Home
ADP Technical Manual - AMADA MIYACHI AMERICA
Contents
1. 24V 500mA max shared with pin 1 GROUND Typical Isolated Input FS2 FS1 F52 FIRE COMMON A yA K FAULT RESET INPUT SCHEDULE LOCK INPUT I O COMMON BINARY 2 BINARY 8 BINARY 32 Advanced unit ONLY I O COMMON WELD END RELAY _ ALARM RELAY TO PLC COMMON TO PLC COMMON TO PLC COMMON RELAY COMMON GROUND Damage may result from improper connection of these pins The optical firing switch 1s intended for use only on Miyachi Unitek heads with this feature In operation an optical switch connects pin 3 to pin 20 to initiate firing Neither of these pins should be used for any other purpose since they connect to internal non isolated points in the unit 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 B 5 APPENDIX B ELECTRICAL AND DATA CONNECTIONS I O Signal Interface General Description 37 Pin Connector Control Signals As seen from the back of the power supply 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 NIG a Se 4560066600066 6560666 OOOO a a losa o o oe 12 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 NIN In SBC Theo cna daw ome 019 tna SORA OOOO a mg par 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY B 6 990 922 APPENDIX B ELECTRICAL AND DATA CONNECTIONS ARO Ca sn da Cs oea Ce rws Ca oom O Co oea SSCSCSCSCS SC SsS SsSsS S S RS 232 Connections As seen from
2. l 2 Press the LIMITS COUNTERS button to select this screen To edit the limits for Pulse 1 press and hold the PULSE 1 button for about one second The screen will turn black to indicate that the Power Supply is in edit mode The upper limit for Pulse 1 will be highlighted Press the A arrow to increase limit or press the V arrow to decrease the limit To edit the lower limit for Pulse 1 press the PULSE 1 button again The lower limit will be highlighted Press the A arrow to increase limit or press the Y arrow to decrease the limit To edit the Action for Pulse 1 press the Pulse 1 button again Press the A or Y arrow to select between CONTINUE or INHIBIT PULSE 2 NOTE When CONTINUE is selected Pulse 2 is enabled whether or not Pulse 1 1s within limits When INHIBIT PULSE 2 is selected Pulse 2 is inhibited when Pulse 1 is out of limits 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 4 4 990 922 CHAPTER 4 OPERATING INSTRUCTIONS Use the PULSE 2 button to set the upper and lower limits for Pulse 2 Press the SAVE button to save any changes made To exit the editing mode without accepting changes press the RUN button on the front panel which will activate the SAVE prompt then press CLEAR to discard changes Set Weld Counter Limit or Reset the Weld Counter The WELD COUNTER and COUNTER LIMITS apply to all weld schedules There is not a separate counter or separate limit for each schedule This
3. 000114 000000 NOTE At any time before you SAVE settings you may recover original system settings including the weld counter values by pressing the CLEAR key at the SAVE 1 To activate the SAVE prompt from the EDIT screen press the RUN key and the SAVE prompt will now appear To discard all new settings and values and return the system to its previous settings press the CLEAR button 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 3 6 990 922 MENU Screen Press the MENU button momentarily to display this screen Editing the MENU Screen Press and hold the MENU button to enter the MENU edit mode This will highlight the buzzer volume for editing To highlight another field press and release the MENU button Use the A Y arrows to change the highlighted values in all fields on the MENU screen 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 BUZZER BAUD RATE DEBOUNCE CHAINING START CHAINING END REMOTE LANGUAGE RESET DEFAULTS FAST WELDING REPEAT MODE REPEAT TIME BUZZER BAUD RATE DEBOUNCE CHAINING START CHAINING END REMOTE LANGUAGE RESET DEFAULTS FAST WELDING REPEAT MODE REPEAT TIME 4 19200 30 MSEC 03 05 OFF ENGLISH OFF ON OFF 0 00 SEC CN 19200 30 MSEC 03 05 OFF ENGLISH OFF ON OFF 0 00 SEC CHAPTER 3 USING DISPLAY SCREENS Section Il MENU Screen 3 CHAPTER 3 USING DISPLAY S
4. 000114 000000 SCHEDULE 08 SQUEEZE 0150 PULSE 1 MS 030 us MEDIUM UPSLOPE OFF PULSE 2 075 ws MEDIUM 5 0 KA 0 0 KA INHIBIT PULSE 2 UPPER LIMIT LOWER LIMIT ACTION 3 0 KA 0 0 KA SCHEDULE 08 WELD COUNTER COUNTER LIMIT 000114 000000 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 3 4 990 922 CHAPTER 3 USING DISPLAY SCREENS PULSE 1 Lower Limit Press and release the PULSE 1 button again until the lower limit parameter is highlighted Use the A Y arrows to set the desired value Use the CLEAR button to enter a value of zero NOTE When UPPER LIMIT and LOWER LIMIT values are both set to zero the limit function is disabled PULSE 2 Limits Limits for Pulse 2 are edited in the same manner as previously described for Pulse 1 PULSE 1 ACTION Press and release the PULSE 1 button until the ACTION parameter is highlighted Use the A Y arrows to select the desired action If ACTION is set to CONTINUE Pulse 2 will be enabled whether or not Pulse 1 is within limits If ACTION is set to INHIBIT PULSE 2 then Pulse 2 will enabled only when Pulse 1 is within limits SQUEEZE 0150 PULSE 1 MS 030 vs MEDIUM UPSLOPE OFF 5 0 KA 0 0 INHIBIT PULSE 2 UPPER LIMIT LOWER LIMIT ACTION 000114 000000 WELD COUNTER COUNTER LIMIT SQUEEZE 0150 PULSE 1 MS aa 030 us MEDIUM UPSLOPE OFF 5 0 KA 0 0 KA WELD COUNTER
5. Copper 2 11 2 11 N 2 2 2 NO APPENDIX E THE BASICS OF RESISTANCE WELDING MATERIAL Nichrome 2 2 2 2 2 14 14 2 J 3 N N 2 a 2 2 2 Cold Rolled 2 Steel J 14 E 14 14 E By 2 14 14 Paliney 7 2 MATERIAL i Steel Dune 2 CCT bums 2 west bums IEC Pin 14 14 14 NIN 2 Cold Rolled Steel D ma CIO CET o Kovar Gold 2 Kulgrid 2 Plate Kovar Gold 2 Nickel 2 Plate Kovar Gold 2 Silver 11 14 Plate Kovar Gold 2 Stainless Steel 2 Plate l 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 E 3 APPENDIX E THE BASICS OF RESISTANCE WELDING MATERIAL MATERIAL Steel 2 Cold Rolled 2 Steel 2 Stainless Steel Molybdenum Molybdenum Nichrome Nichrome Nichrome Nichrome Nickel Nickel Nickel Nickel Nickel Copper 2 Cold Rolled 2 Steel Electrode Maintenance Nickel Alloy Nickel Alloy Nickel Alloy Nickel Alloy Nickel Alloy Nickel Alloy Nickel Alloy Nickel Alloy MATERIAL MATERIAL NiSpan C 2 Cold Rolled 2 Steel NiSpan C Stainless Steel 2 NiSpan C NiSpan C Niobium 2 Paliney 7 Paliney 7 2 Sine T T Cold Rolled Cold Rolled 2 Steel Steel Stainless Steel 2 i Stainless Steel 2 Stainless Steel 2 Platinum Cold Rolled Steel Cold Rolled Steel Stai
6. COUNTER A E 7 EXCEEDS LIMITS Definitions D4 Delay time from the end of HOLD time until the END OF WELD or ALARM relay turns on This time is 25 ms or less in most cases However if the energy remaining in the capacitor bank at the end of pulse 2 is greater than the energy required for Pulse of the next weld the unit will discharge the capacitor bank to the proper energy level The end of weld relay will be delayed until the proper energy level is reached D5 Duration of the END OF WELD relay This is from 100 to 125 ms D6 Delay time from the end of the weld pulse until the OUT OF LIMITS relay turns on This time ranges from 100 to 250 msec D7 Delay time from the end of HOLD time until the COUNTER EXCEEDS LIMIT relay turns On This is from 125 to 250 msec 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 C 3 APPENDIX D Communications Section I Introduction Overview The Power Supply has the ability to communicate with a host computer or with automation control system The communications option uses RS 232 to connect one control to one host Remote Programming The codes needed to perform remote programming are listed in Section I 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 RS 232 Serial Connector Information 1 No Connectio
7. COUNTER LIMIT UPPER LIMIT LOWER LIMIT ACTION 000114 000000 PULSE 2 075 ws MEDIUM 5 0 KA 0 0 KA SCHEDULE PULSE 2 075 ws MEDIUM SCHEDULE 08 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 3 5 CHAPTER 3 USING DISPLAY SCREENS RESET WELD COUNTER From the LIMITS COUNTERS edit screen press and release the LIMITS COUNTERS button until the weld counter field is highlighted Press the CLEAR key to clear the weld counter to 000000 NOTE The weld counter value can not be changed using the A Y arrows EDIT COUNTER LIMIT From the LIMITS COUNTERS edit screen press and release the LIMITS COUNTERS button until the COUNTER LIMIT field is highlighted Press the A V arrows to set a desired limit value or use the CLEAR key to reset to the limit to 000000 Setting the counter limit to 000000 will disable the WELD COUNTER RELAY output signal available at the rear panel 37 PIN I O CONNECTOR SQUEEZE 0150 PULSE 1 030 ws MEDIUM UPSLOPE OFF PULSE 2 075 ws MEDIUM 5 0 KA 0 0 KA 5 0 KA 0 0 KA INHIBIT PULSE 2 000000 UPPER LIMIT LOWER LIMIT ACTION WELD COUNTER COUNTER LIMIT SCHEDULE 08 SQUEEZE 0150 PULSE 1 030 ws MEDIUM UPSLOPE OFF PULSE 2 075 ws MEDIUM 5 0 KA 0 0 KA 5 0 KA 0 0 KA INHIBIT PULSE 2 UPPER LIMIT LOWER LIMIT ACTION WELD COUNTER COUNTER LIMIT SCHEDULE 08
8. MEDIUM UPSLOPE OFF 4 8 ka 24 TO 5 0 4 2 TO 5 0 WELD COUNTER 000114 SCHEDULE 100 0 3 SQUEEZE HOLD 0150 PULSE 14 PULSE 2 0050 UPSLOPE OFF 4 8 KA 3 4 KA 4 2 TO 5 0 24 TO 5 0 WELD COUNTER 000114 SCHEDULE 100 0 3 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 3 2 990 922 CHAPTER 3 USING DISPLAY SCREENS SQUEEZE TIME To edit the squeeze time press the SQZ HOLD button HOLD TIME To edit the hold time press the SQZ HOLD button again Press the SAVE button to save new values and return to the original screen NOTE If you have not edited any values press the RUN button to return to the blue RUN screen To discard edited values and restore previously saved values press the RUN key The system will respond with the SAVE prompt which appears at the bottom of the screen Press SAVE to save changes CLEAR to discard The system will revert to the original screen NOTE Whenever the RUN MENU or LIMITS COUNTERS buttons are pressed before edited values are saved the SAVE prompt will appear at the bottom of the screen SQUEEZE 0150 MAS 090 ws MEDIUM UPSLOPE OFF 3 4 a 24 TO 5 0 PULSE 2 075 us MEDIUM 4 8 ka 4 2 TO 5 0 WELD COUNTER 000114 A oo 100 SQUEEZE PULSE 1 030 ws MEDIUM UPSLOPE OFF 3 4 a 24 TO 5 0 MS 08 HOLD ca PULSE 2 075 us MEDIUM 4 8 ka 4 2 TO 5 0 WELD COUNTER
9. RC M RR gt PRM WELD ZERO CR WELD LIMIT CS LOAD M LR M LS Read Read Read Set Read Read Read Read Read Set Set Set Read Set DATA None Returns Type of Welder None Returns status of last weld None Returns the rear panel status None Reset an Error None Returns the current weld counter None Returns Good and Bad Weld counts None Returns Weld count Limit None Returns of stored welds Request 1 6 or Retransmission F READ ORDER N new O Old O Local 1 Remote Reset Weld Counter zero 1 Weld Limit Value None Returns current schedule number 01 63 Sets active schedule SIZE O Bytes O Bytes O Bytes O Bytes O Bytes O Bytes O Bytes O Bytes 1 Byte Byte 2 Bytes Total 1 Byte 1 Byte 6 Bytes O Bytes 2 Bytes 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 D 3 APPENDIX D COMMUNICATIONS SCHEDULE SCHEDULE SR SS Read Set weld length O Very short 1 Short 2 Medium 3 Long weld polarity 0 Positive 1 Negative 2 Alternating Schedule Reads current schedule data SCHEDULE SQZ Squeeze Time WS 1 Energy in Watt Seconds WS 2 Energy in Watt Seconds HOLD Hold Time PULSE weld length PULSE2 weld length POLARITY 1 weld polarity POLARITY 2 weld polarity UP Up Slope 0 Off 1 On 2 Bytes 2 Bytes 4
10. Very Short VS B Medium 0 Long No Upslope With Upslope Vary Short WS Stor Medium W oe O Typical Pulse duration times at Max Energy into a 1 milliohm load with very low inductance Duration measured at 10 of peak currents 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 A 3 APPENDIX A TECHNICAL SPECIFICATIONS Description 125ADP 1 to 125 Watt Seconds Ws in 0 1 Ws increments for 1 0 gt 10 0 Ws otherwise Watt Second 1 Ws increments Adjustment Range 300ADP 3 to 300 Watt Seconds Ws in one Ws increments 1000ADP 10 to 999 Watt Seconds Ws in one Ws increments Positive Negative or Alternating on 125ADP 300ADP only TON Upon Reaching Buzzer sounds after each weld Output relay activates imit Input Debounce Time Approximately 32 msec Weld ready 24VAC or 30VDC max 500mA max Control Outputs Weld end 24VAC or 30VDC max 500mA max See Appendix B for Counter reached limit 24VAC or 30VDC max 500mA max details 24 VDC and return for optical firing switch Environmental Operating Humidity 5 to 95 Non condensing Operating Temperature 5 C to 40 C Ambient Temperature 24 VAC 0 5A maximum Valve power 24 VDC 0 5 A maximum including any current drawn from pins 1 and 19 of the 37 pin I O connector 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY A 4 990 922 APPENDIX B Electrical and Data Connections Section I Elect
11. manual and air actuated weld heads The Nias e OFF ON Power Supply provides repeatable process Kik 3 4 a 4B w control and protection from weld schedule ieee S changes by unauthorized personnel gt SCHEDULE e Dual pulse welding can eliminate weld splash and improve weld quality especially f when welding plated materials e A peak current monitor displays actual peak current delivered to the weld on each pulse e User programmable monitor limits on each pulse can help to detect poor welding conditions Programmable test pulses in conjunction with the INHIBIT SECOND PULSE feature can inhibit welding when conditions are out of limits on the test pulse VIN TOL ISS 300ADP DUAL PULSE STORED ENERGY POWER SUPPLY e The upslope feature improves welding when parts are oxidized surfaces are contaminated or parts do not mate well e Alternating polarity allows the user to program pulse polarity changes each time the welder is fired This allows the user to equalize the wear between two electrodes in many parallel gap welding processes This feature is not present in the 1000ADP e Five relays provide rear panel output signals for UNIT READY TO WELD WELD COMPLETED WELD OUT OF LIMITS ALARM and WELD COUNTER PRESET LIMIT 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 1 1 CHAPTER 1 DESCRIPTION e Two air valve drivers are provided for sequential control of two separate air operated w
