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UB25 Cover+Front Matter [Rev C] -- 1-02

1. oed bd uds usen added o 3 10 olet de mule E E 3 10 Pre Wed C eok sss ets d DI An MM 3 11 P Dreier 3 11 3 11 Chapter 4 Operating Instructions 4 1 Section Introduction petat tapes 4 1 Section Setup S ice ce crac ete tco eiit ttai A 4 2 Checks e creta 4 2 Connect os ss possa Nos ru abate o Road um MD stated 4 2 ln 4 2 MOTTA SSE Ne tA tO 4 2 Initial Set p Instructions tuvo ee one 4 2 Section Programming Weld Schedules tendo eet tius tta ohne iara 4 3 4 3 Select A Weld Seliedule t 4 3 Eater New 4 3 Simp les Pulse T ay 4 4 Upslope Downslope Weld Schedule eda peek rea HI aee PV re eek sa po Lee eb een 4 5 Weld Schedule uestes sug 4 6 Section IV Programming The Weld 4 7 Section V Programming
2. Messa bui ___ 3 4 s e eodeni dent nd E A er 3 4 D l Pulse Weld iere oec ete soin Dei Feist 3 5 Applications nci d eo ad to p aedi ao eru 3 5 DOSCHDLUOLD celina Sea ule 3 5 Section HT Programmable Feedback a odds enr 3 7 0115 tta e add Cu dE 3 7 Current Mode d aee etin rd ir Ga ERR RN Leute d tn ade a de ed rax 3 7 Applications 3 7 CST OI PL DA MMC DUC IE 3 7 Voltage Rp can 3 7 APPHCAUONG 3 7 DGS CEI ENOL 3 7 Power Mode Serta ees dun dua sca M eR M LE adu em 3 7 vero dod aea mee mv auc ene M 3 7 Description a spe Sete 3 7 spectrom IV Weld MOBIOE uetus en e oret tog es hd esum rtl e p 3 8 117 110 6 101615 ona i ind M ME 3 8 Active Part 3 8 Spp CATIONS Es Hat ctu D uM MT pA EA sents oct ute 3 8 DESC UO s oii qe be d addit bob ui beu dpa det tube 3 8 CM RC DM 3 9 DOS iesu de adt Se 3 10 Energy Eni EAS 3 10
3. Que sod 5 23 Reset All Schedules sh ba 5 23 Section Communication And Data 5 24 conet oe UE 5 24 CIO 5 24 Lia rete ben etta he ted E ERE NE ca ae 5 25 Baud Rate dd uet anton mesa dst ive eisdem 5 25 Chapter 6 User 6 1 Section T Precautions ree ci dada ee ad ea teet ia er oa 6 1 Section II Operator Maintenance 6 1 Section MI a 6 1 General Kinds of Problems iue bibe o EP e UI ect o 6 1 6 2 6 2 T chnical Assistance 6 5 6 6 Parts 6 6 Mir dar MERCI DD NET 7 1 Section UOTE NE 7 1 OVETVIEW 7 1 Calibration Equipment Required 7 1 EP OTL SE E EN 7 2 Section Calibration Equipment Setup tenen
4. Pana NOTE The SETUP 3 menu 15 only SETUP 3 PID TEST WELD available through the SETUP 2 menu 1 DO TEST WELD ALWAYS 2 IGNORE FIRST LAST 0 2 ms 4 Toscroll back through SETUP 2 and SETUP 1 menus press the UP key Salact Main manu Pana 2 5 When you have finished programming the desired functions press the MENU key on the front panel to return to MAIN MENU UB25 LINEAR DC RESISTANCE WELDING CONTROL 5 4 990 665 CHAPTER 5 SETUP SOFTWARE Section Ill Operator Preferences Display Contrast 1 Gotothe SETUP 2 menu DISPLAY CONTRAST DISPLAY CONTRAST 80 2 Pressthe 1 key to access the DISPLAY CONTRAST adjustment screen 0 10 20 30 40 50 60 70 80 90 3 Usethe A V keys to adjust the screen contrast for comfortable viewing in the Adjust MENU Previous menu shop environment and different ambient lighting conditions 4 Press MENU to return to the previous screen or keep pressing the MENU key to return to the MAIN MENU Buzzer Loudness 1 Goto the SETUP 2 menu BUZZER LOUDNESS Press the 2 key to access the BUZZER BUZZER LOUDNESS 3090 LOUDNESS adjustment screen Ed 1 L 3 Usethe up A and W keys to adjust 0 10 20 30 0 50 60 79 80 90 buzzer tone so that it can be heard against Adjust MENU Previous menu shop background noise 4 Press MENU to return to the previous screen or keep pressing the MENU key to return to the MAIN MENU
5. x 5 7 Energy Capacity Limit Setting 5 7 Weld Fire Lockout Charge Setting 5 8 Footswitch Weld ADOI 5 8 Switch Debounc Time 5 9 Finna 5 9 MODEL 0825 LINEAR DC RESISTANCE WELDING CONTROL viii 990 665 Table of Contents Continued Page Input Switeli Selecb ausi i dee cq 5 10 Mechanical Selection Hetero eee pes 5 10 OP TO Selects dq after ficit arte eb d fees es 5 11 eee 5 11 Control Signals seleot b etr veo p i dox eet ated ui dex Dn ds 5 12 Weld Counter Functions t edes e ite adve oe b e oh 5 12 5 13 5 14 5 14 Section Ve PID Test Weld breed utet eas eaae es 5 17 C ELEM EDAM II 5 17 DG Rest Weld Options m eset 5 17 First MET 5 18 Section VE Relay Settings 5 19 5 19 Programming dei ria 5 19 Section VIT Special Puncti ris uoo 5 21 H 5 21 Reset Defaults m reete e ta Nuus 5 21 Reser System Parameters
6. 2 1 Section I Planning Bor Installation 2 1 Space Requiremietits Db ec bl od blu bl 2 1 Inline e 2 1 Section e ste Ld ee eoo tk bu E 2 2 Section HI Electrical And Data Connections 2 3 Section 2 4 Manual Weld Head Connections de 2 4 Air Actuated Weld Head Connections s a Gti best REN des es 2 6 Relay Data And Communication 2 7 Chapter 3 Using UB25 Welding And Monitoring Functions 2 2 3 Section 1 stus Set 3 1 Section M Weld 3 2 DEMAIN E 3 2 Weld Sequence TINNE sisene ei a te esto 3 2 Applications ene Di e rU ted 3 3 Weld Head Applicability usce bles uo prc data defi Ls usd 3 3 Smgle P lse Weld Profiles e tot eie te diat e aU edad be 3 4 ones TE RET 3 4 Description RR TE wees 3 4 MODEL 0825 LINEAR DC RESISTANCE WELDING CONTROL 990 665 Table of Contents Continued Page Upslope Downslope Weld Profile Applications 3 4 JNppHoatiOfls
7. 5 7 Switch Debounce Time 0 4 4 1 2 4 11 5 9 System Security 5 13 Waveform Check and Weld Fire Lockout 5 6 System Settings 5 6 Waveform Check ON OFF 5 6 Weld Counter 5 12 T Weld Fire Lockout Charge Setting 5 8 Weld Head Applicability 3 3 Technical Assistance 6 5 Technical Specifications 1 Environmental Characteristics 3 FIRMWARE accen AN NONSE VUA 3 Interface Signals sss 3 Mechanical Characteristics 3 Troubleshooting 5 6 1 Typical Weld Strength Profile C 6 UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 Index 7 INDEX bor odore Mc 3 8 Active Part Conditioner APC 3 8 Applications Ute PIRE 3 8 8 5 eerie bU UR Ras Nds 3 8 How It Works eese 3 8 Energy Limits at eA HA 3 10 Applications 3 10 Description 3 10 Lecta diee Ma ED asi E 3 10 Jntroduction 3 8 Pres Weld Check 3 11 3 11 3 11 Weld Schedules 3 2 Definition 3 2 Dual Pulse Weld Profile 3 5 APphcatons 3 5 Descrip
8. 6 USER MAINTENANCE Section Precautions General Operator Safety ALWAYS wear safety goggles and other appropriate safety equipment when you are performing a welding operation Section Il Operator Maintenance The Control does not require any Operator Maintenance other than calibration To ensure consistently accurate welds Unitek Peco recommends that you calibrate the Control at least once a year For calibration instructions please refer to Chapter 7 Calibration Section Ill Troubleshooting The Control is designed with reliability as a top user priority From time to time however you may run into a problem and need some help to get back to normal operation Reading this Chapter will speed up the process General Kinds of Problems It has been our experience that most resistance welding power supply problems are caused by lack of material control process control and electrode tip surface maintenance The problems that you might encounter fall into two groups Soft and Hard Soft The problem is transient and you can correct it by resetting the system or parameter limits For example you should ensure that e Correct force is set at the weld head e Correct weld energy and time is set at the Control e The equipment is set up properly e All electrical connections are tight Electrode alignment allows flush contact with the weld pieces e Electrodes are properly dressed UB25 LINEAR DC RESISTANCE WELDING C
9. The Firing Switch input has been activated before the Foot Switch has been activated The wrong security code was entered to de activate the System Schedule or Calibration Lock protection features A monitor action is programmed to inhibit the second pulse and the first pulse energy limit was reached The Inhibit input control signal is activated preventing the Control from continuing to operate NOTE Activating the Inhibit input terminates only future operations It does NOT terminate any present Control operation CORRECTIVE ACTION IF REQUIRED TYPE OF MESSAGE Determine the cause of the low current Changes to the welding setup or process can affect the energy delivered Refer to the Troubleshooting Chart in Chapter 6 Limits should be set by qualified by personnel and are designed to identify process variations Remove any unsafe operating conditions at the welding electrodes Reset the Operator Emergency Stop switch Press RUN to reset verify that correct weld schedule is selected Press RUN to clear alarm Check air pressure setting on weld head Check Firing Switch connection Check the weld head for an improperly adjusted firing switch Automation Only Check the timing on the PLC control lines to the Firing Switch and Foot Switch inputs Press MENU select System Security then enter the correct access code to turn off System Schedule or Calibration Lock protection features G
10. APPENDIX 5 Introduction The term repetition rate refers to how often weld pulses can be repeated based on the Control s recharging time The UB25 stores energy internally in a capacitor bank This energy is used to provide the desired weld pulses There are limits to the duration of weld pulses the unit can provide and time must be provided between welds for the capacitor bank to recharge The graph on the next page details the maximum acceptable pulse durations at various current levels for repetition rates of 1 2 and 3 welds per second The graph is divided into sections by the graphed lines The portion of the graph below the lines is labeled Acceptable Durations the area at the top right is labeled Durations Too Long Weld pulses that fall below the lines in the Acceptable Durations section are within the capability of the Control for the stated repetition rates The time to be used in determining the duration is the sum of the weld period and 2 the periods of upslope and downslope if any For dual pulse welding the sum of both pulses must be compared to the chart This graph requires the total resistance of the secondary circuit to be between 0 5 milliohms and 10 milliohms Certain combinations of weld currents durations and repetition rates in the top right portion of the graph may be possible This depends upon the secondary load and resistance For assistance contact the Unitek Peco Applications Lab
11. For welds using the current control mode the durations can be read directly off the chart For welds in the voltage control or power control modes the average current from the monitor screen and the programmed duration can be compared to this chart It is possible that longer durations may be provided by the control depending upon the details of the secondary circuit but the stability of the waveform may decrease In this circumstance a reduction of the secondary circuit resistance and or inductance will be beneficial Shorten weld cables and or tie them together Testing with the actual secondary circuit to be used will be required in this case UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 G 1 APPENDIX REPETITION RATES Maximum Weld Pulse Duration as a Function of Weld Current Duration in Milliseconds 1009 9 9 9 90 7 wai Per 5 M4 DURATIONS 80 TOO LONG 70 N 60 50 40 30 20 1 10 DURATIONS ACCEPTABLE 100 200 300 400 500 600 700 800 900 1 000 Current in Amps UB25 LINEAR DC RESISTANCE WELDING CONTROL G 2 990 665 INDEX ie ense 4 2 A Connectors see Electrical and Data Connectors Active Part Conditioner APC 3 8 Air Actuated Weld Head Connections 2 6 Alarm Messages 6 2 1 Alarm 1 7 1 Of 1 Alph
12. NOODSTOP Open het elektrische circuit om de laskop terug te trekken DSTOPP den elektriska kretsen f r att dra tillbaka svetstr den T KYTKIN POIS Avaa vet ksesihitsausp takaisin ARRET D URGENCE Ouvrez le circuit lectrique pour retirer lat te de soudure NOT AUSSCHALTER W rd den elektrischen Kreis ffnen der Schwei kopf w rd zur ck gezogen EMERGENZA DISINSERITA Aprire il circuito elettrico per ritrarre la testa della saldatura DESCONE EMERG NCIA Abra o circuito el trico para retrair a cabe a da soldadura DESCONECCION DE EMERGENCIA Abra el circuito el ctrico para retraer la cabeza de soldadura Unitek Miyachi Corporation 1820 South Myrtle Avenue Monrovia CA 91017 Tel 626 303 5676 FAX 626 358 8048 e EN61010 1 1993 DECLARATION OF CONFORMITY Application of Council Directive 72 23 EEC Standards to which EN 61010 1 1993 conformity is declared Manufacturer s Name Unitek Miyachi Manufacturer s Address 1820 S Myrtle Ave Monrovia CA 91017 Equipment Description Linear DC Welder Equipment Class 1 Model Number UB25 I the undersigned hereby declare that the equipment specified above conforms to the above Directive s and Standard s Place Wiwo m forna Signature Full Name Gu www Position RD Application of Council Directive 89 336 EEC Standards To Which Conformity Is Declared Manufacturer s Name Man
13. black art and can be achieved through a methodical and statistical approach Time spent up front in weld development will ensure a stable welding process and provide a substantial return in quality and long term consistency Welding problems can more easily be identified and solved if sufficient experimental work is carried out to identify the impact of common variables on the quality and variation of the welded assembly Unitek Peco will frequently use the Screening DOE tool to establish the impact of key variables and also to assist customers with troubleshooting Often the testing as described above will provide the information and understanding to predict common failure modes and causes A troubleshooting guide can be requested in the form of a slide rule to assist users in identification of welding problems and likely causes UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 D 13 APPENDIX LCD DISPLAY MESSAGES Introduction The Control displays three types of messages on the LCD screen to alert the operator of the status of the Control e Alarm e Limits e General Status You may see these messages when setting up and programming the Control or when performing spot welding Relay Activation Alarm and Out Of Limits messages activate the output relays as described in Appendix F Relay Timing Diagrams General Status messages do not activate the output relays Clearing Alarm Conditions to Resume Operation If an alar
