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phasemaster™ 7 direct energy welding control

1. Remote Weld Schedule Selection Refer to figure A 3 To use this feature connect the seven control lines from a user supplied normally open contact open collector or TTL logic levels can also be used to mating CONTROL SIGNALS connector Pins 1 2 3 4 12 5 and 7 Connecting any one of these inputs to Pin 11 will cause the PM7 to load the weld schedule defined by the BCD Switch corresponding pin combination immediately after the initiation switch closes Weld schedules are selected Figure A 3 Remote Schedule according to the binary coded decimal pattern shown in the Selection with a Remote Binary table A 1 Switch Table A 1 Binary Codes for Remote Weld Schedule Selection Schedule Input Pin and Bit Numbers 1 Switch Closed Panel Pin 1 Pin2 Pin3 Pin4 Pin12 Pin5 Pin7 Control 2 2 Number 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 2 0 1 0 0 0 0 0 3 1 1 0 0 0 0 0 4 0 0 1 0 0 0 0 5 126 Binary progression from 5 to 126 127 1 1 1 1 1 1 1 Binary Schedule Selection Code To select a schedule connect the pin s corresponding to the schedule number to Pin 11 The schedules listed below are selected using the pin indicated by the 1 marked under the pin number To select any other schedule number select the schedule numbers whose sum equals the desired schedule then connect all of the corresponding pins For example to select Schedule 127 c
2. OPTIONS 2 The OPTIONS 2 screen has four options e WELD HEAD TYPE You have four lt OPTIONS 2 gt selections within this option as follows WELD HEAD TYPE AUTO FOOTSWITCH TYPE 2 LEVEL AUTO Select AUTO when a Unitek FOOTSWITCH WELD ABORT ON FIRING SWITCH 2 WIRE Peco air or manually actuated weld head is connected to one of the AIR VALVE DRIVER connectors on the A y Select CANG Change More Options amp rear panel The PM7 will automatically sense which type is connected The PM7 will assume that a manual head is connected unless it senses a Unitek Peco air head gt DUAL AIR Activates the 24 VAC AIR VALVE DRIVER 2 connector to drive the Second air head PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 6 3 CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS 6 4 gt MANUAL Select MANUAL when a non Unitek Peco manual head is connected Also use this selection when an externally controlled air head is used and the air solenoid is not connected to one of the AIR VALVE DRIVER connectors AIR Select AIR when an air head controlled by a foot switch is connected to the PM7 FOOTSWITCH TYPE You have three selections within this option gt With the AUTO selection the PM7 will automatically recognize whether a Unitek Peco 1 level or 2 level foot switch is connected to it When a user supplied foot switch is connected to the PM7 select either 1 LEVEL or 2 LEVEL as appropriate 1 LEVEL When th
3. Duty Cycle Current Amps 100 20 50 28 8 70 1 200 Output current can be set from 20 to 99 of the maximum current that could flow during any half cycle Accuracy is 3 of setting Duty cycle is defined as the percentage of time during which the weld current flows in a 1 minute interval There are two extreme conditions for 50 duty cycle ON for every other cycle or ON for 30 seconds Current flow is controlled by SCRs rated at 50 amps 280 volts 50 60 cycles The PM7 380 460 uses 50 amp 480 volt SCRs Weld Schedules You can save write 128 different weld schedules in permanent memory Weld Schedule Numbering System Weld schedules are numbered 1 through 127 They can be protected from unauthorized or inadvertent changes by Unitek s system security feature When the system security state is protected Schedule 0 can still be modified and used as a scratchpad When schedule lock is also turned ON no other schedules can be displayed or used to weld except the currently displayed schedule PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL A 2 990 084 APPENDIX A TECHNICAL SPECIFICATIONS NOTE If the security code is lost Select SYSTEM SECURITY from the main menu Switch the WELD SWITCH to NO WELD press SAVE and the press The status will change to UNPROTECTED Schedule Number at Power Up This feature determines which schedule will be used when the PM7 is switched to ON The option will be either Sch
4. Sufficient electrode 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 energy to produce the heat required to form a weld PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 5 10 990 084 CHAPTER 5 OPERATING INSTRUCTIONS The higher the electrode force the greater the energy current and or time required to produce a given weld Low force usually results in lower bond strength Increased force requires higher energy but usually results in a stronger bond Energy is proportional to time and the square of the welding current Polarity Users of half cycle welders have found that the direction of current flow can have a marked effect on the weld characteristics of some material combinations This effect occurs when welding e Materials with large differences in resistivity such as copper and nickel e Identical materials with thickness ratios greater than 4 to 1 Since polarity can be an important consideration in resistance welding of some material combinations be sure to check the weld schedule results using both positive and negative polarity Polarity can be changed in the PROGRAM state The general rule is that the more resistive material or the thinner material should be placed against the negative electrode Weld Strength Profiles Electrode Force
5. Up Downslope Function SCHEDULE 6 UP DOWNSLOPE NEXT SCH 11 SYSTEM AIR 2 LEVEL WELD 0011111 SO UP WELD EEDOWN HLD The upslope function facilitates welding material combinations such as aluminum to aluminum or platinum to tungsten Since the CYCLES 10 12 10 15 19 current during the first cycle is low upslope CURRENT 25 90 60 allows a reduction in electrode force The RELAY 1 OFF OFF OFF OFF OFF reduced force reduces electrode indentation RELAY 2 ON ON OFF ON OFF material pickup and electrode deformation av Select CHNG Change PROGRAM Upslope can also be used to displace plating or oxides reduce flashing or spitting and reduce thermal shock when welding parts containing metal to glass seals The downslope function assists in the grain refinements of certain heat treatable steels It also prevents cracking in aluminum and certain other materials by reducing the cooling rate The current slope is linearly reduced from the weld current to the down current during the downslope period The PM7 automatically calculates the rate of change and will not allow a rate greater than 50 per cycle or less than 1 per cycle Quench Temper Function This function controls grain refinement in the parts The weld current welds the parts together During the quench COOL period the parts are cooled by the electrodes which are frequently water cooled The TEMPer CURRENT which flows for the duration of the TEMPer period mus
6. Input Connector The INPUT connector is an Amphenol Type 97 3102A 22 9P Unitek PN 520 071 The mating connector which is supplied with the PM7 is an Amphenol Type 97 3 106A 222 9S Unitek PN 520 072 PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL A 16 990 084 APPENDIX A TECHNICAL SPECIFICATIONS Forced Air Option Unipulse welding transformers can be modified for fan cooling A 4 inch muffin type or boxer type fan which includes a filter and grill may be mounted on top of the transformer The corner screws for the fan assembly can be inserted through the slotted louvers CAUTION Air flow must be downward through the transformer at is in the top and out the front next to the output terminals Maximum Repetition Rate Unipulse transformers will operate at a 50 duty cycle when the weld period is an integral number of cycles In unipolar half cycle operation Unipulse transformers can be used at a rate of 5 welds per second The duty cycle for unipolar half cycle operation should no exceed 4 2 at full output which translates to one weld cycle at 99 heat during a 12 cycle period Insulation Unipulse transformer insulation is Class 130 rated at 180 C Transformer Tap Switch The TAP switch located on the front of the transformer selects the output voltage Tap 1 selects the lowest voltage on all transformers For example the rms open circuit output voltage of an X2 230 transformer is 2 0 volts on Tap 1 and 3 2 volts
7. An example of the permanent save procedure option follows l 2 Switch the circuit breaker on the rear panel to OFF then ON Use gt to select Schedule 1 Press PROG Use gt to move to the weld function field Use CHNG to select SEQUENCE Press to move to the SQZ field Use NUMBERS to change the number of squeeze cycles to 5 Press SAVE Switch the circuit breaker to OFF then ON Notice that Schedule 1 has been permanently modified to contain the new parameters An example of the temporary save procedure option follows l Ze Use gt to select Schedule 1 Press PROG Use to move to the weld function field Use NUMBERS to change the number of squeeze cycles to 5 Press RUN Notice that the modified Schedule 1 has been transferred to Schedule 0 because you used RUN instead of SAVE to exit the program state Schedule 0 is a scratch pad into which any schedule that is changed but not saved is transferred In practice you could now make a weld with the modified schedule PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 5 5 CHAPTER 5 OPERATING INSTRUCTIONS Configuring the Weld Sentry You configure the Weld Sentry from the MAIN MENU Each PM7 weld schedule can have five related sentry programs A through E For example for PM7 Weld Schedule 10 the related sentry programs are 10A through 10E To configure a sentry schedule 1 While in the run state
8. NUMBERS to Change until the line voltage returns to within limits for the duration of the restart time AUTO does not affect operation of the line voltage compensation option PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 6 7 CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS 6 8 NOMINAL LINE VOLTAGE Use CHNG to select the wired line voltage range of the PM7 90 110 110 120 200 220 220 240 380 400 or 440 480 Nominal line voltage ranges can be selected from three different line voltage screens PM7 LINE VOLTAGE ALARM LINE VOLTAGE COMPENSATION and PM7 CALIBRATION When nominal line voltage information is changed on one screen the PM7 will automatically change the other two screens ACTUAL LINE VOLTAGE This selection displays the measured value of input line voltage As with any meter it is normal for the value to fluctuate slightly to reflect the true condition of the AC line LOW HIGH LINE LIMITS With this selection you may choose the amount of deviation which will signal the line voltage alarm You set the limits as percentages of the nominal line voltage the low limit between 13 and 5 and the high limit between 5 and 13 If you set the limits at 13 13 the line voltage alarm would be signaled whenever the actual line voltage was less than 13 below the normal line voltage or more than 13 above the normal line voltage RESTART TIME You use this selection only when LINE ALARM MODE is set for AUTO W
9. heads using separate weld schedules for controlling VALVE DRIVER 1 and VALVE DRIVER 2 e Unit is protected from radio frequency and electromagnetic interference to ensure reliable operation even in high electrical noise environments e Can operate on multiple line voltages 90 110 110 120 200 220 220 240 340 400 or 440 480 VAC 50 60 Hz PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 1 3 CHAPTER 2 INSTALLATION Location Install the PM7 in a well ventilated area that is free from dirt and moisture Allow sufficient clearance around the sides and rear of the unit so that cooling air may flow properly Position the PM7 as close as is practical to the weld head Power Line CAUTION Do not connect the line cord at this time This power supply was wired for the specific input line voltage marked on the line cord at the factory The standard PM7 is wired for 230 VAC Reconnection for operation at another voltage may be made by a qualified technician Refer to Chapter 7 under Modifications and Calibration Welding Cables Position the PM7 on the work bench approximately 5 inches behind the weld head Use the cables furnished with the weld head to connect the terminals on the back of the weld head to the appropriate terminals on the welding transformer Refer to Appendix A for welding transformer specifications Convention is to connect the lower electrode of the weld head or handpiece to the output terminal and the upper e
10. shows the result of excessive air pressure the actual force is much greater than the firing force setting Excessive air pressure causes the electrodes to mushroom as well as wear faster PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 4 5 CHAPTER 4 GETTING STARTED Welding Force Welding Force Firing Switch Closes Firing Switch Closes Dial Dial Indicator Indicator Force Setting Force Setting 11 12 13 14 15 16 4 6 Figure 4 4 Results of Excessive Air Pressure Ifa higher welding force is necessary reset the force indicator on the weld head to a larger number then repeat Steps 9 and 10 If a lower welding force is necessary reset the force indicator on the weld head to a smaller number reduce the pressure regulator which controls the air pressure on the top of the air cylinder then repeat Steps 9 and 10 If appropriate configure the Weld Sentry Press MENU select WELD SENTRY followed by SYSTEM SETUP If appropriate configure the Weld Sentry print options relay outputs and communications options Set the Weld Sentry clock for the correct time and date If appropriate modify the Weld Sentry program To develop a Weld Sentry program use the Weld Sentry basic setup option which is accessed by pressing MENU and selecting WELD SENTRY followed by BASIC SETUP If you want to see a graphical representation of a weld schedule select DISPLAY GRAPH OF LAST WELD from the Weld Sentry
11. then press HELP to receive an explanation Alarm messages will be erased from the display as soon as the alarm condition is corrected or when PROG is pressed Refer to Appendix A under Control Signals to remotely clear alarms 1 Refer to the appropriate weld head manual instructions on how to install the welding electrodes 2 To adjust the pressure regulators and flow controls refer to the following instructions or those which are printed on the side of the weld head 3 To prevent the PM7 from firing until you are ready to weld select NO WELD Remove the workpiece from between or beneath the electrodes 4 Set the force indicator on all Unitek weld heads to 3 For more detailed information on setting up each specific weld head refer to their respective manuals See figures 4 1 and 4 2 for illustrations of typical air actuated systems 5 Unlock the regulator s by pulling the red ring up Set the air gauge s for 10 psig Fully open both flow controls 6 The operational sequence with an air head is as follows The first level of a 2 Level foot switch actuates the weld head moving the electrodes together The weld period cannot begin until the second level of the foot switch and the force firing switch in the weld head close The PM7 will enter a standby state until these conditions are met When the firing force is reached the weld period will start Assuming that an alarm does not occur the welding sequence will continue to complet
12. 4 Microprocessor CPU The PM7 uses a Motorola M68HC11A1 CPU with an 8 0 MHz clock 8K bytes of random access memory 512 bytes of electrically programmable read only memory and 128K bytes of ultra violet erasable and programmable read only memory Display This is an electrostatically shielded 8 row by 40 column rear lit liquid crystal cold cathode display A contrast level adjustment potentiometer can be accessed through a hole in the rear panel Cooling Cooling within the housing is provided by a muffin type fan that operates on 115VAC 50 60 Hz power The air inlet is underneath the unit and exhaust is through the rear panel No restriction to air flow should be closer than 2 inches to the sides and rear of the PM7 Do not place the PM7 on a soft pad or on any other surface which could block the air inlets on the bottom of the housing Do not allow the PM7 to sit on surfaces that are covered with heavy dirt or dust PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 A 15 APPENDIX A TECHNICAL SPECIFICATIONS Physical Characteristics Length 12 7 8 in 32 7 cm Width 11 5 8 in 29 6 cm Height 8 3 8 in 21 3 cm Weight 20 lbs 9 kg ANNAN Unipulse Transformers Unipulse transformer designs guarantee repeatable output energy even during half cycle operation They are convection cooled However their performance and duty cycle can be increased with optional fan cooling The four models illustrated in Figure A