12. 000114 A seso 100 SQUEEZE 0150 PULSE 1 MS l MEDIUM UPSLOPE OFF 3 4 a 24 TO 5 0 PULSE 2 075 ws MEDIUM 4 8 ua 4 2 TO 5 0 WELD COUNTER 000114 A seo 100 Press SAVE to save changes CLEAR to discard 08 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 3 3 CHAPTER 3 USING DISPLAY SCREENS Section Il LIMITS COUNTERS Screen LIMITS COUNTERS Screen Momentarily press the LIMITS COUNTERS button to view the blue LIMITS COUNTERS screen Peak current limits for Pulse 1 and Pulse 2 as well as ACTION to be taken when Pulse 1 peak current is out of limits are displayed at the middle of the screen Values for WELD COUNTER and COUNTER LIMIT are displayed at the bottom part of the screen Edit the Limits Counters Screen Press and hold the LIMITS COUNTERS button for about 1 second to enter edit mode When editing on the LIMITS COUNTERS screen use the A V arrows to increment the values of a highlighted parameter PULSE 1 Upper Limit Press and release the PULSE 1 button until the upper limit parameter is highlighted Use the A Y arrows to set the limit to the desired value Use the CLEAR button to enter a value of zero SQUEEZE 0150 PULSE 1 MS PULSE 2 075 ws MEDIUM 030 us MEDIUM UPSLOPE OFF UPPER LIMIT LOWER LIMIT ACTION 3 0 KA 0 0 KA INHIBIT PULSE 2 3 0 KA 0 0 KA WELD COUNTER COUNTER LIMIT
13. 1 DESCRIPTION To edit RUN MENU or LIMITS COUNTERS SQUEEZE screens press the appropriate PULSE 1 PULSE 2 foe PULSE 1 PULSE 2 eaten E tad e 030 ws o 075 ws until the screen changes to indicating MEDIUM MEDIUM you ve entered edit mode UPSLOPE OFF Highlight the item being edited in white as 3 4 KA 4 y 3 KA shown at the right Edit values using the 24 TO 50 42 TO 50 A Y up down arrows keys then advance to the next field WELD COUNTER 000114 SCHEDULE When finished press the SAVE button which will save changes and return the display to the 100 0 83 BLUE run mode screen You re ready to weld NOTE If you edited the limits screen you will need to press RUN after SAVE to enable the weld mode See Chapter 3 Using the Display Screens for details on using these features e The schedule lock feature restricts welding to the one selected weld schedule and prevents changing that schedule e The program lock feature allows the use of all 63 schedules but does not allow editing schedule values e The digital display allows operators to set welding energy accurately and quickly e The Power Supply is compatible with both manually and air actuated weld heads with 1 level or 2 level foot switches e The Power Supply is compatible with force fired and non force fired weld heads SQUEEZE and HOLD delay times are adjustable from 0 to 2 999 seconds e A built in weld counter allows controlling e
14. 1 Install weld cable washers between the screw heads and cable terminals NOT between the cable terminals and Control terminals 2 Dress weld cables together with cable ties to minimize induction loss 1 Turn the AC power turned OFF 2 Connect one end of a weld cable to the negative welding transformer terminal on the Power Supply or external transformer for a 1000ADP 3 Connect one end of the second weld cable to the positive welding transformer terminal on the Power Supply or external transformer for a 1000ADP 4 Connect the other end of the weld cables to the weld head 5 Install electrodes in the weld head electrode holders NOTE If you need additional information about the weld heads please refer to the manufacturer s user manuals 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 2 5 CHAPTER 2 INSTALLATION AND SETUP Foot Pedal Actuated Weld Head FORCE FIRING EMERGENCY ADJUSTMENT SWITCH STOP KNOB a CABLE SWITCH WELD HEAD FORCE INDICATOR Set to 5 REAR PANEL 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 Power Supply firing switch cable connector 3 Connect a normally closed agency compliant EMERGENCY STOP SWITCH across the two leads of the emergency stop switch connector cable This switch when operated open wil
15. A UNITEK 0 0 TO 0 0 9 TO 0 100ADP VER 1 02c WELD COUNTER 000114 CTL VER 1 01b SCHEDULE 08 Start Up Screen and Version Number Normal RUN Screen The unit will take approximately 20 seconds to complete its internal startup routine The Charge Monitor indicator on the front panel will turn green when the startup routine has been complete Using Existing Weld Schedules 1 Use the AV arrows to select the weld schedule you desire 2 Press the WELD NO WELD switch to the WELD position 3 Begin welding using your normal procedures NOTE Welding will be performed using values of the schedule selected until you select a new schedule Modifying Weld Schedules 1 Press the WELD NO WELD switch to the NO WELD position 2 Use the AV arrows to select the weld schedule you wish to modify 3 Press the PULSE 1 button to modify Pulse 1 Hold the button for about 1 second When the screen changes to black the Power Supply is in the edit mode 4 To modify the energy press the A arrow to increase energy or press the W arrow to decrease energy 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 4 3 CHAPTER 4 OPERATING INSTRUCTIONS 5 To modify pulse duration press the PULSE SELECT button until the pulse length you want is indicated beneath the 3 digit energy display NOTE The Very Short setting provides the shortest duration The Short setting provides the highest peak current for a given ener
16. AND SETUP Section Il 125ADP amp 300ADP External Equipment Connections All connections between the Power Supply and external equipment other than the weld cable are made through the rear panel FOOT 24 VAC 24 VDC SWITCH AIR VALVE WELD HEAD eee CONNECTOR DRIVE CONNECTOR FIRING SWITCH y ah CONNECTOR CABLE EMERGENCY STOP SWITCH CONNECTOR CABLE CONNECTOR METANA 37 PIN I O CONNECTOR ON OFF SWITCH CIRCUIT BREAKER AC POWER CONNECTOR Rear Panel Components and Connectors 125ADP and 300ADP NOTE Weld cable connections are made at the front panel for the 125ADP and 300ADP Power Supplies and located on the front panel of the external transformer on the 1000ADP systems Emergency STOP Switch Connect an agency compliant normally closed EMERGENCY STOP SWITCH across the two leads of the emergency stop switch connector cable This switch when operated open will immediately stop the weld cycle See Appendix B Electrical and Data Connections for circuit details NOTE For operation without an EMERGENCY STOP SWITCH verify that the two conductors of the emergency stop cable are shorted together as the system will not operate with this loop electrically open 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 2 4 990 922 CHAPTER 2 INSTALLATION AND SETUP Weld Head Connections to Power Supply Terminals AFA F WELD TERMINALS WELD HEAD WELD CABLES He ay Cat CAUTIONS
17. Bytes 3 Bytes 3 Bytes 4 Bytes 1 Byte 1 Byte 1 Byte 1 Byte 1 Byte 21 Bytes Total Note The SS Set commands for PULSE1 PULSE2 POLARITY 1 and POLARITY 2 do not apply to the 1000ADP LIMITS LIMITS SYSTEM SYSTEM MR Read Schedule MS 6 YR gt VS Set Read Set SCHEDULE P1 Upper Limit P1 Lower Limit P1 Action P2 Upper Limit P2 Lower Limit action action 0 NONE 1 INHIBIT P2 none BAUD RATE rate DEBOUNCE O None 1 30ms BUZZER O 0ff 1 2 3 loud FAST WELDING 0 Off 1 On REMOTE O Off 1 On CHAINING START 0 0ff 01 63 CHAINING END 0 0ff 01 63 rate 0 9600 1 19 2 k 2 38 4 k Baud 2 Bytes 2 Bytes 4 Bytes 4 Bytes 1 Byte 4 Bytes 4 Bytes O Bytes 1 Byte 1 Byte 1 Byte Byte Byte 2 Bytes 2 Bytes 19 Bytes Total 9 Bytes Total 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY D 4 990 922 APPENDIX D COMMUNICATIONS ADP Originated Command Set These are commands returned by the ADP 125 ADP 300 and ADP 1000 to the host computer via the RS 232 port NAME TYPE RESET WELD COUNTER LIMITS COUNT REMOTE COMMAND PTY RX A TG TL RC PRM WELD ZERO CR WELD LIMIT CS LOAD REPORT REAR LS mM LR gt RR gt lt TR Read Set Read Read Read Read Set Set Set S
18. Bytes Total action 0 NONE 1 INHIBIT P2 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 D 7 APPENDIX D COMMUNICATIONS EXAMPLE 1 An example of sending a TYPE command to the ADP lt STX gt TY000D lt ETX gt The command TY The Count is 00 The check sum is OD Which is calculated from the ASCII American Standard code for information interchange and is a two charter ASCII HEX string calculated from the sum of all bytes except lt stx gt lt cksum gt and lt etx gt T Y 0 0O Looking up the value for each character We get 0x54 0x59 0x30 0x30 0x10D HEX In decimal 84 89 48 48 269 decimal The check sum is a value between 0 and 255 Therefore 269 255 n 14 decimal OD hex Where n check sum 255 Here it is only 1 If the check sum was 9C4 hex 2500 decimal Then n 2500 256 9 7 Using only the hole number n 9 The final check sum is 2500 256 9 196 decimal or 0xC4 hex A better way is to take the final check sum and AND it with 255 OxOFF In hex taking the final check sum 0x9C4 and ANDing it with OxFF 0xC4 or in decimal 2500 AND 255 196 EXAMPLE 2 Now we wish to find out how many welds are stored in the ADP weld buffer The total command is lt STX gt TC00F7 lt ETX gt TC is the command 00 is the count and F7 is the check sum If the ADP send back lt STX gt T
19. FIRING ON SWITCH ore WELDING CURRENT D3 SQUEEZE PuLSE1 cooL PULSE2 HOLD Definitions D3 Delay time from firing switch closure to the start of the weld sequence that is start of SQZ This time ranges from 10 to 40 msec depending upon the debounce setting SQZ Squeeze time Selectable range is 0 to 2999 ms Typical accuracy 1s 0 10 Pulse 1 The timing of this weld pulse depends upon the pulse length programmed the energy setting and the impedance of the secondary circuit COOL This time is not programmable by the user It depends upon the energy level of the second pulse and ranges from 20 to 670 msec on the 125ADP and 300 ADP It can range up to 1 5 seconds on the LOOOADP If no second pulse is programmed this time period is skipped Changing pulse widths or polarities may result in longer cool times than if no changes are made to these parameters Pulse 2 The timing of this weld pulse depends upon the pulse length programmed the energy setting and the impedance of the secondary circuit HOLD Hold time Selectable range 1s 0 to 2999 ms Typical accuracy is 0 10 NOTE The firing switch signal needs to be at least 50 msec duration for the unit to recognize it 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY C 2 990 922 APPENDIX C SYSTEM TIMING Relay Timing CURRENT p3 squeeze PuLsE1 cooL PuLse2 HOLD D4 D5 END OF WELD ALARM XK oo E D633 OUT OF LIMITS
20. However as the force is 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 RT the square of the weld current I times the workpiece resistance R times the weld time T Welding Parameter Interaction PROBLEM CAUSE Parts Overhealing yi Excessive Parts Overheating Weak Weld f A Weak Weld Insufficient Nugget LS Insufficient Nugget Metal Expulsion PSK Metal Expulsion gt lt yy Warping Za 0 Warping Ya Discoloration F oy Discoloration gt Electrode Damage Insufficient Electrode Damage 4 Insufficient FORCE PROBLEM CAUSE Parts Overheating ae Excessive Weak Weld Insufficient Nugget FRA Metal Expulsion Warping Discoloration E gt Electrode Damage X insufficient Interaction of Welding Parameters 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 E 1 APPENDIX E 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 steel so that the weld heat is generated by the electrical resi
21. Power Supplies We have made every effort to ensure that information in this manual is both accurate and adequate If you have any questions or suggestions to improve this manual please contact us at the phone number or addresses above Miyachi Unitek Corporation is not responsible for any loss or injury due to improper use of this product 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY vi 990 922 SAFETY NOTES e DEATH ON CONTACT may result if you fail to observe all safety precautions Lethal voltages are present in the Power Supply e Never perform any welding operation without wearing protective safety glasses This instruction manual describes how to operate maintain and service the 125ADP 300ADP 1000ADP Dual Pulse Resistance Welding Power Supplies and provides instructions relating to its safe use A 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 For safety and to effectively take advantage of their full capabilities please read these instruction manuals before attempting to operate weld heads and power supplies Procedures other than those described in these manuals or not performed as prescribed in them may expose personnel to electrical shock or burn hazards After reading these manuals keep them for future reference Please note the foll
22. 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 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 E 5 APPENDIX E THE BASICS OF 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 1 Start at a low weld current voltage or power 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 differen
23. continue in REPEAT MODE When REPEAT MODE is 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 REPEAT TIME which is applicable only to REPEAT MODE sets the cycling rate between welds by controlling how long the electrodes remain open When REPEAT MODE is set to ON and the user keeps the footswitch depressed and firing switch closed the control will repeatedly actuate the weldhead and perform the weld sequence If set to ON a REPEAT TIME other than 0 must also be set You should specify the REPEAT TIME so that it is sufficient to allow the weld head to open the electrodes and to allow you to reposition the work piece before the entire welding sequence repeats When REPEAT MODE 1s set to OFF this function is deactivated 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 3 11 CHAPTER 3 USING DISPLAY SCREENS REPEAT TIME BUZZER 4 A time other than 0 must be set if REPEAT BAUD RATE 19200 MODE is set to ON DEBOUNCE 30 MSEC The REPEAT TIME is the time between the end CHAINING START 03 CHAINING END 05 REMOTE OFF of HOLD and the start of the next weld sequence REPEAT TIME can range from 0 25 to LANGUAGE ENGLISH 9 99 seconds RESET DEFAULTS OFF FAST WELDING ON REPEAT MODE OFF REPEAT TIME 0 00 SEC REPEAT MODE showing R
