EZ Air Dual Air Kit Technical Manual
Contents
1. We have made every effort to ensure that the information in this manual is accurate and adequate Should questions arise or if you have suggestions for improvement of this manual please contact us at the above location numbers Unitek Miyachi Corporation is not responsible for any loss due to improper use of this product DUAL EZ AIR KIT 990 127 Safety Notes This instruction manual describes how to operate maintain and service the Dual EZ Air Kit and provides instructions relating to its SAFE use Separate manuals provide similar information for the Power Supply and the Weld head Procedures described in these manuals MUST be performed as detailed by QUALIFIED and TRAINED personnel For SAFETY and to effectively take advantage of the full capabilities of the workstation please read these instruction manuals before attempting to use the workstation Procedures other than those described in these manuals or not performed as prescribed in them may expose personnel to electrical burn or crushing hazards After reading these manuals retain them for future reference when any questions arise regarding the proper and SAFE operation of the workstation Please note the following conventions used in this manual WARNING Comments marked this way warn the reader of actions which if not followed might result in immediate death or serious injury CAUTION Comments marked this way warn the reader of actions which if not followed m2. 5 micron element part number 10 373 01 catalog number ADAF is recommended CAUTION Compressor supplying air must not be lubricated with synthetic oil Operating Environment 60 113 F 15 5 45 C 93 Relative Humidity maximum at 104 F 40 C DUAL EZ AIR KIT 990 127 1 APPENDIX A SPECIFICATIONS Outline Drawing Dimensions are in inches Figure A 1 Outline Drawing DUAL EZ AIR KIT A 2 990 127
3. AIR DC and electrodes if desired f Figure 2 3 Installation of New Elbow Fittings and Pneumatic Tubes DUAL EZ AIR KIT 2 4 990 127 CHAPTER 3 Operating Instructions Section I Operating Precautions General Operator Safety WARNINGS Always wear safety goggles any time you are operating a weld head Never wear loose clothing or jewelry when operating the weld head It could be caught in the mechanism Before operating a weld head read the manuals on the power supply and the weld head Particularly note the specific hazards associated with those components Section Il Preparing for Operation Pre Operational Checks Before operating the equipment verify that the power and compressed air connections are made to the EZ Air as described in Chapter 2 Section III Verify that all pneumatic connections are secure and that there are no air leaks Verify that the red EZ Clean valve figure 1 1 is slid fully toward the EZ Air non purge position Verify that the weld head and power supply are properly connected Turning the Equipment On To apply power to the unit follow the directions in the respective power supply User s Manual Section Ill Operation Set Up CAUTION Adjustment of the EZ Air should only be done by an experienced and trained individual 1 Refer to the appropriate weld head user s manual for spring force set up Disregard air adjustments 2 Set the down speed control valve adjusters to p
4. ALLA 777 USER S MANUAL990 127 2377 MIYACHI Revision D August 2005 CINI ITE OPERATION AND MAINTENANCE MANUAL FOR THE DUAL EZ AIR KIT Model EZ DAK Copyright 1999 2002 2005 Miyachi Unitek Corporation The engineering designs drawings and data contained herein are the proprietary work of UNITEK MIYACHI 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 17926 10 99 Original publication 19146 1 02 Change name of equipment to Miyachi Unitek 20505 8 05 Addition of EZ AIR DC corporate name change to Miyachi Unitek DUAL EZ AIR KIT 990 127 Contents Chapter 1 Description Section I Resta 1 1 Features ee ee ee te ee 1 1 Section II A 1 2 Reference Publications een ee 1 2 M jor COMpOnemtS ee a 1 2 Section Sequence af Operation cda 1 5 Chapter 2 Getting Started Section 1 Planning fot Installation do 2 1 Space nee 2 1 Power Requirements asien 2 1 Compressed Air Requirements lisis io ile 2 1 A A A 2 2 Upa ii 2 2 DS Alan A II O A e E T 2 2 Removing Existing System from Weld Head sad 2 2 Installing the BAT A A 2 3 Section II Pneumatic and Power Connections aan een 2 3 Preymane ia 2 3 PP ee ee ee ee engen ee 2 4 Chapter 3 Operating Instructions Section Operati