13. Based onthe Declaration cf Conformity Certificates issued by the test faboratores I declare thet the equipment specified above con orms to the fisted directive and stindards Place Monrovia CA Sigrature Robert J Watlish Full Nane or ality Assuan Vice Presi Engi Title Title UNITEK MIYACHI CORPORATION Declaration of Conformity Directive s EMC LOW VOLTAGE MACHINERY Type of Equipment Resistance Welding Power Supply Equipment Applied Standards EN 50081 2 EN 50082 1 EN 55011 TEC 801 2 TEC 801 3 IEC 801 4 EN 60204 1 EN 50063 Model Nos PM7 PM7 100 PM7 208 PM7 115 PM75 PM7S 100 PM7S 208 PM75 114 Authorized Representative Weld Equip Sales BV Within European Community Enpelseweg 217 Postbus 164 5700 AD Helmond HOLLAND Manufacturer s Name and Address UNITEK MIYACHI CORPORATION 1820 South Myrtle Avenne Monrovia CA 91017 USA Based on the Declaration of Conformity Certificates issued by the test laboratories I declare that the equipment specified abave conforms to the listed directive and standards Place Monrovia CA Signature Robert J Wallish Mark G Rodighiero Full Name Full Name Director of Quality Assurance Vice President Engineering Title Title CHAPTER 1 SYSTEM DESCRIPTION Applications The Phasemaster 7 PM7 figure 1 1 is a versatile single phase sequence welding control which can effectively solve most precision small parts resistance welding problems Its context
14. ENERGY WELDING CONTROL 990 084 vii ILLUSTRATIONS Figure Title Page 1 1 PM7 Direct Energy Welding Control oocoooononnnonenionaninnononcnonncnon cono nononcnnancnon cana cono nccancnnos 1 1 2 1 Cable Routing Example Sinisen naa a a abbas 2 2 2 2 Terminal Connection Examples adds 2 2 2 3 PM7 Rear Panel Components a te cata 2 3 2 4 Typical Solenoid Air Valve Assembly with a Single Regulator ooooooccnnncnnncococnconccinnocnss 2 6 2 5 Cable Connections for a Typical Dual Air Actuated Air Head System 0 0 0 ce eeeeeeeeees 2 7 2 6 Reconfiguration for Dual Weld Head Operation oooooconoccniccnonccconncoonocononnonc conc cono cono noconccnnos 2 9 2 7 Weld Cable Installation for Dual Head OperatiOM ooonoccnicnnnoncconononnnononoconaconn cono ncnnnccnncnnnos 2 10 2 8 PM Equipment Interconnection Diari did tds 2 11 O a 8 tee Sse es hates else A Nols a Wage va wee 3 1 3 2 Screen Flow Chart ar iii aria 3 5 4 1 Typical Solenoid Air Valve System with Dual Regulators oononnoconinccnoccnoccnnncnconnaconocnnos 4 2 4 2 Typical Solenoid Air Valve System with a Single Regulator oooonicninncnnnconocccoccnonccconnccnns 4 3 4 3 Measuring Preset Firing Force of the Weld Head with a Force Gauge ocooonoccnncccconcconcnnnos 4 5 4 4 Results of Excessive Air POSSE Ue a Oi a 4 6 4 5 Weld Head Configuration Jumper Selection oooccnnncnnnconicocconnnonnnonnncnnnoconocnnn cono corn nccnnnnnnos 4 7 5 1 Effects of Excessive or Insufficient Heat
15. TECHNICAL SPECIFICATIONS the welding current would be dependent in part on the position of the cables and the position of any magnet work piece placed between the electrodes Automatic Line Voltage Compensation When switched ON this feature increases the CURRENT by 1 for each 1 decrease in line voltage from the rated nominal line voltage Compensation is limited to maximum voltage changes of 13 The PM7 cannot compensate for more than a 13 decrease in line voltage when the CURRENT is set above 86 It cannot compensate for more than a 13 increase in line voltage when the CURRENT is set below 33 The amount of compensation is calculated immediately before the weld period starts The feature which is controlled from the Special Options menu should be switched OFF when the PM7 is being used to develop weld schedules The line voltage monitor measures line voltage during the half cycle before a weld is made You can program the percent deviation that will trigger the line voltage alarm You can configure the PM7 to e Ignore the condition and make a weld e Stop and initiate a voltage alarm e Initiate a voltage standby and wait until the line voltage returns within limits for the duration of the programmed restart time 1 to 60 consecutive cycles This selection does not affect operation of the Line Voltage Compensation feature 87 Delayed Half Cycle Firing This feature delays the first half cycle of the weld period by 87E if
16. While still in the program state scroll down to the Relay 1 Relay 2 information with the down arrow v key Change Relay 1 to read AIR HEAD 2 By doing so the air valve driver will be turned on for the duration of the weld cycle for Weld Schedule 2 and Weld Head 2 until the chaining feature returns to Weld Schedule 1 Relay 2 should still read OFF across all of the weld functions 4 Press the SAVE key to save the Schedule 2 parameters then return the PM7 to Schedule 1 Weld Functions The PM7 allows you program 128 weld schedules Each weld schedule contains all of the information required to execute a specific weld function Typical timing of a weld function is shown in figure 6 1 l l SQUEEZE WELD HOLD 0 99 CYCLES 0 5 0 99 CYCLES 0 99 CYCLES WELD CURRENT 0 99 CYCLES WELD FORCE AIR HEAD ONLY Figure 6 1 Typical Weld Function Timing There are two versions of most functions one for an air actuated weld head and the other for a manually actuated weld head However the basic weld function applies only to a manual weld head the sequence function applies only to an air head Basic Function This function makes a simple spot weld It provides the solution for the majority of the resistance welding applications involving the use of manually actuated weld heads When the force firing switch PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 6 12 990 084 CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS in the weld he
17. between the electrodes Close the downspeed flow control located on the bottom of the cylinder 9 Press the foot switch Adjust the downspeed flow control so that the upper electrode moves at a reasonable rate and does not impact the workpiece hard enough to damage either the electrode or the workpiece If the flow controls interact readjust the air pressure which controls the pressure on the PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 4 4 990 084 CHAPTER 4 GETTING STARTED bottom of the cylinder so that it is identical to that set on the other regulator Then adjust the flow control so that the upper electrode does not slam against the bottom electrode or the downstop 10 Adjust the pressure regulator which controls the air pressure on the top of the air cylinder so that it is just sufficient to cause the Force Firing Switch in the head to close see figure 4 3 When the Force Firing Switch in the head closes the screen on the PM7 will no longer display STANDBY Re adjust both flow controls as necessary FORCE GAUGE ELECTRODES Figure 4 3 Measuring Preset Firing Force of the Weld Head with a Force Gauge CAUTION Resist the temptation to increase the downspeed by increasing the regulator setting since this increases the force applied to the workpiece by the electrodes see figure 4 4 Illustration a in figure 4 4 shows the correct air pressure adjustment the actual force equals the firing force setting Illustration b
18. described in greater detail in Chapter 6 Press the RUN key to enter the run state which is signified by the RUN legend in the lower right hand corner of the screen Press the PROG key to enter the program state which is signified by the PROGRAM legend in the lower right hand corner of the screen Help State Selection The help state provides on line instructions for programming the PM7 Press HELP to enter the help mode When you wish to return to the programming mode press HELP again PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 CHAPTER 5 OPERATING INSTRUCTIONS Selecting a Schedule Press gt or NUMBERS to select any schedule number from 0 to 127 Each schedule will be displayed together with the configuration of the system If you hear a beep audible tone in response to your selection 1t means that no schedule has been defined for that schedule number Changing the Display Format SCHEDULE 2 SEQUENCE Press CHNG to add the status of the output SYSTEM AIR 2 LEVEL WELD 0000001 relays Relay 1 and Relay 2 to the RUN screen ME SO E WELD m HOLD M CYCLES 0 12 0 CURRENT 75 Press CHNG again to substitute the optional RELAY 1 ALARM RELAY 2 OFF ON OFF 4 Y Select Schedule RUN J weld sentry information for relay information The weld sentry information includes the measurement parameter AMP SECONDS 1589 the preset upper and lower limits 1500 and 1650 respectively the weld sentry s
19. fuse ratings Line Voltage Fuse Type 100 250V 1 2A Slo Blo 120 250V 1 2A Slo Blo 208 250V 1 4A Slo Blo 240 250V 1 4A Slo Blo 400 480 440V 1 4A Slo Blo CIRCUIT BREAKER Used as a circuit breaker and a power ON OFF switch ACCESSORY PORT 25 pin sub miniature D connector used to interface the PM7 with other Unitek Peco devices CONTROL SIGNALS 15 pin subminiature D connector used for Remote Schedule Selection Emergency Stop and Process Inhibit and Relay Outputs See Appendix A OUTPUT CABLE 5 foot cable used to connect the PM7 to any Unitek Peco AC Welding Transformer AIR VALVE DRIVER 1 Provides either 24 or 120 VAC to Unitek Peco Air Actuated Weld Heads AIR VALVE DRIVER 2 Provides only 24 VAC to Unitek Peco Air Actuated Weld Heads POWER CABLE 5 foot cable 120 volt model terminated with the appropriate 120 volt plug Firing Switch Connections Connect the weld head or handpiece to the appropriate firing cable or switch located on the rear panel of the PM7 2 4 Mechanical Firing Switch Unitek Peco weld heads and handpieces are force fired and have two pin firing switch connectors which can be connected directly to the mating connector ofthe MECHANICAL FIRING SWITCH located on the rear panel of the PM7 PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 CHAPTER 2 INSTALLATION Users of manually actuated weld heads which do not have force firing switches must connect the two pins i
20. power ON lt CALIBRATE PM7 gt 4 Press the MENU key to access the READING 000 5I menu mode and select the CALIBRATE PM7 screen SET NOMINAL LINE VOLTAGE 240 ADJUST R18 at 60 Hz to O 5 Select the SET NOMINAL LINE ADJUST R19 TO MATCH LINE VOLTAGE VOLTAGE option and use CHNG to select the input line voltage of the PM7 av Select CHNG to Change NOTE You can select the nominal line voltage on any one of three screens When you select the nominal line voltage on one of the screens the other two reflect the change 6 With the av keys position the cursor next to either R18 or R22 The PM7 will automatically determine the correct line frequency and display the appropriate potentiometer R18 or R22 for you to adjust For 60 Hz units R18 will be displayed For 50 Hz units R22 will be displayed If the READING on Line 1 of the display is not 0 5 adjust R18 60 Hz filter adjustment or R22 50 Hz filter adjustment until the READING is 0 5 7 With the av keys position the cursor next to ADJUST R19 TO MATCH THE LINE VOLTAGE The READING line on the screen will now indicate the actual line voltage 8 Using a digital AC voltmeter measure the voltage across TB1 and TB2 on the control PCB The meter reading and the screen READING line should compare within 1 volt If they do not adjust R19 until they do 9 Set power to OFF 10 Replace the cover and top screws Securely tighten all screws PHASEMASTER 7 D
21. sensitive user help screens quickly guides you through even the most complex program GNUNITEK PECO O NO WELD Figure 1 1 PM7 Direct Energy Welding Control PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 1 1 CHAPTER 1 SYSTEM DESCRIPTION The PM7 can be used with manual user actuated or air actuated weld heads It is compatible with Unitek Peco s exclusive UNIPULSE Transformer series which guarantees repeat able output energy even during half cycle operation UNIPULSE Transformers will operate at a 50 duty cycle when the weld period is an integral number of cycles In unipolar half cycle operation UNIPULSE Transformers can be used at rates up to five welds per second You can program up to 128 weld schedules and save them in battery backup memory A built in schedule protection feature protects weld schedules from unauthorized or inadvertent changes Schedule 0 serves as a scratch pad which anyone can use to perform occasional jobs without jeopardizing the integrity of the production line The remote schedule selection feature allows you to reliably select weld schedules in automated applications The PM7 is a multi voltage unit designed for operation in the standard line voltage ranges of 90 110 110 120 200 220 220 240 380 400 or 440 480 VAC 50 60 Hz The automatic line voltage compensation feature ensures that the weld quality will not be affected by normal fluctuations in line voltage one of the major causes o
22. switch Go to the OPTIONS 2 menu and select CHAIN SCHEDULE FEATURE ON NOTE The Chain Schedule Feature is not needed to operate Dual Weld Heads However using the Chain Schedule Feature can facilitate weld head selection by automatically switching between weld heads after a pre programmed number of weld process cycles STEPS Press the PROGRAM key to return to the PROGRAM screen Weld Head 1 Weld Schedule Parameters To select the Weld Head 1 parameters 1 2 Select Schedule 001 and input the correct weld schedule parameters for Weld Head 1 Program the Chain Schedule Feature for NEXT SCH 002 Program STEP COUNT for the number of welds that Weld Head 1 should make before switching to Weld Head 2 While still in the program state scroll down to the Relay 1 Relay 2 information with the v key Make sure that for Schedule 1 Relay 1 reads NOT USED the default reading and Relay 2 reads OFF across all of the weld functions Press the SAVE key to save the Schedule 1 parameters Weld Head 2 Weld Schedule Parameters To select the Weld Head 2 parameters 1 Select Schedule 2 and input the correct weld schedule parameters for Weld Head 2 PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 6 11 CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS 2 Program the Chain Schedule Feature for NEXT SCH 001 Program STEP COUNT for the number of welds that Weld Head 2 should make before switching to Weld Head 1 3
23. the PM7 functions A complete preheat postheat weld function for an air head system is shown at the right The SCHEDULE 5 PRE POSTHEAT PREheat current raises the temperature of the SYSTEM AIR 2 LEVEL WELD 0011111 work pieces during the PREheat period it eS QZ PRE WELD POST mt HLD raises it to a level which stabilizes their oo r m y y e CURRENT 75 90 0 surface condition so that the welds are more consistent PREheat also allows time for the electrodes to seat firmly against the work av Select CHNG Change PROGRAM pieces and force them into intimate contact with each other The weld is performed during the weld period by the welding current The POSTheat CYCLES and POSTheat CURRENT are used to anneal the work pieces In this example POSTheat was set to 0 because small parts do not need annealing In the example program screen shown at the SCHEDULE 3 PRE POSTHEAT right the pre postheat function was used to SYSTEM MANUAL WELD 0011111 weld a nickel tab to a plated steel battery case MWNNNSOZ MEPRE MWELD EEPOST m HLD The 1 cycle PREheat pulse provided sufficient CYCLES 0 l 5 0 0 heat to allow the electrodes to force the CURRENT 30 90 0 plating out of the weld area The 0 5 cycle ld pul lded the nickel tab to the steel jaa pulse welded the nickel tab to the stee AWS Select CHNG Change PROGRAM J PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 6 15 CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS
24. the weld current is greater than 73 The feature prevents the buildup of a DC component in weld transformers using Hypersil core materials The delay reduces the maximum energy that can be delivered during the first half cycle NOTE Unitek Peco transformers do not require the delay Chain Schedules Feature The chain schedules feature is used to automatically change the weld schedule in use to another specified schedule Chain schedules is a system feature and is turned ON using the options menu When chain schedules is turned ON the RUN screen and PROGRAM screen for each schedule will have additional fields for both STEP COUNT and NEXT SCHEDULE STEP COUNT and NEXT SCHEDULE are used to chain schedules together PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 A 9 APPENDIX A TECHNICAL SPECIFICATIONS Step Count STEP COUNT is a weld counter which counts down to 0 Any number from 00001 to 99999 can be entered as a step count When the step count reaches 0 the schedule will change as specified by the NEXT SCHEDULE If a weld sequence is not completed and or the WELD NO WELD switch is set to NO WELD the step counter will not count down Next Schedule NEXT SCHEDULE is the number of the weld schedule to be used when the step count reaches zero Any schedule number from 001 to 127 can be used and any number of schedules can be chained together with some exceptions as follows e Next Schedule 0 Can only be used at the beginning of a
25. transformers Set the rear panel circuit breaker power switch to ON The title and copyright screens will be displayed followed by the run screen Press gt 4 to change the weld schedule number Press CHNG to change the format of the RUN state screen Press HELP to obtain help Press MENU to change any of the system options or to use any of the PM7 utilities Press PROG to make changes to weld schedules 0 to 127 Schedules 1 through 127 cannot be changed when the system security is PROTECTED If SCHEDULE LOCK is also ON only the schedule displayed can be used to weld To change system security and or turn OFF SCHEDULE LOCK press MENU and select SYSTEM SECURITY PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL GNUNITEK PECO WORLD LEADER IN RESISTANCE WELDING PHASEMASTER 7 WELD CONTROLLER UNITEK MTYACHI CORPORATION MONROVIA CALIFORNIA COPYRIGHT 1991 ALL RIGHTS RESERVED RELEASE 1 00 SCHEDULE 9 UP DOWNSLOPE SYSTEM AIR 2 LEVEL WELD 0000001 ms SOZ UP WELD m DOWN mHOLD CYCLES 10 12 10 0 0 CURRENT 30 75 20 A Y Select Schedule g RUN NOTE To override the security code refer to Appendix A under Weld Schedules If appropriate change the output relay configuration with the PROGRAM screen PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 4 1 CHAPTER 4 GETTING STARTED Adjusting an Air Actuated Weld Head NOTE If an alarm occurs press RUN to silence the alarm