14. trod Selection 2 1 aeos 4 Weld Schedule Development 4 Weld Strength Testing 5 Weld Strength 5 MODEL 0825 LINEAR DC RESISTANCE WELDING CONTROL X 990 665 Typical Weld Strength Profile Table of Contents Continued Page Appendix D Quality Resistance Welding Solutions Defining The Optimum Process D 1 or MENT EO CER D 1 Resistance Welding A Material World D 1 A solder or Braz Joint D 2 A Solid State JOM D 2 A FUSION 0 2 Consider Material Properties D 3 Group Conductive Metals Eva in Ee D 3 Group 0 4 Group Refractory Metals D 4 ussiisa E TEL TTE TTE D 4 Weld D 6 Approach to Weld Development D 7 Initial Welding Trials Ihe Look See Tests D 8 D 8 ProGess Perspective ssion onen E EEEE AE E EEEE ETR D 8 Common Problems 0 9 What are Screening D 10 Citera Rog tee MP D 10 What ar Factorial DOE c D 11 Criteria for SUCCESS D 11 RT N oe as D 11 Appen
15. A 9 N Press the schedule key The contents of the source schedule will be copied to the destination schedule overwriting the previous contents of the destination schedule NOTE monitor settings and limits are also copied Reset Defaults The Control is manufactured and shipped with the factory set defaults Any of these settings may be changed Defaults for Setup Menu 1 SYSTEM PARAMETER DEFAULT SETTING Firing Switch AUTO Input Switch Select MECH OPEN Control Signals Select MECH OPEN UB25 LINEAR DC RESISTANCE WELDING CONTROL 5 24 990 665 CHAPTER 5 SETUP SOFTWARE Defaults for Setup Menu 2 SYSTEM PARAMETER DEFAULT SETTING Defaults for Setup Menu 3 SYSTEM PARAMETER DEFAULT SETTING Defaults for Waveform Check and Weld Fire Lockout Subiliy Check Limi Defaults for Communication Menu SYSTEM PARAMETER DEFAULT SETTING Communication Role SLAVE Defaults for Chain Schedules Menu SYSTEM PARAMETER DEFAULT SETTING UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 5 25 CHAPTER 5 SETUP SOFTWARE Defaults for Relay Menu SYSTEM PARAMETER DEFAULT SETTING Relays 1 through 4 ON WHEN ALARM It is common to change system and schedule settings RESET DEFAULTS when you customize the Control for specific welding needs If you wish to reset the Control to the D Miss y 2 RESET ALL SCHEDULES original default settings go to the MAIN MENU EPROM DATE VX
16. Weld Schedule using either AW arrows the numeric keypad 3 Press the SQUEEZE button to enter the squeeze time before the weld Use the numeric 4 keypad to enter the time or use the AW arrows Enter a time between 0 and 999 milliseconds NOTE We recommend 150 milliseconds Press the PULSE 1 UPSLOPE button to enter the amount of time for the Weld Pulse 1 upslope Use the numeric keypad to enter the time or use the AW arrows Enter 0 milliseconds Press the PULSE 1 WELD key to highlight the bottom line of the LCD to enter the weld time Use the numeric keypad to enter the time or use the AW arrows Enter a time between and 99 milliseconds energy Use the numeric keypad to enter the energy level or use the AW arrows The wa Control output ranges are Current from 0 005 1 000 kiloamps Voltage from 0 100 4 900 volts Power from 0 050 4 900 kilowatts Press the PULSE 1 WELD key again to highlight the middle line of the LCD to enter weld Perform one of the following kA Press the kA key to program current as the feedback mode Press V key to program voltage as the feedback mode Press the kW key to program power as the feedback mode Press the PULSE 1 DOWNSLOPE key to enter the amount of time for the Weld Pulse 1 downslope Use the numeric keypad or the AW arrows Enter 0 milliseconds Press the COOL key to enter the amount of time cool
17. Changes to the welding setup or process can affect the energy delivered Refer to the Troubleshooting Chart in Chapter 6 Limits should be set by qualified by personnel and are designed to identify process variations Determine the cause ofthe low current Changes to the welding setup or process can affect the energy delivered Refer to the Troubleshooting Chart in Chapter 6 Limits should be set by qualified by personnel and are designed to identify process variations Determine the cause of the high current Changes to the welding setup or process can affect the energy delivered Refer to the Troubleshooting Chart in Chapter 6 Limits should be set by qualified by personnel and are designed to identify process variations TYPE OF MESSAGE OUT OF LIMITS GENERAL STATUS GENERAL STATUS OUT OF LIMITS OUT OF LIMITS OUT OF LIMITS APPENDIX E LCD DISPLAY MESSAGES MESSAGE CURRENT 2 LOWER THAN LOWER LIMIT EMERGENCY STOP OPERATOR ACTIVATED FIRING DIDN T CLOSE IN 10 SECONDS FIRING SWITCH BEFORE FOOT SWITCH ILLEGAL SECURITY CODE ENTERED INHIBIT 2 PULSE INHIBIT CONTROL SIGNALS ACTIVATED LCD Display Messages DESCRIPTION Actual weld current is less than the user set Lower Limit value for Pulse 2 The Operator Emergency Stop switch has been activated All power outputs are disabled The Firing Switch input was not activated within 10 seconds after the Foot Switch was closed
18. NUMBER Select MENU Previous menu Weld Counter Functions 1 5 14 From the MAIN MENU press the 2 key WELD COUNTERS This will bring up the WELD TOTAL WELDS 0000000 COUNTERS screen Use steps 2 OUT OF LIMITS HIGH 0000000 OUT LIMITS LOW 0000000 through 5 below to reset each counter WITHIN LIMITS 0000000 Press the 1 2 3 or 4 key to select the desired weld counter NOTE The example to the right shows WELD COUNTER the TOTAL WELDS screen TOTAL WELDS 0017429 To reset the counter press 0 on the numeric keypad To input a preset number use the numeric keypad NUMBER Change estore MENU Menu NOTE If you accidentally reset the wrong counter press the period decimal point key The original count will reappear Press the MENU key to return to the WELD COUNTERS screen When all counters have been reset press the MENU key to return to the MAIN MENU UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 CHAPTER 5 SETUP SOFTWARE System Security 1 From the MAIN MENU press 4 SYSTEM SECURITY key to get the SYSTEM SECURITY 1 SCHEDULE LOCK OFF Sore 2 SYSTEM LOCK OFF 3 CALIBRATION LOCK OFF NUMBERS Select MENU Previous menu NOTE SCHEDULE LOCK prevents unauthorized users from selecting any weld schedule other than the displayed schedule and from changing any weld energy time parameters within the weld schedule SYSTEM LOCK prevents unauthorized users from ch
19. then initiated which allows the force to stabilize before the current is fired Squeeze time also allows time for the contact resistances to reduce Squeeze Heat Hold as the materials start to come into closer contact at their interface A hold time is the initiated after current flows to allow the parts to cool under pressure before the electrodes are retracted from the parts Hold time is important as weld strength develops in this period of time This basic form of weld profile is sufficient for the majority of small part resistance welding applications Trigger Force Power supply technology selection is based on both the requirements of the application and process In general closed loop power supply technologies are the best choice for their consistent controlled output and fast response to changes in resistance during the weld for further details see the Unitek Peco slide rule Approach to Weld Development The first stage in developing a quality welding process is to fix as many of the variables as possible in the welding equipment set up The welding variables can be grouped in the following categories e Material variables e Process variables Base material Tooling level of automation Plating Repetition rate Size Part positioning Shape A Maintenance electrode cleaning Weld head amp mechanical variables e Quality requirements Force squeeze hold Pull strength Actuatio
20. 00 which can be used as a scratch pad to develop new weld schedules When time and energy values are entered using the numeric keypad the Control displays a line graph of the weld profile on the LCD screen You can see the graph change as you enter new time and energy values Weld profiles may be programmed for single pulse upslope downslope or dual pulse operation Weld schedules may also use special monitoring features of the Control such as Energy Limit Active Part Conditioner and Pre Weld Check These features are described later in this chapter Weld Sequence Timing A weld schedule is a unique heat profile programmed in constant current voltage or power that is applied over a fixed time period to resistance weld different parts The entire weld can include all of the following time periods Squeeze Time Upslope 1 Weld Pulse 1 Downslope 1 Cool Time Upslope 2 Weld Pulse 2 Downslope 2 and Hold Time The sample dual pulse profile or waveform below shows the weld current and the corresponding position of the weld head The graph labeled WELD CURRENT is what displays on the LCD when you schedule weld profile OL store SLOPE RUN 0 99 msec STATE 9 99 msec oo mace A UE NT 4 OFF rt 1 Jy ul POSITION Vj DOWN PULSE 1 PULSE 2 Sample Weld Sequence Dual Pulse UB25 LINEAR DC RESISTANCE WELDING CONTROL 3 2 990 665 CHAPTER 3 USING 0825 WELDING FUNC
21. 1 SET RELAY TO ON 3 Pressthe 1 key to toggle the relay 2 WHEN ALARM contact signal state ON closed or OFF open NUMBER Select MENU Previous menu 4 Pressthe 2 key to select the WHEN WHEN menu This menu allows you to choose 1 WELD 6 P1 LOW LIMIT when the relay is activated The WHEN 2 END OF WELD 7 P2 HIGH LIMIT 8 P2 LOW LIMIT states are described on the next page 4 OUT OF LIMITS 5 P1 HIGH LIMIT the numeric keypad to select when th 5 Use the numeric keypad to select when the Select MENU Previous menu relay will energize The display screen automatically returns to the WHEN menu UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 5 21 CHAPTER 5 SETUP SOFTWARE 5 22 WELD e END OF WELD e ALARM e OUT OF LIMITS P1 HIGH LIMIT P1 LOW LIMIT e P2 HIGH LIMIT P2LOW LIMIT When welding the relay output signal will start within 5 milliseconds after the start of SQUEEZE and will stay energized for 0 150 milliseconds after the end of the HOLD period When welding the relay output signal will start 0 150 milliseconds after the end of the HOLD period and will stay energized for 350 450 milliseconds If another weld is initiated within this time the END OF WELD relay will be reset at the start of the next weld The relay will still close in the event of an aborted weld The relay output signal will start when the Control senses certain ALARM conditions with the exception of OUT OF LI
22. 1465 ___ _ 12 lbs 10 lbs 30 40 50 60 70 80 90 100 Energy watt seconds Typical Weld Strength Profile UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 APPENDIX D Quality Resistance Welding Solutions Defining the Optimum Process Introduction A quality resistance welding solution can be defined as one that meets the application objectives and produces stable repeatable results in a production environment In order to define the optimum process the user must approach the application in a methodical way and many variables must be considered In this article we will look at the following key stages and principles to be considered when defining the optimum resistance welding process e Materials and their properties e Basic resistance welding principles e Weld profiles e Approach to development Common problems e Use of screening DOE S e Use of factorial DOE S Resistance Welding A Material World The first stage in designing a quality welding solution is to consider the properties of the materials to be joined and also the quality requirements of the desired welded joint When considering these properties it is worthwhile to review the way the resistance welding process works and the likely outcome when the parts are resistance welded There are four main types of structural materials e Metals silver steel platinum e Ceramic alumina sand e Plastics polymers PVC teflon e Se
23. 5 kA Push the current kA current key and observe the current waveform starting to rise as the oxidization breaks down If the current waveform starts to flatten this is an indication that the resistance has stabilized and the parts have come into closer contact 6 eo Push RUN and optimize the energy and time setting of Pulse 1 constant power to provide an adequate tack weld and also a current waveform view in the monitor screen that has started to flatten out but is still rising This indicates that a full melt has not yet occurred 7 21 7 Push the ENERGY button to switch to MONITOR mode Program upper current limit on the MONITOR screen 10 500 STOP Pi none STOP NOTE You can toggle between peak and average readings by pressing the PEAK AVERAGE button UB25 LINEAR DC RESISTANCE WELDING CONTROL 4 10 990 665 10 11 12 990 665 CHAPTER 4 OPERATING INSTRUCTIONS Press the COOL weld period key FHESESTOUT OF LIMITS ACTION 1 none This will bring up the PULSE 1 2 STOP DURING PULSE 1 OUT OF LIMITS ACTION screen 3 INHIBIT PULSE 2 Qalart Draviniie manni Select 4 APC STOP PULSE 1 ALLOW PULSE 2 NOTE For details see Active Part Conditioner in Chapter 3 Since different levels of oxide require different amounts of time to reach the current limit return to the RUN screen and extend the programmed weld
24. Check Footswitch Weld Abort Switch Debounce Time Firing Switch Input Switch Select Overview Do Test Weld Options Function Copy A Schedule Requirements Communication Setup Menus Update Graph After Weld Buzzer On Weld Stop Control Signals Select Weld Counter Functions System Security Calibration Chain Schedules Ignore First Last Programming Instructions Reset Defaults Reset System Parameters Reset Schedules Number Baud Rate UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 5 1 CHAPTER 5 SETUP SOFTWARE Before programming the Control you must be familiar with the location and function of the LCD and front panel controls If you need more information see Chapter 1 of this manual UB25 LINEAR DC RESISTANCE WELDING CONTROL 5 2 990 665 CHAPTER 5 SETUP SOFTWARE Section How to Use Menu Screens Main Menu of the Control s programming functions are MAIN MENU accessed through the MAIN MENU To go to the 0 WAVEFORM CHECK 5 COMMUNICATION 1 SETUP 6 RELAY MAIN MENU press the MENU key on the front Wero COUNTER 7 CALIBRATION of the Control 3 A SCHEDULE 8 TO DEFAULTS 4 SYSTEM SECURITY 9 CHAIN SCHEDULES Each menu screen lists several choices with some NUMBER Select offering additional screens sub menus listing more choices Always look at the prompt at the bottom of each menu screen These prompts vary from screen to scre