5. at slides into the vertical strut channel provides easy mounting of the EZ Air Below the T nut on the EZ Air casing is a location tab which properly positions the assembly into place on the weld head Air Cylinder Up Supply Male elbow fitting 1 4 inch OD tube to inch male NPT brass Connects controlled compressed air to weld head air cylinder bottom port Down Speed Control Valve Adjustments Operator adjustments one for each side of the weld head that allows setting of the downspeed of the electrodes to reduce part impact pressure Weld Head Firing Switch Connectors Female cable jacks Amphenol Type 80 MC2F Mate with connectors Amphenol Type MC23M80 MC2M from each side of the weld head EZ Clean Valve Allows bleeding of input air supply to permit dressing of electrodes Shop Air Supply Input Fitting inch F NPT fitting for connecting shop compressed air to EZ Air Shop air supply must be 85 140 psi 586 965 kPa Fixed Air Regulator Controls pressure of air from shop air source into EZ Air Regulator is factory set for 78 psi 538 kPa and does not require any user adjustment DUAL EZ AIR KIT 1 2 990 127 CHAPTER 1 SYSTEM DESCRIPTION EZ AIR Signal Cable and Connector Two conductor male plug to connect firing signal to the power supply 24 Volt Power Source Cable and Connector Conducts 24 volt solenoid drive power from the power supply to the EZ Air Firina indicators Initialization signal Receiver i
6. eumatic tubes two from each side Figure 2 1 Removing Existing Air System Pneumatics DUAL EZ AIR KIT 990 127 CHAPTER 2 GETTING STARTED Installing the EZ Air 1 From the packing box remove the EZ Air 2 From the weld head vertical support remove the plastic end cap 3 Loosen the mounting bolt figure 1 1 on the EZ Air with the 5mm hex wrench included in the shipping kit so that the T nut will slide into the vertical support slot Figure 2 2 Adjust the EZ Air so that its top is approximately at the same height as the air cylinder and making sure that the guide on the lower end of the EZ Air is in the vertical support slot tighten the mounting screw CAUTION Be sure no part of the EZ Air touches the copper power bars any contact will cause shorting of the weld current Figure 2 2 Installing EZ Air 4 Re install the vertical support end cap DUAL EZ AIR KIT 990 127 2 3 CHAPTER 2 GETTING STARTED Section Ill Pheumatic and Power Connections Pneumatic 1 From the packing kit locate four new elbow joints without valves and install the joints into the two valve ports of each cylinder The elbow fittings should face in the general direction that the earlier valve assemblies faced That is the two lower ones face upwards and the two upper ones face slightly outward of the rear of the weld head NOTE The cuts to be made in step 2 must be smooth and square We recommend using an SMC TKA 1 tube c
7. gh the four way solenoid valve Lower chamber Piston Down Stroke During the Four way Down electrode down stroke air Exhaust gt gt chamber pressure is directed to the upper solenoid valve chamber of the cylinder forcing the piston down Waste air IZ 7 exhausts from the lower air regulator pela ia chamber through the down e solenoid valve and the four way chamber solenoid valve Z Constant Force When the Down electrode reaches weld force w Upper Exhaust 4 chamber the up and down solenoid Four way solenoid valve valves close and air is trapped a in both the upper and lower valve 0 85 130 psi Fixed 78 psi chambers of cylinder Weld 586 897kPa gt 538 kPa force remains constant as the air al regulator solenoid valve cylinder piston cannot move Lower The four way solenoid valve chamber also switches to its off position reversing the air connections to the up and down solenoid Down Upper Exhaust 4 chamber valves solenoid valve Four way Piston VUp Stroke At the completion solenoid of the weld the up and down 85 130 psi Fixed 78 psi valv Up solenoid valves open This ido NE KPa ao ae air regulator solenoid valve causes the application of air yA pressure to the lower chamber of the cylinder returning the piston to its