26. 0 2 10 for rollspot indicates that the rollspot welding CURRENT 20 will continue for as long as the firing switch me P foot switch air weld head remain IFE Select GHING Change PROGRAM J closed CAUTION Do not exceed the duty cycle rating of both the PM7 and the Unipulse welding transformers as listed in Appendix A PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 6 18 990 084 CHAPTER 7 MAINTENANCE Modification and Calibration Unless you are a skilled technician we suggest you telephone our Repair Department at the telephone number shown in the Foreword of this manual for advice before attempting calibration and or modification WARNING Contact with voltages present in this welding control may cause serious or fatal injuries Cover Removal It will be necessary to remove the outside cover to perform calibration or modifications Use the following procedure 1 Set the rear panel circuit breaker power switch to OFF 2 Disconnect the PM7 from its power source 3 Remove the top two screws on each side of the cover 4 Loosen the bottom two screws on each side and lift the cover straight upwards Line Voltage Changes You may reconnect the PM7 to operate at different line voltages 90 110 110 120 200 220 220 240 340 400 or 440 480 VAC 50 60 Hz You may reconnect the PM7 380 to operate at 480 VAC In order to operate the PM7 PM7 100 PM7 120 or the PM7 208 at 480 VAC a factory modification is required To reconfigure
27. 2 5 A A naa Pts an ena nope ust ea ies Aaa aca ai lad Sale E ol E hea alia ce 2 5 Air Actuated Weld Head CONEA ass 2 5 A e a E a E a a ean 2 7 Non Unitek Peco Air Actuated Weld Heads ooooonoocciccnnoncconccconoconnnnnncconccconocnnn nono ncon coco nccnnos 2 8 Air Actuated Weld Heads without Force Firing SwitCheS ooooconnconocnniccnnoonconncconoconnconnncnnnoos 2 8 Second da 2 8 EOI A a e dd Sal o a Fale o cd Eo od 2 8 HE A ds a EE T de dese a e A meee a 2 8 2 Eevel Foots Witch s arar era EEE do 2 8 Dual W ld Head Installation A al 2 9 Internal RECO ido 2 9 Ext rnal RECON La LA A A A toate 2 9 Remote Schedule Selec A RA A A A A A a leans 2 10 AS caee vcscigs tetotucitce a a a aes ois a eevee taba onde 2 10 Interconnection Maer aii x5 A A ES 2 11 CHAPTER 3 OPERATING CONTROLS AND SCREENS 0 cccccccccceccescceseeseeeeeeseeseeseenaes 3 1 Mi soe oa 8 alee cade O cada ao acted A na Made Me aac estes vasa 3 1 SETE OS A A Ra 3 3 PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 CHAPTER 4 GETTING STARTED iia 4 1 Powers ANA AR A AIRES 4 1 Adjusting an Air Actuated Weld Head cccccccccsscsssecssecesecseeeeescecsaeceseesececeaeecsaeceseeseeeenaeecsaeoes 4 2 CHAPTER 5 OPERATING INSTRUCTIONS 000 occcccccceecceeeseeseeseesecaeesecneeecaeeeeeaeeseeaeeneeaes 5 1 Successful Wed ST AAA AE 5 1 Resistance Weldmo Patameler os eins 5 1 Using the Run Program and HELP States isolated ada 5 2 Run and Program State S
28. 4 include a primary tap switch The red pilot lamp on the front of the Unipulse transformer lights when voltage is applied to the transformer primary Refer to Table A 4 for Unipulse transformer specifications Figure A 4 Unipulse Welding Transformers Table A 2 Unipulse Welding Transformer Specifications Model Pri Input KVA Duty Taps Output Voltage rms Short Ckt I Height Width Depth Weight Volts Cycle A in em In em In cm Ibs kg 3 8 50 Pri Sec X2 115RF 115 3 1 1 9 0 75 4 0 3 8 2 4 1 5 1 0 2400 6 5 16 5 6 5 16 5 1 0 27 9 20 9 X2 230RF 230 3 1 1 9 0 75 4 0 3 8 2 4 1 5 1 0 2400 6 5 16 5 6 5 16 5 1 0 27 9 20 9 X2 115 115 2 5 25 1 0 4 0 3 2 2 7 2 4 2 0 2300 6 5 16 5 6 5 16 5 1 0 27 9 20 9 X2 230 230 235 2 5 1 0 4 0 3 2 2 7 2 4 2 0 2300 6 5 16 5 6 5 16 5 1 0 27 9 20 9 X5 115HV 115 9 8 4 5 1 8 4 2 14 to 1 8 in 12 steps 1800 8 3 21 1 6 6 16 8 9 6 24 4 60 27 X5 230HV 230 9 8 4 5 1 8 4 2 14 to 3 5 in 12 steps 1800 8 3 21 1 6 6 16 8 9 6 24 4 60 27 X8 230 230 13 0 8 0 3 2 8 0 5 8 5 3 4 8 4 4 4 0 3 6 3 3 3 0 13 0 33 0 7 0 17 8 4 0 35 6 90 41 X16 230 230 26 0 16 0 6 4 3 2 5 6 4 9 92004 3 HI COM 16000 13 0 33 0 7 5 19 1 4 0 35 6 95 43 3 6 3 3 2 9 LO COM 1 9 1 6 1 4 HI LO X16 480 480 26 0 16 0 64 3 2 5 6 4 9 4 3 HI COM 16000 13 0 33 0 7 5 19 1 14 0 35 6 95 43 3 6 3 3 2 9 LO COM 1 9 1 6 1 4 HI LO
29. 6 1 INOW ESD aT ats ase dre Sad 6 1 PROGRAM Sato castes ianede caxehs essegan eux eahion a R 6 1 PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL vi 990 084 MENU State A A Ia IE acia 6 2 A A teat Rtas anne Geode tues cae ade salt dal eeu cece hte testi Reson 6 10 STANDBY Staten a id PRON Oe aT 6 10 WELDS Cate siiperi ea oe Ea Aes chase a A dia 6 11 Programming a Dual Weld Head Sc e Stasis A e dai 6 11 Weld Head 1 Weld Schedule Parameters as eenihea entseenannivnaeey 6 11 Weld Head 2 Weld Schedule Parameters cu ia 6 11 Weld Function ld dl aia 6 12 MEAS TCSP NCL oat pa ts aes Sa el otek elie ce ll Pale dae os aden cesses nde dod oat dt 6 12 Sequence UMC TIONS ste a ye dslose ORO a a seat 6 13 Sequence Repeat FUMA 6 14 Brazo Funcion 6 15 Pre Post Heat On a TO il 6 15 Up Downstope Punch a ici 6 16 QuEncC Temper FUNCION ta e 6 16 Unbalanced AC Func Mii ii bo dos 6 17 Continuous PU CON A aan aaa Mua east A A 6 17 Rollspot PUC ode ado isos 6 18 CHAPTER 7 MAINTENANCE 00 AI A A eS 7 1 Modification and Cabra es a eRe ela te es 7 1 Cover REMO A akan 7 1 Line Voltage AS AT CG arene ccc N ay E AA E 7 1 ait Abts a eta R a acuta ram anh Roe sci mara oak a ah aaa rece E N gas 7 3 REP aI O Gears aa Sav asd ate eased Sate a a at ee id A 7 4 Telephone Service nt in 7 4 Factory Service Rep aie siesta tiie e EE 7 4 APPENDIX A TECHNICAL SPECIFICATIONS oocoocococcnonononnnonononnncnnnnnnnnnnnnnnnnnnnonnnnncconnnnncnnnnnnnos A 1 PHASEMASTER 7 DIRECT
30. CHEDULE LOCK This selection prevents you from changing weld schedules You may use only the currently selected schedule All other schedules are locked out and cannot be used to weld Use the gt keys to select SCHEDULE LOCK and press CHNG to select ON Then change SECURITY STATUS to PROTECTED NOTE If the security status is unprotected SCHEDULE LOCK will automatically change to OFF LINE VOLTAGE Select this option to program either the line voltage alarm or line voltage compensation Use the gt keys to lt LINE VOLTAGE gt select LINE VOLTAGE ALARM or LINE ELINE VOLTAGE ALARM VOLTAGE COMPENSATION then press ELINE VOLTAGE COMPENSATION ENTER lt A Y Select then ENTER LINE VOLTAGE ALARM Line voltage is measured during the half cycle before a weld is made You can set the line voltage alarm whenever the actual line voltage deviates from the nominal voltage by more than the programmed high low limits When you select LINE VOLTAGE ALARM the PM7 LINE VOLTAGE ALARM screen will be displayed LINE ALARM MODE Use CHNG to TE ee coe VOLTAGE ao gt select either OFF STOP or AUTO OFF NOMINAL LINE VOLTAGE 240 means ignore the condition and make a weld ACTUAL LINE VOLTAGE 238 5 STOP means stop and initiate a VOLTAGE LOW HIGH LINE LIMITS 05 05 ALARM press RUN to clear the alarm RESTART TIME 20 CYCLES AUTO means initiate a voltage standby a voltage standby will cause the PM7 to wait AY Select
31. COPY SCHEDULE 44 TO SCHEDULE LINE ALARM MO DE NOMINAL LINE VOLTAGE ACTUAL LINE VOLTAGE LOW HIGH LINE LIMITS RESTART TIME SECURITY STATUS PROTECTED UNPROTECTED SCHEDULE LOCK ON OFF ENTER CODE TO CHANGE STATUS SYSTEM COPY cal SECURITY SCHEDULE COUNTER 1 CONFIGURE LINE VOLTAGE ALARM 2 LINE VOLTAGE COMPENSA TION LINE ALARM MODE NOMINAL LINE VOLTAGE ACTUAL LINE VOLTAGE LINE VOLTAGE FREQUENCY SCHEDULE REFERENCE VOLTS SENTRY MAIN MENU UNEVM A LAMP USA TAN READING HAN SETNOMINAL LINE VOLTAGE 100 115 208 230 460 ADJUST R18AT 60HZTO 0 ADJUST R19TO MATCH THE LINE VOTAGE CALIBRA TE PN 1 RESET SYSTEM PARAMETERS 2 RESET ALL SC HEDULES PROG RAMS su ee gt ES blm e rg INSTALLATION HELP NSTALLATID KEYBOARD RELAY OUTPUTS CONTROL SIGNALS VALVE OUTPUTS WELD SENTRY DATA OUTPUT REVIEW HELP SYSTEM HELP Figure 3 2 Screen Flow Chart PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 ON OFF POWER FACTOR CORRECTION ON OFF ON OFF 0 5 1 2 4C YC LES AUTO OF F STOP 100 115 208 230 460 VOLTS HH H CYCLES AUTO OF F STOP 100 115 208 230 460 NOLTS 50 60 Hz Volts 3 5 CHAPTER 4 GETTING STARTED Powering Up 1 To prevent the PM7 from firing until you are ready to weld select NO WELD Set the welding transformer tap switch to its lowest tap position This is Tap 1 on UNIPULSE
32. EDULE 9 SEQUENCE REPEAT NEXT SCH 13 SYSTEM AIR2 LEVEL COUNT 11111 SO em WELD m HOLD OFF m RPT The typical program screen for the sequence repeat function shows two additional periods CYCLES 10 12 10 15 OFF and RPT During the OFF period the PM7 CURRENT 75 releases the solenoid on the air actuated weld RELAY 1 AIR HEAD head for sufficient time for the electrodes to open RELAY 2 ON ON OFF ON and allow the parts to be repositioned before the 4 v Select NUMBERS Change PROGRAM J entire welding sequence repeats RPT PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 6 14 990 084 CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS Braze Function The braze function is ideal for both brazing and some non critical reflow soldering applications To ensure complete solidification of the brazing alloy the electrodes which are water cooled SCHEDULE 12 BRAZE SYSTEM AIR 2 LEVEL WELD 0011111 E SO WELD m HOLD IE in these applications cool the work pieces during the hold period CYCLES 0 128 60 CURRENT During the hold period the weld head RELAY 1 OFF OFF ON continues to apply force to the work pieces RELAY 2 OFF OFF OFF The example program screen shows that 60 lt a Y Select CHNG Change PROGRAM cycles was preset for the hold period and that Relay 1 was programmed for ON to control the flow of cooling water to the electrodes Pre Post Heat Function This function is the most versatile of
33. EMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 2 11 CHAPTER 3 OPERATING CONTROLS AND SCREENS Operating Controls Figure 3 1 illustrates the layout of the operating controls on the front panel of the PM7 ES VUNITEK PECO PHASEMASTER 7 WORLD LEADER IN RESISTANCE WELDING AC WELD CONTROL CONTROL CHNG HELP ff SAVE SELECT Figure 3 1 Front Panel Controls PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 3 1 CHAPTER 3 OPERATING CONTROLS AND SCREENS The controls on the front panel are identified as follows NOTE Instructions in the manual to press means that you are to press the key or button described inside the brackets For example Press PROG means that you should press the key labeled PROG on the front panel Press gt means that you should press either the SELECT or the gt SELECT key whichever is appropriate KEY DESCRIPTION DATA KEYPAD gt lt 4 PROG RUN SAVE Use the 10 numeric keys to enter numeric information is used to enter decimal values Use the ENTER key to signify that the data entry you have entered using the keypad is complete In the run state these keys changes gt increases and decreases the schedule number displayed In program and menu states the and SELECT keys are used to move up and down on the screen to select fields In the program and menu states these keys are used to select the pa
34. ENERGY WELDING CONTROL 5 6 990 084 CHAPTER 5 OPERATING INSTRUCTIONS Using the Help Screen for Diagnosis To determine the cause and remedy for an alarm HELP STANDBY FIRING SWITCH press PROG to silence the alarm Then press WAITING FOR FIRING SWITCH ON AIR HEAD TO RUN to return to the run state Now press CLOSE OPEN FLOW CONTROL ON BOTTOM OF HELP to bring up the HELP screen As shown AIR CYLINDER OR USE AIR REGULATOR TO on the HELP screen for the standby alarm the condition resulted from waiting for the force firing switch to close INCREASE AIR PRESSURE OR USE TURN FORCE ADJUSTMENT KNOB TO REDUCE FIRING FORCE HELP to Return Weld Schedule Development Developing a weld schedule is a methodical procedure consisting of making sample welds and evaluating the results You should make the first weld at low energy settings Then you make adjustments to each of the parameters one at a time until a successful weld is made Weld Head Parameters There are two critical weld head parameters that you must pay particular attention to electrode force and electrode face area Electrode Force 1 Install the correct electrodes in the electrode holders on the weld head Refer to table 5 1 for electrode material recommendations 2 Set the force adjustment knob on the weld head to set the firing force Start at a moderate force setting 3 on a Unitek Peco Weld Head Figure 5 1 illustrates the effect of electrode force on the
35. ESET DEFAULTS screen RESET SYSTEM PARAMETERS Use the CHNG key to select YES or NO If you AY Select CHNG to Change select YES all system parameters will be set to factory defaults see table 6 1 Table 6 1 Factory Default Settings on Foreros cometen lon sd PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 6 9 CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS RESET ALL SCHEDULES Use CHNG to select either YES or NO If you select YES all schedules will be reset to factory defaults If the Weld Sentry option is installed all related programs will be reset to factory defaults INSTALLATION This option consists of help screens containing installation information Refer to Chapter 2 for more installation information SYSTEM HELP This option consists of all of the HELP screens HELP State The PM7 offers you context sensitive help when running or programming Press HELP whenever you have a question Press HELP again to return to the original screen For example if you press HELP from the RUN state information on the function of the PM7 keys will be displayed as illustrated below HELP RUN STATE PAGE 1 6 HELP MACHINE STATES PAGE 2 6 ALWAYS REFERS TO A FRONT PANEL KEY CHNG WILL CHANGE THE SCREEN FORMAT USE a OR v TO SELECT SCHEDULES WHICH SAVE IS NOT USED IN THE RUN STATE ARE NUMBERED O THRU 15 USE PROG TO MODIFY A SCHEDULE MENU RUN AND PROG ALWAYS CAUSE THE USE MENU TO DISPLAY THE MENU WH
36. ICH CONTROL TO CHANGE TO THE STATE DEFINED WILL PROVIDE MORE INFORMATION BY THAT KEY gt Next Page HELP to Return 4 Last Page gt Next Page HELP to Return If there is more than one page of HELP screens the current page number and number of pages will be displayed in the upper right hand corner Use lt gt to move from page to page Press HELP or the key defined on the bottom line to return to the run state STANDBY State The PM7 is waiting for a mandatory event to occur such as e The force firing switch in an air head to close or e The schedule number information to be placed on the terminals of the CONTROL SIGNALS connector or e Waiting to be reset to another schedule after a stop command in a chained schedule This state is essentially an alarm condition For details on how to deal with it refer to Chapter 5 under Alarms PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 6 10 990 084 CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS WELD State The firing switch in the weld head has closed and the welding sequence is proceeding Programming a Dual Weld Head General Program Requirements To prepare the dual weld head program 1 2 3 4 Configure Jumpers E2 and E3 on the PC board for dual weld head operation refer to Chapter 2 Go to the OPTIONS 2 menu and select WELD HEAD TYPE Configure the PM7 for WELD HEAD TYPE DUAL AIR and FOOT SWITCH TYPE 1 LEVEL or 2 LEVEL depending on the type of foot
37. IRECT ENERGY WELDING CONTROL 990 084 7 3 CHAPTER 7 MAINTENANCE Repair Service Telephone Service Call our Repair Department at the telephone number shown in the Foreword of this manual Before calling please obtain the model number and serial number from the identification plate on the rear panel Factory Service Repair Unitek Miyachi provides a repair service for both warranty and non warranty repairs Call the Customer Service Department at the telephone number shown in the Foreword of this manual for a Return Material Authorization number All equipment to be returned for repair must be shipped PREPAID Please include information concerning the type of problem you are experiencing Include with the shipping information the name and telephone number of the person whom we should call with the estimated cost of repairs PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 7 4 990 084 APPENDIX A TECHNICAL SPECIFICATIONS Type of Control NEMA Type BS2HX synchronous welding control capable of operating with air actuated or manually actuated weld heads Compatible with 1 level and 2 level foot switches It can sense single pole double pole or optical firing pressure switches Input Power Line Voltage The PM7 may be connected to any 100 120 208 or 240 volt outlet that is capable of supplying 30 amps The voltage drop at the outlet during the weld sequence should be less than 5 Frequency The PM7 is a dual frequency device
