the latest 900 weld data are available to report TYPE type release numbers revision letters lt crlf gt lt lf gt Any Returns 27 1 00 A 37232 for the first release of an HF27 COUNT number gt lt gt Returns the number of weld data available in Control The total number of weld data that the Control holds in the buffer 15 900 NAME schedule name crlf lf Any Returns the current schedule s name up to a maximum of 20 charters STATE state lt gt lt gt Identifies the current state of operation of the Control be in response to the STATE READ Command sent by the host or may be sent as a result of a sta
86. 7 DC RESISTANCE WELDING SYSTEM 3 6 990 3 0 CHAPTER 3 SYSTEM CONFIGURATION 6 COMMUNICATION The following menu screens tell you how to set the Control s communication and data options However to enable the Control to perform these functions you must install the software from the optional DC25 UB25 HF27 Datacom Communications Interface Kit commonly referred to as the Datacom kit or Weldstat in a host computer The Datacom Operator Manual describes cables connections RS 232 operation RS 485 operation sample weld reports data collection and how to use remote commands The Datacom Kit allows you to connect a single Control or multiple Controls to a printer or a computer in order to e Compile store view and print weld history data for detailed analysis e Remotely program weld schedules on the Control s e Remotely program menu items on the Control s Rear mounted RS 232 and RS 485 connectors allow for remote programming weld schedule selection and data logging for SPC purposes Data output provides the necessary process documentation for critical applications and permits data logging for SPC purposes Appendix E Communications in this manual lists all of the commands that the Control will respond to and instructions on how to format commands sent to the Control so it will respond properly The Control contains internal software that gives you a great deal of flexibility in the setup and use of your welding system The Cont
87. CE 91535 Press 5 for the FORCE Calibration LOW GAUGE FORCE HIGH GAUGE FORCE 008 2 017 6 Move the cursor to LOW GAUGE FORCE Press SCHEDULE to start Place a force gauge between the electrodes FORCE GAUGE Press the SCHEDULE button on the Control Panel to close the electrodes NOTE In FORCE CALIBRATION mode the Control will not send weld current to the electrodes f ELECTRODES Let the force stabilize then check the force on the force gauge Press the SCHEDULE button to release the weldhead Repeat steps 3 and 4 to be sure the value has stabilized Enter the number of measured force under LOW GAUGE FORCE on the LCD screen Select HIGH GAUGE FORCE on the control Place a force gauge between the electrodes Press the SCHEDULE button on the Control Panel to close the electrodes Let the force stabilize then check the force on the force gauge Press the SCHEDULE button to release the weldhead HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 APPENDIX C CALIBRATION 10 Repeat steps 7 and 8 to make sure the force has stabilized Enter the measured force under HIGH GAUGE FORCE on the LCD screen Press the FORCE button to save this information FORCE Calibration 1s now complete Example As shown above on the FORCE CALIBRATION screen Low Gauge force was 7 2 lbs High Gauge Force was 17 6 Ibs Set Force tare to Zero To set a new zero without recalibration 1 From the MONITOR keys section
88. E lt LOWER LIMIT 109 NEED TO SET MONITOR LIMIT 990 370 Pulse 2 energy in Joules exceeded the upper limit Pulse 2 energy in Joules did not reach the lower limit Pulse 1 ended after the cutoff time upper limit Pulse 1 ended before the cutoff time lower limit Pulse 2 ended after the cutoff time upper limit Pulse 2 ended before the cutoff time lower limit Measured force during Pulse 1 was greater than the upper force limit Measured force during Pulse 1 was less than the lower force limit Measured force during Pulse 2 was greater than the upper force limit Measured force during Pulse 2 was less than the user lower force limit AN ATTEMPT TO SET A LIMIT ON THE TIME ENERGY SCREEN FAILED BECAUSE A MONITOR LIMIT MUST BE PRESENT BEFORE THIS ACTION IS ALLOWED Joules is power over time If welds are good and message consistently happens decrease the power shorten the time or change the limit Joules is power over time If welds are good and message consistently happens increase the power increase the time or change the limit This message usually signals a bad weld If it consistently happens and the welds are good set the time limits broader or remove them altogether This message usually signals a bad weld If it consistently happens and the welds are good set the time limits broader or remove them altogether This message usually signals a bad weld If it consistently happens and
89. ECT to choose a reference 1 waveform for Pulse 1 and Pulse 2 Z OFFSET none OFFSET none none 3 Press 1 2 or 3 to select the reference SAVE REFERENCE WAVEFORMS wavetorm for Pulse 1 Press 4 5 or 6 to 1 P1 PULSE kA 4 P2 PULSE kA select the reference waveform for Pulse 2 P1 PULSE V 5 P2 PULSE kA 2 3 P1 PULSE kW 6 P2 PULSE kW Number Select an item RUN or MENU 4 The screen on the right shows a current ENVELOPE 1 000 peak P11 004KA 0000511 reference waveform for both P1 and P2 1 OFFSET OFFSET none none none 5 f Press the P1 Time Energy Selector key to input the upper offset from the reference waveform for P1 6 Press the P1 Time Energy Selector key again to input the lower offset from the reference waveform for P1 Repeat this process for P2 if desired 8 Push the Upslope key to adjust the time over which these limits apply NOTES ENVELOPE 1 0737 00000002 Graphic will scale to fit the screen veers as positive and negative offsets are j programmed OFFSET Action Action OFFSET xxx Action Action e From any RUN screen pushing the envelope key will bring up the envelope type limit for the first pulse Pressing it again will switch to the From the RUN screen you will go directly to whichever mode has the envelope limits HF27 DC RESISTANCE WELDING SYSTEM 990 370 5 31 CHAPTER 5 OPERATING INSTRUCTIONS Section XIV Progr
90. EM 2 10 990 3 0 CHAPTER 3 System Configuration Section Getting Started Before You Start Configuration 1s simply a matter of selecting various MENU options so the Control will work with all the components of your welding system e Verify that all connections have been made according to the instructions in Chapter 2 Installation and Setup e Turn the Control ON e Turn any peripherals such as the Proportional Valve and Load Cell Amplifier ON e Turn the shop air supply ON Startup 1 Press the MENU key MAIN MENU SETUP 6 COMMUNICATIONS 2 Press 4 for PROPORTIONAL VALVE WELD COUNTERS 7 RELAY COPY SCHEDULE 8 RESET DEFAULTS NOTE This feature 15 only applicable if PROP VALVE 9 CHAIN SCHEDULES the optional Proportional Valve has been SYSTEM SECURITY installed If a Proportional Valve has not been installed skip this section and continue with Section II Menus NUMBER Select an item 3 Press 1 for FORCE OUTPUT to turn the PROPORTIONAL VALVE tout ON FORCE OUTPUT OFF Mee FORCE UNITS LBS SOFT TOUCH PRESSURE 0 000 LBS 4 Press2to select FORCE UNITS SOFT TOUCH TIME 050 ms Pressing the 2 key will toggle between LBS pounds KG kilograms or N Newtons 5 Press 3 to adjust the SOFT TOUCH PRESSURE NUMBER Select an item RUN or MENU 6 Use the numeric keys to input a force that 1s 25 of the maximum force of the head Refer to the manual supplied with
91. EM 990 370 4 9 CHAPTER 4 INTRODUCTION TO FEEDBACK MODES AND MONITORING 5 Weld Stop Applications e Part to part positioning problems e Electrode to part positioning problems Function To detect work piece resistance changes that occur when parts are positioned incorrectly at the weld head In this case the energy limits will prevent blowouts parts damage and electrode damage Limits can be set to terminate the weld if this occurs Description This function terminates the weld energy during the welding process if pre set weld current voltage or power limits are exceeded In addition to inhibiting the weld the Control has four programmable relay outputs which can be used to trigger alarms to signal operators of weld faults or signal automation equipment to perform pre programmed actions such as stopping the production line so the faulty weld piece can be removed WELD STOP LIMIT REACHED 0000955 1 2 4 00 2 400 002 05 50 0 01000 0 0 0 0 001 ms In the profile above the weld current 15 exceeding the selected upper limit before the end of welding cycle The spike in the current waveform indicates that parts were misplaced In this case the operator has selected the option to terminate the weld energy under this condition so the energy limits monitor terminates the Pulse 1 weld and inhibits the Pulse 2 weld if it had been programmed The monitor measures the weld energy parameters during the weld period
92. EM PARAMETERS right Through this menu you may reset all 2 RESET ALL SCHEDULES 3 RESET SCHEDULE LIMITS system programmed parameters and all weld schedules to the original factory default settings see the table below Number Select an item RUN or MENU HF27 DC RESISTANCE WELDING SYSTEM 3 10 990 370 CHAPTER 3 SYSTEM CONFIGURATION Factory Default System Parameters Buzzer Buzzer Loudness 40 Soft Touch Time Touch Time O0ms ms End of E Communication SLAVE Buzzer Role Update Graph After ON Baud Rate 38 4K m Langage ENGLISH ID ID Number 0000 Do Test Weld ALWAYS Relays 1 2 3 and 4 ur WHEN ALARM 1 RESET SYSTEM PARAMETERS 1 With the reset to defaults screen RESET SYSTEM PARAMETERS gt displayed press the 1 key This will bring up the RESET SYSTEM PARAMETERS query menu as shown at the right Number Select Page RUN or MENU 2 Press the 2 key to select YES This will automatically reset the system to the factory and return the screen to the RESET TO DEFAULTS display 2 RESET ALL SCHEDULES automatically reset all weld schedule parameters to the factory defaults and return the screen to the RESET TO DEFAULTS display 2 Press the MENU key to return to the Number Select Page RUN or MENU MAIN MENU screen HF27 DC RESISTANCE WELDING SYSTEM 990 370 3 11 CHAPTER 3 SYSTEM CONFIGURATION 3 RESET SCHEDULE LIMITS 1 Thelast SCHEDULE you used wi
93. ENVELOPE button on the front screen 2 Instead of setting flat upper and lower limits this function sets limits above and xxx Action Action below an actual weld pulse as you can see _ OFFSET xxx Action Action by the dotted lines on the right The LCD screen will prompt you to press the SELECT key on the front panel to choose a reference pulse for both PULSE 1 and PULSE 2 Any pulse outside the envelope limits will sound an OUT OF LIMITS ALARM Process Tools These tools are proven methods to use the monitor and limit functions described above in order to achieve specific results There are five commonly defined Process Tools 1 Active Part Conditioner Resistance Set Pre Weld Check Weld To A Limit Weld Stop 1 Active Part Conditioner Application e Displace surface oxides and contamination e Reduce contact resistances before delivering the main weld energy Description In the production environment it is common to see large variations in e Oxide and contamination e Plating thickness and consistency e Shape and fit up e Contact resistances due to varying part fit up In order for a weld to occur the surface oxides and contamination must be displaced to allow proper current flow through the parts Levels of oxide and contamination vary from part to part over time which can have an adverse effect on the consistency of the welding process 27 DC RESISTANCE WELDING
94. Electrical and Data Connections for circuit details 5 Setthe WELD NO WELD switch on the Control front panel to the NO WELD position In this position the Control cannot deliver weld energy but the firing switch connection can be verified 6 Setthe circuit breaker on the rear panel RUN peak 419191919194 of the Control to the ON position The default RUN screen will be displayed 1 You will use this screen to enter welding parameters See Chapter 3 0 200 150 1 0 1 0 1 0 1 0 1 0 1 0 1 0 959 ms Using Weld Functions and Chapter 4 Operating Instructions HF27 DC RESISTANCE WELDING SYSTEM 2 6 990 370 CHAPTER 2 INSTALLATION AND SETUP EZ AIR Weld Head Connections AC EZ AIR Weld Head Connection FORCE ADJUSTMEN KNOB m FORCE INDICATOR Set to 5 I EZ AIR AIR WELD HEAD 1 ELECTRODE HOLDER AIR DRIVER CABLE FIRING SWITCH CABLE FOOT SWITCH REAR PANEL il ua E EMERGENCY STOP SWITCH HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 2 CHAPTER 2 INSTALLATION AND SETUP DC EZ AIR Weld Head Connection FORCE ADJUSTMENT Y FORCE INDICATOR Set to 5 IT gu SHOP AIR L ES m OPTIONAL a WELD HEAD wich ELECTRODE HOLDER FIRING SWITCH CABLE LVDT CABLE FOOT SWIT ua EMERGENCY STOP SWITCH 1 Adjust the weld head force adjustment knob to produce 5 units of force as displayed on the forc
95. Feedback Modes and Monitoring Section I Programmable Feedback Modes MP NE 4 GON osos 4 r e 6 0 4 basuriniccd 4 qu 6 NNMERO 4 2 4 2 Section IL Weld Monitoring 4 3 UC HOD oeconomia ___ ___ _ _ _______6_____ 4 3 PEAK and AVERAGE MONITORING eee nennen enhn nennen nenne e n sen annes n nnn senis 4 3 Curent Voltage Power and Kesistance Limits Cot Heel dte ORE IPLE ONE 4 4 ________ 4 4 ____ _____ _ _______ _ _ ____ 4 4 T uc 4 4 4 5 T 4 5 Procese mm 4 5 1 Active Part Conditioner i deutet sueta tetas 4 5 s ERR T 4 7 De m 4 8 ME mm 4 9 SNR IU MNT 4 10 Chapter 5 Operating Instructions oeciton T 5 1 a 5 1 5 1 CODD OOS irn A 5 1 FONE 5 1 A E E TETE E E T E T A 5 1 5 2 E Hon L MIN NU 5 3 Weld SC Me GG ___4_ 6_ ___ 5 3 LpslapeDownslone
96. HEDULE READ SET lt crlf gt parameter name value lt crlf gt lt gt Control State state Description Provides control over the Control schedule parameters When used with the READ keyword all parameters pertaining to the currently loaded schedule are returned see SCHEDULE under Control ORIGINATED COMMANDS When the SET keyword is used the host may set change the value of one or more of the parameters pertaining to the currently loaded schedule The following is a list of valid literal substitutions for the parameter name and value variables FEEDBACK1 I KW feedback type for pulse 1 FEEDBACK2 KAIV KW feedback type for pulse 2 SQUEEZE squeeze time squeeze time UP1 weld time up slope time of pulse 1 WELDI weld time weld time of pulse 1 DOWNI weld time down slope time of pulse 1 COOL weld time cool time UP2 weld time up slope time of pulse 2 WELD2 weld time weld time of pulse 2 DOWN2 weld time down slope time of pulse 2 HOLD hold time hold time ENGI weld_energy energy amount for pulse 1 ENG2 weld energy energy amount for pulse 2 RINDEXI resistance index index value into PID resistance table for pulse 1 RINDEX2 resistance index index value into PID resistance table for pulse 2 EINDEXI energy index index value into PID energy table for pulse 1 EINDEX2 energy index index value into PID energy table for pulse 2 NOTES squeeze time and ho
97. HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 9 7 APPENDIX G DEFINING THE OPTIMUM PROCESS Approach to Weld Development The first stage developing a quality welding process 15 to fix as many of the variables as possible in the welding equipment set up The welding variables can be grouped in the following categories e Material Variables e Process Variables Base material Tooling level of automation Plating Repetition rate Part positioning Shape Maintenance electrode cleaning e Weld Head amp Mechanical Variables Quality Requirements A Force squeeze hold Pull strength Actuation method Visual criteria Electrode material and shape Test method other weld joint requirements e Power Supply Variables Energy Time squeeze weld hold The first stage in developing a quality welding process 15 to fix as many of the variables as possible in the welding equipment set up Welding variables can be grouped in the following categories Initial Welding Trials The Look See Tests Look see welding tests are a series of mini welding experiments designed to provide a starting point for further statistical development of the welding parameters The user should adjust the key welding variables energy force time in order to identify the likely good weld window Close visual inspection of the weld parts will promote better understanding of the heating cha
98. NG SYSTEM F 2 990 3 0 APPENDIX F THE BASICS OF RESISTANCE WELDING MATERIAL MATERIAL MATERIAL Steel 14 Paliney 7 MATERIAL Bronze Copper Silver 11 14 Bronze Copper 4 Cold Rolled 2 Steel Chromel N Copper 14 Stainless Steel Chromel N Dumet Dumet Chromel NO Dumet Nichrome Chromel Dumet 2 Nickel 2 a N N N N N N N N N N N N N 4 gt N N N N N N Chromel Dumet Platinum Chromel 2 Cold Rolled Steel Dumet NO Chromel Evanohm 14 Copper Chromel Gold 14 Gold Gold 4 Consil Kovar NO Consil Hastalloy Titanium Consil Inconel Inconel NO Constantan Inconel Kulgrid Constantan Invar 2 Invar Constantan Iridium 2 Iridium Constantan Iridium 2 Platinum Constantan Iron 2 Iron NO Constantan Karma 2 Karma N Copper Karma Nickel Copper Karma 2 Platinum Kovar Gold Plate 2 Kovar Gold Plate Copper Kovar Gold Plate Copper 2 Kulgrid Kovar Gold Plate Copper 2 Nickel Kovar Gold Plate Copper Silver Kovar Gold Plate N Copper Stainless Steel m Const 2 Copper Magnesium Magnesium HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 F 3 APPENDIX F THE BASICS OF RESISTANCE WELDING ELECT MATERIAL RWMA MATERIAL MATERIAL MATERIAL TYPE Molybdenum 2 Tungsten 2 NiSpan C Cold
99. ONTROL E 15 APPENDIX E COMMUNICATIONS Command Control State Description E 16 NOTES The units of the limit fields parameters depend on the value of the UNITS parameter as follows IN 1000 1 0 001 inches 10 0 01 inches MM 0 01 mm 10 0 1 mm Initial and final thicknesses are positive if the electrodes move farther apart and negative if they move closer together in relation to the zero setting The reference zero setting for thickness measurements may be set using the DISPZERO command Displacement is positive if the electrodes moved closer together during the weld and negative if they moved further apart INITERR controls the HF25 action if an Initial Thickness limit is reached CONT continues the weld and gives an alarm at the end of the weld STOP terminates the weld operation after squeeze time when the initial thickness 1s measured DISPZERO READ CLEAR lt gt Ift Any except while welding Provides control over the Control s displacement measuring zero setting When used with the READ keyword the a d converter counts not actual position for the current zero setting of the upper electrode are returned When used with the CLEAR keyword the host may clear the zero setting and the upper electrode position at the start of the next weld will establish the new zero setting NOTE This zero setting 15 the reference position for the initial and final thickness measurements HF
100. PLAY LCD l WELD PERIOD SELECTOR KEYS CONTROL KEYS KEYPAD ARROW KEYS bip Slee gt MODE KEYS SELECT KEY MONITOR KEYS WELD NO WELD KEY Front Panel Controls HF27 DC RESISTANCE WELDING SYSTEM 1 4 990 3 0 CHAPTER 1 DESCRIPTION Display _ LIQUID CRYSTAL DISPLAY y SCHEDULE SCHEDULE SELECTOR KEY WELD PERIOD SELECTOR KEYS Liquid Crystal Display LCD The Liquid Crystal Display LCD on the front panel allows you to locally program the Control with the front panel controls and read the results of a weld process following its initiation The LCD has three distinct functions depending on the active mode of the Control In the run mode the display permits you to e View the entire weld schedule profile individual weld periods weld energy parameters e View individual weld parameter program changes as you enter them via the weld period selector keys e View completed weld feedback data and use the data to modify the weld schedule In the menu mode the display presents system setup options for you to select In the monitor mode the display is your means of programming the energy limits monitor and viewing actual out of limit conditions HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 1 5 CHAPTER 1 DESCRIPTION Display Controls There are three display control functions e SCHEDULE Selector Key Weld Period Selector Keys e Time Energy Selector Keys SCHEDULE Key Puts
101. PUT TOO LARGE 33 INPUT TOO SMALL 38 LIMIT DELAYS RESET TO 0 39 ACCESS DENIED SYSTEM SECURITY ON 990 3 0 No electrode voltage measurement was made User entered calibration values reset to factory default values The user has tried to program a Lower Limit value that is greater than the Upper Limit value for Weldl or Weld2 time periods User programmed the HF27 25 to automatically reset all 100 weld schedules I O and other system parameters to their factory set default values The HF27 25 internal power dissipation has exceeded the HF27 25 specified capability User has programmed a Lower Limit value for Weldl or Weld2 periods without using an upslope period The HF27 25 will automatically stop when activated because the starting weld energy will always be lower than the Lower Limit The user has attempted to program a weld energy or time that exceeds the capability of the HF27 25 The user has attempted to program a weld energy or time that 15 below the capability of the HF27 25 sum of Pulse 1 or Pulse 2 delays exceeded scheduled time for a pulse limit check Operator tried to change a weld schedule number individual weld schedule parameters I O switch functions and calibration parameters Verity that the Voltage Sense Cable is properly connected to the electrodes or electrode holder NOTE Polarity 15 not important for the cable connection Execute the built in calibration proce
102. RATION 2 WELD COUNTER 1 From the MAIN MENU press the 2 key to go to the WELD COUNTERS screen The total welds counter increments each time a weld 1s made in any weld schedule NOTE The Control breaks down the weld count into three additional categories as WELD COUNTERS gt 1 TOTAL WELDS 2 OUT OF LIMITS HIGH 3 OUT LIMITS LOW 0000000 000000 000000 4 WITHIN LIMITS 000000 Number Select an item RUN or MENU determined by the energy limits monitor rejects due to higher than programmed weld energy rejects due to lower than programmed weld energy and the number of welds within limits 2 select the weld counters press the 1 2 or 4 key to select the desired weld counter The example below shows the TOTAL WELDS screen 3 Toreset the counter press the 0 key 4 input a preset number use the numeric keys 5 If you accidentally reset the wrong counter press the period key The original count will reappear Press the MENU key to return to the MAIN MENU screen 3 COPY A SCHEDULE The Control can store 99 numbered 1 through 99 individual weld energy profiles This function allows you to copy any weld schedule from one numbered weld schedule to another numbered weld schedule 1 From the MAIN MENU press the 3 key to go to the COPY SCHEDULE screen 2 Using the numeric keys enter 1 in the source schedule number field 3 Press the key to select the destination schedule numbe
103. S Page ll Gore X prre Sod Chapter 1 Description E A TENERAS 1 1 72 _______________4 _______ 1 1 TVS 1 1 THOOGUOLTOR 1 2 Scoto 1 4 1 4 Front Panel Display and Display 1 4 DED EA I EA AE ENEE E ARE ETE ARENE E A EEANN 1 5 C OnO E 1 6 SCHEDULE Key 1 6 Weld euro aoreet 1 6 Tini Dneres elector IC YS 1 6 Poat Pinc iData Enny aa Mode oon deed Pn orania tU 1 7 id a 1 7 O O 0 1 7 FI 1 7 MENUT OY n 1 7 1 7 Control Mode Selection Keys 1 8 144 1 8 ddoq 1 8 as UU 1 8 COMBOT A 1 8 1 8 ____ _
104. S SET 4 Arrows to select field RUN or MENU 1 Press the AV buttons to scroll down to the STOP ENERGY AT line 2 Press the keys to scroll right to highlight IN 1000 Press the SELECT key to change to MM This will change all fields to mm Limits and last measurement data will be zeroed HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 5 25 CHAPTER 5 OPERATING INSTRUCTIONS High and Low Limits for Initial Thickness Initial thickness of the parts 15 measured in 1 1000 of an inch or 1 100 of a mm As the electrode goes down the numbers decrease towards zero Initial thickness 1s measured at the end of squeeze time before the weld energy flows Scroll to INITIAL LO LIM Scroll to INITIAL HI LIM LVDT POSITION 092 LO LIM HI LIM LAST INITIAL 037 041 000 FINAL 000 000 000 0000000 CONT DISPLC 000 000 000 XX STOP ENERGY AT 000 XXXX NEW ELECTRODE IS SET 4 Arrows to select field RUN or MENU IN 1000 From the main LVDT screen press the SCHEDULE button to edit the screen Use the numerical keypad on the front of the Control to enter a numerical value Use the numerical keypad on the front of the Control to enter a numerical value Scroll to CONT for Continue If the initial thickness is out of the high or low limits you may choose to have welding continue or stop by pressing the PEAK AVERAGE button it toggles between stop and continue NOTE If you s
