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HF25 Technical Manual - AMADA MIYACHI AMERICA

1. MUNI 11 vili n P E E E E E 1X x Chapter 1 Description we RE NU oo m mms 1 1 A S 1 1 Weld Quality Process M 1 1 1 2 Sec HORE OPONE ____ _______ 1 4 IMSIOP C ORDIDODEC DES E E 1 4 Front Panel Display and Display Controls 1 4 lcs seats enon cose awed 1 5 Display 1 6 SCHEDULE Key 1 6 Selector ________ 1 6 5 M EE 1 6 Front Panel Data Entry and Mode CI Eesti 1 7 1 7 1 7 127 MENU C Ley T 1 7 Control Mode Selbehon en 1 8 soe 1 8 1 8 v 1 8 INIOUIODP C 1 8 ATE
2. M MA NIE 4 3 PEAK and AVERAGE MONITORING ccccccccccccceesecccceesecceceeseccceeeseccecueeccsseuecseeeuecesseneecesseneeeseeeees 4 3 Current Voltage Power and Resistance oe us p IHE ERU IHE 4 4 Moo 4 4 I Active Par APC 4 4 2 ______ 4__________ _ ____ 4 6 _4 _64_ _________ ___ ___ 4 7 4 Weld A Limit ge 4 8 Em 4 9 Chapter 5 Operating Instructions SecHon 5 1 5 1 __ __ _ 6_ 5 1 C OnE CONS 5 1 _ _________ ____ 5 1 COTS SSC ________ 5 1 seers stage AE EE 5 2 wise 06 1 5 3 Singic Pulse Weld CIC CIC 5 3 Upslope Downslope Weld Schedule rence 5 5 Pa PUSS NW eld elles 5 7 Section HE Using the Weld Monitor a aed peeve eee 5 9 Section Active Part Conditioning 5 13
3. 1 1 c 1 1 Control 1 1 Weld Quality Process Tools 1 1 1 2 Major Components c Orten 1 4 COBIFOLIS CV 1 7 Control Mode Selection Keys 1 8 434 0 A 1 8 La C I 1 8 KW d qe t 1 8 hilariter T 1 8 1 9 KA KEY 1 8 quM c 1 8 bas q 1 8 Front Panel Data Entry amp Mode Keys 1 7 e M H 1 7 Mode CYS 1 7 MENU KEY 1 7 1 7 Front Panel Display amp Display Controls 1 4 1 5 Display Controls r 1 6 SCHEDULE 1 6 Time Energy Selector Keys 1 6 Weld Period Selector Keys 1 6 Major Components 1 4 WELD NO WELD Switch 1 9 Emergency Stop Switch Operation 1 9 1 5 3 13 Display Controls 1 6 BES WV Cl m Q 3 14 Dual Pulse Weld Profile 3 23 Dual Pulse Weld Schedule 5 7 HF25 DC RESISTANCE WELDING SYSTEM A Active Part Conditioner APC 4 5 Active Part Conditioning 5 13 Alarm Messages 6 1 6 3
4. cee sede 1 8 DAS A 1 8 dije E E TS 1 8 EE 1 9 WELD NO WELD SAU 1 9 Emergency Stop Switch Operation 1 9 HF25 DC RESISTANCE WELDING SYSTEM 990 371 CONTENTS Continued Page Chapter 2 Installation and Setup Section I Installation NER 2 1 eA 2 1 He ES oo IHR RP HM MEM MEME 2 2 2 2 2 Compressed COO 2 2 2 3 Connections To Exma EQUIPMENT 2 3 Rear Panel Components and mere 2 3 Weld Head Connections 2 4 Foot Pedal Actuated Weld Head Connection 2 6 EZ AIR Weld Head Connections eset teste eon to hereto taa Ra Pe o epe ate 2 7 Non EZ AIR Weld Head Connections 2 10 Chapter 3 System Configuration 3 1 Bee _ 3 1 A M E se de esc ese 3 1 3 1 EC 3 1 PN We e
5. ZEIT 20 KA 150 10 10 190 10 10 10 10 Press the foot switch to actuate the first level The weld head upper electrode should descend smoothly to the DOWN position When it reaches the down position release the foot switch and proceed to Step 12 If it does not descend smoothly proceed to Step 11 11 Adjust the weld head down speed control knob and repeat Step 10 until the upper electrode descends smoothly 12 Press the foot switch all the way down to close both levels The weld head upper electrode should descend smoothly to the DOWN position and send the firing switch signal back to the Control when the preset electrode force 15 reached The upper electrode should then ascend smoothly back to the UP position HF25 DC RESISTANCE WELDING SYSTEM 990 371 2 9 CHAPTER 2 INSTALLATION AND SETUP 2 Weld Head Connections Non EZ AIR heads may be connected to the Control as shown below however you should refer to the manual provided with the weld head you are using for specific instructions UP SPEED CONTROL KNOB DOWN SPEED CONTROL KNOB FORCE ADJUSTMENT KNOB SHOP AIR FORCE INDICATOR al Set to 5 M A AIR INPUT WELD HEAD LOAD CELL ELECTRODE HOLDER FIRING SWITCH CABLE AIR DRIVER CABLE b EMERGENCY STOP REAR PANEL SWITCH HF25 DC RESISTANCE WELDING SYSTEM 2 10 990 371 3 System Configuration Se
6. a E E R EE EE E MEE 5 15 S __6_ __ _6__ _ 5 17 Becton Vl ENERO 5 19 Decion VII MERI SIOD _ _______6__ 5 2 DEODOD EX reer aman IS C gt 5 23 Chapter 6 Maintenance SOGLIODUL Tada ON een UU PUMA MEMINI 6 1 General Idands or POW _____ 6 1 INS 6 1 Section IL _ 6 2 _ ________ 8_ __ _ _ 6 6 2 RM d uU ____ 6 3 HF25 DC RESISTANCE WELDING SYSTEM vi 990 371 ee ene nee one none eee 6 9 Blectrod c ____6______ 6 9 AG id mmi UN 6 9 CO DIN ATEM 6 10 Appendix A Technical Specifications 1 Appendix B Electrical and Data Connections 1 Appendix ____ ____ ______ 1 Appendix D System TIMME D 1 Appendix E Communications ssicecscecassnorinesssancxancascesonreacieancont ines SYN SUL eran ianstertnnteionteetes 1 Appendix The Basics of Resistance Welding 1 Appendix Q
7. 16 NOWERDTRANTORMERDETKCHED CHECK VOLTAGE CABLE amp SECONDARY ORCO eALIDRATIONRESETTODEFAULT O 3 LOWER LIMIT GREATER THANUPPERUNT O TIME ADDED FOR DIFFERENT FEEDBACK m SETTNGTOOSMALE x SWIM amp SCHEDUERESTTODERAUIS OOO OOOO CHaNEDTONEXISCHEDUE 36 SWEENRGYUMTREACHED OOOO TIUmERUMITDHAYSADUSED O O PPLOWER DELAYS ADNUSTED 3 rure om peras aous O 3 UPStOPEREQUIRED ror Lower x 25 LINEAR DC RESISTANCE WELDING CONTROL 990 371 17 APPENDIX E COMMUNICATIONS WELD STATUS CODES Wm x mRESSRUNBHOREWRDNG OOOO PMrDeLavsReserton OOOO 39 ACCES DENIEDISYSTENSECURTVON e OOOO o Ce o _ s 5 m omms a 5s 5 ooren rowem O OOOO 5 vortacer lt iowerum 5 o wmwp HF25 LINEAR DC RESISTANCE WELDING CONTROL E 18 990 371 APPENDIX E COMMUNICATIONS WELD STATUS CODES Wm SCR Message O O 66 SSTEMPARAMETERSARERESET Porse rore vr reac OOOO o weones OOOO WHDSOP UMTREACHD SYSTEM ERROR SOFTWARE INTERRUPT SYSTEM ERROR ILLEGAL INSTRUCTION System enon Diven py ZER
8. 3 3 3 4 Schedule 3 4 DY Sle gt quem 3 4 Index 4 990 371 INDEX U Unpack 2 1 Update After Weld etm 3 13 Upslope Downslope Weld Profile 3 23 Upslope Downslope Weld Schedule 5 5 Using ihe Weld MOBE 5 9 2 2 V 1 8 Voltige Mode ERN aeia i 4 1 W Weld OUI 3 2 Weld Func Hons 3 19 Weld Head Applicability 3 20 Weld Head Connections 2 4 Weld 4 3 Weld Period Selector Keys 1 6 Weld Quality Process Tools tr rns 1 1 Weld Schedule Definition 3 21 Weld Schedule Development 2 5 te F 5 Weld Sequence rene 3 2 bn 3 17 Weld 4 9 5 21 Weld Strength Profiles 6 Weld Strength Testing ssec matan e F 6 Weld I 4 8 5 19 WELDINO WELD 1 9 Welding Applications 3 19 3 22 Welding Parameter Interaction F 1 When Use Functions scjscscecssaeseeveszenvevcaaeneecees 3 20 Weld G 6 Weld Head amp Mechanical Variables G 7 HF25 DC RESISTANCE WELDING SYSTEM 990 371 Index 5
9. 3 2 Ms 3 3 NEC 3 3 3 3 3 ES eas eile ERREUR 3 4 25 SuSte mide E US ope MI DA NIMM EI ___ 3 4 Pin CAVEAT RET 3 4 6 Communication 3 5 l Communication ONS 3 5 2 Band Rale 3 6 3 6 A LD 3 6 3 7 5 Reset _____ ____ 0 3 8 b ISescE GEO __ ____ 3 8 2 Reset Schedules RR 3 9 3 Reset Schedule Limits 3 9 CAI 3 9 HF25 DC RESISTANCE WELDING SYSTEM 990 371 visi emm NA ____ ___ 3 11 l M 3 11 2 VIC Debounce TIME 3 12 EAE E E O ET A O A AT N A EN 3 12 NEN AA EAE AE EA E AE EA E N E 3 12 PES EET E E E E IE E E IE E E 3 12 Wu e E __6_ _ _ _ ___ _ 3 12 E EE 3 13 1 3 13 2 BUA m 3 13 3 Fod OLC Sd AZ ACI 3 13 4 Updat Graph 3 13 L aa E E EE EEE 3 14 vm E E E E A EE E E RE 3 14 Do Test Weld 3 14 IE E EE A AENA S ______ 3 14 c A 3 14 Section
10. EE 3 18 AINS 3 14 Application Perspective G 8 Approach to Weld Development G 7 MMC 3 14 3 12 Basic PrInelpl S G 4 Basics of Resistance Welding F 1 Electrode Maintenance 1 5 oen traer tnn F 5 Blectrode Selection soo inet tsm F 2 Interaction of Welding Parameters F 6 Resistance Welding Parameters 1 Weld Schedule Development F 5 Weld Strength Profiles siccis cscsaresasestedenstiondessts F 6 Weld Strength F 6 Welding Parameter Interaction 1 M 3 6 Before You Start 2 3 1 5 1 C 4 B uzzerJoudileSS 3 13 C Calibrating the Control 1 Calibration 3 6 C 1 Calibrating the Control C 1 Calibration Equipment Required C 1 Calibration Procedure C 2 VEV carat EEEE C 1 Calibration Equipment Required C 1 uci mm tiene DINE 3 9 Common Problems n ironia nane G 9 COMIC AION 3 5 CATION 3 5 DS 1 Compatibility and Comparison H 1 5 1 Compressed Air amp Cooling Water
11. 2 2 Conductive Metals oce cater ot G 3 CGS ONS DU 5 Connections to External Equipment 2 3 Contact Me e vili 990 371 Index 1 INDEX Interaction of Welding Parameters F 6 Introduction to Feedback Modes amp Monitoring 4 1 Programmable Feedback Modes 4 1 Current inen ratre nra 4 1 UOS 4 1 Power od ies her a ed 4 2 Volare Mode WERT 4 1 Weld Monitoring 4 3 Current Voltage Power amp Resistance Limits 4 4 Introduction 4 3 PEAK AVERAGE MONITORING 4 3 PROCESS Lool 4 4 Active Part Conditioner APC 4 4 Pre Weld 4 7 Resislmice Uma 4 6 Weld SIOP 4 9 Weld A 4 8 K 1 8 MEM cc 1 7 1 8 L uuo 3 14 hs En M 3 1 EI ER 6 1 eos mede uM 6 1 Alarm Messages 6 1 General Kinds of Problems 6 1 DTM ACS RR RT 6 9 Electrode Maintenance 6 9 Parts DAC GING EN dote nae 6 9
12. aen mapu Meme 3 15 ____ ________ MM 3 15 A 3 15 MSU OA A 3 15 3 16 3 17 NIOD OE 3 17 JU 3 18 DECOM TV eld Purettobisio 3 19 er 3 19 Weld Head 3 20 Mem 0 UC EEN IUIUS NN snes 3 20 Weld SCC OU Deli __ _ ___ 3 21 Weld Sequence Timing sbicanacteewiasaemesravnecbnaancnetunvaceowbasnemeniavnarinasssuatsuavadeonbasnvacksenartnearsuacsneracnttoertus 3 21 E o eee 3 22 Single Pulse Weld Profile 3 22 Upslope Downslope Weld Profile 3 23 Diah P PrE E IUE 3 23 Chapter 4 Introduction to Feedback Modes and Monitoring Section I Programmable Feedback Modes 4 41 53 53 5 05 4 1 4 1 E ee MEME NE MEME 4 1 4 1 4 2 25 DC RESISTANCE WELDING SYSTEM 990 371 CONTENTS Continued Page Ltt Eb Weld DM a ae 4 3 OE eco
13. e Compile store view and print weld history data for detailed analysis e Check the status of the Control s e Remotely program weld schedules on the Control s e Remotely program menu items on the Control s Remote Programming Most users will find the Weld Stat software functions sufficient for collecting and using weld history information and remote schedule programming However advanced users may wish to perform additional programming for custom welding applications The codes needed to perform remote programming are listed in Section IT Communications Protocol and Commands Using these codes users can write customized software for controlling all functions of the welding control and interfacing the unit to automation control systems For more information on the Weld Stat Kit Amada Miyachi America Part Number 10 600 06 call or e mail us using the Contact Us information 1 the front of this manual RS 485 Connectors The unit has two DB 9 female connectors wired as follows 1 Not Used 6 Not Used 2 Not Used 7 Not Used 3 Not Used 8 Rx 4 TX 9 Rx 5 Tx HF25 LINEAR DC RESISTANCE WELDING CONTROL 990 371 E 4 APPENDIX E COMMUNICATIONS A terminating resistor assembly is supplied with the unit If only one unit is connected to the host the terminating resistor assembly must be installed in that unit If multiple units are connected to the host only one unit the unit
14. Conductive metals dissipate heat and 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 HF25 DC RESISTANCE WELDING SYSTEM 990 371 G 3 APPENDIX DEFINING THE OPTIMUM PROCESS e Group 1 Resistive Metals It is easier to generate and trap heat at the interface of resistive metals and therefore it is possible to form both solid state and fusion welds depending on time and temperature Upslope can reduce contact resistances and provide heating in the bulk material resistance e Group 11 Refractory Metals Refractory metals have very high melting points and excess heating can cause micro structural damage A solid state joint 1s 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 Solid State Copper W Mo electrodes Projection on Group I Fine projections on Group III Group Il Solid State or Fusion Solid state or braze of II Steel on III Projection on III Moly Basic Principles R2 Contact Resistance Resistance Bulk Resistance Time The figure above shows the key resistances in a typical opposed resistance weld and the relationship between contact resistances and
15. The Control has seven operational states NO WELD WELD MENU MONITOR TEST ALARM RUN You go to the NO WELD MENU TEST RUN and MONITOR states through the control panel The WELD and ALARM states are functions of the force firing switch and foot switch input states No Weld State Setting the WELD NO WELD switch on the control panel to the NO WELD position inhibits the delivery of weld energy if a weld is initiated and will display a WELD SWITCH IN NO WELD POSITION alarm on the screen But the Control will still go through its electronic weld cycles as programmed into the selected weld schedule Use the no weld state when adjusting the air regulators on air actuated weld heads Menu State Pressing the MENU key puts the Control in the MAIN MENU gt menu state It brings up menu screens that SETUP 6 COMMUNICATIONS WELD COUNTERS 7 RELAY enable you to select various options common to SCHEDULE B PESE DEFAULTS all weld schedules such as how the Control CALIBRATION 9 CHAIN SCHEDULES interfaces with the force firing switch foot SYSTEM SECURITY switch and weld head Number Select item g 300V 6 900V Test State Programming a schedule for a voltage feedback 421 welding mode or changing the voltage or time settings while in the voltage feedback welding 1 mode puts the Control in the TEST state After making one weld the Control internally optimizes the feedback control loop to produce 150 1 0 18 1
16. 3 11 INE etes EROS 3 12 REMOTE 3 12 Switch Debounce Time 3 12 3 13 Buzzet Loudness osi torret 3 13 Display Contrast Loser irr trees 3 13 End OT Cycle BUZZGE 3 13 3 14 Update Graph After Weld 3 13 3 14 Do Test Weld 3 14 PAN ANS n 3 14 EIO E 3 14 Weld 3 19 Welding Applications 3 19 3 22 Dual Pulse Weld Profile 3 23 Single Pulse Weld Profile 3 22 Upslope Downslope Weld Profile 3 23 Weld Head Applicability 3 22 Weld Schedule Definition 3 21 Weld Sequence Timing 3 21 When To Use Functions 3 20 DVS He spreen e 3 4 System MMIT 3 3 D 1 T Technical Specifications oret 1 A c 3 15 Time Energy Selector 1 6 Troubleshooting i Red 6 2 HF25 DC RESISTANCE WELDING SYSTEM R Continued Resistance Set icis orestis 4 6 5 15 R sistance Welding G I Resistance Welding Parameters 1 Re
17. NUMBER Select A Page RUN or MENU NOTE For more details on this process see Active Part Conditioner in Chapter 4 Using Feedback Modes and Weld Monitoring 10 Since different levels of oxide require different amounts of time to reach the current limit return to the RUN screen and extend the programmed weld time usually double the time works This will ensure that there will be enough time for the current to rise and reach the limit even with heavily oxidized parts HF25 DC RESISTANCE WELDING SYSTEM 990 371 9 13 CHAPTER 5 OPERATING INSTRUCTIONS 11 Try welds with varying oxide clean and dirty The power supply terminates the first pulse when your programmed current is reached A clean part will reach the current limit sooner and the pulse will terminate early A dirty part will require more time before the oxide is broken down and current can flow 12 Program your second welding pulse as peak 447kA 0020031 normal to achieve a strong weld 2 Constant voltage is recommended for round parts and constant current for flat A 1 b ired O 8O0DKkW lt 15mq 3 250V ope may 020 0 5 0 0 0 2 0 3818928 000 ms restrict the current flow early in the second pulse and avoid weld splash HF25 DC RESISTANCE WELDING SYSTEM 5 14 990 371 CHAPTER 5 OPERATING INSTRUCTIONS Section V Resistance Set NOTE The Resistance Set tool is very similar to the Active Part Conditioning tool The difference is
18. e View the entire weld schedule profile individual weld periods weld energy parameters e View individual weld parameter program changes as you enter them via the weld period selector keys e View completed weld feedback data and use the data to modify the weld schedule In the menu mode the display presents system setup options for you to select In the monitor mode the display is your means of programming the energy limits monitor and viewing actual out of limit conditions HF25 DC RESISTANCE WELDING SYSTEM 990 371 1 5 CHAPTER 1 DESCRIPTION Display Controls There are three display control functions e SCHEDULE Selector Key e Weld Period Selector Keys e Time Energy Selector Keys SCHEDULE Key Puts the Control into the weld schedule selection mode Use the keypad to directly enter a desired weld schedule refer to Front Panel Data Entry and Mode Controls this section then press the RUN key SCHEDULE Weld Period Selector Keys WNBP LEIPSHEEVEENXI SQUEEZE UP WELD DOWN COOL UP WELD DOWN HOLD LL PULSE 1 J PULSE 1 Select individual weld periods and weld energy fields in the weld schedule profile for programming See Front Panel Data Entry and Mode Controls Time Energy Selector Keys These two switches one for each of the PULSE 1 and PULSE 2 weld periods select either the bottom line of data or the second to bottom line of data on the screen to be programmed
19. 72 23 EEC Standards to which EN 61010 1 2001 conformity is declared Manufacturers Name Unitek Manufacturer s 1820 S Myrtle Ave Address Monrovia CA 91016 Equipment Description Welding Station Equipment Class Model Number HF25 27 the undersigned hereby declare that the equipment specified above conforms to the above Directive s and Standard s La M Place Ma CHR Signature HET CGU uo c Full Name Wb 7 Position __ Deshe HF25 DC RESISTANCE WELDING SYSTEM 990 371 1 Description Section Features The HF25 High Frequency Resistance Welding System Control precisely controls and monitors both electrical and mechanical weld parameters Control Features e Constant Current Voltage amp Power modes SCHEDULE e Monitor Energy and Resistance e Force Control e Monitor Displacement and Force Weld Quality Process Tools e Envelope Function e Active Part Conditioning e Pre weld Check Weld to Limits Configuration and Chapter 4 Introduction to 2227 Feedback Modes and Weld Monitoring ser MIYACHI D US WODEL HF45 Descriptions of the various control modes and process tools are located in Chapter 3 System Detailed instructions on using these features are located in Chapter 5 Operating Instructions NOTE For the rest of this manual the Miyachi Unitek HF25 High Frequency Re
20. 99 ms 1 0 ms HF25 DC RESISTANCE WELDING SYSTEM 990 371 1 APPENDIX A TECHNICAL SPECIFICATIONS Performance Capabilities Number of Weld Schedules Programmable Weld Periods PVC Se ol pete 0 999 ms 0 99 ms bio 0 99 ms DosytsloDe d 0 99 ms 0 99 ms icm v 0 99 ms li Q 0 99 ms O 0 99 ms 0 999 ms Weld Head System Compatibility Force Fired Foot Actuated Force Fired Single Valve Air Actuated Non Force Fired Single Valve Air or Cam Actuated Force Fired EZ Air Kit Plug and Play 24VDC EZ AIR weld head 301 350 Series Electronic Weldheads Weld Energy Limits Monitoring Weld Pre Check Mode Inhibit second weld pulse when first test pulse exceeds programmed limits Measurement Parameters Current voltage and power Measurement Selection Peak or average Measurement Range and Accuracy 1 24 KA E 2 of scing 52A 0 2 9 999 V 2 of setting 0 02V 0 05 9 999 kW 5 of setting 10W Limit Ranges Same as the measurement ranges Alarms Display alert and four programmable AC DC relay contact outputs HF25 DC RESIST
21. APPENDIX G 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 mislead the course and productivity of the welding experiments In summary the look see welding experiments should be used to fix further variables from an application and process perspective and also to establish a weld window for energy time and force This part of weld development 15 critical in order to proceed to a statistical method of evaluation Design of Experiments or DOEs Random explosions or unexpec
22. Description This function terminates the weld energy during the welding process if pre set weld current voltage or power limits are exceeded In addition to inhibiting the weld the Control has four programmable relay outputs which can be used to trigger alarms to signal operators of weld faults or signal automation equipment to perform pre programmed actions such as stopping the production line so the faulty weld piece can be removed The monitor measures the weld energy parameters during the weld period and compares the measurements against the programmed limits If any of the programmed limits are exceeded the energy limits monitor sets the Control to a state selected from the OUT OF LIMITS ACTION menu In addition the Control s relays can be programmed to trigger alarms or trigger an action in an automated welding system WELD STOP LIMIT REACHED 00200178 1 6 500 8 3001 150 3 0 00 20 00 050 ms In the profile above the weld current limit is at a sufficient level to get a good weld In this case the operator has selected the option to terminate the weld energy under this condition so the energy limits monitor terminates the Pulse 1 weld and inhibits the Pulse 2 weld if it had been programmed NOTE When using the energy limits monitor always select a monitor mode that is different from the feedback mode For example If you are welding in constant current monitor voltage e If you are welding in con
23. The COMMUNICATION ROLE line will now reflect your role selection NUMBERS Select an item RUN or MENU Inthe MASTER role the Control will Send weld data to the host computer after each weld operation Send text data to a serial printer providing a printout of the average voltage and current values for each weld generating a paper history of welds performed Inthe SLAVE role the Control will send weld data only when requested by the host computer You must use this role for RS 485 installations with mulitple controls on one communications channel NOTE For weld data collection and host computer control information refer to the Datacom Operator Manual which describes how to use the MASTER and SLAVE options 2 Press MENU to return to the MAIN MENU HF25 DC RESISTANCE WELDING SYSTEM 990 371 3 5 CHAPTER 3 SYSTEM CONFIGURATION 2 Baud Rate The baud rate at which the data is sent must match the baud rate of the host computer To enter the baud rate proceed as follows 1 From the COMMUNICATION menu lt BAUD press the 2 key to get the BAUD RATE 1200 6 19 2K 2400 7 28 8K selection screen e WE 2 Usethe numeric keypad to select the py baud rate of the receiving device The display automatically returns to the Number Select A Page RUN or MENU COMMUNICATION menu which shows the new baud rate 3 Press MENU to return to the MAIN MENU 3 RS232 485 SELECT Pressing the 3 key
24. energy close by HF25 DC RESISTANCE WELDING SYSTEM 990 371 D CHAPTER 2 INSTALLATION AND SETUP Utilities Power Because of the different electrical requirements for the countries in which the Control 15 used the Control 1s shipped without a power cable connector The required connections for your power cable connector are described in Appendix Electrical and Data Connections Input power requirements for the Control are as listed below Power Input Specifications Input Voltage Copper Wire Amada 50 60 Hz Ckt Brkr Gauge Wire Dia myc HF25 Model 3 phase Amps America Vrms Current A rms 7 strands AWG Volts P N Compressed Air and Cooling Water If you require compressed air and cooling water service for the weld head please refer to the weld head manufacturer s user s manual for service specifications HF25 DC RESISTANCE WELDING SYSTEM 2 2 990 371 CHAPTER 2 INSTALLATION AND SETUP Section Setup Connections to External Equipment All connections other than the weld cable connections between the Control and external equipment are made through the rear panel VOLTAGE SENSE INPUT AIR VALVE DRIVER HEAD 60 Pin I O CONNECTORS FOOT SWITCH 5 CONNECTOR 4 CONFIGURATION J As zN EMERGENCY STOP PLUG SWITCH CABLE POWER INPUT FUSE 1 FIRING SWITCH p CABLE POWER INPUT ere MAIN POWER FUSE 2 m C CIRCUIT BREAKER POW
25. gt 9 999 V e Power 0 05 gt 9 999 kW 6 Perform one of the following to program the Pulse 1 feedback mode From the CONTROL keys section on the front panel press the kA key to program current as the feedback mode From the CONTROL keys section on the front panel press the V key to program voltage as the feedback mode From the CONTROL keys section on the front panel press the kW key to program power as the feedback mode Press the PULSE 1 DOWNSLOPE key to enter the amount of time for the Weld Pulse 1 downslope Use the numeric keypad to enter the time or use the AV arrows Enter a time between 0 and 99 milliseconds Note that in combo mode when the unit reaches a constant current any time programmed in this segment will be added to the weld at the constant current level HF25 DC RESISTANCE WELDING SYSTEM 990 371 CHAPTER 5 OPERATING INSTRUCTIONS 8 10 5 8 Press the COOL key to enter amount of time between Pulse 1 and Pulse 2 Use numeric keypad to enter the time or use the AV arrows Enter a time between 0 and 99 milliseconds We recommend at least 2 milliseconds Program Pulse 2 by repeating Steps 3 through 7 above using the keys for Pulse 2 entering appropriate values for Pulse 2 Press the HOLD key to enter the amount of time for the hold period after the weld Use the numeric keypad to enter the time or use the AV arrows Enter a time between 0 999 milliseconds We recommend
26. 1 NONE TIME 2 10 ms menu screen crop 2 Select the required debounce time by 4 30 ms pressing the 1 2 3 or 4 key NONE represents a debounce time of 0 ms Number Select Page RUN or MENU Use NONE for interfacing with the Miyachi Unitek Model 350C Electronic Weld Force Control 3 The SWITCH DEBOUNCE TIME line will now reflect your switch debounce time selection 3 Firing Switch With the SETUP 1 screen displayed press the 3 key to select this function The firing switch input in conjunction with or without inputs from the foot switch input initiates the weld energy sequence Select the required switch type by pressing the 1 2 or 3 key Pressing the numeric keys automatically returns the display to the SETUP 1 screen 1 Auto FIRING SWITCH The Control accepts a single pole double pole or optical firing switch input from a Miyachi 3 REMOTE Unitek weld head Firing switch activation indicates that the weld head has reached the set weld force thus permitting the weld energy sequence to start Number Select A Page RUN or MENU 2 None When using a non force fired weld head weld energy initiation must be supplied with the foot switch input Additionally you must select sufficient squeeze time to permit the weld force to stabilize after contacting the weld pieces 3 Remote Use this setting in an automation application or when using PLC control The BCD input lines via the CONTROL SIGNALS
27. 6 10 Troubleshooting es 6 2 Alarm Messages 6 1 Troubleshooting 6 2 Major Components 1 4 Material Properties G 3 Materi Variables Loose G 7 Mekito G 3 MENU KEY Aa 1 7 25 DC RESISTANCE WELDING SYSTEM E Electrical amp Thermal Conductivity G 3 Electrical and Data Connections B 1 Electrode Maintenance 6 12 F 5 Electrode Selection F 2 Emergency Stop Switch Operation 1 9 End OECycle 3 13 EZ AIR Weld Head Connections 2 7 F Factorial DOE S TREES G 11 1 1 3 12 Foot Pedal Actuated Weld Head Connection 2 6 Footswitch Weld Abort 3 11 Front Panel Data Entry and Mode Keys 1 7 Front Panel Display amp Display Controls 1 4 Ad CANNON TM C 5 Fusi n G 2 G General Kinds of Problems 6 1 H M M RR G 3 I ROME d NORTE 3 6 Initial Setup 5 2 Initial Welding Trials G 8 Installation and Setup 2 1 2 1 Space Requirements saccsadc