38. LP or additional information from the built in manual Press this key a second time to return to the original state CHNG Changes the contents of alphanumeric fields in the program or menu state Changes the format of the RUN screen in the run state WELD NO Welding current will not flow when this switch is in the NO WELD position WELD However the control will actuate the weld head and execute the welding SWITCH sequence Squeeze Weld and Hold This switch must be in the WELD Screen Formats position in order to make a weld Illustrated below is the information displayed in RUN PROGRAM NO WELD HELP and MAIN MENU screens Note that the PM7 operational state is displayed at the bottom right corner of the operation screens Refer to figure 3 2 for the organization of the screen menus PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 3 3 CHAPTER 3 OPERATING CONTROLS AND SCREENS RUN Screen A B c D SCHEDULE 9 UP DOWNSLOPE E SYSTEM AIR 2 LEVEL WELD 0000001 F saz UP WELD DOWN HOLD CYCLES 10 12 10 0 H CURRENT 30 75 20 B2iselect Schedule PROGRAM Screen SCHEDULE 11 SEQUENCE NEXT SCH 15 SYSTEM AIR 2 LEVEL STEP 99999 S02 WELD co ES CYCLES 10 12 CURRENT 75 RELAY 1 AIR HEAD RELAY 2 ON ON OFF 2 Select NUMBERS Change HELP Screen HELP MACHINE STATES PAGE 1 9 REFERS TO FRONT PANEL KEY USE gt 0R TO SELECT SCHEDULES USE PROG TO MODIFY A SCHEDULE USE PROG TWICE TO
39. MODIFY WELD SENTRY PROGRAM S IF INSTALLED USE MENU TO DISPLAY THE MENU y Schedule number 0 127 Weld function Polarity of weld current Weld counter Type of weld head and foot switch Periods associated with weld function User set time in cycles for each period IQTHEDOJW gt Current state User set welding current in of maximum RUN Screen With Weld Sentry SCHEDULE 9 UP DOWNSLOPE SYSTEM AIR 2 LEVEL WELD 0000001 HA So Mur GWELD PA DOWN HOLD CYCLES 10 12 10 0 0 CURRENT 30 75 20 AMP ECONDS LOWER UPPER SENTRY A 299 1F BY Select Schedule 270 0F 310 0F READY RUN NO WELD Screen SCHEDULE 9 UP DOWNSLOPE SYSTEM AIR 2 LEVEL WELD 0000001 MYY so up Web Down JHOLO CYCLES 10 12 CURRENT 30 RELAY 1 AIR HEAD RELAY 2 ON ON EZ Select Schedule E no weLo F MAIN MENU Screen MAIN MENU gt m OPTIONS m WELD SENTRY m WELD COUNTERS CALIBRATE PM7 m COPY A SCHEDULE m RESET TO DEFAULTS m SYSTEM SECURITY m INSTALLATION m LINE VOLTAGE m SYSTEM HELP ESE Select then ENTER OZBZE PR Weld sentry program lines if Weld Sentry is Installed Program A E results of last weld Measurement unit upper and lower limits and Weld sentry status Next schedule number 1 127 in chain Step count for next schedule Switching status of output relays Typical multipage help screen Run state with NO WELD switch ON PHASEMASTER 7 DIRECT ENERGY WELDING C
40. No 990 084 GNUNITEK PECO ie WORLD LEADER IN RESISTANCE WELDING Revision E January 2002 PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL Model Stock No Model Stock No PM7 1 239 XX PM7S 1 241 XX PM7 115 1 239 XX 01 PM7S 115 1 241 XX 01 PM7 208 1 239 XX 02 PM7S 208 1 241 XX 02 PM7 100 1 239 XX 03 PM7S 100 1 241 XX 03 PM7 460 1 240 XX PM7S 460 1 242 XX QNUNITEK PECO Mana T Notice Units with the built in Weld Sentry Option also require User s Manual No 990 291 For sales and service please call PTB Sales Ph 626 334 0500 Fax 626 334 2151 Toll Free 866 332 0500 SALES www ptb sales com Copyright O 1998 2002 Unitek Miyachi Corporation The engineering designs drawings and data contained herein are the proprietary work of UNITEK MIYACHI CORPORATION and may not be reproduced copied exhibited or otherwise used without the written authorization of UNITEK MIYACHI CORPORATION Printed in the United States of America Revision Record A E ee Led ENRG RLSE Originalrelease o O release 17273 3 98 Bind Addendum 995 084 Rev E into Rev A manual 17417 4 98 Rewrite reorganize and correct manual per Addendum 995 084 Rev E on 18063 1 00 Correct interconnection pin numbers interconnection pin Correct interconnection pin numbers 19146 1 02 Change name to Unitek Peco 7 Update manual PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 FOREWORD Thank you for purchasing a Unitek Peco Ph
41. ONTROL 3 4 990 084 OPTIONS WELD COUNTER COPY A SCHEDULE SYSTEM SECURITY LINE VOLTAGE WELD SENTRY CALIBRATE PM7 RESET TO DEFAULTS INSTALLATION 0 SYSTEM HELP NOTE 1 PRESS MENU TO GO TO MAIN MENU FROM RUN SCREEN OR PROGRAM SCREEN PRESS ENTER TO GO TO NEXT MENU PRESS MENU TO GO TO PREVIOUS MENU NOTE2 gt DISPLAY ONLY AND CANNOT CHANGE SCHEDULE FUNCTION SYSTEM MANAIR NO CYCLES SQZ UP WELD DOWN HOLD CURRENT AMPS STEPCOUNT 0 gt 99999 RUN SCREEN ACCESSED BY PRESSING RUN AT ANY TIME FUNCTIONS 1 BASIC WELD 6 UP DOWNSLOPE 2 SEQUENCE 7 BRAZE 3 SEQUENCEREPEAT 8 UNBALANCED AC 4 QUENCH TEMPER 9 ROLLSPOT 5 PRE POST HEAT 10 CONTINUOUS SEAM SCHEDULE FUNCTION SYSTEM MANIAIR NO CYCLES SQZ WELD HOLD CURRENT AMPS RELAY STATES ON OFF NEXT SCH HN STEPCOUNT 0 gt 99999 PROGRAM SCRECN AC CESSED BY PRESSING PROG AT ANY TIME CHAPTER 3 OPERATING CONTROLS AND SCREENS POWER UP SCHEDULE END OF CYCLE BUZZER KEY CLICK CHAIN SCHEDULES FEATURE af ON OFF ON OFF ON OFF HEAD TYPE AUTO AIR MA NU AL DU AL AR FOOTSWITCH 1 LEVEL 2LEVEL NONE FOOTSWITCH WELD ABORT ON OFF FIRING SWITCH 2WIRE 3 WIRE OPTO NONE ALTERNATE POLARITY 87 DEGREE DELAY SWITCH DEBO UNC E TIME NOTE This screen is replaced by the Weld Sentry weld counter screen when the built n Weld Sentry is installed WELD COUNTER 4444444
42. Press MENU 2 Select WELD SENTRY and follow the instructions given by the help screens or the weld sentry User s Manual Handling Alarm Conditions An alarm condition as exemplified by the standby alarm is indicated in the lower right hand corner of SCHEDULE 2 SEQUENCE NEXTSCH 5 SYSTEM AIR2 LEVEL the screen There are four alarm messages me S07 WELD MHOLD Is CYCLES 0 12 0 CURRENT 75 SCR Alarm RELAY 1 AIR HEAD RELAY 2 OFF ON OFF The output SCRs which control the flow of STAND BY J current to the welding transformer are defective They must be replaced by a qualified technician Emergency Stop An emergency stop signal was received from external user s equipment Input Switch Alarm The foot switch or force firing switch in the weld head closed before the PM7 went to the run state You must release then actuate the foot switch or foot pedal to correct this condition Standby Alarm The force firing switch in the weld head did not close within 10 seconds after the 1 level foot switch or the second level of the 2 level footswitch closed This condition is normally caused by the head hitting the downstop before sufficient force has been applied to the work piece to actuate the force firing switch Either adjust the downstop or increase the length of the upper electrode Sometimes this condition is caused by insufficient air pressure In this case increase air pressure slightly PHASEMASTER 7 DIRECT
43. RIVER receptacles for a dual air actuated weld head located on the rear panel of the PM7 Figure 2 5 shows the connections for a typical Unitek dual air actuated weld head system Weld heads with 4 pin 24 120 VAC connectors can be plugged directly into the AIR VALVE 1 connector Weld Heads with standard 120 volt plugs NEMA 5 15P require an adapter Unitek Peco Model VDAC Valve Driver Adapter Cable When the connection has been made the PM7 will automatically recognize that an Air Head has been connected Up Speed Up Speed Control Knob Control Knob Down Speed Force Adjust Control Knob z Knob orce Air DA nd icator DFS Parallel Switch Box MECHANICAL a FIRING SWITCH FOOT J SWITCH AIR AIR H VALVE 2 Foot Switch VALVET DRIVER Figure 2 5 Cable Connections for a Typical Dual Air Actuated Air Head System PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 2 7 CHAPTER 2 INSTALLATION Non Unitek Peco Air Actuated Weld Heads Users of air actuated weld heads not manufactured by Unitek Peco should connect the air solenoid valve on the head or regulator valve assembly to either the appropriate 24 volt or 115 volt pins of the receptacle on the rear of the PM7 Refer to Appendix A under Control Signals for detailed information Air Actuated Weld Heads without Force Firing Switches Users of air actuated weld heads not having force firing switches must use sufficient squeeze time to allow the head to close and to apply t
44. Time and PressSure cccccnnononononinicnoninnnnanonecos 5 2 5 2 Typical Weld Strength Profile o da 5 11 6 1 Typical Weld Function id scada esa 6 12 7 1 Line Voltage and Capacitor Bank Jumpering ss ssesesessessesesssresseserssressessrssressessessresseese 7 2 7 2 100 VAC Line Voltage Cont IA A RS 7 4 7 3 115 VAC Line Voltage Configuration sessessesesessesseserssressesstssressessrssresseesresresseeseesenssee 7 5 7 4 20S VAC Line Voltage CONSUMO a a dio 7 6 7 5 230 VAC Line Voltage Configura O siria 7 7 TABLES Table Title Page 5 1 Recommended Electrode Materials ani A rs 5 8 5 2 Causes of ImperisctWelds ti sa io a ies 5 10 GAL Lacio DS e oa O ad 6 9 7 1 Power Supply Voltage Range Specifications si A 7 9 PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL viii 990 084 UNITEK MIYACHI CORPORATION Declaration of Conformity Directive s ENC LOW VOLTAGE Type of Equipment Resistance Welding Transformers Applied Standards EN 50081 2 EN50082 1 ENS5011 1EC 801 2780 202 3 IRC 801 3 IRC 801 4 EN6020 1 EN 5008 Model Nos 22115 32 11 5 F 0 230 0 230RP 5 115HV 8230 28 2 30HV 216230 X1630HV X16 180 X16 460 335 130 when used with PM4 PM5 PMU Resisancs Welding Paver Supplies Authonzed Rep esentative Weld Ecuip Sales BY Within Exopeat Community Enceiseweg 217 Pastus 164 5700 AD Helmond FOLLAND Manifacterer s Name and Address UNITEK MIYACHI CORPORATION 1520 South Myrtie Avenue Monrovis CA 91017 TSA
45. Unitek PN 250 199 male connector and a DE 51210 1 Unitek PN 250 200 plastic junction shell The pin assignments are listed below 00000000 6000000 Figure A 2 CONTROL SIGNALS Connector Pin Function Pin Function 1 Remote Weld Schedule 7 Remote Weld Schedule Selection Control Line aP Selection Control Line 26 2 Remote Weld Schedule 8 Relay 1 Input Selection Control Line 2 9 Process Inhibit 3 Remote Weld Schedule 10 Emergency Stop Selection Control Line 2 11 Signal and Chassis Ground 4 Remote Weld Schedule 12 Remote Weld Schedule Selection Control Line 2 Selection Control Line 2 5 Remote Weld Schedule 13 RELAY 2 Return Selection Control Line 2 14 Spare 6 Relay 2 Input 15 RELAY 1 Return Emergency Stop Emergency stop or any other external function that should abort the welding sequence can be implemented by continuously shorting Pin 10 to Pin 11 ofthe CONTROL SIGNALS connector If either Pulse 1 or Pulse 2 has been initiated before the emergency stop signal occurs that pulse will not be interrupted After that no further operation can be initiated until the short has been removed PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 A 13 APPENDIX A TECHNICAL SPECIFICATIONS Process Inhibit Shorting Pin 9 to Pin 11 will close the process inhibit line and inhibit weld current The function is the same as the WELD NOT WELD switch on the front panel All other function continue to operate normally
46. Weld strength profiles are graphic presentations e ai of the varying effects of Y CURRENT C 12 Ibs electrode force and weld strength To make a 2 D 14 lbs weld strength profile start at an initial energy S setting make four or five welds and perform 2 o pull tests for each weld Calculate the average Z WAY pull strength Increase the CURRENT and 032 DIA TINNED repeat the procedure Continue to increase the a COPPER WIRE CURRENT until any unfavorable T0010 A NE RIBBON n a Y RWMA 2 characteristic occurs such as sticking or spitting 20 30 40 50 60 70 80 90 100 Energy watt seconds Perform pull tests and plot the results of CURRENT versus Pull Strength see figure Figure 5 2 Typical Weld Strength Profile 5 2 Repeat this procedure for different forces and plot a separate curve for each electrode force Repeat this procedure using the longer pulse width PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 5 11 CHAPTER 5 OPERATING INSTRUCTIONS In figure 5 2 Curve C shows the highest pull strengths but the lowest tolerance to changes in weld energy Curve B shows a small reduction in strength but considerably more tolerance to changes in weld energy Weld energy current will vary as a result of material variations and electrode wear Curve B is preferred since it shows more tolerance to changes in weld energy and has nearly the same bond strength as Curve C A comparison of weld schedules for several dif
47. a material failure not a weld failure Electrode sticking and or spitting should define a weld as unsatisfactory PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 5 9 CHAPTER 5 OPERATING INSTRUCTIONS Weak Weld If the parts pull apart easily or there is little or no residual material pulled the weld is weak Increase the ENERGY in increments of 1 to 2 The actual weld strength is a user defined specification Electrode Sticking Electrode sticking includes burning sparking and blown welds These problems indicate that either the ENERGY is too high or the electrode force is too low Refer to figure 5 1 Examine the electrode face Resurface it if it is pitted contaminated or burned See Electrode Maintenance later in this chapter Increase electrode force and or decrease ENERGY and save it to the weld schedule you are using Causes of Imperfect Welds Table 5 2 lists the effects of the basic welding parameters on weld quality Table 5 2 Causes of Imperfect Welds Electrode Problem Energy Time Weak Weld Weld Too Low Low Too High Too Too Short DENT Holes Too rotor Too Low Too Small Foe Shon Long Expulsion Burned Pitted Too Low Poor Too Short or Cracked Requires Maintenance Electrodes Maintenance Electrode Force and ENERGY The heat of resistance welding is produced in part by the resistance of the interface between the work pieces to the flow of electricity the contact resistance
48. ack of the PM7 Note that the Air Valve Driver 2 port supplies 24 VAC power so a 115 VAC weld head cannot be used Set each weld head for the proper force psi and flow control speed A Model DFS Switch Box must be used to connect both weld head firing cables to the PM7 firing connector Connect a foot switch which will activate both heads PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 2 9 CHAPTER 2 INSTALLATION Weld Head Cables ie to Weld Head 1 Transformer Terminals Weld Head Cables to Weld Head 2 Figure 2 7 Weld Cable Installation for Dual Head Operation Remote Schedule Selection A 15 pin subminiature D type CONTROL SIGNALS connector located on the rear panel is provided for nine single pole inputs which are used to e Remotely select Weld Schedules 1 through 127 in a binary sequence e Remotely inhibit prevent the flow of weld current which is the same function provided by the front panel WELD NO WELD Switch e Remotely reset and alarm e Invoke the emergency stop condition which abruptly terminates the welding sequence Refer to Appendix A under Control Signals for detailed connector information Relay Outputs Two output relays can be used to provide status timing signals to external devices Relay 1 can also be used to control a second 24 VAC air actuated weld head or to signal an alarm condition Relay 2 can control a 5 to 50 VDC signal When used for status signals these relay
49. ad closes current will flow and the weld will be executed The next weld will be executed when the firing switch opens and closes again As shown in the example program screen to the right the schedule number and name of the weld function appear in the first line of the display The weld period is preset for 0 5 SCHEDULE 0 BASIC WELD SYSTEM MANUAL WELD 0000001 SS EL II CYCLES 5 cycle and the weld current is preset for 75 CURRENT 75 Relay 1 would be switched to ON in the RELAY 1 ALARM event of an alarm and Relay 2 is switched to RELAY 2 ON ON during the weld period aav Select NUMBERS Numbers PROGRAM Sequence Function Sequence function is a term used in the welding industry to describe the basic welding function as it is used with air heads It provides the solution for the majority of the resistance welding applications using air actuated weld heads SCHEDULE 0 SEQUENCE A typical program screen for the sequence SYSTEM AIR 2 LEVEL WELD 0000001 function is shown to the right It is similar to MEE SOZ a WELD E HOLD ias the basic weld program screen except that CYCLES 5 squeeze and hold periods are included CURRENT 75 RELAY 1 ALARM RELAY 2 ON ON OFF Squeeze The squeeze period SQZ is av Select NUMBERS Numbers PROGRAM J used with non force fired heads It has no meaning with manually actuated heads Set SQZ to 0 for Unitek Peco Heads With non force fired heads or if the electrodes ar
50. asemaster 7 Direct Energy Welding 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 Unitek Miyachi Corporation at 1820 South Myrtle Avenue P O Box 5033 Monrovia CA 91017 7133 Telephone 626 303 5676 FAX 626 358 8048 e mail info unitekmiyachi com The purpose of this manual is to supply operating and maintenance personnel with the information needed to properly and safely operate and maintain Phasemaster 7 Direct Energy Welding Control We have made every effort to ensure that the information in this manual is accurate and adequate Should questions arise or if you have suggestions for improvement of this manual please contact us at the above location numbers Unitek Miyachi Corporation is not responsible for any loss due to improper use of this product PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 SAFETY NOTES This instruction manual describes how to operate maintain and service the Phasemaster 7 Direct Energy Welding Control and provides instructions relating to its SAFE use Procedures described in this manual MUST be performed as detailed by QUALIFIED and TRAINED personnel For SAFETY and to effectively take advantage of the full capabilities of the tester please read these instruction manuals before attempting to use the wo