105. SYSTEM 990 3 0 H 1 APPENDIX COMPABILITY AND COMPARISON Comparison While most of the improvements in the Controls are transparent to the user new technology and internal components have changed some of the 60 pin I O connections As a result they are not the same as older models To make these new connections quick and easy blank un wired connectors with screw terminals are provided in the Ship Kit Below 15 a Quick Look comparison showing the differences between the old and new I O connections see Appendix Electrical and Data Connections for complete details NEW 25 HF27 5 HEAD 1 HEAD3 NOT ACTIVE HDDTI NOT ACTIVE HEADA air head NOT ACTIVE HEAD4 air head return NOT ACTIVE Use pin 3 HEAD_ 1 switched on new unit 10 NOT ACTIVE NOT ACTIVE 11 FIRE 1 FIRE 1 12 GND 24COM 13 NOT ACTIVE NOT ACTIVE 14 OPTOP power 24VDC NOT ACTIVE 15 CHASSIS GND I O COMMON 16 FOOT 1 FOOT 1 17 FOOT 2 FOOT 2 18 GND 24COM 19 SPOWER FS1 FS2 FIRE_ COM 20 24 OUT 24V OUT 21 24V OUT 24V OUT 22 24V PULL UP I O COMMON 23 24V COM 24COM 24 SCH 0 SCHEDULE O 25 SCH 1 SCHEDULE 1 26 SCH 2 SCHEDULE 2 27 SCH 4 SCHEDULE 4 OLD 25 27 Chassis GND 2 24V COMMON HEADI HEAD2 Old EZ AIR no longer supported 9 Same same same same Use pin 20 21 24 on new unit Use pin 1 50 or 60 on new unit same Same same Same Same Same Sam
106. SYSTEM 990 370 4 5 CHAPTER 4 INTRODUCTION TO FEEDBACK MODES AND MONITORING If production parts are plated there can also be a plating process variation over time resulting in inconsistent welds These minor material variations are a major cause of process instability and it 1s best welding practice to seek to minimize their effect Active Part Conditioner is designed to cope with material contamination variation and can be programmed to apply the exact power to the parts required to displace oxide or contaminants In addition the Part Conditioner pulse will terminate at a precise current flow preventing the sudden high flow which occurs when the oxide 15 displaced This prevents weld splash and material expulsion which occurs as a result of an excessively fast heating rate Part conditioning can help to reduce variations in contact resistance from part to part caused by different fit up of parts It will stabilize the contact resistances before the main welding pulse therefore reducing variation from weld to weld How It Works Both constant current feedback and constant voltage feedback modes are limited in their ability to deal with varying levels of part contamination and oxide If constant current feedback were used the power supply would ramp the voltage to very high levels in order to achieve current flow through the oxide This rapid input of current 15 likely to cause splash especially with round parts Constant voltage mode 15 n
107. USER S MANUAL 990 370 Revision F November 2014 AMADA MIYACHI AMERICA INC HF27 25kHz HIGH FREQUENCY DC RESISTANCE WELDING SYSTEM MODEL NUMBER STOCK NUMBER HF27 240 1 320 01 HF27 400 1 320 01 01 HF27 480 1 320 01 02 Copyright 1998 2014 Amada Miyachi America The engineering designs drawings and data contained herein are the proprietary work of Amada Miyachi America and may not be reproduced copied exhibited or otherwise used without the written authorization of Amada Miyachi America Printed 1n the United States of America Revision Record A 20294 03 05 None Original edition 21590 09 07 Weld Status Codes added to Appendix E Communications Important Note The HF27 contains advanced technology and improved features yet from an operational standpoint it performs the same as older Miyachi Unitek Controls See Appendix H Compatibility and Comparison for an overview of the differences between the new and old models This manual describes HF27 Models 1 320 01 1 320 01 01 1 320 01 02 manufactured after June 2005 which contain significant differences than older models HF27 models 1 287 01 1 287 01 01 and 1 287 01 02 manufactured before June 2005 require a different manual To get User s Manual 990 335 for older HF27 models order a copy using the phone number or e mail address listed under Contact Us on page ix of this section HF27 DC RESISTANCE WELDING SYSTEM 990 370 CONTENT
108. WELDING SYSTEM 5 22 990 370 CHAPTER 5 OPERATING INSTRUCTIONS Section IX Energy Monitor Press the ENERGY key and the screen on the right appears MONITOR 0 048 2 229 20992511 UPPER LOWER none none none In this screen you can program upper and lower watt second limits for the first and second pulse The display will show the calculated watt second values for the first and second pulse Refer to Section III of this chapter for specific instructions on setting upper and lower limits and out of limit actions Note The upper limit applies to the entire upslope weld and downslope time The lower limit applies for and is checked only at the end of P1 and the end of P2 Note that the energy is cumulative through both pulses The energy displayed at the end of P2 1s the sum of the energy delivered during P1 and P2 HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 5 23 CHAPTER 5 OPERATING INSTRUCTIONS Section X Distance Monitor Distance Limits Displacement Displacement 1s how far the weld pieces collapsed during the weld the difference between the initial part thickness and the final part thickness You can place high and low limits around displacement as well LVDT Main Screen From the LVDT keys section on the LVDT POSITION 092 3600277 front panel press the DISTANCE key LO LIM HI LIM and the screen on the right appears INITIAL 000 000 000 5 FINAL 000 000 000 DISPLC
109. Weld Head Plug and play connector with Firing and Foot switch inputs Voltage Sense input and 24VDC Air Valve Driver output Output Signals Monitor Internal analog voltage signals representing secondary current feedback 0 5 VDC primary current 0 4 VDC or weld voltage 0 5 VDC Air Valve Driver 24 1 amp timing controlled by the HF27 No weld over force protection Alarm Relay Four programmable mechanical relays 24 VAC VDC at 1 amp RS232 Monitor weld parameter data Download and upload schedules RS485 Monitor weld parameter data Daisy chain RS485 input with RS485 output from other HF25 Controls and host computer Download and upload schedules 24V OUT 24 VDC power supply polyfused at 1 amp HF27 DC RESISTANCE WELDING SYSTEM A 4 990 3 0 APPENDIX Electrical and Data Connections Section l Electrical Connection Input Power As described in Chapter 2 you need to supply a connector for the Control input power cable see diagram below Connect the Control power cable to a 3 phase 50 60Hz power source The voltage range for each model is set at the factory by a set of two jumper plugs One jumper plug 15 installed on power connector J23 located on the center chassis plate The other jumper plug P22 plugs into welding transformer cable connector J22 The jumper plug set determines the power wiring configuration between the power board and the welding transformer Input Power Wiring Diagram 1 2
110. ___ 1 8 NTS GY 1 9 NU d 1 9 m 1 9 eund 1 9 d P 1 9 FORCE m 1 9 DISTANCE Key 1 9 ENVELOPE Key 2288 1 9 A WA 1 10 ENERGY 1 10 HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 li CONTENTS Continued Page WELDINO WELD ooo ixi enar temet _ IUE 1 10 wire CODETOLIOT cuo 1 10 Section IM LYDT Capability 1 11 Chapter 2 Installation and Setup ere 2 1 2 1 E RE TTE TTE TT E 2 2 2 a HUHE 2 2 Compressed Arand COO VV AG __ _ ___ 2 2 SEDIS cassetta UE 2 3 Connections to 2 3 Rear Panel Components and 2 3 Weld Head C OIG CHO IG _ _ __ _____ 2 4 Foot Pedal Actuated Weld Head
111. able relay outputs are also provided with this option e The Control has 0 5 volt input for a weld force transducer This input allows the user to put limits around the firing force and the final force used during the weld e The Control has a 0 5 volt output to drive a proportional valve This allows the user to adjust the weld force from the Control and change it in each schedule e The design of the Control is directed toward compactness lightweight operational simplicity and ease of repair Metric hardware is used throughout the chassis to facilitate international servicing and repair The 25 kHz operating frequency ensures that the integral welding transformer 15 light and compact The input output connectors on the rear panel provide for quick connect signal I O cabling facilitating interface with automation systems HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 1 3 CHAPTER 1 DESCRIPTION Section Major Components Major Components The major components are the front panel which contains the operator s controls and indicators and the rear panel which contains fuses circuit breakers and power and signal connectors The rear panel connections are discussed in Chapter 2 Installation and Setup Front Panel Display and Display Controls The front panel of the Control below shows controls and indicators The function of each item 15 described on the following pages LIQUID CRYSTAL 1 QE lt SCHEDULE KEY DIS
112. ailed below To set a new zero without recalibration 1 From the MONITOR keys section on ZERO LVDT OR FORCE the front panel press the ZERO key 1 ZERO LVDT and the menu on the right will appear 2 ZERO TARE FORCE NUMBER Select an item Run or Menu 2 To zero the press 1 and the ZERO LVDT screen on the right will appear A NEW LVDT ZERO WILL BE SET AT THE During the next weld the initial NEXT WELD position will be set to 0 3 Press A to return to the previous menu or press Run to continue welding or press Menu for the MAIN Page Run or Menu MENU HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 C 7 APPENDIX C CALIBRATION Section Ill Force Calibration Overview The following procedures calibrate the Proportional Valve and the Load Cell The Proportional Valve controls the force the Load Cell monitors the force Both must be calibrated simultaneously in order for the Control to perform accurately Force Calibration CAUTION Make sure to connect the electronic pressure regulator according to its voltage range 0 5V or 0 10V OV corresponds to 100 psi and full voltage corresponds to 100 psi Lo psi during calibration will be about 30 psi and Hi psi will be about 80 psi Make sure the force gauge used and the electrodes can withstand the force of the weldhead at 80 psi C 8 Press the CAL key on the front panel to lt FORCE CALIBRATION get the Calibration menu 1 FORCE UNITS LBS 2 FOR
113. al Weld Strength Profile different applications might show that they could be consolidated into one or two weld schedules This would have obvious manufacturing advantages HF27 DC RESISTANCE WELDING SYSTEM F 6 990 370 APPENDIX G Quality Resistance Welding Solutions Defining the Optimum Process Introduction A quality resistance welding solution both meets the application objectives and produces stable repeatable results in a production environment In defining the optimum process the user must approach the application methodically and consider many variables In this article we will look at the following key stages and principles to be considered when defining the optimum resistance welding process e Materials and their properties e Basic resistance welding e principles e Weld profiles e Approach to development e Common problems e Use of screening DOE s e Use of factorial DOE s Resistance Welding A Material World The first consideration in designing a quality welding solution is the properties of the materials to be joined and the quality requirements of the desired welded joint At this stage it is worthwhile to review the way the resistance welding process works and the likely outcome when the parts are resistance welded There are four main types of structural materials e Metals silver steel platinum e Ceramic alumina sand Plastics polymers PVC teflon e Semiconductors silicon geranium
114. amming Relays From the MAIN MENU press the 7 key to go to the RELAY output state selection menu shown at the right The Control has four relays that can provide dry contact signal outputs under many different conditions RELAY OTHER FORCE LIMIT ALARM ALARM ALARM RELAY1 ON RELAY2 ON RELAY3 ON RELAY4 ON Number Select an itemRUN or MENU See Appendix C System Timing for the timing diagrams for the four relays 2 From the RELAY menu press the 1 key RELAY 1 gt to go to RELAY 1 shown at the right 1 SET RELAY TO 2 WHEN 3 Press the 1 key to toggle the relay contact signal state ON closed or OFF open Number Select Page RUN or MENU 4 Press the 2 key to select the WHEN lt WHEN gt menu shown at the right ALARM kKA amp V OUT OF LIMITS kW amp R WELD OTHER END OF WELD MG3 SYNC P1 amp P2 LVDT Number Select Page RUN or MENU 5 Press the 2 key to select OUT OF LIMITS 1 gt as the condition for initiating the Relay 1 SET RELAY TO ON 1 output signal This will bring up the 2 WHEN OUT OF LIMITS RELAY 1 menu screen where the WHEN line will now reflect OUT OF LIMITS Number Select Page RUN or MENU 6 Choosing WHEN options 1 4 9 will RELAY 1 gt complete the relay programming 1 SET RELAY TO ON i 2 WHEN OUT OF LIMITS process Choosing options 5 8 or 0 S DUREE will bring up the RELAY 1 2 3 or 4 screen with a new option
115. anded leads The firing switch cable connector is a 2 pin Amphenol Type 80 MC2FI It mates with the weld head firing switch connector which 15 a 2 Pin Amphenol Type 80 MC2M Firing Switch Connector FIRE 1 to fire Control connect to pin 2 HF27 DC RESISTANCE WELDING SYSTEM 990 370 B 13 APPENDIX ELECTRICAL AND DATA CONNECTIONS Operator Emergency Stop Cable Switch Input Function You must connect a normally closed single pole switch across both cable leads otherwise the Control cannot be turned ON Use the switch during Control operation as an emergency stop switch When operated opened it will immediately halt the weld process NOTE You must press the RUN key on the front panel to reset the Control following an emergency stop operation Connections Connect an approved normally closed emergency stop switch across the 2 foot 61 cm operator emergency stop switch cable When the switch 1s operated opened it de energizes the main power contactor removing three phase input power to the Control HF27 DC RESISTANCE WELDING SYSTEM B 14 990 3 0 APPENDIX B ELECTRICAL AND DATA CONNECTIONS PLC Timing Diagram Weld Head Control Signal Weld Head Position Weld Head Position Signal Squeeze Delay Signal Remote Sched select Inputs HF25 Weld Pulse j i Weld Hold Release Period Period Weld Head Trigger
116. anel press the resistance key and observe the resistance waveform This should appear to begin high then start to drop as a tack weld is made and the resistance decreases From the MONITOR keys section on the front panel press the kA current key and observe the current waveform starting to rise as the resistance decreases If the current waveform starts to flatten this 1s an indication that the resistance has stabilized and the parts have come into closer contact Push RUN and optimize the energy and time setting of Pulse 1 to provide an adequate tack weld and also a current waveform view in the monitor screen that has started to flatten out but 15 still rising This indicates that a full melt has not yet occurred From the MONITOR keys section on the front panel press the kA 2 key to program an upper current limit on the MONITOR screen UPPER 37 ka 2 50 LOWER none STOP P1 STOP NOTE You can toggle between PEAK and AVERAGE readings by pressing the PEAK AVERAGE key Press the COOL weld period PULSE 1 OUT OF LIMITS ACTION key This will bring up the dons PULSE 1 OUT OF LIMITS STOP WELD ACTION screen INHIBIT PULSE2 PART CONDITIONER Stop Pulse1 9 Select 4 PART CONDITIONER Stop Pulse1 NUMBER Select MENU Previous menu HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 9 19 CHAPTER 5 OPERATING INSTRUCTIONS NOTE For more details on this process see Resistance Set
117. apter 5 Operating Instructions Current Mode Application e Flat parts where the part to part and electrode to part contact is controlled and consistent Description This mode delivers the programmed current regardless of work piece resistance changes This compensates for slight changes in part thickness without affecting weld quality Set monitoring limits on voltage Voltage Mode Application e Ideal for welding round or non flat parts Description This mode controls the voltage across the work piece during welding It helps to compensate for part misplacement and force problems and automatically reduces weld splash which 15 often associated with non flat parts and wire welds Set monitoring limits on current HF27 DC RESISTANCE WELDING SYSTEM 990 370 4 1 CHAPTER 4 INTRODUCTION TO FEEDBACK MODES AND MONITORING Power Mode Application Breaking through surface oxides and plating e Automated applications where part or electrode surface conditions can vary over time Description This mode precisely varies the weld current and voltage to supply consistent weld energy to the parts The power mode has been shown to extend electrode life in automated applications Set monitoring limits on current or voltage Combo Mode Application e Ideal or welding round parts or projections especially those with poor initial fit up or oxides Breaking through surface oxides and plating Description Combo mode star
118. atible weld piece projection esign Contaminated weld piece surface plating Incompatible weld piece materials Contaminated electrode surface Wrong electrode tip shape No cover gas on weld piece Excessive weld time set at HF27 25 me eS Se HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 Cause in order of probability Cause in order of probability Excessive weld time set at HF27 25 Weld Piece Over heating Excessive current energy set at HF27 25 Discoloration Insufficient weld head force Wrong electrode material tip shape 1 2 2 3 Incompatible weld piece materials 3 4 Contaminated electrode surface Alarm Messages Alarm Message 01 CHECK CONTROL SIGNALS INPUT STATUS 02 CHECK INPUT SWITCH STATUS 03 FIRING SWITCH BEFORE FOOT SWITCH 04 EMERGENCY STOP ON CONTROL SIGNALS INPUT 05 TRANSISTOR OVERHEATED 06 EMERGENCY STOP OPERATOR ACTIVATED 07 FIRING SWITCH DIDN T CLOSE IN 10 SECONDS 990 3 0 One or more of the I O input control signals 15 preventing the HF27 25 from continuing to operate bits on the remote schedule input port are set ON The Firing Switch input has been activated before the Foot Switch has been activated preventing weld current from flowing The Process Stop signal on the CONTROL SIGNALS connector has been activated immediately terminating weld current The power dissipated by the power
119. ation of dual pulse the Pulse 1 weld period provides sufficient heat to displace the plating or oxides seat the electrodes against the base metals and force the parts into intimate contact The cool period allows time to dissipate the heat generated during Pulse 1 The Pulse 2 weld period completes the structural weld The Pulse 2 weld current is typically greater than the Pulse 1 weld current by a factor of 3 as the first pulse significantly reduces the resistance of the interface between the parts The only use for the downslope period following the Pulse 1 or Pulse weld period is to control grain refinement in brittle parts by slowly reducing the weld current to zero during the downslope period The dual pulse weld profile is very valuable for pre checking gross parts positioning problems and reducing parts scrap Use the Pulse 1 weld at 0 050 kA or less and 2 0 ms as a pre check pulse Experiment with upper and lower limit values that you can use to inhibit the Pulse 2 weld if the test conditions measured by the Pulse 1 weld are out of limits NOTE Upslope is required when a lower limit value is programmed HF27 DC RESISTANCE WELDING SYSTEM 990 370 3 27 4 Introduction to Feedback Modes and Monitoring Section 1 Programmable Feedback Modes Introduction The feedback mode current voltage power or combo is one of the selections entered when programming a weld schedule Programming weld schedules 15 explained in Ch
120. closed loop welding control using internal and external sensors to measure the weld energy delivered to the weld head Weld energy feedback instantly goes to the Control s logic circuits that actively correct the pulse to compensate for any variation in part resistance The Control also has several monitor functions that give you remarkable control over the welding and production process Together these features ensure precise consistent welds higher productivity a lower rejection rate and longer electrode life Before operating the Control it is important to know how to match the Control s capabilities to specific weld applications This section provides Weld details in the following order e Weld Schedules Single Pulse Upslope Downslope Dual Pulse Chapter 5 Operating Instructions contains the step by step instructions on how to program each of the functions above HF27 DC RESISTANCE WELDING SYSTEM 990 370 3 23 CHAPTER 3 SYSTEM CONFIGURATION Weld Schedule Definition Weld Schedule 15 the name given to each of 99 separate weld profiles stored the Control numbered from 01 to 99 A weld profile is the graphic representation or waveform of the numeric weld time and weld energy values NOTE There is an additional weld schedule numbered 00 which can be used as a scratch pad to develop new weld schedules When time and energy values are entered using the numeric keypad the Control displays a line graph of the weld profile
121. d Control State Description Command Control State Description Command Control State Description 990 3 0 APPENDIX E COMMUNICATIONS OHMS number of data lt crlf gt data lt crlf gt data lt crlf gt data lt crlf gt lt If gt Any Returns the Resistance waveform data of the last weld First field is the number of data to be sent Then follows the packets of data Each data is separated by lt crlf gt and this command ends with lt crlf gt lt If gt number_of_data This is the number of data that shall be included in this Command The Control samples Current and Voltage every 40 us For a weld less than 80 ms weld time the number of data will be approximately total weld time 40 us This number will be always less than 2000 integer number in unit of mOhms ENERGY number of data lt crlf gt data gt data crlf data crlf lf Any Returns the energy waveform data of the last weld First field 1 the number of data to be sent Then follows the packets of data Each data is separated by lt gt and this command ends with lt crlf gt lt If gt number of This is the number of data that shall be included in this Command The Control samples Current and Voltage every 40 us For a weld less than 80 ms weld time the number of data will be approximately total weld time 40 us This number will be always less than 2000 Data An integer number in units of joules
122. damage prior to its installation Should there be any damage please immediately contact the shipping company to file a claim and notify us at Amada Miyachi America 1820 South Myrtle Avenue P O Box 5033 Monrovia CA 91017 7133 Telephone 626 303 5676 FAX 626 358 8048 e mail info amadamiyachi com The purpose of this manual is to supply operating and maintenance personnel with the information needed to properly and safely operate and maintain the Miyachi Unitek HF25 Resistance Welding System Control We have made every effort to ensure that the information in this manual is accurate and adequate Should questions arise or if you have suggestions for improvement of this manual please contact us at the above location numbers Amada Miyachi America is not responsible for any loss due to improper use of this product HF27 DC RESISTANCE WELDING SYSTEM 990 370 SAFETY NOTES e Lethal voltages exist within this unit Do not perform any maintenance inside this unit e Never perform any welding operation without wearing protective safety glasses This instruction manual describes how to operate maintain and service the HF25 resistance welding system control and provides instructions relating to its safe use separate manual provides similar information for the weld head used in conjunction with the power supply Procedures described in these manuals must be performed as detailed by qualified and trained personnel
123. dback performance The weld status message TEST disappears after the internal control parameters are optimized Pressing the kW key selects power as the control mode for this schedule The control will output the power waveform shown on the LCD This allows the user to start a weld in voltage or power mode and then switch to a constant current when the user selected current level 1s reached NOTES COMBO mode can be selected independently for pulse 1 and pulse 2 e Limits and Monitor functions will still apply for this mode Monitor Keys These keys allow you to view the results of the last weld and to set the limits of the welding parameters beyond which the energy limits monitor terminate the weld and or initiate alarms Pressing the kA key displays the current monitor This screen shows the results of the most recent weld This screen also allows the operator to set limits that automatically interrupt the weld when they are reached You can also program the current monitor to output an alarm when the limits are exceeded HF27 DC RESISTANCE WELDING SYSTEM 1 8 990 370 990 370 CHAPTER 1 DESCRIPTION Pressing the V key displays the voltage monitor This screen shows the results of the most recent weld This screen also allows the operator to set limits that automatically interrupt the weld when they are reached You can also program the voltage monitor to output an alarm when the limits are exceeded P