25. Hlectrical and thermal conductivity Melting point Hardness It is also important to consider the surface properties of each material such as plating coatings and oxides The figure below gives an idea of the variance in resistivity and melting point for some of the more common materials used today in micro resistance welding The materials can be grouped into three common catagories Ti 6AI AV nconel Nichrome OFF Scale 800 Group oan 600 Resistivity Stainless Steels 304 316 etc Ti 400 Group 200 1500 2000 2500 3000 3500 Melting Point C The types of joints achievable within each of the main groups are as follows Groupl Conductive Metals Conductive metals dissipate heat and it can also be difficult to focus heat at the interface A solid state joint is therefore preferred Typically resistive electrode materials are used to provide UB25 LINEAR DC RESISTANCE WELDING CONTROL D 4 990 665 APPENDIX D DEFINING THE OPTIMUM PROCESS additional heating UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 D 5 APPENDIX D DEFINING THE OPTIMUM PROCESS e Group ll Resistive Metals tis easier to generate heat and trap heat at the interface of resistive metals and therefore it is possible to form both solid state and fusion welds depending on the time and temperature Upslope can reduce contact resistances and provide heating in the bulk material resis
26. Jumpers uo ecrit 1 13 End Of Cycle Buzzer 5 4 End Ot Weld Relay acea F 2 Energy Capacity Limit Setting 5 7 Energy Linsen ede tot tei 3 10 Enter New Values 4 3 Environmental Characteristics 3 Features 1 1 Firing Switch 5 9 B 9 ES ed DES 3 190 muna 10 Footswitch Weld 5 8 G General Kinds of Problems 6 1 General Operator Safety 4 11 Getting Started sc 2 1 Installati n enaner oM S 2 1 Space Requirements 2 1 Unpacking 2 2 Utility Requirements 1 2 eerte nter tent 2 1 Graphed 1 7 UB25 LINEAR DC RESISTANCE WELDING CONTROL Index 2 990 665 INDEX H How It Works 3 8 How to Use Menu Screens 5 2 I Number 5 25 Signal Interface A 4 Signal Interface 6 Rmus DARE d 4 2 Input Swatch Select i enter treten 5 10 Installation 0 2 2 1 L LCD rerit Eo 1 4 Liquid Crystal Display LCD and Weld Selector Keys 1 8 M Main Menu 7 5 2 Manual Wel
27. Power All modes 2 Weld to weld repeatability with fixed load Repeatability resistance and input line voltage steady state Rise Time Limited by external secondary circuit Data Communications Remote capability to upload download weld schedule monitor welds set up parameters select schedule and read weld results buffer Weld Monitor Range User selectable limits on peak values of one of three parameters current voltage or power When a parameter goes outside Voltage from 0 to 6 5 volts of limits the unit can be set to report the Power from 0 to 8 0 kilowatts error terminate the weld or inhibit a second pulse APC functionality also included Current Monitoring Accuracy The sum of 2 of setting and 2A Average value after settling time Reference is actual current delivered Voltage Monitoring Accuracy The sum of 2 of setting and 0 05 V at Average value after settling time Voltage values greater than 0 1 V monitoring is not guaranteed below 0 1 V Current from 0 to 1 2 kiloamps Reference is actual voltage delivered Power Monitoring Accuracy The sum of 590 of setting and 20W Average value after settling time Reference is actual power delivered UB25 LINEAR DC RESISTANCE WELDING CONTROL A 2 990 665 APPENDIX TECHNICAL SPECIFICATIONS Mechanical Characteristics DESCRIPTION VALUE VENE Size 12 75 H x 9 25 W x 23 5 L 324 mm H x 235 mm W x 597 mm L Weight 52 Ibs 24 kg N
28. SETUP 3 MENU screen This is the prompt to the operator whether to do a test weld or not User has attempted to program a Lower Limit value for Weld 1 or Weld 2 periods without using an upslope period Actual weld voltage is greater than the user set Upper Limit value for Pulse 1 Actual weld voltage is less than the user set Lower Limit value for Pulse 1 Actual weld voltage is greater than the user set Upper Limit value for Pulse 2 CORRECTIVE ACTION IF REQUIRED CAUTION Be careful when using the MENU default features There is no way to undo a reset to defaults action Normal Operation Press MENU to skip the test weld Press RUN to perform the test weld See Chapter 5 for programming information Delete the Weld 1 or Weld 2 Lower Limit value Add an upslope period before Weld 1 or Weld 2 if a Lower Limit value is desired Determine the cause of the high voltage Changes to the welding setup or process can affect the energy delivered Refer to the Troubleshooting Chart in Chapter 6 Limits should be set by qualified by personnel and are designed to identify process variations Determine the cause of the low voltage Changes to the welding setup or process can affect the energy delivered Refer to the Troubleshooting Chart in Chapter 6 Limits should be set by qualified by personnel and are designed to identify process variations Determine the cause of the high voltage Changes to the welding setu
29. Stop Switch Re Set After EMERGENCY STOP 1 Clear the condition that caused the EMERGENCY STOP condition whether initiated by an Operator or by a programmed action from the PLC 2 Inspect the electrodes weld head and weld cables to make sure there are no shorts or damage that could prevent normal welding Inspect the production area to verify it is ready to continue welding 4 Press the RUN key on the front of the Control and verify the desired weld schedule is displayed on the LCD 5 Continue to weld following normal automation procedures UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 4 13 5 SETUP SOFTWARE Section Introduction Overview The Control contains internal software that gives you a great deal of flexibility in the setup and use of your welding system The Control software displays various menu screens on the LCD each containing prompts telling you which of the Control s front panel controls to use in order to customize operating parameters set the Control for use in an automated welding system and program communication settings for use with data gathering devices such as a host computer This chapter is divided into the following sections How to Use Menu Screens Operator Preferences System Settings PID Test Weld Setup Relay Settings Special Functions Communication and Data Main Menu Display Contrast Buzzer Loudness End Of Cycle Buzzer Waveform
30. This mode delivers the programmed current regardless of work piece resistance changes This compensates for slight changes in part thickness without affecting weld quality Voltage Mode Application e Ideal for welding round or non flat parts Description This mode controls the voltage across the work piece during welding It helps to compensate for part misplacement and force problems and automatically reduces weld splash which is often associated with flat parts and wire welds Power Mode Application e Breaking through surface oxides and plating e Automated applications where part or electrode surface conditions can vary over time Description This mode precisely varies the weld current and voltage to supply consistent weld energy to the parts The power mode has been shown to extend electrode life in automated applications NOTE In weld profile a different feedback mode be used for each pulse For example a constant power first pulse can be used to break through plating in combination with a constant current second welding pulse UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 3 7 CHAPTER 3 USING 0825 WELDING FUNCTIONS Section IV Weld Monitor Introduction The Control s feedback sensors not only control weld energy output but they can also be used to monitor each weld The Control s monitor features allow you to view graphic representations of welds visually compare programmed we
31. Voltage Steps 0 100 4 90V 1 mV steps Actual achievable output based on load See Appendix G Repetition Rates Programmable Output Power Steps 0 050 4 9kW 1 W steps Actual achievable output based on load Programmable See Appendix G Repetition Rates Weld Periods For each of the upslope downslope and weld periods in each of the two dual pulses Duty Cycle Based on load See Appendix G Repetition Rates Weld Control Weld Current Voltage or Power with Average values are regulated simultaneous limits on one unregulated parameter Weld Control Ripple 2 of energy setting peak to peak Worst case At power line frequency UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 A 1 APPENDIX TECHNICAL SPECIFICATIONS DESCRIPTION VALUE NOTES Steady State Regulation During Output 2 of reading Line voltage within 15 10 Line Fluctuations tolerance Load variation from 0 5 to 10 milliohms Regulation During Load Current t 2 of setting exclusive of ripple After weld time of 2 Resistance Fluctuation Voltage 2 of setting Power 5 of setting ms Steady state Control Accuracy Current 2 of setting After weld time of 2 ms Voltage 2 of setting Power 5 of setting Initial Control Accuracy Current 5 of setting 2A During first 2 ms with load resistance Maximum transients Voltage 5 of setting 0 05V greater than 2 milliohms Power t 10 of setting 20W Current Voltage
32. XX then press the 8 key to get the RESET DEFAU LTS menu NIIMRER Qalart MENII Draviniie mani This menu allows you to reset all system programmed parameters and all weld schedules to the original factory default settings Reset System Parameters RESET SYSTEM PARAMETERS 1 From the MAIN MENU press the 8 key to go to the RESET DEFAULTS menu 2 From RESET DEFAULTS press the 1 key to go tothe RESET SYSTEM PARAMETERS menu 3 Pressthe 2 key to select YES This will automatically reset the system parameters to the factory defaults and return the screen to the RESET DEFAULTS menu 4 Press MENU to return to the MAIN MENU NIIMRED Calact Draviane manni Reset Schedules 1 Fromthe RESET DEFAULTS menu mu RESET ALL SCHEDULES press the 2 key to get tothe RESET ALL SCHEDULES menu 2 Pressthe 2 key to select YES This will 1 ALL WELD SCHEDULES ARE RESET automatically reset all weld schedule a lt parameters to the factory defaults and return the display to RESET DEFAULTS screen UB25 LINEAR DC RESISTANCE WELDING CONTROL 5 26 990 665 CHAPTER 5 SETUP SOFTWARE 3 Press MENU to return to the MAIN MENU UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 5 27 CHAPTER 5 SETUP SOFTWARE Section VIII Communication and Data Requirements The following menu screens tell you how to set the Control s communication and data options However to enable the Control to perform these fun
33. and force This part of weld development is critical in order to proceed to a statistical Design of Experiments method of evaluation Random explosions or unexpected variables will skew statistical data and waste valuable time Poor Follow up Sparks Insufficient Force Sparks Impact Force Variation lt lt Variation sparks No Squeeze No Hold Sparks i ss Variation The figure above shows common welding problems that can often be identified in the basic set up of the force energy and time welding profile These problems can lead to weld splash and inconsistency and variation contact Unitek Peco for further information and support UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 D 11 APPENDIX D DEFINING THE OPTIMUM PROCESS What are Screening DOE S The purpose of a Screening DOE Design of Experiments is to establish the impact that welding and process parameters have on the quality of the weld Quality measurement criteria should be selected based on the requirements of the application A Screening DOE will establish a relative quality measurement for the parameters tested and also the variation in the welded result This is important as variation in process is critical in establishing the best production settings Typical welded assemblies are assessed for strength of joint and variation in strength A Screening DOE tests the high and low settings for a parameter and will help est
34. are replaced or resurfaced you can manually switch back to Schedule 01 to restart the sequence You can program any of the Control s 99 stored schedules to chain to any other schedule or back to itself as in the second example above The chain code becomes part of each weld schedule You can turn the Chain Schedules feature ON or OFF or re program chains any time you want 5 16 UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 8 From the MENU press 9 key to go to the CHAIN SCHEDULES menu NOTE You should program or setup the chain of schedules you want before you turn this feature ON Press the 1 key to toggle CHAIN SCHEDULES ON or OFF From the CHAIN SCHEDULE menu press 2 key to go to the CHAIN SCHEDULE SETUP menu Usethe Up Down keys on the front panel to scroll vertically through the schedules to highlight the weld count for the schedule you want to chain Use the numeric keypad to enter the number of times you want this schedule to weld before going to the next schedule Use the SCHEDULE key to move the highlight horizontally to select NEXT Use the numeric keypad to enter the number of the next schedule in the chain Use the SCHEDULE key to move the highlight horizontally back to the WELD COUNT column Repeat Steps 4 through 8 to program the rest of the chain CHAPTER 5 SETUP SOFTWARE CHAIN SCHEDULES 1 CHAIN SCHEDULE OFF 2 SETUP CHAIN SCHEDULES NUMBER Select MENU