28. Any Requests the Control to erase all the weld reports SYNC lt crlf gt lt lf gt Any Provides synchronization of the commands The Control returns SYNC command back to the host computer CURRENT lt crlf gt lt lf Any Requests the Control to report the sampled Current data of the last weld Control shall return with CURRENT report See CURRENT command under Control Originating Commands section VOLTAGE lt crlf gt lt lf Any Requests the Control to report the sampled Voltage data of the last weld Control shall return with a VOLTAGE report See VOLTAGE command under Control Originating Commands section POWER ccrlf lf Any Requests the Control to report the sampled Power data of the last weld Control shall return with POWER report See POWER command under Control Originating Commands section HF25 LINEAR DC RESISTANCE WELDING CONTROL E 5 APPENDIX E COMMUNICATIONS Command Control State Description Command Control State Description Command Control State Description Command Control State Description Command Control State Description E 6 OHMS lt crlf gt lt lf gt Any Requests the Control to report the sampled resistance data of the last weld Control shall return with OHMS report See OHMS command under Control Originating Commands section STATE READ RUN MENU lt crlf gt lt lf gt Any Commands the Control to identify its current state READ keyword see STATE under CONTROL O
29. Head amp Mechanical Variables e Quality Requirements A Force squeeze hold Pull strength Actuation method Visual criteria Electrode material and shape Test method other weld joint requirements e Power Supply Variables Energy Time squeeze weld hold The first stage in developing a quality welding process 15 to fix as many of the variables as possible in the welding equipment set up Welding variables can be grouped in the following categories Initial Welding Trials The Look See Tests Look see welding tests are a series of mini welding experiments designed to provide a starting point for further statistical development of the welding parameters The user should adjust the key welding variables energy force time in order to identify the likely good weld window Close visual inspection of the weld parts will promote better understanding of the heating characteristics of the application The mini experiments should also be used to understand the weld characteristics from both application and process perspective Key factors in this understanding are as follows Application Perspective e Materials Resistivity melting point thermal mass shape hardness surface properties e Heat balance Electrode materials shape Polarity heating rate upslope e Observation visual criteria cross section and impact of variables on heat balance HF25 DC RESISTANCE WELDING SYSTEM G 8 990 371
30. Material Properties ote Pip G 3 COMIC Metals G 3 Electrical amp Thermal Conductivity G 3 Va RET G 3 Melting G 3 Refractory Metals G 4 Resistive Metals G 4 Resistance Welding G 1 Joint G 2 Solder Braze 1 G 2 Solid State Joint 2 ertt oro rito entree G 2 Soreening DOE S totus G 10 Weld G 6 R Rear Panel Components and Connectors 2 3 Recommended Gauge Thickness C 4 Metals G 4 D ee ne re en ee 3 7 KEMO 3 12 Repair 6 10 Reset All Schedules 3 9 Reset Schedule bits 3 9 Reset System ParatHe lC ES 3 8 Reset To Defaults neret itta 3 8 HF25 DC RESISTANCE WELDING SYSTEM 990 371 Index 3 INDEX Weld Counter 3 2 Reset System Parameters 3 8 Operational States 3 18 Alarmi Stale c 3 21 Memu Stale Nn 3 18 Monit r 3 20 N Weld State 3 18 e E OE 3 19 OEC 3 18 Weld SU Ale 3 20 3 1 GU M Mv 3 11 3 12 Firing 3 12 Footswitch Weld Abort
31. NOT ACTIVE FORCE SET 10 same same same same same same same same same 41 42 Use EMO cable on new unit Output range 0 10V 3 HF27 ONLY option NOT ACTIVE FORCE GROUND Input range 0 10V HF27 ONLY option No 15VDC available on new unit No 15VDC available on new unit 45 NOT ACTIVE 1SVDC power ISVDC power FORCE INPUT FORCE READ 10 INPUT NOT ACTIVE NOT ACTIVE FORCE READ 5 INPUT FORCE GROUND CHASSIS GND NOT ACTIVE LVDTGND LVDTPRII LVDTPRD LVDTSECI LVDTSEC2 LVDTGND FORCE SET 5 FORCE GROUND CHASSIS GND 47 Different input range 0 5V HF27 ONLY option 50 Same 51 52 53 54 55 56 57 58 59 CHASSIS GND NOT ACTIVE LVDTPRII LVDTPRD LVDTSECI LVDTSEC2 LVDTCG NOT ACTIVE FORSET same Different HF27 ONLY option Different HF27 ONLY option Different HF27 ONLY option Different HF27 ONLY option Different HF27 ONLY option Different HF27 ONLY option Different output range 0 5V HF27 ONLY option Same Q Q J J CHASSIS GND HF25 DC RESISTANCE WELDING SYSTEM 990 371 H Index Control Features 1 1 1 7 Control Mode Selection Keys 1 8 DD CG GUIS tn meu T MEUM 3 3 Criteria for SUCCESS redo testas estes G 10 G 11 Mode 4 1 Current Voltage Power amp Resistance Limits 4 4 D Declaration OT Conformity Xi DEST
32. Pulse 1 weld and inhibits the Pulse 2 weld if it had been programmed The monitor measures the weld energy parameters during the weld period and compares the measurements against the programmed limits NOTE When using the energy limits monitor always select a monitor mode that 15 different from the feedback mode For example If you are welding in constant current monitor voltage If you are welding in constant voltage monitor current If you are welding in constant power monitor current or voltage HF25 DC RESISTANCE WELDING SYSTEM 990 371 4 9 5 Operating Instructions Section I Introduction Before You Start Before operating the Control you must be familiar with the following e The location and function of Controls and Indicators For more information see Chapter 1 of this manual e How to select and use the Control functions for your specific welding applications For more information see Chapter 3 System Configuration e The principles of resistance welding and the use of programmed weld schedules For more information see Appendix E The Basics of Resistance Welding For additional information on the welding process see Appendix F Quality Resistance Welding Solutions Defining the Optimum Process Pre Operational Checks Always perform these checks before attempting to operate the Control Connections Verify that the Control has been connected to a manual or air actuated weld head
33. Section Installation Unpacking The Control is shipped to you completely assembled together with the accessories you ordered and a shipping kit The contents of the shipping kit available accessories and contents of the Datacom Kit are listed in Appendix A Technical Specifications Be sure that the accessories that you ordered have been packed and the contents of the shipping kit and Datacom kit are as listed Verify that the Control shows no signs of damage If it does please contact the carrier Also contact Amada Miyachi America Customer Service immediately at the postal or e mail address or telephone or FAX number shown in the Foreword of this manual Space Requirements e Allow ample workspace around the Control 0 inches so that it will not be jostled or struck while 229 mm welding e Allow sufficient clearance around both sides and back of the Control for power and signal cabling runs 12 8 inches e Install the Control in a well ventilated area 325mm that is free from excessive dust acids corrosive gases salt and moisture e Other installation considerations The work surface must be level stable free from vibration and capable of supporting the combined weight of the total welding system The weight of the Control is 62 lbs 28 kg The Control must be far enough from the weld head to avoid contact with weld splash There are no sources of high frequency
34. Time For Lower Limit PILDLY2 delay value Pulse 1 Lower Delay End Time For Lower Limit PIUDLY1 delay value Pulse 1 Upper Delay Start Time For Upper Limit PIUDLY2 delay value Pulse 1 Upper Delay End Time For Upper Limit P2LDLY1 delay value Pulse 2 Lower Delay Start Time For Lower Limit P2LDLY2 delay value Pulse 2 Lower Delay End Time For Lower Limit P2UDLY1 delay value Pulse 2 Upper Delay Start Time For Upper Limit P2UDLY2 delay value Pulse 2 Upper Delay End Time For Upper Limit limit value 15 the parameter that specifies the range of the valid readings If the reading was within the range of the imit value no alarm will occur If the reading was out of the valid range an alarm will occur If the monitor type 15 KA the limit value is in unit of 1A If the monitor type is V the imit value is in unit of ImV If the monitor type is kW the limit value is in unit of IW The valid number for imit value is 1 through 9999 and 0 is for none The delay value is the parameter that defines the time for the given period in 0 1ms Valid range is from 0 to 99 Lower delay value is only valid during WELD time Upper delay value is valid during UP time WELD time and DOWN time Command RELAY READ SET lt crlf gt parameter name value lt crlf gt lt gt Control State Any except while welding Description Provides control over the Control schedule parameters for relay settings When used with the READ keyw
35. Type 80 MC2M Firing Switch Connector FIRE 1 24COM Operator Emergency Stop Cable Switch Input Function You must connect a normally closed single pole switch across both cable leads otherwise the Control cannot be turned ON Use the switch during Control operation as an emergency stop switch When operated opened it will immediately halt the weld process NOTE You must press the RUN key on the front panel to reset the Control following an emergency stop operation Connections Connect an approved normally closed emergency stop switch across the 2 foot 61 cm operator emergency stop switch cable When the switch is operated opened it de energizes the main power contactor removing three phase input power to the Control HF25 DC RESISTANCE WELDING SYSTEM B 12 990 371 APPENDIX ELECTRICAL AND DATA CONNECTIONS PLC Timing Diagram Weld Head Control Signal Weld Head Position Weld Head Position Signal Squeeze Dela Signal Remote Sched Select Inputs HF25 Weld Pulse Weld Hold Release Period Weld Head Trigger Squeeze gt 20 I lt 1sec BCD Welding Schedule Selection Scheme Weld Bit 2 Bit 2 Bit 2 Bit 2 Pin 1 4 12 Pin 14 BCD progression from 5 to 98 n HF25 DC RESISTANCE WELDING SYSTEM 990 371 B 13 APPENDIX ELECTRICAL AND DATA CONNECTIONS Relay Outputs Function Four m
36. Update Graph After Weld From the SETUP 2 screen press the 4 key to toggle the update graph after weld ON or OFF function The UPDATE GRAPH AFTER WELD line will now reflect your state selection ON means that the actual weld energy profile will overlay the programmed weld profile after each weld 1s made The weld graph 1s useful for detecting weld splash which 1s indicated by vertical gaps in the overlap You can reduce weld splash and eliminate it in some cases by using the upslope weld energy profile HF25 DC RESISTANCE WELDING SYSTEM 990 371 3 13 CHAPTER 3 SYSTEM CONFIGURATION 5 Language Press the 5 key to toggle between English and German menu items and instructions on the screen will be in the language selected Setup 3 1 DO TEST WELD In voltage mode the unit will do a test weld to optimize response to varying weld conditions Press 1 to bring up the following choices 1 ALWAYS A test weld will be done if e The voltage level changes e The time in any element of the schedule changes e Ifthe weld energy field is highlighted and the V key is pressed 2 ASK The user will be prompted to choose if a test weld is done or not upon the following conditions e The voltage level changes e The time in any element of the schedule changes e Ifthe weld energy field is highlighted and the V key is pressed HF25 DC RESISTANCE WELDING SYSTEM 3 14 990 371 CHAPTER 3 SYSTEM CONFIGURATION Section 111 Operational States
37. and compact The input output connectors on the rear panel provide for quick connect signal I O cabling facilitating interface with automation systems HF25 DC RESISTANCE WELDING SYSTEM 990 371 1 3 CHAPTER 1 DESCRIPTION section Major Components Major Components The major components are the front panel which contains the operator s controls and indicators and the rear panel which contains fuses circuit breakers and power and signal connectors The rear panel connections are discussed in Chapter 2 Installation and Setup Front Panel Display and Display Controls The front panel of the Control below shows controls and indicators The function of each item 1s described on the following pages LIQUID CRYSTAL x SCHEDULE KEY DISPLAY LCD WELD PERIOD CONTROL KEYS Gam KEYPAD MODE KEYS MONITOR KEYS WELD NO WELD KEY WELO Front Panel Controls HF25 DC RESISTANCE WELDING SYSTEM 1 4 990 371 CHAPTER 1 DESCRIPTION Display _ LIQUID CRYSTAL DISPLAY y SCHEDULE SCHEDULE SELECTOR KEY WELD PERIOD SELECTOR KEYS Liquid Crystal Display LCD The Liquid Crystal Display LCD on the front panel allows you to locally program the Control with the front panel controls and read the results of a weld process following its initiation The LCD has three distinct functions depending on the active mode of the Control In the run mode the display permits you to
38. as described in Chapter 2 of this manual Verify that the Emergency Stop Switch shorting wires are connected or verify that an Emergency Stop Switch is connected properly Power Verify that power is connected as described in Chapter 2 of this manual Compressed Air If you are using an air actuated weld head verify that compressed air is connected as described in the appropriate sections of your weld head manual Turn the compressed air ON and adjust it according to the instructions in your weld head manual HF25 DC RESISTANCE WELDING SYSTEM 990 371 5 1 CHAPTER 5 OPERATING INSTRUCTIONS Initial Setup 1 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 2 Set the WELD NO WELD switch on the Control front panel to the NO WELD position In this position the Control will operate the weld head without producing weld energy NOTE When you are ready to perform a weld be sure to set this switch back to the WELD position 3 Turn the ON OFF switch on the rear panel of the Control to the ON position The default RUN screen will be displayed You will use this screen to enter welding parameters 150 1 0 1 9 19 10 10 19 1 0 O59 ms Default RUN Screen HF25 DC RESISTANCE WELDING SYSTEM 5 2 990 371 CHAPTER 5 OPERATING INSTRUCTIONS Section Il Operation Single Pulse Weld Schedule l 990 3
39. at least 50 milliseconds HF25 DC RESISTANCE WELDING SYSTEM 990 371 CHAPTER 5 OPERATING INSTRUCTIONS Section Ill Using the Weld Monitor The Control allows you to adjust extremely precise limits for the amount of energy and weld time Like all welding processs development you ll need to make several test welds and view the waveforms and limits of actual welds in order to fine tune the limits to your needs The energy limits appear as horizontal dotted lines on the LCD screen The UPPER LIMIT line is longer than the lower limit line because it includes the UPSLOPE WELD and DOWNSLOPE portions of the actual weld waveform The LOWER LIMIT line is shorter because it only includes the WELD portion of the waveform Ifthe line of either limit crosses the weld energy waveform the Control can trigger an alarm inhibit the second pulse or stop the weld energy See Chapter 4 Using Feedback Modes and Weld Monitoring for more details MONITOR LIMITS UPPER LIMIT 2090 pesi 20904 0000014 LOWER LIMIT UPPER 3 201V LOWER 2 100 none MONITOR 3 060V peak 0 000V 0000074 UPPER 3 201V LOWER 2 100V RAISE OR LOWER LIMIT VALUES UPPER LIMIT Eomae d hel veh se E RI EE uM LOWER LIMIT M ere P 1 UPPER 3 201V none LOWER GOO none As you can see by the LCD screens above you can shorten the length of the time of the LOWER LIMIT so it will not cross the weld waveform This allows you to raise or lower t
40. bulk resistances over time during a typical resistance weld HF25 DC RESISTANCE WELDING SYSTEM G 4 990 371 APPENDIX DEFINING THE OPTIMUM PROCESS R1 amp R7 The electrode resistances affect the conduction of energy and weld heat to the parts and the rate of heat sinking from the parts at the end of the weld R2 R4 amp 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 Alternately conductive materials can be welded by using high contact resistance and fast heating because their bulk resistance is not high and cannot be relied upon for heat generation If a weld is initiated when both parts and electrodes are fitted up correctly the contact resistance 15 lower and bulk resistance now controls the heat generat
41. current 2 peak voltage 2 average power 2 peak power 2 average resistance 2 peak resistance 2 null 3 Always zero null 4 Always zero Weld count The unit number assigned to the unit The schedule number of the weld The status of the weld The average current of pulse 1 in A The average voltage of pulse 1 1 mV The peak current of pulse 1 in A The peak voltage of pulse 1 in mV The average power of pulse 1 in W The peak power of pulse 1 in W The average resistance of pulse 1 in 1070 The peak resistance of pulse 1 in 1070 The average current of pulse 2 in A The average voltage of pulse 2 in mV The peak current of pulse 2 in A The peak voltage of pulse 2 in mV The average power of pulse 2 in W The peak power of pulse 2 in W The average resistance of pulse 2 in 1070 The peak resistance of pulse 2 in 1070 The number of this weld assigned by the unit HF25 LINEAR DC RESISTANCE WELDING CONTROL E 16 990 371 APPENDIX E COMMUNICATIONS WELD STATUS CODES Wm satus message OO O O CONTROL SGNALSNPOT STATUS 3 emcewmrswmnsmmus ___ O O Oo 3 FHMNGSWICHBEORPFOUTSWOH stor ox conTROLSIGNAISINPUT rower TRANSISTOR OVERHEATED 6 EMERGENCY STOP OPERATORACTVATED 8 WELD TRANSFORMER OVERHEATED wswup OOOO e VOUAGESHECHONFLUGRMSSNG MBTCONOLSUNAISACIVATID m _ m NOCUMENTREADNG SSS NOVOHAGEREADNG OOOO
42. heat generation for resistive materials in a fusion weld In the first stage the heat 1s focused in the part to part and electrode to part contact areas since contact resistance 15 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 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 HF25 DC RESISTANCE WELDING SYSTEM G 6 990 371 APPENDIX G DEFINING THE OPTIMUM PROCESS Bonding temperature of materials different for solid state vs Fusion welds TEMPERATURE Weld Profiles The basic welding profile or schedule consists of a controlled application of energy and force over time Precision power supplies control the energy and time and therefore heating rate of the parts The weld head applies force from the start to finish of the welding process The figure on the right Welding Force shows a typical welding sequence where the force 1s applied to the parts a Squeeze time 15 initiated which al
43. hold_time hold time RINDEXI resistance index index value into PID resistance table for pulse 1 RINDEX2 resistance index index value into PID resistance table for pulse 2 EINDEXI energy index index value into PID energy table for pulse 1 EINDEX2 energy index index value into PID energy table for pulse 2 NOTES squeeze time and hold time are the parameter that defines the time for the given period in 1 msec Valid range is from 0 to 999 weld time is the parameter that defines the time for the given period Each count of weld _ time is equivalent to 0 01 for increments from 0 1 100 99 msec and increments of 0 1 msec for 1 0 to 9 9 msec and increments of 1 0 msec for 10 0 to 99 0 msec see table next page HF25 LINEAR DC RESISTANCE WELDING CONTROL 990 371 E 7 APPENDIX E COMMUNICATIONS Command Control State Description HOST CONTROL meemens Range TimeRange nerements _ weld_energy is the parameter that specifies the amount of weld energy In the current feedback mode weld energy 1s in unit of 0 001K A In the voltage feedback mode weld energy is in units of 0 001V In the power feedback mode weld energy is in units of 0 001kW volt multiplier is an index value for a table of resistance vs a PID multiplier for voltage mode Note Not used in versions where RINDEXx and EINDEXx are present resistance index is an index value into a table of resistance vs energy PID tables If 0 then a test pul
44. 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 HF25 DC RESISTANCE WELDING SYSTEM G 2 990 371 APPENDIX DEFINING THE OPTIMUM PROCESS Consider the Material Properties The important material properties to be considered in the resistance welding process are e Electrical and thermal conductivity e Melting point Plating and coating 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 6AI 4V OFF Scale Inconel Nichrome 800 Group TE 600 e i Resistivity Stainless Steels nano ohm 304 316 etc i Group 400 Group Br f Pt Ir 200 gt 500 1000 1500 2000 2500 3000 3500 Melting Point 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
45. lower limits for welds and vary the time periods for these limits during the weld pulse These limits can be used for several purposes Common uses for out of limits welds are to stop a weld or to trigger a relay to remove parts with bad welds from the production line These functions are accessed using the MONITOR buttons on the front panel To use these functions see Chapter 5 Operating Instructions MONITOR LIMITS TIME IONITOR 3 060V k V _ 000014 UPPER LIMIT gt ie RBS ANB atte pere RR c LOWER LIMIT 1 UPPER 3201V LOWER 7 100V one none none 4 TME SHORTEN LENGTHEN OR MOVE TIME VALUES MONITOR 3 060V 0 000 00000714 1 UPPER 3 201 z5 LOWER 2 100V nor _ LONER LEMITVALUES UPPER LIMIT roe ia LOWER LIMIT a UPPER 3 201V none 13 282 BOOK none none none PEAK and AVERAGE MONITORING The Control is always monitoring both the PEAK and AVERAGE of current voltage power and resistance at the same time When you press the PEAK lt gt AVERAGE key the top line in the LCD simply toggles back and forth so you can view either PEAK or AVERAGE values whenever you choose HF25 DC RESISTANCE WELDING SYSTEM 990 371 4 3 CHAPTER 4 INTRODUCTION TO FEEDBACK MODES AND MONITORING Current Voltage Power and Resistance Limits With the RUN screen selected you can select what you want to
46. open will immediately stop the weld cycle See Appendix B Electrical and Data Connections for circuit details 4 Setthe WELD NO WELD switch on the Control front panel to the NO WELD position In this position the Control cannot deliver weld energy but the firing switch connection can be verified 5 Setthe circuit breaker on the rear panel 2000001 of Control to ON position The default RUN screen will be displayed 1 You will use this screen to enter ZELDA 2 KA 501040 128 10 1810 welding parameters HF25 DC RESISTANCE WELDING SYSTEM 2 6 990 371 CHAPTER 2 INSTALLATION AND SETUP EZ AIR Weld Head Connections AC EZ AIR Weld Head Connection FORCE ADJUSTMEN KNOB m FORCE INDICATOR Set to 5 I EZ AIR AIR WELD HEAD _ 1 ELECTRODE HOLDER AIR DRIVER CABLE FIRING SWITCH CABLE FOOT SWITCH REAR PANEL il ua E EMERGENCY STOP SWITCH HF25 DC RESISTANCE WELDING SYSTEM 990 371 2 7 CHAPTER 2 INSTALLATION AND SETUP DC EZ AIR Weld Head Connection FORCE DJUSTMENT ____ FORCE INDICATOR Set to 5 7 SHOP AIR WELD HEAD 3 ELECTRODE HOLDER WELD HEAD CABLE REAR PANEL gt EMERGENCY STOP SWITCH 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 s
47. other schedule or back to itself as in the second example above The chain code becomes part of each weld schedule You can turn the Chain Schedules feature ON or OFF or re program chains any time you want From the MAIN MENU press the 9 key to go to the CHAIN SCHEDULES menu NOTE You should program or setup the chain of schedules you want before you turn this feature ON CHAIN SCHEDULES 1 CHAIN SCHEDULE 2 SETUP CHAIN SCHEDULES Number Select an item RUN or MENU 2 Pressthe 1 key to toggle CHAIN SCHEDULES ON or OFF 3 From the CHAIN SCHEDULES menu press the 2 key to go to the CHAIN SCHEDULE SETUP menu 4 Usethe AV Up Down keys on the front panel to scroll vertically through the schedules to highlight the weld count for the schedule you want to chain 5 Use the numeric keypad to enter the number of times you want this schedule to weld before going to the next schedule 6 Use the SCHEDULE key to move the highlight horizontally to select NEXT 7 Use the numeric keypad to enter the number of the next schedule in the chain 8 Use the SCHEDULE key to move the highlight horizontally back to the WELD COUNT column Repeat Steps 4 through 8 to program the rest of the chain CHAIN SCHEDULE SETUP SCHEDULE NUMBER WELD COUNT 01 0001 02 0001 0001 04 0001 Scroll SCHEDULE Select MENU CHAIN SCHEDULE SETUP SCHEDULE NUMBER WELD COUNT 4 0001 05 0001 06 0001 0001 Scroll SCHEDUL
48. surface plating Wrong electrode material tip shape Insufficient weld head force Excessive current energy set at HF25 Excessive weld time set at HF25 Contaminated electrode surface Slow weld head follow up Metal Expulsion Insufficient current energy set at HF25 Wrong electrode material tip shape Worn mushroomed electrodes Insufficient weld time set at HF25 Incorrect weld head polarity Contaminated weld piece surface plating 2 Excessive weld head force 3 Insufficient weld head force 3 Contaminated electrode surface 3 Incompatible weld piece projection design 3 Slow weld head follow up 4 Incompatible weld piece materials 4 Nocover gas on weld piece Excessive current energy set at HF25 Insufficient weld head force Slow weld head follow up 1 1 1 1 Incompatible weld piece projection design 1 1 2 2 Contaminated weld piece surface plating Wrong electrode tip shape Wrong electrode material Contaminated electrode surface Excessive weld time set at HF25 Excessive weld head force Incompatible weld piece projection design 2 2 Di pe o po dw De qo x Incompatible weld piece materials Wrong electrode tip shape Excessive current energy set at HF25 Excessive current energy set at HF25 Insufficient weld head force Slow weld head follow up Incompatible weld piece projection esign Contaminated weld piece surface plating Incompatible weld piece materia
49. that the first pulse 15 programmed as all Upslope for Resistance Set where it 1s programmed as all Weld Time Square Wave for Active Part Conditioning The Resistance Set pulse is programmed as all Upslope to keep both the Voltage and Current low at the beginning of the pulse 1 Press the SCHEDULE key then select a Weld Schedule using either the AV arrows or the numeric keypad 2 Program a single pulse for Constant Power operation but program the time in the Upslope portion of Pulse 1 Program the Weld Time and Downslope of Pulse 1 to 0 0 ms Program the power level and Upslope time to cause slight sticking between the two parts Make a few welds and pull them apart Increase or decrease the power setting until a light tack weld is achieved From the MONITOR keys section on the front panel press the voltage V key and observe gradual rise of the voltage waveform From the MONITOR keys section on the front panel press the resistance key and observe the resistance waveform This should appear to begin high then start to drop as a tack weld is made and the resistance decreases From the MONITOR keys section on the front panel press the kA current key and observe the current waveform starting to rise as the resistance decreases If the current waveform starts to flatten this 1s an indication that the resistance has stabilized and the parts have come into closer contact Push RUN and optimize the energy and time setting of Puls
50. the Operator Emergency Stop switch Turn off power to the HF25 then turn it on again Verity that the Voltage Sense Cable is properly connected to the electrodes or electrode holder NOTE Polarity is not important for the cable connection Reset the Upper Limit for Weldl to a larger value Increase the energy setting Check the weld head for an improperly adjusted firing switch Automation Only Check the timing on the PLC control lines to the Firing Switch and Foot Switch inputs HF25 DC RESISTANCE WELDING SYSTEM 990 371 CHAPTER 6 MAINTENANCE FIRING DIDN T The Firing Switch on a Miyachi Unitek Press RUN and readjust the air pressure to the CLOSE IN 10 air actuated weld head did not activate Miyachi Unitek air actuated weld head SECONDS within 10 seconds after the Foot Switch was initially activated ILLEGAL The wrong security code was entered to Press MENU select System Security then enter SECURITY CODE de activate the System Schedule or the correct access code to turn off System ENTERED Calibration Lock protection features Schedule or Calibration Lock protection features NOTE Entering a security code of 280 will always unlock the system INHIBIT CONTROL The Inhibit input control signal is Remove the Inhibit signal condition preventing SIGNALS activated preventing the HF25 from further HF25 operation ACTIVATED continuing to operate NOTE The correct removal action depends on NOTE Activatin
