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500DP and 875DP Technical Manual

Contents

1. Typical at nominal line voltage Minimum Zat nominal line voltage Typical at lo line voltage Model 875DP Power Supply Minimum at tmaximum intermittent low line voltage L repetition rate Weld Sentry software not installed enun spem ay vonnaday Figure A 1 875DP Repetition Rate 10 500 uF anuin SPRW ey uonnccxrlLuruupas Figure A 2 875DP Hit Rate 10 500 pF 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES APPENDIX A TECHNICAL SPECIFICATIONS A 6 SmUIN SPISM sex uonedox f 3 E Percent Energy N Ww 00X00o Typical at nominal line voltage Typical at low li
2. iv Weak welds scsi ina yil 5 6 Went ai A 25 Weld counter specifications A 14 Weld evaluation 5 6 Weld functions Basie EE IR 6 5 General n eN Ee 6 4 A 9 Repeat stand 6 6 RO SDOE Ee ans 6 7 Weld head compatibility iese sesse A 9 Weld head configuration jumpering 4 6 A 16 Weld head parameters 5 2 Weld schedule Development 5 1 W continued Specifications A 6 INDEX 3 INDEX Weld Sentry options and utilities A 7 Weld strength profiles 5 8 Welding aceite Geen Lu aS 5 5 Welding cable installation 2 1 Welding considerations 5 1 Welding parameters 5 1 Welding schedule specifications A 6 Welding speed specifications A 3 Wiring diagram interconnection 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES INDEX 4 990 290
3. A 11 A A A 10 Initiation switch A 12 Options SERE SE ee A 7 Polarity selection A 3 Power input A 1 Weld counter A 14 Weld schedule A 6 Welding speed A 4 Squeeze time definition A 9 STANDBY Salad 6 2 States 875DP FIRE asa 6 4 HELP n on 6 4 MENU stress 6 3 NO WED stages 6 4 PROGRAM GE codes 6 2 RUN is 6 1 STANDBY cnn penini n 6 2 S continued 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 Step Count in eieiei A 13 Sticking electrodes 5 6 Switch debounce time A 11 System Default parameters A 8 Features a dis 1 2 Location considerations 2 1 aT Technical specifications A 1 Telephone repair service 7 11 Testing destructive 5 8 Three wire firing switch connections 2 4 Troubleshooting 7 10 Turning power on 4 1 U Utilities main menu A 8 V Voltage changes line 7 2 Voltage range specifications 7 9 W Warning definition Of
4. 3 4 Display screen formats 3 3 E Electrode force considerations 5 7 Electrode maintenance 5 9 Electrode materials recommended 5 3 Electrode sticking 5 6 Emergency stop A 17 End of cycle buzzer A 14 Excessive air pressure in weld head 4 5 F Factory repair service 7 11 Features of system 1 2 FIRE stiie a ss didas 6 4 Firing switch connections JWE DIE RA at qi has 2 4 A 11 Mechanical 2 4 A 11 Optical 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 INDEX 1 INDEX Firing switch specifications A 11 Footswitch connections 2 7 level Catan te 2 7 2 Level iii 2 8 Footswitch specifications A 10 Footswitch weld abort A 10 Force gauge usage 4 4 FOreWOId si alot 111 Front panel switches esse sesse ese 3 1 A 23 BUSES midi A 22 G Getting started ta 4 1 Guide Operator s CE following Contents H HELP state situa asis 6 4 HOLD time definition A 9 I If you need assistance 111 Information
5. I youms Buu 80104 PEOH PISM OV OV TO od s euBis o1Juoo jddns 1emod daS48 g ajou aas yoyms Buyl WOO 9GAS ON WOO ON J8MOd NY LHM 1719 OND WOO LOH L ZH 09 05 VS OV ASLL Figure 2 5 875DP Equipment Interconnection Diagram 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 2 9 990 290 CHAPTER 3 OPERATING CONTROLS AND SCREENS Operating Controls Figure 3 1 illustrates the layout of the operating controls on the front panel of the 875DP l ON o LC OFF O CONTROL GEE E g NO WELD En UNITEK PECO Rime WORLD LEADER iN RESISTANCE WELGIN Figure 3 1 Front Panel of the 875DP 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 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 D gt lt PROG RUN SAVE 3 2 DESCRIPTION In the RUN state this key changes gt increases and decreases the schedule number displayed In PROGRAM and MENU states the gt and k
6. connected across the capacitor bank discharging the bank to the required level The turndown circuit deadband is approximately 0 6 of full scale voltage Line Failure Turndown When input power is interrupted a turndown resistor is automatically connected discharging the capacitor bank 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES A 2 990 290 APPENDIX A TECHNICAL SPECIFICATIONS Over Voltage Lockout Protects the capacitor bank from damage due to circuit malfunction or improper calibration The circuit breaker opens removing primary power and the line failure turndown circuit automatically discharges the capacitor bank The circuit is adjusted to operate when 440 1 volts is placed across the capacitor bank Charge Lockout Circuit Nominal 120 millisecond commutation pulse generated in the microprocessor inhibits the charging circuit until the output SCR has been switched off Polarity Selection Positive and negative polarity can be achieved by reversing the cables which connect the Output Transformer to the weld head Polarity sets the initial direction of the weld current flow through the workpiece This feature is useful for welding applications which are sensitive to the direction of weld current flow because of dissimilar materials and or materials with thickness ratios greater than 4 to 1 Welding Speed Repetition rate is the average number of welds allowable in 1 minute based upon the th
7. that pulse will not be interrupted After that no further operation can be initiated until the short has been removed 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 A 17 APPENDIX A TECHNICAL SPECIFICATIONS Charge Process Inhibit Shorting Pin 9 to Pin 11 will close the charge process inhibit line and prevent recharging of the capacitor bank The charge inhibit line is used during remote schedule selection to prevent the capacitors from recharging to a higher energy schedule when loading a lower energy schedule This saves the time required to discharge the capacitors unnecessarily The charge inhibit line must be closed immediately after the power supply fires and before the 60 millisecond commutation pulse has ended The line must then be opened before the next schedule can be executed Charge inhibit can also be used instead of RUN to remotely clear any error stop alarm Short Pin 9 to Pin 11 momentarily and immediately open the short to clear the alarm Remote Weld Schedule Selection Refer to figure A 6 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 and 4 Connecting any one of these inputs to Pin 11 will cause the power supply to load the weld schedule defined by the corresponding pin combination immediately after the initiation switch closes Weld sch
8. 2 Rear of Unit Im The output ofthe AIR VALVE DRIVER 2 E10 E10 receptacle provides 24 VAC to power a second atr actuated weld head Jumpers E10 and E11 El El located near the lower right hand corner of the control board must be moved to the correct a positions as shown in figure 4 5 Jumpers Jumpers n n E11 E11 Single Air Head Dual Air Head Air valve driver 2 is wired only for 24 VAC through receptacle Pins 1 and 2 Pins 3 and 4 are not provided To provide power to Air valve driver 2 move Jumpers E10 and E11 and program WELD HEAD TYPE to DUAL AIR Figure A 6 Jumper Selection for NOTE When air valve driver 2 is used Relay 1 Pit valve Driver CONIO cannot be used Air Valve Driver Receptacles The 4 pin receptacles located on the rear panel are AMP P N 206430 1 Unitek Peco PN 550 062 The mating plug is an AMP 206429 1 Unitek Peco PN 520 107 which uses a cable clamp AMP 206358 2 Unitek Peco 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 4 Air head sensing externally connected to Pin 2 NOTE Connect Pin 2 to Pin 4 on a non Unitek Peco air actuated weld head 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 seven single pole i
9. 25 Polarity of current flow considerations 5 7 Polarity selection A 3 Power requirements A 1 Power line input 2 1 Power supply 875DP parameters 5 5 Powering UD A ese Ned sede eN See ees 4 1 Process definitions 6 1 Process Mba A 18 Profiles weld strength 5 8 PROGRAM sstate 6 2 990 290 R Rear panel components 2 3 Recommended electrode materials 5 3 Relay outputs 2 8 A 20 Remote schedule selection 2 8 A 18 Removing the cover 7 1 Repair service 7 11 Repeat weld function 6 6 Resistance welding parameters 5 1 Revision record manual ii Rollspot weld function 6 7 RUN State ass 6 1 S Safety Notes usasapa EE Sus iv Screen flowchart 3 5 Screen formats 3 3 Second air head connections 2 7 Selecting remote schedules 2 8 Size S7SDP iia A 25 Specifications Air valve driver A 15 Capacitor bank A 1 Firing switch
10. POLARITY WIDTH SHORT PULSE 1 PULSE 2 ENERGY 010 0 036 0 RELAY 1 RUN STATE RELAY 2 OFF OFF lt v y Select CHNG Change STANDBY In this state the power supply will allow you to change and save write to permanent memory any weld chedule Press PROG to enter the PROGRAM state which is signified by the legend PROGRAM lin the lower right hand corner of the screen In those units 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 6 2 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS 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 SCHEDULE 000 FUNCTION BASIC POLARITY WIDTH SHORT NE PULSE PULSE NE ENERGY 010 0 036 0 RELAY 1 RUN STATE RELAY 2 OFF OFF gt gt Select CANG Change PROGRAM MENU State In this state the power supply 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 The OPTIONS selection of the MAIN MENU screen has three sub screens OPTIONS 1 OPTIONS 2 and OPTIONS 3 lt MAIN MENU gt lt OPTIONS 1 gt OPTIONS m WELD SENT
11. R E A a nee 3 Wire Firings A Re SO EE ERA Ee BES GE EENS EEN ER Ee RS EG Re Air Actuated Weld Head Connections Ge ie Deeg dd Ait Valve A das Non Unitek Peco Air Actuated Weld Heads Air Actuated Weld Heads without Force Firing Switches Second Air Head inusitada I OOS WUC Hes cena canted a ta EE EG De Ee GR WE ARET Level POOLS ic io 2 Level BOOS WI a eee Remote Schedule S l tfIonnu nn a di ies Relay Outputs sm aa A AA EN A A E ie AAA Be A eh Interconmect on Diari a him ias NS ai ner CHAPTER 3 OPERATING CONTROLS AND SCREENS peras Control cos Screen POr EE EE EE RE RRS CHAPTER 4 GETTING STARTED POW SEU UD uya Re EE a ae N EE A Be ee ER Bea Adjusting an Air Actuated Weld Head 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 iv CHAPTER 5 OPERATING INSTRUCTIONS SUCCESS TUL Mel NE TO Resistance Welding Parameters Gene Re Ge Re ees Weld Schedule Development iii rias Weld Head PALAS A A ee Power Supply PA A A D Ge Gee ed Making a ORE EE OR ER OE RO EO sans Evaluatine the Welt ios E tado olla er e elle de Weak A A Plectrode SUCKing a y a UPS S te hA u Le u aa GI uu Causes or Imperfect Wed italia Electrode Force and Energy u nn seges ves vee bede de be ed See Ge ee Ses ee eke ER eg a
12. SHORT MEDIUM LONG OFF TIME sec NEXTSCH _ STEP COUNT 0 99999 1 KEYBOARD 2 RELAY OUTPUTS 3 CONTROL SIGNALS 4 VALVE OUTPUTS 5 WELD SENTRY 6 DATA OUTPUT 7 REVIEW HELP RUN SCREEN SYSTEM HELP CERREN BY PRESSING RUN AT ANY TIME LU gt E at O SCHEDULE m SENTRY MAIN MENU U FUNCTION BASIC REPEAT ROLL SPO z LI PULSE HHH H a lt PULSE 2 HHH cc POLARITY ie WIDTH SHORT MEDIUM LONG O OFF TIME sec m NEXTSCH _ a STEP COUNT 0 gt 999999 1 RESET SYSTEM PARAMETERS ACCESSED BY PRESSING PROG AT ANY TIME RESET TO DEFAULTS 2 RESET ALL SCHEDULES PROGRAMS ADJUST R104 TO 10002A X 0 524 AT TP6 ADJUST E TO 408V AT CapBank ADJUST R108 TO cw ccw CORRECT ADJUST R97 TO 0 K5mV AT TP4 ADJUST R12 AT U3 Pin 14 CALIBRATION INSTALLATION HELP INSTALLATIO Figure 3 2 Screen Flow Chart 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 3 5 CHAPTER 4 GETTING STARTED Powering Up 1 2 Set the front panel POWER Switch to ON To prevent the power supply from firing until you are ready to weld select NO WELD Press gt 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 power supply s utilities Press PROG to make changes to wel