124. de to its UP position so that you may re position the weld pieces If you do not release the foot switch at the first level and proceed to the second level the force firing switch in the weld head will close Weld current will flow and the Control will automatically return the upper electrode to its UP position Using the supplied Configuration plug on Pins 11 20 allows the use of the Miyachi Unitek 2 level footswitch directly If a PLC or other means of trigger 1s used refer to the O Signal Interface General Description on page B 3 Foot 2 to activate Foot Switch Level 2 connect to pin 4 24COM Standard Air Valve Driver Output Connector The air valve driver output 24V AC is initiated when Foot Switch Level 1 is initiated Using the supplied Configuration plug on Pins 11 20 allows the use of the Miyachi Unitek 2 level footswitch directly If a PLC or other means of trigger 15 used refer to the Signal Interface General Description on page B 3 The mating connector is an AMP type 206429 1 using cable clamp AMP type 206358 2 The two male pins used are Amp type 66361 2 Air Valve Driver 24 VAC Connector 24V AC for solenoid HEAD 1 Switched 24V common HF27 DC RESISTANCE WELDING SYSTEM 990 370 T APPENDIX ELECTRICAL AND DATA CONNECTIONS Voltage Sense Input Connector The voltage leads are connected to the electrode holders to sense weld voltage Voltage Sense Input Connector Description
125. displacement and allows the user to set a thickness at which the unit will stop providing energy to the weld This key brings up the ENVELOPE function for the graphical monitor trace presently on the screen or last used monitor screen if the unit 1s in the RUN mode This allows setting independent upper and lower offsets around the waveform displayed on the screen Independent envelope modes current voltage or power can be selected for Pulse 1 and Pulse 2 The function of the time screen 1s to allow the user to program limits around the Cut Off time The Cut Off time 15 defined as the time when the control system commands current to turn off Current can be turned off either by reaching a weld to type of limit or by reaching the end of the pulse HF27 DC RESISTANCE WELDING SYSTEM 1 9 CHAPTER 1 DESCRIPTION The user will be able to program upper and lower energy limits for the first and second pulse The display will show the calculated watt second value for the first and second pulse The limits will apply for the entire upslope weld and downslope time WELD NO WELD Switch When the switch is in the WELD position the programmed weld sequence can initiate weld energy When you set this switch to the NO WELD position weld current can flow However the Control can execute a complete weld sequence This function is required to adjust the weld head prior to operation NO WELD Emergency Stop Switch Operation If you
126. ditions to ensure that all functional criteria will be met Validation testing 1s usually required to prove the robustness of the process under production conditions HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 G 11 APPENDIX G DEFINING THE OPTIMUM PROCESS Conclusion The resistance welding process can deliver a reliable and repeatable joining solution for a wide range of metal joining applications Defining the optimum welding process and best production settings can be achieved through a methodical and statistical approach Time spent up front in weld development will ensure a stable welding process and provide a substantial return in quality and long term consistency Welding problems can more easily be identified and solved if sufficient experimental work is carried out to identify the impact of common variables on the quality and variation of the welded assembly Amada Miyachi America frequently uses the Screening DOE tool to establish the impact of key variables and to assist customers with troubleshooting Often the testing described above will provide the information and understanding to predict common failure modes and causes A troubleshooting guide can be requested in the form of a slide rule to assist users in identification of welding problems and likely causes HF27 DC RESISTANCE WELDING SYSTEM G 12 990 370 APPENDIX H Compatibility and Comparison Compatibility While the HF27 contains advanced technology and improved features
127. ds Make a few welds and verify that the welds are acceptable 3 From the MONITOR keys section on the front panel press the kA current V voltage kW power and resistance keys observe the resulting waveforms NOTE You can toggle between PEAK and AVERAGE readings by pressing the PEAK AVERAGE key 4 Press the V voltage key and observe the voltage waveform Observe the peak and average readings on the voltage monitor screen Make several more welds and observe the range of voltage readings from weld to weld 6 E Press the Pulse 1 weld key to highlight the upper limit field for the weld period Use the numeric keypad to enter the upper limit value for the Pulse 1 weld period Program an upper voltage limit that 1s slightly above the peak voltage readings observed in step 5 above 7 Press the voltage V key to save the setting as an upper voltage limit 8 Press the COOL weld period PULSE 1 OUT OF LIMITS ACTION key This will bring up the i PULSE 1 OUT OF LIMITS ACTION screen 3 INHIBIT PULSE2 4 PART CONDITIONER Stop Pulse1 9 Select 1 STOP WELD NUMBER Select MENU Previous menu 10 Toggle the Pulse 1 weld key to highlight the lower limit field for the Pulse 1 weld period Use the numeric keypad to enter a lower limit value with a voltage level that 1s slightly lower than the voltages observed in step 3 above 11 Press the voltage V key to save the setting as a lower voltage limit
128. dure to get the correct setting Re program the invalid Lower Limit value CAUTION Be careful when using the MENU default features There is no way to restore a default action Reduce duty cycle Reduce weld time Delete the 1 or Weld2 Lower Limit value Add an upslope period before Weldl or Weld2 if a Lower Limit value 15 desired Re program welding parameters to be within the capability of the HF27 25 Re program welding parameters to be within the capability of the HF27 25 Revisit Pulse 1 or Pulse 2 delays and set them to acceptable values Press MENU select System Security then enter the correct access code to turn off the System or Calibration Lock protection features NOTE Entering a security code of 280 will always unlock the system HF27 DC RESISTANCE WELDING SYSTEM 6 5 6 40 ILLEGAL SECURITY CODE ENTERED 47 ACCESS DENIED SCHEDULE LOCK ON 48 INITIAL THICKNESS LO 49 INITIAL THICKNESS HI 50 FINAL THICKNESS LO 51 FINAL THICKNESS HI 52 DISPLACEMENT 53 DISPLACEMENT 54 WELD STOP DISPLACEMENT REACHED 55 P1 CURRENT gt THAN UPPER LIMIT 56 CURRENT 1 lt THAN LOWER LIMIT 6 6 The wrong security code was entered to de activate the System Schedule or Calibration Lock protection features Operator tried to change a weld schedule or
129. e Same Same Same Same Same HF27 DC RESISTANCE WELDING SYSTEM 990 370 APPENDIX COMPABILITY AND COMPARISON OLD 25 27 NEW 25 27 SCH 8 SCH 16 SCH 32 INHIBIT STOP RELAY 1 RELAY IR RELAY 2 RELAY 2R RELAY 3 RELAY 3R RELAY 4 RELAY 4R Con Ret for EMO 24V AC for EMO NOT ACTIVE NOT ACTIVE NOT ACTIVE I5VDC power ISVDC power SCHEDULE 8 SCHEDULE 16 SCHEDULE 32 WELD INHIBIT CURRENT STOP RELAY 1 RELAY IR RELAY 2 RELAY 2R RELAY 3 RELAY 3R RELAY 4 RELAY 4R NOT ACTIVE NOT ACTIVE FORCE GROUND FORCE READ 10 INPUT NOT ACTIVE NOT ACTIVE 28 same 29 30 3l 32 33 34 35 36 37 38 39 Same Same Same Same Same Same Same Same Same Same Same Same 41 42 43 Use EMO cable on new unit 45 Input range 0 10V HF27 ONLY option No 15VDC available on new unit 47 No 15VDC available on new unit Different input range 0 5 27 ONLY option FORCE INPUT FORCE READ 5 INPUT GND FORCE GROUND CHASSIS GND CHASSIS GND NOT ACTIVE NOT ACTIVE LVDTPRII LVDTGND LVDTPRD LVDTPRII LVDTSECI LVDTPRD LVDTSEC2 LVDTSECI LVDTCG LVDTSEC2 NOT ACTIVE LVDTGND same 50 same 51 52 53 54 55 56 57 same Different HF27 ONLY option Different HF27 ONLY option Different HF27 ONLY option Different HF27 ONLY option Different HF27 ONLY option Different HF27 ONLY option Different output range 0 5V 27 ONLY 58 FORSET FORCE SET 5 op
130. e Control to enter a numerical value of the displacement when you want the weld energy to stop Example On the LVDT screen the WELD STOP DISPLC REACHED 8MS 0000283 results show that the STOP ENERGY AT LOLIM HILIM LAST displacement was programmed for 003 INITIAL 000 000 056 GONT 2 The STOP ENERGY AT T FINAL 000 000 046 E DURO ANA DISPLC 000 000 010 18 always be less than the actual STOP ENERGY AT 003 008 IN 1000 displacement The actual displacement NEW ELECTRODE IS SET was 4010 as shown in the LAST AW Arrows to select field RUN or MENU column Last Weld The time at which the weld reached the displacement limit is shown in the LAST column On the RUN screen the same WELD STOP DISPLC REACHED 8MS 0000276 information is displayed on the right 1 The current shaded graph was turned OFF before the programmed time because the WELD TO thickness was 150 ai Fia 1 0 D O50 ms reached NOTE See relay screens for options to signal operators or automation of errors HF27 DC RESISTANCE WELDING SYSTEM 5 28 990 370 CHAPTER 5 OPERATING INSTRUCTIONS Section Xl Force Monitor Force Limits Description Force Control FORCE OUTPUT can control one electronic pressure regulator This electronic pressure regulator 15 often referred to as a proportional valve Output Force 15 programmed in Ibs kg or using front panel controls Once the Operator calibrates the output and programs the Output Force the Cont
131. e exceeded In addition to inhibiting the weld the Control has four programmable relay outputs which can be used to trigger alarms to signal operators of weld faults or signal automation equipment to perform pre programmed actions such as stopping the production line so the faulty weld piece can be removed The monitor measures the weld energy parameters during the weld period and compares the measurements against the programmed limits If any of the programmed limits are exceeded the energy limits monitor sets the Control to a state selected from the OUT OF LIMITS ACTION menu In addition the Control s relays can be programmed to trigger alarms or trigger an action in an automated welding system WELD STOP LIMIT REACHED 0000178 1 2 5000 2 300 159 3 0 3 0 00 20 00 00 050 ms In the profile above the weld current limit is at a sufficient level to get good weld In this case the operator has selected the option to terminate the weld energy under this condition so the energy limits monitor terminates the Pulse 1 weld and inhibits the Pulse 2 weld if it had been programmed NOTE When using the energy limits monitor always select a monitor mode that is different from the feedback mode For example e If you are welding in constant current monitor voltage e If you are welding in constant voltage monitor current e If you are welding in constant power monitor current or voltage HF27 DC RESISTANCE WELDING SYST
132. e indicator index 2 Connect the weld head firing switch cable connector to the Control firing switch cable connector 3 Connect a normally closed approved emergency stop switch across the two leads of the operator emergency stop switch cable This switch when operated open will immediately stop the weld cycle and retract the weld head See Appendix B Electrical and Data Connections for circuit details 4 Connect a Model FS2L Foot Switch to the Control FOOT SWITCH connector HF27 DC RESISTANCE WELDING SYSTEM 2 8 990 3 0 CHAPTER 2 INSTALLATION AND SETUP 5 Refer to the weld head manufacturer user s manual Connect the weld head air valve solenoid cable connector to the Control AIR VALVE DRIVER connector NOTE This connector supplies 24 power only and will drive 115 air valves 6 Connecta properly filtered air line to the air inlet fitting on the weld head Use 0 25 inch O D by 0 17 inch I D plastic hose with a rated burst pressure of 250 psi Limit the length of the air line to less than 40 in 1 m or electrode motion will be very slow NOTE Use a lubricator only with automated installations 7 Turn on the air system and check for leaks 8 Setthe WELD NO WELD switch on the Control front panel to the NO WELD position In this position the Control cannot deliver weld energy but it can control the weld head 9 Setthe circuit breaker on the rear panel 419104019194 of the Control
133. e more common materials used micro resistance welding today Ti 6AI 4V OFF Scale Inconel Nichrome 800 Group Il TE 600 e i Resistivity Stainless Steels nano ohm 304 316 etc Group 400 Group Br f Pt Ir 200 gt 500 1000 1500 2000 2500 3000 3500 Melting Point C The materials can be grouped into three common categories The types of joints achievable within each of the main groups are detailed below e Groupl Conductive Metals Conductive metals dissipate heat and can be difficult to focus heat at the interface solid state Joint 1s therefore preferred Typically resistive electrode materials are used to provide additional heating HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 5 3 APPENDIX G DEFINING THE OPTIMUM PROCESS e Group Il Resistive Metals It is easier to generate and trap heat at the interface of resistive metals and therefore it is possible to form both solid state and fusion welds depending on time and temperature Upslope can reduce contact resistances and provide heating in the bulk material resistance Group 11 Refractory Metals Refractory metals have very high melting points and excess heating can cause micro structural damage A solid state joint 15 therefore preferred The chart below gives some guidance on the type of joint that can be expected and design considerations required when joining materials fr
134. e number COUNTERS READ TOTAL HIGH LOW lt gt lt gt Requests the Control to return the Control weld counter contents TOTAL Returns the total number of weld counter HIGH Returns the out of limits high counter LOW Returns the out of limits low counter GOOD Returns the within limits counter REPORT ALL 1 1 ERASE number lt crlf gt lt lf gt Requests the Control to send the weld report All a request to send the number of oldest weld reports all fields since the last data collection The reported weld data will not be erased P1 a request to send the number of oldest weld reports only pulse 1 related fields since the last data collection The reported weld data will not be erased P2 a request to send the number of oldest weld reports only pulse 2 related fields since the last data collection The reported weld data will not be erased LVDT a request to send the number of oldest weld reports only the LVDT related fields since the last data collection The reported weld data will not be erased HF27 LINEAR DC RESISTANCE WELDING CONTROL 990 370 APPENDIX E COMMUNICATIONS Description ERASE a request to erase the number of oldest welds Continued number the number of weld data to be sent If the number is greater than the number of weld data in the buffer less than the number of weld data will be sent NOTE There must be at leas
135. e user must establish an acceptable window for energy time and force thus preventing voided results It is common practice to include one or all of the above variables in a Screening DOE This 15 only recommended if sufficient understanding has been established for the other application and process variables that can impact quality Users should first try to screen out all common application and process variables that require further exploration from the results of the look see mini experiments and then include the three key welding variables energy force and time Several Screening DOE s may be required Results should be interpreted carefully Typically one would look for the highest result in terms of quality with the least variation A Screening DOE provides only a measurement that indicates the relative importance of a parameter and not the ideal setting Factorial DOE s should be used to establish the correct or best setting for a parameter once many of the other variables have been screened and fixed This 15 also the time to assess the measurement accuracy and consistency of the test method and procedure Variation in test method can invalidate the test and lead to misinterpretation of results What are Factorial DOE s The purpose of a Factorial DOE 15 to narrow in on the optimal setting for a particular parameter This method is generally used when the critical or main key variables have been identified and we need to establish the b
136. ed by the software using inputs from a calibration setup during a weld process Following a few calibration inputs the Control will adjust itself and store the calibration values in RAM where they will be used as standards for the operational welding parameters CAUTION Only authorized personnel should perform this procedure Calibration Equipment Required The required equipment for the setup 1s as follows e 2 weld cables No 2 0 1 ft 30 cm long PN 2 0 e 100010 coaxial shunt resistor accurate to 0 2 Source for shunt resistor Model R7500 8 T amp M Research Products Inc 139 Rhode Island Street NE Albuquerque NM 87108 Telephone 505 268 0316 e Shielded voltage sense cable PN 4 32998 01 e Digital oscilloscope Tektronix 724C or equivalent e Male BNC to dual binding post e 2 wire normally open switch for weld initiation mating connector PN 520 011 Coaxial BNC to BNC cable HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 C 1 APPENDIX C CALIBRATION Calibration Procedure FIRING SWITCH WELDING CABLES RG 58 COAXIAL OSCILLOSCOPE LEAD Initial Calibration Setup l Connect the calibration setup to the CALIBRATION Control as shown HF27 CALIBRATION LVDT GAUGE 2 Turn the Control ON LVDT CALIBRATION LVDT QUICK CALIBRATION From the MONITOR keys section on the FORCE CALIBRATION front panel press the CAL key and the menu on the right will appear Number Se
137. elect CONT it will continue to weld even if it 15 out of limits If you choose STOP it will stop and not weld 7 Verify that the weld schedule has at least 1 msec squeeze time Amada Miyachi America recommends 150 msec Example In the screen on the right The INITIAL LO LIM was set to 037 0 the HI LIM was set to 041 0 and Continue was set to Stop if the parts were out of limits This weld was stopped because the LAST shows only 0 022 inch ower than the INITIAL LO LIM This indicates a weld piece was missing or too thin LVDT POSITION 092 LO LIM HILIM LAST INITIAL 037 041 022 FINAL 000 000 000 0000000 STOP DISPLC 000 000 000 STOP ENERGY 000 XXXX NEW ELECTRODE IS SET 4 Arrows to select field RUN or MENU IN 1000 NOTE See Section XIV Programming Relays for setting relay actions High and Low Limits for Final Thickness FINAL thickness 1s measured at the end of hold time after the weld You can put high and low limits around final thickness The Control will give you an alarm on the screen which says out of limits See Section XIV Programming Relays for setting relay actions HF27 DC RESISTANCE WELDING SYSTEM 5 26 990 370 CHAPTER 5 INSTRUCTIONS 1 Scroll to FINAL LO LIM LVDT POSITION 092 0000000 LOLIM HI LIM LAST 2 Use the numerical keypad on the front INITIAL 037 041 4000 CONT of the Control to enter a numerical FINAL 000 000 0
138. ent for the parameters tested and the variation in the welded result This is important as identifying variation in process 15 critical in establishing the best production settings Typically welded assemblies are assessed for strength of joint and variation in strength A Screening DOE tests the high low settings of a parameter and will help establish the impact of a parameter on the process Screening DOE 15 a tool that allows the user to establish the impact of a particular parameter by carrying out the minimum number of experiments to gain the information A five factor screening DOE can be accomplished in as few as 24 welds with three welds completed for each of 8 tests By comparison it would take 96 welds to test every combination The DOE promotes understanding of many variables in a single experiment and allows the user to interpret results thus narrowing the variables for the next level of statistical analysis If many variables are still not understood multiple Screening DOE s may be required Amada Miyachi America provides a simple Screening DOE tool that 15 run in Excel and 15 sufficient for the majority of possible applications contact Amada Miyachi America for details Sophisticated software 15 also available from other vendors designed specifically for this purpose HF27 DC RESISTANCE WELDING SYSTEM G 10 990 370 APPENDIX G DEFINING THE OPTIMUM PROCESS Criteria for Success Before running the series of experiments th
139. ent limit checking parameters NOTES The units of the limit fields parameters depend on the value of the UNITS parameter as follows IN 1000 1 0 001 inches 10 0 01 inches MM 1 0 01 mm 10 0 1 mm Initial and final thickness are positive if the electrodes move farther apart and negative if they move closer together in relation to the zero setting The reference zero setting for thickness measurements may be set using the DISPZERO command see Host Originated Commands section Displacement is positive if the electrodes moved closer together during the weld and negative if they moved further apart DISPZERO ad counts crlf lf Any except while welding Reports the current zero setting of the Control system displacement measuring device This value is in a d converter counts not actual position If zero the position of the upper electrode at the start of the next weld will establish the new zero setting NOTE This zero setting 1s the reference position for the initial and final thickness measurements HF27 LINEAR DC RESISTANCE WELDING CONTROL 990 370 APPENDIX F The Basics Of Resistance Welding Resistance Welding Parameters Resistance welding heat 1s produced by passing electrical current through the parts for a fixed time period The welding heat generated 15 a function of the magnitude of the weld current the electrical resistance of the parts the contact resistance between the parts and the weld
140. ently happens set envelope limits broader or remove them altogether If welds are good and message consistently happens set envelope limits broader or remove them altogether If welds are good and message consistently happens set envelope limits broader or remove them altogether If welds are good and message consistently happens set envelope limits broader or remove them altogether If welds are good and message consistently happens set envelope limits broader or remove them altogether If welds are good and message consistently happens set envelope limits broader or remove them altogether If welds are good and message consistently happens set envelope limits broader or remove them altogether If welds are good and message consistently happens set envelope limits broader or remove them altogether HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 6 124 Pulse 2 power exceeded the envelope If welds are good and message consistently 2 PWR gt upper limit happens set envelope limits broader or remove UPPER LIMIT them altogether 125 Pulse 2 power did not reach the envelope If welds are good and message consistently P2 PWR lt ENV lower limit happens set envelope limits broader or remove LOWER LIMIT them altogether 126 Pulse 2 LVDT displacement exceeded If welds are good and message consistently P2 DISP gt the envelope upper limit happens set
141. ents for the Control are as listed below Power Input Specifications Input Voltage Copper Wire Amada 50 60 Hz Brkr Gauge Wire Dia mac HF27 Model 3 phase Amps America Current rms 7 strands AWG Volts P N Compressed Air and Cooling Water If you require compressed air and cooling water service for the weld head please refer to the weld head manufacturer s user s manual for service specifications HF27 DC RESISTANCE WELDING SYSTEM 2 2 990 3 0 CHAPTER 2 INSTALLATION AND SETUP Section Setup Connections to External Equipment connections other than the weld cable connections between the Control and external equipment are made through the rear panel VOLTAGE SENSE INPUT AIR VALVE DRIVER WELD HEAD FOOT SWITCH DATACOM a CONNECTORS 60 Pin CONNECTOR CONFIGURATION E EMERGENCY STOP PLUG lt SWITCH CABLE POWER INPUT FUSE 1 FIRING SWITCH POWER INPUT MAIN POWER FUSE 2 CIRCUIT BREAKER POWER INPUT CABLE Rear Panel Components and Connectors NOTES e The weld cable connections from the weld head are made at the weld cable terminals on the front panel e The pre wired Configuration Plug allows the use of Miyachi Unitek standard foot switches and weld heads without further configuration The Control requires configuration of the I Os to accept any inputs For normal use this