8. ight result in either damage to the equipment or injury to the individual if subject to long term exposure to the indicated hazard DUAL EZ AIR KIT vi 990 127 CHAPTER 1 Description Section I Features Features The Dual EZ Air Kit herein called EZ Air is an accessory for weld heads that pneumatically controls the actuation of the electrodes and maintains the preset firing force At a predetermined firing force the EZ Air closes inlet and outlet valves to the weld head actuation cylinder and eliminates over force EZ Air operates from power supply generated power and has the following features Is compactly packaged and can be retrofitted to Miyachi Unitek Model 88A or 89A weld heads without removal of the weld head covers Powered from the power supply no separate control box required EZ AIR 24 VAC EZ AIR DC 24 VDC Contains EZ CLEAN Valve which eliminates the need to re adjust force after cleaning and dressing electrodes Contains operator visible firing indicator lights Permits easy set up of multiple weld heads to fire at the same force Contains a built in down speed limiter to eliminate weld over force and limit excessive impact force One knob force setting per electrode which requires no resetting simplifies set up and setting maintenance with the following effects e Process stability reduces process maintenance and training for users e Delivers accurate and repeatable force set up with reduced process variation e P
9. ndicator Air cylinder down supply one on each side Mounting bolt Air cylinder up supply one on each side Down speed control Valve adjusters Weld head firing switch connectors F7 Clean valve Shop air supply Input fitting Fixed air regulator Signal cable and connector 24 volt power source cable and connector Figure 1 1 Dual EZ AIR Components DUAL EZ AIR KIT 990 127 1 3 CHAPTER 1 SYSTEM DESCRIPTION EZ AIR DC EZ AIR DC 8 pin connector Connects to back of the welder Includes signals for 24VDC valve driver firing switch and voltage sense BACK SIDE VOLTAGE SENSING CONNECTOR Figure 1 2 Dual EZ AIR DC Cables and Connectors DUAL EZ AIR KIT 1 4 990 127 CHAPTER 1 SYSTEM DESCRIPTION Section Ill Sequence of Operation EZ Air uses a single four way solenoid valve to direct air between the down solenoid valve and the up solenoid valve figure 1 2 The following steps describe the sequence of operation of the EZ Air kit elnitial Air Applied Upon initial De application of air whether or not Exhaust chamber power is applied air pressure is lee applied through the four way sarno valve solenoid valve and the up solenoid 85 130 psi Fixed 78 psi Up valve to the lower chamber of the 586 89 KPa f m See hes gt e air regulator solenoid valve cylinder driving the piston up Air is exhausted throu
10. ng Preesufons ostende 3 1 Sac ae ee een 3 1 Section II Preparing for Operation ac 3 1 Pre Operational ee einen 3 1 Turning the Equipment ON io 3 1 Section Ml Operation zn 3 1 A A 3 1 DUAL EZ AIR KIT 990 127 iii Chapter 4 User Maintenance Section ee ee 4 1 General Oper tor pala 4 1 Section I Operator Maintenant aos 4 1 PreventveManlenaner een ee 4 1 Corrective Maintenance aaa 4 1 Clearing Clogged Four Way Valve seen nee 4 3 ELE i AE iio 4 3 Appendix A Specifications esse nee A 1 DUAL EZ AIR KIT iv 990 127 Contact Us Thank you for purchasing a Miyachi Unitek Dual EZ Air Kit 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 Unitek Miyachi Corporation 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 supply operating and maintenance personnel with the information needed to properly and safely operate and maintain the Miyachi Unitek Dual EZ Air Kit This kit can be added to an existing weld head typically a Model 88A or 89A and will replace a standard air kit The installation instructions give procedures for retrofitting a weld head that has a standard air kit installed
11. pply Refer to appropriate footswitch or cable power supply manual connections Down Speed Control valve s are closed Turn valve s counterclockwise to open Speed Control valve of side that doesn t move is stuck Contact company representative DUAL EZ AIR KIT 990 127 CHAPTER 4 USER MAINTENANCE One or both sides of weld Down Speed Limiter Contact company head move downward too valve requires representative forcefully when adjustment footswitch is pressed first position for two step foot switches Clearing Clogged Four Way Valve Occasionally a speck of foreign matter may get into the EZ Air and cause the four way valve to stick If this happens you may be able to clear the valve by pressing the valve override The four way valve override is accessible without removing the EZ Air cover figure 4 1 Repair If problems cannot be resolved using the above troubleshooting table contact Unitek Miyachi at the address telephone fax shown in the Foreword Figure 4 1 Location of Four Way Valve Override DUAL EZ AIR KIT 990 127 4 3 APPENDIX A Specifications item Specification Dimensions 5 25 in 133 35 mm 5 50 in 139 70 mm 11 49 in 291 85 mm EINEM Power Requirements EZ AIR 24 VAC 10 A Derived from power supply EZ AIR DC 24 VDC 10 A Derived from power supply Compressed air 85 140 psi 586 965 kPa Reguwemenis An auto drain air filter with a