13. 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 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 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 E lt AIR PRESSURE REGULATOR lt AIR GAUGE AIR INPUT POWER CORD Figure 2 4 Typical Solenoid Air Valve Assembly with a Single Regulator Air Valve Driver Connect the solenoid air valve to the AIR VALVE DRIVER 1 receptacle located on the rear panel of the power supply Weld heads with 4 pin 24 115 VAC connectors can be plugged directly into the power supply Weld Heads with standard 115 volt plugs NEMA 5 15P require an adapter Unitek Peco Model VDAC Valve Driver Adapter Cable When the connection has been made the power suppl
14. adjustments are set at the factory and with the possible exception of the alarm volume and display contrast should not require adjustment in the field The potentiometers and their specific functions are 990 290 R 108 R 97 R 36 R 12 Calibrate Display R 104 Reference Adjustment Offset Adjustment R 135 Alarm Volume EOut R 131 Display Contrast Overvoltage Adjustment 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 7 9 CHAPTER 7 MAINTENANCE To adjust the trimpots press ENTER to display the calibration screen listing the trimpot adjustments Adjust the trimpots as instructed on the screen NOTE The current measured at TP5 must not drift more than 1 5 MA Replace the cover and top screws Securely tighten all screws Troubleshooting If the circuit breaker trips repeatedly one of the following is probably the cause Erg monde Overload Exceeding the duty cycle Lockup of the output SCR Q6 switches ON but not OFF Shorting of the charging Triac Q1 See Control Board Charge shunting SCR Q2 shorted or locked ON Charging bridge rectifier diode s shorted Malfunction in the charging regulator which turns on the Overvoltage Protection Lockout Circuit Malfunction or improper adjustment of the Overvoltage Protection Lockout Circuit Defective circuit breaker Miscellaneous short circuits or mis connection of the pulse transformer or the control board Test the Triac by removing U
15. 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 workstation 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 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES iv 990 290 CONTENTS Revision RECON iii iii E Safety NGIES a EE ATA SNS a D a aaa Declaration of Conformity iss SE ESE EER SR Gede iisen eiiie e aE Ee EE EI E EE CHAPTER 1 SYSTEM DESCRIPTION PRPC AU ons u u A dun Sa au dus ER EE nn a tn nd A a RD EN CHAPTER 2 INSTALLATION A saa EE EE EE EE N EN EN Power Linera in Welding Cables pc ii ld oleo q aayqa Rear Panel Components ennes a Ad Firing Switch Connections iii ia Mechanical Firing Solsticio Optical Biring SACS MV A A
16. connected to any 100 115 208 or 230 volt outlet that is capable of supplying the peak currents specified in table A 4 Circuit Breakers Circuit breakers are used to protect the incoming power line The circuit breakers may need to be replaced if the power supply is reconnected for a different line voltage see table A 4 Fuses A amp fuse F1 is located near the top center of the control printed circuit board The power supply is shipped wired for 115 VAC unless otherwise specified Power Input Connector The standard power connector is an IEC 320 with a harmonized molded power cord 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES A 22 990 290 APPENDIX A TECHNICAL SPECIFICATIONS Table A 4 Input Power Specifications Nominal Line Voltage Line Peak Input Circuit Breaker Circuit Line Voltage Range Frequency Current Amps Size Amps Breaker Volts RMS Volts RMS Hz 500DP 500HV 875DP 500DP 500HV 875DP Quantity 208 iso 235 soe 23 a 3 s s s 2 230 200 260 soe 20 2 8 8 8 2 Front Panel Switches There are 22 electro statically shielded membrane switches which are integral to the front panel The function of each key is defined in Chapter 4 Microprocessor CPU The power supply 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 ultraviolet eras
17. 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 015 can be used and any number of schedules can be chained together with some exceptions as follows X Next Schedule 0 Can only be used at the beginning of a chain X Next Schedule Current Schedule Prevents chaining When the step count reaches 0 it will reset and the current schedule will remain in use X Next Schedule period Causes the power supply to stop after the step count has reached 0 and issue a standby stop command alarm X Weld Function Rollspot Can only be used as the last schedule in a chain 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 A 13 APPENDIX A TECHNICAL SPECIFICATIONS CAUTION If weld schedules are chained together do NOT change polarity All schedules in the chain must have the same polarity or the relay contacts may be damaged Step Counts STEP COUNTS between 00001 and 99999 can be specified The Step Counter counts down to 0 Ifa weld schedule is not completed and or the WELD NO WELD switch is set to NO WELD the Step Counter will not be decremented 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 w
18. for illustrations of typical air actuated systems UPSPEED AIR y UPSPEED AIR VALVE B VALVE A AIR AIR CYLINDER B CYLINDER A DOWNSPEED AIR 7E DOWNSPEED AIR VALVE B wa J VALVE A AIR GAUGE B TOP amp BOTTOM AIR PRESURE gt REGULATOR B TOP amp BOTTOM I i t NE AIR PRESURE i A REGULATOR A I q AA MA AIR GAUGE A POWER CORD B Figure 4 1 Typical Solenoid Air Valve System with Dual Regulators 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 4 2 990 290 CHAPTER 4 GETTING STARTED ur SPEED FLOW VALVE DOWN SPEED FLOW VALVE AIR CYLINDER PULL UP AND TURN CLOCK WISE TO INCREASE PRESSURE PUSH DOWN TO LOCK AIR PRESSURE REGULATOR AIR INPUT POWER CORD Figure 4 2 Typical Solenoid Air Valve System with a Single Regulator 5 Unlock the regulator s by pulling the red ring up Set the air gauge s for 25 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 power supply 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 n
19. g Cool Time Rollspot Function h Off Time Repeat Function i Status of Relay 1 j Status of Relay 2 Weld Schedules 1 through 15 can be protected from unauthorized or inadvertent changes by Unitek Peco s System Security Feature When the System Security is Protected Schedule 0 is the only schedule which can be modified NOTE Ifthe security code is lost Select SYSTEM SECURITY from the main menu Switch the WELD SWITCH to NO WELD press SAVE and then press The status will change to UNPROTECTED Options You can change the following options from the main menu a b Units of Measure for Energy Schedule Number at Power Up End of Cycle Buzzer ON OFF Chain Schedule ON OFF Squeeze Time f Weld Head Type g Footswitch Type h Footswitch Weld Abort ON OFF i Firing Switch Type j Switch Debounce Time k Hold Time 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 A 7 APPENDIX A TECHNICAL SPECIFICATIONS Schedule Number at Power Up This option determines which schedule will be used when the power supply is switched to ON The option will be either Schedule Number 0 15 or the schedule which was selected just before the power was switched to OFF Utilities The following Utilities are available to the operator from the main menu a Change System Security Status c Reset Default Parameters b Copy a Schedule d Set Weld Counter Information Information on the following subjects is a
20. m INSTALLATION m SYSTEM HELP Weld Sentry program lines Program A E last weld results measurement unit upper lower limits Sentry status Weld function basic repeat or roll spot Weld counter step count for next schedule Pulse width of Weld Pulses 1 and 2 Switching status of output relays Run state with NO WELD switch ON Typical multi page help screen 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 3 4 990 290 CHAPTER 3 OPERATING CONTROLS AND SCREENS DISPLAY UNITS LENERGY WATT SE POWER UP SCHEDULE END OF CYCLE BUZZER ON OFF CHAIN SCHEDULE FEATURBN OFF SQUEEZE TIME 0 gt 9 9 SEC HEAD TYPE AUTO AIR MANUAL DUAL AIR FOOTSWITCH 1 LEVEL 2 LEVEL NONE FOOTSWITCH WELD ABORON OFF FIRING SWITCH 2 WIRE 3 WIRE OPTO NONE SWITCH DEBOUNCE TIME 0 10 20 30ms OPTIONS OPTIONS OPTIONS WELD COUNTER HAE WELD COUNTER COPY SCHEDULE SYSTEM SECURITY SYSTEM HELP WELD SENTRY CALIBRATION RESET TO DEFAULTS INSTALLATION MAIN MENU COPY SCHEDULE TO SCHEDULE 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 NOTE 2 DISPLAY ONLY AND CANNOT CHANGE SECURITY STATUS PROTECTED UNPROTECTED ENTER CODE TO CHANGE STATUS SYSTEM SECURIT SCHEDULE r WELD 1 WELD 2 HE H HE FUNCTION BASIC REPEAT ROLL SPOJ POLARITY le WIDTH
21. maintenance esse sesse A 8 Initiation switch specifications A 12 Input power line 2 1 A 22 Installation instructions 2 1 Interconnection wiring diagram 2 9 J Jumper selection of weld heads 4 6 A 16 K REV Click a a A 14 L Line power Input 2 1 A 22 Line voltage changes sesse esse ee se 7 2 Locating system for installation 2 1 M Main menu information A 8 Main menu utilities A 8 Maintenance Electrodes iese see ee ee ee 5 9 Power SUPPLY sens 7 2 Manual Revision Record ii Mechanical firing switch connections 2 4 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES INDEX 2 MENU State airada 6 3 Microprocessor CPU A 23 Modification ips 7 1 N Next SOHO IMIG pto A 13 NO WELD state 6 4 O Operating controls 3 1 A 21 Operating Instructions 5 1 Operator s Guide CE following Contents Optical firing switch connections 2 4 Options specifications A 7 Output relays usa ik 2 8 P Percent energy considerations 5 5 Physical characteristics A
22. supply determines whether it is connected to an air or manual head whenever it enters the RUN state The options menu can be programmed to override the automatic selection feature Squeeze Time For air head operation squeeze time is the delay from the footswitch closure until the start of the weld period For manual head operation squeeze time is the delay from firing switch closure until the start of the weld period The delay can be set from 0 00 to 9 99 seconds Cool Time Cool time is the time between welds In the rollspot function the electrodes are wheels The cool time and the rotational speed of the wheels determine the distance between welds An air head will not open until the footswitch is released Cool time can be set between 0 00 and 9 99 seconds Hold Time Hold time is the delay from the end of the weld pulse until the head valve opens Hold time applies only to an air head The delay can be set from 0 00 to 9 99 seconds 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 A 9 APPENDIX A TECHNICAL SPECIFICATIONS Footswitch Type These power supplies require the use of a 1 level or 2 level footswitch in order to control an air actuated weld head They will automatically detect whether a Unitek Peco 1 level or 2 level footswitch is connected to the FOOTSWITCH connector located on the rear panel The power supply assumes that a 1 level footswitch is used if the input to the 2nd level is continuously cl