51. the Ship Kit Below 15 a Quick Look comparison showing the differences between the old and new I O connections See Appendix B Electrical and Data Connections for complete details NEW 25 27 NOTES HEAD 1 NOT ACTIVE NOT ACTIVE HDDTI NOT ACTIVE HDDT2 24VAC NOT ACTIVE Use pin 3 HEAD_ 1 switched on new unit 10 NOT ACTIVE 2 GN 24COM 13 NOT ACTIVE 14 NOT ACTIVE 15 COMMON OLD HF25 27 Chassis GND 24V COMMON HEADI HEAD2 HEAD3 Old EZ AIR no longer supported S 7 Same Same Use pin 20 21 24 OUT on new unit Use pin 1 50 or 60 on new unit Use pin 3 HEAD_1 switched on new unit 00000 pin 20 or 21 24V_OUT on new unit Use pin 1 50 or 60 on mew unit 16 FOOT 1 17 FOOT 2 I8 GND 24COM 19 FSU FS2 FIRE COM 20 24 OUT 21 24V_OUT 22 I O COMMON 23 24COM 24 SCHEDULE 25 SCHEDULE 1 26 SCHEDULE 2 27 SCHEDULE 4 28 SCHEDULE 29 SCHEDULE 16 30 SCHEDULE 32 HF25 DC RESISTANCE WELDING SYSTEM av 990 371 APPENDIX COMPABILITY AND COMPARISON OLD HF25 HF27 NEW 25 HF27 NOTES 31 Same 32 33 34 35 36 37 38 39 INHIBIT STOP RELAY 1 RELAY 1 RELAY 2 RELAY 2R RELAY 3 RELAY 3R RELAY 4 RELAY 4R Con Ret for EMO 24 for EMO NOT ACTIVE WELD INHIBIT CURRENT STOP RELAY 1 RELAY IR RELAY 2 RELAY 2R RELAY 3 RELAY 3R RELAY 4 RELAY 4R NOT ACTIVE
52. the current should be low about 10 of the Pulse 2 current Pulse 1 should be used as a measurement pulse and should not perform a weld O 4A7kA 0020031 2 9 368kA 8 020 O O 1 0 1 0 3 0 QOQ1ms Pre Weld Check Waveform Example To detect misaligned parts use constant current and set upper and lower voltage limits for Pulse 1 If parts are misaligned the work piece resistance will be higher so the voltage will be higher If parts are missing voltage will be lower In either case the Pulse 1 upper or lower limits will be exceeded and Pulse 1 can be inhibited NOTE You must have upslope programmed into the pulse in order to set a lower limit In addition to inhibiting the weld the Control has four programmable relay outputs which can be used to trigger alarms to signal operators of weld faults or signal automation equipment to perform pre programmed actions such as stopping the assembly line so the faulty weld piece can be removed HF25 DC RESISTANCE WELDING SYSTEM 990 371 4 7 CHAPTER 4 INTRODUCTION TO FEEDBACK MODES AND MONITORING 4 Weld To A Limit Applications e Parts with narrow weld window e Part to part positioning problems e Electrode to part positioning problems Function To stop the weld when a sufficient current voltage or power level is reached Using limits in this way ensures a more consistent input of energy which produces consistently good welds
53. to another schedule number From schedule number and to schedule number may be any number from 0 to 99 Copying a schedule to itself has no effect other than to invoke a schedule printout when PRINT SCHEDULES PROGRAMS is enabled SCHEDULE lt crlf gt lt lf gt Any state except while welding Requests the Control to return the currently selected schedule number SCHEDULE READ SET lt crlf gt parameter name value lt crlf gt lt RUN state Provides control over the Control schedule parameters When used with the READ keyword all parameters pertaining to the currently loaded schedule are returned see SCHEDULE under Control ORIGINATED COMMANDS When the SET keyword is used the host may set change the value of one or more of the parameters pertaining to the currently loaded schedule The following 15 a list of valid literal substitutions for the parameter name and value variables ENGI weld energy energy amount for pulse 1 FEEDBACK1 I KW feedback type for pulse 1 ENG2 weld energy energy amount for pulse 2 FEEDBACK2 KAIV KW feedback type for pulse 2 SQUEEZE squeeze time squeeze time UP1 weld time up slope time of pulse 1 WELDI weld time weld time of pulse 1 DOWNI weld time down slope time of pulse 1 COOL weld time cool time UP2 weld time up slope time of pulse 2 WELD2 weld time weld time of pulse 2 DOWN2 weld time down slope time of pulse 2 HOLD
54. to toggle the relay contact signal state ON closed or OFF open Press the 2 key to select the WHEN menu shown at the right Press the 2 key to select OUT OF LIMITS as the condition for initiating the Relay 1 output signal This will bring up the RELAY 1 menu screen where the WHEN line will now reflect OUT OF LIMITS Choosing WHEN options 1 4 or 9 will complete the relay programming process Choosing options 5 8 or 0 will bring up the RELAY 1 2 3 or 4 screen with a new option number 3 Press 3 to access the next level menus which are shown on the next page RELAY 1 gt 1 SET RELAY TO 2 WHEN Number Select Page RUN or MENU WHEN 6 PILOW 7 P2HIGH 8 P2LOW 9 MG3 SYNC ALARM OUT OF LIMITS WELD END OF WELD P1HIGH Number Select Page RUN or MENU RELAY 1 gt 1 SET RELAY TO N 2 WHEN OUT OF LIMITS Number Select Page RUN or MENU RELAY 1 gt 1 SET RELAY TO ON 2 WHEN OUT OF LIMITS Number Select A Page RUN or MENU 990 371 HF25 DC RESISTANCE WELDING SYSTEM 3 CHAPTER 3 SYSTEM CONFIGURATION 8 RESET TO DEFAULTS From the MAIN MENU press the 8 key to go to RESET TO DEFAULTS the RESET TO DEFAULTS menu as shown at the 1 RESET SYSTEM PARAMETERS right Through this menu you may reset all 2 RESET ALL SCHEDULES b 5 y 3 RESET SCHEDULE LIMITS system programmed parameters and all weld schedules to the original fact
55. 01 0 1 0 1 0 1 0 881 ms the fastest rise time minimum overshoot weld pulse The TEST state is automatically replaced by the run state for subsequent welds HF25 DC RESISTANCE WELDING SYSTEM 990 371 3 15 CHAPTER 3 SYSTEM CONFIGURATION Run State Pressing the RUN key puts the Control in the run state In the run state the screen shows a trace that represents your programmed parameters for 1 a given weld schedule You may select 2 5 0 2 ifferent weld schedule t ith different weld schedule to be programmed wi 150 18148 18 18 18190 the SCHEDULE key and keypad or with the up and down arrows Then you may program squeeze time up slope weld time weld energy down slope and cool time with the trace segment selector keys In the example on the right the top line of the RUN 4012V Peak 1 014V 9005237 screen shows that the Control is in the RUN state the voltage at the voltage sense lead connections p N A for the PULSE 1 weld period was 1 012 volts the 3 monitor 15 set for displaying peak voltage rather than average voltage the voltage at the voltage 220 1 0 2 0 1 0 05810 3 0 1 0 030 ms 1 connection for PULSE 2 weld period was 1 014 volts and the total weld count since the weld counter was last reset is 5 237 6 6560kk 060 00 The weld profile trace is an analog display of the electrical parameters programmed with the weld per
56. 1 closure to Weld Force start Maximum delay time 15 ms plus switch debounce time Switch debounce time can be set to none 10 20 or 30 ms with the SETUP 1 menu screen Soft touch time Delay time from Foot Switch Level 2 to Firing Switch closure Maximum D1 time 1s 10 seconds If the firing switch does not close within 10 seconds the message FIRING SWITCH DIDN T CLOSE IN 10 SECONDS will be displayed Delay time from Firing Switch closure and Foot Switch Level 2 closure to squeeze time SQZ Maximum D2 time is 2 ms plus switch debounce time Squeeze time Selectable range is 0 to 999 ms Note that for SQZ to start Foot Switch level 2 must be ON Soft touch time must be complete and the firing switch must be closed Up slope time Selectable range is 0 0 to 99 0 ms Weld time Selectable range is 0 0 to 99 0 ms Down slope time Selectable range 15 0 0 to 99 0 ms Cool time Selectable range is 0 0 to 99 0 ms Hold time Selectable range is 0 to 999 ms HF25 DC RESISTANCE WELDING SYSTEM 990 371 APPENDIX Communications Overview The Control has the ability to communicate with a host computer or with automation control system The communications option uses either RS 232 to connect one control to one host or RS 485 multi drop architecture to connect up to 30 controls to one host on a single channel The optional Miyachi Unitek Weld Stat software will allow you to connect a single or multiple Controls to a computer in order to
57. 27 Models 1 315 xx 1 320 xx The HF25DA features have been incorporated into the HF27 FEATURES OLD HF25A HF25DA HF27A NEW 25 HF27 LVDT connector HF25A NO HF25 NO HF25DA YES HF25D Not available HF27A YES HF27 SAME YES new 8 pin connector incorporating Firing switch voltage sense and 24VDC valve output for new plug and play weld heads used with new EZ AIR plug and play weld heads NO RS232 485 YE SAME Firing Switch cable YE SAME YE YE YE Weld Head connector 60 pin Phoenix connectors Physically smaller size Appendix B Electrical and Data Connections describes Software selection for polarity of input and mech opto type Force output range 10V to 10V to 5V 0 to 10V HF27 ONLY Force input range HF25DA and HF27 ONLY 0 to 5V 0 to 10V 10 to 10V HF27 ONLY 24VDC output for customer YES limited to about 500mA with YES polyfused to 1 amp without voltage drop use voltage drop Upgrade from HF25 to HF27 N A YES at factory Eliminated no longer necessary HF25 DC RESISTANCE WELDING SYSTEM 990 371 H 1 APPENDIX COMPABILITY AND COMPARISON I O Comparison While most of the improvements in the Controls are transparent to the user new technology and internal components have changed some of the 60 pin I O connections As a result they are not the same as older models To make these new connections quick and easy blank un wired connectors with screw terminals are provided in
58. 71 Press SCHEDULE key then select a Weld Schedule using either the arrows the numeric keypad Press the SQUEEZE key to enter the squeeze time before the weld Use the numeric keypad to enter the time or use the AV arrows Enter a time between 0 and 999 milliseconds Press the PULSE 1 UPSLOPE key to enter the amount of time for the Weld Pulse 1 upslope Use the numeric keypad to enter the time or use the AV arrows Enter 0 milliseconds Press the PULSE 1 WELD key to highlight the bottom line of the LCD to enter the weld time Use the numeric keypad to enter the time or use the AV arrows Enter a time between 0 and 99 milliseconds Press the PULSE 1 WELD key again to highlight the middle line of the LCD to enter weld energy Use the numeric keypad to enter the energy level or use the AV arrows The Control output ranges are Current from 0 1 2 4 kA e Voltage 0 2 gt 9 999 V Power 0 05 gt 9 999 kW Perform one of the following From the CONTROL keys section on the front panel press the kA key to program current as the feedback mode From the CONTROL keys section on the front panel press the V key to program voltage as the feedback mode From the CONTROL keys section on the front panel press the kW key to program power as the feedback mode Press the PULSE 1 DOWNSLOPE key to enter the amount of time for the Weld Pulse 1 downslope Use the numeric keypad or the AV arrows Enter 0 millisecon
59. ANCE WELDING SYSTEM 990 371 APPENDIX A TECHNICAL SPECIFICATIONS Input Signals NOTE Except where parenthetically noted below all input signals accept 5 to 24 VDC normally open or normally closed positive or negative logic Inputs are optically isolated Firing Switch Initiation 1 level foot switch 2 level foot switch or opto firing switch Remote Control Barrier Strip Remote weld schedule select process inhibit emergency stop RS232 Change weld schedules and individual weld parameters RS485 Change weld schedules and individual weld parameters Daisy chain RS485 input with RS485 output from other HF25 controls and host computer Voltage Weld voltage signal for voltage feedback operation 0 to 10 volt peak Weld Head Plug and play connector with Firing and Foot switch inputs Voltage Sense input and 24VDC Air Valve Driver output Output Signals Monitor Internal analog voltage signals representing secondary current feedback 0 5 VDC primary current 0 4 VDC or weld voltage 0 5 VDC Air Valve Driver 24 VAC 1 amp timing controlled by the HF25 No weld over force protection Alarm Relay Four programmable mechanical relays 24 VAC VDC at 1 amp RS232 Monitor weld parameter data Download and upload schedules RS485 Monitor weld parameter data Daisy chain RS485 input with RS485 output from other HF25 Controls and host computer Download and upload schedules 24V OUT 24 VDC power supply polyfused a
60. APPENDIX ELECTRICAL AND DATA CONNECTIONS Modification of I O Configuration The inputs of this unit are grouped into two major blocks which can be independently configured FOOT SWITCH FIRE SWITCH INPUTS commen inputs FS1 FS2 FIRE COM WELDNO WELD HF25 DC RESISTANCE WELDING SYSTEM B 8 990 371 APPENDIX ELECTRICAL AND DATA CONNECTIONS Configuration for Common Input Connections 24N OUT O 24V OUT IO COMMON I O COMMON 24 O 24COM 24VDC EXT SCHEDULE 04 SCHEDULE 0 SCHEDULE 1 1 SCHEDULE 1 Dry Contact Input Common Positive Input External Power 24V OUT O I O COMMON 4 24 O _ SCHEDULE 04 SCHEDULE 1 IS 24V OUT COMMON 24 24VDC EXT SCHEDULE 0 SCHEDULE 1 Common Positive Input Common Negative Input Internal Power External Power NOTE The preceding configuration methods can be used for both input blocks HF25 DC RESISTANCE WELDING SYSTEM 990 371 B 9 APPENDIX ELECTRICAL AND DATA CONNECTIONS Two Level Foot Switch Connector When you press the foot switch to the first level the Control energizes the air actuated weld head This causes the upper electrode to descend and apply force to the weld pieces If you release the foot switch before pressing it to the second level the Control will automatically return the upper electrode to its UP position so that you may re position the weld p
61. Connector Description Weld Head Connector The Weld Head Connector combines all the inputs and outputs necessary to connect a plug and play EZ AIR Miyachi Unitek weld head Using the supplied Configuration plug on Pins 11 20 allows the use of the Miyachi Unitek 2 level footswitch directly If PLC or other means of trigger 15 used refer to the Signal Interface General Description on page B 3 Weld Head Connector Description HEAD 1 switched 24 common 24V OUT 24VDC for solenoid 24COM FIRE 1 PIN 6 PIN 5 PIN 8 ns VOLT IN VOLT COM AIRHEAD PIN 2 Not used HF25 DC RESISTANCE WELDING SYSTEM APPENDIX 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 15 2 Pin Amphenol
62. DS 0000000 If you accidentally reset the wrong counter press the period key The original count will reappear Press the MENU key to return to the MAIN MENU screen NUMBER Change Restore Page MENU HF25 DC RESISTANCE WELDING SYSTEM 990 371 CHAPTER 3 SYSTEM CONFIGURATION 3 COPY A SCHEDULE The Control can store 99 numbered 1 through COPY SCHEDULE gt 99 individual weld energy profiles This function allows you to copy any weld schedule COPY SCHEDULE 1 TO SCHEDULE 2 from one numbered weld schedule to another numbered weld schedule 1 From MAIN MENU press the 3 key to Enter NUMBERS followed by SCHEDULE go to the COPY SCHEDULE screen 2 Using the numeric keys enter 1 in the COPY SCHEDULE source schedule number field COPY SCHEDULE 1 TO SCHEDULE 2 3 Press the key to select the destination schedule number field 4 Using the numeric keys enter 2 in the destination schedule number field Enter NUMBERS followed by SCHEDULE 5 Press the SCHEDULE key to copy the schedule and exit the screen 6 Press the MENU key to return to the main menu The contents of Weld Schedule 1 will be copied to Weld Schedule 2 overwriting the previous contents of Weld Schedule 2 Note that this function will copy schedule settings monitor limits and envelope offsets but it will not copy the reference waveforms for envelope limits 4 CALIBRATION From the MAIN MENU press the 4 key to go to l
63. E 1 WELD key to highlight the bottom line of the LCD to enter the weld time Use the numeric keypad to enter the time or use the AV arrows Enter a time between 0 and 99 milliseconds Press the PULSE 1 WELD key again to highlight the middle line of the LCD to enter weld energy Use the numeric keypad to enter the energy level or use the AV arrows The Control output ranges are e Current from 0 1 2 4 kA e Voltage 0 2 gt 9 999 V e Power 0 05 gt 9 999 kW Perform one of the following From the CONTROL keys section on the front panel press the kA key to program current as the feedback mode From the CONTROL keys section on the front panel press the V key to program voltage as the feedback mode From the CONTROL keys section on the front panel press the kW key to program power as the feedback mode 4 Press the PULSE 1 DOWNSLOPE key to enter the amount of time for the Weld Pulse 1 downslope Use the numeric keypad or the AV arrows to enter the time Enter a time between 0 and 99 milliseconds A good starting point is 5 milliseconds Note that in combo mode when the unit reaches a constant current any time programmed in this segment will be added to the weld at the constant current level HF25 DC RESISTANCE WELDING SYSTEM 5 5 CHAPTER 5 OPERATING INSTRUCTIONS 8 10 5 6 Press the COOL key to enter the amount of time for the cool period after Pulse 1 Use the numeric keypad to enter the time or use t
64. E Select MENU CHAIN SCHEDULE SETUP SCHEDULE NUMBER WELD COUNT 4 0001 05 0002 06 0001 0001 Scroll SCHEDULE Select MENU CHAIN SCHEDULE SETUP SCHEDULE NUMBER WELD COUNT 04 0001 05 0002 06 0001 0001 Scroll SCHEDULE Select MENU HF25 DC RESISTANCE WELDING SYSTEM 3 10 21 02 04 05 06 05 06 04 05 06 990 371 CHAPTER 3 SYSTEM CONFIGURATION 9 When you finish programming the chain press the MENU key to return to the CHAIN SCHEDULES menu 10 Press the 1 key to toggle between ON or OFF 11 Press the RUN key on the front panel then use the AV keys to select the first weld schedule in the chain you want to use The Control will now weld in the chain mode until you turn the Chain Schedules feature OFF NOTE When Chain Schedules is turned ON the LCD screen changes to show the chain information on the right side of the screen ERN cee CHAIN SCHEDULES Wd INDICATION NEXT In NEXT SCHEDULE NUMBER Eris T COUNT 2002 a 010 20 40 10 27 787 m3 W Below current schedule number you can see the number of times the current schedule will be repeated and the number of the next schedule in the chain Setup 1 1 Footswitch Weld Abort From the SETUP 1 screen press the 1 key to toggle between ON a
65. ELAY 1 shown at the right 1 SET RELAY TO 2 WHEN 3 Press the 1 key to toggle the relay contact signal state ON closed or OFF open Number Select A Page RUN or MENU 4 Pressthe 2 key to select the WHEN WHEN gt menu shown at the right ALARM 6 PILOW OUT OF LIMITS 7 P2HIGH WELD 8 P2LOW END OF WELD 9 MG3 SYNC P1HIGH Number Select Page RUN or MENU 5 Press the 2 key to select OUT OF LIMITS RELAY 1 gt as the condition for initiating the Relay 1 SET RELAY TO ON 1 output signal This will bring up the 2 WHEN OUT OF LIMITS RELAY 1 menu screen where the WHEN line will now reflect OUT OF LIMITS Number Select Page RUN or MENU 6 Choosing WHEN options 1 4 or 9 will RELAY 1 gt complete the relay programming 1 SET RELAY TO process Choosing options 5 8 or 0 2 WHEN OUT OF LIMITS will bring up the RELAY 1 2 3 or 4 screen with a new option number 3 Press 3 to access the next level menus which are shown on the next page Number Select A Page RUN or MENU HF25 DC RESISTANCE WELDING SYSTEM 990 371 5 23 6 Maintenance Section 1 Introduction General Kinds of Problems It has been our experience that most resistance welding power supply problems are caused by lack of material control process control and electrode tip surface maintenance The problems that you might encounter fall into two groups e Soft The problem is transient and you can correct it by resetting the sy
66. ER INPUT CABLE Rear Panel Components and Connectors NOTES The weld cable connections from the weld head are made at the weld cable terminals on the front panel The pre wired Configuration Plug above 15 colored red for clarity actual color may vary This plug allows the use of Miyachi Unitek standard foot switches and weld heads without further configuration The Control requires configuration of the I Os to accept inputs For normal use this plug must be connected to pins 11 through 20 on the 60 pin connector For other configurations see Appendix Electrical and Data Connections HF25 DC RESISTANCE WELDING SYSTEM 990 371 2 3 CHAPTER 2 INSTALLATION AND SETUP Weld Head Connections VOLTAGE SENSING CABLE Polarity Not Important REAR WELD HEAD WELD TERMINALS WELD CABLES Weld CAUTIONS Cable Washer 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 Connect one end of a weld cable to the negative welding transformer terminal on the Control 2 Connect one end of the second weld cable to the positive welding transformer terminal on the Control 3 Connect the other end of the weld cables to the weld head 4 Attach the voltage sensing cable connector to the VOLTAGE SENSE INPUT connector 5 Install e
67. O BB SYSTEM ERROR SPURIOUS INTERRUPT 87 TEST WELD MENU NO RUN YES _ m 9 oa m SCHEDULE schedule number lt gt lt gt Control State Any Description Returns the current schedule number to the host schedule number may be any number from 0 to 99 Command SCHEDULE schedule number lt crlf gt ENGI weld energy lt crlf gt HF25 LINEAR DC RESISTANCE WELDING CONTROL 990 371 E19 APPENDIX E COMMUNICATIONS Control State Description E 20 FEEDBACKI ENG2 FEEDBACK2 SQUEEZE UPI WELDI DOWNI COOL UP2 WELD2 DOWN2 HOLD RINDEXI RINDEX2 EINDEXI EINDEX2 gt KW lt crlf gt weld energy lt gt KW lt crlf gt squeeze time lt crlf gt weld time lt crlf gt weld time lt crlf gt weld time lt crlf gt weld time lt crlf gt weld time lt crlf gt weld time lt crlf gt weld time lt crlf gt hold time lt crlf gt resistance index crlf resistance index crlf energy index crlf energy index crlf Reports the settings of the currently loaded Control schedule parameters The schedule number variable identifies which schedule is currently loaded and may be any value from 0 to 99 squeeze time and hold time the parameter that defines the time for the given period in 1 msec Valid range is from 0 to 999 weld time is equivalent to 0 01 for Increments
68. OR screen provides instant visual feedback on the actual current voltage or L 2 power used to make each weld It permits you to program adjustable limits for both id pul UPPER 37 ka SISTI TA weld pulses LOWER none STOP P1 none STOP Monitor Screen HF25 DC RESISTANCE WELDING SYSTEM 1 2 990 371 CHAPTER 1 DESCRIPTION e Rear mounted RS 232 and RS 485 connectors allow for remote programming weld schedule selection and data logging for SPC purposes The Control has communication and data options that allow you to connect a single Control or multiple Controls to a printer or a computer in order to Compile store view and print weld history data for detailed analysis Remotely program weld schedules on the Control s Remotely program menu items on the Control s Appendix E Communications in this manual lists all of the commands that the Control will respond to and instructions on how to format commands sent to the Control so it will respond properly These commands have been implemented in the Miyachi Unitek Weld Stat program that provides PC based communication and control of the HF27 e The design of the Control is directed toward compactness lightweight operational simplicity and ease of repair Metric hardware is used throughout the chassis to facilitate international servicing and repair The 25 kHz operating frequency ensures that the integral welding transformer is light
69. P Applications include parts that WELD HEAD POSITION e Are plated with cadmium tin zinc or nickel e Have heavy oxide coatings such as aluminum Are round or not flat By programming the appropriate weld period time and weld energy amplitudes for the weld period segments you can program an appropriate weld schedule profile to perform the above applications Typical applications and recommended weld schedule profiles are defined in the table below For more information about resistance welding see Appendix F The Basics Of Resistance Welding and Appendix G Quality Resistance Welding Solutions Defining The Optimum Process Welding Applications Weld Function Typical Application Single Pulse Make single spot welds on simple flat parts without plating or on conductive parts such as those made of copper or brass Up Downslope Weld round parts parts that are not flat spring steel parts or heavily plated or oxidized parts such as aluminum Dual Pulse Use for best control of miniature and small parts spot welding with or without plating HF25 DC RESISTANCE WELDING SYSTEM 990 371 3 19 CHAPTER 3 SYSTEM CONFIGURATION Weld Head Applicability The weld functions can be used with Miyachi Unitek force fired manual weld heads air actuated weld heads or Series 300 Weld Heads SQUEEZE TIME is used to allow sufficient time for the electrodes to close and apply the required weld force to the parts before the weld current beg
70. RIGINATED COMMANDS section or go to either RUN state or PROGRAM State LOAD schedule_number lt crlf gt lt lf gt RUN state Selects the schedule number as the currently loaded schedule schedule number may be any number from 0 to 99 There must be a space between LOAD and schedule number COUNTERS READ TOTAL HIGH LOW GOOD lt crlf gt lt If gt Any Requests the Control to return the Control weld counter contents TOTAL Returns the total number of weld counter HIGH Returns the out of limits high counter LOW Returns the out of limits low counter GOOD Returns the within limits counter REPORT OLD ERASE number lt crlf gt lt lf Any Requests the Control to send the weld report OLD requests to send the number of oldest weld reports since the last data collection The reported weld data will be erased ERASE a request to erase the number of oldest welds number the number of weld data to be sent If the number 15 greater than the number of weld data 1 the buffer less than the number of weld data will be sent NOTE There must be at least one space between each of the three fields HF25 LINEAR DC RESISTANCE WELDING CONTROL 990 371 Control State Description Command Control State Description Command Control State Description APPENDIX E COMMUNICATIONS COPY from_schedule_number to_schedule_number lt crlf gt lt lf Any Allows one schedule to be copied
71. SISTANCE WELDING SYSTEM 990 371 3 1 CHAPTER 3 SYSTEM CONFIGURATION From the SETUP 1 screen press the key lt SETUP page 2 of 3 gt The SETUP 2 screen 1s shown on the right with BED LOUDMESS typical settings END OF CYCLE BUZZER OFF From the SETUP 2 screen press the V key SETUP page 3 of 3 gt The SETUP 3 screen is shown on the right with 1 DO TEST WELD typical settings 2 WELD COUNTER 3 2 UPDATE GRAPH AFTER WELD LANGUAGE ENGLISH Number Select an item AW Page RUN or MENU ALWAYS Number Select an item Page RUN or MENU From the MAIN MENU press the 2 key lt WELD COUNTERS to go to the WELD COUNTERS screen 1 TOTAL WELDS 0000000 The total welds counter increments each 2 OUT OF LIMITS HIGH 000000 3 OUT LIMITS LOW 000000 time a weld is made weld 4 WITHIN LIMITS 000000 schedule Number Select an item RUN or MENU NOTE The Control breaks down the weld count into three additional categories as determined by the energy limits monitor rejects due to higher than programmed weld energy rejects due to lower than programmed weld energy and the number of welds within limits To select the weld counters press the 1 2 3 or 4 key to select the desired weld counter The example below shows the TOTAL WELDS screen To reset the counter press the 0 key To input a preset number use the lt WELD COUNTERS numeric keys 1 TOTAL WEL