24. 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 is 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 is 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 1s 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 best settings for the process A fa
25. outside limits The 125APD allows programmed values for SQUEEZE HOLD Energy in tenths of watt seconds for energy ie ren A A settings between 1 0 and 10 0 Ws The energy ts settings for the 125ADP between 10 and 125 Ws 006 9 di 059 0 jidi can only be set in whole number increments UPSLOPE OFF The energy settings for the 300ADP and 0 0 KA 0 a 0 KA 1000A DP can only be set in whole number 0 5 TO 7 2 0 5 TO 7 1 increments WELD COUNTER 000155 The 125ADP RUN screen is the same as the SCHEDULE 300ADP and 1000ADP RUN screens except the 01 Energy setting is shown with the tenths digit as shown in the screen shown on the right 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 3 1 CHAPTER 3 USING DISPLAY SCREENS Editing the Run Screen PULSE 1 To edit Pulse 1 pulse width polarity and upslope settings press and hold the PULSE 1 button for about 1 second to highlight the values in WHITE as shown on the right Use the A V arrows PULSE WIDTH and POLARITY SELECT buttons to change the values for Pulse 1 To change the energy values for Pulse 1 press and hold the PULSE 1 button for about 1 second and then use the A W arrows to change the values for Pulse 1 NOTE Pulse width and polarity are not user settable in 1000ADP PULSE 2 To edit the same values for Pulse 2 press the PULSE 2 button and repeat the procedures for Pulse 1 SQUEEZE 0150 PULSE 1 MS PULSE 2 075 ws
26. the back of the power supply 5 4 3 2 1 9 8 7 6 MIN o eo Ca eo ra OOOO aman 2 sie Ce ocom OOOO Ce ocom 2 Co ooms 2 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 B 7 APPENDIX B ELECTRICAL AND DATA CONNECTIONS Two Level Foot Switch Connector es onon OOOO rn 2 Fo o Sich elcome in 3 Foot 2 to activate Foot Switch Level 2 connect to pin 4 When you press the foot switch to the first level the Power Supply 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 Power Supply will automatically return the upper electrode 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 Power Supply will automatically return the upper electrode to its UP position Standard Air Valve Driver Output Connector Air Valve Driver 24 VAC Connector a amento O 1 24VAC for solenoid or 24VDC HEAD 2 Switched 24VDC common The air valve driver output 24V AC is initiated when Foot Switch Level 1 is initiated Ifa PLC or other means of trigger is used refer to the 7 O Signal Interface General Description on page B 3 The mating connector is an AMP type 206429 1 using cable c
27. ADP 999Ws Description Output Energy Max per pulse Voltage turndown circuit 50W average power Automatic turndown upon power interruption Weld schedules 63 Weld pulses per Schedule 2 Energy 125ADP 300ADP 1000ADP 1Ws 300 min 2 Ws 300 min 3Ws 235 min 750 min 4 Ws 220 min 5 Ws 190 min 7 Ws 160 min 10Ws 140 min 520 min 170 min 13 Ws 122 min 17 Ws 112 min 20 Ws 100 min 25Ws 90 min 345 min Repetition Rate 35 Ws 80 min Pulses per minute 40 Ws 72 min 50Ws 66 min 240 min 130 min 75Ws 55 min 200 min 85 Ws 52 min 100Ws 47 min 175 min 125 Ws 45 min 150Ws 140 min 200Ws 120 min 225Ws 105 min 250Ws 65 min 300Ws 80 min 500 Ws 35 min 750Ws 17 min 1000Ws 10 min 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY A 2 990 922 APPENDIX A TECHNICAL SPECIFICATIONS Description Energy 125ADP 300ADP 1000ADP 1Ws 345 min 2 Ws 310 min 3Ws 285 min 750 min 4 Ws 275 min 5 Ws 265 min 7 Ws 245 min 10Ws 225 min 520 min 170 min 13 Ws 210 min 17 Ws 196 min 20 Ws 185 min 25Ws 172 min 345 min 35 Ws 155 min 40 Ws 145 min Hit Rate 50Ws 137 min 240 min 130 min Pulses per minute 60 Ws 125 min 75Ws 105 min 200 min 85 Ws 95 min 100Ws 75 min 175 min 125 Ws 60 min 150Ws 140 min 200Ws 120 min 225Ws 105 min 250Ws 65 min 300Ws 80 min 500 Ws 35 min 750Ws 17 min 1000Ws 10 min NOTE The Hit Rates for the 300ADP and 1000ADP are the same as their Repetition Rates Rise Times at Max Energy into a 1 milliohm
28. C0600000522 lt ETX gt then the command is TC or current weld counter the data count is 6 06 and the number of welds stored is 5 000005 The check sum is 22 hex in decimal 84 67 48 54 48 48 48 48 48 53 546 546 256 2 13 Therefore the check sum is 546 256 2 34 decimal or 22 hex 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY D 8 990 922 ADP Commands Alphabetically CR CS LR LS MR MS Reset Weld Counter Set Weld Limit Read current schedule Set active schedule Monitor Limits Read Monitor Limits Set Number of reports stored Set Remote Read Report Reset an Error Schedule Read Schedule Set Read Weld Counter Read Good amp Bad Counters Read Weld Count Limit Rear Panel Status Read Status of last weld Read the Type System Read System Set APPENDIX D COMMUNICATIONS 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 D 9 APPENDIX E The Basics Of Resistance Welding Resistance Welding Parameters Resistance welding heat is produced by passing electrical current through the parts for a fixed time period The welding heat generated is a function of the magnitude of the weld current the electrical resistance of the parts the contact resistance between the parts and the weld force applied to the parts Sufficient weld force is required to contain the molten material produced during the weld
29. CREENS BAUD RATE Press the MENU button again the highlight the BAUD RATE field This is the speed used for RS 232 communications DEBOUNCE Press the MENU button again for the debounce setting Use the 0 MSEC setting for applications where a PLC communicates with the unit CHAINING START Press the MENU button again to edit the starting value for a weld chain In chaining all schedules from CHAINING START to CHAINING END are welded one time and in numeric order When the last schedule in the chain is completed the system returns to the CHAINING START schedule Whenever a schedule within a chain is selected the chain will start at that schedule When the last schedule in the chain is completed the system returns to the CHAINING START schedule BUZZER BAUD RATE DEBOUNCE CHAINING START CHAINING END REMOTE LANGUAGE RESET DEFAULTS FAST WELDING REPEAT MODE REPEAT TIME BUZZER BAUD RATE DEBOUNCE CHAINING START CHAINING END REMOTE LANGUAGE RESET DEFAULTS FAST WELDING REPEAT MODE REPEAT TIME BUZZER BAUD RATE DEBOUNCE CHAINING START CHAINING END REMOTE LANGUAGE RESET DEFAULTS FAST WELDING REPEAT MODE REPEAT TIME 4 19200 30 MSEC 03 05 OFF ENGLISH OFF ON OFF 0 00 SEC 19200 03 05 OFF ENGLISH OFF ON OFF 0 00 SEC F 19200 30 MSEC 03 05 OFF ENGLISH OFF ON OFF 0 00 SEC NOTE If the schedules that are ch
30. DP 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 1 5 CHAPTER 1 DESCRIPTION PULSE 1 DATA PULSE 2 DATA DISPLAY UP DOWN SCREEN BUTTONS PULSE z 030 ws MEDIA UFSLOPE OFF 3 4 a 4 8 ca 103 TO 68 1 6 2 Th 0 L l WELD COUNTER 500714 PULSE 1 MENU PULSE 2 CLEAR LIMITS COUNTERS WELD NO WELD SAVE CHARGE SQUEEZE HOLD MONITOR Front Panel Controls 1000ADP UP DOWN Buttons The UP and DOWN buttons have two functions e During normal operation up and down buttons are used to scroll through the 63 schedules to select a desired schedule The schedule number displays at the lower right corner of the front panel display screen e In editing mode these buttons also are used to increase or decrease highlighted values 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 1 6 990 922 Polarity Select POLARITY AL SELECT Pulse Select PULSE SELECT MENU MENU CHAPTER 1 DESCRIPTION This button is only active when the Power Supply is in the editing mode Press this button repeatedly until the polarity you want displays adjacent to the Pulse 1 or Pulse 2 3 digit energy display For example the front panel display screen shown on the previous page indicates positive polarity selected for both Pulse 1 and Pulse 2 Note This button is not present on the 1OOOADP This button is
31. DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 B 9 APPENDIX B ELECTRICAL AND DATA CONNECTIONS Operator Emergency Stop Cable Switch Input Function Connect an agency recognized normally closed Emergency Stop Switch to the cable provided on the rear panel Use the switch during Power Supply operation as an Emergency Stop Switch When operated opened it will immediately halt the weld process and de energize all ADP outputs Connections You must connect the Emergency Stop Switch Cable leads otherwise the Power Supply will not function Connect an agency recognized normally closed Emergency Stop Switch between conductors of the 2 foot 61 cm operator Emergency Stop Switch cable When the switch is operated opened it de energizes all power outputs from the Power Supply If you choose not use an Emergency Stop Switch an electrical short is required between cable leads for the Power Supply to be functional 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY B 10 990 922 APPENDIX C System Timing Basic Weld Operation Air Head System with Two Level Foot Switch FOOT SwiTcH f L_ LEVEL 1 _ WELD FORCE FOOT SWITCH ik LEVEL 2 FIRING SWITCH WELDING CURRENT p2 p3 SQuEEZE PuLse1 cooL PULSE2 HoLD Definitions D1 Delay time from Foot Switch Level 1 closure to Weld Force start This time ranges from 10 to 40 msec depending upon the debounce setting D2 Delay time from Weld Force st
32. E E 1 1 PE A SS IO on Pp A OU 1 1 Da A o Oo seceded pss eet onan nota anenaee ecsegtaaete 1 2 DESIDIA rebp 1 4 Section Ll Major COMPOncatS li ere eee 1 5 Major E Ot OTC IMS oreren e E E EE E ion ac p 1 5 Front Eer CONO tao 1 5 UBDOWN DOTON pee os spe ees see ees ceca da 1 6 ns A Pe O AP A 1 7 Prison neon etitan ete sascaeesoed 1 7 RUN a 1 7 INE O E E E A A E E A teneusceatse sep E E 1 7 BIMIES COUNTERS demersal 1 7 MAR AA A 1 7 OA HOLD A e ener ere 1 7 e O oo EE 1 7 A PP A 1 7 CHARGE MONITOR Linterna 1 8 WELCO NOWI EDSN E eE acc ET EE EE E AEE E E E AEE E N 1 8 Emergency Stop Switch Operation occcccccccnnnnnononononononnnnnnnnnnnnonnnnnnnnnnnnn non nnnn nn nnnnnnnnnnnnnnnnnnnnnnnnnnnns 1 8 Chapter 2 Installation and Setup Section E LOSA ea 2 1 is AA 2 1 gt 9 UN Ges S eee ee eee A eee eee eee ee en ee eee eee 2 1 NVI A cece E E T T E AS 2 2 PP E O O UU E E S 2 2 Compressed Air and Cooling Water siccsissaciaiaadsiavarpainawtssvebeiandabensiainaseaiunboduaedwieeteespeemdandedecsiateus 2 3 pn Logi Om IEO tea 2 3 Section I 125ADP 300ADP External Equipment Connections oooooonnnnnccccnnnnnnnnnnnnnnononononananoccccnnnnnos 2 4 EGE CMC SONO WC eeoa E E E E E diles 2 4 Weld Head Connections to Power Supply Terminals cccccccccecsseeeeeeeeeeeeeeeeeeeeeeeees 2 5 Foot Pedal Actuated Weld Head Connection ooooooooonooooonononononnnnnnnnnnnononononononnnnnnn nono nono ono nnnnnnnnos 2 6 EZ AIR Weld H
33. EPEAT TIME REPEAT RUN TIME STATE RUN REPEAT STATE SQZ WELD HOLD TIME SQZ WELD HOLD WELD HEAD POSITION 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 3 12 990 922 CHAPTER 4 Operating Instructions Section I Introduction Before You Start Before operating the Power Supply you must be familiar with the following e The location and function of Controls and Indicators For more information see Chapter I Description of this manual e How to select and modify items on the Power Supply display screen Make sure you have read Chapter 3 Using Display Screens 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 Power Supply Connections Verify the Power Supply is connected to a manual or air actuated weld head as described in Chapter 2 Installation amp Setup in this manual Verify the EMERGENCY STOP SWITCH connector cable located on the rear panel is connected properly Power Verify AC input power is connected as described in Chapter 2 Installation amp Setup in this manual Compressed Air If you are using an air actuated weld head verify that compr
34. LC or other external device to supply 24VDC to activate or to turn an input ON This configuration is accomplished by changing two jumpers To replace the footswitch and firing switch with PLC or other 24VDC TRUE SIGNALS remove the cover of the unit and locate jumper P6 Move it to the HIGH TRUE position as shown below Note that this position is only used if Miyachi Unitek footswitch and weldhead firing switch connections are replaced by 24VDC TRUE INPUTS If a Miyachi Unitek mechanical footswitch and standard weldhead firing switch are used this jumper should remain in the LOW TRUE position To reconfigure all other inputs Binary schedule select lines weld inhibit etc for HIGH TRUE move jumper P7 to the HIGH TRUE position as shown in the photograph TOP VIEW Cover Removed JUMPER JUMPER ha z ae Lj 4 CHASSIS JUMPER CON NECTOR Jumper Removed LOW TRUE JUMPER HIGH TRUE 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 B 3 APPENDIX B ELECTRICAL AND DATA CONNECTIONS Configuration for Low True Inputs Switch Closure to Activate Inputs Default Configuration lt Q USER SIDE QJ oo 0 co Go Ma Mo PJ mL h UNIT SIDE gt 24V 500mA max shared with pin 19 OPTO FIRING SWITCH INPUT FIRE FS1 WELD INHIBIT INPUT WELD COUNT RESET INPUT PROGRAM LOCK INPUT BINARY 1 BINARY 4 BINARY 16 Advanced Unit ONLY DUAL HEAD INP
35. LY 1 8 990 922 CHAPTER 1 DESCRIPTION CHARGE MONITOR Light When the green CHARGE MONITOR light is lit capacitors are fully charged and ready to weld The light will turn off for a short time during the weld discharge period and while the capacitor bank is recharging Once capacitor charging has been completed the CHARGE MONITOR light will again illuminate When the WELD NO WELD switch is in the NO WELD position the CHARGE MONITOR light will not light because the system is not ready to weld WELD NO WELD Switch With the WELD switch is in the WELD position weld current is enabled and programmed weld sequences execute normally With the WELD switch to the NO WELD position weld current is INHIBITED and output relays are disabled however all other control functions execute in a normal manner This feature allows adjustment of weld head and SQUEEZE HOLD delay parameters prior to actual welding NO WELD Emergency Stop Switch Operation If your work station has an EMERGENCY STOP SWITCH connect it to the cable provided at the rear panel of the unit When pressed the EMERGENCY STOP SWITCH will immediately halt the welding process and de energize all air valves and power circuits Additionally an EMERGENCY STOP status display message will appear near the bottom of the display screen To resume operation reset the EMERGENCY STOP SWITCH to the normal position which will automatically return the system to RUN mode NOTE Durin