23. 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 power supply 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 The power supply will automatically detect that the system is using a 3 wire switch if Pin 2 is low at power up 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 2 4 990 290 CHAPTER 2 INSTALLATION Air Actuated Weld Head Connections Solenoid valve regulator assemblies which are separate from the weld head such as the Unitek Peco Models 80 or 82 Thinline Weld Heads should be mounted at a convenient location on the bench Connect the inlet port on the air valve solenoid to a properly filtered air supply 65 psig maximum Use 0 25 inch OD x 0 17 LD 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 typical 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 All
24. 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 different 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 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 5 8 990 290 CHAPTER 5 OPERATING INSTRUCTIONS 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 conce
25. 1 on the Control Board This should switch the Triac OFF and no current should flow If it does not turn off replace the Triac Test all diodes for shorts by using an ohmmeter Disconnect the capacitor bank Charge the bank with an external 400 volt DC power supply After five minutes the steady state current should be less than 12 milliamps If it is not one or more of the capacitors is shorted Discharge the bank with a 500 2000 ohm 25 watt resistor and replace the defective capacitor WARNING Do not discharge the capacitor bank by shorting it directly to ground The stored energy could be sufficient to melt the shorting tool in an explosive manner After making any repairs and checking the results replace the cover and tighten all screws 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 7 10 990 290 CHAPTER 7 MAINTENANCE Repair Service Telephone Service Call the Unitek Miyachi 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 to Unitek Miyachi for repair must be shipped PREPAID Please
26. 4 5700 AD Helmond HOLLAND Manufacturer s Name and Address UNITEK MIYACHI CORPORATION 1820 South Myrtle Avenue Monrovia CA 91017 U S A Based on the Declaration of Conformity Certificates issued by the test laboratories I declare that the equipment specified above conforms to the listed directive and standards Place Monrovia CA FAAN Signature Robert L Wallish Full Name Director of Quality Assurance Title CHAPTER 1 SYSTEM DESCRIPTION Applications The 875DP figure 1 1 is a versatile 875 watt second stored energy capacitor discharge dual pulse power supply which can effectively solve most precision small parts resistance welding problems Its exclusive context sensitive User Help Screens quickly guide the user through even the most complex program NO WELD NUNITEK PECCO PECO sro Sr RY NER NUNIEK FECU LEADER IN RESISTANCE WELDING Figure 1 1 875DP Dual Pulse Resistance Welding Power Supply 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 1 1 CHAPTER 1 SYSTEM DESCRIPTION Unitek Peco s Schedule Protection feature protects Schedules from unauthorized or inadvertent changes One of its 16 schedules serves as a scratch pad which anyone can use to perform occasional jobs without jeopardizing the integrity of the production line The exclusive Weld Fire Lockout feature guarantees that weld quality is independent of line voltage fluctuations and the speed at which the power su
27. ATING INSTRUCTIONS Weld Strength Profiles Electrode Force Weld strength profiles are graphic presentations A 8 lbs of the varying effects of ENERGY and B 10 Ibs electrode force To make a weld strength N C 12 bs Me 2 D 14 Ibs profile start at an initial energy setting make four or five welds and perform pull tests for S each weld Calculate the average pull strength 2 Increase the ENERGY and repeat the Q procedure Continue to increase the n MOLY ENERGY until any unfavorable characteristic WIRE occurs such as sticking or spitting ER X 0 030 Ni RIBBON F RWMA 2 Perform pull tests and plot the results of ENERGY versus Pull Strength see figure 5 20 30 40 50 60 70 80 100 2 Repeat this procedure for different forces Energy watt seconds or Current and plot a separate curve for each electrode force Figure 5 2 Typical Weld Strength Profile Perform pull tests and plot the results of ENERGY versus Pull Strength see figure 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 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
28. ESISTANCE WELDING POWER SUPPLIES 990 290 vii Air Valve Driver fs nun kau u tas A 15 Air Valve Driver A a ecards eal AR A 16 Air Valve Driver Receptacles csi arar ees ie A 16 Control Signals Connector a ii ii A 16 Emergency SLOP ina A 17 Charee Pr c ssy Inhibitu u A eee eee A 18 Remote Weld Schedule Selection A ee ae A 18 Binary Schedule Selection Codes A 19 Relay Cipsa ros GE acia ollas pe deso el delo A 20 ACCES SOY PO A Aum en ns A 21 Input Output Cable Connectors and Fusing ss A 22 Input Eme PO Wero ii A 22 CILCUIE Breakers nuria dida bil A 22 USER ER a sam HARE EE HE coi OE HE dl A 22 Power Input Conn cta RE eek la N GE aqasha Qa na but s nd A 22 Front Panel S Wite ici aa A 23 Microprocessor CP Uat iS A 23 Display A ee Seed Ba ee A 23 CORNE sra Sat kunu Su M EE ER ka Gu iq Ad A 24 Physical Characteristics s tl e o ner A 25 Index O A AAA A A AE NT Index 1 viii 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 ILLUSTRATIONS Figure Title 1 1 875DP Dual Pulse Resistance Welding Power Supply 2 1 Cable Routing Examples 2 2 Terminal Connection Examples 2 3 Rear Panel Components Sak Front Panel Controls a a es oe ee oi SSS Ge Coe 3 2 Screen Flow Chart uy ys RE kaysa ee eed he ae Re 4 1 Typical Solenoid Air Valve System with Dual Regulators 4 2 Typical S
29. F 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 in 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 power supply 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 power supply 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 Switch Debounce Time Single pole mechanical firing switch contacts bounce when they close The switch d
30. No 990 280 NUNITEK PECO ee WORLD LEADER IN RESISTANCE WELDING Revision D January 2002 875DP 500DP 500HV DUAL PULSE STORED ENERGY RESISTANCE WELDING Model Stock No Model Stock No 875DP 1 253 XX 875DPS 1 257 XX 875DP 208 1 253 XX 01 875DPS 208 1 257 XX 01 875DP 230 1 253 XX 02 875DPS 230 1 257 XX 02 875DP 100 1 253 XX 03 875DPS 100 1 257 XX 03 500DP 1 251 XX 500DPS 1 255 XX 500DP 208 1 251 XX 01 500DPS 208 1 255 XX 01 500DP 230 1 251 XX 02 500DPS 230 1 255 XX 02 500DP 100 1 251 XX 03 500DPS 100 1 255 XX 03 500HV 1 252 XX 500HVS 1 256 XX 500HV 208 1 252 XX 01 500HVS 208 1 256 XX 01 500HV 230 1 252 XX 02 500HVS 230 1 256 XX 02 500HV 100 1 252 XX 03 500HVS 100 1 256 XX 03 Units with the built in Weld Sentry Option also require User s Manual No 990 291 Copyright 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 17280 12 19 07 1 Correct clarify calibration procedures 2 Add operating features za 17678 11 3 98 Specify output load for HV500 Models C 18578 11 14 00 1 Add Declaration of Conformity Add tolerance to pulse output voltage Clarify operation of relay outputs 19146 01 02 Add Unitek Peco name LAS Update ma
31. PULSE a PULSE 2 wan ENERGY 010 0 035 0 RELAY 1 RUN STATE RELAY 2 ON lt lt Select NUMBER Change J PROGRAM ff O HELP Screen Q HELP PULSE 2 PAGE 2 3 DUAL PULSE IS USED TO WELD PLATED MATER IALS PULSE 1 SHOULD MAKE A LIGHT TACK WELD AND PULSE 2 SHOULD WELD TO BASE METAL PULSE 2 IS USUALLY SET TO 3 TIMES THE ENERGY OF PULSE 1 TO WELD SMALL WIRES TO SUBSTRATE USE 4 Last HELP to Return Next Schedule number 0 15 Polarity of output welding pulses Energy of Weld Pulse 1 Energy of Weld Pulse 2 dual pulse Type of weld head and foot switch Graphic display of Weld Pulse 1 energy Weld counter step count for next schedule Pulse width of Weld Pulses 1 and 2 Next schedule number 1 15 in chain Present state of power supply ner AMOO wD K RUN Screen with Weld Sentry SCHEDULE PULSE 1 PULSE 2 001 10 0 35 0 BASIC WELD POLARITY WIDTH SHORT AIR HEAD 2 L WELD 00001 NEXT 001 AMP SECONDS LOWER UPPER SENTRY 001A 299 1 270 07 31007 READY lay Select Schedule RUN l NO WELD Screen SCHEDULE PULSE 1 PULSE 2 001 10 0 35 0 BASIC WELD POLARITY WIDTH SHORT AIR HEAD 2 L COUNT 00001 NEXT 001 RELAY 1 RUN STATE RELAY 2 ON OFF law Select Schedule l NO WELD l Last HELP to Return Next gt omoz EF P MAIN MENU Screen MAIN MENU m OPTIONS m WELD SENTRY m WELD COUNTERS m CALIBRATE 250DP m COPY A SCHEDULE m RESET TO DEFAULTS m SYSTEM SECURITY
32. Page Recommended Electrode Materials odia 5 3 Causes ot Imperfect Welds ess Ee E da AA AA 5 6 Power Supply Voltage Range Specifications ees esse se ee ee ee Se ke ee ee 7 9 Paulse CharacteriSfICSu EES GE EG DE A RG GE SAG A 2 Welding SPCC Sen aS A Ge Ge SE he teen ee A 4 Binary Codes for Remote Weld Schedule Selection A 19 Input Power Specifications td id ital eee Nan A 23 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 UNITEK MIYACHI CORPORATION EMC Applied Standard s EN50081 2 EN50082 1 EN55011 IEC 801 2 IEC 801 3 IEC 801 4 Directive s Type of Equipment Resistance Welding Power Supply Equipment Model No s 500DP 100 500DPS 100 500DP 500DPS 500DP 230 500DPS 230 500DP 208 500DPS 208 Authorized Representative Weld Equip Sales BV within European Community Engelseweg 217 Postbus 164 5700 AD Helmond HOLLAND Mannfartmreric Name and AdArace TInitalr Mack Carnaratian UNITEK MIYACHI CORPORATION Declaration of Conformity Directive s EMC LOW VOLTAGE MACHINERY Type of Equipment Resistance Welding Power Supply Equipment Applied Standards ENS0081 2 EN50082 1 EN55011 TEC 801 2 TEC 801 3 TEC 801 4 EN60204 1 ENS0063 Model Nos 875DP 100 875DPS 100 875DP 875DPS 875DP 230 875DPS 230 875DP 208 875DPS 208P Authorized Representative Weld Equip Sales BV Within European Community Engelseweg 217 Postbus 16
33. RY DISPLAY UNITS ENERGY mg WELD COUNTERS mg CALIBRATE 875DP m COPY SCHEDULE RESET TO DEFAULTS POWER UP SCHEDULE LAST m SYSTEM SECURITY nm INSTALLATION END CYCLE BUZZER OFF mg SYSTEM HELP CHAIN SCHEDULE FEATURE OFF gt Select then ENTER 2 Select CHNG Change More Options gt lt OPTIONS 2 gt lt OPTIONS 3 gt WELD HEAD TYPE AUTO SQUEEZE TIME 0 00 sec FOOTSWITCH TYPE AUTO HOLD TIME 0 00 sec FOOTSWITCH WELD ABORT ON FIRING SWITCH 2 WIRE SWITCH DEBOUNCE TIME 10 msec L Select CHNG Change More Options L Select CHNG Change More Options gt 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 6 3 CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS HELP State The power supply 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 power supply keys will be displayed as illustrated below Emz RUN STATES PAGE 1 6 HELP MACHINE STATES PAGE 2 6 REFERS TO A FRONT PANEL KEY m USE 2 OR TO SELECT SCHEDULES WHICH m CHNG WILL CHANGE THE SCREEN FORMAT ARE NUMBERED 0 THRU 15 TO INCLUDE THE STATUS OF EITHER THE a USE HE TO MODIFY A SCHEDULE OUTPUT RELAYS OR THE WELD SENTRY m USE TO DISPLAY THE MENU WHICH WILL SAVE IS NOT USED IN THE RUN STATE PROVIDE MORE INFORMATION HELP to R
34. Unless you are a skilled technician we suggest you telephone the Unitek Miyachi 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 power supply 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 front panel POWER switch to OFF 2 Disconnect the power supply 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 To disconnect the right half of the capacitor bank from the left half refer to figure 7 1 and proceed as follows WARNING After turning power OFF wait at least 5 minutes for the capacitors to discharge before starting this procedure 1 Display units should be set to Energy not Watt Seconds 2 Set the front panel POWER switch to OFF 3 Remove the cover 4 Remove Jumper A connecting the center terminals 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 7 4 CHAPTER 7 MAINTENANCE 5 Remove Jumper B connecting the positive terminals 6 Replace the cover Line Voltage Changes You may reconnect the power supply to operate at different line voltages 100 115 208 or 230 VAC 50 60 Hz To reconfigure the line power input circui