72. TING TOO SMALL FIRING SWITCH BEFORE FOOT SWITCH 6 4 Actual weld current is greater than the user set Upper Limit value for Weldl Actual weld current is greater than the user set Upper Limit value for Weld2 Actual weld current is less than the user set Lower Limit value for Weldl Actual weld current is less than the user set Lower Limit value for Weld2 The Operator Emergency Stop switch has been activated power to the HF25 is immediately terminated No electrode voltage measurement was made Actual weld current is greater than the user set Upper Limit value for Weldl While in the voltage or power feedback mode the HF25 could not control the energy setting because the required current was smaller than the minimum current specified The Firing Switch input has been activated before the Foot Switch has been activated preventing weld current from flowing Reset the Upper Limit for Weldl to a larger value Reset the Upper Limit for Weld2 to a larger value Weld splash can cause the actual weld current to drop below the user set Lower Limit for Weldl Add upslope to reduce weld splash Reset the lower Limit for Weld1 to a smaller value Weld splash can cause the actual weld current to drop below the user set Lower Limit for Weld2 Add upslope to reduce weld splash Reset the lower Limit for Weld2 to a smaller value Remove any unsafe operating conditions at the welding electrodes Reset
73. The bottom line of data is weld period time in milliseconds The second to bottom line 15 Weld Energy in the units selected by the energy units selection keys See Front Panel Data Entry and Mode Controls HF25 DC RESISTANCE WELDING SYSTEM 1 6 990 371 CHAPTER 1 DESCRIPTION Front Panel Data Entry and Mode Keys Key Pad The keypad consists of the numeric keys and the up down left right keys 3 Numeric Keys The numeric keys allow you to 4 E 6 e Enter or modify weld period time and energy values m o pu To use the numeric keypad you must first select a time energy weld period key or the schedule key Enter or modify monitor and limit values Directly recall a specific weld schedule Mode Keys The mode keys consist of the RUN key and the MENU key RUN Key Sets the Control to the operating mode Used to terminate program mode if already in the RUN screen EE MENU Key You access the menu screen with this key Menu items control MENU system parameters such as setup and weld counter operation Refer to Menus in Chapter 3 Section II for details of the functions accessible through that screen Control Keys HF25 DC RESISTANCE WELDING SYSTEM 990 371 1 7 CHAPTER 1 DESCRIPTION Control Mode Selection Keys These keys allow you to select the control mode when programming with the WELD time energy selector keys Monitor Keys Pressing the kA key selects current as the control mode fo
74. USER S MANUAL 990 371 O A DA Revision E November 2014 AMADA MIYACHI AMERICA INC HF25 25kHz HIGH FREQUENCY DC RESISTANCE WELDING SYSTEM MODEL NUMBER STOCK NUMBER HF25 240 1 315 01 HF25 400 1 315 01 01 HF25 480 1 315 01 02 Copyright 1998 2014 Amada Miyachi America The engineering designs drawings and data contained herein are the proprietary work of Amada Miyachi America and may not be reproduced copied exhibited or otherwise used without the written authorization of Amada Miyachi America Printed in the United States of America Revision Record 20411 03 05 None Original edition 21590 09 07 Weld Status Codes added to Appendix E Communications 34461 12 09 Updated technical information amp specifications 42840 10 13 Updated to new corporate name and logo 43480 11 14 Updated to Amada Miyachi America name and logo Important Note This manual describes HF25 Models 1 315 01 1 315 01 01 1 315 01 02 manufactured after June 2005 These contain significant differences than earlier models HF25 models 1 280 XX 03 1 280 XX 04 1 280 XX 05 1 285 01 1 285 01 01 1 285 01 02 manufactured before June 2005 require a different manual To get User s Manual 990 335 for older HF25 models order a copy using the phone number or e mail address listed under Contact Us on page viii of this section HF25 DC RESISTANCE WELDING SYSTEM 990 371 5 CO
75. and make several welds Observe that under normal conditions the welds are not aborted and that consistent strong welds can be produced HF25 DC RESISTANCE WELDING SYSTEM 990 371 5 17 11 12 CHAPTER 5 OPERATING INSTRUCTIONS Try making welds with only one part present Also try making welds with misaligned parts Observe that the power supply terminates the weld during the first pulse as soon as the voltage limits are reached If the voltage limits not being reached with these conditions present return to the voltage monitor screen and adjust the limits accordingly You may also have to adjust the Pulse 1 current from the RUN screen if needed to optimize the Pre Weld Check settings The Pre Weld Check function can now U 447 0020031 be used to detect misaligned or missing 2 parts before the Pulse 2 welding current is delivered to the parts 0 8 2 36 020 0 010 0010 00 0 0 001 ms Pre Weld Check Waveform HF25 DC RESISTANCE WELDING SYSTEM 5 18 990 371 CHAPTER 5 OPERATING INSTRUCTIONS Section VII Weld To A Limit NOTE The Weld to a Limit function is used to stop the weld when a specific current voltage or power level sufficient to produce good welds is reached Using limits in this way ensures a more consistent input of energy which produces consistently good welds for some applications The Weld to a Limit function should only be programmed after a wel
76. ber of bytes exchanged per weld times 8 bits per byte must in all cases remain less than the theoretical maximum capacity of the channel the baud rate selected on the unit This capacity is not an issue on RS 232 channels A good guideline is that on a line free of electrical noise the number calculated above must remain less that 70 of the theoretical maximum capacity Electrical noise on the communications lines will further reduce this capacity Shielded cables are recommended Several commands require the unit to be in HOST mode for the unit to accept them Those commands include the REPORT command and all SET commands See the MASTER CNTL command in Chapter 3 and the REMOTE command below for more information HF25 LINEAR DC RESISTANCE WELDING CONTROL 990 371 E 3 APPENDIX E COMMUNICATIONS Section ll Communications Protocol and Commands Command Format 0 KEYWORD parameters lt gt lt gt UNIT IDENTIFICATION ID ID is any number from 00 to 30 must be a two digit number COMMAND KEYWORDS BOLD VARIABLE italics REQUIRED PARAMETERS enclosed in braces one required and only one parameter allowed CHOICE OF PARAMETERS separated by vertical bar I indicates one OR another of choices presented REQUIRED OPTIONAL PARAMETERS enclosed in brackets one or more allowed used in the SET parameter zero allowed in the READ parameter RANGE OF PARAMETERS low_end high_end separated by h
77. ber of data that shall be included in this command The Control samples Voltage every 40 us For a weld less than 80 ms weld time the number of data will be approximately total weld time 40 us This number will always be less than 2000 data Aninteger number in unit of mV POWER number of data data lt crlf gt data data crlf 1f Any Returns the Power waveform data of the last weld First field is the number of data to be sent Then follows the packets of data Each data is separated by lt crlf gt and this command ends with lt crlf gt lt If number of data This 15 the number of data that shall be included in this Command The Control samples Current and Voltage every 40 us For a weld less than 80 ms weld time the number of data will be approximately total weld time 40 us This number will be always less than 2000 data Aninteger number in unit of W HF25 LINEAR DC RESISTANCE WELDING CONTROL 990 371 Control State Description Command Control State Description Command Control State Description 990 371 APPENDIX COMMUNICATIONS OHMS number of data lt crlf gt data gt data lt crlf gt data lt crif gt lt lf gt Any Returns the Resistance waveform data of the last weld First field is the number of data to be sent Then follows the packets of data Each data is separated by lt crlf gt and this command ends with lt crlf gt lt If gt
78. ce resistance changes This compensates for slight changes in part thickness without affecting weld quality Set monitoring limits on voltage Voltage Mode Application e Ideal for welding round or non flat parts Description This mode controls the voltage across the work piece during welding It helps to compensate for part misplacement and force problems and automatically reduces weld splash which 15 often associated with non flat parts and wire welds Set monitoring limits on current HF25 DC RESISTANCE WELDING SYSTEM 990 371 4 1 CHAPTER 4 INTRODUCTION TO FEEDBACK MODES AND MONITORING Power Mode Application e Breaking through surface oxides and plating e Automated applications where part or electrode surface conditions can vary over time Description This mode precisely varies the weld current and voltage to supply consistent weld energy to the parts The power mode has been shown to extend electrode life automated applications Set monitoring limits on current or voltage HF25 DC RESISTANCE WELDING SYSTEM 4 2 990 371 CHAPTER 4 INTRODUCTION TO FEEDBACK MODES AND MONITORING Section Weld Monitoring Introduction The Control s feedback sensors not only control weld energy output but they can also be used to monitor each weld The Control s MONITOR features allow you to view graphic representations of welds visually compare programmed welds to actual welds look at peak or average energy values set upper and
79. connector see Appendix B Electrical and Data Connections select weld energy schedules and initiate the weld energy sequence HF25 DC RESISTANCE WELDING SYSTEM 3 12 990 371 CHAPTER 3 SYSTEM CONFIGURATION Setup 2 1 Display Contrast 1 From the SETUP 2 screen press the 1 DISPLAY CONTRAST gt key to go to the DISPLAY CONTRAST DISPLAY CONTRAST 50 adjustment screen 2 Use the A and V keys to adjust the Saas screen contrast for comfortable viewing 0 10 20 30 40 50 60 70 80 in the shop environment AV Adjust Page RUN or MENU 3 Press the key to return to the SETUP PAGE 2 of 3 screen 2 Buzzer Loudness l From the SETUP 1 screen press the 2 lt BUZZER LOUDNESS gt key to go to the BUZZER LOUDNESS DISPLAY CONTRAST 50 96 adjustment screen 2 Usethe and V keys to adjust the buzzer tone so that it can be heard against shop background noise 0 10 20 30 40 50 60 70 80 90 AV Adjust A Page RUN or MENU 3 Press the key to return to the SETUP PAGE 2 of 3 screen 3 End Of Cycle Buzzer 1 With the SETUP 2 screen displayed press the 3 key to toggle the end of cycle buzzer ON or OFF This function is normally used with manually actuated weld heads ON means that an audible signal will be given at the end of each weld process to signal you to release the foot pedal 2 Toselect the ON OFF states toggle the 3 key The END OF CYCLE BUZZER line will now reflect your state selection 4
80. crlf gt Ift Any Provides control over the Control s system parameters When used with the READ keyword all system parameters are returned see SYSTEM under CONTROL ORIGINATED COMMANDS When used with the SET keyword the host may set change the value of one or more of the system parameters HF25 LINEAR DC RESISTANCE WELDING CONTROL 990 371 990 371 APPENDIX E COMMUNICATIONS The following is a list of valid literal substitutions for the parameter_name and value variables LIGHT light_value LCD contrast LOUDNESS loudness_value Buzzer Loudness BUZZER OFF ON end of cycle buzzer DISPLAY PEAK AVG Display mode SWSTATE switch_state Input Switch Type CTSTATE switch_state Control Signals Type FIRESW AUTO REMOTE NONE Firing Switch Type GRAPH OFF ON Update Graph WELDABORT OFF ON Footswitch weld abort DEBOUNCE NONE 10 20130 Switch debounce time in Msec These parameters pertain to the settings of the option menus available via the front panel user interface light_value is a number 0 to 100 for brightness of the LCD 0 is dark and 100 is the brightest loudness_value 15 a number to 100 for buzzer loudness 0 is off and 100 is the loudest switch_state MECHOPEN MECHCLOSED OPTOOPEN OPTOCLOSED PLCOV PLC24V HF25 LINEAR DC RESISTANCE WELDING CONTROL APPENDIX E COMMUNICATIONS Command Control State Description Command Control State Descrip
81. ction Menus Before You Start Configuration is simply a matter of selecting various MENU options so the Control will work with all the components of your welding system e Verify that all connections have been made according to the instructions in Chapter 2 Installation and Setup Turn the Control ON e Turn the shop air supply ON Overview You program the system settings of the Control MAIN MENU gt through the MAIN MENU screen and its sub SETUP 6 COMMUNICATIONS WELD COUNTERS 7 RELAY MDC ie MAIN COPY A SCHEDULE 8 RESET DEFAULTS pressing the MENU key on the front panel of the CALIBRATION 9 CHAIN SCHEDULES Control SYSTEM SECURITY of the menu screens have similar prompts that tell you how to go to a function on the menu and or get to the next menu Number Select an item e At the NUMBER Select an item prompt use the numeric keypad to select one of the functions on the menu e Press the down AV keys to go to the next or previous menu Each additional menu gives you choices for additional functions e Press the MENU key to return to the main menu Main Menu 1 SETUP From the MAIN MENU screen press 1 to go to the SETUP page 1 of 3 SETUP 1 screen 1 FOOTSWITCH WELD ABORT OFF 2 SWITCH DEBOUNCE TIME 10ms The SETUP 1 screen is shown on the right with 3 FIRING SWITCH AUTO typical settings Number Select an item V Page RUN or MENU HF25 DC RE
82. ding schedule which produces acceptable results has been developed The welding schedule includes the time and energy settings as well as the electrode force setting In the following steps a Constant Voltage weld is used as an example to show how the Weld to a Limit function is programmed 1 few Press the SCHEDULE key then select a Weld Schedule using either the AV arrows or the numeric keypad 2 Program a single pulse for Constant Voltage operation as required to make strong welds 3 From the MONITOR keys section on the front panel press the kA current V voltage power and resistance keys and observe the resulting waveforms NOTE You can toggle between PEAK and AVERAGE readings by pressing the PEAK AVERAGE key 4 A Press the kA current key and observe the current waveform If the current waveform J 1s still rising at the end of the pulse the Weld to a Limit function may work well for the application If the current waveform quickly rises and flattens out early in the pulse the Weld to a Limit function is not appropriate for the application Di Observe the peak current reading on the current monitor screen Make several more welds and observe the range of peak current readings from weld to weld 6 Press the Pulse 1 weld key to highlight the upper limit field for the weld period Use the numeric keypad to enter the upper limit value for the Pulse 1 weld period Program a current level that is the
83. dl to a smaller value Reduce the weld cable length or increase the diameter of the weld cables Reset the Lower Limit for Weld2 to a smaller value Verify the Voltage Selection Plug connection on the Weld Transformer HF25 DC RESISTANCE WELDING SYSTEM 6 7 CHAPTER 6 MAINTENANCE WELD STOP The user set Upper Limit value has been This 15 MONITOR LIMITS feature activated LIMIT REACHED exceeded and automatically terminated by the selecting the ENERGY key then the weld energy programming the Upper Limit values for Weldl and Weld2 If the terminated weld energy is not adequate for the weld re set the Upper Limit values for Weldl and Weld2 WELD SWITCH IN User has tried to activate the HF25 with Set the Weld No Weld switch to the Weld NO WELD the Weld No Weld Switch in the No position POSITION Weld Position No weld current will flow WELD TIME TOO The user has attempted to program zero Re program the welding parameters to be within SMALL for all upslope weld and downslope the capability of the HF25 time periods HF25 DC RESISTANCE WELDING SYSTEM 6 8 990 371 CHAPTER 6 MAINTENANCE Section Ill Maintenance Electrode Maintenance When a welding schedule has been suitable for a particular welding application over many welds but poor quality welds are now resulting electrode deterioration could be the problem If you need to increase welding current to maintain the same weld heat the electrode tip has p
84. ds Note that in combo mode when the unit reaches a constant current any time programmed in this segment will be added to the weld at the constant current level HF25 DC RESISTANCE WELDING SYSTEM 5 3 CHAPTER 5 OPERATING INSTRUCTIONS 8 Press the COOL key to enter the amount of time for the cool period after Pulse 1 Use the numeric keypad to enter the time or use the AV arrows Enter 0 5 milliseconds 9 Program Pulse 2 by repeating Steps 3 through 7 above using the keys for Pulse 2 entering the value O in each step 10 Press the HOLD key to enter the amount of time for the hold period after the weld Use the numeric keypad or the AV arrows Enter a time between 0 and 999 milliseconds We recommend at least 50 milliseconds as weld strength is formed in the hold time HF25 DC RESISTANCE WELDING SYSTEM 5 4 990 371 CHAPTER 5 OPERATING INSTRUCTIONS Upslope Downslope Weld Schedule l 990 371 Press SCHEDULE key then select a Weld Schedule using either the AV arrows the numeric keypad Press the SQUEEZE key to enter the squeeze time before the weld Use the numeric keypad to enter the time or use the AV arrows Enter a time between 0 and 999 milliseconds Press the PULSE 1 UPSLOPE key to enter the amount of time for the Weld Pulse 1 upslope Use the numeric keypad or the AV arrows to enter the time Enter a time between 0 and 99 milliseconds A good starting point is 5 milliseconds Press the PULS
85. e to provide an adequate tack weld and also a current waveform view in the monitor screen that has started to flatten out but is still rising This indicates that a full melt has not yet occurred From the MONITOR keys section on the front panel press the kA li 2 key to program an upper current limit on the MONITOR screen UPPER 37 ka 5 kA LOWER none STOP P1 none STOP NOTE You can toggle between PEAK and AVERAGE readings by pressing the PEAK AVERAGE key Press the COOL weld period PULSE 1 OUT OF LIMITS ACTION key This will bring up the 1 none PULSE 1 OUT OF LIMITS 2 STOP WELD ACTION screen 3 INHIBIT PULSE 2 4 PART CONDITIONER Stop Pulse1 9 Select 4 PART CONDITIONER Stop PULSE1 NUMBER Select Page RUN or MENU HF25 DC RESISTANCE WELDING SYSTEM 990 371 5 15 CHAPTER 5 OPERATING INSTRUCTIONS NOTE For more details on this process see Resistance Set in Chapter 4 Using Feedback Modes and Weld Monitoring 10 Since different levels of resistance require different amounts of time to reach the current limit return to the RUN screen and extend the programmed weld time usually double the time works This will ensure that there will be enough time for the current to rise and reach the limit even with wide variations in initial resistance 11 The power supply terminates the first pulse when your programmed current 1s reached A low resistance part will reach the current limit so
86. e Weld Monitor 5 9 VV OD 5 21 Weld 5 19 Operational States 3 18 8 6 9 PEAK amp AVERAGE MONITORING 4 3 Power 2 2 5 1 POWEE NOUE 4 2 Power Supply Variables G 7 Pre Operatiotial Checks 5 1 Pre Weld Check 4 7 5 17 Process P rspecli vo G 8 Process TOO S rererere reini ER UM 4 4 Process Variables G 7 Programmable Feedback Modes 4 1 Programming Relays 5 23 Q Quality Requirements sucus aciei ert dod eae dins G 7 Quality Resistance Welding Solutions Defining the Optimum Process G 1 Approach to Weld Development G 7 Material Variables G 7 Power Supply Variables G 7 Process Variabl s G 7 Quality Requirements G 7 Weld Head amp Mechanical Variables G 7 G 4 Common Problems G 9 Criteria for Success G 10 G 11 Factorial DOE G 11 Initial Welding Trials itte retentis G 8 Application Perspective G 8 Process Perspective G 8 Tao G 1
87. e heat generated during Pulse 1 The Pulse 2 weld period completes the structural weld The Pulse 2 weld current is typically greater than the Pulse 1 weld current by a factor of 3 as the first pulse significantly reduces the resistance of the interface between the parts The only use for the downslope period following the Pulse 1 or Pulse weld period is to control grain refinement in brittle parts by slowly reducing the weld current to zero during the downslope period The dual pulse weld profile is very valuable for pre checking gross parts positioning problems and reducing parts scrap Use the Pulse 1 weld at 0 050 kA or less and 2 0 ms as a pre check pulse Experiment with upper and lower limit values that you can use to inhibit the Pulse 2 weld if the test conditions measured by the Pulse 1 weld are out of limits NOTE Upslope is required when a lower limit value is programmed HF25 DC RESISTANCE WELDING SYSTEM 3 24 990 371 4 Introduction to Feedback Modes and Monitoring Section 1 Programmable Feedback Modes Introduction The feedback mode current voltage or power is one of the selections entered when programming a weld schedule Programming weld schedules 15 explained in Chapter 5 Operating Instructions Current Mode Application e Flat parts where the part to part and electrode to part contact is controlled and consistent Description This mode delivers the programmed current regardless of work pie
88. e wire 15 not connected no alarm will occur and the weld control will produce more than 20 ripple in the weld output waveform HF25 DC RESISTANCE WELDING SYSTEM 990 371 APPENDIX ELECTRICAL AND DATA CONNECTIONS Section ll Connectors Overview The control can be configured several different ways in order to match your welding needs Configuration 15 achieved by using the pre wired Configuration Plug and by fabricating your own I O cables using three un wired plugs of these connectors are supplied in the Ship Kit Complete connection information 15 in Section III I O Configuration Before fabricating I O cables you should be familiar with the physical characteristics of the Control s I O connectors The 60 pin I O connector 15 located on the Control s rear panel as shown on the right This connector can accommodate six 10 pin plugs including the factory supplied Configuration Plug Selected pins contain red inserts as shown below These inserts prevent properly configured 10 pin plugs from being plugged into the wrong sections of the 60 pin connector HF25 DC RESISTANCE WELDING SYSTEM B 2 990 371 APPENDIX ELECTRICAL AND DATA CONNECTIONS 10 Pin Connectors Three un wired blank 10 pin connectors are supplied in the Ship Kit These connectors are used for the configurations described in Section III I O Configuration These connectors easily snap apart and use screw terminal wire connection
89. echanical relays on the control board can be independently programmed to supply alarm or weld status contact signal outputs You can access the programming function through the main menu as described in Chapter 3 The events that you can program for each relay and their timing diagrams are as follows Relay contacts closed or open in the energized state Relays are energized when 1 Weld cycle starts 2 Weld cycle ends Time Relay Weld Cycle Energized Time 50 ms Relay Energized Relay will stay energized until 50 ms after weld cycle is complete 0 ms Relay will stay energized for 200 ms 3 Alarm state 15 detected 4 Weld is out of programmed limits Time Time Relay Alarm State Energized Is Cleared Relay Out of Limits Energized Alarm Is Cleared Relay will stay energized until alarm state is cleared Relay will stay energized until out of limits alarm is cleared HF25 DC RESISTANCE WELDING SYSTEM B 14 990 371 APPENDIX Calibration Section Calibrating the Control Overview The Control is calibrated by the software using inputs from a calibration setup during a weld process Following a few calibration inputs the Control will adjust itself and store the calibration values in RAM where they will be used as standards for the operational welding parameters CAUTION Only authorized personnel should perform this procedure Calibration Equipment Required The required equipment for the setup is as fol
90. eld2 to a smaller value POWER The power dissipated by the power Reduce duty cycle TRANSISTOR transistors has exceeded the HF25 Reduce weld time OVERHEATED specified capability PROCESS STOP ON The Process Stop signal on the Remove the Process Stop activating signal from CONTROL CONTROL SIGNALS connector has the CONTROL SIGNALS connector SIGNALS INPUT been activated immediately terminating weld current SAFE ENERGY The HF25 internal power dissipation has Reduce duty cycle LIMIT REACHED exceeded the HF25 specified capability Reduce weld time SCHEDULES ARE User programmed the HF25 to CAUTION Be careful when using the MENU RESET automatically reset all 100 weld default features There is no way to restore a schedules to their factory set default default action values HF25 DC RESISTANCE WELDING SYSTEM 6 6 990 371 CHAPTER 6 MAINTENANCE SYSTEM PARAMETERS ARE RESET SYSTEM amp SCHEDULE RESET TO DEFAULTS UPSLOPE REQUIRED FOR LOWER LIMIT VOLTAGE 1 GREATER THAN UPPER LIMIT VOLTAGE 2 GREATER THAN UPPER LIMIT VOLTAGE 1 LOWER THAN LOWER LIMIT VOLTAGE 2 LOWER THAN LOWER LIMIT VOLTAGE SELECTION PLUG IS MISSING 990 371 User programmed the 25 to automatically reset all I O and other system parameters to their factory set default values User programmed the HF25 to automatically reset all 100 weld schedules I O and other system parameters to their factory set default valu
91. es User has programmed a Lower Limit value for Weldl or Weld2 periods without using an upslope period The HF25 will automatically stop when activated because the starting weld energy will always be lower than the Lower Limit Actual weld voltage is greater than the user set Upper Limit value for Weldl Actual weld voltage is greater than the user set Upper Limit value for Weld2 Actual weld voltage current 15 less than the user set Lower Limit value for Weld Actual weld voltage current 15 less than the user set Lower Limit value for Weld2 The Voltage Selection Plug on the Weld Transformer is missing or improperly connected CAUTION Be careful when using the MENU default features There is no way to restore a default action CAUTION Be careful when using the MENU default features There is no way to restore a default action Delete the Weld1 or Weld2 Lower Limit value Add an upslope period before Weldl or Weld2 if a Lower Limit value 15 desired Weld splash can cause the actual weld voltage to exceed the user set Upper Limit for Weldl Add upslope to reduce weld splash Reset the Upper Limit for Weldl to a larger value Weld splash can cause the actual weld voltage to exceed the user set Upper Limit for Weld2 Add upslope to reduce weld splash Reset the Upper Limit for Weld2 to a larger value Reduce the weld cable length or increase the diameter of the weld cables Reset the Lower Limit for Wel