36. P 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 3 9 CHAPTER 3 USING DISPLAY SCREENS RESET DEFAULTS Press the MENU button again to select the RESET DEFAULTS The default selection is OFF To set all schedules limits weld counter weld counter limits and all menu items back to their factory default values select ON then press SAVE to save changes To discard changes press RUN to activate the SAVE PROMPT and at the prompt press CLEAR to discard changes After saving or discarding new settings the display will revert to the original screen selected FAST WELDING Press the MENU button again to highlight the FAST WELDING selection When this is set to OFF weld data is saved to non volatile memory periodically When FAST WELDING is set to ON weld data is saved to non volatile memory only when the user presses the SAVE button See Chapter 4 for more information about the FAST WELDING feature 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 3 10 BUZZER BAUD RATE DEBOUNCE CHAINING START CHAINING END REMOTE LANGUAGE RESET DEFAULTS FAST WELDING REPEAT MODE REPEAT TIME BUZZER BAUD RATE DEBOUNCE CHAINING START CHAINING END REMOTE LANGUAGE RESET DEFAULTS FAST WELDING REPEAT MODE REPEAT TIME BUZZER BAUD RATE DEBOUNCE CHAINING START CHAINING END REMOTE LANGUAGE RESET DEFAULTS FAST WELDING REPEAT MODE
37. PERATING INSTRUCTIONS Extended Shut down Procedure If the ADP unit has been turned off and non operational for a period of 3 months or longer an extended warm up sequence is recommended Turn the unit ON Set the energy to the maximum level Example set the 1000ADP to 999 Watt Seconds Fire the unit once Leave the power ON and wait 15 minutes Se a Program the desired schedule and resume normal operation 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 4 9 CHAPTER 5 Maintenance Section Troubleshooting Troubleshooting Cause of Problems Order of Probability Highest Probability High Probability Low Probability Lowest Probability Cause in order of probability Cause in order of probability Electrode Damage Electrode Sticking Electrode Sparking 1 Excessive energy setting 1 Excessive or insufficient weld head force 1 Wrong electrode tip shape 2 Contaminated weld piece surface plating 2 Excessively short pulse time setting 2 Wrong electrode material 2 Contaminated electrode surface Weld Piece Warping 1 Contaminated weld piece surface plating 1 Wrong electrode material tip shape Insufficient weld head force Excessive energy setting Contaminated electrode surface Slow weld head follow up Excessive energy setting Insufficient weld head force Slow weld head follow up Incompatible weld piece projection esign Wrong electro
38. Pt Ta 3 Al Ag T 1 Mo w 500 1000 1500 2000 2500 3000 350 G 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 Group I Conductive Metals Conductive metals dissipate heat and it can be difficult to focus heat at the interface A solid state joint is therefore preferred Typically resistive electrode materials are used to provide additional heating 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 F 3 APPENDIX F DEFINING THE OPTIMUM PROCESS e Group ll Resistive Metals It 1s 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 e Group lll Refractory Metals Refractory metals have very high melting points and excess heating can cause micro structural damage A solid state joint is therefore preferred The chart below gives some guidance on the type of joint that can be expected and design considerations required when joining materials from the different groups Group Group Il Group Ill Group Solid State Solid State e Solid State Copper W Mo electrodes Projection on Group I Fine projections on Group III Group Il Solid State or Fusion Solid state o
39. REPEAT TIME 4 19200 30 MSEC 03 05 OFF ENGLISH ON OFF 0 00 SEC 4 19200 30 MSEC 03 05 OFF ENGLISH ON OFF 0 00 SEC pal 19200 30 MSEC 03 05 OFF ENGLISH OFF LON OFF 0 00 SEC CHAPTER 3 USING DISPLAY SCREENS REPEAT MODE Press the MENU button again to highlight the REPEAT MODE selection When this is set to ON the control provides an automatic repeat of eee i BAUD RATE 19200 the weld sequence for simple automated air DEBOUNCE 30 MSEC actuated applications This weld function is i CHAINING START 03 ideal for volume production which requires a CHAINING END 05 single schedule REMOTE OFF REPEAT MODE can only be used with an Air SAO Sober Actuated Weld Head On Force Fired Air RESET DEFAULTS Orr FAST WELDING ON REPEAT MODE REPEAT TIME 0 00 SEC Actuated Weld Heads weld current begins when both levels of a two level Foot Switch are closed and held down and then the Force Firing Switch in the Air Actuated Weld Head closes sending a fire signal When REPEAT MODE is used with a Non Force Fired Air Actuated Weld Head the Squeeze SQZ Period must be used to allow sufficient time for the electrodes to close and apply the required weld force to the parts before the Weld Period begins Weld current begins when the Squeeze Period ends and a fire signal is received During this whole operation both levels of a two level Foot Switch must remain closed to
40. USER S MANUAL 990 922 244 5 37 7 MIYACHI RevisionB September 2012 LON Oe KE ADVANCED DUAL PULSE STORED ENERGY RESISTANCE WELDING POWER SUPPLIES 006 5 055 0 20 0 0 INIA EK cA T7 OOADP p DUAL PUL P ULsE Model Stock No 125ADP 115 230 1 305 01 300ADP 115 230 1 296 01 1000ADP 115 230 1 297 01 Copyright 2012 Miyachi Unitek Corporation The engineering designs drawings and data contained herein are the proprietary work of Miyachi Unitek Corporation and may not be reproduced copied exhibited or otherwise used without the written authorization of Miyachi Unitek Corporation Printed in the United States of America Revision Record A 42027 6 12 None Original edition 42170 9 12 Add Repeat Mode function and 125ADP Ws programming in 0 1 Ws increments Your New ADP Welder Shipment Contains The Following Items The ADP unit User manual 990 922 Ship Kit 4 81179 01 External current coil 1000ADP only A SS NOTE The 1000ADP will also have an external transformer shipped on a separate pallet Ship Kit Contents Ship Part Number 4 81179 01 205 129 Power Cord 115 VAC 245 162 Backshell 37 pin D sub 250 409 D sub 37 pin connector 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY li 990 922 CONTENTS Page REVISION RC CODEC AU dodo teeesaeveidecsonitiaiateveesseueidecacseyes 11 TU a vi Sa O AAA A vil Chapter 1 Description UN Ee E rc A E E
41. UT WELD READY RELAY _ _ COUNTER LIMIT RELAY _ OUT OF LIMIT RELAY Advanced unit ONLY 24V 500mA max shared with pin 1 GROUND Typical Isolated Input FS2 FS1 FS2 FIRE COMMON A yn FAULT RESET INPUT SCHEDULE LOCK INPUT I O COMMON BINARY 2 BINARY 8 BINARY 32 Advanced unit ONLY I O COMMON WELD END RELAY _ ALARM RELAY RELAY COMMON GROUND Damage may result from improper connection of these pins The optical firing switch 1s intended for use only on Miyachi Unitek heads with this feature In operation an optical switch connects pin 3 to pin 20 to initiate firing Neither of these pins should be used for any other purpose since they connect to internal non isolated points in the unit 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY B 4 990 922 APPENDIX B ELECTRICAL AND DATA CONNECTIONS Configuration for High True Inputs PLC or 24V to Activate Inputs lt Q USER SIDE UNIT SIDE gt 1 24V 500mA max shared with pin 19 OPTO FIRING SWITCH INPUT FIRE FS1 0 Ga 6 600 40 Ca Go Pa o ha Je an 5 ca ho 00 4 Gu jc WELD INHIBIT INPUT WELD COUNT RESET INPUT PROGRAM LOCK INPUT BINARY 1 BINARY 4 BINARY 16 Advanced Unit ONLY DUAL HEAD INPUT WELD READY RELAY _ COUNTER LIMIT RELAY OUT OF LIMIT RELAY Advanced unit ONLY
42. adia 3 8 DEDONGO sa ds 3 8 CS ATTA last 3 8 as 3 9 pia 3 9 E O E OUEN 3 9 O A IIA 3 10 Fast N MN sia nal pcbs 3 10 Gia ME AAPP 3 11 REDE PINS so dea 3 12 Chapter 4 Operating Instructions Seccion le IO dUCHON marnan cdaed 4 1 BELLOS Y OU Mons 4 deg et Operational ROCKS bs 4 1 C ONTECO e ate 4 1 POW EIEE E EEA NE IE E 4 GID SSC so PPP O A 4 1 MAMAS ayi APO ON UU M S 4 2 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY iv 990 922 Be Cll Ont IL O AO reia 4 3 A Oe A A 4 3 Use ESEE Wet 9 Ch SG retocar pain 4 3 Modin me WeldScasqules escritores 4 3 Set Peak Current Monitor limits oooooocoononoooooooooononnnnnnnnnnnnnnnnnnnnnnn nono nonno nono non nono nono nn non nn non nnn nro nnnnnns 4 4 Set Weld Counter Limits or Reset the Weld Counter occcccnnnnnnnnnonononnnnncnnncnnnnnnnnnnnnnnnnnnnnononinocononons 4 5 Sl MENTRE srta ino 4 5 Dial etica Opor O ae nr eee 4 6 POT AIT LOOK econo 4 6 SC TS LOC aten 4 6 Cuan me Un ei adds 4 6 Section I Operational NOTES cia 4 7 Rep GON A nota dio 4 7 Amomane rower Tuta DOWN ataco E EE N 4 7 Oper Load Protection aras iio ideas 4 7 Extended Shutdown LOCC altoandinas 4 9 Chapter 5 Maintenance Section l Trouble SIO Oi Ayo repito oil 5 1 ol A A eee eee 5 1 Error Messades metro od EA E E 5 2 Seccion UL IV nS Th ANN Sa pp lisa 5 4 AC AMOR AOU gazste cat deseo anes E E E E E E E ES 5 4 Electrode Maintenance ras 5 4 Pare R 6 2 67 0 8 0 ere
43. ained together differ in pulse widths or polarities a delay of 50 to 350 msec may be required between schedules to switch to the new settings 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 3 8 990 922 CHAPTER 3 USING DISPLAY SCREENS CHAINING END Press the MENU button again to edit the ending value for a weld chain REMOTE Press the MENU button again to highlight the REMOTE selection When this is set to OFF serial communication commands to read data are active but commands to change programs and settings are not active When REMOTE is set to ON all serial communication commands are active LANGUAGE Press the MENU button again to select the language ENGLISH ESPANOL DEUTSCH The language on screen will change when this field is saved BUZZER BAUD RATE DEBOUNCE CHAINING START CHAINING END REMOTE LANGUAGE RESET DEFAULTS FAST WELDING REPEAT MODE REPEAT TIME BUZZER BAUD RATE DEBOUNCE CHAINING START CHAINING END REMOTE LANGUAGE RESET DEFAULTS FAST WELDING REPEAT MODE REPEAT TIME BUZZER BAUD RATE DEBOUNCE CHAINING START CHAINING END REMOTE LANGUAGE RESET DEFAULTS FAST WELDING REPEAT MODE REPEAT TIME 4 19200 30 MSEC 03 05 OFF ENGLISH OFF ON OFF 0 00 SEC 4 19200 30 MSEC 03 05 ENGLISH OFF ON OFF 0 00 SEC pal 19200 30 MSEC 03 05 OFF ENGLISH OFF ON OFF 0 00 SEC 125AD
44. al criteria will be met Validation testing is usually required to prove the robustness of the process under production conditions 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 F 11 APPENDIX F 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 Unitek Equipment 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 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY F 12 990 922
45. art to Firing Switch closure Maximum D2 time is 10 seconds If the firing switch does not close within approximately 10 seconds the message FIRING SWITCH DIDN T CLOSE IN 10 SECONDS will display D3 Delay time from Firing Switch closure and Foot Switch Level 2 closure to squeeze time SQZ Maximum D3 time is 60 ms SQZ Squeeze time Selectable range is 0 to 2999 ms Typical accuracy 1s 0 10 Pulse 1 The timing of this weld pulse depends upon the pulse length programmed the energy setting and the impedance of the secondary circuit COOL This time is not programmable by the user It depends upon the energy level of the second pulse and ranges from 20 to 670 msec on the 125ADP and 300 ADP It can range up to 1 5 seconds on the 1OOOADP If no second pulse is programmed this time period is skipped Changing pulse widths or polarities may result in longer cool times than if no changes are made to these parameters Pulse 2 The timing of this weld pulse depends upon the pulse length programmed the energy setting and the impedance of the secondary circuit HOLD Hold time Selectable range 1s 0 to 2999 ms Typical accuracy is 0 10 NOTE The inputs signals FS1 FS2 and firing switch need to be at least 50 msec duration for the unit to recognize them 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 C 1 APPENDIX C SYSTEM TIMING Basic Weld Operation Manual Head System with Firing Switch Operation REMOTE
46. ctorial DOE may also give an indication as to how wide the acceptable weld window is 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 can 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 is one that can run in a real production environment Welded assemblies should be tested over time and under real use conditions to ensure that all function
47. d electrode tip surfaces and shapes in a certified machine shop Parts Replacement There are no user serviceable parts inside the power Supply 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 9 4 990 922 CHAPTER 5 MAINTENANCE Section Ill Repair Service If you have problems with your power Supply that you cannot resolve please contact our service department at the address phone number or e mail address listed under Contact Us in the front of this manual 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 5 5 APPENDIX A Technical Specifications NOTE The specifications listed in this appendix may be changed without notice Description 9 9 inches 252 mm i I l 11 5 inches 292 mm 125ADP Control Unit 300ADP Control Unit 1000ADP Control Unit Dimensions 125ADP 44 lbs 20kg e 300ADP 69 lbs 31 kg 1000ADP control unit 29 lbs 13kg 14 3 inches 364 mm 1000ADP Transformer Dimensions 135 lbs 61 kg 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 A 1 APPENDIX A TECHNICAL SPECIFICATIONS 90 138 VAC 50 or 60 Hz Input line voltage 180 264 VAC 50 or 60 Hz Overvoltage Detection Internal switch Input VA Max demand 1300 VA Charge circuit type Switched mode Weld Capacitor Charge Voltage 430 V max Weld Capacitance As required to achieve Output Energy 125ADP 125Ws 300ADP 300Ws 1000