35. able and programmable read only memory Display This is an electro statically 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 right side of the cover The energy display accuracy is 0 5 The resolution of the display ranges from 0 1 to 0 6 energy depending upon the amount of energy selected Energy can be displayed in either watt seconds or of 875 500 for the SOODP and 500HV watt seconds 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 A 23 APPENDIX A TECHNICAL SPECIFICATIONS Cooling Cooling within the housing is provided by a muffin type fan that operates on 115 VAC 50 60 Hz power The atr 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 power supply Do not place the power supply 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 power supply to sit on surfaces which are covered with heavy dirt or dust 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES A 24 990 290 APPENDIX A TECHNICAL SPECIFICATIONS Physical Characteristics 500DP 500HV and 875DP Control Unit Figure A 9 875DP Physical Dimensions NOTE Dimensions include any protrusions Height 12 5 inches 31 8 cm Width 16 5 inches 41 9
36. acteristics are measured at the power output terminals across an output load as follows 875DP and 500DP 0 001 ohm with a tolerance of no greater than 42 including weld cable SOOHV 0 004 ohm with a tolerance of no greater than 42 including weld cable Rise time is measured between zero and peak amplitude and pulse width between the 10 amplitude points See table A 1 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 A 1 APPENDIX A TECHNICAL SPECIFICATIONS Table A 1 Pulse Characteristics Pulse Transformer Capacitor Connections Bank Pulse Height SHORT Parallel 9 5 V 10 5V MEDIUM 8 5 V 9 4 V LONG Series 7 3 V 8 0 V SHORIT Parallel 19 0 V 20 9 V MEDIUM 6000 uF 17 0 V 18 7 V LONG Series 14 6 V 16 1 V SHORT Parallel 11 5 V 12 7 V MEDIUM 10500 uF 10 2 V 11 2 V LONG Series 7 8 V 8 6 V Weld Fire Lockout Output of the error amplifier inhibits the firing circuit during the charge and turndown intervals This helps prevent poor welds caused by firing the power supply before the capacitor bank is properly charged or discharged Line Voltage Regulation Maintains voltage on the capacitor bank within 0 25 of setting for a 13 change from the nominal rated line voltage Turndown Circuit When voltage from the error amplifier exceeds that required to turn off the charging circuit a resistor is
37. air actuated head the initiation switch is the footswitch The first level of a 2 level footswitch instructs the power supply to 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES A 12 990 290 APPENDIX A TECHNICAL SPECIFICATIONS 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 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 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 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 Ifa weld sequence is not completed and or the WELD NO WELD switch is set to NO WELD the step
38. ally changing weld energy to compensate for electrode wear Schedule protection and system security features protects weld schedules except Schedule 0 from changes by unauthorized personnel Power up schedule selection allows any of the 16 schedules or the last schedule used to be specified as the default power up schedule The digital display allows operators to set welding energy accurately and quickly The 875DP is compatible with manually actuated weld heads and air actuated heads with 1 level or 2 level footswitches The 875DP is compatible with force fired and non force fired weld heads Squeeze delay time adjustable from 0 to 9 9 seconds An end cycle buzzer sounds at the end of each weld sequence as a signal to the operator to release the foot pedal There are two output relays which can be used to provide status signals to external devices One relay can also be used to control a second 24 or 115 VAC air actuated weld head The built in weld counters allow you to control events which are a function of the number of welds which have been made The firing circuit uses single pole double pole or optical firing pressure switches Weld fire lockout helps prevent poor welds caused by firing the power supply before the capacitor bank is properly charged or discharged 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 1 3 CHAPTER 1 SYSTEM DESCRIPTION e The foot switch weld abort safety feature
39. atinum Gold Plated Kovar Kulgrid Nickel Silver Stainless Steel Magnesium Molybdenum Nickel Tungsten Nichrome Nickel C R Steel Stainless Steel Nickel C R Steel Stainless Steel Tantalum Tungsten Electrode RWMA Type 14 NN NNN D D D D D D Material Nickel Alloy NiSpan C Niobium Platinum Paliney 7 Silver Cold Rolled Steel Stainless Steel Tantalum Titanium Tungsten Zinc Electrode RWMA Type 11 14 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES Material Tinned Brass Beryllium Copper Consil Tinned Copper Nichrome Nickel C R Steel NiSpan C C R Steel Stainless Steel Niobium Platinum Paliney 7 Silver Cadium C R Steel Stainless Steel Palladium C R Steel Stainless Steel Tantalum Stainless Steel Tungsten Tantalum Titanium Tungsten Rhenium Zinc Electrode RWMA Type 14 2 NN D D ND RE 11 13 14 N 14 990 290 CHAPTER 5 OPERATING INSTRUCTIONS 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 recomme
40. ay 1 would be switched to ON in the event of an alarm and Relay 2 is switched to ON during both weld periods SCHEDULE 000 FUNCTION BASIC POLARITY WIDTH SHORT EN Pu SE 1 SSE PULSE 2 ENERGY 010 0 036 0 RELAY1 ALARM RELAY2 ON ON gt Select CANG Change PROGRAM N The PROGRAM State Screen for the Basic Function When the firing switch in the weld head closes the weld sequence Pulse 1 followed by Pulse 2 will be executed The next sequence will not be executed until the firing switch opens and closes again The weld period consists of one or two weld pulses The weld period starts after the second level of a 2 level foot switch closes and after the firing switch in the head closes It includes the time required to recharge the capacitor bank for the second pulse In AC welding a hold period is usually included as part of a basic weld function It allows the electrodes to cool the work piece However the energy level of the power supply is not sufficient to require a hold period so it has been omitted from the basic function Weld energy is measured as the energy stored in the capacitor bank which provides the current required to make a weld The USER OPTION menu permits you to display this energy as a percentage of 875 watt seconds or as watt seconds You can set the energy for both weld pulses independently If you set the energy level of Pulse 2 to 0 the weld will consist of one pulse There are two output relays
41. cations A 1 Caution definition of iv Chain schedules feature A 13 Charge inhibit A 18 Circuit breakers 2 3 A 22 Components Front panel 3 1 Rear panel asta 2 3 Connections 3 wire firing switch 2 4 Air actuated weld heads 2 5 2 7 Air valve driver 2 6 A 15 Control signals A 16 Footswitch 2 7 Mechanical firing switch 2 4 Non Unitek Peco air actuated weld heads 2 7 C continued Optical firing switch 2 4 Second air head 2 7 Controls front panel 3 1 CONTROL SIGNALS connector A 16 Cool time definition A 9 Cooling 875DP A 24 Cover removal sisi 7 1 CPU microprocessor A 23 D Debounce time switch A 11 Declaration of Conformity following CE Operator Guide Default parameters system A 8 Destructive testing 5 8 DIMENSIONS 2e ee a ts A 25 DISPI li A 23 Display screen flowchart
42. causes the power supply to abort the welding process if the operator releases the footswitch on an air actuated system before the end of the welding sequence e The line failure turndown safety feature discharges the capacitor bank when input power is interrupted e The 875DP is protected from radio frequency interference and electromagnetic interference to ensure reliable operation even in high electrical noise environments Input switch debounce circuitry eliminates false triggering 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 1 4 990 290 CHAPTER 2 INSTALLATION Location Install the power supply 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 power supply as close as 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 unit is wired for 115 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 power supply 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 front of th
43. changes 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 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 Resistance Welding Parameters The three basic welding parameters are heat time and pressure These welding parameters are controlled by Controlling Factors ENERGY selected on power supply PULSE WIDTH selected on power supply Number of pulses selected on power supply Pressure Electrode firing force set on weld head 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 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 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 5 1 CHAPTER 5 OPERATING INSTRUCTIONS 5 2 PROBLEM CAUSE PROBLEM CAUSE Parts Overheating Excessive Parts Overheating Exce
44. cheduled to be closed during any successive periods it will not open at the end of the first period but will remain closed during both or all periods for which it is scheduled to be closed The 24 to 115 VAC input and output for Relay 1 are Pins 8 and 15 respectively of the CONTROL SIGNALS connector The 5 to 50 VDC input and output for Relay 2 are Pins 6 and 13 respectively You must supply the voltage source and in each case the ungrounded side of the AC power source for Relay 1 The DC power source for Relay 2 should be connected to the power supply as illustrated in figure 4 5 in Chapter 4 Either relay is capable of switching up to 250 ma RELAY 1 is also used to control Air Valve Driver 2 The options menu can be used to specify Dual Air Head 2 Under this condition Relay 1 will display Dual Air In the program state the options for Relay 1 then must be either AIR HEAD 2 or NOT USED The second air head will be actuated in any schedule in which Relay 1 is defined as AIR HEAD 2 The standard valve driver will be actuated in any weld schedule in which Relay 1 is defined as NOT USED Accessory Port A 15 pin sub miniature D type connector located on the rear panel is provided to control other devices contemplated for the future 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 A 21 APPENDIX A TECHNICAL SPECIFICATIONS Input Output Cable Connectors and Fusing Input Line Power The power supply may be
45. cm Depth 16inches 40 6 cm Weight 69 pounds 31 5 kg 500DP 500HV 77 pounds 35 kg 875DP 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 A 25 APPENDIX A TECHNICAL SPECIFICATIONS Physical Characteristics 500DP 500HV and 875DP Welding Transformers NUNITEK PECO Figure A 10 Physical Characteristics 500DP 500HV and 875DP Welding Transformers NOTE Dimensions include any protrusions 500DP 500HV 875DP Height 12 inches 30 5 cm 14 25 inches 36 2 cm Width 9 Inches 22 9 cm 9 inches 22 9 cm Depth 10 inches 25 4 cm 10 inches 25 4 cm Weight 79 pounds 36 kg 121 pounds 55 kg 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES A 26 990 290 Index A ACCESSOLY port A 21 Air actuated weld head Adjustments 4 1 Connections 2 5 Excessive atr pressure results 4 5 Air valve driver connections 2 6 A 15 Air valve driver specifications A 15 Alarms sista AN A 15 Application of system 1 1 Audible buzzer ee ee ee ee ee ee A 14 B Basic weld function 6 5 Binary Schedule Selection Code A 19 Buzzer audible A 14 C Calibration 7 1 7 8 Capacitor bank Specifi