12. roduces higher yields with reduced scrap from process variation due to incorrect force set up DUAL EZ AIR KIT 990 127 1 1 CHAPTER 1 SYSTEM DESCRIPTION Section Il Kit Components Reference Publications Related manuals which you will need include the manuals that are provided with your weld head and your power supply If you need additional copies of any of these manuals they can be procured from Miyachi Unitek Major Components Figure 1 1 shows the major components of the unit Normally these will be the only components associated with installation and operation The function of each item is described below Firing Indicators A green indicator one for each side of the weld head which lights when the firing switch closes and stays lit until the end of the weld cycle Thus if a malfunction occurs the operator can determine whether a firing signal is present Initialization Signal Received Indicator An amber indicator visible through the hole in the EZ Air cover that lights when the initialization signal is received from the power supply and stays lit until the pre set force is reached If a problem occurs the operator can determine whether the problem is internal to the EZ Air Air Cylinder Down Supply Male elbow fitting 74 inch OD tube to inch male NPT brass Connects controlled compressed air to weld head air cylinder top port Mounting Bolt A single Allen head knurled socket screw attached to a single T nut th
13. rovide an acceptable welding speed NOTE Once set up is completed there are no separate steps required during weld head operation except that the EZ Clean valve can be actuated to purge the air during electrode dressing To do so push the EZ Clean red slide valve away from the EZ Air To restore pressure slide the valve toward the EZ Air DUAL EZ AIR KIT 990 127 3 1 CHAPTER 4 User Maintenance Section 1 Precautions General Operator Safety WARNINGS Always wear safety goggles any time you are operating a weld head Never wear loose clothing or jewelry when operating the weld head It could be caught in the mechanism Before operating a weld head read the manuals on the power supply and the weld head Particularly note the specific hazards associated with those components Section Il Operator Maintenance Preventive Maintenance The only preventive maintenance required for the EZ Air is occasional lubrication of the EZ Clean valve whenever necessary The valve should only be lubricated with a petroleum or lithium based grease CAUTION Do not use synthetic oil It will damage the EZ Air Corrective Maintenance The only recommended user corrective maintenance is clearing foreign matter that might jam a valve open If the weld head fails to move up or down refer to table 4 1 and perform the actions prescribed DUAL EZ AIR KIT 990 127 ds CHAPTER 4 USER MAINTENANCE Neither weld head moves upward when air is fir
14. s parts needed to install the EZ Air NOTE Carefully place the packing materials back in the packing boxes and store for future shipping Table 2 1 Ship Kit List Fitting Adapter for shop air input 325 185 Allen wrench Install EZ Air 770 027 Elbow fitting Replace existing fitting on weld head 325 200 User s Manual Installation Operation instructions 990 127 Installation Installation consists of physically mounting the EZ Air on the weld head connecting the power and signal cables and connecting the pneumatic tubing If the EZ Air is a retrofit the original air system must first be removed and the new kit installed Removing Existing Air System from Weld head 1 3 Turn off shop air and remove connection to existing kit Remove the existing tubes to the top and bottom of each cylinder Note which way each of the four valve assemblies are facing Remove the two existing valve assemblies from the top and bottom of each of the two air cylinders Clean any pipe joint sealant from the cylinders figure 2 1 Disconnect the weld head firing switch cables from air kit connectors and the air kit cables from the power supply Remove the existing air kit from the vertical support NOTE If weld head cylinder has exceeded 10 million cycles we recommend replacing it at this time See your weld head manual for instructions Remove four valve and regulator assemblies two from each side Remove four pn