48. de tip shape Excessively short pulse time setting Wrong electrode material l l l l d 1 Contaminated weld piece surface plating 1 2 2 2 Contaminated electrode surface Excessive weld time setting Excessive weld head force Incompatible weld piece projection design 2 Incompatible weld piece materials 2 Wrong electrode tip shape 3 Excessive current energy setting 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 9 1 CHAPTER 5 MAINTENANCE Cause in order of probability Cause in order of probability Insufficient Weld Nugget Insufficient energy setting Metal Excessive current energy setting Expulsion Wrong electrode material tip shape Insufficient weld head force Worn mushroomed electrodes Slow weld head follow up Incompatible weld piece projection esign 1 1 1 2 Excessively long pulse time setting 2 Incorrect weld head polarity 2 Contaminated weld piece surface plating 1 1 1 j de Contaminated weld piece surface 2 plating 2 Incompatible weld piece materials 2 2 3 4 l 2 Excessive weld head force Contaminated electrode surface 3 Insufficient weld head force Wrong electrode tip shape 3 Contaminated electrode surface No cover gas on weld piece Excessively short weld time set at 25DP 300DP 3 Incompatible weld piece projection design 3 Slow weld head follow up 4 Incompatible weld piece materials 4 Nocover gas on
49. e E AEE A N AA TE E E E E T E 5 4 DCC Om LL Repar SEVICE ro 5 5 Appendix A Technical Specifications occcccccooooonnccnnnnnnnnnonononnncnnnnnononnnocnncnnnnnnnnnnnnnnncnnnnnnnnnnnns A 1 Appendix B Electrical and Data Connections oooonncnnncnconcccnnnnnnonnccnnnonnnnccnnnnnnnoncnnnnnnnnnnccnnnnnnnos B 1 APpendix E Ste LIO arios C 1 Appendix D Communications oocccccnnccoccnnnnnnnnncncnnnnnnonononnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnncnnnnnnnns D 1 Appendix E The Basics of Resistance Welding ccccoonoooonnccccnnnnnnononocccnnnnnnnnnononncncnnnnnonnnonons E 1 Appendix F Quality Resistance Welding Solutions Defining the Optimum Process F 1 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 V CONTACT US Thank you for purchasing a Miyachi Unitek Resistance Welding System Control Upon receipt of your equipment please thoroughly inspect it for shipping damage prior to its installation Should there be any damage please immediately contact the shipping company to file a claim and notify Miyachi Unitek at 1820 South Myrtle Avenue P O Box 5033 Monrovia CA 91017 7133 Telephone 626 303 5676 FAX 626 358 8048 e mail info unitekmiyachi com The purpose of this manual is to provide the information required for proper and safe operation and maintenance of the Miyachi Unitek 125ADP 300ADP 1000ADP Dual Pulse Resistance Welding
50. ead Connections ic cxigedaoneciveseqadstiedwteudseangudedoncsauctiasqadstodtauddeandadsloncsouctoninaation 2 7 ANDOL AR iba 2 7 ANAC AU E E E E E A E EEE A EA AE EE E A EAE eae 2 8 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 jii CONTENTS Continued Page Section II 1000ADP External Equipment Connections ccccccnnnnnnnnnnnnnnnnnnnnccncnnnnnnnnnnonononnnnnonananonncnnnnos 2 10 A nn nn ee eee ee 2 10 Connecting the LOOOADP Transformer e oooonccnnccncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninnns 2 11 Chapter 3 Using Display Screens no 5101000 1 RUNS 6 bai ab nen eee 3 1 KON SOE roban 3 2 Editing h RUN Screech at 3 1 TURE T e E E E E E E essen vet teaeeveaa 3 1 PUSE a E er EA E EA E E E E E E E E E E E E EE 3 2 Squeeze IME paritaria eoni a a a a EEE E E E i EE 3 2 Hont TINE aa 3 2 Section II LIMITS COUNTERS screen 00 0 ccccccccecsasseeeseeeeeeeececcceeceeeeeeeesauaaanseeseeeeeeeeeeeeeees 3 4 EIME COUNTERS a EE EA AAE siiabos 3 4 Edit th LIMITS COUNTERS Scre n sesncrioais cion cdn dan diri ilatina 3 4 Pulso L Up Li ta eee eee 3 4 PUISS L ENE 3 5 PIS ZAS aaa 3 5 Pulse ACUM aaron 3 5 RESEt Wed G0 00s Gee re eee E ree 3 6 Edit Counter Lal asco catceaseaes dan ienctgesstnencobetdanoasdessaestntiiessaceiatohoeesouaeodanteaigansiuonatdstcateseeoeencdanienteass 3 6 PC CUO ME MENO SE taa 3 7 MENU SITCOM nda 3 7 Brrr ha MEN ESOS na 3 7 PUIK E est
51. eed Dual pulse welding improves weld quality and can eliminate weld splash Dual pulse means each weld is performed with two pulses with independent energy levels and independent polarity When welding parts with plating or contamination the first pulse can be used to consistently seat the electrodes onto the part surfaces The second pulse welds the base metals The remote schedule feature allows the weld schedules to be selected in automated applications ADP Power Supplies are designed to operate at either 100 120VAC or 200 240VAC 50 60 Hz and can be used with manual user actuated or air actuated weld heads 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 1 4 990 922 CHAPTER 1 DESCRIPTION Section ll Major Components Major Components The major components are the front panel which contains operator controls and indicators and the rear panel which contains fuses circuit breakers power and signal connectors The rear panel connections are discussed in Chapter 2 Installation and Setup Front Panel Controls The function of each item is described on the following pages PULSE 1 DATA PULSE 2 DATA POLARITY DISPLAY UP DOWN SELECT SCREEN BUTTONS Mc ir g a PULSE A PULSE 3 pan 030 090 ON SELECT gt PULSE 1 Oo i i a 1 R T PULSE 2 CLEAR r LIMITS COUNTERS WELD NO WELD SAVE CHARGE SQUEEZE HOLD MONITOR Front Panel Controls 125ADP 300A
52. eld heads when desired As shipped Air Valve Driver 2 is configured for 24 VAC weld head operation but may be reconfigured for 24VDC compatibility when required See Appendix B Electrical amp Data Connections for details on how to make this conversion Air Valve Driver 1 1s only compatible for 24VDC e Remote schedule selection simplifies use in automated systems The CONTROL SIGNALS connector provides remote control capability for EMERGENCY STOP REMOTE WELD INHIBIT and REMOTE WELD SCHEDULE SELECTION e The CHAIN SCHEDULE feature allows consecutive schedules to be chained together e An advanced charging circuit provides rapid recharging and greater throughput Display Screens Large remarkably intuitive screens allow the user to see everything at a glance See Chapter 3 Using Display Screens for complete instructions Briefly the RUN screen is BLUE welds within limits display GREEN and welds out of limits display RED as indicated below SQUEEZE SQUEEZE 0150 PULSE 1 PULSE 2 0150 PULSE 1 PULSE 2 MS 0 MS LE 030 WS 075 WS 030 ws 075 ws MEDIUM MEDIUM MEDIUM MEDIUM UPSLOPE OFF UPSLOPE OFF 3 4 wn 4 8 a 99 a 48 k 0 0 TO 0 0 0 0 TO 0 0 0 0 TO 5 0 0 0 TO 5 0 WELD COUNTER 000114 WELD COUNTER 000114 SCHEDULE SCHEDULE 08 08 Out of Limits Pulse 1 amp Pulse 2 Limits OFF Pulse 1 Out of Limits Pulse 2 Within Limits 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 1 2 990 922 CHAPTER
53. es loaded 7 Power board fuse blown 8 Communication error between control board and front panel 9 Exiting Edit mode 10 Emergency Stop EMO input is open 11 Invalid Chaining start or end value 12 Last Weld was out of Limits lt ACK OR NAK gt BAUD RATE rate DEBOUNCE O None 1 30ms BUZZER O 0ff 1 2 3 4 loud FAST WELDING 0 Off 1 On REMOTE O 0ff 1 On CHAINING START 0 Off 01 63 CHAINING END 0 Off 01 63 rate 0 9600 1 19 2 k 2 38 4 k Baud 1 Byte 1 Byte 1 Byte 1 Byte 1 Byte 1 Byte 2 Bytes 2 Bytes 9 Bytes Total 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY D 6 990 922 APPENDIX D COMMUNICATIONS SCHEDULE SS Set lt ACK OR NAK gt 1 Byte SCHEDULE SR Read SCHEDULE 2 Bytes SQZ Squeeze Time 4 Bytes WS 1 Energy in Watt Seconds 3 Bytes WS 2 Energy in Watt Seconds 3 Bytes HOLD Hold Time 4 Bytes PULSE weld length 1 Byte PULSE2 weld length 1 Byte POLARITY 1 weld polarity 1 Byte POLARITY2 weld polarity 1 Byte UP Up Slope 0 Off 1 On 1 Byte 21 Bytes Total weld length O Very short 1 Short 2 Medium 3 Long weld polarity 0 Positive 1 Negative 2 Alternating MONITOR MS Set lt ACK OR NAK gt 1 Byte MONITOR MR Read SCHEDULE 2 Bytes P1 Upper Limit 4 Bytes P1 Lower Limit 4 Bytes P1 Action action 1 Byte P2 Upper Limit 4 Bytes P2 Lower Limit 4 Bytes 19
54. essed air is connected as described in the appropriate sections of your weld head manual Turn the compressed air ON and adjust 1t according to the instructions in your weld head manual 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 4 1 CHAPTER 4 OPERATING INSTRUCTIONS Initial Setup 1 Set the WELD NO WELD switch on the Power Supply front panel to the NO WELD position In this position the Unit will operate the weld head without producing weld current 2 Set the ON OFF switch on the rear panel of the Power Supply to the ON position 3 Adjust the weld head force adjustment knob for a force appropriate for your welding application A good starting point is the mid point in the range of the weld head force 4 Press the foot switch to activate the first level switch and clamp the material Check the head for suitable clamping pressure Release the footswitch to release the material Check the head for smooth operation of the electrodes 5 When you are ready to perform a weld be sure to set the WELD NO WELD switch back to the WELD position 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 4 2 990 922 CHAPTER 4 OPERATING INSTRUCTIONS Section Il Operation Start Up Turn the Power Supply ON Verify that the Start Up screen displays briefly then changes to the RUN screen SQUEEZE 0150 PULSE 1 PULSE 2 MS 030ws 075 ws MEDIUM MEDIUM UPSLOPE OFF PETER MIYACHI 3 4 EP
55. esult This is important as identifying variation in process 1s 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 A Screening DOE 1s 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 Unitek Equipment provides a simple Screening DOE tool that is run in Excel and is sufficient for the majority of possible applications contact Unitek Equipment for details Sophisticated software is also available from other vendors designed specifically for this purpose 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY F 10 990 922 APPENDIX F DEFINING THE OPTIMUM PROCESS Criteria for Success Before running the series of experiments the user must establish an acceptable window
56. et Read Read Read DATA ADP Release and Revision Example ADP 300 1 02 C Reset an Error Returns STATUS TS The current weld counter Good 6 bytes and Bad 6 bytes counters Weld count Limit Returns of stored welds lt ACK OR NAK gt lt ACK OR NAK gt lt ACK OR NAK gt lt ACK OR NAK gt The active schedule Schedule 1 to 63 Weld Status 0 Good 1 Out of Limits Ist pulse Current 2nd pulse Current Weld Number Returns the rear panel status in HEX Dual Weld Head 0 Weld Inhibit 1 Schedule Lock 2 Program Lock 3 Emergency Stop 4 FS2 5 FS1 6 Fire Switch 7 SIZE 14 Bytes 1 Byte 6 Bytes 12 Bytes 6 Bytes 4 Bytes 1 Byte 1 Byte 1 Byte 1 Byte 2 Bytes 2 Bytes 1 Byte 3 Bytes 3 Bytes 6 Bytes 15 Bytes Total 1 Byte 1 Bit 1 Bit 1 Bit 1 Bit 1 Bit 1 Bit 1 Bit 1 Bit 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 D 5 APPENDIX D COMMUNICATIONS STATUS SYSTEM SYSTEM PTS Y S 6 YR gt Read Set Read Status of unit or the last weld 0 GOOD 2 Bytes 1 Capacitors did not discharge in 15 seconds 2 Capacitor does not charge in time 3 Firing switch does not close within 10 seconds of FS2 closing 4 The capacitor calibration value is outside of limits 5 Internal EEPROM memory error 6 Internal EEPROM values corrupted Default valu
57. feature is useful for counting welds made on a set of electrodes to determine when to change electrodes This feature can also be used to count the number of welds during a particular shift or work day After the limit is reached the Power Supply will beep each time a weld is made This signals the Operator to take action To clear the counter or edit limit values l Press the LIMITS COUNTERS button to select this screen Press and hold the LIMITS COUNTERS button for about one second The screen will turn black to indicate edit mode The WELD COUNTER field will be highlighted Press the CLEAR button to reset this value to 000000 NOTE The Aor Y arrows do not change the Weld Counter value To change the COUNTER LIMIT field press the LIMITS COUNTERS button again The COUNTER LIMIT field will be highlighted Press the CLEAR button to set this to zero or use the A or V arrows to change the value Press the SAVE button to save changes To exit editing mode without accepting changes press RUN to activate the SAVE PROMPT then press CLEAR on the front panel to discard changes Set MENU Entries The MENU screen contains set up and configuration values that apply to all schedules l Press the MENU button to select this screen Press and hold the MENU button for about one second The screen will turn black to indicate edit mode The BUZZER field will be highlighted To adjust the buzzer volume press the A or V arrows to go f
58. g the 20 second startup period when the Power Supply is first turned ON an activation of the Emergency Stop will interrupt 24V power to the Air Valve Driver output to ensure the weldhead 1s not actuated When the 20 second startup period is completed the EMERGENCY STOP message will be displayed and the buzzer will sound If your work station is not equipped with an EMERGENCY STOP SWITCH be sure that the conductors of the emergency stop input cable are shorted together as the system will not operate with this loop electrically open 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 1 9 CHAPTER 2 Installation and Setup Section Installation Unpacking When you unpack the shipping container be sure that the contents of the shipping kit match the list in Appendix A Technical Specifications and that you have also received the accessories you ordered If the Power Supply shows any signs of shipping damage promptly contact both the carrier and Miyachi Unitek Customer Service See CONTACT US in the front of this manual to get in touch with us by e mail telephone or regular mail Space Requirements e Allow ample workspace around the Power 9 9 inches Supply so that it will not be impacted 252 mm during operation e Allow sufficient clearance around the sides and back of the Power Supply to allow for connecting cables 41 5 inches e Allow enough ventilation space so the 292 mm Power S