46. d schedules 0 to 15 Schedules 1 through 15 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 NOTE To override the security code refer to Appendix A under Weld Schedules 8 If appropriate change the output relay configuration with the PROGRAM screen Adjusting an Air Actuated Weld Head NOTE If an alarm occurs press RUN to silence the alarm 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 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 4 1 CHAPTER 4 GETTING STARTED 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 power supply 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 Peco 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
47. e 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 ALARM SCR The output SCR which discharges the capacitor bank into the pulse transformer may be defective 2 ALARM EMERGENCY STOP An emergency stop signal was received via the CONTROL SIGNALS connector 3 ALARM FIRING SWITCH The force firing switch in the weld head either did not stay closed during the weld sequence or did not close within 10 seconds after the 1 level footswitch or the second level of a 2 level footswitch closed Air Valve Driver The air valve driver provides power to control the solenoid of an air actuated weld head The power supplies 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 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 A 15 APPENDIX A TECHNICAL SPECIFICATIONS Air Valve Driver
48. e output transformer Convention is to connect the lower electrode of the weld head or hand piece to the output terminal and the upper electrode to the output terminal of the power supply If the weld head cables are unserviceable use the following criteria in selecting new cables e Use No 2 AWG welding cables or No 2 0 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 To reduce energy losses follow these recommendations e Route cables so that they do not surround magnetic materials such as air solenoids tooling or steel weld heads see figure 2 1 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 2 1 CHAPTER 2 INSTALLATION Tape cables together to minimize the inductive losses A separation of weld cables surrounding an area of one square foot could result in losses of up to 65 figure 2 1 DO Cables taped together and routed away from steel structure and electromagnetic field T gt N Sieel Fixture N Steel Weld Head 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 output transformer and the terminals of the cables Tighten connect
49. e the status of the output relays or e changes the contents of alphanumeric fields in the PROGRAM or MENU states ENTER Use this key to signify that the data entry you have entered using the keypad is complete KEYPAD Use the 10 numeric keys to enter numeric information is used to enter decimal values 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 position in order to make a weld ALARM Adjusts the volume of the alarm buzzer It is located on the front right hand VOLUME side of the cover DISPLAY Adjusts the contrast of the LCD Display It is located on the front right hand CONTRAST side of the cover Screen Formats Illustrated below is the information displayed in RUN PROGRAM NO WELD HELP and MAIN MENU screens Note that the 875DP operational state is displayed at the bottom right corner of the operation screens Figure 3 2 shows the detailed sequence of the screens 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 3 3 CHAPTER 3 OPERATING CONTROLS AND SCREENS RUN Screen A B C D PULSE 1 PULSE 2 10 0 35 0 BASIC WELD POLARITY WIDTH SHORT E AIR HEAD 2 L WELD 00001 NEXT 011 G H J PROGRAM Screen LM N SCHEDULE 001 NEXT SCH 011 MODE BASIC STEP CNT 0001 POLARITY WIDTH SHORT mm
50. ebounce time feature allows you to specify that the firing switch must remain closed for 0 10 20 or 30 milliseconds before the weld period can be initiated The power supply will automatically set the switch debounce time to 0 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 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 ree APPENDIX A TECHNICAL SPECIFICATIONS Unitek Peco PN 520 008 with strain relief It mates with an Amphenol 80 MC2M Unitek Peco PN 520 001 Pin 2 is ground Optical Firing Switch Connector This connector is a 5 pin AMP 212044 1 Unitek Peco PN 150 064 located on the rear panel see figure A 5 It mates with an AMP Assembly consisting of an AMP 212437 3 Plug 212435 7 Ferrule and 212 800 1 Strain Relief The connector is wired as follows Pin Description Shell Shield 1 Switch Normally Closed 2 Switch Common 3 Switch Normally Open 5 VDC 5 Switch Common Figure A 5 Pin Numbers as Viewed from the Rear Panel Initiation Switch Manual Head Operation If the power supply is connected to a manual head the initiation switch is the force firing switch located in the weld head Air Head Operation If the power supply is connected to an
51. edules are selected according to the binary pattern shown in the table A 3 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES A 18 990 290 APPENDIX A TECHNICAL SPECIFICATIONS Table A 3 Binary Codes for Remote Weld Schedule Selection INPUT PIN NUMBERS Sauna rane 1 Switch Closure 1 2 22 327 42 Control Number 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 15 connect the pins which correspond to the numbers totaling 15 Schedule 15 1 2 4 8 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 A 19 APPENDIX A TECHNICAL SPECIFICATIONS Connect Pins 1 2 3 4 to Pin 11 ground External Input External Input Connector Connector BCD Switch 875 500DP Couplers 875 500DP Figure A 8 Remote Schedule Selection with a Remote Binary Switch 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 The capacitor bank will begin to recharge 120 milliseconds after the end of the previous pulse unless the charge inhibit line is gr
52. ermal rating of the system components The averaging period used to determine the repetition rate can be as long as 20 minutes Hit rate or maximum intermittent welding speed defines how fast the power supply can make consecutive welds on a non continuous basis See table A 2 and figures A 1 and A 2 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 A 3 APPENDIX A TECHNICAL SPECIFICATIONS Table A 2 Welding Speed 6000 uF Capacitor Bank 10500 uF Capacitor Bank Rep Rate Hit Rate Rep Rate Hit Rate Percent Bull Energy welds min welds min welds min welds min under 2 116 10 116 25 78 50 51 75 36 100 27 Conditions 25 C Ambient Nominal Line Voltage 60 Hz In dual pulse operation the repetition rate or hit rate for each individual pulse may be calculated as follows RR First Pulse Rep Rate Hit Rate RR Second Pulse Rep Rate Hit Rate Calculate RR 1 2 Rep Rate Hit Rate for dual pulse operation RR i RR2 RR 12 ET RR RR For example if wired for the 10 500 uF Capacitor Bank the energy level of Pulse 1 is 25 and Pulse 2 is 75 the repetition rate for the dual pulse weld would be 80 40 RRas 26 7 welds min 80 40 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES A 4 990 290 990 290 APPENDIX A TECHNICAL SPECIFICATIONS Percent Energy o A m o mo oO
53. eturn Next gt lt Last HELP to Return Next Typical HELP screens If there is more than one page of Help the number of pages will be displayed in the upper right hand corner Use lt or to move from page to page Press HELP to return to the previous state NO WELD State The WELD NO WELD switch is in the NO WELD position The power supply will execute any weld schedule but the capacitor bank will not be discharged and no welding current will flow FIRE State The firing switch in the weld head has closed and the welding sequence is proceeding Weld Function Field The power supply allows you program 15 weld schedules Each schedule can use one of its three weld functions There are two versions of the basic and rollspot functions one for an air actuated weld head and the other for a manually actuated weld head The repeat function only applies to an air actuated weld head 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 6 4 990 290 CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS Basic Function This function makes a simple spot weld It provides the solution for the majority of the resistance welding applications It is designed for both air actuated weld heads and manually actuated weld heads The example shown below illustrates the dual pulse feature that is energies have been specified for both weld pulses The name of the weld function appears in the second line of the display In this example Rel
54. eys are used to move up and down on the screen to select fields In the PROGRAM and MENU states lt and are used to move to the right and left on the Screen to select fields Causes the Power Supply to enter the PROGRAM state so that you can make changes to Schedules 0 through 15 Press PROGRAM from any screen to return to the PROGRAM screen Causes the Power Supply 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 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 to permanent memory The Power Supply will then exit the PROGRAM state and return to the RUN state This key has no function in the RUN state 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 CHAPTER 3 OPERATING CONTROLS AND SCREENS KEY DESCRIPTION MENU In either the RUN or PROGRAM states MENU will provide you with a menu which allows you to select or change options which are common to all schedules HELP Press this key whenever you need HELP or additional information from the built in manual Press this key a second time to return to the original state CHNG Changes the format of the Screen in the RUN state to display e A graphic representation of the energy level of the capacitor bank or
55. 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 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 7 11 APPENDIX A TECHNICAL SPECIFICATIONS Type Power Supply Stored energy power supply which can operate in a Single or Dual Pulse Mode and is capable of operating with Air or Manually Actuated Weld Heads Compatible with 1 Level or 2 Level Footswitches It can sense Single Pole Double Pole or Optical Firing Pressure Switches The Model 875DP is rated 5 25 to 875 watt seconds joules The Model 500DP and 500HV are rated 3 0 to 500 watt seconds Power Requirements LINE VOLTAGE is single phase 100 115 208 or 230 volts 50 60 Hz The 875DP 500DP and 500HV use approximately 3300 watts initially during charging and 50 watts stand by Capacitor Bank The 875DP consists of 28 capacitors which total 10 500 uF 5 at 20 C The Capacitor Bank for the 500DP and 500HV consists of 16 capacitors which total 6000 uF 45 The capacitors are grouped in banks of four capacitors At full rating the Capacitor Banks are operated at 408 volts The following features are related to the capacitor bank Output Pulse Characteristics Pulse width can be specified for each of the 16 weld schedules Internal switching relays are used to implement this feature Pulse char