51. ce to another specified ammm SQZ mm WELD m HOLD schedule after a specified number of welds CYCLES 0 12 0 have occurred With this feature a limited CURRENT 75 degree of automation can be achieved with RELAY 1 ALARM minimum user investment RELAY 2 OFF ON OFF 4 Y Select NUMBERS Change PROGRAM J SCHEDULE 2 SEQUENCE NEXT SCH 15 SYSTEM AIR 2 LEVEL STEP 99999 When the CHAIN SCHEDULE FEATURE is ON the RUN screen for each schedule will display a NXT SCH field and a STEP field When CHAIN SCHEDULES FEATURE is first switched ON the PM7 will automatically set NEXT SCH for each schedule as its own schedule number Press PROG to specify A STEP count and a NEXT SCHedule to advance to after the count has expired NOTE You cannot use Schedule 0 in a chain of schedules Schedule 0 is reserved for scratch pad work For example if the NEXT SCH number for Schedule 1 is 5 and the STEP count for Schedule 1 is 100 the PM7 will use Schedule 1 to make 100 welds the automatically advance to Schedule 5 If the NEXT SCH number for Schedule 5 is 5 the PM7 will not advance and will continue to make welds using Schedule 5 When you enter for NEXT SCH it means stop For example if the NEXT SCH number for Schedule 6 is 9 and the NEXT SCH number for Schedule 9 is a period the schedules will sequence from 9 to 6 After Schedule 6 is completed the PM7 will enter the standby state and wait for you to enter a new schedule number
52. ceived via the CONTROL SIGNALS connector from external equipment 3 INPUT SWITCH The force firing switch in the weld head or the footswitch closed before the PM7 was in the RUN state 4 STAND BY Waiting for the force firing switch in the weld head and or the second level of the footswitch to close PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 A 11 APPENDIX A TECHNICAL SPECIFICATIONS Air Valve Drivers The air valve drivers provide power to control the solenoid of an air actuated weld head The PM7 can sequentially operate two separate air actuated weld heads using two receptacles on the rear panel AIR VALVE DRIVER 1 and AIR VALVE DRIVER 2 Air Valve Driver 1 The output from the AIR VALVE DRIVER 1 receptacle is 12 volt amps at 24 or 115 volts AC This circuit is fused together with the control printed circuit board by Fuse F1 located on the control printed circuit board The receptacle is wired so that either 115 or 24 volts are available Air Valve Driver 1 is configured through the options menu WELD HEAD TYPE and selecting either AIR or AUTO Air Valve Driver 2 The output of the AIR VALVE DRIVER 2 E2 E2 receptacle provides 24 VAC to power a second Jum per air actuated weld head Jumpers El and E2 E located near the lower right hand corner of the Jumper control board must be moved to the correct positions as shown in figure A 1 od Jumper Air valve driver 2 is wired only for 24 VAC K1 ae through receptacle Pin
53. chain e Next Schedule Current Schedule Prevents chaining When the step count reaches 0 it will reset and the current schedule will remain in use e Next Schedule period Causes the PM7 to stop after the step count has reached 0 and issue a standby stop command alarm e Weld Function Rollspot Can only be used as the last schedule in a chain Audible Buzzer During alarm conditions an audible tone buzzer is generated for 5 seconds It can be immediately silenced by pressing RUN It is also used to signal the operator of an incorrect keyboard entry The volume can be adjusted with a potentiometer on the control printed circuit board The potentiometer is accessible for adjustment through a hole in the upper front right hand corner of the cover End Of Cycle Buzzer ON OFF This feature is normally used with manual heads ON means that an audible signal will be given at the end of each weld sequence as a signal to the operator to release the footpedal The end of cycle buzzer is controlled from the options menu Key Click Whenever a key is pressed a click sound is generated PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL A 10 990 084 APPENDIX A TECHNICAL SPECIFICATIONS Weld Counter An eight digit weld counter automatically increments after each complete weld sequence You can display the full count by selecting the Weld Counter menu This counter can be reset back to 0 at any time unless the system security is
54. d in the same manner as illustrated in the previous quench temper example Unbalanced AC can be combined with the quench temper function by reducing WELD1 CURRENT setting the COOL period to greater than 0 and making the WELD2 CURRENT significantly larger than the WELD1 CURRENT Continuous Function SCHEDULE 13 CONTINUOUS SEAM SYSTEM AIR 2 LEVEL WELD 0000001 This function can be used for seam ee SQZ a WELD welding or brazing Weld current flows CYCLES 10 CONT as long as the initiation switch remains CURRENT 75 closed A typical program is shown at the right av Select CHNG Change PROGRAM CAUTION Do not exceed the duty cycle rating of both the PM7 and the Unipulse welding transformers as listed in Appendix A PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 6 17 CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS Rollspot Function This function is a special form of seam welding Assuming that the rotational speed of the wheel is fixed the WELD period controls the length of the spot The COOL period controls the distance between the spots Assuming a reasonable wheel speed the COOL period could be reduced so that the spots would overlap As shown in the rollspot program to the right SCHEDULE 10 ROLLSPOT the welds would not overlap since the WELD SYSTEM AIR2 LEVEL WELD 0000001 period is considerably shorter than the COOL ESO WELD COOL RPT me period The RPT legend in the program screen CYCLES
55. e foot switch closes the PM7 will energize the air valve on the weld head The upper electrode will then close applying force to the work piece If the operator releases the foot switch before the weld head applies the preset firing force the PM7 will remove the voltage from the air valve The upper electrode will then return to the open position 2 LEVEL When the operator presses a 2 level foot switch to the first level the weld head will close and apply force to the work pieces At this point if the operator does not press further down harder and actuate the second level the operator can release the foot switch to reposition the work pieces When the operator has actuated the second level a 2 level foot switch will operate just like a 1 level foot switch A 2 level foot switch is recommended if the operator will be required to reposition the work pieces It will also allow the operator to actuate an air head without initiating the weld cycle This is because both the force firing switch and the second level of the foot switch must close before the weld portion of the sequence can begin FOOTSWITCH WELD ABORT Make this selection when the connected foot switch is being used with an air actuated weld head You have two selections with this option as follows gt ON This selection means that if the operator releases the foot switch or foot pedal during the weld sequence the sequence will terminate immediately It may be a safety re
56. e footpedal or footswitch to bring the electrodes into light contact with the polishing disk Move the polishing disk in a rotary motion PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 5 12 990 084 CHAPTER 6 PROCESS DEFINITIONS AND WEL PM7 States D FUNCTIONS The PM7 has seven states RUN NO WELD PROGRAM MENU HELP STANDBY and WELD The MENU RUN and PROG keys cause the PM7 to change to the state defined by that key RUN State In this state the PM7 is ready to make a weld You can select but not change any weld schedule by using the a or v keys on the front panel You can also change weld schedules by keying in the appropriate schedule number 000 through 127 The run screen is showing that Schedule 2 is selected In this schedule the sequence function is SCHEDULE 2 SEQUENCE SYSTEM AIR 2 LEVEL WELD 0000001 E SO E WELD m HOLD ee CYCLES 0 12 0 CURRENT 75 A Y Select Schedule programmed and the system is an air actuated weld head with a 2 level footswitch The weld period is preset for 12 cycles and the weld current is preset for 75 of maximum NO WELD State When you set the WELD NO WELD switch to the NO WELD position the legend RUN in the lower right hand corner of the run screen will be replaced by NO WELD The PM7 will execute any weld schedule but will not deliver welding current to the weld head PROGRAM State In this state the PM7 will allow you to change and save write to per
57. e used to form the work pieces SQZ must be set so that it allows sufficient time for the head to apply the proper force to the work pieces The first level of a 2 level foot switch is used to start the SQZ period The weld period cannot start until the SQZ period ends and the second level of the foot switch and the force firing switch in the head both close Weld The weld period is measured as the number of cycles of the AC power source during which welding current flows The weld period starts after three events have transpired The SQZ period has expired the second level of the foot switch has closed and the firing switch in the weld had has closed You can set weld time for 0 5 cycle or from 1 to 999 cycles in 1 cycle increments Hold The hold period is measured as the number of AC cycles of the AC power source after the weld period The period can be set from 0 to 99 cycles in 1 cycle increments It has no meaning when used with a manual weld head PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 6 13 CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS An air actuated weld head will continue to apply force to the work pieces during the hold period In resistance brazing or soldering applications the hold period provides time for the brazing alloy or solder to solidify Hold time is seldom used in welding applications where the electrodes are not water cooled and or where the weld time is less than 5 or 10 cycles In these app
58. edule Number 0 127 or the schedule which was selected just before the power was switched to OFF Weld Schedule Data The contents of a weld schedule is as follows Schedule number 0 127 Weld function Weld head type Foot switch type system parameter Weld polarity Alternate polarity status system parameter Next chained schedule Names of the weld function periods for example squeeze upslope weld hold Cycle length of the weld function periods Weld current flow during the weld function periods in percentage of maximum current Output Relay 1 status Output Relay 2 status System status for example run standby weld hold emergency stop Weld sentry status optional Weld Functions The PM7 offers ten weld functions as follows Basic manual head only Upslope downslope Sequence air head only Braze Sequence repeat air head only Unbalanced AC Quench Temper Rollspot Preheat postheat Continuous seam PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 A 3 APPENDIX A TECHNICAL SPECIFICATIONS Half Cycle Operation Half cycle operation is possible with these weld functions basic weld sequence sequence repeat preheat postheat upslope downslope and rollspot Time Period Durations The duration of the time periods and the corresponding welding currents are as follows Period Cycles Current Squeeze 0 99 None Upslope 0 99 Adjustable from 1 to 50 cycle Weld 1 0 99 20 99 Quench 0 99 None We
59. edule number Use the sequence welding function which is an appropriate function for 80 of the PM7 applications refer to Chapter 6 under Weld Functions Switch the Line Voltage Compensation to OFF refer to Chapter 6 under Line Voltage Compensation Set the parameters as follows e WELD CYCLES 0 5 e SQUEEZE and HOLD air head only 0 e CURRENT 60 Making a Weld CAUTION Always observe safety precautions when welding Wear your safety glasses In making a weld the objective is to obtain a consistent weld with the shortest possible weld time and a CURRENT setting between 60 and 90 1 Select RUN and WELD on the PM7 2 Position the parts between the electrodes 3 Press the footpedal or footswitch to initiate the welding sequence When weld current flows the red pilot light on the UNIPULSE Transformer will light It may be difficult to see where the CURRENT is less than 50 and or WELD CYCLES is set to 0 5 4 Assuming no weld occurred increase the tap switch setting until the parts begin to weld If you reach the highest primary tap and if applicable the highest secondary tap without obtaining a weld increase the weld period from 0 5 to 1 cycle 5 Use the CURRENT to refine the characteristics of the weld Evaluating the Weld 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
60. election ista 5 2 Help State Selectionner ienie sirian A A dake 5 2 Selectine A A e a E ENON 5 3 Changing the Display Format dead entera le dla dan do an e 5 3 Changing Schedule Para A cara A a aaa aad 5 3 Changing Output Relay States idea 5 4 Saving Weld Schedules ai aia 5 4 Configuring the Weld Sentry e ios 5 6 Handling Alarmi Condittons A A E A gee a i AS 5 6 SORA LAMAS A A AA A A A A A AA 5 6 o ceca c races ates E E ve teas a0 oains cv E eas Bas Ne a 5 6 Input Switeh Alarmi anginan o e E AR Wl T aM cee tess eee 5 6 Standby AA A ays ie gach decease tac A A GLE RE 5 6 Using the Help Screen for DiaOn Osis ars dd dis 5 7 Weld Schedule Development serisccit cet ds cede Deana R TUI 5 7 Weld Head Paradis id A A dace ad ARI 5 7 Welding Transformer Parameters a 5 8 PM Control A E cae R A A NN 5 9 IVAN a Weld nedenine A A aN 5 9 Eval a ting the Weldanasinineeta Oi E 5 9 Weak Weldir hannarna e A a a r a a A a a a SeA 5 10 Electrode A A a a a a a a E CEN 5 10 Causes OF lmperteet W Clas 5 05 a2 4s e ai 5 10 Electrode Force and Energy its 5 10 Polarity rt spend e A a A r A E A a A 5 11 Weld Strength Pro le E a Leeann Rela aot 5 11 MS SUPE ESE caacs adic aga css cages oc Setnu vba Gate oan aces va ce aliases Matsa we eed ons e aa eos 5 12 Electrode Manta mc it Cabra 5 12 CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS oooocccicccoccoonoconicnnonnconocnnos 6 1 PIV States A SL 6 1 RUN aN oe ae ate tae a ah olathe te Mela a teen ta ata tte aaaeei
61. f both levels of a 2 level foot switch Foot Switch Connector The FOOTSWITCH connector is a 4 pin Amphenol 91 PC4F Unitek PN 550 006 that mates with an Amphenol 91 MC4M Unitek PN 520 009 Connect Pin 2 to Pin 3 on a user supplied 1 level footswitch This connector is wired as follows Pin Description 1 Chassis Ground 2 Footswitch Level 1 or Single Level Footswitch 3 Footswitch Level 2 4 Common PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 A 5 APPENDIX A TECHNICAL SPECIFICATIONS Footswitch Weld Abort Feature The footswitch weld abort feature is controlled from the options menu Footswitch Weld Abort On With FOOTSWITCH WELD ABORT ON selected the welding sequence is initiated by the closure of the initiation switch and continues to its conclusion as long as the initiation switch remains closed If the initiation switch or the force firing switch open during the welding sequence the sequence will terminate within one cycle after the switch opens FOOTSWITCH WELD ABORT ON is preferred since it allows the operator to abort the welding sequence by releasing the footswitch or footpedal in the case of a manual head Footswitch Weld Abort Off With FOOTSWITCH WELD ABORT OFF selected the welding sequence is initiated by a single momentary closure of the initiation switch Opening the initiation switch during the welding sequence will not terminate the welding sequence The initiation switch must open and re close i
62. f defective welds The unit is supplied with a line cord and a 30 amp combined circuit breaker power ON OFF switch The 460 volt unit requires a user supplied circuit breaker disconnect and input wiring Features e Multi function microprocessor control provides repeatable process control and is compatible with air or manually actuated weld heads e User friendly context sensitive help screens guide you through work set up and operation e Digital display allows you to set welding current accurately and quickly e Half cycle welding capability is critical for the welding of small parts e Automatic line voltage compensation compensates for up to 13 changes in line voltage which eliminates the major electrical cause of inconsistent weld quality e 128 discrete weld schedules facilitate multiple applications at one work station e Weld schedule protection feature protects 127 weld schedules from being changed by unauthorized personnel e Remote weld schedule selection simplifies use in automated systems e Chain schedule feature with automatic step function allows automation of simple tasks e Ten unique weld functions provide solutions for the most complex welding applications PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 1 2 990 084 CHAPTER 1 SYSTEM DESCRIPTION e Automatic power factor correction improves weld quality e Airhead capability is a standard feature which allows the unit to control single or dual air actuated weld