35. have been reset to factory default procedure to get the correct setting GENERAL DEFAULT values See Calibration section in manual STATUS CAPACITY LIMIT Pulse 1 is below the limit at the Shorten weld time lower energy EXCEEDED P1 end of the waveform setting or reduce repetition rate See OUT OF Chapter 5 for programming LIMITS instructions instructions CHAINED TO NEXT Chain Schedules function is active Normal operation See Chapter 5 for SCHEDULE Schedule has been incremented more information poen TATU CHECK CONTROL One or more of the I O input Remove the I O input control signal SIGNALS INPUT control signals Schedule condition preventing further Control STATUS Selection Process Inhibit or operation For more information see ALARM ISTOP is preventing the Control Chapter 5 NOTE The correct removal action depends on how the control signal select in the Setup 1 menu was programmed by the user CHECK INPUT One or more of the Firing or Foot Remove the I O input control signal SWITCH STATUS Switch input signals is preventing condition preventing further Control the Control from continuing to operation ALARM operate NOTE The correct removal action depends on how the INPUT SWITCH SELECT in the Setup 1 menu was programmed by the user UB25 LINEAR DC RESISTANCE WELDING CONTROL E 2 990 665 CAPACITY LIMIT Pulse 2 is below the limit at the Shorten weld time lower energy EXCEEDED P2 end of the waveform se
36. menu screen Ignore First Last 1 5 20 NUMBER Select MENU Previous menu From the SETUP 3 menu screen press IGNORE FIRST LAST the 2 key to access the IGNORE FIRST LAST screen IGNORE FIRSTILAST Wis Use the numeric keypad to enter the time in milliseconds that the Control ignores when calculating the load resistance during NUMBER Change MENU Previous menu the PID Test Weld The delay time prevents the Control from measuring noise early in the test weld and allows for more accurate load resistance to be measured Press MENU to return to the SETUP 3 menu screen UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 CHAPTER 5 SETUP SOFTWARE Section Relay Settings Function The Control s four relays can be programmed to activate outputs under eight user programmed conditions Relay connections are made through the 25 pin connector I O Signal Interface A on the rear of the Control See Appendix B Electrical And Data Connectors for pin connections Appendix F Relay Timing Diagrams provides the timing sequences for the four relays Programming Instructions NOTE Programming for each of the relays is identical 1 From MAIN MENU press 6 RELAY key to get the relay menu 1 RELAY 1 ON WHEN ALARM 2 RELAY2 ON WHEN ALARM 3 RELAY 3 ON WHEN ALARM 4 RELAY 4 ON WHEN ALARM NUMBER Select MENU Previous menu 2 From RELAY menu press the 1 2 RELAY 1 3 or 4 key to selecta relay menu
37. numeric keypad Press the SQUEEZE button to enter the squeeze time before the weld Use the numeric keypad to enter the time or use the AW arrows We recommend 150ms Press the PULSE 1 UPSLOPE button to enter the amount of time for the Weld Pulse 1 upslope Use the numeric keypad to enter the time or use the AW arrows Enter a time between 0 and 99 milliseconds Press the PULSE 1 WELD key to highlight the bottom line of the LCD to enter the weld time Use the numeric keypad to enter the time or use the AW arrows Enter a time between we and 99 milliseconds Press the PULSE 1 WELD key again to highlight the middle line of the LCD to enter weld energy Use the numeric keypad to enter the energy level or use the AW arrows The wa Control output ranges Current from 0 005 1 000 kiloamps Voltage from 0 100 gt 4 900 volts Power from 0 050 4 900 kilowatts Perform one of the following to program the Pulse 1 feedback mode kA Press the kA key to program current as the feedback mode Press V key to program voltage as feedback mode Press kW key to program power as feedback mode Press the PULSE 1 DOWNSLOPE key to enter the amount of time for the Weld Pulse 1 downslope Use the numeric keypad to enter the time or use the AW arrows Enter a time 9 between 0 and 99 milliseconds Press the COOL key to enter the amount of time between Pulse 1 and Puls
38. overshoot weld pulse The Control can be programmed to ALWAYS do a test weld after a schedule is changed ASK to do a test weld after a schedule is changed or only IF REQUIRED do a test weld after a schedule is changed When an air actuated weld head is being used the Control will go to the STANDBY state when the footswitch is pressed When a start signal has been received the Control enters the SQUEEZE state for the duration programmed in the schedule An adequate amount of squeeze time should be programmed to allow the weld head to settle before the WELD period begins The default SQUEEZE time is 150 milliseconds NOTE In addition to the debounce time there is a delay of no greater than 2 5ms before the start signal is recognized by the Control The WELD period begins after SQUEEZE time has ended and includes both weld pulses as well as the Cool time between Pulse 1 and Pulse 2 The HOLD period begins after the WELD period ends and lasts for the duration programmed in the schedule An adequate amount of hold time should be programmed to allow the electrodes to sink the heat away from the welded parts The default HOLD time is 50 milliseconds It is during the HOLD time that the weld strength is formed The Control will enter the END state after the HOLD period if the firing switch or footswitch has not yet been released This state allows you to view waveforms of weld voltage current power and resistance Press the ENERGY key to go
39. period after Pulse 1 Use numeric keypad to enter the time or use the AW arrows Enter 0 5 milliseconds Program Pulse 2 by repeating Steps 3 through 7 above using keys for Pulse 2 entering value 0 in each step Press the HOLD key to enter the amount of time for the hold period after the weld Use the numeric keypad or the AW arrows Enter a time between 0 and 999 milliseconds We oto recommend at least 50 milliseconds as weld strength is formed in hold time UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 4 5 CHAPTER 4 OPERATING INSTRUCTIONS Upslope Downslope Weld Schedule 1 10 4 6 Press the SCHEDULE button then select a Weld Schedule using either AV arrows the numeric keypad Press the SQUEEZE button to enter the squeeze time before the weld Use the numeric keypad to enter the time or use the AW arrows We recommend 150ms Press the PULSE 1 UPSLOPE button to enter the amount of time for the Weld Pulse 1 upslope Use the numeric keypad or the AV arrows to enter the time Enter a time between w 0 and 99 milliseconds A good starting point is 5 milliseconds Press the PULSE 1 WELD key to highlight the bottom line of the LCD to enter the weld time Use the numeric keypad to enter the time or use the AW arrows Enter a time between wae and 99 milliseconds Press the PULSE 1 WELD key again to highlight the middle line of the LCD to enter weld energy Use the nu
40. return to MAIN MENU Buzzer On Weld Stop This function only applies to weld schedules that have STOP ON PULSE 1 or STOP ON PULSE 2 programmed in the monitor refer to Chapter 4 Section IV Programming the Weld Monitor ON means that an audible signal will be given when a limit is reached 1 SETUP 2 menu SETUP 2 1 DISPLAY CONTRAST 080 2 Press the 5 key to toggle the buzzer 2 BUZZER LOUDNESS 030 funcion ON or OFF 3 END OF CYCLE BUZZER OFF 4 UPDATE GRAPH AFTER WELD ON 3 Keep pressing the MENU key on the 5 BUZZER ON WELD STOP OFF front panel to return to the MAIN MENU Salact Main AW Pana NOTE After setting Operator Preferences press the RUN button on the front panel to perform welding UB25 LINEAR DC RESISTANCE WELDING CONTROL 5 6 990 665 CHAPTER 5 SETUP SOFTWARE Section IV System Settings Waveform Check and Weld Fire Lockout Even though the Control optimizes the output pulse misaligning parts or operating at the outer edges of the Control s operational range may degrade the waveform The WAVEFORM CHECK feature which includes STABILITY CHECK and ENERGY CAPACITY LIMIT can be used to confirm that the proper waveform was produced The WELD FIRE LOCKOUT feature guarantees that the capacitor bank is charged to a user defined percentage before the Control is allowed to fire This advanced feature prevents poor welds caused by operating at too high of a r
41. schedule is still displayed on the front panel and then resume welding UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 1 15 CHAPTER 1 DESCRIPTION For user convenience pins 9 and 13 of I O Connector have an additional input to stop the functioning of the unit This input will stop weld current and raise the weldhead This input requires the microprocessor to be operational and is not the emergency stop for the unit UB25 LINEAR DC RESISTANCE WELDING CONTROL 1 16 990 665 CHAPTER 1 DESCRIPTION Section VI Related Publications Related publications which you may wish to obtain from Unitek Peco are DC25 UB25 Advanced Serial Datacom Communications Interface No 990 661 e Series 300 Fast Response Weld Head System No 990 115 Please consult your Unitek Peco representative to obtain this information In addition check the Unitek Peco website listed in the Foreword of this manual to see the latest technical update information called Nuggets UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 1 17 2 GETTING STARTED Section Planning for Installation Space Requirements We recommend that the Control be installed in a well ventilated area that 1s free from excessive dust acids corrosive gasses salt and moisture Other installation considerations are Allow sufficient clearance around both sides and the back for power and signal cable runs e Allow ample workspace around the Control so that it wi
42. start of the pulse will not be used when the average deviation is calculated Press MENU to return to the WAVEFORM CHECK menu Energy Capacity Limit Setting 1 5 8 From WAVEFORM CHECK menu press 4 key to access the ENERGY CAPACITY LIMIT screen Use the numeric keypad to enter the capacity limit This limit is the below the set point the energy is allowed to be at the end of the weld pulse Press MENU to return to the WAVEFORM CHECK menu The ENERGY CAPACITY LIMIT will display your programmed setting along with the Pulse 1 and Pulse 2 ENERGY CAPACITY readings from the most recent weld STABILITY CHECK DLY ms STABILITY CHECK DLY ms 20 NUMBER Change MENU Previous menu ENERGY CAPACITY LIMIT ENERGY CAPACITY LIMIT 05 NUMBER Change MENU Previous menu UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 CHAPTER 5 SETUP SOFTWARE Weld Fire Lockout Charge Setting 1 WAVEFORM CHECK menu press the 5 key to access the WELD FIRE LOCKOUT screen WELD FIRE LOCKOUT CHRG 90 WELD FIRE LOCKOUT CHRG 2 Use the numeric keypad to enter the required amount of energy in the capacitor bank before the next weld is allowed NUMBER Change MENU Previous menu 3 Press MENU to return to the WAVEFORM CHECK menu The WELD FIRE LOCKOUT line will display your programmed setting along with the actual CHARGE from the most recent weld Footswitch Weld Abort 1 Go
43. term exposure to the indicated hazard MODEL UB25 LINEAR DC RESISTANCE WELDING CONTROL iv 990 665 Table of Contents Page Chapter 1 Description eere ein en ead dass e e de a en ie ede ddan lees deae d rax Ud 1 1 DEC HOM MIS 1 1 1 1 APP ications ele dust a uUa 1 2 Section T Desctipligl 1 3 Section IM eset ice ect dum tere aiu itn 1 4 eed 1 4 E 1 4 ucc to de EU us 1 5 1 5 Data ite en eae 1 5 1 5 ii 1 7 Section IV Controls And Indicators 1 8 Introduction seen ps 1 8 Liquid Crystal Display LCD Weld Selector Keys 2 2 1 8 Numeric Keypad And Operational Controls essen 1 10 Section V Emergency Stop Switch And 24v Jumpers 1 13 Section VT Related Publications nie 1 14 Chapter 2 Getting Started
44. using 10 msec of weld time NOTE Actual weld strength is a user defined specification Polarity as determined by the direction of weld current flow can have a marked effect on the weld characteristics of some material combinations This effect occurs when welding materials with large differences in resistivity such as copper and nickel or when welding identical materials with thickness ratios greater than 4 to 1 The general rule is that the more resistive material or the thinner material should be placed against the negative electrode Polarity on the Control can only be changed by reversing the Weld Cables Weld Strength Testing Destructive tests should be performed on a random basis using actual manufacturing parts Destructive tests made on spot welds include tension tension shear peel impact twist hardness and macro etch tests Fatigue tests and radiography have also been used Of these methods torsional shear is preferred for round wire and 45 degree peel test for sheet stock Weld Strength Profiles Creating a weld strength profile offers the user a scientific approach to determining the optimum set of welding parameters and then displaying these parameters in a graphical form 1 Startat a low weld current voltage or power making five or more welds then perform pull tests for each weld Calculate the average pull strength Increase weld current voltage or power and repeat this procedure Do not change the weld t
45. various values that need to be calibrated in order for the Control to operate and monitor accurately There are 12 Calibration Points The instructions in Section II Calibration Procedure tell you how to perform the procedures the illustration below gives a quick overview of the process Operator Uses Oscilloscope To Measure The Average OUTPUT Of The Control Then Adjusts The Control Until The Waveform Matches The Value On The Scope CALIBRATION POINTS Values EnteredDuring Calibration High End Of Range HIGH RANGE gt MONITOR Low End Of Range CURRENT OUTPUT High End Of Range N we MONITOR Low Of Range igh High End Of Range di HIGH RANGE p MONITOR Low End Of Range VOLTAGE OUTPUT High End Of Range LOW RANGE go MONITOR gt Low End Of Range High End Of Range 7 Low End Of Range High End Of Range asc HIGH RANGE pe MONITOR POWER OUTPUT Z N N LOW RANGE eU MONITOR Low End Of Range MEM Operator Triggers The Firing Switch The Control Learns New MONITOR Reference Values Calibration Points UB25 LINEAR DC RESISTANCE WELDING CONTROL 7 2 990 665 CHAPTER 7 CALIBRATION Section Calibration Equipment Setup Get the required calibration equipment listed in Section and set it up as shown below E VOLTAGE SPECIAL CALIBRATION CABLE SENSE INPUT FIRING SWI