142. envelope limits broader or remove UPPER LIMIT them altogether 127 Pulse 2 LVDT displacement did not If welds are good and message consistently P2 DISP lt reach the envelope lower limit happens set envelope limits broader or remove LOWER LIMIT them altogether HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 6 11 6 Section lll Maintenance Electrode Maintenance When a welding schedule has been suitable for a particular welding application over many welds but poor quality welds are now resulting electrode deterioration could be the problem If you need to increase welding current to maintain the same weld heat the electrode tip has probably increased in surface area mushroomed effectively increasing weld current density thus cooling the weld Try replacing the electrodes The rough surface of a worn electrode tip tends to stick to the work pieces So periodic tip resurfacing dressing 1s required to remove pitting oxides and welding debris from the electrode You should limit cleaning of an electrode on the production line to using a 400 600 grit electrode polishing disk If you must clean a badly damaged tip with a file you must use a polishing disk after filing to ensure the electrode faces are smooth The best method of preventing electrode problems is to regularly re grind electrode tip surfaces and shapes in a certified machine shop Parts Replacement Below 15 list of
143. ess MENU to return to the MAIN MENU HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 CHAPTER 3 SYSTEM CONFIGURATION 7 RELAY l From the MAIN MENU press the 7 key to go to the RELAY output state selection menu shown at the right The Control has four relays that can provide dry contact signal outputs under many different conditions RELAY OTHER FORCE LIMIT ALARM ALARM ALARM RELAY1 ON RELAY2 ON RELAY3 ON RELAY4 ON Number Select an item RUN or MENU See Appendix C System Timing for the timing diagrams for the four relays From the RELAY menu press the 1 key to go to RELAY 1 shown at the right Press the 1 key to toggle the relay contact signal state ON closed or OFF open Press the 2 key to select the WHEN menu shown at the right Press the 2 key to select OUT OF LIMITS as the condition for initiating the Relay 1 output signal This will bring up the RELAY 1 menu screen where the WHEN line will now reflect OUT OF LIMITS Choosing WHEN options 1 4 or 9 will complete the relay programming process Choosing options 5 8 or 0 will bring up the RELAY 1 2 3 or 4 screen with a new option number 3 Press 3 to access the next level menus which are shown on the next page RELAY 1 gt 1 SET RELAY TO 2 WHEN Number Select Page RUN or MENU WHEN amp amp MG3 SYNC LVDT ALARM OUT OF LIMITS WELD END OF WELD
144. est settings for the process A factorial DOE may also give an indication as to how wide the acceptable weld window 18 in relation to quality requirements We recommend data be gathered from a monitoring perspective so that this can provide a starting point for establishing a relationship between quality and the monitored measurement parameter Criteria for Success Critical parameters should be identified from the list of unfixed variables left from the Screening DOE s A mini experiment may be required establishing reasonable bounds for the combination of parameters to be tested This will prevent void data and wasted time At this stage it is useful to record multiple relevant quality measurement or inspection criteria so that a balanced decision can be reached For example if part marking and pull strength are the relevant criteria a compromise in ideal setting may be required As with all experiments the test method should be carefully assessed as a potential source of variation and inconsistency Once the optimum parameters have been established in this series of experiments a validation study be run which looks at the consistency of results over time It is good practice to build in variables such as electrode changes and cleaning as well as equipment set up by different personnel This will ensure that the solution 15 one that can run in a real production environment Welded assemblies should be tested over time and under real use con
145. eters When used with the READ keyword all parameters pertaining to the currently loaded schedule are returned see SCHEDULE under Control ORIGINATED COMMANDS When the SET keyword is used the host may set change the value of one or more of the parameters pertaining to the currently loaded schedule The following is a list of valid literal substitutions for the parameter name and value variables UPPER LOWER FIRE ACTION value value value STOP Upper Force Limit Lower Force Limit Upper Force Limit Out of Limit Action for force HF27 LINEAR DC RESISTANCE WELDING CONTROL 990 370 Control State Description Command Control State Description Command Control State Description 990 3 0 APPENDIX E COMMUNICATIONS VALVE READ SET lt crlf gt parameter name value lt crlf gt lt gt RUN state Provides control over the Control schedule parameters When used with the READ keyword all parameters pertaining to the currently loaded schedule are returned see SCHEDULE under Control ORIGINATED COMMANDS When the SET keyword is used the host may set change the value of one or more of the parameters pertaining to the currently loaded schedule The following is a list of valid literal substitutions for the parameter name and value variables SOFT value Soft pressure value TIME time Soft Pressure time FINAL value Final P
146. eys section on the front panel press the kA key to program current as the feedback mode From the CONTROL keys section on the front panel press the V key to program voltage as the feedback mode From the CONTROL keys section on the front panel press the kW key to program power as the feedback mode e fer From the CONTROL keys section on the front panel press the COMBO key to program combo as the feedback mode 7 Press the PULSE 1 DOWNSLOPE key to enter the amount of time for the Weld Pulse 1 downslope Use the numeric keypad or the arrows to enter the time Enter a time between 0 and 99 milliseconds good starting point is 5 milliseconds Note that in combo mode when the unit reaches a constant current any time programmed in this segment will be added to the weld at the constant current level HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 5 5 CHAPTER 5 OPERATING INSTRUCTIONS 8 10 5 6 Press the COOL key to enter the amount of time for the cool period after Pulse 1 Use the numeric keypad to enter the time or use the AV arrows Enter 0 5 milliseconds Program Pulse 2 by repeating Steps 3 through 7 above using the keys for Pulse 2 entering the value O in each step Press the HOLD key to enter the amount of time for the hold period after the weld Use Bs the numeric keypad or the AW arrows Enter a time between 0 and 999 milliseconds We recommend at least 50 milliseconds as weld strength is formed in
147. f PILDLY1 delay value crlf PILDLY2 delay value crlf PIUDLYI delay value crlf PIUDLY2 delay value lt gt P2LDLY1 delay_value lt crlf gt P2LDLY2 delay_value lt crlf gt P2UDLY1 delay value crlf P2UDLY2 delay value crlf st Control State Description Reports the settings of the weld monitor of the currently loaded Control schedule The schedule_number variable identifies which schedule is currently loaded and may be any value from 0 to 99 The possible value for all variables listed after their parameter name correspond to the values listed under MONITOR in Host Originated Commands of this manual HF27 LINEAR DC RESISTANCE WELDING CONTROL 990 370 E 29 APPENDIX E COMMUNICATIONS Command E 30 RELAY lt crlf gt ACTIVE1 HIGH LOW lt crlf gt CONDITIONI condition_value lt crlf gt SUBCONDI textended condition value gt ACTIVE2 HIGH LOW CONDITION2 condition value lt gt SUBCOND2 textended condition value gt ACTIVE3 HIGH LOW lt crlf gt CONDITION3 condition value lt gt SUBCOND3 textended condition value gt ACTIVEA HIGH LOW lt gt CONDITION4 condition_value lt crlf gt SUBCOND4 extended_condition_value gt lt gt condition value ALARM LIMITS WELD END P1 P2 KW R OTHER MG3 DISP NOTE extended condition value not valid unless condition value 1s P1 P2 or
148. ge or power that 15 applied over a fixed An example of a fully programmed weld profile Y WELD WELD time period to resistance weld different parts is shown at the right emen i acs id UP Applications include parts that WELD HEAD POSITION e Are plated with cadmium tin zinc or nickel e Have heavy oxide coatings such as aluminum e Are round or not flat By programming the appropriate weld period time and weld energy amplitudes for the weld period segments you can program an appropriate weld schedule profile to perform the above applications Typical applications and recommended weld schedule profiles are defined in the table below For more information about resistance welding see Appendix F The Basics Of Resistance Welding and Appendix G Quality Resistance Welding Solutions Defining The Optimum Process Welding Applications Weld Function Typical Application Single Pulse Make single spot welds on simple flat parts without plating or on conductive parts such as those made of copper or brass Up Downslope Weld round parts parts that are not flat spring steel parts or heavily plated or oxidized parts such as aluminum Dual Pulse Use for best control of miniature and small parts spot welding with or without plating HF27 DC RESISTANCE WELDING SYSTEM 3 22 990 3 0 CHAPTER 3 SYSTEM CONFIGURATION Weld Head Applicability The weld functions can be used with Miyachi Unitek force fired manual weld heads ai
149. has exceeded the drive Reduce the total electrical resistance by HIGH capability of the HF27 25 The HF27 25 will not be able to maintain the user set weld parameters increasing the weld cable diameter Check cable and weld head connections Verify that all three phases from the input power lines are functioning 16 Cable connecting the Control and Power Verify installation of the welding NO WELD PCB s 15 open transformer rectifier module connections TRANSFORMER Cable connecting the Power PCB to the DETECTED Weld Transformer is open 17 User has tried to activate the HF27 25 Set the Weld No Weld switch to the Weld WELD SWITCH IN with the Weld No Weld Switch in the position NO WELD No Weld Position POSITION No weld current will flow 18 One or more of the Firing or Foot Switch Remove the I O input control signal condition CHECK INPUT input signals is preventing the HF27 25 preventing further HF27 25 operation SWITCH STATUS from continuing to operate NOTE The correct removal action depends on how the INPUT SWITCH SELECT in the Setup 1 menu was programmed by the user HF27 DC RESISTANCE WELDING SYSTEM 6 4 990 3 0 6 18 CHECK VOLTAGE CABLE 19 CALIBRATION VALUES RESET TO DEFAULT 20 LOWER LIMIT GREATER THAN UPPER LIMIT 23 SYSTEM amp SCHEDULE RESET TO DEFAULTS 26 SAFE ENERGY LIMIT REACHED 31 UPSLOPE REQUIRED FOR LOWER LIMIT 32 IN
150. he LVDT must have a zero reference point for example when the two electrodes touch each other there 1s zero distance between them AII distances calculated by the LVDT are measured from this zero When you change electrodes in your weld head or agressiveley clean the electrodes the electrodes may not be in the same exact position as the old electrodes so zero may no longer be the same therefore you must set a new zero There are two ways to set a new zero Either perform the quick calibration procedure detailed above or perform the new zero procedure detailed below The preferred method 15 to set a new zero and recalibrate as detailed above To set a new zero without recalibration From the monitor keys section on OR the front panel press the ZERO 1 ZERO LVDT key The screen on the right 2 ZERO TARE FORCE appears Select option 1 for ZERO LVDT 2 During next weld the initial un Number Select an item RUN MENU position will be set to 0 3 screen should now show NEW ELECTRODE IS SET Changing from Inches to Millimeters MM Before programming LVDT screens select LVDT POSITION 092 0000000 inches IN or millimeters MM as your units of LO LIM HILIM LAST measurement The default is IN To change to INITIAL 00 00 00 00 400 00 STOP FINAL 00 00 00 00 00 00 MM DISPLC 4000 000 000 XX STOP ENERGY AT 000 XXXX IN 1000 NEW ELECTRODE I
151. he above Directive s and Standard s 47 7 hes J t vr f TS 5 31 56 de 41 i j z D a nl T e a om W onrov CA Signature m Full Name m Gusning Position RD HF27 DC RESISTANCE WELDING SYSTEM 990 370 CHAPTER 1 Description Section Features The HF27 High Frequency Resistance Welding System Control precisely controls and monitors both electrical and mechanical weld parameters Control Features e Constant Current Voltage amp Power modes e Monitor Energy and Resistance e Force Control e Monitor Displacement and Force Weld Quality Process Tools e Envelope Function e Active Part Conditioning e Pre weld Check e Combo Mode e Weld to Limits Descriptions of the various control modes and process tools are located Chapter 3 System Configuration and Chapter 4 Introduction to Feedback Modes and Weld Monitoring ih N Detailed instructions on using these features located in Chapter 5 Operating Instructions NOTE For the rest of this manual the Miyachi Unitek HF27 High Frequency Resistance Welding System Control will simply be referred to as the Control HF27 DC RESISTANCE WELDING SYSTEM 990 370 1 1 CHAPTER 1 DESCRIPTION Section ll Introduction This Control contains advanced technology and improved features yet from an operational standpoin
152. he rise of the current waveform 15 proof positive that the oxide 15 breaking down and the parts are fitting up together ready to weld The first pulse therefore should be programmed to be much longer than generally required The power supply will terminate the pulse based on the reading of current in the power supply s monitor 2 Resistance Set Application e Reduce variations in Resistance prior to the weld e Reduce contact resistances before delivering the main weld energy Description Resistance Set is used when parts vary in initial resistance due to e Shape and part fit up e Very small parts Resistance Set is very similar to APC except that there are applications where you do not want a high voltage at the beginning of the pulse Instead you want to start both voltage and current low and build on an upslope This would be used primarily where resistance would vary from weld to weld coping with material contamination and variation due to part fit up problems It can be programmed to apply the exact power to the parts required to reduce the resistance to a consistent level for every weld Resistance Set uses a dual pulse output The first pulse is programmed for upslope power and the second for either constant current constant voltage or constant power Constant voltage is used if there 1s still a chance of weld splash The purpose of a dual pulse operation 15 to enable the first pulse to target variations in resistance the seco
153. hing either PULSE button will toggle between upper and lower limits PULSE 1 and for PULSE 2 can be programmed to monitor the same units or monitor separate units For example PULSE 1 can monitor kA and PULSE 2 can monitor V NOTE Whichever unit you select the upper and lower limits for a single pulse must be in the same units such as kW Force Limits To access FORCE amp LIMITS press the FORCE button on the front screen However the PROP VALVE OUTPUT FORCE function will only work if you have an optional Proportional Valve connected to the weld head and connected to the Control The LO LIM low limit HI LIM high limit and LAST functions will only work 1 you have an optional Load Cell installed the weld head and a Load Cell Amplifier Signal Conditioner connected to the Control Installation and setup instructions for the Proportional Valve Load Cell and Load Cell Amplifier Signal Conditioner are supplied by the manufacturers of these devices Instructions for making electrical connections to the Control are in Appendix B Electrical and Data Connections NOTE You can use a Proportional Valve without using a Load Cell and you can use a Load Cell without using a Proportional Valve Distance Limits To access DISTANCE LIMITS press the DISTANCE button on the front screen however it will only be operational if you have an optional LVDT on the weld head and connected to the Control This function allows you to set high and lo
154. his number will always be less than 2000 integer number in unit of A VOLTAGE number of data crlf data erlt data erlf lt data lt crlf gt lt If gt Any Returns the Voltage waveform data of the last weld First field is the number of data to be sent Then follows the packets of data Each data is separated by crlf and this command ends with lt crlf gt lt If gt number of data This is the number of data that shall be included in this command The Control samples Voltage every 40 us For a weld less than 80 ms weld time the number of data will be approximately total weld time 40 us This number will always be less than 2000 data Aninteger number in unit of mV POWER number of data lt crlf gt data lt crlf gt data crlf data crlf 1f Any Returns the Power waveform data of the last weld First field 15 the number of data to be sent Then follows the packets of data Each data is separated by lt crlf gt and this command ends with lt crlf gt lt If number of data This 15 the number of data that shall be included in this Command The Control samples Current and Voltage every 40 us For a weld less than 80 ms weld time the number of data will be approximately total weld time 40 us This number will be always less than 2000 data Aninteger number in unit of W HF27 LINEAR DC RESISTANCE WELDING CONTROL 990 370 Control State Description Comman
155. holder as shown on the right 8 Puta strain relief on each voltage sensing lead to its corresponding electrode holder so that the leads will not break away under heavy operating conditions NOTES e not attach the firing switch foot switch or EMERGENCY STOP cables at this time The polarity of the voltage feedback connections 15 not important e Ifthe tapped holes and screws for the voltage sensing connections are not present on the electrode holders the holders must be modified to include the tapped holes and screws prior to installation of the equipment HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 2 5 CHAPTER 2 INSTALLATION AND SETUP Foot Pedal Actuated Weld Head Connection LVDT CABLE REAR PANEL ADJUSTMENT KNOB h a i FORCE ATS T7 FORCE INDICATOR Set to 5 n 2l OPTIONAL WELD HEAD FIRING SWITCH CABLE ELECTRODE HOLDER 1 Adjust the weld head force adjustment knob to produce 5 units of force as displayed on the force indicator index 2 Connect the weld head firing switch cable connector to the Control firing switch cable connector 3 Connectthe LVDT cable to the LVDT input connector 4 Connect a normally closed approved emergency stop switch across the two leads of the operator emergency stop switch cable This switch when operated open will immediately stop the weld cycle See Appendix B
156. ible with longer weld times when using bulk resistance In general conductive materials benefit from a faster heating rate as the higher contact resistances assist heat generation in the weld Resistive materials benefit from slower heating rates which allow the contact resistances to reduce significantly Bulk resistances therefore become the major source for heat generation The heat affected zone is also much smaller in this case producing a weld with less variation The following figure shows the three stages of heat generation for resistive materials in a fusion weld In the first stage the heat 1s focused in the part to part and electrode to part contact areas since contact resistance 1s high relative to bulk resistance In the second stage contact resistance decreases as the electrodes seat better to the parts Less heat 15 generated in the electrode to part contact areas and greater amount of heat 1s generated in the parts as the bulk resistance increases In the third stage the bulk resistance becomes the dominant heat generating factor and the parts can reach their bonding temperature at the part to part interface The stages of heat generation for conductive materials will be similar to that of resistive materials but there will be less heat generated in the bulk resistance due to the conductivity of the materials HF27 DC RESISTANCE WELDING SYSTEM G 6 990 3 0 APPENDIX G DEFINING THE OPTIMUM PROCESS Bonding temperature
157. ighlight horizontally back to the WELD COUNT column Repeat Steps 4 through 8 to program the rest of the chain CHAIN SCHEDULE SETUP SCHEDULE NUMBER WELD COUNT NEXT 01 0001 01 02 0001 02 0001 04 0001 04 Select field RUN or MENU CHAIN SCHEDULE SETUP SCHEDULE NUMBER WELD COUNT NEXT 24 0001 Q4 05 0001 05 06 0001 06 0001 Select field RUN or MENU CHAIN SCHEDULE SETUP SCHEDULE NUMBER WELD COUNT 0001 0002 0001 0001 Select field RUN or MENU CHAIN SCHEDULE SETUP SCHEDULE NUMBER WELD COUNT 0001 0002 0001 0001 4 Select field RUN or MENU HF27 DC RESISTANCE WELDING SYSTEM 3 13 CHAPTER 3 SYSTEM CONFIGURATION 9 When you finish programming the chain press the MENU key to return to the CHAIN SCHEDULES menu 10 Press the 1 key to toggle between ON or OFF 11 Press the RUN key on the front panel then use the AV keys to select the first weld schedule in the chain you want to use The Control will now weld in the chain mode until you turn the Chain Schedules feature OFF NOTE When Chain Schedules is turned ON the LCD screen changes to show the chain information on the right side of the screen ERN cee CHAIN SCHEDULES ON Wd INDICATION NEXT In NEXT SCHEDULE NUMBER Eris T COUNT 2002 a 010 20 48 20 10 20 40 27 7 27 W Below the current schedule number you
158. ight appears Verify the electrodes LVDT QUICK CAL PUT THE THICK CALIBRATION GAUGE OF 0 100 in are securely installed in the electrode BETWEEN THE ELECTRODES holders Place the calibration piece PRESS FOOTSWITCH between the electrodes and press the footswitch ABORT CAL HF27 DC RESISTANCE WELDING SYSTEM C 6 990 370 APPENDIX C CALIBRATION NOTE if your reference piece 15 too thin or not properly placed between the electrodes you will see the prompt at LVDT QUICK CAL PIECE MISSING OR TOO THIN START AGAIN the bottom of the screen on the left PUSH THE CAL KEY TO START OVER QUICK CAL will restart from the beginning ABORT CAL 4 Release the footswitch to complete the LVDT QUICK CAL quick calibration procedure The screen on the right appears QUICK CALIBRATION DONE PUSH DISTANCE FOR LVDT SCREEN A ABORT CAL Set New Electrodes to Zero The LVDT must have a zero reference point for example when the two electrodes touch each other there is zero distance between them distances calculated by the LVDT are measured from this zero When you change electrodes in your weld head or agressiveley clean the electrodes the electrodes may not be in the same exact position as the old electrodes so zero may no longer be the same therefore you must set a new zero There are two ways to set a new zero Either perform the quick calibration procedure detailed above or perform the new zero procedure det
159. in Chapter 4 Using Feedback Modes and Weld Monitoring 10 Since different levels of resistance require different amounts of time to reach the current limit return to the RUN screen and extend the programmed weld time usually double the time works This will ensure that there will be enough time for the current to rise and reach the limit even with wide variations initial resistance 11 The power supply terminates the first pulse when your programmed current 15 reached low resistance part will reach the current limit sooner and the pulse will terminate early A highly resistive part will require more time before the resistance decreases and current can flow 12 Program your second welding pulse as RUN 0 373kA 0 424kA 20000305 normal to achieve a strong weld 2 Constant voltage 15 recommended for round parts and constant current for flat _ lt 2000 parts An upslope may be required to 150 10 GOH 20 30 80 00 000 ms restrict the current flow early in the second pulse and avoid weld splash HF27 DC RESISTANCE WELDING SYSTEM 5 16 990 370 CHAPTER 5 OPERATING INSTRUCTIONS Section Vl Pre Weld Check Note The Pre Weld Check function is used to detect misaligned or missing parts before the weld 15 performed Therefore the Pre Weld Check function should only be programmed after the welding schedule has been developed The welding schedule includes the time and energy set