59. gy setting The Long setting provides the longest duration and lowest peak current for a given energy setting The Medium setting provide and intermediate option between the Short and Long settings Upslope applies to the Short Medium and Long settings only and is turned ON or OFF with the PULSE SELECT button Note Pulse duration is not user settable on the 1000ADP To modify POLARITY in edit mode press the POLARITY SELECT button repeatedly until the polarity you want is indicated in the display Note Polarity is not user settable on the 1OOOADP 7 10 11 To modify the squeeze time press the SQZ HOLD button The SQUEEZE field will be highlighted Press the A arrow to increase squeeze time or press the V arrow to decrease the Squeeze time To modify the hold time press the SQZ HOLD button again The HOLD field will be highlighted Press the A arrow to increase hold time or press the Y arrow to decrease hold time To modify the settings for Pulse 2 press and hold the Pulse 2 button to enter edit mode Repeat steps 4 through 6 to program the settings for Pulse 2 Press the SAVE button to save any changes made To exit editing mode without accepting changes press the RUN button on the front panel which will activate the SAVE prompt then press CLEAR to discard changes Set Peak Current Monitor Limits Each of the 63 schedules has an associated set of Monitor Limits To edit these limits select the desired schedule then
60. he editing mode without accepting changes press RUN to activate the SAVE prompt then press CLEAR on the front panel to discard changes Dual Weldhead Operation For dual weldhead operation only schedules and 2 are active To set this feature connect pin 13 of the 37 pin Control Signal connector to the I O common pin 28 or pin 32 See Appendix B Electrical amp Data Connections for connection details 1 Connect weldhead 2 to the 4 pin Standard Air Valve Driver Output Connector 2 Connect Weldhead 1 to the 8 pin Weld Head Connector 3 Connect the Dual Weldhead Input pin 13 on the 37 pin connector to the I O common pin 28 or 32 on the 37 pin connector 4 Schedule 1 will then use weldhead 1 and schedule 2 will use weldhead 2 These two heads and schedules will fire alternately with the Footswitch input Do not use the RS 232 commands or the Binary Schedule Select inputs to change weld schedules when Dual Weldhead operation is active Programming Lock The programmed values of the 63 schedules can be locked so that no changes are possible To set this lock connect pin 9 of the 37 pin Control Signal connector to the I O common pin 28 or pin 32 See Appendix B Electrical amp Data Connections for connection details NOTE The schedule numbers can still be changed but the values stored in each schedule can not be changed Schedule Lock The programmed values of the 63 schedules and the schedule number itself can be
61. instructions are for both 24VDC and 24VAC EZair weld heads 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 Power Supply firing switch cable connector 3 Connect a normally closed agency compliant EMERGENCY STOP SWITCH across the two leads of the emergency stop switch connector 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 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 2 8 990 922 CHAPTER 2 INSTALLATION AND SETUP 4 Connect a Model FS2L or FS1L Foot Switch to the Power Supply FOOT SWITCH connector 5 Refer to the weld head manufacturer s User Manual for instructions on connecting the weld head air valve solenoid cable to the Power Supply AIR VALVE DRIVER connector 6 Connect a 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 air line length to less than 40 in 1 m or electrode motion may be slow NOTES e EZ AIR operates from 85 to 130 psi e Use lubricators only with automated installations 7 Turn air system ON and check for leaks 8 Set the WELD NO WELD switch on the Power Supply front panel to the NO WELD position In this positio
62. is turned off all data in the volatile memory is lost When the unit is turned on all data in the non volatile memory is copied to the volatile memory That data will then be available to the user Turning the Unit OFF Weld counters and weld data are saved periodically to the non volatile memory in the unit In order to maximize welding speed this data is not saved to non volatile memory after every single weld In order to assure that all data is saved to non volatile memory before turning the unit OFF press the SAVE button 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 4 7 CHAPTER 4 OPERATING INSTRUCTIONS Section Ill Operational Notes Repetition Rate The 125ADP 300 ADP and 1000 ADP Power Supplies monitor the overall repetition rate and do not accept fire signals that occur at greater rates than listed in Appendix A Technical Specifications The 125 ADP does allow for two consecutive welds to be at a faster rate than the Repetition Rate This faster rate for two consecutive welds is listed in Appendix A as the Hit Rate The user must maintain hit rates below those specified Automatic Power Turn Down The user must limit the power dissipated in the automatic turn down circuit to the 50W limit listed in Appendix A Technical Specifications Rapid firing of different schedules with significantly different energy level can exceed this limit To calculate the total power dissipated in this circuit 1 De
63. istance contact Miyachi Unitek for assistance 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 9 3 CHAPTER 5 MAINTENANCE Section Il Maintenance Calibration Calibration must be performed by factory trained and qualified personnel If your Power Supply needs calibration contact your local Miyachi Unitek service representative or contact our service department at the address phone number or e mail address listed under Contact Us in the front of this manual 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 decreasing 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 grin
64. ists 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 Welding Force shows a typical welding sequence where the force is applied to the parts a Squeeze time is initiated which allows the force to stabilize before the current is fired Squeeze time also allows time for the contact resistances to reduce as the Squeeze Heat Hold materials start to come into closer contact at their interface A hold time 1s 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 is sufficient for the majority of small part resistance welding applications Trigger Force Current Power supply technology selection is 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 Unitek Equipment slide rule tool 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 F 7 APPENDIX F DEFINING THE OPTIMUM PROCESS Approach to Weld Development The first stage in developi
65. l immediately stop the weld cycle and retract the weld head See Appendix B Electrical and Data Connections for circuit details Set the ON OFF switch on the rear panel of the Power Supply to the ON position Set the active schedule to the minimum energy level of the Power supply Set the weldhead force to 5 or greater oo ok A A Smoothly close the weldhead Verify that the power supply fires 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 2 6 990 922 CHAPTER 2 INSTALLATION AND SETUP EZ AIR Weld Head Connections 24 VDC EZ AIR NOTE These instructions describe connection to the Miyachi Unitek EZ AIR weld head Non EZ AIR heads may be connected to the Power Supply but are not covered in these instructions For non EZ AIR head instructions refer to the manual provided by the weld head manufacturer FORCE ADJUSTMENT KNOB M FORCE INDICATOR Set to 5 y EZAIR rn lt A SHOP AIR WELD HEAD gt E eer A L lk T a WELD HEAD CABLE EMERGENCY STOP SWITCH FOOT SWITCH REAR PANEL 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 2 7 CHAPTER 2 INSTALLATION AND SETUP 24 VAC EZ AIR FORCE ADJUSTMENT ___ xknog 11 FORCE INDICATOR i Set to 5 EZ AIR gon IIA lt lt SHOP AIR we WELD HEAD VALVE DRIVER CABLE FIRING SWITCH CABLE gt EMERGENCY STOP SWITCH FOOT SWITCH REAR PANEL NOTE These
66. lamp AMP type 206358 2 The two male pins used are Amp type 66361 2 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY B 8 990 922 APPENDIX B ELECTRICAL AND DATA CONNECTIONS 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 is 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 is 5 feet long Type 2 C 600 volt cable containing two shielded twisted pair 22 AWG stranded leads The firing switch cable connector is a 2 pin Amphenol Type 80 MC2FI It mates with the weld head firing switch connector which 1s a 2 Pin Amphenol Type 80 MC2M Firing Switch Connector Description Weld Head Connector Weld Head Connector HEAD 1 switched 24V common for solenoid PIN 6 PIN 5 PIN 8 24V OUT 24VDC for solenoid iS r AIRHEAD owe O OOo opos The Weld Head Connector combines all the inputs and outputs necessary to connect a plug and play EZ AIR Miyachi Unitek weld head If PLC or other means of trigger is used refer to the O Signal Interface General Description on page B 3 125ADP 300ADP 1000A
67. lead 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 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 F 9 APPENDIX F DEFINING THE OPTIMUM PROCESS Poor Follow up Sparks Insufficient Force Impact Force gt Sparks Variation a Tf lt lt We Variation sparks an NS No Squeeze No Hold Sparks a Hold 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 Unitek Equipment for further information and support What are Screening DOE S The purpose of a Screening DOE is 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 measurement for the parameters tested and the variation in the welded r
68. llowed when these screens are displayed Additional instructions on using the LIMITS COUNTERS screen are in Chapter 3 Using Display Screens Pulse 1 amp Pulse 2 Pulse 2 amp SQZ HOLD Press and hold either of these buttons for approximately 1 second to put the unit into edit mode which allows modification of weld schedule settings Press and hold the Pulse 1 button waiting for the screen background to change from BLUE to BLACK Energy pulse width and polarity for Pulse 1 may now be edited To accept changes press the SAVE button To exit editing mode without accepting changes press the front panel RUN button then at the SAVE prompt press the CLEAR button to discard To edit Pulse 2 parameters follow the same procedures described for Pulse 1 Pressing this button during edit mode causes the editing highlight to move to the SQUEEZE field Pressing this button again moves the highlight to the HOLD field Pressing this button saves changes made during editing Press this button before turning the unit OFF in order to save Weld Counter values and the most recent weld schedule data Press this button to clear the SQUEEZE HOLD WELD COUNTER COUNTER LIMIT PULSE 1 amp PULSE 2 UPPER amp LOWER LIMIT fields Pressing this button discards changes made during editing at the SAVE prompt Press SAVE to save changes CLEAR to discard 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPP
69. locked so that no changes are possible To set this lock connect pin 27 of the 37 pin connector to the I O common pin 28 or pin 32 See Appendix B Electrical amp Data Connections for connection details 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 4 6 990 922 CHAPTER 4 OPERATING INSTRUCTIONS Fast Welding This feature is set in the MENU and determines whether data is saved automatically to non volatile memory When Fast Welding is ON data is not saved automatically to non volatile memory The user must push the Save button to save the data to non volatile memory If the unit is turned off before the Save button is pressed the data will be lost When Fast Welding is OFF the data will be saved automatically in either of two timings If there is no weld fire signals for 12 seconds the unit will save the data to non volatile memory If weld fire signals occur at intervals less than 12 seconds the unit will stop accepting fire signals and save the data to non volatile memory after 200 welds have been accumulated The unit will take approximately 30 milliseconds to save the data and will ignore fire signals during this time When the Power Supply is turned OFF any data that has not yet been saved to non volatile memory will be lost The volatile and non volatile memory locations each 9800 welds of data Once the locations have 9800 welds the oldest weld will be dropped when the next weld is performed When the unit
70. low CURRENT SENSE CONNECTOR TRANSFORMER CABLE TRANSFORMER CONNECTOR Rear Panel Connectors for the 1000ADP 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 2 10 990 922 CHAPTER 2 INSTALLATION AND SETUP Connecting the 1000ADP Transformer 1 Locate the connector at the top rear of the 1000ADP external transformer TRANSFORMER CONNECTOR 2 Align the RED dot on the transformer cable connector to the RED dot on the transformer connector 3 Once the RED dots are aligned push the cable into the transformer connector until it stops then twist counterclockwise until the connectors are secured together 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 2 11 CHAPTER 2 INSTALLATION AND SETUP WELDING TRANSFORMER ee 00011 WELD TERMINALS CURRENT SENSING COIL CURRENT SENSE CONNECTOR 1000ADP REAR PANEL 4 Connect the current coil around ONE of the two weld cables you can use either the or cable For best weld monitoring accuracy use tie wraps to secure the loop end of the current coil the end farthest from the opening secured by the Velcro strap in a fixed position relative to the weld cable 5 Plug the connector on the current coil cable to the CURRENT SENSE connector on the back of the power supply 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 2 12 990 922 CHAPTER 3 Using Display Screens Sec
71. n 6 No Connection 2 RS 232 Transmit 7 No Connection 3 RS 232 Receive 4 No Connection 5 Signal Ground RS 232 settings Baud Rate 9600 19 2k and 38 4k Baud Data bits 8 Stop bit l Parity None NOTES e The host must be set to the same baud rate as the unit 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 I 233 running Windows 98 Windows ME Windows 2000 Windows XP or Windows NT 4 0 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 D 1 APPENDIX D COMMUNICATIONS Section Il Communications Protocol and Commands Command Format Each external command will be formatted as follows lt stx gt lt cmd gt lt cnt gt lt data gt lt cksum gt lt etx gt Definition of a Command lt stx gt 1 BYTE The data packet will start with a STX start of text 0x02 character lt cmd gt 2 BYTES This is a two character ASCII string denoting the command i e TY lt cnt gt 2 BYTES This is a count of data bytes to follow converted into a decimal ASCII number 00 to 99 lt data gt n BYTES This is ASCII numbers or ASCII data and may or may not be required by the command See the individual command Multiple byte ordering is MSB LSB lt cksum gt 2 BYTES This is a two charter ASCII HEX string calculated from the sum of all bytes except lt