46. weld schedule values using the two digit weld schedule number Select A Weld Schedule 1 select weld schedules first make sure that the RUN state is displayed on the LCD If not press the RUN button on the front of the Control 2 Press the SCHEDULE button on the right of the Control 3 Useeither of the methods below to select a schedule Use the Up Down buttons to scroll through the list OR Use the numeric keypad to enter the two digit number of the schedule you want Enter New Values Some welding applications require no more than a simple weld schedule programmed for Single Pulse Upslope Downslope or Dual Pulse operation For other applications you may want to use the Energy Limits Monitor or Active Part Conditioning features of the Control To enter new values follow the instructions for Single Pulse Upslope Downslope or Dual Pulse weld schedules on the following pages NOTE If drastically different energy values are entered for Pulse 1 and Pulse 2 the Control will require a minimum of 0 5 ms Cool Time If different feedback modes are programmed for a dual pulse weld the Control will require minimum of 0 5 ms Cool Time If a Cool Time is set lower than 0 5 ms but not zero the Control will default to 0 5 ms Cool Time UB25 LINEAR DC RESISTANCE WELDING CONTROL 4 4 990 665 CHAPTER 4 OPERATING INSTRUCTIONS Single Pulse Weld Schedule 1 10 Press the SCHEDULE button then select
47. 23 24 PIN 22 PIN 21 NOT USED PIN 20 NOT USED PIN 19 NOT USED PIN 18 NOT USED PIN 17 NOT USED PIN 16 24VOUT PIN 15 SPOWER PIN 14 24VGND 11 O UNUSED 10 24VGND 9 PIN 8 RELAY4P 7 4 6 5 PIN 4 RELAY2P PIN 3 RELAY2N PIN 2 RELAY1P PIN 1 RELAY1N Specification Table on next page UB25 LINEAR DC RESISTANCE WELDING CONTROL B 4 990 665 APPENDIX B ELECTRICAL DATA CONNECTORS 10 20mA RELAY2N 230V ac or 30V dc No weld input Switch normally open 3A 3A 3A 3A 3A 3A 3A 3A 3A 3A 3A A 230V ac or 30V dc 8 RELAYaP 230V ac or 30V dc gt o eee e uw Jews ams 24V de GND Power can be from internal or external source for Schedule Select Process Inhibit Istop 24V dc out through 200 ohm SPOWER Ed 24 dc open 48mA at 24Vdc circuit 24VOUT Not used Not used Not used Not used Not used HEAD 24V ac 24V acRET 24V ac Return ESON 24V 24V ac UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 B 5 APPENDIX ELECTRICAL AND DATA CONNECTORS Signal Interface B PIN 1 ISCHO PIN 14 NOT USED PIN 2 ISCH1 PIN 15 NOT USED PIN 3 ISCH2 PIN 16
48. 7 Data Datacom Kit 1 1 1 14 2 2 5 24 m 1 1 Alphanumeric Data 1 5 Applications ossi tovs 1 2 Data error 1 5 jn E 1 1 1 7 1 4 Menu Screens 1 5 Operational States esses 1 5 Display Contrast 5 4 Do Test Weld Options uscire pea 5 17 Dual Pulse Weld Profile 3 5 Dual Pulse Weld Schedule 4 6 E Electrical and Data Connectors B 1 25 Pin Mating Plug with Emergency Stop Shorting Wires for sace QUIS Ur rale EE ESSE B 8 25 Pin Mating Plug with Internal Jumper for I O Connector B 8 E Continued AC Input Power Connection B 11 Air Valve Driver 24 ibt B 9 Firing Switch rab set B 9 10 Signal Interface A 4 Signal Interface 6 ino B 3 RS 485 In and B 2 Voltage Sense B 1 Weld Tetminals e couette tete B 12 Electrode Maintenance 6 6 C 4 Electrode Selection suem etes C 2 Emierdency Stop 4 12 Emergency Stop Switch and DAY
49. AIN MENU UB25 LINEAR DC RESISTANCE WELDING CONTROL 5 28 990 665 CHAPTER 5 SETUP SOFTWARE 1 0 Number The host computer may be used to talk with multiple Controls using a single RS 485 communications line Each Control sharing that line must have a unique identification number To enter an identification number for the Control proceed as follows 1 From the MENU press the 5 1 0 NUMBER key to go to the COMMUNICATIONS 10 NUMBER MENU 2 Fromthe COMMUNICATIONS MENU screen press 2 key to get NUMBER Change MENU Previous menu the 1 0 NUMBER entry screen 3 Enteratwo digit number from 01 to 99 in the I D NUMBER field 4 Press the MENU key to get the COMMUNICATION menu screen This time the 1 0 NUMBER line will display your I D number entry 5 Press MENU to return to the MAIN MENU Baud Rate The baud rate at which the data is sent must match the baud rate of the host computer To enter the baud rate proceed as follows 1 990 665 From the COMMUNICATION menu BAUD RATE press the 3 key to get the BAUD 1 1200 6 19 2K 2 2400 7T 28 8K RATE selection screen 3 4800 Use the numeric keypad to select the baud rate of the receiving device The display 4 14 4K automatically returns to the NIIMPRED Channa MENII manii COMMUNICATION menu which shows the new baud rate Press MENU to return to the MAIN MENU UB25 LINEAR DC RESISTANCE WELDING CONTROL 5 29
50. D Re program welding parameters to be within the capability of the Control Re program welding parameters to be within the capability of the Control Re program the invalid Lower Limit value Check that a closed secondary circuit 15 present when the Control fires If message persists possible blown internal fuse on Capacitor Charging Power Supply contact Unitek Peco for support Check that a closed secondary circuit is present when the Control fires Check voltage cable connection If message persists possible blown internal fuse on Capacitor Charging Power Supply contact Unitek Peco for support Determine the cause of the high power Changes to the welding setup or process can affect the energy delivered Refer to the Troubleshooting Chart in Chapter 6 Limits should be set by qualified by personnel and are designed to identify process variations Determine the cause ofthe low power Changes to the welding setup or process can affect the energy delivered Refer to the Troubleshooting Chart in Chapter 6 Limits should be set by qualified by personnel and are designed to identify process variations TYPE OF MESSAGE GENERAL STATUS GENERAL STATUS GENERAL STATUS OUT OF LIMITS OUT OF LIMITS OUT OF LIMITS OUT OF LIMITS APPENDIX E LCD DISPLAY MESSAGES MESSAGE POWER 2 GREATER THAN UPPER LIMIT POWER 2 LOWER THAN LOWER LIMIT POWER TRANSISTOR OVERHEATED SCHEDULES ARE R
51. D position 5 Select the desired weld schedule and begin welding using normal operating procedures Normal STOP When finished welding turn the Control OFF Automated Welding Operation Verify that all components of your welding system have been properly connected and turned ON 2 Verify that all welding components are operating properly and ready for use 3 Venfy that you have programmed the Control with all necessary schedules for your welding application 4 Verify that the Automation and Communication software has been properly programmed 5 Perform all software Test and Setup procedures to verify that the PLC is communicating properly with the Control 6 the WELD NO WELD switch on the front panel to the WELD position 7 Begin welding using normal automation operating procedures UB25 LINEAR DC RESISTANCE WELDING CONTROL 4 12 990 665 CHAPTER 4 OPERATING INSTRUCTIONS Normal STOP When finished welding follow the Turn Off Power Down procedures established for your automated welding system 2 the Control OFF unless the procedures for your automated welding system require leaving it ON EMERGENCY STOP NOTE Connections for an external Emergency Stop Switch are described in Appendix B 1 Push Operator Emergency Stop Switch any time necessary to prevent injury to personnel damage to weld pieces or the welding system 2 Clearthe condition that caused the operator to hit the Operator Emergency
52. ELECT ELECT MATERIAL RWMA MATERIAL RWMA TYPE TYPE Tungsten ELECT ELECT RWMA MATERIAL RWMA TYPE TYPE 2 2 2 2 2 2 2 2 2 Cold Steel NiSpan C NiSpan C NiSpan C 2 2 2 2 14 Paliney 7 Electrode Maintenance Depending use periodic resurfacing 15 required to remove oxides and welding debris from electrodes Cleaning of electrodes on production line should be limited to use of 2400 600 grit electrode polishing disks For less critical applications a file can be used to clean a badly damaged tip However after filing polishing disks should then be used to ensure that the electrode faces are smooth If this is not done the rough surface of the electrode face will have a tendency to stick to the work piece Weld Schedule Development Developing a weld schedule is a methodical procedure which consists of making sample welds and evaluating the results The first weld should be made at low energy settings Adjustments are then made to each of the welding parameters one at a time until a successful weld is made 1 Install the correct electrodes in the electrode holders on Weld Head See the preceding Table for electrode material recommendations 2 Usea flat electrode face for most applications Use domed face if surface oxides are a problem If either of the parts is a wire the diameter of the electrode face should be equal to or grea
53. ENERAL STATUS OUT OF LIMITS NOTE Entering a security code of 414 will always unlock the system Normal operation if this function is used See Chapter 4 Operating Instructions Remove the Inhibit signal condition preventing further the Control operation NOTE The correct removal action depends on how the control signal logic was programmed the user UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 MESSAGE INPUT TOO LARGE INPUT TOO SMALL LOWER LIMIT GREATER THAN UPPER LIMIT NO CURRENT READING NO VOLTAGE READING POWER 1 GREATER THAN UPPER LIMIT POWER 1 LOWER THAN LOWER LIMIT UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 APPENDIX E LCD DISPLAY MESSAGES LCD Display Messages DESCRIPTION The user has attempted to program a weld energy or time that exceeds the capability of the Control The user has attempted to program a weld energy or time that is below the capability of the Control The user has tried to program a Lower Limit value that is greater than the Upper Limit value for Pulse 1 or Pulse 2 time periods No current measurement was made Possible open circuit No voltage measurement was made Possible open circuit or possible voltage lead connection problem Actual weld power is greater than the user set Upper Limit value for Pulse 1 Actual weld power is less than the user set Lower Limit value for Pulse 1 CORRECTIVE ACTION IF REQUIRE
54. ENNEN less shipping kit or shipping materials Environmental Characteristics DESCRIPTION VALUE NOTES Operating Ambient Air Temperature 0 40 degrees C c Operating Humidity 10 95 Relative Humidity Non condensing Interface Signals DESCRIPTION VALUE NOTES Input Output 24 V ac dc inputs and outputs 2500 V rms optically isolated hardware selectable positive or negative logic Fail safe emergency power off input External or internal power supplied to inputs Inputs to be current sourcing or sinking Dedicated connectors for 24 V air head 2 wire force firing switch voltage sense cable computer interface foot switch Additional connections for weld head schedule selection process inhibit emergency stop Four general purpose programmable relays RS 232 and RS 485 communications included Firmware is subject to change without prior notice Contact Unitek Peco for latest version UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 A 3 APPENDIX ELECTRICAL AND DATA CONNECTORS Introduction This Appendix describes the electrical and data connectors located on the rear panel of the DC25 Each connector is illustrated with pin identification Following each picture is a table listing the technical specifications for that connector Connectors are described in the order in which they appear on the rear panel of the DC25 starting at the top left Note The specifications listed in this Appendix may
55. ESET STABILITY LIMIT EXCEEDED P1 STABILITY LIMIT EXCEEDED P2 STOP ON CONTROL SIGNALS INPUT UB25 LINEAR DC RESISTANCE WELDING CONTROL LCD Display Messages DESCRIPTION Actual weld power is greater than the user set Upper Limit value for Pulse 2 Actual weld power is less than the user set Lower Limit value for Pulse 2 The power dissipated by the power transistors has exceeded the Control specified capability User programmed the Control to automatically reset all 100 weld schedules to their factory set default values The average deviation of Pulse 1 is beyond the allowable amount programmed in the Stability Check function The default value for the limitis 790 The default value for the delay at the start of the pulse is 2 milliseconds The average deviation of Pulse 2 is beyond the allowable amount programmed in the Stability Check function The default value for the limitis 790 The default value for the delay at the start of the pulse is 2 milliseconds The ISTOP function has been activated Welding has been inhibited CORRECTIVE ACTION IF REQUIRED Determine the cause of the high power Changes to the welding setup or process can affect the energy delivered Refer to the Troubleshooting Chart in Chapter 6 Limits should be set by qualified by personnel and are designed to identify process variations Determine the cause ofthe low power Changes to the welding setup or process c
56. End Of Cycle Buzzer 1 Gotothe SETUP 2 menu SETUP 2 1 DISPLAY CONTRAST 080 2 Press the 3 key to toggle the end of cycle 2 BUZZER LOUDNESS 030 buzzer ON or OFF 3 END OF CYCLE BUZZER OFF 4 UPDATE GRAPH AFTER WELD ON NOTE This function is normally used with 5 BUZZER ON WELD STOP OFF manually actuated weld heads ON means that an audible signal will be given at the end of each weld process to signal the operator to release the foot pedal 3 Press the MENU key to return to the MAIN MENU Calact Main man AW Dana UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 5 5 CHAPTER 5 SETUP SOFTWARE Update Graph After Weld 1 SETUP 2 menu SETUP 2 1 DISPLAY CONTRAST 080 2 Press the 4 key to toggle the update 2 BUZZER LOUDNESS 030 function ON or OFF 3 END OF CYCLE BUZZER OFF 4 UPDATE GRAPH AFTER WELD ON NOTE ON means that the actual weld 5 BUZZER ON WELD STOP OFF energy profile shaded graph will overlay the programmed weld profile line graph on the LCD after each weld is made The weld graph is useful for detecting a faulty weld which will be indicated by the shaded graph not filling completely OFF gives you the fastest operating time multiple welds per second for automated welding because the control processor does not have to redraw the screen Qalact Main man Dana 3 Keep pressing the MENU key on the front panel to