92. f experiments to gain the information A five factor screening DOE can be accomplished in as few as 24 welds with three welds completed for each of 8 tests By comparison it would take 96 welds to test every combination The DOE promotes understanding of many variables in a single experiment and allows the user to interpret results thus narrowing the variables for the next level of statistical analysis If many variables are still not understood multiple Screening DOE s may be required Amada Miyachi America provides a simple Screening DOE tool that is run in Exce and 1s sufficient for the majority of possible applications contact Amada Miyachi America for details Sophisticated software is also available from other vendors designed specifically for this purpose HF25 DC RESISTANCE WELDING SYSTEM G 10 990 371 APPENDIX DEFINING THE OPTIMUM PROCESS Criteria for Success Before running the series of experiments the user must establish an acceptable window for energy time and force thus preventing voided results It is common practice to include one or all of the above variables in a Screening DOE This 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
93. firing switch mode 15 selected under the Setup 1 menu Definitions DELAY SQZ UP WELD DOWN COOL HOLD 990 371 Firing Switch 7 cC 1 Welding Current DELAY saz WELD bown HOLD E nis t t puse 1 Delay time from Remote Schedule Select Signal to the start of the weld sequence that is start of SQZ DELAY time is 23 ms Squeeze time Selectable range is 0 to 999 ms Up slope time Selectable range is 0 0 to 99 0 ms Weld time Selectable range is 0 0 to 99 0 ms Down slope time Selectable range 15 0 0 to 99 0 ms Cool time Selectable range is 0 0 to 99 0 ms Hold time Selectable range is 0 to 999 ms HF25 DC RESISTANCE WELDING SYSTEM APPENDIX SYSTEM TIMING Basic Weld Operation Air Head System with Two Level Foot Switch Definitions 1 2 D1 D2 SQZ UP WELD DOWN COOL HOLD D 4 _ T1 24VAC 24 VDC FOOT SWITCH H WELD PRESSURE LEVEL1 gt 1 gt 1 14 SOFT TOUCH TIME WELD FORCE SOFT TOUCH PRESSURE FOOT SWITCH 4 LEVEL 2 SWITCH FIRING L WELDING CURRENT 01 02 squeeze uP wero pown cooL WELD powN HOLD t Pulse 1 _4 Pulse 2 NOTE The SOFT TOUCH PRESSURE feature is not available on HF25 Controls it is only available on HF27 Controls Delay time from Foot Switch Level
94. from 0 1 100 99 and increments of 0 1 msec for 1 0 to 9 9 msec and increments of 1 0 msec for 10 0 to 99 0 msec see table below HOST CONTROL weenens Penge TmeRage 0 01 1 0 0 01ms 0 1 0 99 0 1 0 99 ms 10 00 99 0 10 0 99 0 ms 1 ms HF25 LINEAR DC RESISTANCE WELDING CONTROL 990 371 APPENDIX E COMMUNICATIONS weld_energy 15 the parameter that specifies the amount of weld energy e Current Feedback mode the weld_energy range for the HF25 is from 10 to 2 400A 10 2400 e Voltage Feedback mode weld_energy for the HF25 15 in units of 0 001 V and the range 1s from 0 200 to 9 9V 200 to 9900 Note Maximum attainable voltage is dependent on the HF25 model and the load resistance e Power Feedback mode weld energy for the HF25 is in units of 1W and the range is from 10W to 9900W 10 to 9900 volt multiplier is the index value for a table of resistance vs a PID multiplier for voltage mode used for the last weld Note Not used in versions where RINDEXx and EINDEXx present resistance index 15 the index value into a table of resistance vs energy PID tables used for the last weld energy index 15 the index value into a PID energy vs PID values table used for the last weld Command MONITOR schedule number crlf MONTYPE1 KAIVIKWIR gt limit_value lt crlf gt LOWERI limit_value lt crlf gt ACTIONI none STOP INHIBIT APC lt crlf
95. furthest from the host must have the terminating resistor assembly installed RS 232 Serial Connector Information The serial port pin assignment 15 as follows 1 Not Used 6 DTR Data Terminal Ready 7 CTS Clear to Send 8 RTS Request to Send 2 TXD Transmit Data 3 RXD Receive Data 4 DSR Data Set Ready 9 RI Ring Indicator 5 SGND Signal Ground Host settings Baud Rate 1 2k 2 4k 4 8k 9 6k 14 4k 19 2k 28 8k 38 4k set on the unit Data bits 8 Stop bit 1 Parity None NOTES e The host must be set to the same baud rate as the unit The computer hardware and operating system needed to support communication depends upon the RS 485 adapter or converter box used e For a microprocessor based conversion such as the Edgeport USB converter from Inside Outside Networks the host computer should be at least a Pentium 233 running Windows 98 Windows ME Windows 2000 Windows XP or Windows NT 4 0 For a hardware based converter without an internal microprocessor such as the Telebyte model 285 the host computer should be at least a Pentium 550 running Windows 98 Windows ME Windows 2000 Windows XP or Windows NT 4 0 HF25 LINEAR DC RESISTANCE WELDING CONTROL E 2 990 371 APPENDIX E COMMUNICATIONS For RS 485 communication do not exceed the capacity of each channel The product of total number welds per second on all welders on that channel times total num
96. g reasonable bounds for the combination of parameters to be tested This will prevent void data and wasted time At this stage it 1s useful to record multiple relevant quality measurement or inspection criteria so that a balanced decision can be reached For example 1f 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 15 one that can run 1 a real production environment Welded assemblies should be tested over time and under real use conditions to ensure that all functional criteria will be met Validation testing is usually required to prove the robustness of the process under production conditions HF25 DC RESISTANCE WELDING SYSTEM 990 371 G 11 APPENDIX 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 statist
97. g the Inhibit input how the control signal I O logic was terminates only future operations It does programmed by the user NOT terminate any present HF25 operation INPUT TOO LARGE The user has attempted to program a Re program welding parameters to be within the weld energy or time that exceeds the capability of the HF25 capability of the HF25 INPUT TOO SMALL The user has attempted to program a Re program welding parameters to be within the weld energy or time that 1s below the capability of the HF25 capability of the HF25 LOAD The total electrical resistance comprised Reduce the total electrical resistance by reducing RESISTANCE TOO of the weld cables weld head and parts the weld cable length HIGH to be welded has exceeded the drive Reduce the total electrical resistance by capability of the HF25 increasing the weld cable diameter The HF25 will not be able to maintain Check cable and weld head connections the user set weld parameters Verify that all three phases from the input power lines are functioning LOW BATTERY The battery supplying backup power to Replace the memory battery on the Main Control the HF25 internal memory is out of PCB VISITE CAUTION Replace the battery while power is ON otherwise all memory contents will be lost LOWER LIMIT The user has tried to program a Lower Re program the invalid Lower Limit value GREATER THAN Limit value that is greater than the Upper UPPER LIMIT Limit value fo
98. gt MONTY PE2 KA I KWIR gt UPPER2 limit_value lt crlf gt LOWER2 limit_value lt ACTION2 STOP lt crlf gt PILDLY1 delay value crlf PILDLY2 delay value crlf PIUDLYI1 delay value crlf PIUDLY2 delay value crlf P2LDLY1 delay_value lt crlf gt P2LDLY2 delay value crlf P2UDLY1 delay_value lt crlf gt P2UDLY2 delay value crlf Control State Description Reports the settings of the weld monitor of the currently loaded Control schedule The schedule_number variable identifies which schedule is currently loaded and may be any value from 0 to 99 The possible value for all variables listed after their parameter name correspond to the values listed under MONITOR in Host Originated Commands of this manual HF25 LINEAR DC RESISTANCE WELDING CONTROL 990 371 F904 APPENDIX E COMMUNICATIONS Command Control State Description Command Control State Description E 22 RELAY lt crlf gt ACTIVE1 HIGH LOW CONDITIONI condition_value lt crlf gt SUBCONDI textended condition value gt ACTIVE2 HIGH LOW CONDITION2 condition value crlf SUBCOND2 textended condition value gt ACTIVE3 HIGH LOW lt crlf gt CONDITION3 condition value lt gt SUBCOND3 textended condition value gt ACTIVEA HIGH LOW lt crlf gt CONDITION4 condition_value lt crlf gt SUBCOND4 extended_conditi
99. he AV arrows Enter 0 5 milliseconds Program Pulse 2 by repeating Steps 3 through 7 above using the keys for Pulse 2 entering the value 0 in each step wy Press the HOLD key to enter the amount of time for the hold period after the weld Use the numeric keypad or the AV arrows Enter a time between 0 and 999 milliseconds We recommend at least 50 milliseconds as weld strength is formed in the hold time HF25 DC RESISTANCE WELDING SYSTEM 990 371 CHAPTER 5 OPERATING INSTRUCTIONS Dual Pulse Weld Schedule 1 Press the SCHEDULE key then select a Weld Schedule using either the AV arrows the numeric keypad 2 Press the SQUEEZE key to enter the squeeze time before the weld Use the numeric keypad to enter the time or use the AV arrows Enter a time between 0 and 999 milliseconds 3 Press the PULSE 1 UPSLOPE key to enter the amount of time for the Weld Pulse 1 upslope Use the numeric keypad to enter the time or use the AV arrows Enter a time between 0 and 99 milliseconds 4 Press the PULSE 1 WELD key to highlight the bottom line of the LCD to enter the weld time Use the numeric keypad to enter the time or use the AV arrows Enter a time between 0 and 99 milliseconds 5 Press the PULSE 1 WELD key again to highlight the middle line of the LCD to enter weld energy Use the numeric keypad to enter the energy level or use the AV arrows The Control output ranges are e Current from 0 1 2 4 e Voltage 0 2
100. he LOWER LIMIT closer to the peak of the actual waveform without crossing the weld waveform For some welds it may be very important to get up to the peak voltage or current to get the right melting and get there at the right time during the pulse Every millisecond could be very important HF25 DC RESISTANCE WELDING SYSTEM 990 371 95 CHAPTER 5 OPERATING INSTRUCTIONS I 5 10 EN Press the SCHEDULE key then select a Weld Schedule using either the AV arrows or the numeric keypad Fire the welder and view the output waveform shaded graph on the display key to view the desired waveform Note that the other monitor keys do not have graphical waveforms weld period Use the numeric keypad or the AV arrows to enter the upper limit value Toggle the Pulse 1 weld time energy selector key to select the upper limit field for the for the Pulse 1 weld period Perform one of the following to program the Pulse 1 monitor limit mode Press the kA key to program current as the limit mode Press the V key to program voltage as the limit mode Press the kW key to program power as the limit mode Press the key to program resistance as the limit mode Toggle the Pulse 1 weld time energy selector key to select the lower limit field for the weld period Enter the lower limit value for the Pulse 1 weld period NOTE In order for a Pulse 1 lower limit to be programmed you must first program a Pulse 1 upslope i
101. he next page Typical Weld Strength Profile 4 Repeat steps through 3 using a different but fixed weld time Typical Weld Strength Profile The picture on the right illustrates a typical weld strength profile The 14 Ib electrode force curve lade shows the highest pull strengths but the lowest tolerance to changes in weld current voltage i pii power The 12 Ib 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 2 a I a The 12 Ib electrode force curve is preferred It shows more tolerance to changes in weld current S 49 50 60 70 80 9D 100 voltage or power and has nearly the same bond Energy strength as the 14 Ib electrode force curve A comparison of weld schedules for several Typical Weld Strength Profile different applications might show that they could be consolidated into one or two weld schedules This would have obvious manufacturing advantages HF25 DC RESISTANCE WELDING SYSTEM F 6 990 371 APPENDIX Quality Resistance Welding Solutions Defining the Optimum Process Introduction A quality resistance welding solution both meets the application objectives and produces stable repeatable results in a production environment In defining the optimum process the user must approach the appl
102. he weld period Use the numeric keypad to enter the upper limit value for the Pulse 1 weld period Program an upper voltage limit that 15 slightly above the peak voltage readings observed in step 5 above 7 Press the voltage V key to save the setting as an upper voltage limit 8 Press the COOL weld period PULSE 1 OUT OF LIMITS ACTION key This will bring up the 1 none PULSE 1 OUT OF LIMITS E THIET BULGE 5 ACTION screen 4 PART CONDITIONER Stop Pulse 1 9 Select 2 STOP WELD NUMBER Select Page RUN or MENU 10 Toggle the Pulse 1 weld key to highlight the lower limit field for the Pulse 1 weld period Use the numeric keypad to enter a lower limit value with a voltage level that is slightly lower than the voltages observed in step 3 above HF25 DC RESISTANCE WELDING SYSTEM 990 371 5 21 CHAPTER 5 OPERATING INSTRUCTIONS 11 y Press the voltage V key to save the setting as a lower voltage limit 12 several more welds and verify that under normal circumstances the limits are not reached and the welds are not aborted If limits are reached under normal welding conditions adjust the levels and times of the upper and lower voltage limits accordingly 13 Return to the RUN screen and make several welds Observe that under normal conditions the welds are not aborted and that consistent strong welds can be produced 14 Try making welds with only one part present Also try making welds with misaligned part
103. hrough the oxide This rapid input of current is likely to cause splash especially with round parts Constant voltage mode 15 not ideal for this purpose either as the voltage will be restricted from reaching sufficient levels to break down the oxide Constant power is ideal for this purpose As the power supply tries to achieve constant power to the weld it raises the voltage to high levels early in the output waveform since current cannot flow due to the oxide As the high voltage breaks down the oxide layer more current flows to the weld and the voltage and resistance drop It will achieve this in a controlled fashion to maintain constant power to the weld POWER VOLTAGE CURRENT WAVEFORM WAVEFORM WAVEFORM Constant Power Waveform With Corresponding Voltage and Current Waveforms Active Part Conditioning uses a dual pulse output The first pulse is programmed for constant power and the second for either constant current constant voltage or constant power Constant voltage is used if there is still a chance of weld splash The purpose of a dual pulse operation is to enable the first pulse to target displacement of oxides and good fit up the second pulse achieves the weld HF25 DC RESISTANCE WELDING SYSTEM 990 371 4 5 CHAPTER 4 INTRODUCTION TO FEEDBACK MODES AND MONITORING 7 424 20000305 lt 9m0 2 000 150 0010 00 20 30 80 0 0 650 ms Active Part Conditioning Waveform The use
104. ical approach Time spent up front in weld development will ensure a stable welding process and provide a substantial return in quality and long term consistency Welding problems can more easily be identified and solved if sufficient experimental work is carried out to identify the impact of common variables on the quality and variation of the welded assembly Amada Miyachi America frequently uses the Screening DOE tool to establish the impact of key variables and to assist customers with troubleshooting Often the testing described above will provide the information and understanding to predict common failure modes and causes A troubleshooting guide can be requested in the form of a slide rule to assist users in identification of welding problems and likely causes HF25 DC RESISTANCE WELDING SYSTEM G 12 990 371 APPENDIX Compatibility and Comparison Compatibility While the HF25 contains advanced technology and improved features from an operational standpoint it performs the same as older Miyachi Unitek Controls Older HF25 models 1 280 03 1 280 04 1 280 XX 05 1 285 01 1 285 01 01 1 285 01 02 manufactured before June 2005 require a different manual For information on getting that manual use the phone number or e mail address listed under Contact Us in the front of this manual Below 15 a Quick Look comparison showing the differences between old HF25A HF25DA HF27A Models 1 280 xx 1 285 xx 1 287 xx and new HF25 HF
105. ication methodically and consider many variables In this article we will look at the following key stages and principles to be considered when defining the optimum resistance welding process e Materials and their properties e Basic resistance welding e principles e Weld profiles e Approach to development e Common problems e Use of screening DOE s e Use of factorial DOE s Resistance Welding A Material World The first consideration in designing a quality welding solution is the properties of the materials to be joined and the quality requirements of the desired welded joint At this stage it is worthwhile to review the way the resistance welding process works and the likely outcome when the parts are resistance welded There are four main types of structural materials e Metals silver steel platinum e Ceramic alumina sand 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 HF25 DC RESISTANCE WELDING SYSTEM 990 371 G 1 APPENDIX G DEFINING THE OPTIMUM PROCESS Alloys are a mixture of two or more metals An alloy is normally harder less conductive and more Alloy brittle than the parent metal which has bearing on the type of joint one can expect when resistance welding a combination of different metals gt Metals atoms are naturall
106. ieces If you do not release the foot switch at the first level and proceed to the second level the force firing switch in the weld head will close Weld current will flow and the Control will automatically return the upper electrode to its UP position Using the supplied Configuration plug on Pins 11 20 allows the use of the Miyachi Unitek 2 level footswitch directly If a PLC or other means of trigger 15 used refer to the Signal Interface General Description on page B 3 Foot Switch Connector Description Chassis Ground ES Foot 1 Connect to pin 4 to activate Foot 2 Connect to pin 4 to activate 24COM Standard Air Valve Driver Output Connector The air valve driver output 24V is initiated when Foot Switch Level 1 is initiated Using the supplied Configuration plug on Pins 11 20 allows the use of the Miyachi Unitek 2 level footswitch directly If a PLC or other means of trigger is used refer to the I O Signal Interface General Description on page B 3 The mating connector is an AMP type 206429 1 using cable clamp AMP type 206358 2 The two male pins used are Amp type 66361 2 Air Valve Driver 24 VAC Connector 24V AC for solenoid HEAD 1 Switched 24V common HF25 DC RESISTANCE WELDING SYSTEM B 10 990 371 APPENDIX ELECTRICAL AND DATA CONNECTIONS Voltage Sense Input Connector The voltage leads are connected to the electrode holders to sense weld voltage Voltage Sense Input
107. ins Weld current begins when the squeeze period ends When the weld functions are used with any type of air actuated weld head the hold period can be used to automatically keep the electrodes closed on the parts after weld current has terminated to provide additional heat sinking or parts cooling NOTES e Miyachi Unitek Series 300 Electronic Force Controlled Weld Heads The SQUEEZE TIME is controlled by the weld head not the Control SQUEEZE TIME begins when the force firing switch closes therefore you will set the Control SQUEEZE TIME to zero and set the DEBOUNCE TIME to zero Air Actuated Weld Heads For force fired air actuated weld heads SQUEEZE TIME begins when both levels of a two level foot switch are closed and the force firing switch in the air actuated weld head closes e Manual Weld Heads For manually actuated weld heads SQUEEZE TIME begins when the force firing switch closes Using SQUEEZE TIME is optional depending on the welding process you have developed When To Use Functions To ensure accurate consistent welds the Control delivers extremely precise pulses of energy to the weld head Each pulse is comprised of weld time and weld energy voltage current or power values pre programmed by the user The Control is a closed loop welding control using internal and external sensors to measure the weld energy delivered to the weld head Weld energy feedback instantly goes to the Control s logic circuits that activel
108. iod selector keys When the weld is initiated a profile of the actual weld energy delivered during the weld cycle or both weld cycles will be overlaid on the trace The large type number 1 is the selected weld schedule The values 0 050kA and 0 060kA below the trace are respectively the weld current values programmed for PULSE 1 and PULSE 2 weld periods You may optionally program weld energy in volts or kilowatts with the energy units selection keys Use the time energy selector keys to toggle between the weld energy value field and the bottom line of text which 15 the weld period time selection field Use the weld period selector keys to enable the weld periods for programming and use the numeric pad keys for entering time values in milliseconds See Chapter 5 Operating Instructions for application related descriptions of the weld schedule profile HF25 DC RESISTANCE WELDING SYSTEM 3 16 990 371 CHAPTER 3 SYSTEM CONFIGURATION Weld State Once weld current is flowing the Control is in the WELD state You can terminate weld current in five ways e Remove the first level of a single level foot switch assuming weld abort is ON e Remove the second level of a two level foot switch assuming weld abort is ON e Input the process stop signal refer to Appendix B Electrical and Data Connections e Open the normally closed switch across the operator emergency stop switch cable NOTE This action removes all power from the Control e Thr
109. ion This type of weld is achieved with a slower heating rate and normally longer time 15 preferred for welding resistive materials which can generate heat through their bulk resistance The contact resistances present at the weld when the power supply is fired have a great impact on the heat balance of a weld and therefore the heat affected zone HF25 DC RESISTANCE WELDING SYSTEM 990 371 G 5 APPENDIX DEFINING THE OPTIMUM PROCESS The figure below shows a weld that 1s fired The figure shows weld that 15 initiated when the early on in the weld sequence when the contact resistance 15 lower this example we are contact resistance 15 still quite high using bulk resistance to generate our weld heat n Resistan Contact Resistance Contact Resistance Resistance 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 heat generation in the weld Resistive materials benefit from slower heating rates which allow the contact resistances to reduce significantly Bulk resistances therefore become the major source for heat generation The heat affected zone is also much smaller in this case producing a weld with less variation The following figure shows the three stages of
110. ive Not Active Not Active Not Active Active Not Active Not Active Not Active Not Active Active CHASSIS GROUND 990 371 25 DC RESISTANCE WELDING SYSTEM 5 APPENDIX ELECTRICAL AND DATA CONNECTIONS Input Output Signals CHASSIS GROUND Chassis Ground 24COM NEGATIVE of internal 24 VDC power supply 3 HEAD 1 COMMON for air valve solenoid switched For 24VDC operation Connect other end of solenoid to 24 OUT For 24VAC operation Connect other end of solenoid to 24VAC oe wee n SCHEDULE 0 Binary Schedule input terminals used for schedule selection m m 2 EEC EN WELD INHIBIT INHIBIT Inhibits weld CURRENT STOP Interrupts weld current lt 100 us from current stop trigger to end of weld current with debounce set to 0 RELAY 1 Relay 1 output dry contact programmable RELAY IR Contact rating 24VDC AC 1 amp RELAY 2 Relay 2 output dry contact programmable HF25 DC RESISTANCE WELDING SYSTEM B 6 990 371 APPENDIX ELECTRICAL AND DATA CONNECTIONS RELAY 2R Contact rating 24VDC AC 1 amp RELAY 3 Relay 3 output dry contact programmable RELAY 3R Contact rating 24VDC AC 1 amp RELAY 4 Relay 4 output dry contact programmable 40 RELAY4R Contact rating 24VDC AC 1 amp we HF25 DC RESISTANCE WELDING SYSTEM 990 371 E
111. k SCHEDULE current 1 24VDC active or source current OVDC active A typical input section is shown on the right See Modification of I O Configuration on page B 6 i SCHEDULE 1 for both complete input sections Factory Configuration Plug FIRE 1 The factory default setting is OVDC active and 15 set by connecting the CONFIGURATION plug into I O connector labeled 11 through 20 The plug s WELD NO WELD internal wiring is shown on the right 24COM Not Active COMMON FOOT 1 FOOT 2 24COM FS1 FS2 FIRE COMMON 24V OUT a a RA N HF25 DC RESISTANCE WELDING SYSTEM B 4 990 371 APPENDIX ELECTRICAL AND DATA CONNECTIONS I O Signal Interface General Description m UNIT SIDE ol TME 1 AMP ali Gn USER SIDE mi CHASSIS GROUND HEAD 1 Active Not Active Not Active 24 Not Active Not Active Not Active FIRE 1 24C OM Not Active Not Active VO COMMON FOOT 1 FOOT 2 24COM 51 52 COM 24V OUT 24V OUT COMMON 24COM SCHEDULE 0 SCHEDULE 1 SCHEDULE 2 SCHEDULE 4 SCHEDULE 8 SCHEDULE 16 SCHEDULE 32 INHIBIT CURRENT STOP RELAY 1 RELAY 2 RELAY 3 RELAY 41 Mot Active Not Active Not Active Not Active Mot Active Not Active Not Active Not Active Not Active Not Act
112. key and observe the high peak of the voltage waveform From the MONITOR keys section on the front panel press the Q resistance key and observe the resistance waveform This should appear to begin high then start to drop as a tack weld is made and oxides are removed From the MONITOR keys section on the front panel press the kA current key and observe the current waveform starting to rise as the oxidization breaks down If the current waveform starts to flatten this 1s an indication that the resistance has stabilized and the parts have come into closer contact Push RUN and optimize the energy and time setting of Pulse 1 constant power to provide an adequate tack weld and also a current waveform view in the monitor screen that has started to flatten out but 1s still rising This indicates that a full melt has not yet occurred From the MONITOR keys section ile Due MM LETT ME o on the front panel press the kA Rue key to program an upper current limit on the MONITOR screen UPPER 50 LOWER STOP P1 STOP NOTE You can toggle between PEAK and AVERAGE readings by pressing the PEAK AVERAGE key Press the COOL weld period PULSE 1 OUT OF LIMITS ACTION key This will bring up the 1 none PULSE 1 OUT OF LIMITS 2 STOP WELD ACTION screen 3 INHIBIT PULSE 2 4 PART CONDITIONER Stop 5 1 9 Select 4 PART CONDITIONER Stop Pulse1
113. key welding variables energy force and time Several Screening DOE s may be required Results should be interpreted carefully Typically one would look for the highest result in terms of quality with the least variation A Screening DOE provides only a measurement that indicates the relative importance of a parameter and not the ideal setting Factorial DOE s should be used to establish the correct or best setting for a parameter once many of the other variables have been screened and fixed This 15 also the time to assess the measurement accuracy and consistency of the test method and procedure Variation in test method can invalidate the test and lead to misinterpretation of results What are Factorial DOE s The purpose of a Factorial DOE 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 factorial DOE may also give an indication as to how wide the acceptable weld window 1s 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 establishin