72. n the Power Supply cannot deliver weld energy but it can activate the weld head 9 Set the ON OFF switch on the rear panel of the Power Supply to the ON position 10 Press the foot switch part way to actuate the first level switch 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 the upper electrode does not operate smoothly proceed to Step 11 11 Adjust the weld head down speed knob and repeat Step 10 until the upper electrode descends smoothly 12 Press the foot switch all the way down to close both level switches The weld head upper electrode should descend smoothly to the DOWN position and then send the firing switch signal back to the Power Supply when the preset electrode force is reached After firing the upper electrode should ascend smoothly back to the UP position 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 2 9 CHAPTER 2 INSTALLATION AND SETUP Section lll 1000ADP External Equipment Connections Overview Most of the external connections for the 1000ADP are identical to those for the 125ADP and 300ADP described in Section IT however there are two notable exceptions e The 1000ADP uses a separate external Weld Transformer e The 1000ADP uses a separate external Current Sense Coil Both of these must be connected to the Power Supply using the rear panel connectors shown be
73. ng 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 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY F 2 990 922 APPENDIX F 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 e Plating and coating e Oxides e Hardness The figure below illustrates the variance in resistivity and melting points for some of the more common materials used in micro resistance welding today Ti 6Al1 4V OFF Scale tonel Nichrome 800 Group Il E 600 Fo Resistivity Stainless Steels nano ohm 304 316 etc Group foi 400 Group Ill Br Phlr fgesssssssssensnnttecssssssassssnennneansne ae Er Bro a
74. ng a quality welding process 1s 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 size Part positioning Shape Maintenance electrode cleaning e Weld Head amp Mechanical Variables e Quality Requirements Force squeeze hold Pull strength Actuation method Visual criteria Electrode material and shape e Power Supply Variables Energy Time squeeze weld hold Test method other weld joint requirements The first stage in developing a quality welding process 1s 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 characteristics of the application The mini experiments should also be used to understand the weld characteristics from both application and process per
75. nless Steel 3 2 2 Titanium Tungsten Tungsten Zinc Depending on use periodic tip resurfacing is required to remove oxides and welding debris from electrodes Cleaning of electrodes on production line should be limited to use of 400 600 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 is not done the rough surface of the electrode face will have a tendency to stick to the work piece 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY E 4 990 922 APPENDIX E THE BASICS OF RESISTANCE WELDING Weld Schedule Development Developing a weld schedule is 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 one at a time until a successful weld is made 1 Install the correct 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 a problem If either of the parts is 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
76. onformity Is Declared ENG1000 4 2 EN61000 4 3 EN61000 4 4 EN61000 4 5 EN61000 4 6 EN61000 4 8 EN61000 4 11 Manufacturer s Name Unitek Miyachi 1820 S Myrtle Avenue Manufacturer s Address Monrovia CA 91016 626 303 5676 Equipment Description Welder Electrical Equipment Measurement Equipment Class Control amp Laboratory Use Model Numbers 1000ADP I the undersigned hereby declare that the equipment specified above conforms to the above Directive s and Standard s low ce Signature me iT C ELin j J Full Name 29 r Loio 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 Ix CHAPTER 1 Description Section Features Features Miyachi Unitek 125ADP 300ADP 1000ADP Dual Pulse Resistance Welding Power Supplies precisely control welding energy and weld head timing For the rest of this manual the ADP Dual Pulse Resistance Welding Power Supply will simply be called the Power Supply The 125ADP and 300ADP contain the same set of control features The 1000ADP has all of the features of the ADP product family except the polarity is fixed and not user settable in weld schedules In addition the pulse width is not user settable in weld schedules Both the polarity and pulse width are set in the 1000ADP at the Factory prior to shipment e Multi function microprocessor control r r gt facilitates multiple applications at a single a anes Y work station and is compatible with both A 030 075m
77. only active when the Power Supply is in the editing mode Press this button repeatedly until the pulse duration you want is indicated directly below the 3 digit energy display The front panel display screen shown on the previous page indicates MEDIUM UPSLOPE pulse duration selected for Pulse 1 and MEDIUM pulse duration selected for Pulse 2 NOTE The VERY SHORT setting provides the shortest duration for a given energy setting The SHORT setting will provide the highest peak current for a given energy setting The LONG setting will provide the lowest peak current and longest duration for a given energy setting Note This button is not present on the 1000ADP Pressing the RUN button causes the BLUE RUN screen shown on the previous page to be displayed Welding is allowed only when the BLUE RUN screen is displayed Pressing this button momentarily causes the Menu screen to be displayed Press and hold this button for 1 second to display the Menu editing screen Welding is not allowed when these Menu screens are displayed Additional instructions for the Menu screen are in Chapter 3 Using Display Screens 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 1 7 CHAPTER 1 DESCRIPTION LIMITS COUNTERS LIMITS A COUNTERS Press this button momentarily to display the Limits Counters screen Press and hold this button for 1 second to display the Limits Counters editing screen Welding is not a
78. oth 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 1s 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 e Plastics polymers PVC teflon e Semiconductors silicon geranium Of these only metals can be resistance welded because they are electrically conductive soften on heating and can be forged together without breaking 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 F 4 APPENDIX F DEFINING THE OPTIMUM PROCESS Alloys are a mixture of two or more metals An alloy is normally harder less conduc
79. owing conventions used in this manual WARNING Comments marked this way warn the reader of conditions which might result in immediate death or serious injury CAUTION Comments marked this way warn the reader of conditions which might result in damage to the equipment 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 vil Declaration of Conformity Application of Council Directive 89 336 EEC Standards To Which EN61326 1998 Conformity Is Declared EN55011 Class A Group 1 EN61000 4 2 EN61000 4 3 EN61000 4 4 EN61000 4 5 EN61000 4 6 EN61000 4 8 EN61000 4 11 Manufacturer s Name Miyachi Unitek 1820 5 Myrtle Avenue Manufacturer s Address Monrovia CA 91016 626 303 5676 Equipment Description Dual Pulse Welder Laboratory Measurement amp Equipment Class Process Control Equipment Industrial Environment 300ADP Model Numbers Inclusive of 125ADP 100ADP I the undersigned hereby declare that the equipment specified above conforms to the above Directive s and Standard s ee eee Plate Signature mE Full Name y eta Eng seag Position 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY viii 990 922 5969 Robinson Ave Riverside CA 92503 951 637 2630 FAX 951 637 2704 A Declaration of Conformity Application of Council Directive 2004 108 EC Standards To Which EN61326 1 2006 ENS5011 Class A Group 1 C
80. r braze of II Steel on III Projection on III Group Ill e Solid State 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 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY F 4 990 922 APPENDIX F DEFINING THE OPTIMUM PROCESS R1 8 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 R 6 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 to 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 Alte
81. rical Connection Input Power As described in Chapter 2 Installation amp Setup a 115V power cord is supplied The female end of the power cable is an IEC 320 C13 standard plug Connect the Power Supply power cable to a 1 phase 50 60Hz power source The nominal voltage can be either 100 120V or 200 240V 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 B 1 APPENDIX B ELECTRICAL AND DATA CONNECTIONS Section Il External Input Outputs Converting Air Valve Driver 2 to DC output The unit is shipped from the factory configured for 24VAC output on Air Valve Driver 2 This output can be configured to provide DC voltage This configuration is made with one jumper To convert to DC output remove the cover of the unit and locate jumper HEAD2 Move it to the DC position as shown below JUMPER TOP VIEW Cover Removed es ui oe oa maT IE mA rt PTA hominy ARES SE aS Es 3AN ere rt ie r FEA Binay ti 1 1 ra 4 4 j H ch hy F j i f n r ti F I a la oe 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY B 2 990 922 APPENDIX B ELECTRICAL AND DATA CONNECTIONS Input Logic Configuration The unit 1s shipped from the factory configured for LOW TRUE INPUTS This is a common set up when using a switch closure to ground to activate or to turn an input ON The unit can also be configured for HIGH TRUE INPUTS This is a common set up for using a P
82. rnately 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 is lower and bulk resistance now controls the heat generation This type of weld is achieved with a slower heating rate and normally longer time is preferred for welding resistive materials which can generate heat through their bulk resistance The contact resistances present at the weld when the power supply is fired have a great impact on the heat balance of a weld and therefore the heat affected zone 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 F 5 APPENDIX F DEFINING THE OPTIMUM PROCESS The figure below shows a weld that is fired The figure shows a weld that is initiated when the early on in the weld sequence when the contact resistance is lower in this example we are contact resistance is still quite high using bulk resistance to generate our weld heat Contact Resistance Contact Resistance Resistance l Weld Pulse Resistanc Weld Pulse Bulk Resistance Bulk Resistance Time Heat Affected Zone NOTE Larger nuggets are possible with longer weld times when using bulk resistance In general conductive materials benefit from a faster heating rate as the higher contact resistances assist hea
83. rom 1 quiet to 4 loud To set the RS 232 baud rate press the MENU button again The BAUD rate field will be highlighted Press the A or Y arrows to select the desired baud rate To set the input switch debounce time press the MENU button again Press the A or V arrows to select either 0 or 30 MSEC debounce time To set the starting schedule for a weld chain press the MENU button again Press the A or V arrows to select the starting schedule To set the ending schedule for a weld chain press the MENU button again Press the A or Y arrows to select the ending schedule Press the MENU button again to select the REMOTE field 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 4 5 CHAPTER 4 OPERATING INSTRUCTIONS 8 Press the A or Y arrows to select ON or OFF When this is set to OFF the Power Supply will not accept RS 232 commands from a remote source to change schedule or control settings When this is set to ON the unit will accept these commands In either case the unit will accept and respond to RS 232 commands to send out weld data and information 9 Press the MENU button again to select the RESET DEFAULTS field Use theA or Y arrows to select ON or OFF If this value is set to ON and is saved then all schedules all weld limits Pulse 1 actions WELD COUNTER WELD COUNTER LIMIT and all MENU screen entries are set back to factory defaults 10 Press the SAVE button to save any changes made To exit t
84. s within limits and the error persists contact Miyachi Unitek for service 3 Firing Switch timeout The firing switch did not close Adjust the weldhead and or within 10 seconds of FS2 closing parts to be welded so that the firing switch closes within 10 seconds of FS2 closing 4 Calibration value out of The value of the capacitance entered Contact Miyachi Unitek for limits during calibration is out of limits service 5 Memory write error The internal memory writing process Contact Miyachi Unitek for did not complete within 1 second Service Memory error The values stored in memory have Contact Miyachi Unitek for been corrupted Default values have service been reloaded into the unit Internal communication An error occurred in the internal Contact Miyachi Unitek for error communication between the front service panel and control board MO Le The emergency stop input is open Close the emergency stop switch Chaining error An error happened in a chaining 1 Reset the chaining sequence sequence to the first schedule in the chain 2 If the error persists contact Miyachi Unitek for service 12 Open load detected The resistance of the secondary 1 Verify that the weldhead circuit is too high is closed when the unit fires 2 Verify that the weld cables are tightly connected 3 Verify that the electrode is properly installed in the weldhead If the process requires operation with a high secondary circuit res