57. For Active Part Conditioning 4 9 Section 0 EP 4 11 General Operator Safety RE 4 11 Manual Welding GB NU 4 11 E 4 11 Normal Stop 4 11 Automated WV 4 11 Operation 4 11 4 12 Emergency StoP 4 12 Re Set After Emergency Stop 4 12 Chapter 5 Setup SoftWare 5 1 Section T Introduction 5 1 9 DU 5 1 Section IL How To Use Menu Screens 5 2 Man MEDU TD 5 2 SCUD IVI NIG MR RE eM 5 2 Section III Operator 5 4 Display 5 4 Buzzer 5 4 End Of Cycl BUZET srir irait reire Er iS 5 4 Update Graph After Weld 5 5 Buzzer On Weld StoP M 5 5 Section TV System EEEE EA E 5 6 Waveform Check And Weld Fire 5 6 Waveform Check ON OFF pc 5 6 Stability Check Limit tiei 5 6 Stability Check
58. HAPTER 3 USING 0825 WELDING FUNCTIONS INHIBIT 2ND PULSE 2000945 Pre Weld Check Waveform Example To detect misaligned parts use constant current and set upper and lower voltage limits for Pulse 1 If parts are misaligned the work piece resistance will be higher so the voltage will be higher If parts are missing voltage will be lower In either case the Pulse 1 upper or lower limits will be exceeded and Pulse 1 can be inhibited NOTE You must have upslope programmed into the pulse in order to set a lower limit In addition to inhibiting the weld the Control has four programmable relay outputs which can be used to trigger alarms to signal operators of weld faults or signal automation equipment to perform pre programmed actions such as stopping the assembly line so the faulty weld piece can be removed UB25 LINEAR DC RESISTANCE WELDING CONTROL 3 12 990 665 4 OPERATING INSTRUCTIONS Section Introduction This Chapter tells you how to turn the Control on use menu screens to customize operating parameters match the Control to your welding system and how to operate the Control This chapter is divided into the following sections e Initial Setup Programming Weld Schedules e Programming The Weld Monitor e Programming For Active Part Conditioning e Operation Before operating the Control you must be familiar with the following The location and function of Controls and Indicators For more in
59. LDING CONTROL 5 18 990 665 CHAPTER 5 SETUP SOFTWARE Section V PID Test Weld Setup Overview The Control is designed to learn the load of specific pieces to be welded by performing a test weld Once it has learned the load resistance it can automatically adjust itself to deliver the optimum output waveform the fastest rise time without overshoot and the smoothest waveform possible To do this the Control does a Test Weld of the actual pieces you want to weld during production The Test Weld is done on the first weld performed after a change to the weld schedule has been made Test Welds are only done for schedules programmed for voltage V and or power KW feedback Test Welds are not done for schedules programmed for only current feedback The Control allows you to set the conditions for when the Test Welds will be done and also allows you to specify the length of time at the beginning and end of the weld pulse to be ignored by the Test Weld when calculating the load resistance 1 MAIN MENU press 1 to access SETUP 3 PID TEST WELD the SETUP 1 screen 1 DO TEST WELD 2 Pressthe down arrow key to access the i SE SETUP 3 PID TEST WELD menu screen NUMBER Select MENU Main menu A Page 2 Do Test Weld Options The DO TEST WELD menu screen allows you choose when the Control performs Test Welds The three options for DO TEST WELD are e If Required Ask Always Regardless of the opti
60. MITS alarms and will stay energized until the ALARM state is cleared by pressing the RUN button refer to Appendix E LCD Display Messages The relay will switch when the Control senses any OUT OF LIMITS condition It will start 0 150 milliseconds after the end of HOLD and will stay energized until the OUT OF LIMITS alarm state is cleared by pressing the RUN button or at the start of the next weld refer to Appendix E LCD Display Messages The relay signal will switch when the Control senses that the Pulse 1 energy is higher than the programmed upper limit It will start 0 150 milliseconds after the end of HOLD and will stay energized until the OUT OF LIMITS alarm state is cleared by pressing the RUN button or at the start of the next weld refer to Appendix E LCD Display Messages The relay signal will switch when the Control senses that the Pulse 1 energy is lower than the programmed lower limit It will start 0 150 milliseconds after the end of HOLD and will stay energized until the OUT OF LIMITS alarm state is cleared by pressing the RUN button or at the start of the next weld refer to Appendix E LCD Display Messages The relay signal will switch when the Control senses that the Pulse 2 energy is higher than the programmed upper limit It will start 0 150 milliseconds after the end of HOLD and will stay energized until the OUT OF LIMITS alarm state is cleared by pressing the RUN button or at the start of the next weld refer to A
61. NOT USED PIN 4 ISCH3 PIN 17 NOT USED PIN 5 ISCH4 PIN 18 NOT USED PIN 6 ISCH5 PIN 19 NOT USED PIN 7 ISCH6 PIN 20 NOT USED PIN 8 INHIBIT PIN 21 NOT USED PIN 9 ISTOP PIN 22 NOT USED PIN 10 IFIRE PIN 23 IFOOT1 PIN 11 24VOUT PIN 24 IFOOT2 PIN 12 FPOWER PIN 25 CGND PIN 13 24VGND Specification Table on next page UB25 LINEAR DC RESISTANCE WELDING CONTROL B 6 990 665 APPENDIX B ELECTRICAL DATA CONNECTORS SIGNAL INTERFACE B CONNECTOR SPECIFICATIONS wwe wo mas owe toa 1 s mmm ume puma wma awa 12 FPOWER 24V dc 20mA I Powercan from internal or external source for Footswitch Firing Switch 24VGND 24V de GND 13 4 ot used 5 ot used 6 ot used 7 ot used 8 9 ot used 20 ot used 2 ot used 22 ot used 24 IFOOT2 Foot switch normally open Level 2 23 UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 B 7 APPENDIX ELECTRICAL AND DATA CONNECTORS 25 Pin Mating Plug with EMERGENCY STOP Shorting Wires for I O Connector A This connector should be attached to I O Connector A when it 1s shipped from the factory Pins 24 amp 25 are connected to the shorting wires see illustration below for
62. ONITOR or RUN is displayed in the MONITOR state press the V key to view the voltage graph on the LCD display feedback mode for Pulse 1 or Pulse 2 First use the WELD key to highlight the energy field then enter the desired output level with the numeric keypad and then press the kW key to change the feedback mode to power When MONITOR or RUN is displayed in the MONITOR state this key is used to set power as the limit parameter for Pulse 1 or Pulse 2 First use the WELD key to highlight the energy field then enter the desired limit level with the numeric keypad and then press the kW key to change the limit parameter to power When MONITOR or RUN is displayed in the MONITOR state press the kW key to view the power graph on the LCD display WELD position when a weld is initiated the Control delivers energy to the weld head NO WELD allows the Control to execute a complete weld sequence but does not deliver energy to the weld head This function is useful for testing and adjusting the weld head before operation and when cleaning When PROGRAM displayed this key is used to set power as the UB25 LINEAR DC RESISTANCE WELDING CONTROL 1 14 990 665 CHAPTER 1 DESCRIPTION LU Section V Emergency Stop Switch and 24V Jumpers The Control 15 shipped with two 25 pin mating plugs installed on the two I O connectors on the rear panel of the Control These two plugs connected to Connector A and I O Connector B ar
63. ONTROL 990 665 6 1 CHAPTER 6 USER MAINTENANCE Hard The problem is embedded in the system and some form of repair will be needed For example repair might include replacing a broken weld head flexure In either case you may telephone the Unitek Peco Applications Laboratory for assistance by calling the telephone number listed in the Foreword and asking for the Applications Laboratory Alarm Messages Built in automatic self test and self calibration routines will bring up alarm messages on the display screens These messages will usually let you know what action is required of you to correct the reason for the alarm For a complete listing of the alarm messages what they mean and what to do about them please refer to Appendix E LCD Display Messages Troubleshooting The following Troubleshooting Chart 15 a comprehensive listing of system and equipment problems and their probable cause Troubleshooting Chart PROBLEM CAUSE In Order of Probability Air operated weld head will not close Air valve driver cable not connected Check that the Control switches to STANDBY state when footswitch is activated Blown fuse located on the Rear Panel Valve Driver Fuse 3 A 125 V Slow Blow Check that the air supply is properly connected to the weld head Electrode Damage Excessive current energy set at the Control Excessive or insufficient weld head force Wrong electrode tip shape Misaligned parts Excessive weld time set a
64. Previous menu CHAIN SCHEDULE SETUP SCHEDULE NUMBER WELD COUNT 0001 0001 0001 AY SCHEDULE select MENU menu CHAIN SCHEDULE SETUP SCHEDULE NUMBER WELD COUNT 04 0001 05 0001 0001 AY Wo SCHEDULE select MENU menu CHAIN SCHEDULE SETUP SCHEDULE NUMBER WELD COUNT 0001 04 0002 05 0001 06 0001 07 AY SCHEDULE select MENU menu CHAIN SCHEDULE SETUP SCHEDULE NUMBER WELD COUNT 0001 04 0002 05 0001 06 0001 07 AY d SCHEDULE select MENU menu When you finish programming the chain press MENU key to return to the CHAIN SCHEDULES menu 10 Press the 1 key to toggle between ON or OFF UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 NEXT CHAPTER 5 SETUP SOFTWARE 11 Pressthe RUN key on the front panel then use the AW Up Down keys to select the first weld schedule in the chain you want to use The Control will now weld in the chain mode until you turn the Chain Schedules feature OFF NOTE When Chain Schedules is turned ON the LCD screen changes to show the chain information on the right side of the screen RUN 1 020 1 030V 09000114 CHAIN SCHEDULES a P INDICATION 4 17 NEXT SCHEDULE NUMBER 100 100 COUNT 0002 010 20 40 20 10 20 40 22 YT REPEAT COUNT Below the current schedule number you can see the number of times the current schedule will be repeated and the number of the next schedule in the chain UB25 LINEAR DC RESISTANCE WE
65. ROL 990 665 D 7 APPENDIX D DEFINING THE OPTIMUM PROCESS The figure below shows a weld that 15 fired The figure below shows a weld that 15 initiated when early on in the weld sequence when the contact the contact resistance is lower and in this example we resistance is still quite high are using bulk resistance to generate our weld heat Resi Contact Resistance Resistance amp Resistance Weld Pulse Resistanc Weld Pulse Bulk Resistance Bulk Resistance Time Time Heat Affected Zone NOTE Larger nuggets are possible with longer weld times when using bulk resistance general conductive materials benefit from a faster heating rate as the higher contact resistances assist heat generation in the weld Resistive materials benefit from slower heating rates that allow the contact resistances to reduce significantly thus bulk resistances become the major source for heat generation Weld Profiles The basic welding profile or schedule consists of a controlled application of energy and force over time Precision power supplies control the energy time and therefore heating rate of the parts The weld head applies force from the start to finish of the welding process UB25 LINEAR DC RESISTANCE WELDING CONTROL D 8 990 665 APPENDIX D DEFINING THE OPTIMUM PROCESS The figure on the right shows Welding Force a typical welding sequence where the force is applied to the parts a squeeze time is
66. SHOULD BE PERFORMED BY A 1 Fromthe MAIN MENU press the 7 QUALIFIED TECHNICIAN ONLY key to access the first CALIBRATION REFER TO MANUAL FOR CALIBRATION SETUP screen 2 navt mani 2 Follow the calibration procedures in Chapter 7 Calibration Chain Schedules This feature allows you to automatically change from any weld schedule to any other schedule after a preset count creating a chain of schedules that can accommodate a variety of welding needs For example A single work piece requires four welds two weld points require the same weld schedule each of the other two points require different weld schedules In this case you would program a sequence or chain that looks like this Schedule 01 2 times 3 Schedule 02 1 time Schedule 03 1 time gt Schedule 01 This sequence will repeat or Joop until you tum Chain Schedules OFF Some applications require a lower current for a number of welds after the electrodes have been replaced or resurfaced Once the electrodes have been seasoned the current can be increased as required If the electrodes require 100 welds to season Schedule 01 can be programmed with a lower current and Schedule 02 can be programmed with a higher current The chain would look like this Schedule 01 100 times gt Schedule 02 1 time gt Schedule 02 1 time In this chain Schedule 02 will just keep repeating after the 100 welds made using Schedule 01 When the electrodes
67. Screens Menu screens are text screens that allow you to select and customize the operating parameters of the Control and performance of the welding equipment Each menu screen lists several choices with some offering additional menu screens listing more choices The numeric keypad 15 used to select choices from the menu Data Screens The Data screens display the information necessary to program run and monitor welds Data is displayed in both alphanumeric and graphic form the same screen The graph displays time values from left to right and energy values from bottom to top showing the waveform of the weld schedule The waveform gives you an easy to see before and after comparison of how you programmed the weld and how the weld was actually performed Alphanumeric Data Values Of Last Weld Performed Operational State Weld Counter Top Data Line RU 0 29TKH Peak 09 297 8600025 Middle Data Line Weld Energy Values rT 5 Bottom Data Line Time Periods And Corresponding Values Alphanumeric Data Alphanumeric data is displayed on three lines Operating instructions will refer to alphanumeric data as the Top Line Middle Line and Bottom Line as shown above Chapter 4 Operating Instructions describes how to enter alphanumeric data and how to select between voltage current power peak average display and operational states Operational States Each Data Screen displays the current operational stat