114. lect SCHEDULE CHANGE STATUS LOCK This will bring up the CHANGE STATUS screen as shown at the right PASSWORD 2 Entera 7 digit number from 0000001 to 9999999 in the code field and then NUMBERS for code followed by enter a period This will bring up the SYSTEM SECURITY menu screen this time with SCHEDULE LOCK ON With ON selected all other weld schedules are locked out and cannot be modified or used for welding 3 Tounlock the Control from security protection return to the CHANGE STATUS screen and enter the code that you entered in Step 2 This will bring up the SYSTEM SECURITY menu screen this time with SCHEDULE LOCK OFF 4 Ifyou forget the security code and wish to unlock the Control from security protection e Return to the CHANGE STATUS screen e Enter a security code of 280 HF25 DC RESISTANCE WELDING SYSTEM 3 4 990 371 CHAPTER 3 SYSTEM CONFIGURATION 6 COMMUNICATION The following menu screens tell you how to set the Control s communication and data options However to enable the Control to perform these functions you must install the software from the optional DC25 UB25 HF27 Datacom Communications Interface Kit commonly referred to as the Datacom kit or Weldstat in a host computer The Datacom Operator Manual describes cables connections RS 232 operation RS 485 operation sample weld reports data collection and how to use remote commands The Datacom Kit allows you to connect a single Control or
115. lectrodes in the weld head electrode holders NOTE If you need additional information about the weld heads please refer to their user s manuals HF25 DC RESISTANCE WELDING SYSTEM 2 4 990 371 CHAPTER 2 INSTALLATION AND SETUP 6 Connect the voltage sensing cable clips that are packed in the shipping kit to the voltage sensing cable leads Use either the or 1 8 diameter clip as appropriate to the electrode diameter VOLTAGE SENSING LEADS 7 Attach a clip directly to each electrode as shown on the right 8 Puta strain relieve on each voltage sensing lead to its corresponding electrode holder so that the lead clips will not break away under heavy operating conditions NOTE not attach the firing switch foot switch or EMERGENCY STOP cables at this time HF25 DC RESISTANCE WELDING SYSTEM 990 371 2 5 CHAPTER 2 INSTALLATION AND SETUP Foot Pedal Actuated Weld Head Connection REAR PANEL FORCE ADJUSTMENT KNOB FORCE INDICATOR Set to 5 WELD HEAD FIRING SWITCH CABLE ELECTRODE HOLDER 1 Adjust the weld head force adjustment knob to produce 5 units of force as displayed on the force indicator index 2 Connect the weld head firing switch cable connector to the Control firing switch cable connector 3 Connect a normally closed approved emergency stop switch across the two leads of the operator emergency stop switch cable This switch when operated
116. ll not be saved to memory Any welds done in this condition will use the older unedited values still stored 1 the memory HF25 DC RESISTANCE WELDING SYSTEM 990 371 5 11 CHAPTER 5 OPERATING INSTRUCTIONS 10 5 12 NOTE lower limits apply only to the Pulse 1 and Pulse 2 WELD periods Lower limits do not cover any upslope or downslope periods All upper limits apply to the entire Pulse 1 and Pulse 2 periods including their upslope and downslope periods Set an UPPER LIMIT and LOWER LIMIT using the procedures in Chapter 4 Using Feedback Modes and Weld Monitoring Perform a weld to see how the limits dotted lines appear compared to the weld graph R aise or lower the UPPER LIMIT and LOWER LIMIT as necessary using the procedures in Chapter 4 Using Feedback Modes and Weld Monitoring To lengthen or shorten the time periods go to the MONITOR screen Press the UPSLOPE key for PULSE 1 or PULSE 2 to get the MONITOR LIMITS screen NOTE INGNORE 1st deletes time PULSE 1 MONITOR LIMITS gt from the beginning of the limit IGNORE LOWER LIMIT IGNORE 1ST 0 0 5 LAST deletes time from the end of the LOWER LIMIT IGNORE LAST au UPPER LIMIT IGNORE 1ST 0 0ms limit This will not only shorten the UPPER LIMIT IGNORE LAST 0 0ms limit time but depending on the amount of time deleted on each end of the limit the limit will appear to move horizontally across the screen This allows you to fit the LOWER LIMIT preci
117. lows 2 weld cables No 2 0 1 ft 30 cm long PN 2 0 100010 coaxial shunt resistor accurate to 0 2 Source for shunt resistor Model R7500 8 T amp M Research Products Inc 139 Rhode Island Street NE Albuquerque NM 87108 Telephone 505 268 0316 e Shielded voltage sense cable PN 4 32998 01 e Digital oscilloscope Tektronix 724C or equivalent e Male BNC to dual binding post e 2 wire normally open switch for weld initiation mating connector PN 520 011 e Coaxial BNC to BNC cable HF25 DC RESISTANCE WELDING SYSTEM 990 371 C 1 APPENDIX CALIBRATION Calibration Procedure FIRING SWITCH 7 WELDING CABLES RG 58 COAXIAL OSCILLOSCOPE LEAD p COAXIAL SHUNT Initial Calibration Setup 1 Connect the calibration setup to the MAIN MENU gt Control as shown SETUP 6 COMMUNICATIONS WELD COUNTERS 7 RELAY 2 Turn the Control ON COPY A SCHEDULE 8 RESET DEFAULTS CALIBRATION 9 CHAIN SCHEDULES In the MAIN MENU press 4 to enter the SYSTEM SECURITY calibration screen Number Select an item 4 Press 1 for HF25 CALIBRATION which CAUTION will bring up the CAUTION screen on CALIBRATION SHOULD BE PERFORMED BY A 5 REFER TO MANUAL FOR CALIBRATION SETUP next MENU menu 5 Press 2 to calibrate the HF25 lt PRE CALIBRATION gt TEST HF25 T 232 REQUIRED CALIBRATE HF25 RESET CALIBRATION SET CURRENT SHUNT VALUE TEST SERIAL PORT Menu menu 6 P
118. lows the force to stabilize before the current Trigger Force 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 is 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 2 e 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 Miyachi Unitek slide rule tool HF25 DC RESISTANCE WELDING SYSTEM 990 371 G 7 APPENDIX DEFINING THE OPTIMUM PROCESS Approach to Weld Development The first stage in developing a quality welding process 15 to 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
119. ls Contaminated electrode surface Wrong electrode tip shape No cover gas on weld piece Excessive weld time set at HF25 HF25 DC RESISTANCE WELDING SYSTEM 990 371 CHAPTER 6 MAINTENANCE Cause in order of probability Cause in order of probability Weld Piece Over heating Weld Piece Excessive weld time set at HF25 Discoloration Excessive weld time set at HF25 Excessive current energy set at HF25 No cover gas on weld piece Insufficient weld head force Wrong electrode material tip shape 2 2 3 Incompatible weld piece materials 3 4 Contaminated electrode surface Alarm Messages Alarm Message ACCESS DENIED SYSTEM SECURITY ON ACCESS DENIED SCHEDULE LOCK ON CALIBRATION RESET TO DEFAULT CHECK CONTROL SIGNALS INPUT STATUS CHECK INPUT SWITCH STATUS CHECK VOLTAGE CABLE 990 371 Operator tried to change a weld schedule number individual weld schedule parameters I O switch functions and calibration parameters Operator tried to change a weld schedule or individual weld parameters User entered calibration values reset to factory default values One or more of the I O input control signals is preventing the HF25 from continuing to operate One or more of the Firing or Foot Switch input signals is preventing the HF25 from continuing to operate No electrode voltage measurement was made Excessive current energy set at HF25 Insufficient weld head force Conta
120. m Chromel 2 Cold Rolled Steel Dumet 1 NO Chromel Evanohm 14 Copper Chromel Gold 14 Gold Gold P Consil Kovar N Consil Hastalloy Titanium Consil Inconel Inconel NO Constantan Inconel Kulgrid Constantan Invar 2 Invar Constantan Iridium 2 Iridium Constantan Iridium 2 Platinum Constantan Iron 2 Iron NO Constantan Karma 2 Karma N Copper Karma Nickel Copper Karma 2 Platinum Kovar Gold Plate 2 Kovar Gold Plate Copper Kovar Gold Plate Copper 2 Kulgrid Kovar Gold Plate Copper 2 Nickel Kovar Gold Plate Copper Silver Kovar Gold Plate N Copper Stainless Steel m Const 2 Copper Magnesium Magnesium HF25 DC RESISTANCE WELDING SYSTEM 990 371 F 3 APPENDIX THE BASICS OF RESISTANCE WELDING ELECT MATERIAL RWMA MATERIAL MATERIAL MATERIAL TYPE Molybdenum 2 Tungsten 2 NiSpan C Cold Rolled 2 Steel Nichrome 2 Cold Rolled 2 Platinum Platinum 2 Steel Nickel 2 Cold Rolled 2 Silver 11 14 Cadmium 13 Steel Nickel 2 Stainless Steel 2 Cold Rolled 2 Cold Rolled 2 Steel Steel Nickel 2 Tantalum 2 Cold Rolled Stainless Steel 2 Steel Nickel 2 Tungsten 2 Cold Rolled Tantalum 2 Steel Nickel Alloy 2 Nickel Alloy Stainless Steel Stainless Steel Nickel Alloy 2 Beryllium 2 Tantalum Tantalum 2 Copper Nickel Alloy 2 Cold Rolled 2 Steel Electrode Maintenance Depending on use
121. minated weld piece surface plating Wrong electrode material tip shape Contaminated electrode surface Press MENU select System Security then enter the correct access code to turn off the System or Calibration Lock protection features NOTE Entering a security code of 280 will always unlock the system Press MENU select System Security then enter your access code to turn off System Security NOTE Entering a security code of 280 will always unlock the system Execute the built in calibration procedure to get the correct setting Remove the I O input control signal condition preventing further HF25 operation NOTE The correct removal action depends on how the control signal select in the Setup 1 menu was programmed by the user Remove the I O input control signal condition preventing further HF25 operation NOTE The correct removal action depends on how the INPUT SWITCH SELECT in the Setup 1 menu was programmed by the user Verity that the Voltage Sense Cable 15 properly connected to the electrodes or electrode holder NOTE Polarity is not important for the cable connection HF25 DC RESISTANCE WELDING SYSTEM 6 3 CHAPTER 6 MAINTENANCE CURRENT 1 GREATER THAN UPPER LIMIT CURRENT 2 GREATER THAN UPPER LIMIT CURRENT 1 LOWER THAN LOWER LIMIT CURRENT 2 LOWER THAN LOWER LIMIT EMERGENCY STOP OPERATOR ACTIVATED CHECK VOLTAGE CABLE CURRENT 1 GREATER THAN UPPER LIMIT ENERGY SET
122. mium Plating Aluminum 1 Tinned Brass Aluminum 1 Tinned Copper 1 Gold Plated Dumet Aluminum 1 Gold Plated Kovar Aluminum Aluminum 1 Kovar Aluminum 1 Magnesium 1 Cold Rolled Steel Aluminum Aluminum 1 Beryllium 2 Copper Beryllium Copper Copper NO Beryllium Copper Beryllium 2 Stainless Steel Copper Beryllium 2 Copper Tinned Copper E E 2 zi 1 A 14 14 2 2 D 2 E 2 14 14 E Beryllium 2 MATERIAL MATERIAL Beryllium Copper Beryllium i i i Cold Rolled Steel Stainless Steel J 2 Tinned Brass Consil Constantan Copper Nichrome Nickel NiSpan C Paliney 7 Silver 11 14 Stainless Steel Cold Rolled Steel Tinned Copper 2 2 14 2 2 14 Tinned Copper 14 2 2 2 2 2 2 2 14 2 HF25 DC RESISTANCE WELDING SYSTEM F 2 990 371 APPENDIX THE BASICS OF RESISTANCE WELDING MATERIAL MATERIAL MATERIAL 2 Steel 14 Paliney 7 2 MATERIAL Bronze Copper Silver 11 14 Bronze Copper 14 Cold Rolled 2 Steel Chromel N Copper 14 Stainless Steel Chromel N Dumet Dumet Chromel NO Dumet Nichrome Chromel Dumet 2 Nickel 2 N N N N N N N N N N N N N 4 4 N N N N N N Chromel Dumet Platinu
123. monitor by pressing the following MONITOR keys above kA current V voltage and kW power and resistance These monitors allow you to program upper and lower limits for PULSE 1 and for PULSE 2 These limits will display as dotted lines on the LCD screen Pushing either PULSE button will toggle between upper and lower limits PULSE 1 and for PULSE 2 can be programmed to monitor the same units or monitor separate units For example PULSE 1 can monitor kA and PULSE 2 can monitor V NOTE Whichever unit you select the upper and lower limits for a single pulse must be in the Same units such as kW Process Tools These tools are proven methods to use the monitor and limit functions described above in order to achieve specific results There are five commonly defined Process Tools 1 Active Part Conditioner APC Resistance Set Pre Weld Check Weld To A Limit Weld Stop eS 1 Active Part Conditioner APC Application e Displace surface oxides and contamination e Reduce contact resistances before delivering the main weld energy Description In the production environment it is common to see large variations in e Oxide and contamination e Plating thickness and consistency e Shape and fit up e Contact resistances due to varying part fit up In order for a weld to occur the surface oxides and contamination must be displaced to allow proper current flow through the parts Levels of oxide and contamination vary from part to
124. 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 HF25 DC RESISTANCE WELDING SYSTEM 990 371 F 5 APPENDIX 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 different weld forces then create a plot of part pull strength versus weld current voltage or power for different weld forces as shown in the illustration on t
125. multiple Controls to a printer or a computer in order to e Compile store view and print weld history data for detailed analysis e Remotely program weld schedules on the Control s e Remotely program menu items on the Control s Rear mounted RS 232 and RS 485 connectors allow for remote programming weld schedule selection and data logging for SPC purposes Data output provides the necessary process documentation for critical applications and permits data logging for SPC purposes Appendix E Communications in this manual lists all of the commands that the Control will respond to and instructions on how to format commands sent to the Control so it will respond properly The Control contains internal software that gives you a great deal of flexibility in the setup and use of your welding system The Control software displays various menu screens on the LCD each containing prompts telling you which of the Control s front panel controls to use in order to customize operating parameters set the Control for use in an automated welding system and program communication settings for use with data gathering devices such as a host computer 1 Communication Role 1 From the MAIN MENU press the 6 key COMMUNICATION to go to the COMMUNICATION menu COMMUNICATION ROLE SLAVE 5 a BAUD RATE 9600 shown with default settings 78 5 4 SELECT acm From the COMMUNICATION menu toggle 4 LD NUMBER r the 1 key to select MASTER or SLAVE
126. n the weld schedule The lower limit mode current voltage or power will automatically be the same as the upper limit mode programmed in Step 4 Press the COOL weld period key PULSE 1 OUT OF LIMITS ACTION This will bring up the PULSE 1 1 none 2 STOP WELD OUT OF LIMITS ACTION screen 3 INHIBIT PULSE 2 This screen allows you to select 4 PART CONDITIONER Stop Pulse1 the action that the Control will take if the Pulse 1 upper or lower limits are exceeded You have four choices NUMBER Select Page RUN or MENU e NONE takes no action if upper or lower energy limits are exceeded e STOP WELD stops the weld immediately during Pulse 1 and prevents Pulse 2 from firing if applicable e INHIBIT PULSE 2 stops the weld at the end of Pulse 1 and prevents Pulse 2 from firing This function will not operate if both pulses are joined without a cool time HF25 DC RESISTANCE WELDING SYSTEM 990 371 CHAPTER 5 OPERATING INSTRUCTIONS e PART CONDITIONER Stop PULSE1 stops Pulse 1 immediately after upper or lower energy limits are exceeded but allows Pulse 2 to fire This function will not operate if both pulses are joined without a cool time NOTE See Section IV Programming For Active Part Conditioning After making your selection the display will automatically return to the monitor screen 8 Program the upper and lower limits for Pulse 2 by repeating Steps 4 through 6 above using the keys for Pulse 2 entering appro
127. nd OFF This function controls how the Control interfaces with a foot switch a force firing switch or a programmable logic control PLC Any of these switches could be the weld initiation switch in your system setup ON means that the welding process 15 initiated by closure of the initiation switch and continues to its conclusion while the initiation switch remains closed If the initiation switch opens during the welding process the welding process will terminate The ON state 15 preferred for human operated welding stations since it allows you to abort the weld process by releasing the foot switch or the foot pedal in the case of a manually actuated weld head OFF is preferred for computer or PLC controlled welding stations since a single start pulse can be used to initiate the welding process To select the ON OFF states press the 1 key The FOOTSWITCH WELD ABORT line will now reflect your selection 2 Switch Debounce Time The contacts of single pole mechanical firing switches bounce when they close The switch de bounce time function allows you to specify that the initiation switch contacts must remain closed for 10 HF25 DC RESISTANCE WELDING SYSTEM 990 371 3 11 CHAPTER 3 SYSTEM CONFIGURATION 20 or 30 milliseconds before the weld period can be initiated thereby avoiding false starts caused by the switch contact bouncing 1 From the SETUP 1 screen press the 2 lt SWITCH DEBOUNCE TIME gt key to go to the SWITCH DE BOUNCE
128. number_of_data This is the number of data that shall be included in this Command The Control samples Current and Voltage every 40 us For a weld less than 80 ms weld time the number of data will be approximately total weld time 40 us This number will be always less than 2000 data An integer number in unit of mOhms SYNC lt crlf gt lt If gt Any The Control return SYNC command back to the host computer when the SYNC command is received from the host computer SYSTEM lt crlf gt LIGHT light_value lt gt BUZZER OFF ON lt crlf gt LOUDNESS loudness_value lt crlf gt DISPLAY PEAK AVG lt crlf gt SWSTATE switch state lt crlf gt CTSTATE switch_state lt crlf gt FIRESW AUTO REMOTE NONE lt crlf gt FIRESW AUTO NONE lt gt GRAPH OFF ON lt crlf gt WELDABORT OFF ON lt crlf gt DEBOUNCE NONE 10 20 30 crl lt Reports the current settings of the Control system parameters light_value is a number 0 to 99 for brightness of the LCD 0 is dark and 100 is the brightest loudness_value is a number 0 to 99 for buzzer loudness 0 15 off and 100 is the loudest switch state MECHOPEN MECHCLOSED OPTOOPEN OPTOCLOSED PLCOV PLC24V HF25 LINEAR DC RESISTANCE WELDING CONTROL E 15 APPENDIX E COMMUNICATIONS Command REPORT type of report number of reports lt crlf gt report crlf report lt crlf gt Control S
129. of a current limit monitor for the first pulse enables the pulse to be terminated when a predetermined amount of current flow is achieved The rise of the current waveform 15 proof positive that the oxide is breaking down and the parts are fitting up together ready to weld The first pulse therefore should be programmed to be much longer than generally required The power supply will terminate the pulse based on the reading of current in the power supply s monitor 2 Resistance Set Application e Reduce variations in Resistance prior to the weld e Reduce contact resistances before delivering the main weld energy Description Resistance Set is used when parts vary in initial resistance due to e Shape and part fit up e Very small parts Resistance Set is very similar to APC except that there are applications where you do not want a high voltage at the beginning of the pulse Instead you want to start both voltage and current low and build on an upslope This would be used primarily where resistance would vary from weld to weld coping with material contamination and variation due to part fit up problems It can be programmed to apply the exact power to the parts required to reduce the resistance to a consistent level for every weld Resistance Set uses a dual pulse output The first pulse is programmed for upslope power and the second for either constant current constant voltage or constant power Constant voltage is used if there 1s s
130. on_value gt lt condition_value ALARM I LIMITS WELD END P1HI PILOW P2HI P2LOW extended condition value P1HI PILOW P2HI P2LOW NOTES PILOW Pulse 1 low hi limit reached P2HI P2LOW Pulse 2 low hi limit reached Any Reports the relay settings SECURITY crlf SCHEDULE ON OFF lt crlf gt SYSTEM ON OFF lt crlif gt CALIBRATION ON OFF i crlf lt Any Returns the current status of the security settings HF25 LINEAR DC RESISTANCE WELDING CONTROL 990 371 APPENDIX F 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 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 the square of the weld current I times the workpiece resistance R times the
131. oner and the pulse will terminate early A highly resistive part will require more time before the resistance decreases and current can flow 12 Program your second welding pulse as O 373kA 424 0000305 2 normal to achieve a strong weld Constant voltage is recommended for round parts and constant current for flat parts An upslope may be required to 150 10 00 0 0 20308000 000 ms restrict the current flow early in the second pulse and avoid weld splash HF25 DC RESISTANCE WELDING SYSTEM 5 16 990 371 CHAPTER 5 OPERATING INSTRUCTIONS Section Vl Pre Weld Check Note The Pre Weld Check function is used to detect misaligned or missing parts before the weld is performed Therefore the Pre Weld Check function should only be programmed after the welding schedule has been developed The welding schedule includes the time and energy settings as well as the electrode force required to produce strong consistent welds 1 EE Press the SCHEDULE key then select a Weld Schedule using either the AV arrows or the numeric keypad 3 Program the second pulse as required to produce strong consistent welds Then program the first pulse for Constant Current operation Program the first pulse current level to approximately 10 of the second pulse current Program the first pulse upslope time to 1 ms and first pulse weld time to 2 ms Program 2 ms of cool time between the pulses Make a few welds and verify that the welds a
132. ord the relay settings of the currently loaded schedule are returned see RELAY under Control ORIGINATED COMMANDS When the SET keyword is used the host may set change the value of one or more of the relay settings of the currently loaded schedule The following is a list of valid literal substitutions for the parameter name and value variables ACTIVEI HIGH LOW Relay 1 Active High or Active Low CONDITIONI condition_value Relay 1 Active Conditions SUBCONDI extended condition value Relay 1 Extended Conditions ACTIVE2 HIGH LOW Relay 2 Active High or Active Low CONDITION2 condition value Relay 2 Active Conditions HF25 LINEAR DC RESISTANCE WELDING CONTROL 990 371 APPENDIX E COMMUNICATIONS Command Control State Description E 10 SUBCOND2 extended condition value Relay 2 Extended Conditions ACTIVE3 HIGH LOW Relay 3 Active High or Active Low CONDITION3 condition value Relay 3 Active Conditions SUBCOND3 extended condition value Relay 3 Extended Conditions ACTIVE4 HIGH LOW Relay 4 Active High or Active Low CONDITION4 condition_value Relay 4 Active Conditions SUBCOND4 extended condition value Relay 4 Extended Conditions condition value ALARM I LIMITS WELD END P1HI PILOW P2HI P2LOW MG3 NOTE extended condition value NOTES P1ILOW Pulse 1 hi low limit reached P2HI P2LOW Pulse 2 hi low limit reached SYSTEM READ SET lt crlf gt parameter name value lt
133. ory default settings see the table below Number Select item RUN or MENU Factory Default System Parameters Buzzer Loudness ON WHEN ALARM End of Cycle Buzzer OFF Update Graph After ON Weld 1 RESET SYSTEM PARAMETERS 1 With the reset to defaults screen RESET SYSTEM PARAMETERS gt displayed press the 1 key This will bring up the RESET SYSTEM PARAMETERS query menu as shown at the right Number Select A Page RUN or MENU 2 Press the 2 key to select YES This will automatically reset the system to the factory and return the screen to the RESET TO DEFAULTS display HF25 DC RESISTANCE WELDING SYSTEM 3 8 990 371 CHAPTER 3 SYSTEM CONFIGURATION 2 RESET ALL SCHEDULES 1 Press 2 key This will lt RESET ALL SCHEDULES gt automatically reset all weld schedule parameters to the factory defaults and return the screen to the RESET TO DEFAULTS display 2 Press the MENU key to return to the Number Select A Page RUN or MENU MAIN MENU screen 3 RESET SCHEDULE LIMITS 1 last SCHEDULE you used will lt SCHEDULE LIMITS appear as highlighted You may SCHEDULE 01 change this to SCHEDULE number you want to reset using the numeric keypad PUSH TO RESET THIS SCHEDULE S LIMIT VALUES 2 Press the V key to reset the limits of the schedule you highlighted Number Select an item AW Page RUN or MENU 3 Press the MENU key to return to the MAIN MENU sc
134. ough the action of the monitor settings Completion of the firing state 15 indicated by a profile of actual delivered weld energy superimposed on the programmed weld energy trace as shown in the example above Monitor State From the MONITOR keys section on the front MONITOR 373kKA 424kA 0000315 panel press the V KW Q key to goto the CIE T monitor state In this state when the Control detects an out of limits condition it will take one of four actions for PULSE 1 and one of two STOP P1 STOP actions for PULSE 2 depending on the selection made with the MONITOR display as shown at the right Also an alarm message will be displayed and any relay set for ALARM or OUT OF LIMITS will be energized The selections for PULSE 1 are The weld cycle will continue e STOP WELD The weld cycle will stop immediately Pulse 2 1f applicable will not fire e INHIBIT PULSE 2 During the COOL time the Control calculates the average of the Weldl pulse including upslope weld and downslope If the average of the Weldl pulse is out of limits the weld cycle will stop and the Weld2 pulse will be inhibited e PART CONDITIONER Stop Pulse 1 stops Pulse 1 immediately after upper or lower energy limits are exceeded but allows Pulse 2 to fire The selections for PULSE 2 are e NONE The weld cycle will continue e STOP WELD The weld cycle will stop immediately The di
135. output of the shunt resistor to the VOLTAGE SENSE INPUT connector using the male BNC to binding post adapter and voltage sense cable Follow the screen instructions for this step and the next step 4 CALIBRATION LOW FIRING SWITCH 7 REAR PANEL VOLTAGE SENSING CABLE WELDING CABLES BNC TO POST ADAPTER m Final Calibration Setup 11 The last calibration screen is 5 END OF CALIBRATION Press the MENU key HF25 calibration is now complete COAXIAL SHUNT HF25 DC RESISTANCE WELDING SYSTEM 990 371 C 3 APPENDIX D System Timing Basic Weld Operation Air Head System with Two Level Foot Switch Definitions 11 D1 D2 SQZ UP WELD DOWN COOL HOLD 990 371 T1 24VAC 24 VDC FOOT SWITCH Pr LEVEL 1 SOFT TOUCH PRESSURE WELD FORCE at FOOT SWITCH H lo LEVEL 2 SWITCH FIRING __ LL WELDING i CURRENT D1 D2 squeeze UP pown cooL WELD powN HOLD Pulse 1 4 _ Pulse 2 NOTE The SOFT TOUCH PRESSURE feature is not available on 25 Controls it is only available on HF27 Controls Delay time from Foot Switch Level closure to Weld Force start Maximum delay time is ms plus switch debounce time Switch debounce time can be set to none 10 20 or 30 ms with the SETUP 1 menu screen Delay time from Weld Force start to Firing Switch closure Maximum D1 time 15 10 seconds If the firing switch does not clo
136. ower monitor This screen shows the results of the most recent weld This screen also allows the operator to set limits that automatically interrupt the weld when they are reached You can also program the power monitor to output an alarm when the limits are exceeded 1 8 HF25 DC RESISTANCE WELDING SYSTEM 990 371 CHAPTER 1 DESCRIPTION Pressing the key displays the resistance monitor This screen shows the results of the most recent weld The Control is always monitoring both the PEAK and AVERAGE of current voltage power and resistance When you press this key the top line in the LCD screen toggles back and forth between displaying PEAK and AVERAGE WELD NO WELD Switch When the switch is in the WELD position the programmed weld sequence can initiate weld energy When you set this switch to the NO WELD position no weld current can flow However the Control can execute a complete weld sequence This function is required to adjust the weld head prior to operation NO WELD Emergency Stop Switch Operation If your work station 1s equipped with an emergency stop switch connected to the emergency stop connection of the Control operate the switch to immediately stop the welding process power to the air valves and power circuits will be disconnected To restart the Control you must press the RUN key on the front panel HF25 DC RESISTANCE WELDING SYSTEM 990 371 1 9 2 Installation and Setup