160. in Chapter 6 Calibration Section II Calibrating the LVDT in addition to the procedures below Press the SCHEDULE key then select Weld Schedule using either the AV arrows the numeric keypad Press the SQUEEZE key to enter the squeeze time before the weld Use the numeric keypad to enter the time or use the AV arrows Enter a time between 0 and 999 milliseconds If using the LVDT enter a time between 1 and 999 milliseconds If using a relay for MG3 synchronization enter a time between 50 and 999 milliseconds NOTE We recommend 150 milliseconds Press the PULSE 1 UPSLOPE key to enter the amount of time for the Weld Pulse 1 upslope Use the numeric keypad or the AV arrows to enter the time Enter a time between 0 and 99 milliseconds good starting point is 5 milliseconds Press the PULSE 1 WELD key to highlight the bottom line of the LCD to enter the weld time Use the numeric keypad to enter the time or use the AV arrows Enter a time between 0 and 99 milliseconds Press the PULSE 1 WELD key again to highlight the middle line of the LCD to enter weld energy Use the numeric keypad to enter the energy level or use the AV arrows The Control output ranges are e Current from 0 1 2 4 Voltage 0 2 gt 9 999 V e Power 0 05 gt 9 999 kW e Combo The pulse starts in either Voltage or Power using the above limits and has a current limit as shown above 6 Perform one of the following From the CONTROL k
161. individual weld parameters At start of weld the LVDT position was outside the lower limit At start of weld the LVDT position was outside the upper limit At end of of weld the LVDT position was outside the lower limit At end of weld the LVDT position was outside the upper limit Measured displacement from start of weld to end of weld was less than the expected lower limit Measured displacement from start of weld to end of weld was more than the expected upper limit Weld was terminated when the measured displacement reached the weld stop limit Actual weld current is greater than the user set Upper Limit value for Weldl at the Current Monitor screen Actual weld current 1s less than the user set Lower Limit value for Weldl at the Current Monitor screen Press MENU select System Security then enter the correct access code to turn off System Schedule or Calibration Lock protection features NOTE Entering a security code of 280 will always unlock the system Press MENU select System Security then enter your access code to turn off System Security NOTE Entering a security code of 280 will always unlock the system Check Calibrate LVDT At the Distance Screen consider a lower initial LO LIM or removing this limit check by setting it to zero Check Calibrate LVDT At the Distance Screen consider a higher initial HI LIM or removing this limit check by setting it to zero Check Calibrate LVDT A
162. ion Plug Selected pins contain red inserts as shown below These inserts prevent properly configured 10 pin plugs from being plugged into the wrong sections of the 60 pin connector REAR PANEL HF27 DC RESISTANCE WELDING SYSTEM B 2 990 3 0 APPENDIX ELECTRICAL AND DATA CONNECTIONS 10 Pin Connectors Five un wired blank 10 pin connectors are supplied in the Ship Kit These connectors are used for the configurations described in Section III I O Configuration These connectors easily snap apart and use screw terminal wire connections so no soldering 15 required Each pin of this connector has tab on top as shown below 10 PIN CONNECTOR Assembled CONNECTOR SHELL 10 PIN CONNECTOR Disassembled When you fabricate I O cables according to the configuration instructions you must also cut off the tabs on the top of specific pins as indicated by the black shading below 11 12 13 14 15 16 17 18 1920731 32 33 34 35 36 37 38 39 40 TRI 51 52 53 54 55 56 57 58 59 60 41 42 43 44 45 46 47 48 49 50 21 22 23 24 25 26 27 28 29 30 123 45 6 7 8 910 Example To fabricate a connector for pins 31 gt 40 you must remove the tabs for pins 34 35 and 36 If you do not remove the appropriate tabs you will not be able to insert the plug into the Control HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 APPENDIX ELECTRICAL AND DATA CONNECTIONS NOTE Depending on the periphe
163. ir qe 3 4 Weld He UNC UIOINS griserie 3 22 Weld Head amp Mechanical Variables G 7 Weld Head Applicability isses rta 3 23 Weld Head Connections Joe rer deret rh Prats 2 4 Weld Monitoring 4 3 Weld Period Selector Keys 1 6 Wold Proleg MN Rm G 6 Weld Quality Process Tools 1 1 Weld Schedule 3 24 Weld Schedule Development F 5 Weld Sequence Pim rentis 3 24 NV GIG P 3 20 Dunn M 4 10 ME 5 21 Weld Strength Profiles mb Pp F 6 Weld Strength Testing sese F 6 NETT 4 9 5 19 WELD NO WELD Switch 1 10 Welding Applications 3 22 3 25 Welding Parameter Interaction F 1 When To Use Functions lt rte esee 3 23 Z ZERO T 1 9 HF27 DC RESISTANCE WELDING SYSTEM Index 6 990 370
164. ld time are the parameter that defines the time for the given period in 1 msec Valid range is from 0 to 999 weld time is the parameter that defines the time for the given period Each count of weld _ time 15 equivalent to 0 01 for increments from 0 1 to 0 99 msec and increments of 0 1 msec for 1 0 to 9 9 msec and increments of 1 0 msec for 10 0 to 99 0 msec see table next page HOST CONTROL Range TmeRange _ weld energy is the parameter that specifies the amount of weld energy In the current feedback mode weld energy 1s in unit of 0 001K A In the voltage feedback mode weld energy is in units of 0 001V In the power feedback mode weld energy 15 in units of 0 001kW volt multiplier 15 an index value for a table of resistance vs a PID multiplier for voltage mode HF27 LINEAR DC RESISTANCE WELDING CONTROL E 8 990 370 APPENDIX E COMMUNICATIONS NOTE Not used in versions where RINDEXx EINDEXx are present resistance index 18 an index value into a table of resistance vs energy PID tables If 0 then a test pulse will occur on the next weld to determine the actual resistance Note customer control of this value is not recommended energy index is an index value into a PID energy vs PID values table NOTE customer control of this value is not recommended Command MONITOR READ SET lt crlf gt parameter name lt gt lt gt Control State Any except while welding
165. lect an item Run or Menu 4 Press 1 for HF27 CALIBRATION which CAUTION will bring up the CAUTION screen on CALIBRATION SHOULD BE PERFORMED BY A the right QUALIFIED TECHNICIAN ONLY REFER TO MANUAL FOR CALIBRATION SETUP next MENU menu 5 Press 2 to calibrate the Control lt PRE CALIBRATION gt TEST HF27 T 232 REQUIRED CALIBRATE HF27 RESET CALIBRATION SET SHUNT VALUE Number Select an item Run or Menu HF27 DC RESISTANCE WELDING SYSTEM C 2 990 3 0 APPENDIX C CALIBRATION 6 The first calibration screen is the CAUTION screen If you are qualified to proceed with the calibration press V to continue Shunt value 0987 6 pQ 7 next page 15 for the CALIBRATION SHUNT This screen asks for the actual Number change Proceed value of the 1000 micro ohm shunt CALIBRATION SHUNT gt The actual value 15 printed on the exterior of the R7500 8 shunt Enter this value using the number keys and press V to continue NOTE The next calibration screen is the CURRENT SHUNT It is not necessary to change the current shunt value unless the internal welding transformer was changed If it was changed remove the top cover and enter the shunt value which 15 stamped on the copper conductor connected to the transformer Press to continue 8 The next two screens are 1 CALIBRATE V READING D A HIGH and 2 CALIBRATE D A LOW y Following the screen instructions adjust the energy
166. lid State Joint A solid state joint can be formed when the materials are heated to between 70 80 of their melting point e Fusion Joint A fusion joint can be formed when both metals are heated to their melting point and their atoms mix Many micro resistance welding challenges involve joining dissimilar metals in terms of their melting points electrical conductivity and hardness A solid state joint can be an ideal solution for these difficult applications there is no direct mixing of the two materials across the weld interface thus preventing the formation of harmful alloys that could form brittle compounds that are easily fractured Remember that in a solid state joint the metals are only heated to 70 80 of their respective melting points resulting in less thermal stress during heating and subsequent joint cooling in comparison to a fusion weld As there is no real melting of the materials in a solid state joint there is less chance of weld splash or material expulsion A weld nugget can still be achieved with a solid state joint HF27 DC RESISTANCE WELDING SYSTEM G 2 990 370 APPENDIX DEFINING THE OPTIMUM PROCESS Consider the Material Properties The important material properties to be considered in the resistance welding process are e Electrical and thermal conductivity e Melting point Plating and coating e Oxides e Hardness The figure below illustrates the variance in resistivity and melting points for some of th
167. limits P2HI P2LOW Pulse 2 hi low limit reached condition value explanations KALIMIT Current Limit Reached VLIMIT Voltage Limit Reached PIKALOW Pulse 1 Current hi low error P2KAHI P2KALOW Pulse 1 Current hi low error PIVLOW Pulse 2 Voltage hi low error P2VHI P2VLOW Pulse 2 Voltage hi low error KW R condition value explanations KWLIMIT Power Limit Reached RLIMIT Resistance Limit Reached PIKWHI PIKWLOW Pulse 1 Power hi low error P2KWHI P2KWLOW Pulse 1 Power hi low error P1RHI PIRLOW Pulse 2 Resistance hi low hi error P2RHI P2RLOW Pulse 2 Resistance hi low error OTHER condition value explanations FRLIMIT STFORCE Starting force limit reached EDFORCE Ending force limit reached EGLIMIT Energy limit reached EGHI EGLOW Energy hi low limit reached TMLIMIT Time limit reached TMHI TMLOW Time hi low limit reached DISP condition value explanations HF27 LINEAR DC RESISTANCE WELDING CONTROL 990 370 Control State Description 990 3 0 APPENDIX E COMMUNICATIONS ANY Any displacement error ILO IHI Initial thickness low hi error FLO FHI Final thickness low hi error DLO DHI Final displacement low hi error INI Initial thickness error DSP Any final displacement error SEA Stop energy at error SYSTEM READ lt gt parameter name lt gt Ift Any Provides control over the Control s system
168. ll RESET SCHEDULE LIMITS appear as highlighted You may SCHEDULE 01 change this to any SCHEDULE number PUSH V RESET THIS SCHEDULE S you want to reset using the numeric LIMIT VALUES keypad 2 Press the V key to reset the limits of the schedule you highlighted Number Select AW Page RUN or MENU 3 Press the MENU key to return to the MAIN MENU screen 9 CHAIN SCHEDULES This feature allows you to automatically change from any weld schedule to any other schedule after a preset count creating a chain of schedules that can accommodate a variety of welding needs For example e A single work piece requires four welds two weld points require the same weld schedule each of the other two points require different weld schedules In this case you would program a sequence or chain that looks like this Schedule 01 2 times Schedule 02 1 time Schedule 03 1 time Schedule 01 This sequence will repeat or loop until you turn Chain Schedules OFF e Some applications require a lower current for a number of welds after the electrodes have been replaced or resurfaced Once the electrodes have been seasoned the current can be increased as required If the electrodes require 100 welds to season Schedule 01 can be programmed with a lower current and Schedule 02 can be programmed with a higher current The chain would look like this Schedule 01 100 times Schedule 02 1 time Schedule 02 1 time I
169. lse 2 in mV peak current 2 The peak current of pulse 2 in A peak voltage 2 The peak voltage of pulse 2 in mV average power 2 The average power of pulse 2 in W peak power 2 The peak power of pulse 2 in W average resistance 2 The average resistance of pulse 2 in 1070 peak resistance 2 The peak resistance of pulse 2 1070 time 2 MG3 cutoff time null 2 The field 15 always zero disp units The displacement measurement units 0 inches 1000 mm disp initial The displacement initial thickness value Disp final The displacement final thickness value Disp displacement The displacement value initial minus final Monitor limit The time reached in ms Disp SEA flag The SEA limit reached O FALSE 1 TRUE Disp SEA time The limit time 1n ms off time 1 The error cutoff time off time 2 The error cutoff time energy 1 The total energy for pulse 1 Energy 2 The total energy for pulse 2 Start force force at the start of the weld end force The force at the end of the weld Weld count The number of this weld assigned by the unit NOTE disp xxxx values are signed integer values that have units that depend on disp units as follows units 0 inches 1000 0 001 inches 10 0 01 inches units 1 mm 1 0 01 mm 10 0 10 mm HF27 LINEAR DC RESISTANCE WELDING CONTROL 990 3 0 E 23 APPENDIX E COMMUNICATIONS WELD STATUS CODES Wm satus message 0 o Ww
170. m voltage as the limit mode Press the kW key to program power as the limit mode Press the key to program resistance as the limit mode weld period Enter the lower limit value for the Pulse 1 weld period NOTE In order for a Pulse 1 lower limit to be programmed you must first program a Pulse 1 upslope in the weld schedule The lower limit mode current voltage or power will automatically be the same as the upper limit mode programmed in Step 4 Press the COOL weld period key PULSE 1 OUT OF LIMITS ACTION This will bring up the PULSE 1 1 none 2 STOP WELD OUT OF LIMITS ACTION screen 3 INHIBIT PULSE2 This screen allows you to select PART CONDITIONER Stop Pulse the action that the Control will take if the Pulse 1 upper or lower limits are exceeded You have four choices NUMBER Select MENU Previous menu e NONE takes no action if upper or lower energy limits are exceeded e STOP WELD stops the weld immediately during Pulse 1 and prevents Pulse 2 from firing if applicable e INHIBIT PULSE2 stops the weld at the end of Pulse 1 and prevents Pulse 2 from firing This function will not operate if both pulses are joined without a cool time HF27 DC RESISTANCE WELDING SYSTEM 5 10 990 370 CHAPTER 5 OPERATING INSTRUCTIONS PART CONDITIONER Stop Pulse1 stops Pulse immediately after upper or lower energy limits are exceeded but allows Pulse 2 to fire This function will not operate if b
171. mode or changing the voltage or time settings while the voltage feedback welding 1 mode puts the Control in the TEST state After making one weld the Control internally optimizes the feedback control loop to produce 150 1 0 18 1 01 0 1 0 1 0 1 0 881 ms the fastest rise time minimum overshoot weld pulse The TEST state 15 automatically replaced by the run state for subsequent welds HF27 DC RESISTANCE WELDING SYSTEM 3 18 990 3 0 CHAPTER 3 SYSTEM CONFIGURATION Run State Pressing the RUN key puts the Control in the run state In the run state the screen shows trace that represents your programmed parameters for 1 given weld schedule You may select L 1 different weld schedule to be programmed with 15 18 the SCHEDULE key and keypad with the up Am zo PES down arrows Then you may program squeeze time up slope weld time weld energy down slope and cool time with the trace segment selector keys In the example on the right the top line of the RUN 10127 Peak 1014 0005237 screen shows that the Control 16 in the RUN state the voltage at the voltage sense lead connections 1 for the PULSE 1 weld period was 1 012 volts the monitor is set for displaying peak voltage rather than average voltage the voltage at the voltage sense input connection for the PULSE 2 weld period was 1 014 volts and the total weld count since the weld co
172. mple If a weld has too much displacement a relay could trigger an alarm for the operator or automation ELECTRODE WELD PIECE ELECTRODE gt ELECTRODE 1 Zero The point where the two electrodes touch zerodistance between them 2 Initial Thickness The thickness of the weld pieces beforewelding takes place measured at the end of squeeze time HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 1 11 CHAPTER 1 DESCRIPTION 3 Final Thickness The thickness of the weld after welding takes place measured at the end of hold time 4 z Displacement The amount of collapsewhen the weld pieces were forced together during the weld the difference between Initial Thickness and Final Thickness 5 Stop Energy At 50 referred to as WELD STOP thickness of the weld pieces programmed by the user at which weld energy stops Note that further displacement will occur even after the weld energy is cut off HF27 DC RESISTANCE WELDING SYSTEM 1 12 990 3 0 2 Installation and Setup Section Installation Unpacking The Control is shipped to you completely assembled together with the accessories you ordered and a shipping kit The contents of the shipping kit available accessories and contents of the Datacom Kit are listed in Appendix A Technical Specifications Be sure that the accessories that you ordered have been packed and the contents of the shipping kit and Datacom kit
173. ms that you might encounter fall into two groups Soft The problem is transient and you can correct it by resetting the system or parameter limits For example you should ensure that Correct force 1s set at the weld head Correct weld energy and time 15 set at the Control The equipment is set up properly electrical connections are tight Electrode alignment allows flush contact with the weld pieces Electrodes are properly dressed Hard The problem is embedded in the system and some form of repair will be needed For example repair might include replacing a broken weld head flexure Alarm Messages Built in automatic self test and self calibration routines will bring up alarm messages on the display screens These messages will usually let you know what action 1s required of you to correct the reason for the alarm For a complete listing of the alarm messages what they mean and corrective actions see Section Troubleshooting 990 3 0 HF27 DC RESISTANCE WELDING SYSTEM 6 1 CHAPTER 6 MAINTENANCE Section Troubleshooting Troubleshooting Cause in order of probability Cause in order of probability Electrode Damage Electrode Sticking Insufficient Weld Nugget 6 2 1 Excessive current energy set at HF27 25 Electrode 1 Excessive or insufficient weld head Sparking force 1 Wrong electrode tip shape 2 Excessive weld time set at HF27 25 2 Contaminated weld piece surface
174. n addition to the procedures below 1 Press the SCHEDULE key then select Weld Schedule using either the arrows or the numeric keypad Press the SQUEEZE key to enter the squeeze time before the weld Use the numeric keypad to enter the time or use the AV arrows Enter a time between 0 and 999 milliseconds If using the LVDT enter a time between 1 and 999 milliseconds If using a relay for MG3 synchronization enter a time between 50 and 999 milliseconds NOTE We recommend 150 milliseconds Press the PULSE 1 UPSLOPE key to enter the amount of time for the Weld Pulse 1 upslope Use the numeric keypad to enter the time or use the AV arrows Enter 0 milliseconds Press the PULSE 1 WELD key to highlight the bottom line of the LCD to enter the weld time Use the numeric keypad to enter the time or use the AV arrows Enter a time between 0 and 99 milliseconds Press the PULSE 1 WELD key again to highlight the middle line of the LCD to enter weld energy Use the numeric keypad to enter the energy level or use the AV arrows The Control output ranges are e Current from 0 1 2 4 Voltage 0 2 gt 9 999 V e Power 0 05 gt 9 999 kW Combo The pulse starts in either Voltage or Power using the above limits and has a current limit as shown above 6 Perform one of the following From the CONTROL keys section on the front panel press the kA key to program current as the feedback mode From the CONTROL keys section on
175. n this chain Schedule 02 will just keep repeating after the 100 welds made using Schedule 01 When the electrodes are replaced or resurfaced you can manually switch back to Schedule 01 to restart the sequence HF27 DC RESISTANCE WELDING SYSTEM 3 12 990 3 0 CHAPTER 3 SYSTEM CONFIGURATION You can program any of the Control s 99 stored schedules to chain to any other schedule or back to itself as 1n the second example above The chain code becomes part of each weld schedule You can turn the Chain Schedules feature ON or OFF or re program chains any time you want From the MAIN MENU press the 9 key to go to the CHAIN SCHEDULES menu NOTE You should program or setup the chain of schedules you want before you turn this feature ON CHAIN SCHEDULES 1 CHAIN SCHEDULE 2 SETUP CHAIN SCHEDULES OFF Number Select an item RUN or MENU Press the 1 key to toggle CHAIN SCHEDULES ON or OFF From the CHAIN SCHEDULES menu press the 2 key to go to the CHAIN SCHEDULE SETUP menu Use the AV Up Down keys on the front panel to scroll vertically through the schedules to highlight the weld count for the schedule you want to chain Use the numeric keypad to enter the number of times you want this schedule to weld before going to the next schedule Use the key to move the highlight horizontally to select NEXT Use the numeric keypad to enter the number of the next schedule in the chain Use the 4 key to move the h
176. nal disp displacement monitor limit disp SEA flag disp SEA time Number of reports This is the number of reports that shall be included in this command If the host computer requests more weld data than 15 available in the weld data buffer the Control sends only the weld reports in the weld buffer and the number of reports is the number of weld reports available in the weld data buffer After the report 1s sent to the host computer the Control does not erase the weld data sent to the host from the weld data buffer You must use the REPORT ERASE command to erase weld data from the weld buffer unit number The unit number assigned to the unit Schedule number The schedule number of the weld weld status The status of the weld Average current l The average current of pulse 1 in A Average voltage 1 The average voltage of pulse 1 1 mV peak current 1 The peak current of pulse 1 in A peak voltage 1 The peak voltage of pulse 1 mV HF27 LINEAR DC RESISTANCE WELDING CONTROL E 22 990 370 APPENDIX E COMMUNICATIONS average power 1 The average power of pulse 1 in W peak power 1 The peak power of pulse 1 in W average resistance 1 The average resistance of pulse 1 in 1070 peak resistance 1 The peak resistance of pulse 1 in 1070 time 1 APC or MG3 cutoff time null 1 The field is always zero average current 2 The average current of pulse 2 in A average voltage 2 The average voltage of pu
177. nd pulse achieves the weld Q 373kA 424 020000305 2 OBOOkW lt 9 0 2 000V 150 10 0 0 0 0 2 0 3 0 B O 90 000 ms Resistance Set Waveform The use of a current limit monitor for the first pulse enables the pulse to be terminated when a predetermined amount of current flow 1s achieved The rise of the current to a consistent level ensures a HF27 DC RESISTANCE WELDING SYSTEM 990 370 4 7 CHAPTER 4 INTRODUCTION TO FEEDBACK MODES AND MONITORING consistent resistance at the beginning of the second pulse Depending on the initial resistance the amount of time required to bring the resistance down will vary from weld to weld The first pulse therefore should be programmed to be much longer than generally required to ensure that the current limit 15 always reached The power supply will terminate the pulse based on the reading of current in the power supply s monitor 3 Pre Weld Check Application e Detect Misaligned or Missing parts Function This 15 used to see if parts are misaligned or missing before a welding pulse 15 delivered to the weld head Ifa part 1s missing or misaligned you do not want the machine to weld because the result would be an unacceptable weld and or damaged electrodes When using a Pre Weld Check Pulse 1 should be very short 1 2 milliseconds and the current should be low about 10 of the Pulse 2 current Pulse 1 should be used as a measurement pulse should not perform a weld 0
178. nds before the weld period can be initiated thereby avoiding false starts caused by the switch contact bouncing 1 From the SETUP 1 screen press the 2 SWITCH DEBOUNCE TIME key to go to the SWITCH DE BOUNCE 1 NONE TIME 2 10 ms menu screen irem 2 Select the required debounce time by 4 30 ms pressing the 1 2 3 or 4 key NONE represents a debounce time of 0 ms Number Select Page RUN or MENU Use NONE for interfacing with the Miyachi Unitek Model 350C Electronic Weld Force Control 3 The SWITCH DEBOUNCE TIME line will now reflect your switch debounce time selection 3 Firing Switch With the SETUP 1 screen displayed press the 3 key to select this function The firing switch input in conjunction with or without inputs from the foot switch input initiates the weld energy sequence Select the required switch type by pressing the 1 2 or 3 key Pressing the numeric keys automatically returns the display to the SETUP 1 screen FIRING SWITCH gt The Control accepts a single pole double pole or optical firing switch input from a Miyachi 3 REMOTE Unitek weld head Firing switch activation indicates that the weld head has reached the set weld force thus permitting the weld energy sequence to start Number Select Page RUN or MENU 2 None When using a non force fired weld head weld energy initiation must be supplied with the foot switch input Additionally you must select sufficie