68. TCH zs zoeomEcwizn pz oi v wo H DIGITAL OSCILLOSCOPE FILTER LI STANDARD CABLE MATING CONNECTOR NUMBER 2 0 WELD CABLES COAXIAL SHUNT RESISTOR BNC T CONNECTOR Ema Calibration Setup NOTES The ground of the oscilloscope should be isolated from the ground of the electrical live by an isolation transformer or other means The filter in the Calibration Kit goes between the BNC cable and the oscilloscope input UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 7 3 CHAPTER 7 CALIBRATION 1 Section Calibration Procedure Verify that the equipment is connected as shown in Calibration Setup Turn the Control ON MAIN MENU 0 WAVEFORM CHECK 5 COMMUNICATION 3 Pressthe MENU key to bring up the 1 SETUP 6 RELAY MAIN MENU screen 2 WELD COUNTER 7 CALIBRATION 3 SCHEDULE 8 RESET DEFAULTS 4 Pressthe 7 key to select 4 SYSTEM SECURITY 9 CHAIN SCHEDULES CALIBRATION NUMBER Select an item 5 From the first calibration screen press CAUTION the keypad down W down key to the CALIBRATION SHOULD BE PERFORMED BY A QUALIFIED TECHNICIAN ONLY PRE CALIBRATION screen REFER TO MANUAL FOR CALIBRATION SETUP W Next MENU menu 6 From PRE CALIBRATION PRE CALIBRATION screen press the 3 key to RESET 1 TEST UB25 T 232 REQUIRED CALIBRATION before performin 5 3 RESET CALIBRATION the following pr
69. TIMING DIAGRAMS END OF WELD ON gt M 7 4 350 450 5 lt lt ano Relay Active 0 150ms Relay Active For 350 4505 After End Of HOLD Period When welding the relay output signal will start 0 150 milliseconds after the end of the HOLD period and will stay energized for 350 450 milliseconds The relay will still close in case of an aborted weld Tf another weld is initiated within this time the END OF WELD relay will be reset at the start of the next weld ALARM OFF Relay Active When Relay Remains Active ALARM Detected Until ALARM State Is Cleared The relay output signal will start when the Control senses certain ALARM conditions with the exception of OUT OF LIMITS alarms and will stay energized until the ALARM state is cleared by pressing the RUN button refer to Appendix E LCD Display Messages UB25 LINEAR DC RESISTANCE WELDING CONTROL F 2 990 665 APPENDIX RELAY TIMING DIAGRAMS OUT OF LIMITS P1 HIGH LIMIT e P1LOW LIMIT P2 HIGH LIMIT e P2LOW LIMIT TIME Relay Active When Relay Remains Active OUT OF LIMITS Until OUT OF LIMITS Alarm Detected Alarm State 15 Cleared 0 150ms After End of HOLD When RUN Is Pressed Or At the Start of the Next Weld The relay will switch when the Control senses any OUT OF LIMITS condition It will start 0 150 milliseconds after the end of HOLD and will s
70. TIONS Welding Applications Weld Pulse Profile Typical Application Can be used for many of spot welding applications Use on flat parts without plating or on conductive parts such as those made of copper or brass Single Pulse Upslope Downslope Sf NL Upslope Downslope should be used for the majority of spot welding applications Weld round parts parts that are not flat spring steel parts or heavily plated or oxidized parts Dual Pulse Use for spot welding parts with plating First pulse be used to displace plating or oxides and the second pulse to achieve the weld For a detailed coverage of resistance welding theory please refer to Appendix C The Basics of Resistance Welding Weld Head Applicability The Control is best used with Unitek Peco force fired manual weld heads or air actuated weld heads For manually actuated weld heads the weld sequence begins when the force firing switch closes For force fired air actuated weld heads the weld sequence begins when both levels of a two level foot switch are closed and the force firing switch in the air actuated weld head closes When the Control 15 used with any air actuated weld head the squeeze period must be long enough to allow sufficient time for the electrodes to close and apply the required weld force to the parts before the weld current begins Weld current begins when the squeeze period ends In addition the hold period can be used to automatically kee
71. TTENZIONE Questo simbolo indica un operazione che richiede un tecnico qualificato ed il manuale dell utente i CUIDADO Este s mbolo indica uma opera o que requer um t cnico qualificado e o Manual do Usu jPRECAUCI Este s mbolo designa una operaci n que requiere un t cnico competente y el Manual del usuario 1 Install power supply system Installeer het voedingssysteem Installera kraftaggregatsystemet Asenna voimanl hdej rjestelm Installer le syst me d alimentation lectrique Das Elektroenergieversorgungssystem installieren Installazione del sistema d alimentazione elettrico Instale o sistema de fonte de aliment o Instale el sistema de fuente de alimentaci n 2 Refer all program or setting changes to a qualified technician Alle programma of instellingswijzigingen moeten door een gekwalificeerd technicus nvisa alla program och inst llnings ndringar till en kvalificerad tekniker Anna kaikki ohjelman tai asetusten muutokset asiantuntevan teknikon suoritettaviksi Confier toutes les modifications de programme ou der glages un technicien qualifi S mtliche Programm oder Einstellungs nderungen m ssen einem qualifizierten Techniker berlassen werden Rivolgersi ad un tecnico qualificato per tutti 1 cambiamenti di programma di impostazione Consuite um t cnico qualificado quanto a qualquer altera o de programa ou ajuste Comfiele a un t cnico competente todos los cambios de programas o ajustes 3 Use eye protectio
72. This prevents weld splash and material expulsion which occurs as a result of an excessively fast heating rate Part conditioning can help to reduce variations in contact resistance from part to part caused by different fit up of parts It will stabilize the contact resistances before the main welding pulse therefore reducing variation from weld to weld UB25 LINEAR DC RESISTANCE WELDING CONTROL 3 8 990 665 CHAPTER 3 USING 0825 WELDING FUNCTIONS How It Works Both constant current feedback and constant voltage feedback modes are limited in their ability to deal with varying levels of part contamination and oxide If constant current feedback were used the power supply would ramp the voltage to very high levels in order to achieve current flow through the oxide This rapid input of current is likely to cause splash especially with round parts Constant voltage mode is not ideal for this purpose either as the voltage will be restricted from reaching sufficient levels to break down the oxide Constant power is ideal for this purpose As the power supply tries to achieve constant power to the weld it raises the voltage to high levels early in the output waveform since current cannot flow due to the oxide As the high voltage breaks down the oxide layer more current flows to the weld and the voltage and resistance drop It will achieve this in a controlled fashion to maintain constant power to the weld Power Voltage Current Waveform Waveform
73. USER S MANUAL QNUNITEK PECO No 990 665 Revision C WORLD LEADER IN RESISTANCE WELDING January 2002 MODEL UB25 LINEAR DC RESISTANCE WELDING CONTROL MODEL NUMBER STOCK NUMBER UB25 1 284 01 UB25 230 1 284 01 01 DOWN UP DOWM MOLD i suu mu Copyright 2002 Unitek Miyachi Corporation The engineering designs drawings and data contained herein are the proprietary work of UNITEK MIY ACHI 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 ro oss 18653 501 Original Release B 18860 5 01 Technical changes 19146 2 02 Technical changes MODEL UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 FOREWORD Thank you for purchasing a Unitek Peco UB25 Linear DC Welding Control Upon receipt of your equipment please thoroughly inspect it for shipping damage prior to its installation Should there be any damage please immediately contact the shipping company to file a claim and notify us at Unitek Miyachi 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 maintenance and service personnel with the information needed to properly and safely operate main
74. Waveform Constant Power Waveform With Corresponding Voltage And Current Waveforms Active Part Conditioning uses a duakpulse output The first pulse is programmed for constant power and the second for either constant current constant voltage or constant power Constant voltage is used if there is still a chance of weld splash The purpose of a dual pulse operation is to enable the first pulse to target displacement of oxides and good fit up the second pulse achieves the weld Active Part Conditioning Waveform The use of a current limit monitor for the first pulse enables the pulse to be terminated when a predetermined amount of current flow 15 achieved The rise of the current waveform is proof positive that the oxide 15 breaking down and the parts are fitting up together ready to weld The first pulse therefore should be programmed to be much longer than generally required The power supply will terminate the pulse based on the reading of current in the power supply s monitor UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 3 9 CHAPTER 3 USING 0825 WELDING FUNCTIONS Instructions Instructions for programming for Active Part Conditioning are listed Chapter 4 Operating Instructions Energy Limits Applications Part to part positioning problems e Electrode to part positioning problems e Parts with narrow weld window Energy Limits can be used in two different ways e detect work piece resistance c
75. ablish the impact of a parameter on the process A Screening DOE is a tool that allows the user to establish the impact of a particular parameter by carrying out the minimum number of experiments to gain the information A five factor screening DOE can be accomplished in as few as 24 welds with three welds completed for each of 8 tests By comparison it would take 96 welds to test every combination It promotes understanding of many variables in a single experiment and allows the user to interpret results and thus narrow the variables for the next level of statistical analysis If many variables are still not understood multiple Screening DOE S may be required Unitek Peco provides a simple Screening DOE tool that is run in excel and 1s sufficient for the majority of applications contact us for details Bespoke sophisticated software is also available from other vendors designed specifically for this purpose Criteria for Success Before running the series of experiments the user must establish an acceptable window for energy time and force This will prevent voided results It is common practice to include one or all of the above variables in a Screening DOE This is only recommended if sufficient understanding has been established for the other application and process variables that can impact quality Users should first try to screen out all common application and process variables that require further exploration from the results of the look
76. alibration to be accurate Continue to follow the instructions on the LCD screens When calibration is complete keep pressing the MENU button on the front of the Control until the MAIN MENU is displayed on the LCD Disconnect the Control from the Calibration Setup then re connect the Control as required for your welding system Press the RUN button to return to normal operation UB25 LINEAR DC RESISTANCE WELDING CONTROL 7 5 APPENDIX A TECHNICAL SPECIFICATIONS General The UB25 is a linear DC resistance welding power supply that sends energy directly into a weld without the use of a welding transformer It is capable of executing any weld function at low current voltage or power levels with high stability and good control Note The specifications listed in this Appendix may be changed without notice DESCRIPTION VALUE NOTES Input Line Voltage 1 phase Standard nominal voltages Model UB25 115 115 Vac 15A Model UB25 230 230 Vac 10 A Line Voltage Tolerance referred 115 15 10 functions perform normally to nominal 230 15 10 functions perform normally Input max demand UB25 1 5 be used for sizing input power UB25 230 1 5 KVA Output Capability max available Based on load See Appendix G Repetition Rates to load Output Current Steps 0 005 1 000 steps Actual achievable output based on load Programmable See Appendix G Repetition Rates Output
77. als and force the parts into intimate contact The cool period allows time to dissipate the heat generated during Pulse 1 The Pulse 2 weld period completes the structural weld The Pulse 2 weld current is typically greater than the Pulse 2 weld current by a factor of 3 as the first pulse significantly reduces the resistance of the interface between the parts The only use for the downslope period following the Pulse 1 or Pulse weld period is to control grain refinement in brittle parts by slowly reducing the weld current to zero during the downslope period The dual pulse weld profile is very valuable for pre checking gross parts positioning problems and reducing parts scrap Use the Pulse 1 weld at 0 050 kA or less and 2 0 ms as a pre check pulse Experiment with upper and lower limit values that you can use to inhibit the Pulse 2 weld if the test conditions measured by the Pulse 1 weld are out of limits NOTE Upslope is required when a lower limit value is programmed UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 CHAPTER 3 USING 0825 WELDING FUNCTIONS Section Programmable Feedback Modes Introduction The feedback mode current voltage power is one of the selections entered when programming a weld schedule Programming weld schedules is explained in Chapter 4 Operating Instructions Current Mode Application Flat parts where part to part and electrode to part contact is controlled and consistent Description