63. f the schedule to be copied Then use lt and NUMBERS to enter the number of the schedule to be changed In the COPY SCHEDULE screen shown Schedule 1 and Schedule 9 will be identical and the date previously in Schedule 9 will be lost lt SYSTEM SECURITY gt SYSTEM SECURITY Select this option to SECURITY STATUS UNPROTECTED protect all weld schedule data except Schedule 0 from changes by unauthorized persons Use the X keys to select SYSTEM SECURITY on the ENTER CODE TO CHANGE STATUS TIT MAIN MENU screen and press ENTER to access the SYSTEM SECURITY screen NUMBERS for Code followed by ENTER SCHEDULE LOCK OFF PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 6 6 990 084 CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS SECURITY STATUS You can change security status to protected when you enter a user selected security code To change to protected enter your security code on the bottom line of the SYSTEM SECURITY screen and press ENTER The SECURITY STATUS line on the SYSTEM SECURITY screen will now display PROTECTED Your security code may be any seven digit number from 1 to 9 999 999 If you forget the security code you may change status back to unprotected with the override key combination Set the WELD NO WELD switch to the NO WELD position Press the 3 key then the SAVE key The system will now be unprotected and the SECURITY STATUS line on the SYSTEM SECURITY screen will now display UNPROTECTED again S
64. ferent applications might show that they could be consolidated into one or two weld schedules This would have obvious manufacturing advantages Destructive Testing Destructive Testing can be performed on the actual work piece or on test specimens For small inexpensive parts actual production samples taken on a random basis should be used 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 Electrode Maintenance Depending on use periodic tip resurfacing is required to remove oxides and welding debris from electrodes On the production line you should use No 400 600 grit electrode polishing disks For less critical applications you can use a file to clean a badly damaged tip After filing however use polishing disks to ensure that the electrode faces are smooth and parallel If you don t the rough surface of the electrode face will have a tendency to stick to the work piece or if the faces are not parallel energy will be concentrated at the point of contact and a blowout will result To dress the electrode tip 1 Select NO WELD 2 On air actuated weld heads reduce the air pressure to a value just sufficient to lower the upper electrode arm 3 Place the polishing disks between the electrodes and actuate th
65. he proper force to the workpieces Second Air Head Connect the solenoid air valve of a second air actuated Unitek Peco weld head to the AIR VALVE DRIVER 2 receptacle Only weld heads with 4 pin 24 VAC connectors can be plugged directly into this connector Footswitch Connect either a 1 Level or 2 Level Footswitch to the FOOTSWITCH receptacle located on the rear panel The PM7 will automatically recognize which type Unitek Peco Footswitch has been connected 1 Level Footswitch When the operator fully depresses the 1 level footswitch the PM7 will energize the air valve on the weld head The upper electrode will close and apply force to the workpiece If the operator releases the footswitch before the weld head applies the preset firing force the PM7 will remove the voltage from the air valve and the upper electrode will return to the open position If the FOOTSWITCH WELD ABORT option has been set to ON by changing the status on the OPTIONS menu the welding sequence will be terminated if the footswitch is released before the welding sequence is completed If the FOOTSWITCH WELD ABORT option has been set to OFF the welding process will continue to its conclusion regardless of the position of the footswitch once the preset firing force has been applied to the workpiece by the upper electrode of the weld head 2 Level Footswitch When a 2 level footswitch is pressed to the first level the weld head will close and apply force to the wor
66. hen the line voltage goes outside the programmed limits the PM7 will initiate a voltage standby The voltage standby will be cleared when the line remains within limits for the duration of the RESTART TIME Use NUMBERS to enter from 1 to 60 cycles TENE MOI AE COMPENSATION lt LINE VOLTAGE COMPENSATION gt Selection of LINE VOLTAGE LINE COMPENSATION COMPENSATION will bring up the LINE NOMINAL LINE VOLTAGE VOLTAGE COMPENSATION screen You can ACTUAL LINE VOLTAGE set the PM7 to automatically compensate for LINE VOLTAGE FREQUENCY i deviations in the line voltage For each 1 SCHEDULE REFERENCE VOLTAGE 234 VOLTS decrease in line voltage the PM7 will increase current by 1 For each 1 increase in line AY Select CHNG to Change voltage the PM7 will decrease ocurrent by 1 NOTE The PM7 will not compensate for more than a 13 change in line voltage from the rated nominal line voltage 100 120 208 240 380 or 480 volts Select OFF when the PM7 is used to develop weld schedules LINE COMPENSATION Select ON to configure the PM7 to compensate for changes in line voltage as described previously under LINE VOLTAGE COMPENSATION NOTE If you do not use line compensation the heating energy programmed in weld schedules will not be repeatable from one location to another NOMINAL LINE VOLTAGE Use CHNG to select the input line voltage of the PM7 90 110 110 120 200 220 220 240 380 400 or 440 480 volts You can select n
67. iations by requiring the firing switch to remain closed 0 5 1 2 or 4 cycles before initiating the weld For operation at speeds below 0 5 welds per second or with 3 wire firing switches select 0 5 If the PM7 is not being initiated reliably first try 1 then 2 then 4 cycles If none of these selections is successful use a single pole double three 3 wire firing switch WELD COUNTER Select this option to display and reset the weld counter to zero Use the keys to select WELD COUNTER on the MAIN MENU screen and press ENTER to TOTAL NUMBER OF WELDS 9999999 access the WELD COUNTER screen lt WELD COUNTER gt The total number of welds increments each time a weld is made in any schedule The value displayed on this screen corresponds to the weld count displayed in the run state When the chain schedules feature is on the step count is displayed instead CHNG Reset or Restore If the Weld Sentry is installed three counters are added to the WELD COUNTER screen Reject Hi Reject Lo and Accept Refer to the Weld Sentry user s manual for details about these counters COPY A SCHEDULE Select this option to lt COPY SCHEDULE gt save one weld schedule to another weld schedule Use the gt keys to select COPY A SCHEDULE on the MAIN MENU screen and press ENTER to access the COPY SCHEDULE screen COPY SCHEDULE 1 TO SCHEDULE 9 lt gt Select NUMBERS Change ENTER Proceed Use NUMBERS to enter the number o
68. ically set the switch debounce time to 0 milliseconds whenever a 3 wire or optical switch is selected Mechanical Firing Switch Cable This cable is 5 feet long It is a Type 2 C 600 volt cable containing two shielded twisted 22 AWG conductors of high flex stranded wire The firing switch connector is a 2 pin Amphenol 80 MC2FI Unitek PN 520 008 with strain relief It mates with an Amphenol 80 MC2M Unitek PN 520 001 Pin 2 is ground Optical Firing Switch Connector This connector is a 5 pin AMP 212044 1 Unitek PN 150 064 located on the rear panel It mates with an AMP Assembly consisting of an AMP 212437 3 Plug 212435 7 Ferrule and 212800 1 Strain Relief The connector is wired as follows Pin Description Shell Shield 1 Switch Normally Closed 2 Switch Common 3 Switch Normally Open 4 DG di Pin Numbers as Viewed 5 Switch Common from the Rear Panel PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 A 7 APPENDIX A TECHNICAL SPECIFICATIONS Initiation Switch Manual Head Operation If the PM7 is connected to a manual head the initiation switch is the force firing switch located in the weld head Air Head Operation If the PM7 is connected to an air actuated head the initiation switch is the footswitch The first level of a 2 level footswitch instructs the PM7 to e Switch the valve driver to ON which causes the upper electrode of the weld head to apply force as determined by the air regulator connected
69. in 2 the PM7 assumes that a manual head is being used The options menu can be programmed to override the automatic selection feature Footswitch Type The PM7 requires the use of a 1 level or 2 level footswitch in order to control an air actuated weld head The PM7 will automatically detect whether a Unitek 1 level or 2 level footswitch is connected to the FOOTSWITCH connector located on the rear panel The PM7 assumes that a 1 level footswitch is used if the input to the 2nd level is continuously closed The PM7 determines whether it is connected to a 1 level or 2 level footswitch whenever it enters the RUN state The options menu can be used to override the automatic selection feature Manual Head Initiation Switch If the PM7 is connected to a manual weld head the initiation switch is the force firing switch in the weld head Air Head Initiation Switch If the PM7 is connected to an air actuated weld head the initiation switch is the foot switch The first level of a 2 level foot switch instructs the PM7 to e Switch the valve driver ON This causes the upper electrode of the weld head to apply force to the work pieces The amount of force is determined by the air regulator on the weld head air cylinder e Start the squeeze period The second level of the foot switch initiates the start of the weld period provided that the force firing switch has closed and the squeeze period has ended A 1 level foot switch combines the functions o
70. in the protected state The Weld Sentry option allows you to set upper and lower limits for each Weld Sentry program To implement this feature there are three additional counters which keep track of the number of welds under the lower limit 999 999 over the upper limit 999 999 and within these limits 9 999 999 These counters can be independently reset to 0 at any time unless system security is in the protected state Note that all counters retain their counts when the input power is interrupted because the contents of these counters are stored in battery backed up memory Calibration Check The PM7 monitors both the input line frequency and the line voltage The Calibration menu allows you to verify the actual frequency and voltage level The information on this menu confirms that the PM7 is correctly configured and properly calibrated Alarms The PM7 issues three alarms All alarms terminate or inhibit the welding sequence To clear an alarm press RUN or toggle the remote process inhibit line Alarm conditions are processed in a priority order corresponding to the following list 1 SCR ALARM The output SCR devices are defective The output SCR devices control the flow of current to the welding transformer The PM7 has detected that the output SCR devices conducted current during restricted time periods for four consecutive cycles Repair by a qualified technician is required 2 EMERGENCY STOP An emergency stop signal was re
71. ion and the weld head will rise at the end of the hold period If FOOT SWITCH WELD ABORT is ON releasing the foot switch at any time during the welding sequence will terminate the sequence PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 4 2 990 084 UPSPEED AIR gt VALVE B DOWNSPEED AIR VALVE B AIR GAUGE B TOP amp BOTTOM REGULATOR B CHAPTER 4 GETTING STARTED UPSPEED AIR VALVE A AIR CYLINDER A Vn DOWNSPEED AIR VALVE A TOP amp BOTTOM s MES lt AR PRESURE 5 REGULATOR A AIR GAUGE A POWER CORD B Figure 4 1 Typical Solenoid Air Valve System with Dual Regulators PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 4 3 CHAPTER 4 GETTING STARTED UP SPEED FLOW VALVE DOWN SPEED FLOW VALVE _ AIR CYLINDER PULL UP AND TURN CLOCK WISE TO INCREASE PRESSURE PUSH DOWN TO LOCK lt AIR PRESSURE REGULATOR lt AIR GAUGE AIR INPUT POWER CORD Figure 4 2 Typical Solenoid Air Valve System with a Single Regulator 7 Adjust the upspeed flow control on the top of the cylinder so that the upper arm of the weld head moves at a reasonable rate but does not slam against the upstop This adjustment is made by pressing then quickly releasing the foot switch 8 Adjust the regulator that controls the air pressure on the top of the cylinder to obtain the desired welding force Place the workpiece in position
72. kpiece At this point if the operator does not press further harder and actuate the second level the footswitch can be released so that the workpiece can be re positioned Once the second level has been actuated a 2 level footswitch will operate in the same manner as a 1 level footswitch PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 2 8 990 084 CHAPTER 2 INSTALLATION Dual Weld Head Installation For dual weld head operation the PM7 must be reconfigured Internal Reconfiguration Two jumpers on the PC board must be reconfigured for dual weld head operation CAUTION Unplug the PM7 before proceeding with this procedure Remove the PM7 cover and locate the two yellow jumper headers labeled El and E2 in the lower left area of the PC board In the shipped positions shown as Before Change in figure 2 6 the jumper headers are installed for the operation of such devices as enunciators automated lines and alarms via relays Reinstall the jumper headers in the After Change positions shown in figure 2 6 Replace the PM7 cover and reconnect PM7 power External Reconfiguration E2 2HD Jumper K1 Jumper K1 2HD 2HD Jumper E1 E1 Before Change After Change Figure 2 6 Jumper Reconfiguration for Dual Weld Head Operation Connect the weld cables to the transformer as shown in figure 2 7 Refer to figure 2 8 Connect the air valve drivers for weld head 1 and weld head 2 to their respective ports on the b
73. ld 2 Y 0 99 20 99 Downslope 0 99 Adjustable from 1 to 50 cycle Cool 0 99 None Hold 0 99 None Off 0 999 None Accuracy Linearity of the CURRENT is 3 of setting at 50 or 60 Hz Weld Sentry The Weld Sentry can be installed in the PM7 as an option The self contained unit is installed inside the PM7 chassis and is mounted on the rear panel with four captive screws The option which is configured from the front panel includes a voltage sensing cable and a current pickup When the option is installed the Sentry Menu provides the following options and utilities a Basic Setup f Set Time and Date b Print Utilities g System Setup c Print Options h Calibrate Sentry d Relay Output I Communications e SPC Head Type The PM7 can be used with a manual user actuated weld head or a single or dual air actuated weld head Air actuation means that the PM7 will provide a 24 or 120 VAC output which can be used to control an air valve solenoid on an air actuated weld head When the dual head function is used Output Relay 1 can be used to control the 24 VAC AIR VALVE DRIVER 2 connector The PM7 can automatically detect the presence of a Unitek Peco air actuated weld head PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL A 4 990 084 APPENDIX A TECHNICAL SPECIFICATIONS You can indicate the presence of a user supplied non Unitek air head by jumpering Pin 4 to Pin 2 on the AIR VALVE DRIVER connector If Pin 4 is not connected to P
74. lectrode to the output terminal of the PM7 To reduce energy losses follow these recommendations e Use No 2 AWG welding cables or No 00 AWG welding cables if the cables are more than 12 inches long The diameter of the cables should be as large as practical e Use the shortest possible welding cables It is not uncommon to have losses up to 50 per foot for No 6 cable and 20 for No 2 cable e Route cables so that they do not surround magnetic materials such as air solenoids tooling or steel weld heads see figure 2 1 PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 2 1 CHAPTER 2 INSTALLATION 2 2 DO Cables taped together and routed away from steel structure and electromagnetic field au a Steel Fixture Steel Weld Cables not dressed together and close to steel fixture Solenoid Figure 2 1 Cable Routing Examples Bolt connections directly together Do not place washers between the terminals of the PM7 and the terminals of the cables Tighten connections securely they must be free from oxidation dirt and or grease see figure 2 2 Note Attach both welding cables on the same side of the weld head Cap Head Screw and Flat Washer Upper Welding Cable Lower Electrode Holder N Screw Flat Washer Nut 2 Places Lower W elding Cable Install flat washer under screw head not welding cable terminal Figure 2 2 Terminal Connection Examples Tape cables together to mini
75. lications hold time allows the electrodes to cool the work pieces Weld Current The weld current CURRENT is measured as a percentage of the maximum welding current that could flow during each half cycle of the weld period The welding current is controlled by circuit that proportions current over time to obtain the required heating effect For example ignoring losses if the CURRENT is increased from 80 to 90 the welding energy will increase from 64 to 81 of the maximum You can set CURRENT from 20 to 99 in 1 increments Weld quality should improve if you set CURRENT between 65 and 85 Output Relays Two output relays Relay 1 and Relay 2 can be used to supply status signals to external devices Relay 1 can also be used to control a second air actuated weld head or to signal an alarm condition The status of each relay is shown on screen Lines 6 and 7 You set the relay conditions in the program state and confirm them in real time in the run state When used for status signals you can program the relay states to close when e The PM7 is initiated e Any portion of the welding sequence is completed e The firing switch opens e The PM7 is waiting for the welding sequence to start Sequence Repeat Function This function provides a repeat capability for simple automated air actuated applications It is ideal for volume production requiring a single weld schedule Note that it can be used only with air actuated weld heads SCH