56. information on Line 6 and Line 7 SCHEDULE PULSE 1 PULSE 2 SCHEDULE PULSE 1 PULSE 2 000 75 0 0 0 000 75 0 0 0 BASIC WELD POLARITY WIDTH SHORT BASIC WELD POLARITY WIDTH SHORT MANUAL HEAD WELD 000029 AIR HEAD 2 L WELD 0000823 RELAY 1 ON OFF Line 6 RELAY 2 READY STATE bine eee i Jaw Select Schedule il RUN a Select Schedule ll NO WELD a RUN State Showing Pulse 1 Energy Level b NO WELD State showing Relay Manual Head using Basic Weld Function Status 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 6 1 CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS SCHEDULE WELD 1 WELD 2 SCHEDULE PULSE 1 PULSE 2 001 75 0 0 0 001 75 0 0 0 ROLLSPOT WELD POLARITY WIDTH SHORT BASIC WELD POLARITY WIDTH SHORT AIR HEAD 2 L law Select Schedule WELD 0000223 i WELD dees LOWER UPPER SENTRY 001A 270 0 31007 READY lt AE c Run State showing Weld 1 Energy Level d Run State with the Weld Sentry Air Head using Rollspot Weld Function Installed and Sentry Status Displayed STANDBY State The power supply 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 PROGRAM State SCHEDULE 000 FUNCTION BASIC
57. inless Steel Beryllium Copper Brass Copper Tinned Copper Nickel C R Steel Stainless Steel Brass Tinned Brass Bronze Consil Constantan Copper Tinned Copper Dumet Nichrome Nickel NiSpan C Paliney 7 Silver C R Steel Stainless Steel Bronze 875DP 500DP 500HV DUAL PULSE CHAPTER 5 OPERATING INSTRUCTIONS Electrode RWMA Type Material 2 2 2 Chromel EER D D D D D Consil N N Constantin Roa 14 Copper Roa ARN D D ND D ND No Dumet N N Electrode RWMA Type 14 Material Tinned Copper Tron Nichrome Nickel Chromel Constantan Copel Copper Tinned Copper Dumet Nichrome C R Steel Consil Tinned Copper Dumet Constantan Copper Tinned Copper Tron Nichrome Nickel Copper Dumet Invar Karma Manganin Nichrome Nickel Paliney 7 Silver C R Steel Stainless Steel Dumet Nichrome Nickel Platinum C R Steel RESISTANCE WELDING POWER SUPPLIES Electrode RWMA Type 14 2 2 2 Ro AANNN Ro NED NNN Ro ABN NNN ZNNNNN N NN D D D D ND 5 3 CHAPTER 5 OPERATING INSTRUCTIONS Material Evanohm Gold Hastalloy X Inconel Invar Iridium Iron Karma Kovar Gold Plated Magnesium Molybdenum Nichrome Nickel 5 4 Electrode RWMA Type 14 Material Copper Gold Kovar Titanium Inconel Kulgrid Invar Iridium Platinum Iron Karma Nickel Pl
58. ions 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 Screw Flat Washer Nut 2 Places Lower Welding Cable Install flat washer under screw head not welding cable terminal Figure 2 2 Terminal Connection Examples 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 CHAPTER 2 INSTALLATION Rear Panel Components A B O D E T REMOTE FIRINGSWTCH N T DATABUS 14 AR VALVE DRIVER 2 L ol Figure 2 3 Rear Panel of the 875DP 500DP 500HV CIRCUIT BREAKER S is used to protect the incoming power line INPUT POWER CABLE 5 foot cable is terminated with the appropriate 115 or 230 volt plug The standard plug for the 115 VAC power supply a NEMA 5 15P rated for 15 amps FIRING CABLE 4 foot cable is used to connect the power supply to the Force Firing Switch 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 only used with air or electrically actuated weld heads FIRING SWITCH 5 pin receptacle is used to connect the Power Supply to Weld Heads with either a 3 wire Firing S
59. ith 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 Weld Counter A seven digit weld counter automatically increments after each complete weld sequence This counter can be reset back to 0 at any time unless the system security is 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 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES A 14 990 290 APPENDIX A TECHNICAL SPECIFICATIONS Alarms These power supplies issue three alarms Allalarms terminat
60. nction NOTE The OFF Period is only used with this function 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 6 6 990 290 CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS Rollspot Function While the force firing switch remains closed the weld cool sequence will be repeated The cool time and the rotational speed of the wheel electrodes determines the distance between spots Assuming a reasonable wheel speed the cool period could be reduced so that the spots would overlap The energy required for the first spot Weld 1 should be less than that required for all subsequent spots Weld 2 in the sequence Rollspot cannot be used in a chain Dual pulse and or Footswitch Weld Abort OFF are not permitted in Rollspot SCHEDULE 10 MODE ROLLSPOT POLARITY WIDTH SHORT ay WELD 1 BB WELD N COOL ENERGY 020 0 022 5 0 25 sec RELAY 1 OFF OFF OFF RELAY 2 OFF OFF OFF Kar Select E PROGRAM N The PROGRAM State Screen for the Rollspot Weld Function In the rollspot application shown on the above screen the welds would not overlap if the rotational speed of the wheel exceeded 0 25 inches second assuming a spot which is 1 16 inch long because the recharge time was approximately 0 050 seconds refer to Appendix A under Welding Speed and the cool time was set to 0 250 seconds 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 6 7 CHAPTER 7 MAINTENANCE Modification and Calibration
61. nded Power Supply Parameters You can develop weld schedules using Schedule 0 then copy it to any other schedule number Single Pulse Operation Select pulse width and energy as follows Pulse Width Short Energy Pulse 1 10 Energy Pulse 2 0 Dual Pulse Operation Dual pulse operation can be helpful when welding plated materials materials with heavy oxidation or small wires For these applications start as follows Pulse Width Short Energy Pulse 1 5 Energy Pulse 2 15 NOTE Pulse 1 should be Y to the energy of the Pulse 2 Making a Weld CAUTION Always observe safety precautions when welding Wear your safety glasses 1 2 Select RUN and WELD on the power supply Position the parts between the electrodes Press the footpedal or footswitch to initiate the power supply Assuming no weld occurred increase ENERGY in increments of 5 until the parts begin to weld If you are using dual pulse operation increase Pulse 2 in increments of 5 and change the energy of Pulse 1 to maintain the to 4 ratio 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 5 5 CHAPTER 5 OPERATING INSTRUCTIONS 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 a material failure not a weld failure Electrode sticki
62. ne _ Minimum at nominal line voltage Model 500DP Power Supply Minimum maximum intermittent a ow line voltage repetition rate Weld Sentry software not rinstalled Figure A 3 500DP Rep Rate 6000 pF Model 500DP Power Supply maximum continuous repetition rate Figure A 4 500DP Hit Rate 6000 pF 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 Weld Schedules APPENDIX A TECHNICAL SPECIFICATIONS You can save write 16 different weld schedules in EEPROM Electrically Erasable Programmable Read Only Memory In this manual EEPROM is referred to as permanent memory Weld schedules are numbered 0 through 15 Weld Schedule Definition A weld schedule is defined as the following information a Schedule number 0 15 b Weld Function c Pulse Width d Next Schedule e Step Count f Energy of Pulse 1 and Pulse 2
63. ned next to the instruction NOTE It is not necessary to turn the trimpots if you are only performing a calibration check NOTE 500 875DP 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 power ON Use a DVM to check the voltage at each of the points listed in table 7 1 Use TP0 as reference ground 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 7 8 990 290 CHAPTER 7 MAINTENANCE Table 7 1 Power Supply Voltage Range Specifications Power Supply Test Point Acceptable Range V i oo oro ie eee eae ee C26 4 75 to 5 25 Commutation CR35 cathode 101 5 to 106 5 Supply 5V Ref U19 Pin 6 4 75 to 5 25 NOTE With line voltage at nominal 0 1 volt 4 Switch power OFF and disconnect BP13 on the control printed circuit board and remove IC chip US Push power ON NOTE It is not necessary to turn the trimpots Steps 5 and 6 if you are only performing a calibration check 5 Turn R12 and R36 fully counter clockwise 6 Turn R108 R97 and R104 to mid range 7 Press ENTER to display the calibration screen Entering Capacitor Bank Values Press ENTER to display the next calibration screen and follow the instructions on that screen Adjustment Potentiometers Seven trimpots are located on the control printed circuit board These
64. ng and or spitting should define a weld as unsatisfactory 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 Weak Weld TooLow Too High Blow Holes Too High Too Low Too Small Too Long Expulsion Burned Pitted Too Low Poor Too Short or Cracked Requires Maintenance Electrodes Maintenance 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 5 6 990 290 CHAPTER 5 OPERATING INSTRUCTIONS 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 Sufficient electrode force is required to contain the molten material produced duri
65. ng 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 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 stored energy equipment 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 CAUTION If weld schedules are chained together do NOT change polarity All schedules in the chain must have the same polarity or the relay contacts may be damaged 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 5 7 CHAPTER 5 OPER
66. nputs The relays and switch inputs are used to e Remotely select Weld Schedules 1 through 15 e Remotely inhibit recharging the capacitor bank e Invoke an emergency stop condition to abruptly terminate the welding sequence 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES A 16 990 290 APPENDIX A TECHNICAL SPECIFICATIONS The CONTROL SIGNALS connector figure A 5 is a Viking DMRST15RA05CG Unitek Peco PN OOG OD 250 195 The mating connector which included 000000 in the shipping kit is a TRW Cinch Connector comprised of a DA 15P Unitek Peco PN 250 199 male connector and a DE 51210 1 Unitek Peco Figure A 7 CONTROL SIGNALS PN 250 200 plastic junction shell The pin Connector assignments are listed below 7 Function Remote Weld Schedule Selection Control Line 2 Remote Weld Schedule Selection Control Line 2 Remote Weld Schedule Selection Control Line 27 Remote Weld Schedule Selection Control Line 2 No Connection Relay 2 Input No Connection Relay 1 Input Process and Charge Inhibit 10 Emergency Stop 11 Signal and Chassis Ground 12 No Connection 13 RELAY 2 Return 14 No Connection 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
67. ntrated 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 the footpedal or footswitch to bring the electrodes into light contact with the polishing disk Move the polishing disk in a rotary motion 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 5 9 CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS Power Supply States The power supply has seven states RUN NO WELD PROGRAM MENU HELP STANDBY and FIRE The MENU RUN and PROG keys cause the power supply to change to the state defined by that key RUN State In this state the power supply 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 00 through 15 CHNG will change lines 6 and 7 of the RUN state screen as shown below a through d to display either X a and c graphic below showing the energy of Pulse 1 for a manual or air head or X b the status of the output relays or X d the status of the Weld Sentry If NO WELD has been selected the legend RUN in the right lower corner will be replaced by No WELD L as shown in b Press CHNG to display different
68. nual 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 FOREWORD Thank you for purchasing a Unitek Peco 875DP 500DP 500HV Dual Pulse Resistance Welding Power Supply Upon receipt of your equipment please thoroughly inspect it for shipping damage prior to its installation Should there be any damage please immediately contact the shipping company to file a claim and notify Unitek Miyachi Corporation at 1820 South Myrtle Avenue P O Box 5033 Monrovia CA 91017 7133 Telephone 626 303 5676 FAX 626 358 8048 e mail info unitekmiyachi com The purpose of this manual is to supply operating and maintenance personnel with the information needed to properly and safely operate and maintain the 875DP SOODP SOOHV Dual Pulse Resistance Welding Power Supply 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 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 SAFETY NOTES This instruction manual describes how to operate maintain and service the 875DP 500DP 500HV Dual Pulse Resistance Welding Power Supply and provides instructions relating to its SAFE use Procedures described in this manual MUST be performed