15. st applied Only one side of the weld head moves upward when air is first applied Neither side of the weld head goes downward when footswitch is pressed first position for two level foot switches One side of the weld head does not go downward when footswitch is pressed first position for two step foot switches Table 4 1 Troubleshooting Table NOTE Table presumes all power and pneumatic connections are made and properly adjusted Neither green firing indicators nor amber initialization signal received indicator light Amber initialization signal received indicator is lit Green firing indicator on side of weld head that does not go downward is not lit Green firing indicator on side of weld head that does not go downward lights Problem with input shop air Verify correct input shop air pressure See Chapter 2 Compressed Air Requirements EZ Clean valve is closed away from EZ Air Four way valve is Clear four way valve stuck Speed Control valve Contact company of side that doesn t representative move is stuck Open valve by pushing valve toward EZ Air Check cable connections Refer to appropriate power supply manual Problem exists in power supply footswitch or cable connections Four way valve is Clear four way valve stuck Down Speed Control Turn valve s valve s are closed counterclockwise to open Problem exists in Check cable connections power su
16. up position Figure 1 2 Sequence of Operation DUAL EZ AIR KIT 990 127 1 5 CHAPTER 2 Getting Started Section I Planning for Installation EZ Air is about the same size as the standard air system and uses power from the weld head power supply Therefore there should be no space or power problems in installing the EZ Air onto an existing weld head Space Requirements An outline drawing of the EZ Air is included in Appendix A The specific dimensions are Width 5 25 in 133 35 mm Depth 5 50 in 139 70 mm Height 11 49 in 291 85 mm Weight 3 4 lb 1 5 kg Power Requirements Power is derived directly from the power supply no special considerations are required The EZ Air requires the following power EZ AIR 24 VAC V10 power 3 4 A EZ AIR DC 24VDC 3 4 A Compressed Air Requirements The EZ Air has a inch F NPT fitting for connection to a shop air source of 85 140 psi 586 965 kPa It is recommended that a auto drain air filter with a 5 micron element part number 10 373 01 catalog number ADAF be placed in the air line CAUTION A shop air compressor using synthetic oil will cause damage to the EZ Air Petroleum based oil only is recommended DUAL EZ AIR KIT 990 127 2 1 CHAPTER 2 GETTING STARTED Section Il EZ Air Set up Unpacking Unpack the EZ Air from its shipping box and verify that all parts are present Table 1 2 lists the components of the ship kit part number 4 81109 01 which contain
17. utter Do not use pliers wire nippers or scissors 2 From the packing kit locate the pneumatic tubing for connections between the EZ Air and the up and down ports of each cylinder Cut four pieces of tubing 9 inches long The remaining tubing can be used for the shop air connection step 4 3 Using the included push in fittings connect the pneumatic tubing NOTE Be sure the tubing is pushed in all of the way to prevent leakage leading to imperfect welds As shown in figure 2 3 the connections are intuitive That is the upper valve goes to the cylinder s upper port the lower valve to the lower port On each side of the EZ Air are two fittings the fittings on each side go to the respective cylinder of that side with the top fitting of the EZ Air going to the top fitting of the cylinder and the bottom fitting of the EZ Air going to the bottom fitting of the cylinder 4 Connect the shop air to the EZ Air shop air supply input fitting Power 1 Connect the weld head firing switch cables to the firing switch connectors on the EZ Air left side to left connector right side to right connector 2 24VAC EZ AIR Connect the valve driver cable connector to 24 volt connector on the rear of the power supply Connect the signal cable connector to the firing switch connector on the power supply 24VDC EZ AIR DC Connect weld head driver cable to connector labeled WELD HEAD on control Connect voltage sense cable between EZ
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