76. lliamps of current at 3 to 50 VDC ON and OFF means that the relay will be switched ON and OFF during the portion of the weld sequence noted on Line 3 of the screen SQZ WELD HOLD If the programmed application does not have a SQZ HOLD or OFF period there will be no entry for that column If you select NO for all of the available fields the relay will be switched to ON during the run state ALARM means that the relay will be switched ON for any alarm condition The alarms are Emergency Stop Shorted SCR Input Switch Line Voltage Out Of Limits AIR HEAD 2 means that Relay 2 will control the 24 VAC VALVE DRIVER 2 connector This feature allows the PM7 to control two air actuated weld heads The second air head will be actuated in any schedule in which Relay 1 is defined as AIR HEAD 2 The standard air head will be actuated in any schedule in which Relay 1 is defined as ON OFF or ALARM Saving Weld Schedules When you have selected the appropriate parameters for a weld schedule you have two ways of saving them to the weld schedule e Press SAVE All of the selected parameters will be saved to the selected weld schedule in permanent memory Then you press RUN to go to the run state Or e Press RUN All of the selected parameters will be saved to Schedule 0 in temporary memory and the PM7 will automatically go to the run state PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 5 4 990 084 CHAPTER 5 OPERATING INSTRUCTIONS
77. manent memory any weld schedule Press PROG to enter the PROGRAM state which is signified by the legend PROGRAM fin the lower right hand corner of the screen In those units SCHEDULE 2 SEQUENCE SYSTEM AIR 2 LEVEL WELD 0000001 MEE SO E VELD m HOLD EE CYCLES 0 12 0 CURRENT 75 RELAY 1 ALARM RELAY 2 OFF ON OFF av Select CHNG Change J PROGRAM J PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 6 1 CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS which include the Weld Sentry option the PROGRAM state also allows you to change the measurement unit the limits related to the Weld Sentry program and the other parameters associated with the Weld Sentry Use the cursor to move to the field you wish to change After you have made the changes press SAVE to exit to the RUN state and save the changes MENU State In this state the PM7 will display a menu which allows you to select options which are common to all weld schedules to access the Weld Sentry option and obtain general information Press MENU to select the menu state The MAIN MENU screen will be displayed lt MAIN MENU gt m OPTIONS m WELD SENTRY m WELD COUNTER CALIBRATE PM7 OPTIONS Use the gt keys to move the m COPY A SCHEDULE m RESET TO DEFAULTS cursor to OPTIONS on the MAIN MENU m SYSTEM SECURITY m INSTALLATION screen Then press ENTER to select OPTIONS m LINE VOLTAGE m SYSTEM HELP There are three screens page
78. mize the inductive losses A separation of weld cables surrounding an area of one square foot could result in losses of up to 65 PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 CHAPTER 2 INSTALLATION Rear Panel Components The input and output connections located on the rear panel of the PM7 figure 2 3 are listed below LCD CONTRAST MECHANICAL FIRING SWITCH OPTICAL FIRING SWITCH VOLTAGE FOOT INPUT SWITCH CURRENT INPUT O ACCESSORY PORT O AIR VALVE DRIVER O CONTROL SIGNALS 000a CJofola Figure 2 3 PM7 Rear Panel Components 1 WELD SENTRY CONTROL CLUSTER Controls for PM7 models incorporating the Weld Sentry 2 OPTICAL FIRING SWITCH 5 pin receptacle is used to connect the PM7 to Weld Heads with either a 3 wire Firing Switch or an Optical Switch 3 LCD CONTRAST Allows the user to adjust the contrast of the LCD Display for optimum viewing PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 2 3 CHAPTER 2 INSTALLATION 4 MECHANICAL FIRING SWITCH 6 foot cable is used to connect the PM7 to the Force Firing Switch 10 11 12 13 in all Unitek Peco Weld Heads and Handpieces FOOTSWITCH RECEPTACLE Used to connect either a 1 Level or 2 Level Unitek Peco Footswitch Footswitches are used only with air or electrically actuated weld heads FUSES F1 F2 Used to protect the internal Control Boards and the Valve Driver Circuits The following table defines the
79. n order to start the next sequence FOOTSWITCH WELD ABORT OFF is used in automated process control systems where operator intervention is not an issue Firing Switch Type The PM7 can use as an input signal either a e Single pole single throw switch e Double pole double throw 3 wire switch or an e Optical switch The input signal will indicate when the weld head has applied the proper force to the workpiece Weld heads with single pole firing switches should be connected to the MECHANICAL FIRING SWITCH connector A 3 wire switch or optical firing switch either of which should be connected to the OPTICAL FIRING SWITCH connector eliminates switch bounce which causes false triggering and should be used when the welding speed exceeds 1 5 welds per second Firing Circuit The firing circuit requires external contact closure or low logic level for firing Internal filtering prevents premature firing due to radio frequency interference The PM7 will automatically detect that the system is using a 3 wire switch whenever it enters the RUN state if Pin 1 is shorted to Pin 2 PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL A 6 990 084 APPENDIX A TECHNICAL SPECIFICATIONS Switch Debounce Time Single pole mechanical firing switch contacts bounce when they close The switch debounce time feature allows you to specify that the firing switch must remain closed for 0 5 1 or 2 cycles before the weld period can be initiated The PM7 will automat
80. n the mechanical firing switch to an external switch in order to initiate the PM7 Air actuated weld heads which do not have force firing switches rely on the squeeze time to ensure that the weld head has time to close and apply the proper force to the workpieces Use the squeeze time option and select NO FIRING SWITCH from the Options Menu refer to Chapter 3 Optical Firing Switch Users of weld heads with pressure switches using a 3 wire switch or an optical device should use the OPTICAL FIRING SWITCH receptacle located on the rear panel of the PM7 refer to Appendix A under Initiation Switch 3 Wire Firing Switches Users of weld heads with single pole double throw 3 wire pressure switches should also use the OPTICAL FIRING SWITCH connector located on the rear panel of the PM7 The PM7 will automatically detect that the system is using a 3 wire switch if Pin 2 is low at power up Air Actuated Weld Head Connections Solenoid valve regulator assemblies which are not mounted on the weld head should be located as close as possible to the weld head Use the shortest air lines possible to obtain the fastest mechanical response Connect the inlet port on the air valve solenoid to a properly filtered air supply 65 psig maximum Use 0 25 inch OD by 0 17 inch ID plastic hose with a rated burst pressure of 250 psi to connect the outlet ports of the solenoid regulator assembly to the flow controls on the air cylinders Figure 2 4 illustrates a ty
81. n when no firing switch is connected Typically this would be the case where an externally controlled air actuated weld head and squeeze time are being used OPTIONS 3 The OPTIONS 3 screen has four options lt OPTIONS 3 gt ae 4 ALTERNATE POLARITY OFF POWER FACTORY CORRECTION ON e ALTERNATE POLARITY An ON 87 DEGREE DELAY OFF selection means that the polarity of the SWITCH DEBOUNCE TIME 0 5 CYCLES first half cycle of output will change with each weld This feature can be used to prevent non Unitek Peco welding 2 y Select CHNG Change More Options transformers from saturating Use the OFF selection if you are using Unitek Peco welding transformers since they do not use Hypersoil cores e POWER FACTOR CORRECTION Select ON when the PM7 is used with a Unitek Peco welding transformer This selection will ensure that the welding current is independent of the welding load power factor Select OFF if you are using non Unitek Peco welding transformers and welding times exceeding 5 cycles e 87 DEGREE DELAY Select ON when using wound core welding transformers and or welding transformers with water cooled secondary windings Select OFF for Unitek Peco welding transformers PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 6 5 CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS e SWITCH DEBOUNCE TIME The contacts of single pole switches bounce as they close The debounce feature will avoid resulting false init
82. ominal line voltage from three different line voltage screens LINE VOLTAGE COMPENSATION PM7 LINE VOLTAGE ALARM or PM7 CALIBRATION When you change nominal line voltage on one of the screens the PM7 will automatically change the other two screens PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS ACTUAL LINE VOLTAGE This line displays the measured value of the PM7 line voltage As with any meter it is normal for the value to fluctuate slightly to reflect the true condition of the AC line LINE VOLTAGE FREQUENCY The PM7 will automatically determine the frequency of the line voltage and display either 50 Hz or 60 Hz SCHEDULED REFERENCE VOLTAGE Use this selection when LINE COMPENSATION is ON Use NUMBERS to enter the actual line voltage experienced when an original weld schedule was established The line voltage compensation function will use this value along with the nominal voltage to provide correct heating energy WELD SENTRY Use this option to access the Weld Sentry module if it is installed Refer to the Weld Sentry User s manual for operating instructions CALIBRATE PM7 Use this option to calibrate the PM7 Refer to Chapter 7 for instructions lt RESET DEFAULTS gt RESET SYSTEM PARAMETERS NO RESET ALL SCHEDULES NO RESET TO DEFAULTS From the MAIN MENU screen select RESET TO DEFAULTS with the gt lt keys and press the ENTER key to bring up the R
83. on Tap 4 The open circuit secondary voltages specified in Table A 4 are within 5 of the values listed when measured with the specified rated voltage applied to the primary winding of the transformer Duty Cycle To obtain the thermal rating at duty cycles other than those specified in Table A 4 multiply the KVA rating at 50 by the rating factor listed below The averaging period is 1 minute Duty Cycle Rating Factor Duty Cycle Rating Factor 1 7 08 20 1 58 2 5 00 30 1 29 3 4 07 50 1 00 5 3 15 70 0 845 8 2 5 80 0 790 10 2 23 100 0 707 PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 A 17
84. onnect the pins that correspond to the numbers totaling 127 Schedule 127 1 2 4 8 16 32 64 Connect Pins 1 2 3 4 12 5 and 7 to Pin 11 ground PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL A 14 990 084 APPENDIX A TECHNICAL SPECIFICATIONS When all input pins are open control of the power supply remains at the front panel When any one of the pins is shorted the front panel controls are disabled Alarm stop conditions can also be cleared remotely by toggling the process inhibit line Relay Outputs There are two output relays which can be used to provide status timing signals to external devices Relay 1 can also be used to control a second 24 VAC air actuated weld head as part of a dual air head system or to signal an alarm condition Relay 2 can provide a 5 to 50 VDC signal When used for status signals these relays can be independently programmed to close when either e Any portion of the welding sequence is completed e The firing switch opens or e The PM7 is waiting for the weld sequence to start Either relay is capable of switching up to 250 milliamps The power source is user supplied in each case Accessory Port A 25 pin sub miniature D type connector located on the rear panel is provided to control other devices contemplated for the future Front Panel Switches There are 22 electrostatically shielded membrane switches which are integral to the front panel The function of each key is defined in Chapter
85. ose applications where the heating at the interface between the work pieces is dependent on the direction of the current flow This dependency occurs with identical materials whose thickness ratio is greater than 4 1 and with dissimilar material combinations such as copper and nickel CAUTION This function can introduce heavy transients into the AC power line These transients could affect the operation of other equipment connect to the same power line In some applications the electrode material that would normally be selected cannot be used without it contaminating the work pieces When the geometry of the work pieces requires that one electrode be significantly smaller than the other the unbalance AC function has been used successfully with some material combinations to reduce the temperature of the small electrode and thus increase its life In the example program shown to the a SCHEDULE 17 UNBALANCED AC right two cycles were required to produce i l SYSTEM MANUAL WELD 0000001 a satisfactory weld WELD CURRENT is ELD 1 ol WELD MEE preset to 85 during the positive half CYCLES 1 0 0 cycle and 35 during the negative half CURRENT 85 35 cycle The heat generated during the two positive half cycles was sufficient to form a weld av Select CHNG Change PROGRAM J The heat generated during the two negative half cycles was just sufficient to prevent the work pieces from cooling The COOL and WELD periods could be use
86. pical single regulator installation for a Unitek Peco Series 80 Weld Head Turn the regulator s fully counter clockwise to ensure minimum air pressure Turn on the air supply Repair leaks if necessary PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 2 5 CHAPTER 2 INSTALLATION UP SPEED FLOW VALVE DOWN SPEED FLOW VALVE AIR CYLINDER PULL UP AND TURN CLOCK WISE TO INCREASE PRESSURE PUSH DOWN TO LOCK lt AIR PRESSURE REGULATOR lt AIR GAUGE AIR INPUT POWER CORD Figure 2 4 Typical Solenoid Air Valve Assembly with a Single Regulator All Thinline weld heads are capable of cycling at a rate of 1 weld per second provided that the tubing between pressure regulators and the air cylinder is kept as short as possible Increasing the length of the tubing produces very sluggish mechanical motion Do not use lubrication on the input air line because as the internal seals on the air cylinder wear lubricating oil will leak past these seals and contaminate the electrode and the workpiece with a fine oil mist Once every six months or every million operations whichever occurs first remove the top flow control valve and place two drops of light machine oil in the top of the air cylinder s PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 2 6 990 084 CHAPTER 2 INSTALLATION Air Valve Drivers Connect the Air Valve Solenoid to the VALVE DRIVER Receptacle or both air valves and VALVE D
87. print utility menu PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 CHAPTER 4 GETTING STARTED 17 If you are using a second air actuated weld head a Connect the second air head to the AIR VALVE DRIVER 2 connector on the rear panel b There are two jumper headers El and E2 located on the lower right hand area of the control printed circuit board Re jumper the headers to the dual air configuration as shown in figure 4 5 refer to Chapter 2 under Dual Weld head Installation for the procedure c Press MENU and select OPTIONS d Change the weld head type to DUAL AIR e Press PROG and move the cursor to the RELAY 1 field f Press CHNG until AIR HEAD 2 is displayed g Press SAVE to store the changes E2 Jumper K1 2HD Jumper K1 Jumper K1 2HD 2HD Jumper E1 E1 Single Air Dual Air Figure 4 5 Weld Head Configuration Jumper Selection PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 4 7 CHAPTER 5 OPERATING INSTRUCTIONS Successful Welding This chapter is a guide to be used in establishing the parameters required to make a successful weld then making and evaluating a weld The development of an optimum weld schedule will aid in achieving a repeatable reliable process You will find additional useful information in the Fundamentals of Resistance Welding data sheet Part No 991 140 Resistance Welding Parameters The three basic welding parameters are heat time and pre