179. nt squeeze time to permit the weld force to stabilize after contacting the weld pieces 3 Remote Use this setting an automation application or when using PLC control The BCD input lines via the CONTROL SIGNALS connector see Appendix B Electrical and Data Connections select weld energy schedules and initiate the weld energy sequence HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 3 15 CHAPTER 3 SYSTEM CONFIGURATION Setup 2 1 Display Contrast l From the SETUP 2 screen press the 1 DISPLAY CONTRAST gt key to go to the DISPLAY CONTRAST DISPLAY CONTRAST 50 96 adjustment screen 2 Use the lt and keys to adjust the p screen contrast for comfortable viewing 0 10 20 30 40 50 60 70 80 in the shop environment lt P Adjust Page RUN or MENU 3 Press the A key to return to the SETUP PAGE 2 of 3 screen 2 Buzzer Loudness 1 From the SETUP 1 screen press the 2 lt 22 LOUDNESS gt key to go to the BUZZER LOUDNESS DISPLAY CONTRAST 50 96 adjustment screen 2 Use the lt and keys to adjust the buzzer tone so that it can be heard against shop background noise 0 10 20 30 40 50 60 70 80 44 Adjust Page RUN or MENU 3 Press the A key to return to the SETUP PAGE 2 of 3 screen 3 End Of Cycle Buzzer 1 With the SETUP 2 screen displayed press the 3 key to toggle the end of cycle buzzer ON or OFF This function 15 normally used with manually actuated weld heads ON mean
180. o cause multiple welding problems when welding resistive materials including e Part marking and surface heating e Weld splash or expulsion e Electrode sticking e Weak welds Alternately conductive materials can be welded by using high contact resistance and fast heating because their bulk resistance is not high and cannot be relied upon for heat generation If a weld is initiated when both parts and electrodes are fitted up correctly the contact resistance 1s lower and bulk resistance now controls the heat generation This type of weld 1s achieved with a slower heating rate and normally longer time 15 preferred for welding resistive materials which can generate heat through their bulk resistance The contact resistances present at the weld when the power supply 15 fired have a great impact on the heat balance of a weld and therefore the heat affected zone HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 3 5 APPENDIX G DEFINING THE OPTIMUM PROCESS The figure below shows a weld that 15 fired The figure shows weld that 15 initiated when the early on in the weld sequence when the contact resistance 1s lower in this example we are contact resistance 15 still quite high using bulk resistance to generate our weld heat i n Resistan Contact Resistance Contact Resistance Resistance Weld Pulse Resistanc Weld Pulse Bulk Resistance Bulk Resistance Time Time Heat Affected Zone NOTE Larger nuggets are poss
181. of materials different for solid state vs Fusion welds TEMPERATURE Weld Profiles The basic welding profile or schedule consists of a controlled application of energy and force over time Precision power supplies control the energy and time and therefore heating rate of the parts The weld head applies force from the start to finish of the welding process The figure on the right shows a typical welding sequence where the forceis Trigger Force applied to the parts a squeeze time 15 initiated which allows the force to stabilize before the current is fired Squeeze time also allows time for the contact p resistances to reduce as the Squeeze Heat Hold Welding Force Current materials start to come into closer contact at their interface A hold time 15 initiated after current flows to allow the parts to cool under pressure before the electrodes are retracted from the parts Hold time 1s important as weld strength develops in this period This basic form of weld profile 1 sufficient for the majority of small part resistance welding applications Power supply technology selection 15 based on the requirements of both the application and process In general closed loop power supply technologies are the best choice for consistent controlled output and fast response to changes in resistance during the weld for further details comparison see the Miyachi Unitek slide rule tool
182. oise the number calculated above must remain less that 70 of the theoretical maximum capacity Electrical noise on the communications lines will further reduce this capacity Shielded cables are recommended several commands require the unit to be in HOST mode for the unit to accept them Those commands include the REPORT command and all SET commands See the MASTER CNTL command in Chapter 3 and the REMOTE command below for more information HF27 LINEAR DC RESISTANCE WELDING CONTROL 990 3 0 E 3 APPENDIX E COMMUNICATIONS Section Communications Protocol and Commands Command Format ID KEYWORD parameters lt gt lt gt UNIT IDENTIFICATION ID ID is any number from 00 to 30 must be a two digit number COMMAND KEYWORDS BOLD VARIABLE italics REQUIRED PARAMETERS enclosed braces one required and only one parameter allowed CHOICE OF PARAMETERS separated by vertical bar I indicates one OR another of choices presented REQUIRED OPTIONAL PARAMETERS enclosed in brackets one or more allowed used in the SET parameter zero allowed in the READ parameter RANGE OF PARAMETERS low_end high_end separated by hyphen END OF PARAMETER TERMINATOR lt crlf gt carriage return followed by linefeed TERMINATION OF COMMAND lt linefeed must be preceded by the end of line terminator lt gt Each unit identifier command keyword and parameters must be separated by one or more
183. om the different groups Group Group Il Group Ill Group Solid State Solid State Solid State Copper W Mo electrodes Projection on Group I Fine projections on Group III Group Il Solid State or Fusion Solid state or braze of II Steel on III Projection on III Moly Basic Principles R2 Contact Resistance Resistance Bulk Resistance Time The figure above shows the key resistances in a typical opposed resistance weld and the relationship between contact resistances and bulk resistances over time during a typical resistance weld HF27 DC RESISTANCE WELDING SYSTEM G 4 990 370 APPENDIX DEFINING THE OPTIMUM PROCESS R1 amp R7 The electrode resistances affect the conduction of energy and weld heat to the parts and the rate of heat sinking from the parts at the end of the weld R2 R4 amp R6 The electrode to part and part to part Contact Resistances determine the amount of heat generation in these areas The contact resistances decline over time as the parts achieve better fit up R3 amp R5 The metal Bulk Resistances become higher during the weld as the parts are heated Ifa weld is initiated when the contact resistances are still high the heat generated is in relation to the level and location of the contact resistances as the materials have not had a chance to fit up correctly It is common for the heat generated at the electrode to part and part to part resistances t
184. on ovem iren detis 5 oi po P G 2 G General Kinds of Problems 6 1 Sred 3 1 lotus a E TA G 3 High amp Low Limits for Displacement 5 27 High amp Low Limits for Initial Thickness 5 26 I LO oov edge 3 8 T 5 2 Initial Welding G 8 Installation and Setup 2 1 Tosta llati on 2 1 Space Reguiremenis 2 1 2 1 2 2 Compressed Air and Cooling Water 2 2 IMPER 2 2 E 2 3 Connections to External Equipment 2 3 HF27 DC RESISTANCE WELDING SYSTEM Index 2 990 370 INDEX I Continued EZ AIR Weld Head Connections 2 7 Foot Pedal Actuated Weld Head Connection 2 6 Non EZ AIR Weld Head Connections 2 9 Optional Load Cell Connection 2 10 Optional Proportional Valve Connection 2 10 Rear Panel Components and Connectors 2 3 Weld Head Connections 2 4 Interaction of Welding Parameters F 6 Introduction to Feedback Modes amp Monitoring 4 1 Programmable Feedback Modes 4 Combo Mode 4 2 Mod 4 1 ntroduction
185. on ZERO LVDT OR FORCE the front panel press the ZERO key 1 ZERO LVDT and the menu on the right will appear 2 ZERO TARE FORCE NUMBER Select an item Run or Menu 2 To zero the FORCE Tare press 2 and the screen on the right will appear 3 Press A to return to the previous FORCE GAUGE HAS BEEN SET TO ZERO TARED menu or press Run to continue welding or press Menu for the MAIN MENU A Page Run or Menu HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 C 9 APPENDIX D System Timing Basic Weld Operation Air Head System with Two Level Foot Switch T1 24VAC or 24 VDC FOOT SWITCH e Pr LEVEL 1 SOFT TOUCH PRESSURE WELD FORCE 56 FOOT SWITCH H lo LEVEL 2 SWITCH FIRING 1 WELDING i CURRENT 1 02 saueEze uP pow coot WELD powN HOLD Pulse it Pulse 2 NOTE 5 TOUCH PRESSURE only applies when a Proportional Valve 15 being used Definitions T1 Delay time from Foot Switch Level 1 closure to Weld Force start Maximum delay time is 1 ms plus switch debounce time Switch debounce time can be set to none 10 20 or 30 ms with the SETUP 1 menu screen D1 Delay time from Weld Force start to Firing Switch closure Maximum D1 time is 10 seconds If the firing switch does not close within 10 seconds the message FIRING SWITCH DIDN T CLOSE IN 10 SECONDS will be displayed D2 Delay time from Firing Switch closure and Foot Switch Level 2 closure to squeeze time SQZ
186. oportional valve output ground 0 valve output ground CHASSIS GROUND Chassis ground HF27 DC RESISTANCE WELDING SYSTEM B 8 990 370 APPENDIX ELECTRICAL AND DATA CONNECTIONS Modification of I O Configuration The inputs of this Control are grouped into two major blocks which can be independently configured SWITCH FIRE SWITCH INPUTS commen mous FS1 FS2 FIRE COM WELDNO WELD HF27 DC RESISTANCE WELDING SYSTEM 990 370 B 9 APPENDIX ELECTRICAL AND DATA CONNECTIONS Configuration for Common Input Connections 24 OUT I O COMMON 24 24VDC EXT SCHEDULE 0 SCHEDULE 0 SCHEDULE 1 3 24W SCHEDULE 1 1 Dry Contact Input Common Positive Input External Power 24V OUT 24V OUT IO COMMON 4 24 24VDC EXT SCHEDULE 0 SCHEDULE 1 Common Positive Input Common Negative Input Internal Power External Power NOTE The preceding configuration methods can be used for both input blocks HF27 DC RESISTANCE WELDING SYSTEM B 10 990 370 APPENDIX B ELECTRICAL AND DATA CONNECTIONS Two Level Foot Switch Connector When you press the foot switch to the first level the Control energizes the air actuated weld head This causes the upper electrode to descend and apply force to the weld pieces If you release the foot switch before pressing it to the second level the Control will automatically return the upper electro
187. ot ideal for this purpose either as the voltage will be restricted from reaching sufficient levels to break down the oxide Constant power is ideal for this purpose As the power supply tries to achieve constant power to the weld it raises the voltage to high levels early in the output waveform since current cannot flow due to the oxide As the high voltage breaks down the oxide layer more current flows to the weld and the voltage and resistance drop It will achieve this a controlled fashion to maintain constant power to the weld POWER VOLTAGE CURRENT WAVEFORM WAVEFORM WAVEFORM Constant Power Waveform With Corresponding Voltage and Current Waveforms Active Part Conditioning uses a dual pulse output The first pulse 15 programmed for constant power and the second for either constant current constant voltage or constant power Constant voltage is used if there 15 still a chance of weld splash The purpose of a dual pulse operation 15 to enable the first pulse to target displacement of oxides and good fit up the second pulse achieves the weld HF27 DC RESISTANCE WELDING SYSTEM 4 6 990 3 0 CHAPTER 4 INTRODUCTION TO FEEDBACK MODES AND MONITORING Q 373kA 0 424 20000305 0 8000 lt 9m0 2 000 159 0010 00 2 0 30 80 0 0 650 ms Active Part Conditioning Waveform The use of a current limit monitor for the first pulse enables the pulse to be terminated when a predetermined amount of current flow 15 achieved T
188. oth pulses are joined without a cool time NOTE See Section IV Programming For Active Part Conditioning After making your selection the display will automatically return to monitor screen 8 Program the upper and lower limits for Pulse 2 by repeating Steps 4 through 6 above using the keys for Pulse 2 entering appropriate values for Pulse 2 NOTES e The monitor limit mode current voltage power or resistance for Pulse 2 can be different than the monitor limit mode for Pulse 1 e To fine tune the monitor limits to very precise values see Chapter 4 Introduction to Feedback Modes and Monitoring 9 oy Press the HOLD period key PULSE 2 OUT OF LIMITS ACTION BE This will bring up the PULSE 2 OUT OF LIMITS ACTION screen 2 STOP WELD This screen allows you to select the action that the Control will take if the Pulse 2 upper or NUMBER Select MENU Previous menu lower limits are exceeded You have two choices NONE takes no action if upper or lower energy limits are exceeded STOP WELD stops PULSE 2 immediately after upper or lower energy limits are exceeded 10 After you have made your selection the MONITOR 1 232V peak 1 700V 09090315 LII SN display will automatically return to the e de TIT MONITOR screen errare NOTE The Control adds dotted lines UPPER 1 400V 1 800V 1 LOWER 0 951 INHIBIT 1 351 STOP
189. output using the measuring parameter feature of the oscilloscope NOTE Do not use a visual assessment DO NOT INCLUDE THIS SECTION FOR MEASUREMENTS USE THIS SECTION 1 Press the period key to advance to the next step Calibration Signal 9 The next calibration screen is CALIBRATE HIGH Disconnect the oscilloscope from the shunt resistor and connect the output of the shunt resistor to the VOLTAGE SENSE INPUT connector using the male BNC to binding post adapter and voltage sense cable Follow the screen instructions for this step and the next step 4 CALIBRATION LOW FIRING SWITCH 7 a EL NA d EL 9 i g REAR PANEL WELDING CABLES VOLTAGE SENSING CABLE enero vost aoaoren Le M pmi B m COAXIAL SHU NT Final Calibration Setup 10 The last calibration screen is 5 END OF CALIBRATION Press the MENU key Calibration 15 now complete HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 C 3 APPENDIX C CALIBRATION Section Calibrating the LVDT Before You Start Before using the LVDT during welding it is extremely important to calibrate the LVDT order to verify that the measurements displayed on the LCD screen match the actual distance between the electrodes The only equipment required for LVDT calibration 15 a calibration gauge or piece of metal machined to an exact known thickness This will be placed be
190. ower making five or more welds then perform pull tests for each weld Calculate the average pull strength Increase weld current voltage or power and repeat this procedure Do not change the weld time weld force or electrode area 2 Continue increasing weld current voltage or power until any unfavorable characteristic occurs such as sticking or spitting 3 Repeat steps 1 through 3 for different weld forces then create a plot of part pull strength versus weld current voltage or power for different weld forces as shown in the illustration on the next page Typical Weld Strength Profile 4 Repeat steps through 3 using a different but fixed weld time Typical Weld Strength Profile The picture on the right illustrates a typical weld strength profile The 14 Ib electrode force curve lade shows the highest pull strengths but the lowest 12 lbs tolerance to changes in weld current voltage or i p power The 12 lb electrode force curve shows a small reduction in pull strength but considerably more tolerance to changes in weld energy Weld heat will vary as a result of material variations and electrode wear wW 2 a I a The 12 Ib electrode force curve 1s preferred It shows more tolerance to changes in weld current 30 40 50 80 70 BO 80 100 voltage or power and has nearly the same bond Energy WE strength as the 14 Ib electrode force curve A comparison of weld schedules for several Typic
191. pical Application be used for many of spot welding applications Use on flat parts Single Pulse without plating or on conductive parts such as those made of copper or brass Upslope Downslope should be used for the majority of spot welding Upslope Downslope applications Weld round parts parts that are not flat spring steel parts or heavily plated or oxidized parts Dual Pul Use for spot welding parts with plating First pulse can be used to displace plating oxides and the second pulse to achieve the weld For a detailed coverage of resistance welding theory please refer to Appendix D The Basics of Resistance Welding Single Pulse Weld Profile Applications e Flat parts that do not have any plating or heavy oxides Conductive parts made of copper or brass Description Single Pulse is a term used by the industry to describe the simplest heat profile used for many resistance spot welding applications SQUEEZE WELD HOLD TIME TIME TIME 0 999 msec 0 99 msec 0 999 msec Single Pulse Weld Profile HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 3 25 CHAPTER 3 SYSTEM CONFIGURATION Upslope Downslope Weld Profile Applications e Round or non flat parts and most resistive materials Description Upslope allows a gradual application of weld energy which permits the parts to come into better contact with each other reducing the electrode to part contact resistances Upslope can allow a smaller elect
192. r actuated weld heads or Series 300 Weld Heads SQUEEZE TIME 15 used to allow sufficient time for the electrodes to close and apply the required weld force to the parts before the weld current begins Weld current begins when the squeeze period ends When the weld functions are used with any type of air actuated weld head the hold period can be used to automatically keep the electrodes closed on the parts after weld current has terminated to provide additional heat sinking or parts cooling NOTES e Miyachi Unitek Series 300 Electronic Force Controlled Weld Heads The SQUEEZE TIME is controlled by the weld head not the Control SQUEEZE TIME begins when the force firing switch closes therefore you will set the Control SQUEEZE TIME to zero and set the DEBOUNCE TIME to zero e Air Actuated Weld Heads For force fired air actuated weld heads SQUEEZE TIME begins when both levels of a two level foot switch are closed and the force firing switch in the air actuated weld head closes e Manual Weld Heads For manually actuated weld heads SQUEEZE TIME begins when the force firing switch closes Using SQUEEZE TIME 15 optional depending on the welding process you have developed When To Use Functions To ensure accurate consistent welds the Control delivers extremely precise pulses of energy to the weld head Each pulse 1s comprised of weld time and weld energy voltage current or power values pre programmed by the user The Control is a
193. r at 12 Duty Cycle and a Combined PULSE 1 and PULSE 2 Pulse Width of 50 ms 6 0 kW max Output Be T RE 2400A Max Peak Output Voltage at Max Peak Output 5 2V Duty Cycle at Max Peak Output 000 3 Max Load Resistance for Max Output 2 2 22 0 0 21 2 Imt Output Adjustment Range Resolution and Accuracy NOTE Actual maximum and minimum current voltage or power achievable depends on transformer and load resistance 100 2400 A 0 001 kA 2 of setting 2A 0 2 9 99 V 0 001 V 2 of setting 0 02V 0 05 9 99 kW 0 001 kW 5 of setting 10W Weld Periods 0 0 9 9 ms 0 1 ms 20 us 10 99 ms 1 0 ms HF27 DC RESISTANCE WELDING SYSTEM 990 370 1 APPENDIX TECHNICAL SPECIFICATIONS Physical Specifications 9 0 inches ate see illustration Weight 62 Ibs 28 kg 12 8 inches 325mm Performance Capabilities Number of Weld Schedules ess 100 Programmable Weld Periods SII 0 999 ms M 0 99 ms n
194. r field 4 Using the numeric keys enter 2 in the destination schedule number field WELD COUNTERS gt 1 TOTAL WELDS 0017429 NUMBER Select Restore Page MENU COPY SCHEDULE gt COPY SCHEDULE 1 TO SCHEDULE 2 Enter NUMBERS followed by Use SCHEDULE to copy COPY SCHEDULE COPY SCHEDULE 1 TO SCHEDULE 21 Enter NUMBERS followed by Use SCHEDULE to copy HF27 DC RESISTANCE WELDING SYSTEM 3 4 990 3 0 CHAPTER 3 SYSTEM CONFIGURATION Press the SCHEDULE key to copy the schedule and exit the screen 6 Press the MENU key to return to the main menu The contents of Weld Schedule 1 will be copied to Weld Schedule 2 overwriting the previous contents of Weld Schedule 2 Note that this function will copy schedule settings monitor limits and envelope offsets but it will not copy the reference waveforms for envelope limits 4 PROP VALVE Proportional Valve Option From the MAIN MENU press the 4 key to go to up PROPORTIONAL gt PROPORTIONAL VALVE screen This screen 1 FORCE OUTPUT OFF 2 FORCE UNITS LBS allows you to program the features for the force 3 TOUCH PRESSURE 0 000 LBS output on the HF27 4 SOFT TOUCH TIME 050 ms NUMBERS Select an item RUN or MENU 1 Force output The function allows the user to turn the proportional valve output ON or OFF 2 Force units This function allows the user to set the units for force measurement The user can choose
195. r work station 15 equipped with an emergency stop switch connected to the emergency stop connection of the Control operate the switch to immediately stop the welding process power to the air valves and power circuits will be disconnected To restart the Control you must press the RUN key on the front panel HF27 DC RESISTANCE WELDING SYSTEM 1 10 990 370 CHAPTER 1 DESCRIPTION Section LVDT Capability The Control is fully capable of using a Linear LVDT CONNECTING Variable Differential Transformer This is a CABLE combination of an electro mechanical device X attached to the weld head which 15 electronically linked to software installed the GN Control For the rest of this manual this BRACKET combination will be referred to simply as the adi ADJUSTING The LVDT allows the user to SCREWS e Measure initial part thickness as the electrodes close on the part If too thin parts may be missing If too VERTICAL thick something extra may be in the way STROKE OF LVDT of the parts e Measure displacement during the weld To measure the collapse of the parts during welding e Measure final part thickness after the weld Too thick maybe an indication of a cold weld Too thin maybe an over welded or blown weld e Weld to a preset displacement The weld energy will stop when the parts reach a user programmed displacement value e Actuate a relay when specific LVDT conditions are reached Exa
196. racteristics of the application The mini experiments should also be used to understand the weld characteristics from both application and process perspective Key factors in this understanding are as follows Application Perspective e Materials Resistivity melting point thermal mass shape hardness surface properties e Heat balance Electrode materials shape Polarity heating rate upslope e Observation visual criteria cross section and impact of variables on heat balance HF27 DC RESISTANCE WELDING SYSTEM G 8 990 3 0 APPENDIX DEFINING THE OPTIMUM PROCESS Process Perspective What are the likely variables in a production process How will operators handle and align the parts What tooling or automation will be required How will operators maintain and change the electrodes What other parameters will operators be able to adjust What are the quality and inspection requirements What are the relevant production testing methods and test equipment Do we have adequate control over the quality of the materials Common Problems During this stage of process development it 15 important to understand that the majority of process problems are related to either materials variation or part to electrode positioning Some examples are shown below Material Control Part To Part Positioning Electrode To Part Positioning The changes detailed above generally result in a change in contact resistance and always affect
197. ral equipment you use you may be connecting wires from different devices to the same plug in order to match pins on the plugs to the pins on the 60 pin connector Example As shown on the right some wires from the LOAD CELL and the PROPORTIONAL VALVE both go to the plug connected to pins 21 gt 30 gt PROPORTIONAL VALVE HF27 DC RESISTANCE WELDING SYSTEM B 4 990 3 0 APPENDIX ELECTRICAL AND DATA CONNECTIONS Section Ill Configuration Factory Configuration Plug A pre wired CONFIGURATION PLUG is supplied in the Ship Kit which allows the use of Miyachi FIRE 1 O 11 Unitek standard foot switches and weld heads without any further configuration 22808 Before normal use this plug should be WELD NO WELD connected to pins 11 through 20 on the 60 pin Not Active connector as shown above In addition five un wired plugs are supplied in the Ship Kit so you I O COMMON may fabricate your own custom I O cables The factory default setting 15 OVDC The plug s internal wiring is shown on the right FOOT 1 FOOT 2 24COM O OO Oc OO 0 0 FS1 FS2 FIRE COMMON 24V OUT Input Section Example COMMON This Control employs bi directional opto isolators which allow the user to configure the inputs to sink SCHEDULE 6 current 1 e 24VDC active or source current 1 e OVDC active typical input section 15 shown on the right see Modification of I O Configuration on page B 6 SCHEDULE 1 for