69. o Footswitch has been connected 1 Level Footswitch When the operator fully depresses the 1 level footswitch the power supply 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 power supply 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 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 2 7 CHAPTER 2 INSTALLATION 2 Level Footswitch When a 2 level footswitch is pressed to the first level the weld head will close and apply force to the workpiece 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 Remote Schedule Selec
70. oekoutu ER RE EE ED EE EE GE EE ee Line Voltage Regulation vcd GN N Gegee RD ee Reese ed gede de ii Wi Kei OR OE Le EE N ER ENE ld Rl iat pe Rina e led Pine Estlure Purrido wig se ee NG Sd Over Voltdse o kOUut ER Re MEE i GE GE ee es Charse Lockout Creatas Polarity Selec AE OE AR RE OR NE OE OE OE us Welding Speed ss au anaq mapa td asec ee DE GEE RR SA da Weld Se he Gules ss uqa mu m puma De Aa un aaa a te ia eet Weld Schedule Definition iese endian an ithe wae Gee Options Suite schedule Number at POWER 2 A A fes dd se DURS Gabi a a calas SUEZ LINE AA o II IN h SSS as GOO Tame ali te Hold IME e and a Footswitceh Peri A aaa egal FOOTS WITCH ComectOr aa iii Footswitch Weld Abort Feature Footswitch Weld Abort On ss Footswitch Weld Abort Off Hiring o a agate ted AE de a uc aca a E at ee aes Firing Citi A assia aaa Switch Debounce MT AE EE MERE EE EG N GE O ay as Mechanical Firing Switch Cable den aan nn tee ea de Optical Firing Switch Connector ns Initiation SWITCH sr nn amiens titi Manual Head Operations nun as A Air Head Operation fesses nt ren GS te fn tes Chain Sch d l s He atire a su qasan ui at ataca Step Brel ie di desd a bed disse Next Schedule ita nd o nd dsd Audible B0ZZer aaa da End of Cycle Buzzer ONJOFF einen se Peens ee Ke Gee GR De Ge Gee ees e ese ee Key iek u s Sp e tn eg ee Ge ES on unata ER eed Weld COUNT AS AA ERA AA Be RSS A O O ON Alt Valve AN 875DP 500DP 500HV DUAL PULSE R
71. olenoid Air Valve System with a Single Regulator 43 Measuring Preset Firing Force of the Weld Head with a Force Gauge 4 4 Results of Excessive Air Pressure 5 1 Effects of Excessive or Insufficient Heat Time and Pressure 5 2 Typical Weld Strength Profile cocidas 7 1 Line Voltage and Capacitor Bank Jumpering esse esse esse se ee ee ee Ge Se ee 7 2 100 VAC Line Voltage Configuration 7 3 115 VAC Line Voltage Configura nit tos 7 4 208 VAC Line Voltage Configuration 7 5 230 VAC Lane Voltage Configuration iia A 1 875DP Rep Rate with 10500 uF Capacitor Bank A 2 875DP Hit Rate with 10500 uF Capacitor Bank A 3 500DP Rep Rate with 6000 uF Capacitor Bank A 4 500DP Hit Rate with 6000 uF Capacitor Bank A 5 Pin Numbers as Viewed from the Rear Panel A 6 Jumper Selection for Air Valve Driver Control A 7 CONTROL SIGNALS Connector sisi A 8 Remote Schedule Selection with a Remote Binary Switch A 9 875DP Physical Dimensions A 10 500DP Physical Dimensions 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 2 4 Typical Solenoid Air Valve Assembly with a Single Regulator 2 5 875DP Equipment Interconnection Diagram esse esse esse ee see ee Se ee ee ed 4 5 Weld Head Configuration Jumper Selection 7 1 A 1 A 2 A 3 A 4 TABLES Title
72. osed The power supply 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 You can simulate a 1 level footswitch by connecting Pins 3 and 4 on the Footswitch connector FOOTSWITCH Connector The FOOTSWITCH connector is a 4 pin Amphenol 91 PC4F Unitek Peco PN 550 006 that mates with an Amphenol 91 MC4M Unitek Peco PN 520 009 Connect Pin 3 to Pin 4 on a user supplied 1 level footswitch This connector is wired as follows Pin Description Chassis Ground Footswitch Level 1 or Single Level Footswitch Footswitch Level 2 Common D 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 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 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES A 10 990 290 APPENDIX A TECHNICAL SPECIFICATIONS Footswitch Weld Abort Off With FOOTSWITCH WELD ABORT OF
73. ot occur the welding sequence will continue to completion 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 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 4 3 CHAPTER 4 GETTING STARTED 7 10 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 up stop This adjustment is made by pressing then quickly releasing the foot switch 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 between the electrodes Close the down speed flow control located on the bottom of the cylinder 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 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 Adjust the pressure regulator which controls the air pressure on the top of the air cylinder so that it is Just sufficien
74. ounded Therefore any change in the schedule selection code should be made during this 120 millisecond period and or while the charge inhibit line is grounded Alarm stop conditions can also be cleared remotely by toggling the charge inhibit line Relay Outputs Two output relays can be used to provide status timing signals to external devices They can also provide an on closed state during a Run state or if there is an alarm Relay 1 can also be used to control a second 24 VAC air actuated weld head Relay 2 can provide a 5 to 50 VDC signal 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES A 20 990 290 APPENDIX A TECHNICAL SPECIFICATIONS When used to provide status timing signals the relays can be independently programmed as follows e In Basic Mode each relay can be programmed on closed or off open during either of the two weld periods e In Roll Spot Mode each relay can be programmed on closed or off open during either of the two weld periods or during the cool period between each spot weld cycle e In Repeat Mode each relay can be programmed on closed or off open during either of the two weld periods or during the off period between each Repeat cycle e When the power supply is waiting for the weld sequence to start In all of the above cases if the relay is programmed to be on closed it will close at the beginning of the scheduled period and open at the end of that period If s
75. pply is operated Dual Pulse Welding an exclusive and unique feature of Unitek Peco power supplies improves weld quality and eliminates weld splash Dual Pulse means each weld is performed with two pulses with independent energy levels The first pulse is used to displace the plating or contamination and reforms the surface so that it is in intimate contact with the electrode The second pulse welds the base metals The Automatic Step feature can be used to step to a new schedule after a preset number of welds in order to compensate for electrode wear The 500DP a modification of the 875DP uses a different output transformer which provides 500 watt seconds The 500HV provides 500 watt seconds and uses an output transformer whose output voltage is double that of the 500DP The SOOHV is frequently used in honeycomb welding and or in those applications which use handpieces whose cable lengths exceed 5 feet Except for those specifications which are directly related to energy rating and or output pulse characteristics the 500DP and 500HV are identical to the 875DP The optional built in Unitek Peco Weld Sentry adds a weld monitoring capability to the 875DP which improves Process Control by detecting subtle changes in voltage current and power The Remote Schedule Feature allows the 875DP to reliably select weld schedules in automated applications The 875DP can be used with manual user actuated or air actuated weld heads The 875DP is a multi
76. s Ee ARE EO N AO OE EE ER EE HA IE Weld Strength Protes sis in i Destructive Testing is SEE DE Re ES AG GR Ve GE aaa nds Electrode Maimt naniee ads eo os airis CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS POWER Supply SIES ee EE ia RUN State Sas ua nA De BRAN LATER IE DE BES HR At ll PACS Ae STANDBY Sta u EE NE EO DE EE ER N PROGRAM State siii da aiii MENUS tatoo han oR ES HEBP States asna a ee le i ee NOWP DS OE EE ED EE RA DIRES Ale ete oe E EE DE Bed tats ene EER ED ED de Weld Function Field ci Se ee ee ee phi uQ ens E EA eve staan ge Basic Punt OR EE ER EE OE dsd Repeat FUNCIONA isa eh ca ee EE ee nn nr nn qa Re Ee Rollspet Eunetion ss sn eN RR N ge ee Re N De aan ee CHAPTER 7 MAINTENANCE Modification and Calibration ee EE ER ee ee EE ee es COVER Removal Se Plauen SG EED a Ya calcd Line Voltage Changes SG EE Ge eg AA N Gee DE GR ee GR GE GE aaa eg See Calibration y Es iia Susa Sas Troubles ONE a n A ale EE a A inte GR ea EG a n eg Rep it Servicen en AO EE EE a ON EK EG EK ls ES NE ER EO tees an N Ge Ca iS ua te Factory Service Repair usines nn Rs in Ant Ee ee ee DS DO Eg seke 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES vi 990 290 APPENDIX A TECHNICAL SPECIFICATIONS Type Power Suppl st Ee I tn E OR EE NG GE use Power Re qUe RR Ge ee Ge Ee Capacitor BaBK ua uu OE N ER ad Output Pulse COardet msties u L l iea ee ee Weld FireE
77. ssive Weak Weld Weak Weld Insufficient Nugget Insufficient Nugget PULSE Metal Expulsion Metal Expulsion Warping ENERGY Warping WIDTH Discoloration Discoloration Electrode Damage Insufficient Electrode Damage Insufficient PRESSURE PROBLEM CAUSE Parts Overheating Excessive Weak Weld Insufficient Nugget Metal Expulsion Warping Discoloration Electrode Damage FIRING FORCE Insufficient Figure 5 1 Effects of Excessive or Insufficient Heat Time and Pressure 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 work piece 3 Adjust the air pressure for air operated weld heads 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 Material Alumel Aluminum Beryllium Copper Brass Bronze 990 290 Table 5 1 Recommended Electrode Materials Electrode RWMA Type 2 Material Alumel Chromel Dumet Aluminum Aluminum Alloys Cadmium Plating Tinned Brass Tinned Copper Gold Plated Dumet Gold Plated Kovar Kovar Magnesium C R Steel Sta
78. t 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 power supply 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 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 4 4 990 290 CHAPTER 4 GETTING STARTED 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 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 Welding Force Welding Force Firing Switch Closes Firing Switch Closes Dial Dial j Indicator Indicator Force Setting Force Setting Figure 4 4 Results of Excessive Air Pressure 11 If a higher welding force is necessary reset the force indicator on the weld head to a larger number then repeat Steps 9 and 10 12 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
79. the top of the air cylinder then repeat Steps 9 and 10 13 If appropriate configure the Weld Sentry Press MENU select WELD SENTRY followed by SYSTEM SETUP 14 If appropriate configure the Weld Sentry print options relay outputs and communications options Set the Weld Sentry clock for the correct time and date 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 4 5 CHAPTER 4 GETTING STARTED 15 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 16 17 4 6 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 print utility menu If you are using a second air actuated weld head a Connect the second air head to Air Valve Driver 2 Jumper b There are two jumper headers E10 and E11 located on the lower right hand Jum per area of the control printed circuit board Re jumper the headers to the dual air configuration as shown in Jum per figure 4 5 c Press MENU and select OPTIONS E11 per en d Change the weld head type to DUAL AIR Single Air Head Dual Air Head e Press PROGRAM and move the Figure 4 5 Weld Head Configuration Jumper cursor to the RELAY 1 field Selection f Press CHNG until AIR HEAD 2 is displayed g Press SAVE to store the