88. quirement for non tooled systems Always use this feature when a manual head is being used This way the welding sequence will terminate if the force firing switch in the weld head opens usually as a result of the operator releasing the foot switch prematurely during the welding sequence OFF This selection means that once the operator presses a 1 level foot switch or the second level of a 2 level footswitch and the preset firing force has been applied to the work pieces the operator cannot terminate the welding sequence PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS e FIRING SWITCH You have four selections with this option Make the selection according to the type of firing switch connected to the PM7 gt 2 WIRE Make this selection when the firing switch connected to the MECHANICAL FIRING SWITCH connector on the rear panel is a single pole single throw ON OFF switch This type of switch is used in a standard force fired Unitek Peco weld head gt 3 WIRE Make this selection when the firing switch connected to the OPTICAL FIRING SWITCH connector on the rear panel is a single pole double throw switch This type of switch is used where weld rates exceed 1800 welds per hour gt OPTO SWITCH Make this selection when the firing switch connected to the OPTICAL FIRING SWITCH connector on the rear panel is an optically coupled firing switch gt NONE Make this selectio
89. rameter to the right 3 or left 3 of the parameter which is highlighted In the run state these keys are used to display weld sentry program lines A through E if the Weld Sentry is installed Causes the PM7 to enter the program state so that you can make changes to Schedules 0 through 127 If a Weld Sentry is installed when PROG is pressed a second time you can make changes to the Weld Sentry programs related to each weld schedule Press PROG to return to the PROGRAM screen refer to Screen Formats next in this chapter Causes the PM7 to exit the program state without saving the changed schedule The changed schedule will become Schedule 0 and will not be written to permanent memory If no changes are made to the schedule or the Weld Sentry program then it will not be transferred to Schedule 0 Welding is done in the run state In the program state pressing this key saves writes any schedule and its related Weld Sentry programs to permanent memory The PM7 will then exit the program state and return to the run state This key has no function in the run state PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 3 2 990 084 CHAPTER 3 OPERATING CONTROLS AND SCREENS KEY DESCRIPTION MENU In either the run or program state MENU will provide you with a menu which allows you to select or change options which are common to all schedules HELP The PM7 contains a built in operation manual Press this key whenever you need HE
90. rkstation Procedures other than those described in this manual or not performed as prescribed in it may expose personnel to electrical hazards After reading this manual retain it for future reference when any questions arise regarding the proper and SAFE operation of the tester 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 PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL iv 990 084 CONTENTS O feat ade ciete 11 O 111 SAI asraon iare aa IROA ERE KEEA ube is ae aeeen anus ev A iv Declaration of Conformity io ceas ss caal bays petroownss eden aan eadearendnetavantteeeabers following Table of Contents CHAPTER 1 SYSTEM DESCRIPTION 0 ccccccscssssssscsseessesssccesesscessessecsaeestecesesseessesseeseeeeaes 1 1 Applications A A te ad aang 1 1 ESAS a dior os dolia E 1 2 CHAPTER 2 INSTALLATION cid iO ia IATA 2 1 Location sioen cached E A E E aad E a anita ah eee ee dale 2 1 Power Eme ernen gn E E N N E E OE 2 1 Welding a e oe ele EN 2 1 Rear Panel Components 1 dd Avs a a Gas Sen ee da 2 3 Firing Switch Comcel a 2 4 Mechanical Pirin A dao 2 4 eli o AA A ut tahini
91. s associated with da y Select then ENTER the OPTIONS selection The first time that you select OPTIONS the OPTIONS 1 screen will appear After you have made selections from the OPTIONS 1 screen you can proceed directly to the OPTIONS 2 screen and from there to the OPTIONS 3 screen or you may return from any of the three OPTIONS screens to the MAIN MENU OPTIONS 1 The OPTIONS 1 screen has four options lt OPTIONS 1 gt POWER UP SCHEDULE END CYCLE BUZZER e POWER UP SCHEDULE This option KEY CLICK determines which schedule number will come CHAIN SCHEDULE FEATURE up when the PM7 is switched on Use the keypad to enter any number between 0 and 127 To power up in the last schedule that 2 y Select CHNG Change More Options was displayed when power was switched off enter e ENDCYCLE BUZZER This option is usually used for manual weld heads An ON selection means that an audible signal will be given at the end of each weld sequence as a signal to the operator to release the foot pedal Use the CHNG key to select ON or OFF e KEY CLICK An ON selection means that whenever a key is pressed the operator will hear a key click sound OFF means that no sound will be heard Use the CHNG key to select ON or OFF PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 6 2 990 084 CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS e CHAIN SCHEDULES ON An ON selection means that the schedule will automatically advan
92. s 1 and 2 Pins 3 and 4 2HD are not provided To provide power to Air El Jumper valve driver 2 move Jumpers El and E2 and program WELD HEAD TYPE to DUAL AIR Single Air suk a NOTE When air valve driver 2 is used Relay Figure A 1 Jumper Selection for Air Valve 1 cannot be used Driver Control Air Valve Driver Receptacles The 4 pin receptacles located on the rear panel are AMP P N 206430 1 Unitek PN 550 062 The mating plug is an AMP 206429 1 Unitek PN 520 107 which uses a cable clamp Amp 206358 2 Unitek PN 245 084 Air Valve Driver 1 is wired as follows Pin Description 1 24 VAC 2 115 and 24 VAC return 3 115 VAC 5 Air head sensing externally connected to Pin 2 NOTE Connect Pin 2 to Pin 4 on a non Unitek Peco air actuated weld head PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL A 12 990 084 APPENDIX A TECHNICAL SPECIFICATIONS CONTROL SIGNALS Connector A 15 pin sub miniature D type CONTROL SIGNALS connector located on the rear panel is provided for the two relays and nine single pole inputs The relays and switch inputs are used to e Remotely select Weld Schedules 1 through 127 e Remotely inhibit the flow of weld current e Invoke an emergency stop condition to abruptly terminate the welding sequence The CONTROL SIGNALS connector figure A 2 is a Viking DMRST1I5RA05CG Unitek PN 250 195 The mating connector which included in the shipping kit is a TRW Cinch Connector comprised of a DA 15P
93. s can be independently programmed to close when e The PM7 is initiated e Any portion of the welding sequence is completed PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 2 10 990 084 CHAPTER 2 INSTALLATION e The firing switch opens e The PM7 is waiting for the welding sequence to start Refer to Appendix A under Control Signals and Relay Outputs for more detailed information Interconnection Diagram Refer to figure 2 8 for a wiring diagram of the PM7 that shows its interconnections with external equipment 115 VAC 15 A 50 60 Hz 1N HOT COM GND BLK WHT GRN POWER NO COM N C 5VDCCOM WELD HEAD FIRING SWITCH PENES FIRING SWITCH CABLE FORCE FIRING SWITCH SEE NOTE 2 PM7 WELD CABLES Y WELDING CONTROL SEE NOTE 1 AY ecccooes POWER OUTPUT AIR VALVE RTN AIR SOLENOID er DRIVER leeis 7 24 115 VAC ft AUTO SENSE CONTROL SIGNALS FOOTSWITCH i PNEUMATIC I INPUT C DC AC_ AC INB_GNDEMRGND 2 2 2 2 GNDLV1 Lv2com 1 77 TIE WELD CABLES TOGETHER FOR NON FORCE FIRED OPERATION SHORT PINS 1 AND 2 ON THE FIRING SWITCH CONNECTOR IF AN OPTICAL FIRING SWITCH IS USED THE FIRING SWITCH CONNECTION IS NOT USED i 5 50VDC 24 115VACI CHG EMERGENCY WELD SCHEDULE INITIATE RELAY2 RELAY1 INHIB STOP SELECT USER SUPPLIED USER SUPPLIED DASHED LINES REPRESENT AIR POWER 1 PROGRAMMABLE LOGIC CONTROL ACTUATED WELD HEAD CONNECTIONS Figure 2 8 PM7 Equipment Interconnection Diagram PHAS
94. ssure These welding parameters are controlled by Controlling Factors Y CURRENT selected during the weld period s on PM7 Primary tap setting of the welding transformer Secondary tap connections of the welding transformer Time Weld cycle selected during the weld periods s on the PM7 Pressure 1 Electrode firing force set on weld head 2 Surface area of electrode faces The effects of excessive or insufficient heat time and pressure on a weld are illustrated in figure 5 1 You should consider the interaction between these basic welding parameters when developing a weld schedule PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 5 1 CHAPTER 5 OPERATING INSTRUCTIONS PROBLEM Parts Overheating Weak Weld Insufficient Nugget Metal Expulsion Warping Discoloration Electrode Damage CAUSE PROBLEM Excessive Parts Overheating Weak Weld Insufficient Nugget Metal Expulsion ENERGY Warping Discoloration Insufficient Electrode Damage PRESSURE PROBLEM CAUSE Parts Overheating Excessive Weak Weld Insufficient Nugget Metal Expulsion FIRING Warping FORCE Discoloration Electrode Damage Insufficient CAUSE Excessive PULSE WIDTH Insufficient Figure 5 1 Effects of Excessive or Insufficient Heat Time and Pressure Using the Run Program and HELP States Run and Program State Selection Welding is done in the run state and programming is done in the program state These states are
95. t generate sufficient heat to achieve the desired grain alignment Type 410 stainless steel is one of the materials that must be heat treated annealed in order to eliminate the brittle crystalline structure caused by the weld current The quench temper sequence for parts that are SCHEDULE 7 QUENCH TEMPER NEXT SCH 12 smaller than those just described is programmed SYSTEM AIR2 LEVEL COUNT 00099 differently The program more commonly used SO WELD MCOOLE TEMP m HLD is shown at the right It is showing a program CYCLES 10 12 10 15 19 for welding a tungsten filament to a CURRENT 75 60 molybdenum ribbon The WELD CURRENT RELAY 1 AIR HEAD is used to force the oxides out of the weld zone RELAY 2 ON ON OFF OFF ON The parts cool during the COOL period and are av Select NUMBERS Change PROGRAM welded during the TEMPer period The WELD CURRENT is set so that it 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 then allows time to dissipate the heat generated during the WELD period The structural weld is made during the TEMPer period by the TEMPer CURRENT In this instance the TEMPer CURRENT should be greater than the WELD CURRENT by a factor of 2 or 3 PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 6 16 990 084 CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS Unbalanced AC Function This function is used in th
96. tatus SCHEDULE 19 BASIC WELD ON and the weld sentry schedule number and SYSTEM AIR 2 LEVEL WELD 0000001 mode 19 BASIC WELD SS VELO IN CYCLES 10 CURRENT 75 AMP SECONDS LOWER UPPER SENTRY 1589 1500 1650 ON A Y Select Schedule RUN J Changing Schedule Parameters Use the keys to select a schedule You can change Schedule 0 whenever the PM7 is in the program state You can change Schedules through 127 only if the system security feature is OFF Press PROG to select the program state The data or value field that was last changed will start to flash Use the lt keys to move the flashing cursor to the field that you wish to change The bottom line of the screen will advise you whether to use the CHNG key or the NUMBERS keys to change the contents of the flashing field PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 5 3 CHAPTER 5 OPERATING INSTRUCTIONS Changing Output Relay States Use the gt keys to move to either of the RELAY fields Use lt to move the cursor to the first field located to the right of the colon Pressing CHNG will cause this field change from ON to OFF to ALRM to AIR HEAD and back to ON Relay 1 is an AC relay capable of controlling any external function which requires up to 250 milliamps of current at 12 to 120 VAC When a dual air head is used you can program Relay 1 to control the 24 VAC VALVE DRIVER 2 connector Relay 2 is a DC relay that can switch up to 250 mi
97. the line power input circuitry proceed as follows 1 Set the rear panel circuit breaker power switch to OFF 2 Remove the cover 3 Refer to figure 7 1 Reconfigure the power transformer primary connections according to your line voltage input PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 7 1 CHAPTER 7 MAINTENANCE 4 34099 01 g 95V 0 3A 25 2V 2A Co 2 O O0 O O0 O O0 O OO O z o Jo Figure 7 1 Connection Diagram for Standard AC Voltage Ranges 4 Install the correct circuit breaker Refer to Appendix A under Input Output Cable Connections and Fusing 5 Install the line cord plug appropriate to your line voltage supply 6 Change all labels and tags so that they indicate the correct line voltage 7 Replace the cover PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 7 2 990 084 CHAPTER 7 MAINTENANCE Calibration Calibration should be performed only by a qualified technician Do not hesitate to call our Repair Department at the telephone number shown in the Foreword of this manual The PM7 should not require any regular adjustments Calibration consists only of adjusting two potentiometers on the control PCB The only test equipment required is a digital AC voltmeter NOTE PM7 power should be on for at least 5 minutes before attempting calibration 1 Switch power OFF 2 Remove the cover CAUTION Exercise static protection procedures so that no IC chips are damaged 3 Switch
98. to the top of the air cylinder on the weld head to the workpiece e Start the squeeze period The 2nd level initiates the start of the weld period provided that the force firing switch has closed and the squeeze period has ended A 1 level footswitch combines the functions of both levels of a 2 level footswitch Polarity Selection Polarity sets the initial direction of weld current flow through the work pieces Direction may be either positive negative or alternate This feature is useful for some types of half cycle welding applications These are applications involving dissimilar materials or materials with thickness ratios greater than 4 1 Alternate polarity means that the polarity of the first half cycle of output changes with each weld Alternate polarity can also be used to prevent Hypersil welding transformers from saturating NOTE Unitek Peco welding transformers do not use Hypersil cores Alternate polarity overrides the positive or negative polarity selection on all weld schedules and is controlled from the Special Options menu Positive and negative polarity are controlled by the individual weld schedules Power Factor Correction Microprocessor controlled automatic power factor correction ensures that the actual welding current percentage is within 3 of the value selected regardless of the load power factor Without this feature PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL A 8 990 084 APPENDIX A
99. whose microprocessor automatically compensates for 50 or 60 Hz operation The PM7 automatically determines and displays the frequency of the power line when it is placed in the calibrate mode Circuit Breakers and Fuses The PM7 is supplied with a combination 30 amp circuit breaker power switch located on the rear panel It protects both legs of the incoming power line at any of the specified voltages The Model PM7 460 requires a user supplied circuit breaker disconnect and input power cable The control PCB and valve driver circuits are protected by a fuse F1 located on the rear panel The rating of the fuse is as follows Line Voltage Fuse Type 100 250V 1 2A Slo Blo 120 250V 1 2A Slo Blo 208 250V 1 4A Slo Blo 240 250V 1 4A Slo Blo 400 480 440V 1 4A Slo Blo PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 A 1 APPENDIX A TECHNICAL SPECIFICATIONS POWER and OUTPUT CABLES These cables are 5 feet long with stranded wire leads The standard POWER connector is a NEMA L6 30P Unitek PN 520 093 240 volt 3 pronged twist lock plug rated for 250 volts 30 amps The OUTPUT connector is a Meltric 63 13045 480V LCE172 Unitek PN 520 124 The output connector is wired as follows PIN DESCRIPTION 1 Output from SCR to H1 side of output transformer N L2 side of input power line and H2 side of output transformer G Chassis ground Output Current The maximum output current capability as a function of duty cycle is
100. work piece 3 Adjust the air pressure for air operated weld heads refer to Chapter 4 under Adjusting an Air Actuated Weld Head for the procedure PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 990 084 5 7 CHAPTER 5 OPERATING INSTRUCTIONS Table 5 1 Recommended Electrode Materials Electrode Electrode Electrode Electrode Material RWMA Material RWMA Material RWMA Material RWMA Type Type Type Type 4 Aluminum Gold Plated Manganin Silver Alloys Dumet Beryllium Gold Plated Molybdenum Stainless Copper Kovar Steel Inconel Vickel Tinned 14 Brass Invar Jickel Alloy Tinned 14 re Paliney 7 Electrode Face Use a flat electrode face for most applications Use a domed face if surface oxides are a problem If either of the work pieces is a wire the diameter of the electrode face should be equal to or greater than the diameter of the wire If both work pieces are flat the face should be at least one half the diameter of the electrodes Pencil point electrodes reduce the overall quality of the welding process and are not recommended Welding Transformer Parameters Set the primary tap and the secondary tap if appropriate as follows Primary Tap No 1 the lowest tap on the Unitek Peco transformers Secondary Tap Lowest PHASEMASTER 7 DIRECT ENERGY WELDING CONTROL 5 8 990 084 CHAPTER 5 OPERATING INSTRUCTIONS PM7 Control Parameters You can develop weld schedules using Schedule 0 then copy it to any other sch

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