198. raph Weld Displacement Accuracy 0 003 0 076mm Displayed Resolution 0 001 0 01mm Measurement Resolution 0 00025 0 006mm Repeatability 1 Maximum Weld Rate 2 weld per second LVDT ACCURACY Lu 5 e 44 gt 5 2 0 25 05 ACTUAL DISTANCE NOTE The suggested minimum weld force to use with the LVDT is 2 Ibs 0 9 kgf HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 3 APPENDIX TECHNICAL SPECIFICATIONS Weld Head System Compatibility Force Fired Foot Actuated Force Fired Single Valve Air Actuated Non Force Fired Single Valve Air or Cam Actuated Force Fired EZ Air Kit Plug and Play 24VDC EZ AIR weld head 301 350 Series Electronic Weld Heads Input Signals NOTE Except where parenthetically noted below all input signals accept 5 to 24 VDC normally open or normally closed positive or negative logic Inputs are optically isolated Firing Switch Initiation 1 level foot switch 2 level foot switch or opto firing switch Remote Control Barrier Strip Remote weld schedule select process inhibit emergency stop and force set 0 5 VDC or 0 10 VDC and force read 0 5 VDC or 0 10 VDC RS232 Change weld schedules and individual weld parameters RS485 Change weld schedules and individual weld parameters Daisy chain RS485 input with RS485 output from other HF25 controls and host computer Voltage Weld voltage signal for voltage feedback operation 0 to 10 volt peak
199. rements of 1 0 msec for 10 0 to 99 0 msec see table below HOST CONTROL eemens Range Tmefane norements _ HF27 LINEAR DC RESISTANCE WELDING CONTROL 990 370 APPENDIX E COMMUNICATIONS weld energy is the parameter that specifies the amount of weld energy e Current Feedback mode the weld energy range for the HF27 is from 10 to 2 400A 10 2400 e Voltage Feedback mode weld energy for the HF27 is in units of 0 001 V and the range 15 from 0 200 to 9 9V 200 to 9900 e NOTE Maximum attainable voltage is dependent on the HF27 model and the load resistance e Power Feedback mode weld energy for the HF27 is in units of 1W and the range is from 10W to 9900W 10 to 9900 volt multiplier 15 the index value for a table of resistance vs a PID multiplier for voltage mode used for the last weld Note Not used in versions where RINDEXx and EINDEXx present resistance index 18 the index value into a table of resistance vs energy PID tables used for the last weld energy index 15 the index value into PID energy vs PID values table used for the last weld Command MONITOR schedule number crlf MONTYPE1 KAIVIKWIR gt ACTIONI none STOP INHIBIT APC lt gt limit value lt crlf gt LOWERI limit_value lt 1 gt MONTYPE2 KA I V IKW IR gt ACTION2 STOP lt crlf gt UPPER2 limit_value lt LOWER2 limit_value lt crl
200. ressing the kW key displays the power monitor This screen shows the results of the most recent weld This screen also allows the operator to set limits that automatically interrupt the weld when they are reached You can also program the power monitor to output an alarm when the limits are exceeded Pressing the Q key displays the resistance monitor This screen shows the results of the most recent weld The Control is always monitoring both the PEAK and AVERAGE of current voltage power and resistance When you press this key the top line in the LCD screen toggles back and forth between displaying PEAK and AVERAGE This key will bring up a menu with two options e Force This key brings up the CALIBRATION menu with five options e Unit calibration e gauge thickness e LVDT calibration e quick calibration e Force input calibration and force output proportional valve calibration This key brings up the force screen On this screen you can e Set the output force for the proportional valve e Set force limits around the measured value You can set different limits in each schedule Force will be in Ib N or kgf units You can set upper and lower limits for the force at the start and end of the weld NOTE Setting a force value to zero turns that measurement OFF The function is turned totally OFF if these values are set to zero This allows programming high and low limits for initial thickness final thickness
201. ressur SECURITY OFF C Y A lt crlf lt lf gt Allows control of the system security mode OFF sets all security status Control to OFF C SCHEDULE sets the schedule lock to Y SYSTEM sets the system lock to A CALIBRATION sets the calibration lock to ON DISP READ SET lt crlf gt parameter name value lt crlf gt lt gt Any except while welding Provides control over the displacement limit check parameters When used with the READ keyword all parameters pertaining to the currently loaded schedule are returned see DISP under Control Originated Commands When the SET keyword 15 used the host may set change the value of one or more of the parameters pertaining to the currently loaded schedule The following is a list of valid literal substitutions for the parameter name and value variables INITLO Linitial thick lo low limit for initial thickness INITHI initial thick hi high limit for initial thickness FINALLO final thick lo low limit for final thickness FINALHI final_thick_hi high limit for final thickness DISPLO displacement_lo low limit for final displacement DISPHI displacement_hi high limit for final displacement DISPWT displacement_wtd limit for weld to displacement UNITS IN 1000 MM displacement limit units INITERR CONT STOP initial thickness error action HF27 LINEAR DC RESISTANCE WELDING C
202. rode force to be used resulting in a cleaner appearance by reducing electrode indentation material pickup and electrode deformation It can also be used to displace plating and or oxides reduce flashing and spitting or reduce thermal shock when welding parts containing glass to metal seals Downslope annealing assists the grain refinement of certain heat treatable steels and prevents cracking aluminum and other materials by reducing the cooling rate Annealing is not typically used for welding small parts Upslope Downslope Weld Profile Dual Pulse Weld Profile Applications e Flat to flat parts Round to round parts Round to flat small parts that may or may not be plated Description Adding upslope to the front of both weld periods allows a reduction in electrode force this results in a cleaner appearance by reducing electrode indentation material pickup and electrode deformation HF27 DC RESISTANCE WELDING SYSTEM 3 26 990 370 CHAPTER 3 SYSTEM CONFIGURATION DOWN uP DOWN store SLOPE 1 EE SLOPE RUN STAT TIME 0 99 mseg aa 0 88 msec msec STATE 0 88 maec A lt MAXIMUM OFF UP POSITION DOWN L WELD t WELD EE PULSE _ PULSE 2 Upslope will also help to displace plating and or oxides reduce flashing and spitting or reduce thermal shock when welding parts containing glass to metal seals In the normal applic
203. rol converts this to the correct voltage to be sent to the electronic pressure regulator in order to get the desired force Calibration 1s a simple 2 step procedure using front panel controls See Appendix C Calibration for details Operation The electronic pressure regulator attached to the Control should have an association of 0 5V 0 100 psi or 0 10V 0 100 psi depending on the type of regulator used To measure force a sensor has to be connected to the Control 0 5V or 0 10V depending on the sensor type See Appendix B Electrical and Data Connections for details on making the FORCE SET and FORCE READ connections FORCE amp LIMITS Main Screen Press the FORCE key and the screen FORCE amp LIMITS on the right appears PROP VALVE OUTPUT FORCE 010 0 LBS LO LIM HI LIM LAST WELD START 000 0LBS 000 0LBS 000 0LBS WELD END 000 0LBS 000 0LBS 000 0LBS ACTION CONTINUE e PROP VALVE OUTPUT FORCE Enter the desired force at the electrode e WELD START Force Limits Enter the desired low and high force limits The force will be measured at the end of SQUEEZE and displayed in the LAST position e WELD END Force Limits Enter the desired low and high force limits The force will be measured at the end of HOLD and displayed in the LAST position e ACTION CONTINUE will allow the weld to continue and only give an OUT OF LIMIT message STOP will stop the weld process HF27 DC RESISTANCE WELDING SYSTEM 99
204. rol software displays various menu screens on the LCD each containing prompts telling you which of the Control s front panel controls to use in order to customize operating parameters set the Control for use in an automated welding system and program communication settings for use with data gathering devices such as a host computer 1 Communication Role 1 From the MAIN MENU press the 6 key lt COMMUNICATION gt COMMUNICATION ROLE SLAVE shown with default settings BAUD RATE 9600 From the COMMUNICATION menu toggle RS232 485 SELECT RS232 1 0 NUMBER 1 the 1 key to select MASTER SLAVE The COMMUNICATION ROLE line will now reflect your role selection NUMBER Select an item RUN or MENU e Inthe MASTER role the Control will Send weld data to the host computer after each weld operation Send text data to a serial printer providing a printout of the average voltage and current values for each weld generating a paper history of welds performed Inthe SLAVE role the Control will send weld data only when requested by the host computer You must use this role for RS 485 installations with mulitple controls on one communications channel NOTE For weld data collection and host computer control information refer to the Datacom Operator Manual which describes how to use the MASTER and SLAVE options HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 3 7 CHAPTER 3 SYSTEM CONFIGURATION 2
205. rrect electrodes in the electrode holders on the Weld Head See the preceding Table for electrode material recommendations 2 Usea flat electrode face for most applications Use a domed face if surface oxides are problem If either of the parts 1s a wire the diameter of the electrode face should be equal to or greater than the diameter of the wire If both parts are flat the face should be at least one half the diameter of the electrodes Pencil point electrodes cause severe electrode sticking to the parts unexplained explosions and increase the weld heat substantially because of the reduced electrode to part contact area 3 Usethe Force Adjustment Knob on the Weld Head to set the Firing Force and adjust an Air Actuated Weld Head 4 Program a weld schedule then make your first weld Always observe safety precautions when welding and wear safety glasses For a complete procedure on making welds refer to Operating Instructions 5 Use pliers to peel the welded materials apart A satisfactory weld will show residual material pulled from one material to the other Tearing of base material around the weld nugget indicates a material failure NOT a weld failure Excessive electrode sticking and or spitting should define a weld as unsatisfactory and indicates that too much weld current voltage power or time has been used 6 Ifthe parts pull apart easily or there is little or no residual material pulled the weld is weak Increase the weld
206. s connected properly Power Verify that power is connected as described in Chapter 2 of this manual Compressed Air If you are using an air actuated weld head verify that compressed air is connected as described in the appropriate sections of your weld head manual Turn the compressed air ON and adjust it according to the instructions your weld head manual HF27 DC RESISTANCE WELDING SYSTEM 990 370 5 1 CHAPTER 5 OPERATING INSTRUCTIONS Initial Setup 1 Adjust the weld head force adjustment knob for a force appropriate for your welding application good starting point 15 the mid point in the range of the weld head force 2 Setthe WELD NO WELD switch on the Control front panel to the NO WELD position In this position the Control will operate the weld head without producing weld energy NOTE When you are ready to perform a weld be sure to set this switch back to the WELD position 3 Turn the ON OFF switch on the rear panel of the Control to the ON position The default RUN screen will be displayed You will use this screen to enter welding parameters E 4 E ELLA 3 2 0 150101010 10 1810 Default RUN Screen HF27 DC RESISTANCE WELDING SYSTEM 5 2 990 370 CHAPTER 5 OPERATING INSTRUCTIONS Section Il Operation Single Pulse Weld Schedule NOTE If you are using the optional LVDT you must perform the procedures described Appendix 3 Calibration Section II Calibrating the LVDT i
207. s that an audible signal will be given at the end of each weld process to signal you to release the foot pedal 2 Toselect the ON OFF states toggle the 3 key The END OF CYCLE BUZZER line will now reflect your state selection 4 Update Graph After Weld From the SETUP 2 screen press the 4 key to toggle the update graph after weld ON or OFF function The UPDATE GRAPH AFTER WELD line will now reflect your state selection ON means that the actual weld energy profile will overlay the programmed weld profile after each weld 15 made The weld graph 15 useful for detecting weld splash which 15 indicated by vertical gaps in the overlap You can reduce weld splash and eliminate it in some cases by using the upslope weld energy profile HF27 DC RESISTANCE WELDING SYSTEM 3 16 990 3 0 CHAPTER 3 SYSTEM CONFIGURATION 5 Language Press the 5 key to toggle between English and German All menu items and instructions on the screen will be in the language selected Setup 3 1 DO TEST WELD In voltage mode the unit will do a test weld to optimize response to varying weld conditions Press 1 to bring up the following choices 1 ALWAYS A test weld will be done if e The voltage level changes e The time in any element of the schedule changes e Ifthe weld energy field is highlighted and the V key is pressed 2 ASK The user will be prompted to choose if a test weld is done or not upon the following conditions e The voltage level changes
208. se Weld Schedule 5 3 Upslope Downslope Weld Schedule 5 5 Check 5 17 Programming Relays 5 31 R sistance SEU 5 15 Tae LOS T T 5 29 Using the Weld Monitor 5 0 Weld 5 21 5 19 Operational States 3 18 Optional Load Cell Connection 2 10 Optional Proportional Valve Connection 2 10 P Parts Replacement 2 emet p meteo 6 12 PEAK amp AVERAGE MONITORING 4 3 Power oroS 2 2 5 1 Power Mode 4 2 Power Supply Variables G 7 Pre Operational Checks 5 1 Pre Weld C leok breites 4 8 5 17 PROCESS Perspective Dura G 8 PROCESS TOO S p pd 4 5 Process Variables G 7 Programmable Feedback Modes 4 Programming Relays 5 31 Prop Valve Proportional Valve 3 5 Q Quality ttr ne G 7 Quality Resistance Welding Solutions Defining the Optimum Process 1 Approach to Weld Development G 7 Material Variables G 7 Power Supply Variables G 7 Process Variables
209. see the number of times the current schedule will be repeated and the number of the next schedule the chain Setup 1 1 Footswitch Weld Abort From the SETUP 1 screen press the 1 key to toggle between ON and OFF This function controls how the Control interfaces with a foot switch a force firing switch or a programmable logic control PLC Any of these switches could be the weld initiation switch in your system setup ON means that the welding process 15 initiated by closure of the initiation switch and continues to its conclusion while the initiation switch remains closed If the initiation switch opens during the welding process the welding process will terminate The ON state 15 preferred for human operated welding stations since it allows you to abort the weld process by releasing the foot switch or the foot pedal in the case of a manually actuated weld head OFF is preferred for computer or PLC controlled welding stations since a single start pulse can be used to initiate the welding process To select the ON OFF states press the 1 key The FOOTSWITCH WELD ABORT line will now reflect your selection 2 Switch Debounce Time The contacts of single pole mechanical firing switches bounce when they close The switch de bounce time function allows you to specify that the initiation switch contacts must remain closed for 10 HF27 DC RESISTANCE WELDING SYSTEM 3 14 990 3 0 CHAPTER 3 SYSTEM CONFIGURATION 20 or 30 milliseco
210. spaces except the termination of command lt gt must follow the end of parameter terminator lt crlf gt immediately I E gt lt gt 7 HF27 LINEAR DC RESISTANCE WELDING CONTROL E 4 990 370 APPENDIX E COMMUNICATIONS Computer Originated Commands These are the commands sent by the host computer via RS 485 or RS 232 to a Control Command Control State Description Command Control State Description Command Control State Description Command Control State Description Command Control State Description Command Control State Description Command Control State Description Command Control State Description 990 3 0 STATUS lt crlf gt lt lf Any Requests the Control to report the status of the weld data buffer Control returns STATUS with either OK or OVERRUN TYPEx lt crlf gt lt lf gt Any Requests the Control to return the type of welder release number and revision letters COUNT lt crlf gt lt If Any Requests the Control to report the number of weld data accumulated since the last data collection Control returns the COUNT even if there is no weld data available ERASE lt crlf gt lt lf Any Requests the Control to erase all the weld reports SYNC lt crlf gt lt lf gt Any Provides synchronization of the commands The Control returns SYNC command back to the host computer CURRENT lt crlf gt lt lf Any Requests the Control to report the sampled Current da
211. steel so that the weld heat 1s generated by the electrical resistance of the parts and the contact resistance between the parts Use resistive electrodes such as RWMA 13 Tungsten and RWMA 14 Molybdenum to weld conductive parts such as copper and gold because conductive parts do not generate much internal heat so the electrodes must provide external heat Use the following Electrode Selection Table for selecting the proper electrode materials ELECT MATERIAL MATERIAL Alumel Alumel Alumel Chromel Alumel Dumet Aluminum Aluminum Aluminum Alloys Aluminum Aluminum Aluminum Tinned Brass Aluminum Gold Plated Dumet Aluminum Gold Plated Kovar Aluminum Aluminum Kovar Aluminum Magnesium Aluminum Aluminum Stainless Steel Beryllium Copper Beryllium Copper Beryllium Brass Copper Beryllium Copper Copper Beryllium Copper Nickel Beryllium Copper 105 105 2 Aluminum m A Aluminum 4 Aluminum A own Aluminum 2 Aluminum 1 Aluminum k Awmimm A Cadmium Plating Tinned Copper Cold Rolled Steel Tinned Copper ELECT RWMA TYPE 2 2 2 14 2 MATERIAL 2 Cold Rolled 2 Steel Stainless Steel 2 Tinned Copper 4 2 14 Cold 2 Steel Stainless Steel 2 Tinned Copper 14 HF27 DC RESISTANCE WELDI
212. stop signal refer to Appendix B Electrical and Data Connections e Open the normally closed switch across the operator emergency stop switch cable NOTE This action removes all power from the Control e Through the action of the monitor settings Completion of the firing state 1s indicated by a profile of actual delivered weld energy superimposed on the programmed weld energy trace as shown in the example above Monitor State From the MONITOR keys section on the front MONITOR 373kKA 424kA 0000315 panel press the kA V KW Q key to goto the CIE T monitor state In this state when the Control detects an out of limits condition 1t will take one of four actions for PULSE 1 and one of two STOP P1 ERA STOP actions for PULSE 2 depending on the selection made with the MONITOR display as shown at the right Also an alarm message will be displayed and any relay set for ALARM or OUT OF LIMITS will be energized The selections for PULSE 1 are e The weld cycle will continue STOP WELD The weld cycle will stop immediately Pulse 2 1f applicable will not fire INHIBIT PULSE2 During the COOL time the Control calculates the average of the Weldl pulse including upslope weld and downslope If the average of the Weldl pulse is out of limits the weld cycle will stop and the Weld2 pulse will be inhibited PART CONDITIONER Stop Pulse1 stops Pulse 1 immediately after
213. t it performs the same as older Miyachi Unitek Controls see Appendix H Compatibility and Comparison for an overview of the differences between the new and old models The Control is a 25 kHz three phase state of the art inverter power supply for joining precision small parts at high speed with controllable rise times The delivered welding energy is in the form of DC welding energy High speed 40 microseconds digital feedback automatically controls weld current voltage or power providing more welding consistency compared to traditional direct energy AC or capacitive discharge CD technologies This microprocessor technology automatically compensates for changes in work piece resistance load inductance weld transformer saturation and changes in line voltage In addition special power device technology precisely controls the weld energy at both high and low energy levels e You can program the Control from the front MAIN MENU panel using simplified key clusters and on SETUP 6 COMMUNICATION WELD COUNTERS 7T RELAY screen data fields MAIN MENU screen COPY ASCHEDULE 8 RESET TO DEFAULTS allows you select all of the system setup PROP VALVE 9 CHAIN SCHEDULES options for working with inputs from SYSTEM SECURITY external equipment NUMBER Select an item e The RUN screen allows you to easily modify any time period current voltage or power value 102 101 60 e MONITOR screen provides instant visual
214. t Data 3 RXD Receive Data 4 DSR Data Set Ready 9 RI Ring Indicator 5 SGND Signal Ground Host settings Baud Rate 1 2 2 4k 4 8k 9 6k 14 4k 19 2k 28 8k 38 4k set on the unit Data bits 8 Stop bit 1 Parity None NOTES e host must be set to the same baud rate as the unit The computer hardware and operating system needed to support communication depends upon the RS 485 adapter or converter box used e For a microprocessor based conversion such as the Edgeport USB converter from Inside Outside Networks the host computer should be at least a Pentium II 233 running Windows 98 Windows ME Windows 2000 Windows XP or Windows NT 4 0 For a hardware based converter without an internal microprocessor such as the Telebyte model 285 the host computer should be at least a Pentium III 550 running Windows 98 Windows ME Windows 2000 Windows XP or Windows NT 4 0 HF27 LINEAR DC RESISTANCE WELDING CONTROL E 2 990 370 APPENDIX E COMMUNICATIONS For RS 485 communication do not exceed the capacity of each channel The product of total number welds per second on all welders on that channel times total number of bytes exchanged per weld times 8 bits per byte must in all cases remain less than the theoretical maximum capacity of the channel the baud rate selected on the unit This capacity 1s not an 1ssue on RS 232 channels A good guideline 15 that on a line free of electrical n
215. t of valid literal substitutions for the parameter name and value variables of valid literal substitutions for the parameter name and value variables 1 KAI VI KW Energy Type for pulse 1 limit value Upper Limit for pulse 1 LOWERI limit value Lower Limit for pulse 1 ACTIONI STOP INHIBIT Out of Limit Action for pulse 1 TYPE2 KAI VI KW Energy Type for pulse 2 UPPER2 limit_value Upper Limit for pulse 2 LOWER2 limit_value Lower Limit for pulse 2 ACTION2 STOP Out of Limit Action for pulse 2 PILDLY1 delay_value Pulse 1 Lower Delay Start Time For Lower Limit PILDLY2 delay value Pulse 1 Lower Delay End Time For Lower Limit PIUDLY1 delay value Pulse 1 Upper Delay Start Time For Upper Limit PIUDLY2 delay value Pulse 1 Upper Delay End Time For Upper Limit P2LDLY1 delay_ value Pulse 2 Lower Delay Start Time For Lower Limit P2LDLY2 delay value Pulse 2 Lower Delay End Time For Lower Limit P2UDLY1 delay value Pulse 2 Upper Delay Start Time For Upper Limit P2UDLY2 delay valuej Pulse 2 Upper Delay End Time For Upper Limit HF27 LINEAR DC RESISTANCE WELDING CONTROL 990 370 Control State Description Command Control State Description 990 3 0 APPENDIX E COMMUNICATIONS ENVWAVE READ numberc crlf lf ENVWAVE SET number of data points pulse number type lt gt data lt crlf gt
216. t one space between each of the three fields Command COPY from schedule number to_schedule_number lt crlf gt lt lf gt Control State Description Allows one schedule to be copied to another schedule number From schedule number and to schedule number may be any number from 0 to 99 Copying a schedule to itself has no effect other than to invoke a schedule printout when PRINT SCHEDULES PROGRAMS is enabled Command COMBO READ SET lt gt parameter name lt gt lt gt Control State state Description Provides control over the Control schedule parameters When used with the READ keyword all parameters pertaining to the currently loaded schedule are returned see SCHEDULE under Control ORIGINATED COMMANDS When the SET keyword is used the host may set change the value of one or more of the parameters pertaining to the currently loaded schedule The following is a list of valid literal substitutions for the parameter name and value variables TYPEI KA feedback type for combo P1 TYPE2 KA feedback type for combo P2 ENGI weld energy combo cutoff energy for pulse 1 ENG2 weld_energy combo cutoff energy for pulse 2 Command SCHEDULE lt crlf gt lt If gt Control State Any state except while welding Description Requests the Control to return the currently selected schedule number HF27 LINEAR DC RESISTANCE WELDING CONTROL 990 3 0 E APPENDIX E COMMUNICATIONS Command SC