85. spective 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 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY F 8 990 922 APPENDIX F 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 is 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 the heat balance of the weld During weld development these common problems must be carefully monitored so as not to mis
86. stance 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 IMATERIAL ELECT MATERIAL RWMA TYPE i 1 Aluminum Alloys 1 Cadmium Plating a Alumel Alumel Aluminum Aluminum Aluminum Aluminum 1 Tinned Copper 1 Gold Plated Dumet 1 Gold Plated Kovar i i 1 Cold Rolled Steel 1 Stainless Steel 2 Beryllium 2 Copper 2 Tinned Copper mu al Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Beryllium Copper Beryllium Copper Beryllium Copper 2 2 2 1 1 14 14 2 2 2 1 14 Beryllium 14 Copper Beryllium 2 Copper MATERIAL 2 2 14 2 1 Tinned Copper 14 2 2 2 2 2 2 2 14 2 2 14 Cold Rolled Steel ee ee ee gt gt 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY E 2 990 922 MATERIAL Bronze Bronze Chromel Chromel Chromel Chromel Chromel Chromel Chromel Chromel Consil Consil Consil Constantan Constantan Constantan Constantan Constantan Constantan Copper Copper Copper Copper Copper Copper Copper
87. stx gt lt cksum gt and lt etx gt Then masked with 255 OxFF lt etx gt 1 BYTE This terminates the transmission End of text 0x03 The ADP will respond with a Negative Acknowledge Command NK when an error is encountered in response to a command The format and reasons follow lt stx gt NK lt cnt gt lt err gt lt cksum gt lt etx gt Where lt err gt 1 NO lt SOH gt 4 Timeout 2 BAD checksum S In Local 3 Unrecognized command 6 Data Bad A valid command will return EITHER DATA OR AK The lt ACK gt format is lt stx gt AK lt cnt gt lt data gt lt cksum gt lt etx gt The DATA format is lt stx gt lt cmd gt lt cnt gt lt ascii data gt lt cksum gt lt etx gt When you issue a command to the ADP you need to wait for the response before you issue the next command This waiting period should be at least 250 msec The ADP should respond within this timeout VARIABLE italics RANGE OF PARAMETERS low_end high end separated by hyphen 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY D 2 990 922 APPENDIX D COMMUNICATIONS Host Originated Command Set These are commands sent by the host computer via the RS 232 port to the ADP NAME TYPE STATUS REAR RESET WELD COUNTER LIMITS COUNT REPORT REMOTE COMMAND TY PTS lt TR RX TC TG TL
88. t 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 is focused in the part to part and electrode to part contact areas since contact resistance is high relative to bulk resistance In the second stage contact resistance decreases as the electrodes seat better to the parts Less heat is generated in the electrode to part contact areas and a greater amount of heat is 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 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY F 6 990 922 APPENDIX F DEFINING THE OPTIMUM PROCESS Bonding temperature of materials different for solid state vs Fusion welds TEMPERATURE Weld Profiles The basic welding profile or schedule cons
89. t 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 1 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 lb electrode force curve shows the highest pull strengths but the lowest tolerance to changes in weld current voltage or 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 The 12 lb electrode force curve is preferred It shows more tolerance to changes in weld current voltage or power and has nearly the same bond strength as the 14 lb electrode force curve A comparison of weld schedules for several different applications might show that they could be consolidated into one or two weld schedules This would have obvious manufacturing advantages Wi 2 i TA a L Electrode Force 30 40 5D 50 70 BO gO 100 Energy watt seconds Typical Weld Strength Profile 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY E 6 990 922 APPENDIX F Quality Resistance Welding Solutions Defining the Optimum Process Introduction A quality resistance welding solution b
90. termine how many times in one minute the schedule will change from a higher energy to a lower energy 2 Add up the total Watt seconds of energy decrease in one minute 3 Divide this number by 60 to determine the average Watts of power dissipated Example If there are 12 schedule changes per minute where the programmed energy decreases from 300Watt seconds to 100Watt seconds the total change is 2400 Watt seconds per minute Dividing by 60 gives a resultant value of 40 Watts Watt seconds per second equals Watts which is within the capability of the unit Open Load Protection When the unit is fired with an open secondary circuit the energy from the capacitor bank 1s not delivered to the weld Instead it is absorbed by the internal circuitry of the welder If the unit were allowed to fire repeatedly into an open load with significant weld energy it could cause internal circuits to overheat and be damaged In order to prevent this potential failure mode ADP units have open load protection features When an open load is detected by an ADP unit the unit aborts the weld The unit does not provide an error message if this even occurs The threshold for detecting an open load is typically about 10 15 milliohms If your application requires operation with secondary circuits that exceed this resistance please contact Miyachi Unitek for assistance 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 4 8 990 922 CHAPTER 4 O
91. 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 Use the 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 1s little or no residual material pulled the weld is weak Increase the weld time in 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 can 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
92. tion I RUN Screen RUN Screen In the lower middle of the screen the WELD COUNTER and process monitor indicate how many welds have been completed since the weld counter was reset and what percentage of those welds were within programmed limits indicated both numerically and graphically The GREEN bar on the screen above indicates 95 of welds are within limits the RED portion of the bar shows 5 of welds are outside limits The BLUE RUN screen is displayed whenever the l SQUEEZE Power Supply is in RUN mode 0150 PULSE 1 PULSE 2 l E Squeeze and hold times are displayed in the io y upper left and right corners of the screen 0 30 ai 075 F Programmed values for energy pulse width e tier Pi weld polarity and upslope are displayed in the 3 4 KA A 8 KA upper middle of the screen 0 0 TO 0 0 0 0 TO 0 0 Weld limits if any and the peak weld current WELD COUNTER 000114 monitor results for the last weld completed are SCHEDULE displayed in the middle of the screen 0 8 The number of the currently active weld schedule 1s displayed at the lower right corner In the lower middle of the screen the WELD COUNTER and process monitor indicate how many welds have been completed since the weld counter was reset and what percentage of those welds were within programmed limits indicated both numerically and graphically The GREEN bar on the screen above indicates 95 of welds are within limits the RED portion of the bar shows 5 of welds are
93. tive and more brittle than the parent metal which has bearing on the type of joint one can expect when resistance welding a combination of different metals Alloy Metals atoms are naturally attracted to other Metal B metal atoms even in different parent materials 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 is formed There are three main types of bonds that can be formed using the resistance welding process e Solder or Braze Joint A filler material such as a solder or braze compound is either added during the process or present as a plating or coating Soldered joints are typically achieved at temperatures less than 400 C and brazed joints such as Sil Phos materials melt at temperatures above 400 C e Solid 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 melti
94. upply does not overheat 125ADP 8 300ADP Allow 1 inch space on each side 2 inches of space in the rear 1000ADP Allow 1 inch space on each side 2 inches of space in the rear 1000ADP Weld Transformer Allow 1 inch on all sides of the transformer e The work surface must be level stable free from vibration and capable of supporting the combined weight of all system components Weights are listed in Appendix A Technical Specifications e Locate the Power Supply at a sufficient distance from weld heads so as to avoid weld splash e Locate the Power Supply at a sufficient distance from sources of high frequency radiation to avoid electrical interference e The work area must be free of excessive dust acids corrosive gases salt and moisture 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 2 1 CHAPTER 2 INSTALLATION AND SETUP NOTE Unlike the 125ADP and 300ADP Power Supplies which have internal transformers the 1000ADP has a large external transformer that must be located within 2 meters of the power supply 9 9 inches jo F A I 14 3 inches 4 i 364 mm 11 5 inches 292 mm l Emre roa O taji UAL F LSE Tr O Apg Lire EN i C D Utilities Power The Power Supply is shipped with a universally compliant power cable and a North American compliant 115VAC three prong connector For operation in countries with different AC mains requirements remo
95. ve the male three prong mains connector and replace it with an approved mains power connector for the country in which the unit is to be used The required connections for your power cable connector are described in Appendix B Electrical and Data Connections Input power requirements for the Power Supply are as listed below Power Input Specifications Po volage Circuit Breaker COPPET valle Wire Diameter peer Current A rms Gauge mm Single phase Vrms 7 strands AWG 125ADP 300ADP 125ADP 300ADP 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 2 2 990 922 CHAPTER 2 INSTALLATION AND SETUP Compressed Air and Cooling Water If compressed air or cooling water service is required for the weld head please refer to the weld head manufacturer s user manual for service specifications Input Logic Configuration The unit is shipped from the factory configured for LOW TRUE INPUTS which is compatible with switch closures to ground for activation or to enable an input function ON The unit can also be configured for HIGH TRUE INPUTS which is commonly used with a PLC or other external device which supplies 24VDC to activate or to enable inputs ON Detailed instructions for changing the Input Logic Configuration including electrical schematics will be found in Appendix B Electrical and Data Connections 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 2 3 CHAPTER 2 INSTALLATION
96. vents based on number of welds completed The counter limit provides an output signal when the count equals or exceeds the user programmable value e The firing circuit is compatible with single pole double pole or optical firing switches e The energy monitor and lockout prevent poor welds caused by premature firing of the power supply before the capacitor bank has been properly charged or discharged e The line failure turndown safety feature discharges the capacitor bank when input power is interrupted e The Power Supply is protected from radio frequency and electromagnetic interference resulting in reliable operation even in high electrical noise environments Input switch debounce circuitry eliminates false triggering Detailed instructions on using these features are located in Chapter 4 Operating Instructions 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 1 3 CHAPTER 1 DESCRIPTION Description The 125 300 and 1000 Watt second stored energy capacitor discharge dual pulse power supplies are versatile and can effectively solve most precision small part resistance welding problems Up to 63 weld schedules can be programmed and saved into memory A built in schedule protection feature protects weld schedules from unauthorized or inadvertent changes The exclusive charge monitor and firing lockout features guaranteed accurate energy output independent of line voltage fluctuations and or process sp
97. weld piece Weld Piece Excessive energy setting Weld Piece No cover gas on weld piece Over Insufficient weld head force Discoloration 2 Excessive energy setting AONNE Incompatible weld piece materials Insufficient weld head force Wrong electrode material tip shape Contaminated weld piece surface plating Contaminated electrode surface Wrong electrode material tip shape Contaminated electrode surface Error Messages The power Supply displays the following error messages in the bottom line of the display To clear these error codes press either the RUN or CLEAR buttons If the error has gone away the message will then be removed If the error is still present the message will remain on the display ee AA Troubleshooting steps Capacitor Discharge timeout The energy setting in the weld 1 Turn off the unit and schedule was reduced or the wait 30 seconds Turn schedule number was changed to a on the unit and see if the schedule with a lower energy setting error disappears The unit did not reach this new lower energy value within 15 seconds 2 If the error persists contact Miyachi Unitek for service 125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 9 2 990 922 CHAPTER 5 MAINTENANCE EZ A Troubleshooting steps Capacitor Charge timeout The capacitors did not reach the 1 Verify that the AC line programmed energy level within 500 voltage 1s within limits msec 2 Ifthe AC voltage i
Download Pdf Manuals
Related Search
Related Contents
取扱説明書等 - アイ・オー・データ機器 TR 220 - H. Bosma Installatietechniek Siddeburen USER MANUAL - Touch Screens Inc. FAQ (8 & 16-bits) Technical Support 2371 - Jims DeLOCK 5m mini DP/DVI Bosch KGN57S70NE fridge-freezer dotXSIコンバートツール取扱説明書[PDF:2MB] 製品仕様書 Copyright © All rights reserved.
Failed to retrieve file