80. tion A 15 pin subminiature D type CONTROL SIGNALS connector located on the rear panel is provided for seven single pole inputs which are used to e Remotely select Weld Schedules 1 through 15 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 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 They can also provide an on closed state during a Run state or if there is an alarm Relay 1 can also be used to control a second 24 VAC air actuated weld head Refer to Air Actuated Weld Head Connections for the appropriate hook up connections and figure 4 5 for appropriate jumper connections Relay 2 can provide a 5 to 50 VDC signal When used to provide status timing signals the relays can be independently programmed as follows e In Basic Mode each relay can be programmed on closed or off open during either of the two weld periods e In Roll Spot Mode each relay can be programmed on closed or off open during either of the two weld periods or during the cool period between each spot weld cycle e In Repeat Mode each relay can be programmed on closed or off open during either of the two weld periods or d
81. try proceed as follows 1 Set the front panel POWER switch to OFF 2 Remove the cover 3 Select the schematic of the primary circuit for the required voltage figures 7 2 through 7 5 Check the connections and reconfigure the following components e Jumpers E3 and F4 located in the top center area of the control printed circuit board e Bead Pins BP1 BP12 and Terminals El and E2 located along the top edge of the control printed circuit board 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 7 2 990 290 CHAPTER 7 MAINTENANCE ALARM DISPLAY VOLUME CONTRAST JUMPER A JUMPER B CHECK CORRECT JUMPER POSITION FOR LINE VOLTAGE CHANGES Figure 7 1 Line Voltage and Capacitor Bank Jumpering e The taps on Charging Transformer T1 located on the floor of the power supply housing refer to figure 7 1 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 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 7 3 CHAPTER 7 MAINTENANCE Figure 7 2 100 VAC Line Voltage Configuration 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 7 4 990 290 CHAPTER 7 MAINTENANCE 46 300 W 4 300 W 65 ointa F 102 115V El 1 E 115 230V Fig
82. ure 7 3 115 VAC Line Voltage Configuration 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 7 5 CHAPTER 7 MAINTENANCE RI R2 46 300 W 46 300 W Figure 7 4 208 VAC Line Voltage Configuration 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 7 6 990 290 CHAPTER 7 MAINTENANCE F3 PA 46 300 W 46 300 W E E Es E Figure 7 5 230 VAC Line Voltage Configuration 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 7 7 CHAPTER 7 MAINTENANCE Calibration The power supply should not require any regular adjustments Use the following procedure as a guideline to check the calibration Take care not to make unnecessary adjustments however if any components or software are replaced check the calibration Do not hesitate to call the Unitek Miyachi Repair Department with any questions Calibration should be performed only by a qualified technician Test equipment should be calibrated for accuracy Test Equipment Required a Oscilloscope b Digital Voltmeter Keithley 2002 or equivalent Pre Calibration Procedures Calibration is performed using the instructions displayed on the screen and the HELP messages The procedure consists of verifying power supply voltages and capacitor bank values and adjusting five trimpots on the control printed circuit board As each trimpot adjustment is performed it must be displayed on the screen with the cursor positio
83. uring the off period between each Repeat cycle In all of the above cases if the relay is programmed to be on closed it will close at the beginning of the scheduled period and open at the end of that period If scheduled to be closed during any successive periods it will not open at the end of the first period but will remain closed during both or all periods for which it is scheduled to be closed 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 2 8 990 290 CHAPTER 2 INSTALLATION Interconnection Diagram SUOI OOUUOD peeu plam payenjoe uie uaseidai seul payseg p sn JOU SI uoll93uuo2 YAMS Buy ay pesn s yoyms Huny peondo ue J 10 9 uuo2 yms Bull y uo z pue sud Lous uoneiado pailj 9os0J uOU 104 z Jeu1eBo1 s qe9 pam al N 101009 spot qeuuuueiBoid pal ddns sesp j l s dag lquui Jamod pelddns iasn Aey _ z feley 190 ASL l t OQ A0S S eeu enpeuos pem fouabiaw3 OH9 O O qi eo go Qa a LL Ok bb 6 8 SL 9 EL S ON indu oneunaud Cy OV AGEL S foo LE plougjos uy y ajou sas lt lt bl 1 S po10 9l3 di 1 ajou s seldeo PIAM Lo Z gt z ejou seg z ejou sas ELI NOO ZM LAT GND o 12 zZ sZ re s sa GND YW GND E NI youms oo su s ony OV ASLL JOAUp MET SALA MY OV Ave yndjno 18m04 aiqeo youms Bully
84. vailable to the operator from the main menu a Calibration d Description of Relay Outputs b Installation e Description of Control Signals c Description of Keyboard f Description of Valve Outputs Default System Parameters are a Head Type Auto g Power Up Schedule 0 b Footswitch Auto h End Cycle Buzzer Off c Footswitch weld abort On i Chain schedule Feature d Force Firing Switch 2 wire j Switch Debounce 0 01 sec e Display Units Energy k Squeeze Time 0 00 sec f System Security Unprotected 1 Hold Time 0 00 sec 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES A 8 990 290 APPENDIX A TECHNICAL SPECIFICATIONS Weld Functions Three weld functions can be selected Basic repeat and rollspot The duration of the squeeze system option cool rollspot and off time repeat periods can be set between 0 and 9 99 seconds Head Type The power supplies can be used with a manual user actuated or air actuated weld head Air actuation means that the power supply will provide a 24 or 115 VAC output which can be used to control an air valve solenoid on an air actuated weld head The power supplies can automatically detect the presence of a Unitek Peco actuated weld head You can indicate the presence of a user supplied non Unitek Peco air head by jumpering Pin 4 to Pin 2 on the VALVE DRIVER connector If Pin 4 is not connected to Pin 2 the power supply assumes that a manual head is being used The power
85. voltage unit designed for operation at 100 115 208 or 230 VAC 50 60 Hz Features e Multi function microprocessor control with 16 discrete weld schedules provides repeatable process control and is compatible with air or manually actuated weld heads Facilitates multiple applications at a single work station and protects weld schedules from changes by unauthorized personnel e Dual pulse welding eliminates weld splash Improves weld quality especially when welding plated materials e Four weld functions are available gt Basic gt Dual Pulse gt Rollspot seam weld gt Sequence Repeat 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 1 2 990 290 CHAPTER 1 SYSTEM DESCRIPTION User friendly programming serves as a built in manual which quickly guides users through the most complex programs Built in software utilities make it easy to copy schedules and calibrate the power supply An optional built in Weld Sentry integrates into user SPC system which simplifies data collection and statistical analysis Remote schedule selection simplifies use in automated systems Remote external inputs connector accepts control signals for Emergency Stop Remote Weld Inhibit and Remote Weld Schedule Selection The chain schedule feature allows up to 15 schedules to be chained together in a user specified sequence The automatic step feature increases electrode life and reduces downtime for electrode dressing by automatic
86. which you can use to provide status signals to external devices You can also use Relay to control a second air actuated weld head or to signal an alarm condition When used for status signals these relays can be independently programmed to close 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 6 5 CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS X When the power supply is initiated or X After Pulse 1 or X After Pulse 2 or X During the cool or off periods or X When the power supply is in the RUN state waiting for the welding sequence to start The status of each relay shown on Lines 6 and 7 is set in the PROGRAM state and is confirmed in real time in the RUN state Repeat Function This function provides an automatic repeat of the weld sequence for simple automated air actuated applications It is ideal for volume production which requires a single schedule NOTE Repeat can only be used with an air actuated weld head You should specify the off time so that it is sufficient to allow the weld head to open the electrodes and to allow you to reposition the work piece before the entire welding sequence repeats Footswitch Weld Abort OFF is not permitted with the repeat function SCHEDULE 10 MODE REPEAT POLARITY WIDTH SHORT MN PULSE EEN PULSE Did N ENERGY 010 0 030 0 0 25 sec RELAY 1 ON ON OFF RELAY 2 ALARM gt Select N Pos N The PROGRAM State Screen for the Repeat Fu
87. witch or an Optical Switch 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 2 3 CHAPTER 2 INSTALLATION F AIR VALVE DRIVER 1 Provides either 24 or 115 volts AC to Unitek Peco air actuated weld heads AIR VALVE DRIVER 2 is an optional output which is used to control a second air actuated weld head G REMOTE DATA BUS 25 pin sub miniature D connector used to interface with other Unitek Peco devices H CONTROL SIGNALS 15 pin sub miniature D connector used for Remote Schedule Selection See Chapter 10 D OUTPUT POWER CABLE 5 foot cable is used to connect the power supply to the external transformer Firing Switch Connections Connect the weld head or hand piece to the appropriate firing cable or switch located on the rear panel of the power supply Mechanical Firing Switch Unitek Peco weld heads and hand pieces are force fired and have two pin firing switch connectors which can be connected directly to the mating connector of the MECHANICAL FIRING SWITCH located on the rear panel of the power supply Users of manually actuated weld heads which do not have force firing switches must connect the two pins in the mechanical firing switch to an external switch in order to initiate the power supply 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
88. y will automatically recognize that an air head has been connected 2 6 875DP 500DP 500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990 290 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 power supply 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 the 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 the power supply 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 the appropriate 24 volt pins of the receptacle on the rear of the power supply Refer to Appendix A under Control Signals for detailed information Footswitch Connect either a 1 Level or 2 Level Footswitch to the FOOTSWITCH receptacle located on the rear panel The power supply will automatically recognize which type Unitek Pec

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