217. t terminals used for schedule selection Interrupts weld current Interrupts weld current lt 100 us from current stop trigger to end of weld current with debounce set to Relay 1 output dry contact programmable RELAY 1R Contact rating 24VDC AC 1 amp 5 3 RELAY 2 Relay 2 output dry contact programmable HF27 DC RESISTANCE WELDING SYSTEM 990 370 E APPENDIX ELECTRICAL AND DATA CONNECTIONS RELAY 2R Contact rating 24VDC AC 1 amp RELAY 3 Relay 3 output dry contact programmable RELAY 3R Contact rating 24VDC AC 1 amp RELAY 4 Relay 4 output dry contact programmable zz RELAY 4R Contact BM UO 24VDC AC 1 amp amc 42 Not Not Active FORCE SET 10 valve output 0 10V use pin 44 49 or 59 as ground FORCEGROUND GROUND Force Force input proportional valve output ground 00000000000 valve output ground FORCE READ 10 INPUT Force input 0 10V use pin 44 49 or 59 as ground reference DO NOT USE 0 5V FORCE INPUT AT THE SAME ET 464 47 Not Not Active i USE 0 10V FORCE INPUT AT THE SAME FORCEGROUND GROUND Force Force input proportional valve output ground 000000000 valve output ground EA o XM 7 fires x mur 54 LVDTPRI2 O O o LVDT Connections rij LVDT LVDTGND FORCE SET 5 Proportional valve output 0 5V use pin 44 49 or 59 as ground FORCEGROUND 000 GROUND Force Force input pr
218. t the Distance Screen consider a lower final LO LIM or removing this limit check by setting it to zero Check Calibrate LVDT At the Distance Screen consider a higher final HI LIM or removing this limit check by setting it to zero Check Calibrate LVDT At the Distance Screen consider a setting wider initial final limits or removing this limit checks altogether by setting them to zero Check Calibrate LVDT At the Distance Screen consider a setting wider initial final limits or removing this limit checks altogether by setting them to zero None required if this action 1s desired Otherwise clear the weld stop displacement action on the Distance Screen by setting STOP ENERGY AT to zero Reset the Upper Limit for Weldl to a larger value Weld splash can cause the actual weld current to drop below the user set Lower Limit for Weldl Add upslope to reduce weld splash Reset the lower Limit for Weldl to a smaller value HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 6 57 VOLTAGE gt THAN UPPER LIMIT 58 PI VOLTAGE lt THAN LOWER LIMIT 59 POWER 1 gt THAN UPPER LIMIT 60 POWER 1 lt LIMIT 61 RESISTANCE gt THAN UPPER LIMIT 62 RESISTANCE lt THAN LOWER LIMIT 65 SCHEDULES 66 SYSTEM PARAMETERS ARE RESET 69 WELD TIME SMALL 71 CURRENT 2 gt THAN UPPER
219. ta of the last weld Control shall return with CURRENT report See CURRENT command under Control Originating Commands section VOLTAGE lt crlf gt lt lf Any Requests the Control to report the sampled Voltage data of the last weld Control shall return with a VOLTAGE report See VOLTAGE command under Control Originating Commands section POWER ccrlf lf Any Requests the Control to report the sampled Power data of the last weld Control shall return with POWER report See POWER command under Control Originating Commands section HF27 LINEAR DC RESISTANCE WELDING CONTROL E 5 APPENDIX E COMMUNICATIONS Command Control State Description Command Control State Description Command Control State Description Command Control State Description Command Control State Description E 6 OHMS lt crlf gt lt lf gt Any Requests the Control to report the sampled resistance data of the last weld Control shall return with OHMS report See OHMS command under Control Originating Commands section STATE READ RUN MENU lt crlf gt lt lf gt Any Commands the Control to identify its current state READ keyword see STATE under CONTROL ORIGINATED COMMANDS section or go to either RUN state or PROGRAM State LOAD schedule_number lt crlf gt lt lf gt RUN state Selects the schedule number as the currently loaded schedule schedule number may be any number from 0 to 99 There must be a space between LOAD and schedul
220. te change from the Control front panel state name may be RUN MENU or PROG COUNTER lt crlf gt TOTAL number lt crlf gt HIGH number lt crlf gt LOW number lt crlf gt GOOD number lt crlf gt It Any Returns the requested current Control weld counter values HF27 LINEAR DC RESISTANCE WELDING CONTROL APPENDIX E COMMUNICATIONS Command Control State Description Command Control State Description Command Control State Description Command Control State Description E 18 ALARM error_message lt crlf gt lt lf Identifies the current error condition of operation of the Control May be in response to the ALARM READ command sent by the host or may be sent as a result of an error condition occurring in the Control error message 15 a text string describing the error message which 15 the same error message that 15 displayed to the screen CURRENT number of data lt crlf gt data lt crlf gt data crlf data lt crlf gt lt lf gt Any Returns the Current waveform data of the last weld First field is the number of data to be sent Then follows the packets of data Each data is separated by lt crlf gt and this command ends with lt crlf gt lt If gt number of data This 15 the number of data that shall be included in this command The Control samples current every 40 us For a weld less than 80 ms weld time the number of data will be approximately total weld time 40 us T
221. tered there are two ways to calibrate the LVDT Full Calibration Selection 3 Quick Calibration Selection 4 The Quick Calibration procedure 15 designed to expedite the calibration of air operated Miyachi Unitek heads Otherwise use the Full Calibration Both processes are detailed below Full Calibration This procedure does set a new zero point It merely establishes the calibration for the LVDT Use this procedure on automated machinery or in cases where the Miyachi Unitek gauge will not fit between the electrodes For best accuracy the weldhead should be set to the force that will be used for welding NOTE set a new zero point see Set New Electrodes to Zero following this procedure 1 From the MONITOR keys section on the lt CALIBRATION gt front panel press the CAL key for the HF27 CALIBRATION LVDT GAUGE menu on the right then press 3 LVDT CALIBRATION LVDT QUICK CALIBRATION FORCE CALIBRATION Menu menu 2 Verify that the electrodes are securely LVDT CALIBRATION installed in the electrode holders PUT THE ELECTRODES TOGETHER THEN 3 Manually adjust the weld head so the PRESS WHEN THEY ARE TOGETHER electrodes are touching then press the button on the front panel as shown on the screen on the right Press CAL to abort LVDT calibration 4 Open the electrodes 5 Insert the calibration gauge of the value LVDT CALIBRATION requested between the electrodes PUT THE GAUGE OF 0 100
222. the actual weld power to exceed the user set Upper Limit for Weldl Add upslope to reduce weld splash Reset the Upper Limit for Weldl to a larger value Weld splash can cause the actual weld power to drop below the user set Lower Limit for Weldl Add upslope to reduce weld splash Reset the Lower Limit for Weldl to a smaller value Weld splash can cause the actual weld resistance to exceed the user set Upper Limit for Weldl Add upslope to reduce weld splash Reset the Upper Limit for Weldl to a larger value Reduce the electrical resistance of the material being welded Reset the Lower Limit for Weldl to a smaller value CAUTION Be careful when using the MENU default features There is no way to restore a default action CAUTION Be careful when using the MENU default features There is no way to restore a default action Re program the welding parameters to be within the capability of the HF27 25 Reset the Upper Limit for Weld2 to a larger value HF27 DC RESISTANCE WELDING SYSTEM 6 6 72 CURRENT 2 lt THAN LOWER LIMIT 73 P2 VOLTAGE gt THAN UPPER LIMIT 74 P2 VOLTAGE lt THAN LOWER LIMIT 75 P2 POWER 2 gt THAN UPPER LIMIT 76 2 lt LOWER LIMIT 80 WELD STOP LIMIT REACHED 93 LESS THAN 94 SMALL 95 P1 JOULES gt UPPER LIMIT
223. the heat balance of the weld During weld development these common problems must be carefully monitored so as not to mislead the course and productivity of the welding experiments In summary the look see welding experiments should be used to fix further variables from an application and process perspective and also to establish a weld window for energy time and force This part of weld development is critical in order to proceed to a statistical method of evaluation Design of Experiments or DOEs Random explosions or unexpected variables will skew statistical data and waste valuable time HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 G 9 APPENDIX G DEFINING THE OPTIMUM PROCESS Poor Follow up Sparks Insufficient Force Impact Force Sparks Variation Tr Wr Variation sparks No Squeeze No Hold Sparks ssl Variation ea queeze Common welding problems can often be identified in the basic set up of the force energy and time welding profile shown above These problems can lead to weld splash inconsistency and variation contact Amada Miyachi America for further information and support What are Screening DOE S The purpose of a Screening DOE 15 to establish the impact that welding and process parameters have on the quality of the weld Quality measurement criteria should be selected based on the requirements of the application A Screening DOE will establish a relative quality measurem
224. the parts 0 8 2 3 020 0210 0010 2030 8 6 221 ms Pre Weld Check Waveform HF27 DC RESISTANCE WELDING SYSTEM 5 18 990 370 CHAPTER 5 OPERATING INSTRUCTIONS Section VII Weld To A Limit NOTE The Weld to a Limit function is used to stop the weld when a specific current voltage or power level sufficient to produce good welds is reached Using limits in this way ensures a more consistent input of energy which produces consistently good welds for some applications The Weld to a Limit function should only be programmed after a welding schedule which produces acceptable results has been developed The welding schedule includes the time and energy settings as well as the electrode force setting In the following steps a Constant Voltage weld is used as an example to show how the Weld to a Limit function 15 programmed 1 Press the SCHEDULE key then select a Weld Schedule using either the AV arrows or the numeric keypad 2 Program a single pulse for Constant Voltage operation as required to make strong welds Make a few welds and verify that the welds are acceptable 3 From the MONITOR keys section on the front panel press the kA current V voltage kW power and resistance keys observe the resulting waveforms NOTE You toggle between PEAK and AVERAGE readings by pressing the PEAK AVERAGE key 4 Press the kA current key and observe the current waveform If the current
225. the replacement parts for the Control items listed are a quantity of 1 each WARNING Only qualified technicians should perform internal adjustments or replace parts Removal of the unit cover could expose personnel to high voltage and may void the warranty e Amada Miyachi America Input Power Line Protection Fuses F1 and F2 Rear Panel HF27 240 330 071 HF27 400 330 092 HF27 480 330 092 Control Power Protection Fuse F1 330 078 Power PCB Input Power Selection Plug Set Welding Transformer 240 Volts 4 34314 01 Chassis 400 Volts 4 34315 01 480 Volts 4 34316 01 HF27 DC RESISTANCE WELDING SYSTEM 6 12 990 3 0 6 Section Ill Repair Service If you have problems with your Control that you cannot resolve please contact our service department at the address phone number or e mail address indicated in the Foreword of this manual HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 6 13 APPENDIX A Technical Specifications NOTE The specifications listed in this appendix may be changed without notice Power Doa Fron 50 60 Hz 3 phase Input Voltage Range at Maximum Output Current 0 0 216 264 VAC at 25A icis 360 440 VAC at 20A YUY H Y 432 528 VAC at 13A Input Demand e 30 max at 3 duty cycle Output Powe
226. time 1 msec increments Increase weld current voltage or power if a satisfactory weld achieved using 10 msec of weld time NOTE Actual weld strength is a user defined specification 7 Polarity as determined by the direction of weld current flow have a marked effect on the weld characteristics of some material combinations This effect occurs when welding materials with large differences in resistivity such as copper and nickel or when welding identical materials with thickness ratios greater than 4 to 1 The general rule is that the more resistive material or the thinner material should be placed against the negative electrode Polarity on the Control can only be changed by reversing the Weld Cables Weld Strength Testing Destructive tests should be performed on a random basis using actual manufacturing parts Destructive tests made on spot welds include tension tension shear peel impact twist hardness and macro etch tests Fatigue tests and radiography have also been used Of these methods torsional shear is preferred for round wire and a 45 degree peel test for sheet stock HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 5 APPENDIX F THE BASICS RESISTANCE WELDING Weld Strength Profiles Creating a weld strength profile offers the user a scientific approach to determining the optimum set of welding parameters and then displaying these parameters in a graphical form Start at a low weld current voltage or p
227. tings as well as the electrode force required to produce strong consistent welds mma Press the SCHEDULE key then select Weld Schedule using either the AV arrows or the numeric keypad 3 Program the second pulse as required to produce strong consistent welds Then program the first pulse for Constant Current operation Program the first pulse current level to approximately 10 of the second pulse current Program the first pulse upslope time to 1 ms and first pulse weld time to 2 ms Program 2 ms of cool time between the pulses Make a few welds and verify that the welds are strong and consistent y From the MONITOR keys section on the front panel press the voltage V key and observe the peak voltage reading of the first pulse Make several more welds and observe the range of first pulse peak voltage readings from weld to weld Press the Pulse 1 weld key to highlight the upper limit field for the weld period Use the numeric keypad to enter the upper limit value for the Pulse 1 weld period Program a voltage level that 1s slightly higher than the voltages observed in step 3 above Press the voltage V key to save the setting as an upper voltage limit Press the COOL weld period PULSE 1 OUT OF LIMITS ACTION key This will bring up the i mane PULSE 1 OUT OF LIMITS ACTION screen 3 INHIBIT PULSE2 4 PART CONDITIONER Stop Pulse1 select 1 STOP WELD NUMBER Select MENU Previous menu Toggle the Pulse 1 weld key to
228. tion 59 GND FORCE GROUND CHASSIS GND CHASSIS GND Same Same HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 H Index A Active Part Conditioner APC 4 5 Active Part Conditioning 5 13 Alarm Messages tu ans oda 6 1 Alarm INICSS 6 3 Alarm UALS 3 21 3 17 Application Perspective eere tritis G 8 Approach to Weld Development G 7 o e A E 3 17 3 15 B Principles G 4 Basics of Resistance Welding F 1 Electrode Maintenance F 5 Blectrode Selection F 2 Interaction of Welding Parameters F 6 Resistance Welding Parameters 1 Weld Schedule Development F 5 Weld Sirengih PIO UGS onem basi aat dass F 6 Weld Strength Testing ieri decine 6 Welding Parameter Interaction F 1 3 8 Before You Start 3 1 5 1 C 4 ISuzzet Ene Ra 3 16 C CALE A ENAS 1 9 Calibrating the Control isset C 1 Calibraung the LVD T 4 3 6 C 1 Calibrating the Control ioi rtis C 1 Calibration Equipment Required C 1 Calibration Procedure C 2 AZ A N C 1
229. tion line These functions are accessed using the MONITOR buttons on the front panel To use these functions see Chapter 5 Operating Instructions MONITOR LIMITS TIME IONITOR 3 060 k V 0400014 UPPER LIMIT gt pere RR B LOWER LIMIT 1 UPPER 3201V LOWER 2 100 one none none 4 TME SHORTEN LENGTHEN OR MOVE TIME VALUES MONITOR 3 060V 0 000 0000014 1 UPPER 32019 LOWER 21001 nor _ OR LONER LEMITVALUES _ UPPER LIMIT te roe Lic ia LOWER LIMIT a UPPER 3 201V 13 BOOK none and AVERAGE MONITORING gt PEAK The Control is always monitoring both the and AVERAGE of current voltage power and resistance at the same time When you press the PEAK AVERAGE key the top line in the LCD simply toggles back and forth so you can view either PEAK or AVERAGE values whenever you choose HF27 DC RESISTANCE WELDING SYSTEM 990 370 4 3 CHAPTER 4 INTRODUCTION TO FEEDBACK MODES AND MONITORING Current Voltage Power and Resistance Limits With the RUN screen selected you can select what you want to monitor by pressing the following MONITOR keys above kA current V voltage and kW power and resistance These monitors allow you to program upper and lower limits for PULSE 1 and for PULSE 2 These limits will display as dotted lines on the LCD screen Pus
230. ts out in either constant voltage or constant power control When the current produced by that voltage or power control mode exceeds a user programmed limit for up to 0 2 milliseconds the unit switches to constant current control at that level This weld mode 15 1deal for parts that start off with oxides or parts whose current carrying cross section changes significantly during the weld For welds that start out in voltage control set monitor limits on power For welds that start out 1n power set monitor limits on voltage NOTE In a Dual Pulse weld profile a different feedback mode can be used for each pulse For example a constant power first pulse can be used to break through plating in combination with a constant current second welding pulse HF27 DC RESISTANCE WELDING SYSTEM 4 2 990 3 0 CHAPTER 4 INTRODUCTION TO FEEDBACK MODES AND MONITORING Section Weld Monitoring Introduction The Control s feedback sensors not only control weld energy output but they can also be used to monitor each weld The Control s MONITOR features allow you to view graphic representations of welds visually compare programmed welds to actual welds look at peak or average energy values set upper and lower limits for welds and vary the time periods for these limits during the weld pulse These limits can be used for several purposes Common uses for out of limits welds are to stop a weld or to trigger a relay to remove parts with bad welds from the produc
231. tween the electrodes as a reference The recommended calibration gauge thickness 1s shown below Recommended Gauge Thickness Part Thickness 60 Series Heads Other Heads lt 0 025 lt 0 63mm 0 100 2 54mm 0 025 0 63mm 0 025 to 0 100 0 63 to 2 54mm 0 100 2 54mm Before LVDT calibration you must tell the unit the thickness of the calibration gauge you will be using 1 From the MONITOR keys section on the CALIBRATION front panel press the CAL key for the HF27 CALIBRATION menu on the right LVDT GAUGE LVDT CALIBRATION 2 Press 2 for LVDT GAUGE LVDT QUICK CALIBRATION FORCE CALIBRATION Number Select an item Run or Menu 3 Input the gauge thickness for the THICK gauge required Note that the THICK INPUT CALIBRATION CAUGE THICKNESSES gauge must be at least 0 0176 greater THICK THIN 17 6 INCHES 1000 than the thin gauge value programmed THIN 000 0 IN 1000 in step 4 THICK 100 0 IN 1000 LVDT CALIBRATION 4 Input the gauge thickness for the THIN gauge optional If you are not using a CAL Previous menu thin gauge input 000 Example Using a gauge that 1s 0 100 thick enter the numbers 1 0 and 0 They will display as thousands of an in as shown on the right 5 From the MONITOR keys section on the front panel press CAL to return to the CALIBRATION menu HF27 DC RESISTANCE WELDING SYSTEM C 4 990 3 0 APPENDIX C CALIBRATION After the calibration gauge thickness 15 en
232. unter was last reset 1s 5 237 SN O O5ODkA 020 1 0 2 0 1 0 0 50 1 O 3 0 1 0 030 ms The weld profile trace 1s an analog display of the electrical parameters programmed with the weld period selector keys When the weld is initiated a profile of the actual weld energy delivered during the weld cycle or both weld cycles will be overlaid on the trace The large type number 1 is the selected weld schedule The values 0 050kA and 0 060kA below the trace are respectively the weld current values programmed for PULSE 1 and PULSE 2 weld periods You may optionally program weld energy in volts or kilowatts with the energy units selection keys Use the time energy selector keys to toggle between the weld energy value field and the bottom line of text which is the weld period time selection field Use the weld period selector keys to enable the weld periods for programming and use the numeric pad keys for entering time values in milliseconds See Chapter 5 Operating Instructions for application related descriptions of the weld schedule profile HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 3 19 CHAPTER 3 SYSTEM CONFIGURATION Weld State Once weld current is flowing the Control is in the WELD state You can terminate weld current in five ways e Remove the first level of a single level foot switch assuming weld abort is ON e Remove the second level of a two level foot switch assuming weld abort is ON e Input the process
233. upper or lower energy limits are exceeded but allows Pulse 2 to fire The selections for PULSE 2 are e NONE The weld cycle will continue e STOP WELD The weld cycle will stop immediately The display shows the actual trace of the weld current voltage or power and either the peak or the average value for each weld pulse as selected by pressing the PEAK AVERAGE key See Chapter 4 Using Feedback Modes and Weld Monitoring for a detailed description of monitor and energy limits operation HF27 DC RESISTANCE WELDING SYSTEM 3 20 990 3 0 CHAPTER 3 SYSTEM CONFIGURATION Alarm State The Control automatically recognizes many ALARM NO WELD SWITCH alarm conditions The example WELD SWITCH IN NO WELD POSITION alarm screen shown at the right is displayed when you attempt to initiate a weld with the WELD NO WELD switch 0 0600 the NO WELD position 920 1 9 2 0 1 0 09 5910 3 0 1 20 032 ms 0005237 02 HF27 DC RESISTANCE WELDING SYSTEM 990 370 3 21 CHAPTER 3 SYSTEM CONFIGURATION Section IV Weld Functions Welding Applications Some welding applications require the use of RUN SQUEEZE UP 1 1 DOWN 1 COOL E WELD 2 powN 2 RUN rali TUE STATE 0 999ms 0 99ms 0 99ms 0 99 0 99 E 99ms 0 99 0 99ms 0 99 STATE specialized weld functions A weld function 15 a DN unique heat profile created by weld current volta
234. value Weld splash can cause the actual weld power to exceed the user set Upper Limit for Weld2 Add upslope to reduce weld splash Reset the Upper Limit for Weld2 to a larger value Weld splash can cause the actual weld power to drop below the user set Lower Limit for Weld2 Add upslope to reduce weld splash Reset the Lower Limit for Weld2 to a smaller value This is a MONITOR LIMITS feature activated by the selecting the ENERGY key then programming the Upper Limit values for Weldl and Weld2 If the terminated weld energy is not adequate for the weld re set the Upper Limit values for Weldl and Weld2 Restart LVDT gauge calibration procedure Restart LVDT gauge calibration procedure Joules is power over time If welds are good and message consistently happens decrease the power shorten the time or change the limit Joules is power over time If welds are good and message consistently happens increase the power increase the time or change the limit HF27 DC RESISTANCE WELDING SYSTEM 990 3 0 6 97 P2 JOULES gt UPPER LIMIT 98 P2 JOULES lt LOWER LIMIT 100 CUTOFF TIME gt UPPER LIM 101 CUTOFF TIME lt LOWER LIM 102 P2 CUTOFF TIME gt UPPER LIM 103 P2 CUTOFF TIME lt LOWER LIM 105 FORCE gt UPPER LIMIT 106 FORCE lt LOWER LIMIT 107 P2 FORCE gt UPPER LIMIT 108 P2 FORC
235. w limits for INITIAL THICKNESS FINAL THICKNESS and FINAL DISPLACEMENT It also allows you to weld to a specific thickness by entering a thickness value in the STOP ENERGY AT field Time Limits To access TIME CUT OFF press the TIME button on the front screen This function verifies that not only are the other values you programmed consistent but the time it takes to reach them consistent The time displayed in the STOP ENERGY AT field for the limits shown above is the programmed time The actual weld time may vary The TIME CUT OFF function allows you to fine tune the actual weld time by placing high and low limits around the time a weld pulse 15 stopped Example The time entered for the STOP ENERGY AT field 15 programmed for 10 millisecond pulse Actual weld times run at 5 ms but vary between 4 6 ms You can then put a low limit of 3 ms and a high limit of 7 ms If any weld is outside these time limits an OUT OF LIMITS alarm will sound HF27 DC RESISTANCE WELDING SYSTEM 4 4 990 370 CHAPTER 4 INTRODUCTION TO FEEDBACK MODES AND MONITORING Energy Limits To access ENERGY LIMITS press the ENERGY button on the front screen The Control monitors ENERGY as the combination of power multiplied by time throughout the weld measure in kJ killi Joules This function allows you to put high and low limits around the energy of PULSE 1 and PULSE 2 Envelope Limits To access ENVELOPE LIMITS press the ENVELOPE peak 1 073V 900000002

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