137. part over time which can have an adverse effect on the consistency of the welding process HF25 DC RESISTANCE WELDING SYSTEM 4 4 990 371 CHAPTER 4 INTRODUCTION TO FEEDBACK MODES AND MONITORING If production parts are plated there can also be a plating process variation over time resulting in inconsistent welds These minor material variations a major cause of process instability and it 15 best welding practice to seek to minimize their effect Active Part Conditioner is designed to cope with material contamination variation and can be programmed to apply the exact power to the parts required to displace oxide or contaminants In addition the Part Conditioner pulse will terminate at a precise current flow preventing the sudden high flow which occurs when the oxide is displaced This prevents weld splash and material expulsion which occurs as a result of an excessively fast heating rate Part conditioning can help to reduce variations in contact resistance from part to part caused by different fit up of parts It will stabilize the contact resistances before the main welding pulse therefore reducing variation from weld to weld How It Works Both constant current feedback and constant voltage feedback modes are limited in their ability to deal with varying levels of part contamination and oxide If constant current feedback were used the power supply would ramp the voltage to very high levels in order to achieve current flow t
138. 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 HF25 DC RESISTANCE WELDING SYSTEM F 4 990 371 APPENDIX 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 problem If either of the parts 15 a wire the diameter of the electrode face should be equal to or greater than the diameter of the wire If both parts are flat the face should be at least one half the diameter of the electrodes Pencil point electrodes cause severe electrode sticking to the parts unexplained explosions and increa
139. pitting or reduce thermal shock when welding parts containing glass to metal seals Downslope annealing assists in the grain refinement of certain heat treatable steels and prevents cracking in aluminum and other materials by reducing the cooling rate Annealing is not typically used for welding small parts Upslope Downslope Weld Profile Dual Pulse Weld Profile Applications e Flat to flat parts e Round to round parts e Round to flat small parts that may or may not be plated Description Adding upslope to the front of both weld periods allows a reduction in electrode force this results in a cleaner appearance by reducing electrode indentation material pickup and electrode deformation HF25 DC RESISTANCE WELDING SYSTEM 990 371 3 23 CHAPTER 3 SYSTEM CONFIGURATION DOWN MES store SLOPE SL ym SLOPE WE RUN STAT TIME 0 99 mseg 0 99 msec STATE 0 99 maec E Nt lt MAXIMUM OFF IN UP POSITION HL DOWN L WELD t WELD EE PULSE _ PULSE 2 Upslope will also help to displace plating and or oxides reduce flashing and spitting or reduce thermal shock when welding parts containing glass to metal seals In the normal application of dual pulse the Pulse 1 weld period provides sufficient heat to displace the plating or oxides seat the electrodes against the base metals and force the parts into intimate contact The cool period allows time to dissipate th
140. priate values for Pulse 2 NOTES e The monitor limit mode current voltage power or resistance for Pulse 2 can be different than the monitor limit mode for Pulse 1 e To fine tune the monitor limits to very precise values see Chapter 4 Introduction to Feedback Modes and Monitoring 9 a Press the HOLD period key PULSE 2 OUT OF LIMITS ACTION This will bring up the PULSE 2 EE OUT OF LIMITS ACTION screen 2 STOP WELD This screen allows you to select the action that the Control will take if the Pulse 2 upper or lower limits are exceeded You have two choices NUMBER Select A Page RUN or MENU NONE takes no action if upper or lower energy limits are exceeded STOP WELD stops PULSE 2 immediately after upper or lower energy limits are exceeded 10 After you have made your selection the MONITOR 1 232V display will automatically return to the e MONITOR screen NOTE The Control adds dotted lines UPPER 1 4001 EN programmed limits The screen on the right shows how the UPPER LOWER UPPER and LOWER Limits and Alarm actions appear when Limits FOR PULSE 1 Limits FOR PULSE 2 an actual weld trace is displayed on the Alarm Action Alarm Action LCD for PULSE 1 for PULSE 2 11 After entering or changing monitor limits you must press either the appropriate MONITOR or RUN buttons to save the changes If this is not done the last input field will remain highlighted and the changes wi
141. r Weldl or Weld2 time periods HF25 DC RESISTANCE WELDING SYSTEM 990 371 6 5 CHAPTER 6 MAINTENANCE NO WELD Cable connecting the Control and Power Verify installation of the welding TRANSFORMER PCB s 15 open transformer rectifier module connections DETECTED Cable connecting the Power PCB to the Weld Transformer is open POWER 1 Actual weld power is greater than the Weld splash can cause the actual weld power to GREATER THAN user set Upper Limit value for Weldl exceed the user set Upper Limit for Weldl Add UPPER LIMIT upslope to reduce weld splash Reset the Upper Limit for Weldl to a larger value POWER 2 Actual weld power is greater than the Weld splash can cause the actual weld power to GREATER THAN user set Upper Limit value for Weld2 exceed the user set Upper Limit for Weld2 Add UPPER LIMIT upslope to reduce weld splash Reset the Upper Limit for Weld2 to a larger value POWER 1 LOWER Actual weld power 15 less than the user Weld splash can cause the actual weld power to THAN LOWER set Lower Limit value for Weldl drop below the user set Lower Limit for Weldl LIMIT Add upslope to reduce weld splash Reset the Lower Limit for Weldl to a smaller value POWER 2 LOWER Actual weld power 15 less than the user Weld splash can cause the actual weld power to THAN LOWER set Lower Limit value for Weld2 drop below the user set Lower Limit for Weld2 LIMIT Add upslope to reduce weld splash Reset the Lower Limit for W
142. r this schedule The control will output the current waveform shown on the LCD Pressing the V key selects voltage as the control mode for this schedule The control will output the voltage waveform shown on the LCD NOTE Selecting the voltage feedback mode requires you to make a test weld when the voltage or weld pulse time is changed The test weld optimizes the Control feedback performance The weld status message TEST disappears after the internal control parameters are optimized Pressing the kW key selects power as the control mode for this schedule The control will output the power waveform shown on the LCD These keys allow you to view the results of the last weld and to set the limits of the welding parameters beyond which the energy limits monitor terminate the weld and or initiate alarms Pressing the kA key displays the current monitor This screen shows the results of the most recent weld This screen also allows the operator to set limits that automatically interrupt the weld when they are reached You can also program the current monitor to output an alarm when the limits are exceeded Pressing the V key displays the voltage monitor This screen shows the results of the most recent weld This screen also allows the operator to set limits that automatically interrupt the weld when they are reached You can also program the voltage monitor to output an alarm when the limits are exceeded Pressing the kW key displays the p
143. re strong and consistent v From the MONITOR keys section on the front panel press the voltage V key and observe the peak voltage reading of the first pulse Make several more welds and observe the range of first pulse peak voltage readings from weld to weld Press the Pulse 1 weld key to highlight the upper limit field for the weld period Use the numeric keypad to enter the upper limit value for the Pulse 1 weld period Program a voltage level that is slightly higher than the voltages observed step 3 above Press the voltage V key to save the setting as an upper voltage limit Press the COOL weld period PULSE 1 OUT OF LIMITS ACTION key This will bring up the 1 none PULSE 1 OUT OF LIMITS 2 STOP WELD 3 INHIBIT PULSE 2 ACTION screen 4 PART CONDITIONER Stop Pulse1 Select 2 STOP WELD NUMBER Select A Page RUN or MENU Toggle the Pulse 1 weld key to highlight the lower limit field for the Pulse 1 weld period Use the numeric keypad to enter a lower limit value with a voltage level that is slightly lower than the voltages observed in step 3 above Press the voltage V key to save the setting as a lower voltage limit 9 Make several more welds and verify that under normal circumstances the limits are not reached and the welds are not aborted If the limits are reached under normal welding conditions adjust the levels and times of the upper and lower voltage limits accordingly 10 Return to the RUN screen
144. reen 9 CHAIN SCHEDULES This feature allows you to automatically change from any weld schedule to any other schedule after a preset count creating a chain of schedules that can accommodate a variety of welding needs For example e A single work piece requires four welds two weld points require the same weld schedule each of the other two points require different weld schedules In this case you would program a sequence or chain that looks like this Schedule 01 2 times Schedule 02 1 time Schedule 03 1 time Schedule 01 This sequence will repeat or loop until you turn Chain Schedules OFF e Some applications require a lower current for a number of welds after the electrodes have been replaced or resurfaced Once the electrodes have been seasoned the current can be increased as required If the electrodes require 100 welds to season Schedule 01 can be programmed with a lower current and Schedule 02 can be programmed with a higher current The chain would look like this Schedule 01 100 times Schedule 02 1 time Schedule 02 1 time In this chain Schedule 02 will just keep repeating after the 100 welds made using Schedule 01 When the electrodes are replaced or resurfaced you can manually switch back to Schedule 01 to restart the sequence HF25 DC RESISTANCE WELDING SYSTEM 990 371 3 9 CHAPTER 3 SYSTEM CONFIGURATION You can program any of the Control s 99 stored schedules to chain to any
145. ress 2 to calibrate the 25 HF25 DC RESISTANCE WELDING SYSTEM C 2 990 371 APPENDIX CALIBRATION 7 The first calibration screen is the CAUTION screen If you are qualified to proceed with the calibration press V to continue Shunt value 0987 6 8 next page is for CALIBRATION SHUNT This screen asks for the actual Number change W Proceed value of the 1000 micro ohm shunt lt CALIBRATION SHUNT gt The actual value is printed on the exterior of the R7500 8 shunt Enter this value using the number keys and press V to continue NOTE The next calibration screen is the CURRENT SHUNT It is not necessary to change the current shunt value unless the internal welding transformer was changed If it was changed remove the top cover and enter the shunt value which is stamped on the copper conductor connected to the transformer Press V to continue 9 The next two screens are 1 CALIBRATE D A HIGH and 2 CALIBRATE D A LOW i Following the screen instructions adjust T the energy output using the measuring parameter feature of the oscilloscope NOTE Do not use a visual DO NOT INCLUDE THIS assessment SECTION FOR MEASUREMENTS Vang READING OF THE WAVEFORM i USE THIS SECTION Press the period key to advance to the next step Calibration Signal 10 The next calibration screen 15 CALIBRATE HIGH Disconnect the oscilloscope from the shunt resistor and connect the
146. rl lf Any Identifies the current status of the weld data buffer May be in response with or OVERRUN OK means that the Control weld buffer did not over run since the last data collection and all the data are intact OVERRUN means that the Control weld buffer did over run since the last data collection and only the latest 900 weld data are available to report TYPE type release numbers revision letters lt crlf gt lt lf gt Any Returns 25 1 00 A 37250 for the first release of an HF25 COUNT number gt lt gt Returns the number of weld data available in Control The total number of weld data that the Control holds in the buffer is 900 NAME schedule _name lt crlf gt lt lf gt ANY Returns the current schedule s name up to a maximum of 20 charters STATE state_name lt crlf gt lt lf gt Any Identifies the current state of operation of the Control May be in response to the STATE READ Command sent by the host or may be sent as a result of a state change from the Control front panel state name may be RUN MENU or MONITOR COUNTERS lt crlf gt TOTAL number lt crlf gt HIGH number lt crlf gt LOW number lt crlf gt GOOD number lt crlf gt It Any Returns the requested current Control weld counter values HF25 LINEAR DC RESISTANCE WELDING CONTROL E 19 APPENDIX E COMMUNICATIONS Command Control State Description Command Control State Descrip
147. robably increased in surface area mushroomed effectively increasing weld current density thus cooling the weld Try replacing the electrodes The rough surface of a worn electrode tip tends to stick to the work pieces So periodic tip resurfacing dressing 1s required to remove pitting oxides and welding debris from the electrode You should limit cleaning of an electrode on the production line to using a 400 600 grit electrode polishing disk If you must clean a badly damaged tip with a file you must use a polishing disk after filing to ensure the electrode faces are smooth The best method of preventing electrode problems is to regularly re grind electrode tip surfaces and shapes in a certified machine shop Parts Replacement Below 1s a list of the replacement parts for the Control items listed are a quantity of 1 each WARNING Only qualified technicians should perform internal adjustments or replace parts Removal of the unit cover could expose personnel to high voltage and may void the warranty T Amada Miyachi America Input Power Line Protection Fuses F1 and F2 Rear Panel HF25 240 330 071 HF25 400 330 092 HF25 480 330 092 Control Power Protection Fuse F1 330 078 Power PCB Input Power Selection Plug Set Welding Transformer 240 Volts 4 34314 01 8 400 Volts 4 343 15 01 480 Volts 4 34316 01 HF25 DC RESISTANCE WELDING SYSTEM 990 371 6 9 CHAPTER 6 MAINTENANCE Section Ill Repair Service If you have p
148. roblems with your Control that you cannot resolve please contact our service department at the address phone number or e mail address indicated in CONTACT US in the front of this manual HF25 DC RESISTANCE WELDING SYSTEM 6 10 990 371 APPENDIX Technical Specifications NOTE The specifications listed in this appendix may be changed without notice Power Pon ON 50 60 Hz 3 phase Input Voltage Range at Maximum Output Current 5247 1 192 264 VAC at 25A HE2S 200 sce IEEE 320 440 VAC at 20A lg M 384 528 VAC at 13A Input kVA Demand Pr E 30 max at 3 duty cycle Output Power at 12 Duty Cycle and a Combined PULSE 1 and PULSE 2 Pulse Width of 50 ms 6 0 kW max Maximum Output Current tie nenaeeea eetenans 2400A Max Peak Output Voltage at Max Peak Output 5 2V Duty Cycle at Max Peak Output 3 Max Load Resistance for Max Output 2 1 Output Adjustment Range Resolution and Accuracy NOTE Actual maximum and minimum current voltage or power achievable depends on transformer and load resistance 100 2400 A 0 001 kA 2 of setting 2A 0 2 9 99 V 0 001 V 2 of setting 0 02V 0 05 9 99 kW 0 001 kW 5 of setting 10W Weld Periods 0 0 9 9 ms 0 1 ms 20 us 10
149. s Observe that the power supply terminates the weld as soon as the voltage limits are reached If the voltage limits are not being reached with these conditions present return to the voltage monitor screen and adjust the limits accordingly 15 Return to the RUN screen and WELD STOP LIMIT REACHED 2000955 make several welds Verify that 1 the Weld Stop function detects missing and misaligned parts 2 400 G 400kA 002 0 5 5 0 O O 1808 0 0 O 0 OO1 ms Weld Stop Waveform NOTE When using the Weld Stop function always select a monitor mode that 1s different from the feedback mode For example If you are welding in constant current put limits on voltage If you are welding in constant voltage put limits on current e Ifyou are welding in constant power put limits on current or voltage HF25 DC RESISTANCE WELDING SYSTEM 5 22 990 371 CHAPTER 5 OPERATING INSTRUCTIONS Section IX Programming Relays From the MAIN MENU press the 7 key to go to the RELAY output state selection menu shown at the right The Control has four relays that can provide dry contact signal outputs under many different conditions lt RELAY gt ALARM ALARM ALARM ALARM RELAY1 ON RELAY2 ON RELAY3 ON RELAY4 ON Number Select an item RUN or MENU See Appendix C System Timing for the timing diagrams for the four relays From the RELAY menu press the 1 key lt RELAY 1 gt to go to R
150. s may also use special monitoring features of the Control such as Energy Limit Active Part Conditioner and Pre Weld Check These features are described later in this chapter Weld Sequence Timing A weld schedule is a unique heat profile programmed in constant current voltage or power that is applied over a fixed time period to resistance weld different parts The entire weld can include all of the following time periods Squeeze Time Upslope 1 Weld Pulse 1 Downslope 1 Cool Time Upslope 2 Weld Pulse 2 Downslope 2 and Hold Time The sample dual pulse profile or waveform below shows the weld current and the corresponding position of the weld head The graph labeled WELD CURRENT is what displays on the LCD when you schedule a weld profile squeeze WELD OWN OGL WELD DOWN HOLD RUN SLOPE SLOPE SLOPE RUN STATE TIME TIME TIME TIME STATE 0 999 msec 0 99 msec 0 99 msec 0 99 msec 0 999 msec 0 99 msec 0 99 msec 0 99 msec 0 99 msec B WELD POSITION WELD EE __ WELD PULSE 1 PULSE 2 Sample Weld Sequence Dual Pulse HF25 DC RESISTANCE WELDING SYSTEM 990 371 3 21 CHAPTER 3 SYSTEM CONFIGURATION Welding Applications Weld Pulse Profile Typical Application Can be used for many of spot welding applications Use on flat parts Single Pulse without plating or on conductive parts such as those made of copper or brass Upslope Downslope sho
151. s so no soldering 15 required Each pin of this connector has a tab on top as shown below 10 PIN CONNECTOR Assembled CONNECTOR SHELL TERMINAL 10 PIN CONNECTOR Disassembled When you fabricate I O cables according to the configuration instructions you must also cut off the tabs on the top of specific pins as indicated by the black shading below fea A T1112 13 14 15 16 17 18 19 201 31 32 33 34 35 36 37 38 39 40 51 52 53 54 55 56 57 58 59 60 12345678 910 21 22 23 24 25 26 27 28 29 30 41 42 43 44 45 46 47 48 49 50 Example To fabricate a connector for pins 31 gt 40 you must remove the tabs for pins 34 35 and 36 If you do not remove the appropriate tabs you will not be able to insert the plug into the Control HF25 DC RESISTANCE WELDING SYSTEM 990 371 APPENDIX ELECTRICAL AND DATA CONNECTIONS Section Ill Configuration Basic I O Configuration The unit requires configuration of the I Os to accept any inputs A pre wired configuration plug 1s provided which has to be plugged into connector labeled 11 through 20 It allows the use of Miyachi Unitek standard foot switches and weld heads without further configuration For other configuration methods please refer to Modification of I O Configuration on page B 6 Input Section Example COMMON This unit employs bi directional opto isolators which allow the user to configure the inputs to sin
152. same as the peak current readings observed in step 5 above 7 Press the current kA key to save the setting as an upper current limit 8 Press the COOL weld period PULSE 1 OUT OF LIMITS ACTION key This will bring up the 1 none PULSE 1 OUT OF LIMITS 5 ACTION screen 4 PART CONDITIONER Stop Pulse 9 Select 2 STOP WELD NUMBER Select Page RUN or MENU HF25 DC RESISTANCE WELDING SYSTEM 990 371 5 19 CHAPTER 5 OPERATING INSTRUCTIONS 10 Return to the RUN screen and WELD STOP LIMIT REACHED 178 increase the weld time by 1 2 ms Make several welds verify that the upper voltage Me O 500V 300V limit is reached for every weld HE CT BEC and the weld pulse stops before the end of the programmed weld D m Weld to a Limit Waveform 11 Make several more welds and inspect them for consistency of weld quality and or weld strength NOTE When using the Weld to a Limit function always select a monitor mode that 1s different from the feedback mode For example e If you are welding in constant current put limits on voltage If you are welding in constant voltage put limits on current If you are welding in constant power put limits on current or voltage HF25 DC RESISTANCE WELDING SYSTEM 5 20 990 371 CHAPTER 5 OPERATING INSTRUCTIONS Section VIII Weld Stop The Weld Stop function is similar to the Pre Weld Check function as both are
153. se 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 is 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 and nickel or when welding identical materials with thickness ratios greater than 4 to 1 The general rule is that the
154. se will occur on the next weld to determine the actual resistance Note customer control of this value is not recommended energy index is an index value into a PID energy vs PID values table Note customer control of this value is not recommended MONITOR READ lt gt parameter name value lt crlf gt lt Any except while welding Provides control over the basic weld monitor settings of the Control schedule When used with the READ keyword the basic weld monitor settings of the currently loaded schedule are returned see MONITOR under Control ORIGINATED COMMANDS When the SET keyword 15 used the host may set change the value of one or more of the parameters of the basic weld monitor settings pertaining to the currently loaded schedule The following is a list of valid literal substitutions for the parameter name and value variables j Monitor Type for pulse 1 limit_value Upper Limit for pulse 1 LOWERI limit value Lower Limit for pulse 1 ACTIONI STOP INHIBIT Out of Limit Action for pulse 1 MONTYPE2 KAI VI KWIR j Monitor Type for pulse 2 UPPER2 limit_value Upper Limit for pulse 2 LOWER2 limit_value Lower Limit for pulse 2 ACTION2 none STOP Out of Limit Action for pulse 2 HF25 LINEAR DC RESISTANCE WELDING CONTROL E 8 990 371 APPENDIX E COMMUNICATIONS PILDLY1 delay value Pulse 1 Lower Delay Start
155. se within 10 seconds the message FIRING SWITCH DIDN T CLOSE IN 10 SECONDS will be displayed Delay time from Firing Switch closure and Foot Switch Level 2 closure to squeeze time SQZ Maximum D2 time is 2 ms plus switch debounce time Squeeze time Selectable range is 0 to 999 ms Up slope time Selectable range is 0 0 to 99 0 ms Weld time Selectable range is 0 0 to 99 0 ms Down slope time Selectable range 15 0 0 to 99 0 ms Cool time Selectable range is 0 0 to 99 0 ms Hold time Selectable range is 0 to 999 ms HF25 DC RESISTANCE WELDING SYSTEM D 1 APPENDIX SYSTEM TIMING Basic Weld Operation Manual Head System with Firing Switch Operation Remote On Firing Switch Welding Current DELAY saz WELD bown HOLD Pulse 4 t Pulse 2 Definitions DELAY Delay time from firing switch closure to the start of the weld sequence that 1s start of SQZ Maximum DELAY time is 2 ms plus switch debounce time SQZ Squeeze time Selectable range is 0 to 999 ms UP Up slope time Selectable range is 0 0 to 99 0 ms WELD Weld time Selectable range is 0 0 to 99 0 ms DOWN Down slope time Selectable range is 0 0 to 99 0 ms COOL Cool time Selectable range is 0 0 to 99 0 ms HOLD Hold time Selectable range is 0 to 999 ms HF25 DC RESISTANCE WELDING SYSTEM D 2 990 371 APPENDIX SYSTEM TIMING Basic Weld Operation System with Remote Firing Switch NOTE The
156. sely into the waveform graph NUMBER Select an item RUN or MENU Use the numerical keypad to select the number of the limit you want to change When the value is highlighted Example 2 5ms use the numerical keypad to type in a new value You must leave a minimum time of 0 5 ms in order for the changes to be saved in memory Press the RUN or monitor key when you have finished entering new values R aise or lower the UPPER LIMIT and LOWER LIMIT as necessary using the procedures in Section III Programming the Weld Monitor Return to the RUN screen and make a test weld in order to view the waveform to see where the new limits appear compared to the waveform graph Repeat steps 1 gt 10 until the limits are where you want them NOTE Lower limits apply to the programmed weld time only Programming a longer upslope extends the time before a lower limit applies 1n the monitoring screen HF25 DC RESISTANCE WELDING SYSTEM 990 371 CHAPTER 5 OPERATING INSTRUCTIONS Section IV Active Part Conditioning 1 ZA Press the SCHEDULE key then select a Weld Schedule using either the AV arrows or the numeric keypad 2 Program a single pulse for Constant Power operation Program the power level and weld time to cause slight sticking between the two parts Make a few welds and pull them apart Increase or decrease the power setting until a light tack weld is achieved From the MONITOR keys section on the front panel press the voltage V
157. ses This instruction manual describes how to operate maintain and service the HF25 resistance welding system control 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 1 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 weld head and power supply please read these instruction manuals before attempting to use them Procedures other than those described in these manuals or not performed as prescribed in them may expose personnel to electrical burn or crushing hazards After reading these manuals retain them for future reference when any questions arise regarding the proper and safe operation of the power supply Please note the following conventions used in this manual WARNING Comments marked this way warn the reader of actions which if not followed might result in immediate death or serious injury CAUTION Comments marked this way warn the reader of actions which if not followed might result in either damage to the equipment or injury to the individual if subject to long term exposure to the indicated hazard HF25 DC RESISTANCE WELDING SYSTEM 990 371 IX st Engineering 1 10 1 2001 951 637 2630 DECLARATION OF CONFORMITY Application of Council Directive
158. sistance Welding System Control will simply be referred to as the Control HF25 DC RESISTANCE WELDING SYSTEM 990 371 1 1 CHAPTER 1 DESCRIPTION Section Il Introduction The Control is a 25 kHz three phase state of the art inverter power supply for joining precision small parts at high speed with controllable rise times The delivered welding energy is in the form of DC welding energy High speed 40 microseconds digital feedback automatically controls weld current voltage or power providing more welding consistency compared to traditional direct energy AC or capacitive discharge CD technologies This microprocessor technology automatically compensates for changes in work piece resistance load inductance weld transformer saturation and changes in line voltage In addition special power device technology precisely controls the weld energy at both high and low energy levels e You can program the Control from the front MAIN MENUs panel using simplified key clusters and on SETUP 6 COMMUNICATION WELD COUNTER 7 RELAY screen data fields A MAIN MENU screen COPY ASCHEDULE 8 RESET TO DEFAULTS allows you select all of the system setup CALIBRATION 9 CHAIN SCHEDULES options for working with inputs from SYSTEM SECURITY external equipment NUMBER Select an item The RUN screen allows you to easily modify any time period current voltage or power 150 109 10 1 1 6 The MONIT
159. sistive Metals G 4 RECON 11 159232 465 3 6 ss 1 7 M M 3 16 S S X SCHEDULE Key 1 6 Schedule m 3 4 De GG MIMO DOE Sureste tiet sait G 10 MN 2 3 3 4 vizi o2 T 3 11 P 3 13 gt 5 P 3 14 omele Pulse Weld Profile 3 22 Single Pulse Weld Schedule 5 3 Solder or Braze Joint G 2 Solid State Joint G 2 Space T equiPe e DS 2 A 3 1 Switch Debounce Time 1 eet et 3 12 System COMM cie aS peti rere rte 3 1 isse 3 1 Before Y OU Start 3 1 3 1 3 1 Main 3 1 Chain 3 9 ON 3 5 Dand 3 6 Communication Role 3 5 LD Number 3 6 RS232 485 Select 3 6 CODY A Schedule oues eere rtt 3 3 3 7 Reset 3 8 Reset All Schedules 3 9 Reset Schedule Limits 3 9 n 3 1 Systemi
160. splay shows the actual trace of the weld current voltage or power and either the peak or the average value for each weld pulse as selected by pressing the PEAK AVERAGE key See Chapter 4 Using Feedback Modes and Weld Monitoring for a detailed description of monitor and energy limits operation HF25 DC RESISTANCE WELDING SYSTEM 990 371 2 47 CHAPTER 3 SYSTEM CONFIGURATION Alarm State The Control automatically recognizes many ALARM NO WELD SWITCH alarm conditions The example WELD SWITCH IN WELD POSITION alarm screen shown at the right is displayed when you attempt to initiate a weld with the WELD NO WELD switch 0 05 6 6600kA in the NO WELD position 0220 1 0 2 0 1 0 0 50 1 0 3 0 10 HF25 DC RESISTANCE WELDING SYSTEM 3 18 0005237 02 332 ms 990 371 CHAPTER 3 SYSTEM CONFIGURATION Section IV Weld Functions Welding Applications Some welding applications require the use of RUN SQUEEZE UP 1 1 DOWN 1 COOL E WELD 2 powN 2 HOLD RUN TUE STATE 0 999ms 0 99ms 0 99ms 0 99ms 0 99 E 99ms 0 99ms 0 99ms 0 99ms STATE specialized weld functions A weld function is a DN Wage unique heat profile created by weld current voltage or power that 15 applied over a fixed An example of a fully programmed weld profile WELD WELD time period to resistance weld different parts is shown at the right emen i acs id U
161. ssacsitineceosccnecdosisdes 2 1 2 1 MT yee cae estes questo RR 2 2 Compressed Air and Cooling Water 2 2 2 2 DCU 2 3 Connections to External Equipment 2 3 EZ AIR Weld Head Connections 2 7 Foot Pedal Actuated Weld Head Connection 2 6 Non EZ AIR Weld Head Connections 2 9 Rear Panel Components and Connectors 2 3 Weld Head Connections 2 4 Index 2 990 371 INDEX M Continued 3 15 TUER 3 1 reddi 1 7 Montor 1 8 IMO TAI OW SAL Se 3 17 N Weld Stale 3 15 Non EZ AIR Weld Head Connections 2 0 ccm 1 9 Operating nstr ctions 5 Active Part Conditioning uses cocer eara 5 13 Moda Con sorcerers d 5 1 Berore Y State 5 1 Tnt Pos EPUD 5 2 Pre Operational Checks 5 Compressed 5 1 COMUNE CONS 5 1 5 1 SUME 5 3 Dual Pulse Weld Schedule 5 7 Single Pulse Weld Schedule 5 3 Upslope Downslope Weld Schedule 5 5 Pre Weld Check emm 5 15 Programming RELAYS e 5 23 Se 5 15 5 29 Using th
162. stant voltage monitor current e If you are welding in constant power monitor current or voltage HF25 DC RESISTANCE WELDING SYSTEM 4 8 990 371 CHAPTER 4 INTRODUCTION TO FEEDBACK MODES AND MONITORING 5 Weld Stop Applications e Part to part positioning problems e Electrode to part positioning problems Function To detect work piece resistance changes that occur when parts are positioned incorrectly at the weld head In this case the energy limits will prevent blowouts parts damage and electrode damage Limits can be set to terminate the weld if this occurs Description This function terminates the weld energy during the welding process if pre set weld current voltage or power limits are exceeded In addition to inhibiting the weld the Control has four programmable relay outputs which can be used to trigger alarms to signal operators of weld faults or signal automation equipment to perform pre programmed actions such as stopping the production line so the faulty weld piece can be removed WELD STOP LIMIT REACHED 002009955 1 002 05 50 00 10 00 0 0 0 0 001 ms In the profile above the weld current 15 exceeding the selected upper limit before the end of welding cycle The spike in the current waveform indicates that parts were misplaced In this case the operator has selected the option to terminate the weld energy under this condition so the energy limits monitor terminates the
163. stem or parameter limits For example you should ensure that Correct force 15 set at the weld head Correct weld energy and time 15 set at the Control The equipment is set up properly All electrical connections are tight Electrode alignment allows flush contact with the weld pieces Electrodes are properly dressed The problem is embedded in the system and some form of repair will be needed For example repair might include replacing a broken weld head flexure Alarm Messages Built in automatic self test and self calibration routines will bring up alarm messages on the display screens These messages will usually let you know what action 15 required of you to correct the reason for the alarm For a complete listing of the alarm messages what they mean and corrective actions see Section Troubleshooting 990 371 25 DC RESISTANCE WELDING SYSTEM 6 1 CHAPTER 6 MAINTENANCE Section Il Troubleshooting Troubleshooting Cause in order of probability Cause in order of probability Electrode Damage Electrode Sticking Insufficient Weld Nugget 6 2 Electrode Sparking 1 Excessive current energy set at HF25 1 Excessive or insufficient weld head force 1 Wrong electrode tip shape 2 Excessive weld time set at HF25 2 Contaminated weld piece surface plating 2 Wrong electrode material 2 Contaminated electrode surface Weld Piece Warping 1 Contaminated weld piece
164. t CAUTION gt the CALIBRATION screen Refer to the appendix 1 1 CALIBRATION SHOULD BE PERFORMED BY A QUALIFIED TECHNICIAN ONLY REFER TO MANUAL FOR CALIBRATION SETUP Y Next RUN or MENU 5 SYSTEM SECURITY From the MAIN MENU press the 5 key to go to up SYSTEM SECURITY SYSTEM SECURITY screen With this screen 1 SCHEDULE LOCK OFF you can protect the weld schedules from CUERO EE unauthorized changes by programming the Control with a user defined protection code NUMBERS Select an item RUN or MENU HF25 DC RESISTANCE WELDING SYSTEM 990 371 3 3 CHAPTER 3 SYSTEM CONFIGURATION 1 Schedule Lock This function prevents unauthorized users from selecting any weld schedule other than the displayed schedule and from changing any weld energy time parameters within the weld schedule 2 System Lock This function prevents unauthorized users from changing any of the options on the main menu It also prevents unauthorized users from changing weld energy time parameters within weld schedules 1 99 Note that schedule 0 is scratchpad and can still be edited when the System Lock 15 ON This security level allows you to select different schedules from the front panel 3 Calibration This function prevents unauthorized users from modifying any of the calibration settings NOTE All security options use the same procedure to enter a security code and to turn the security code OFF 1 Press the 1 key to se
165. t 1 amp HF25 DC RESISTANCE WELDING SYSTEM 990 371 A 3 APPENDIX A TECHNICAL SPECIFICATIONS Physical Specifications Size see illustration 4 inches i 229 rimi bici 62 Ibs 28 kg 12 8 inches 325mm i HF25 DC RESISTANCE WELDING SYSTEM A 4 990 371 APPENDIX Electrical and Data Connections Section Electrical Connection As described in Chapter 2 you need to supply a connector for the Control input power cable see diagram below Connect the Control power cable to a 3 phase 50 60Hz power source The voltage range for each model is set at the factory by a set of two jumper plugs One jumper plug is installed on power connector J23 located on the center chassis plate The other jumper plug P22 plugs into welding transformer cable connector J22 The jumper plug set determines the power wiring configuration between the power board and the welding transformer Input Power Wiring Diagram HF25 25 POWER L eee POWER CIRCUIT CIRCUIT BLUE CGND GREEN YELLOW INSIDE THE HF25 EXTERNAL POWER CABLE NOTES 1 Measure building voltage from phase to phase not from phase to ground 2 The cable power leads are not phase dependent and may be connected to any of the 3 power connector pins Only the green yellow lead is dedicated to chassis ground CAUTIONS Be sure that the shop source power 15 appropriate for your Control model e Ifthe blue phas
166. tate report lt gt lt 12 gt Description Returns the requested number of weld reports First field is the type of reports to be sent The second field is the number of reports sent Then follows the packets of report One report pack holds the information about the weld requested Each report packet 1s separated by crlf and this Command ends with lt crlf gt lt If gt Type of report This field defines the type of report that was requested by the host computer The fields in the report packet are separated with a comma and all fields are in integer format There are always 24 fields in a report packet OLD Number reports This 15 the number of reports that shall be included in this command If the host computer requests more weld data than is available in the weld data buffer the Control sends only the weld reports in the weld buffer and the number of reports is the number of weld reports available in the weld data buffer After the report 1s sent to the host computer the Control does not erase the weld data sent to the host from the weld data buffer You must use the REPORT ERASE command to erase weld data from the weld buffer unit number Schedule number weld status Average current Average voltage l peak current 1 peak voltage 1 average power 1 peak power 1 average resistance 1 peak resistance 1 null 1 Always zero null 2 Always zero average current 2 average voltage 2 peak
167. ted variables will skew statistical data and waste valuable time HF25 DC RESISTANCE WELDING SYSTEM 990 371 G 9 APPENDIX DEFINING THE OPTIMUM PROCESS Poor Follow up Sparks Insufficient Force Impact Force gt Sparks Variation lt lt Variation sparks No Squeeze No Hold Sparks lee Variation Squeeze Heat Hold Common welding problems can often be identified in the basic set up of the force energy and time welding profile shown above These problems can lead to weld splash inconsistency and variation contact Amada Miyachi America for further information and support What are Screening DOE S The purpose of a Screening DOE 15 to establish the impact that welding and process parameters have on the quality of the weld Quality measurement criteria should be selected based on the requirements of the application A Screening DOE will establish a relative quality measurement for the parameters tested and the variation in the welded result 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 o
168. till a chance of weld splash The purpose of a dual pulse operation 15 to enable the first pulse to target variations in resistance the second pulse achieves the weld Q 373kA 424 020000305 2 OBOOkW lt 9mD 2 000V 150 10 0 0 2 0 0 0 000 ms Resistance Set Waveform The use of a current limit monitor for the first pulse enables the pulse to be terminated when a predetermined amount of current flow is achieved The rise of the current to a consistent level ensures a HF25 DC RESISTANCE WELDING SYSTEM 4 6 990 371 CHAPTER 4 INTRODUCTION TO FEEDBACK MODES AND MONITORING consistent resistance at the beginning of the second pulse Depending on the initial resistance the amount of time required to bring the resistance down will vary from weld to weld The first pulse therefore should be programmed to be much longer than generally required to ensure that the current limit 15 always reached The power supply will terminate the pulse based on the reading of current in the power supply s monitor 3 Pre Weld Check Application e Detect Misaligned or Missing parts Function This is used to see if parts are misaligned or missing before a welding pulse is delivered to the weld head Ifa part 1s missing or misaligned you do not want the machine to weld because the result would be an unacceptable weld and or damaged electrodes When using a Pre Weld Check Pulse 1 should be very short 1 2 milliseconds and
169. tion ALARM READ CLEAR SET error_number DISPLAY alarm_message_string lt crlf gt lt lf gt Any Provides access to the Control alarm logic When used with the READ keyword the current error condition value is returned See Appendix A for list of alarm messages When the CLEAR keyword 1s used all alarm conditions are canceled When the SET keyword 15 used the host may invoke an error identified by error number When the DISPLAY keyword is used an error condition can be created with any message desired The length of the error message must be limited to 40 characters or less No help message will be available in connection with this created error message SECURITY OFF SCHEDULE SYSTEM CALIBRATION lt crlf gt lt lf gt Any Allows control of the system security mode OFF sets all security status Control to OFF SCHEDULE sets the schedule lock to ON SYSTEM sets the system lock to ON CALIBRATION sets the calibration lock to ON HF25 LINEAR DC RESISTANCE WELDING CONTROL 990 371 APPENDIX E COMMUNICATIONS Control Originated Commands These are the commands sent from a Control to a host computer Command Control State Description Command Control State Description Command Control State Description Command Control State Description Command Control State Description Command Control State Description 990 371 STATUS state_name c
170. tion Command Control State Description Command Control State Description ALARM error_message lt crlf gt lt lf Any Identifies the current error condition of operation of the Control May be in response to the ALARM READ command sent by the host or may be sent as a result of an error condition occurring in the Control error message is text string describing the error message which is the same error message that is displayed to the screen CURRENT number of data lt crlf gt data lt crlf gt data lt crlf gt data lt crlf gt lt lf gt Any Returns the Current waveform data of the last weld First field is the number of data to be sent Then follows the packets of data Each data is separated lt crlf gt and this command ends with lt crlf gt lt If gt number of data This 15 the number of data that shall be included in this command The Control samples current every 40 us For a weld less than 80 ms weld time the number of data will be approximately total weld time 40 us This number will always be less than 2000 data integer number in unit of A VOLTAGE number of data data erlt data data lt crlf gt lt If gt Any Returns the Voltage waveform data of the last weld First field is the number of data to be sent Then follows the packets of data Each data is separated by crlf and this command ends with lt crlf gt lt If gt number of data This is the num
171. uality Resistance Welding Solutions Defining the Optimum Process 1 Appendix Compatibility and Comparison seen H 1 HF25 DC RESISTANCE WELDING SYSTEM 990 371 vii 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 us at Amada Miyachi America 1820 South Myrtle Avenue P O Box 5033 Monrovia CA 91017 7133 Telephone 626 303 5676 FAX 626 358 8048 e mail info amadamiyachi com The purpose of this manual is to supply operating and maintenance personnel with the information needed to properly and safely operate and maintain the Miyachi Unitek HF25 Resistance Welding System Control We have made every effort to ensure that the information in this manual 15 accurate and adequate Should questions arise or if you have suggestions for improvement of this manual please contact us at the above location numbers Amada Miyachi America 15 not responsible for any loss due to improper use of this product HF25 DC RESISTANCE WELDING SYSTEM vill 990 371 SAFETY NOTES e Lethal voltages exist within this unit Do not perform any maintenance inside this unit e Never perform any welding operation without wearing protective safety glas
172. uld be used for the majority of spot welding Upslope Downslope applications Weld round parts parts that are not flat spring steel parts or heavily plated or oxidized parts Dual Pul Use for spot welding parts with plating First pulse can be used to displace plating or oxides and the second pulse to achieve the weld For a detailed coverage of resistance welding theory please refer to Appendix D The Basics of Resistance Welding Single Pulse Weld Profile Applications e Flat parts that do not have any plating or heavy oxides Conductive parts made of copper or brass Description Single Pulse is a term used by the industry to describe the simplest heat profile used for many resistance spot welding applications SQUEEZE WELD HOLD TIME TIME TIME 0 999 msec 0 99 msec 0 999 msec Single Pulse Weld Profile HF25 DC RESISTANCE WELDING SYSTEM 3 22 990 371 CHAPTER 3 SYSTEM CONFIGURATION Upslope Downslope Weld Profile Applications e Round or non flat parts and most resistive materials Description Upslope allows a gradual application of weld energy which permits the parts to come into better contact with each other reducing the electrode to part contact resistances Upslope can allow a smaller electrode force to be used resulting a cleaner appearance by reducing electrode indentation material pickup and electrode deformation It can also be used to displace plating and or oxides reduce flashing and s
173. used to detect missing or misaligned parts Both functions are used to stop the weld when a specific current voltage or power level is reached The Weld Stop function stops the weld in the actual welding pulse the Pre Weld Check uses a small pre pulse to stop the weld The Weld Stop function should only be programmed after a welding schedule which produces acceptable results has been developed The welding schedule includes the time and energy settings as well as the electrode force setting In the following steps a Constant Current weld is used as an example to show how the Weld Stop function is programmed 1 EUM Press the SCHEDULE key then select a Weld Schedule using either the AV arrows or the numeric keypad 2 Program a single pulse for Constant Current operation as required to make strong consistent welds Make a few welds and verify that the welds are acceptable 3 From the MONITOR keys section on the front panel press the kA current V voltage kW power and resistance keys and observe the resulting waveforms NOTE You can toggle between PEAK and AVERAGE readings by pressing the PEAK AVERAGE key 4 Press the V voltage key and observe the voltage waveform Observe peak and average readings on the voltage monitor screen Make several welds and observe the range of voltage readings from weld to weld 6 Press the Pulse 1 weld key to highlight the upper limit field for t
174. weld time T Welding Parameter Interaction TIME PROBLEM CAUSE PROBLEM CAUSE Parts Overheating Excessive Parts Overheating Excessive Weak Weld Weak Weld Insufficient Nugget Insufficient Nugget Metal Expulsion Metal Expulsion Warping Warping Discoloration Discoloration Electrode Damage Insufficient Electrode Damage Insufficient FORCE PROBLEM CAUSE Parts Overheating Excessive Weak Weld Insufficient Nugget Metal Expulsion Warping Discoloration Electrode Damage Insufficient Interaction of Welding Parameters HF25 DC RESISTANCE WELDING SYSTEM 990 371 F 1 APPENDIX THE BASICS OF RESISTANCE WELDING Electrode Selection Correct electrode selection strongly influences how weld heat is generated in the weld area In general use conductive electrodes such as RWMA 2 Copper alloy when welding electrically resistive parts such as nickel or steel so that the weld heat 1s generated by the electrical resistance of the parts and the contact resistance between the parts Use resistive electrodes such as RWMA 13 Tungsten and RWMA 14 Molybdenum to weld conductive parts such as copper and gold because conductive parts do not generate much internal heat so the electrodes must provide external heat Use the following Electrode Selection Table for selecting the proper electrode materials MATERIAL MATERIAL Alumel 2 Alumel Alumel 2 Chromel Alumel Dumet Aluminum Aluminum Aluminum Alloys Aluminum Aluminum 1 Cad
175. will alternately select either RS232 or RS485 communications The default selection is RS232 4 1 0 Number The host computer may be used to talk with multiple Controls using a single RS 485 communications line Each Control sharing that line must have a unique identification number To enter an identification number for the Control proceed as follows 1 From the MAIN MENU press the 6 key lt 1 0 NUMBER to go to the COMMUNICATIONS MENU I D NUMBER 01 2 From the COMMUNICATIONS MENU screen press the 3 key to get the I D NUMBER entry screen Number Select A Page RUN or MENU Enter a two digit number from 01 to 30 in the 1 0 NUMBER field 4 Press the MENU key to get the COMMUNICATION menu screen This time the I D NUMBER line will display your I D number entry 5 Press MENU to return to the MAIN MENU HF25 DC RESISTANCE WELDING SYSTEM 3 6 990 371 CHAPTER 3 SYSTEM CONFIGURATION 7 RELAY 1 From the MAIN MENU press the 7 key to go to the RELAY output state selection menu shown at the right The Control has four relays that can provide dry contact signal outputs under many different conditions lt RELAY gt OTHER ALARM ALARM ALARM RELAY1 ON RELAY2 ON RELAY3 ON RELAY4 ON Number Select an item RUN or MENU See Appendix C System Timing for the timing diagrams for the four relays From the RELAY menu press the 1 key to go to RELAY 1 shown at the right Press the 1 key
176. witch cable connector to the Control firing switch cable connector 3 Connect a normally closed approved emergency stop switch across the two leads of the operator emergency stop switch cable This switch when operated open will immediately stop the weld cycle and retract the weld head See Appendix B Electrical and Data Connections for circuit details 4 Connect a Model FS2L or FSIL Foot Switch to the Control FOOT SWITCH connector HF25 DC RESISTANCE WELDING SYSTEM 2 8 990 371 CHAPTER 2 INSTALLATION AND SETUP 5 Refer to the weld head manufacturer user s manual Connect the weld head air valve solenoid cable connector to the Control AIR VALVE DRIVER connector NOTE This connector supplies 24 VAC power only and will not drive 115 VAC air valves 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 the length of the air line to less than 40 in 1 m or electrode motion will be very slow NOTE Use a lubricator only with automated installations 7 Turn on the air system and check for leaks 8 Setthe WELD NO WELD switch on the Control front panel to the NO WELD position In this position the Control cannot deliver weld energy but it can control the weld head 9 Setthe circuit breaker on the rear panel ODODODO of the Control to the ON position The 4 default RUN screen will display lumus
177. y attracted to other metal atoms even in different parent materials Metal B Metals and alloys will bond together once surface contaminants such as dirt grease and oxides removed Resistance welding generates heat at the material interface which decomposes the dirt and grease and helps to break up the oxide film The resultant heat softens or melts the metal and the applied force brings the atoms on either side into close contact to form the bond The strength of the joint develops as it cools and a new structure 1s formed There are three main types of bonds that can be formed using the resistance welding process Solder or Braze Joint A filler material such as a solder or braze compound 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 Solid State Joint A solid state joint can be formed when the materials are heated to between 70 80 of their melting point Fusion Joint A fusion joint can be formed when both metals are heated to their melting point and their atoms mix Many micro resistance welding challenges involve joining dissimilar metals in terms of their melting points electrical conductivity and hardness A solid state joint can be an ideal solution for these difficult applications there is no direct mixing of the two materials across the weld
178. y correct the pulse to compensate for any variation in part resistance The Control also has several monitor functions that give you remarkable control over the welding and production process Together these features ensure precise consistent welds higher productivity a lower rejection rate and longer electrode life Before operating the Control it 1s important to know how to match the Control s capabilities to specific weld applications This section provides Weld details in the following order e Weld Schedules Single Pulse Upslope Downslope Dual Pulse Chapter 5 Operating Instructions contains the step by step instructions on how to program each of the functions above HF25 DC RESISTANCE WELDING SYSTEM 3 20 990 371 CHAPTER 3 SYSTEM CONFIGURATION Weld Schedule Definition Weld Schedule 15 the name given to each of 99 separate weld profiles stored 1n the Control numbered from 01 to 99 A weld profile is the graphic representation or waveform of the numeric weld time and weld energy values NOTE There is an additional weld schedule numbered 00 which can be used as scratch pad to develop new weld schedules When time and energy values are entered using the numeric keypad the Control displays a line graph of the weld profile on the LCD screen You can see the graph change as you enter new time and energy values Weld profiles may be programmed for single pulse upslope downslope or dual pulse operation Weld schedule
179. yphen END OF PARAMETER TERMINATOR lt crlf gt carriage return followed by linefeed TERMINATION OF COMMAND lt linefeed must be preceded by the end of line terminator lt gt Each unit identifier command keyword and parameters must be separated by one or more spaces except the termination of command lt gt must follow the end of parameter terminator lt crlf gt immediately I E gt lt gt 7 25 LINEAR DC RESISTANCE WELDING CONTROL E 4 990 371 APPENDIX E COMMUNICATIONS Computer Originated Commands These are the commands sent by the host computer via RS 485 or RS 232 to a Control Command Control State Description Command Control State Description Command Control State Description Command Control State Description Command Control State Description Command Control State Description Command Control State Description Command Control State Description 990 371 STATUS lt crlf gt lt lf Any Requests the Control to report the status of the weld data buffer Control returns STATUS with either OK or OVERRUN TYPEx lt crlf gt lt lf gt Any Requests the Control to return the type of welder release number and revision letters COUNT lt crlf gt lt If Any Requests the Control to report the number of weld data accumulated since the last data collection Control returns the COUNT even if there is no weld data available ERASE lt crlf gt lt lf

HF25 Technical Manual - AMADA MIYACHI AMERICA

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