78. an affect the energy delivered Refer to the Troubleshooting Chart in Chapter 6 Limits should be set by qualified by personnel and are designed to identify process variations Reduce duty cycle Reduce weld time CAUTION Be careful when using the MENU default features There is no way to undo a reset to defaults action See Chapter 5 for programming instructions Decide whether to adjust the limit delay or schedule settings NOTE The WAVEFORM CHECK function can be turned OFF if desired See Chapter 5 for programming instructions Decide whether to adjust the limit delay or schedule settings NOTE The WAVEFORM CHECK function can be turned OFF if desired Remove any unsafe operating conditions at the welding electrodes Reset the input to the ISTOP See Appendix B for details TYPE OF MESSAGE GENERAL STATUS OUT OF LIMITS OUT OF LIMITS ALARM 990 665 MESSAGE SYSTEM PARAMETERS ARE RESET TEST WELD RUN YES UPSLOPE REQUIRED FOR LOWER LIMIT VOLTAGE 1 GREATER THAN UPPER LIMIT VOLTAGE 1 LOWER THAN LOWER LIMIT VOLTAGE 2 GREATER THAN UPPER LIMIT UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 APPENDIX E LCD DISPLAY MESSAGES LCD Display Messages DESCRIPTION User programmed the Control to automatically reset all I O and other system parameters to their factory set default values The ASK test weld function is programmed in the
79. anging any energy time parameters within weld schedules but does allow different schedules to be selected This function also prevents any changes to menu settings CALIBRATION LOCK prevents unauthorized users from modifying any of the calibration settings NOTE security options use the same procedure to enter a security code and to PASSWORD turn off the security code Press the 1 key to select SCHEDULE LOCK This will bring up the CHANGE STATUS screen CHANGE STATUS NUMBERS for code followed by PERIOD Enter a 7 digit number from 0000001 to 9999999 in the code field then enter a period This will bring up the SYSTEM SECURITY menu screen this time with SCHEDULE LOCK ON With ON selected all other weld schedules are locked out and cannot be modified or used for welding To unlock the Control from security protection retum to the CHANGE STATUS screen and enter the code that you entered in Step 2 This will bring up the SYSTEM SECURITY menu screen this time with SCHEDULE LOCK OFF If you forget the security code and wish to unlock the Control from security protection a Retumto the CHANGE STATUS screen b Entera security code of 414 followed by a period Keep pressing the MENU key to return to the MAIN MENU UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 5 15 CHAPTER 5 SETUP SOFTWARE Calibration NOTE Calibration should only be performed by CAUTION authorized personnel CALIBRATION
80. anumeric 1 5 1 2 Automated Welding 4 11 B c 5 25 Buzzer Loudness Lees eie NI NNUS err 5 4 Buzzer Weld Stop Lei rv 5 5 Basics of Resistance Welding C 1 Electrode Maintenance C 4 Electrode Selection C 2 Resistance Welding Parameters C 1 Typical Weld Strength Profile C 6 Weld Schedule Development 4 Weld Strength Profiles C 5 Weld Strength Testing C 5 Welding Parameter Interaction C 1 7 1 Calibration Points i0 esto reco ines 7 2 Equipment Required 7 1 Equipment Setup mess 7 3 7 1 RN 7 4 Chain Schedules 5 17 Common Problems D 9 Communication and Data 5 24 UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 Index 1 INDEX Control Signals Select 5 12 Controls and Indicators 1 8 Liquid Crystal Display LCD and Weld Selector Keys 1 8 Numeric Keypad and Operational Controls 1 10 A Schedule 5 21 Curent Mode 3
81. asher 1 Install weld cable washers between the screw heads and cable terminals NOT between the cable terminals and Control terminals 2 Dress weld cables together with cable ties to minimize induction loss Air Head Connections Connect the Model FSIL or FS2L Foot Switch cable connector to the Control connector marked FOOT SWITCH 2 Connect weld head air valve solenoid cable connector to the Control connector marked AIR VALVE DRIVER 24V UB25 LINEAR DC RESISTANCE WELDING CONTROL 2 8 990 665 CHAPTER 2 GETTING STARTED NOTE This connector provides 24 Vac power only It will not drive 115 V ac air valves Refer to the weld head manufacturer s manual UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 2 9 CHAPTER 2 GETTING STARTED Relay Data And Communication Connections For the Control programmable relay connections PLC data logging or other connections you will have to fabricate the appropriate connecting cables For the Control connector pin identification and specifications see Appendix B Electrical And Data Connectors UB25 LINEAR DC RESISTANCE WELDING CONTROL 2 10 990 665 Chapter 3 Using 0 25 Welding and Monitoring Functions Section Introduction To ensure accurate consistent welds the Control delivers extremely precise pulses of energy to the weld head Each pulse is comprised of weld time and weld energy voltage current or power values pre programmed by the user The Contr
82. ays can be used in conjunction with visual and audible signals for operators and automation interface Active Part Conditioning compensates for varying part conditions and oxide layers Rear mounted RS 232 and RS 485 connectors allow for remote programming weld schedule selection and data logging for SPC purposes e Calibration traceable to NIST standards Optional DC25 UB25 Advanced Serial Datacom Communications Interface kit commonly called the Datacom kit available for process logging Password protection provides process security UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 1 1 CHAPTER 1 DESCRIPTION Applications The Control is ideal for microjoining applications which require exceptional control and highest quality throughput The Control has a closed loop feedback circuit that allows the user to program constant current constant voltage or constant power welding pulses Chapter 3 Using UB25 Welding And Monitor Functions describes the Control s functions and how to use them for different welding applications The Control requires only single phase input power and can supply weld power up to 1 000 amps The advanced linear control circuit provides instantaneous update of the welding pulse in response to changes in the resistance of the work piece during the weld This level of control is essential to achieve consistent welds in applications where the resistance changes dramatically The graph
83. be changed without notice Voltage Sense Input PIN 1 Analog Ground PIN 2 Input 1 PIN 3 Input 2 VOLTAGE SENSE INPUT CONNECTOR SPECIFICATIONS CU me Dm NAME pu VOLTAGE CURRENT COMMENTS dI t 2 larity 1 ti rtant UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 B 1 APPENDIX ELECTRICAL AND DATA CONNECTORS RS 485 IN and RS 485 OUT NOTE Pin connections and specifications for both RS 485 connectors are identical B 2 PIN 1 SIGNAL GROUND PIN 2 USED PIN NOT USED PIN 4 TRANSMIT PIN 5 TRANSMIT PIN 6 NOT USED PIN 7 NOT USED PIN 8 RS 485 RECEIVER PIN 9 5 485 RECEIVER wwa 0825 LINEAR DC RESISTANCE WELDING CONTROL 990 665 RS 232 990 665 APPENDIX B ELECTRICAL DATA CONNECTORS PIN 1 NOT USED PIN 2 TX TRANSMIT DATA PIN 3 RX RECEIVE DATA PIN 4 NOT USED PIN 5 SIGNAL GROUND PIN 6 NOT USED PIN 7 NOT USED PIN 8 NOT USED PIN 9 NOT USED SSS ignal Ground Analog Ground ISOGND1 O oo PNNO _ pf Noted 6 LN i EN E UB25 LINEAR DC RESISTANCE WELDING CONTROL B 3 APPENDIX B ELECTRICAL AND DATA CONNECTORS Signal Interface PIN 13 INOWELD PIN 25 24V PIN 12 I UNUSED PIN 24 ESON un PIN
84. ce of the parts and the contact resistance between the parts Use resistive electrodes such as RWMA 13 Tungsten and RWMA 14 Molybdenum to weld conductive parts such as copper and gold because conductive parts do not generate much internal heat so the electrodes must provide external heat Use the following Electrode Selection Table for selecting the proper electrode materials ELECT ELECT MATERIAL RWMA MATERIAL RWMA TYPE TYPE Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Alloys Cadmium Plating Tinned Copper Gold Plated Dumet Aluminum Beryllium Copper Beryllium Copper Beryllium Copper Beryllium Copper Kovar Magnesium Cold Rolled Steel Stainless Steel Beryllium Copper det Tinned Copper 1 Aluminum 1 Gold Plated Kovar ELECT ELECT MATERIAL RWMA MATERIAL RWMA TYPE TYPE Beryllium 2 Nickel Copper Beryllium 2 Cold Rolled Copper Steel Beryllium Stainless Steel Copper Brass 2 14 Tinned Copper APPENDIX C THE BASICS RESISTANCE WELDING MATERIAL RWMA MATERIAL RWMA MATERIAL RWMA MATERIAL RWMA TYPE TYPE TYPE TYPE NEN ofa A 2 0825 LINEAR DC RESISTANCE WELDING CONTROL C 4 990 665 MATERIAL APPENDIX C THE BASICS OF RESISTANCE WELDING
85. ces 5 4 Display Contrast 5 4 Buzzer Loudness 5 4 End Of Cycle Buzzer 5 4 Update Graph After Weld 5 5 Buzzer On Weld Stop 5 5 OVERVIEW Mc P 5 1 PID Test Weld Setup 5 17 Do Test Weld Options 5 17 c 5 18 no 5 18 5 18 Ignore First Last 5 18 OVERVIEW 5 17 Relay Settings EM REM 5 19 FUNCION FOURIER 5 19 Programming Instructions 5 19 Special Functions 5 21 Copy A Schedule 5 21 Reset Defaults 5 21 Reset All Schedules 5 23 UB25 LINEAR DC RESISTANCE WELDING CONTROL Index 6 990 665 INDEX resanse 5 6 U Calibration 5 14 Chain Schedules 5 17 Unitek Peco Contact Information ill Control Signals Select 5 12 U bpacking o UNSER hierba 2 2 Firing Switch 5 9 Update Graph After Weld 5 5 Footswitch Weld Abort 5 8 Upslope Downslope Weld Profile Input Switch Select 5 10 Applications sese 3 4 Mechanical Selection 5 10 Upslope Downslope Weld S
86. chedule 4 5 Selection 5 11 PLC Selection 5 11 V Switch Debounce Time 5 9 System Security 5 13 User Maintenance 6 1 Waveform Check and PRECAUTIONS iic 6 1 Weld Counter Functions 5 12 Operator Maintenance 6 1 Energy Capacity Troubleshooting 6 1 Stability Check Alarm Messages 6 2 Limit Setting 5 6 Electrode Maintenance 6 6 Stability Check Delay Setting 5 7 General Kinds of Problems 6 1 Waveform Check ON OFF 5 6 TRUST 6 2 Weld Fire Lockout NT TN EE 6 1 Charge Setting 5 8 Parts Replacement 6 6 Weld Fire Lockout 5 6 Technical Assistance 6 6 Limit Setting 5 7 Troubleshooting 6 2 Single Pulse Weld Schedule 4 4 Utility Requirements 1 iet ent 2 1 Space Requirements Jue tincid esiti ines 2 1 aeo ise io et 3 7 Special Functions sees 5 21 Voltage Sense Input 2 2022 B 1 Stability Check Limit Setting 5 6 Stability Check Delay Setting
87. contents of the container agree with the kit list The Control is shipped to you completely assembled and ready to use The available accessories for the Control are 2 Level Foot Switch e DC25 UB25 Advanced Serial Datacom Communications Interface Kit e Weld Head appropriate for the welding application Input Output Mating Connectors For use on cables connecting the Control to external equipment Verify that the equipment shows no signs of damage If you see any damage please contact the carrier Also contact Unitek Peco immediately by telephone FAX or the postal or e mail address shown in the Foreword of this manual NOTE Save the packing material Carefully place the packing materials back in the packing boxes and store for future shipping UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 2 3 CHAPTER 2 GETTING STARTED Section Electrical and Data Connections connections between the Control switches the weld head and external equipment such as PLC and data are made on the rear panel VOLTAGE SENSE INPUT 6 ES 7 INPUT OUTPUT CONNECTORS POSITIVE COMMUNICATION WELD RELAYS DATA ETC TERMINAL NEGATIVE N WELD TERMINAL PLUG WITH SHORTING WIRES 24VAC AIR VALVE DRIVER FUSE ON OFF SWITCH FIRING AC INPUT POWER CONNECTION SWITCH INPUT FOOT SWITCH INPUT UB25 Rear Panel Connections NOTE The Control is shipped with two 25 pin mating plugs instal
88. ctions you must install the software from the optional DC25 UB25 Advanced Serial Datacom Communications Interface Kit commonly referred to as the Datacom kit in a host computer The Datacom Operator Manual describes cables connections RS 232 operation RS 485 operation sample weld reports data collection and how to use remote commands The manual also lists all of the commands that the Control will respond to and instructions on how to format commands sent to the Control so it will respond properly Communication 1 From the MAIN MENU press the 5 COMMUNICATION key to go to the COMMUNICATION 1 COMMUNICATION ROLE SLAVE menu shown with default settings 2 1 0 NUMBER 3 BAUD RATE 2 From COMMUNICATION menu toggle the 1 key to select MASTER or SLAVE The COMMUNICATION ROLE line will now reflect your role selection e Inthe MASTER role the Control will Send weld data to the host computer after each weld operation NUMBER Select MENU Previous menu Send text data to a serial printer providing a printout of the average voltage and current values for each weld generating a paper history of welds performed Inthe role the Control will send weld data only when requested by the host computer NOTE For weld data collection and host computer control information refer to the Datacom Operator Manual which describes how to use the MASTER and SLAVE options 3 Press MENU to return to the M
89. d To select the value use eitherthe X lt gt up down keys or use the numeric keypad to enter the numbers The squeeze time will start after a firing signal is given to the Control NOTE In addition to the debounce time there is a delay of no greater than 2 5ms before the start signal is recognized by the Control A group of 3 individual keys used to program the time and energy for Pulse 1 Each key is described below up WELD DOWN PULSE 1 Press to enter amount of time Weld Pulse 1 upslope To select the value use either the X lt gt up down keys or use the numeric keypad to enter the numbers This switch toggles between the middle and bottom data lines on the LCD To enter weld energy values energy level and feedback mode press the switch to highlight the middle line To enter weld time values in milliseconds press the WELD switch again to highlight the bottom line To select energy and time values use either the up down keys or use the numeric keypad to enter the numbers and decimal point To select feedback mode press the kA V or KW key Press to enter the amount of time for Weld Pulse 1 downslope To select the value use either the lt gt up down keys or use the numeric keypad to enter the numbers and decimal point Press to enter the amount of time for the cool period To select the value use either the lt gt up down keys or use the numeric keypad to enter the numb
90. d Head Connections 2 4 Manual Welding erret 4 11 Mechanical Characteristics A 3 Mechanical Switch Selection 5 10 Menu Screens 1 5 Normal Stop 4 11 Numeric Keypad and Operational Controls 1 10 Nuggets Unitek Peco Website Operating Instructions 2 0 4 1 4 1 Compressed 4 2 CONNECHONS 4 2 Initial Setup Instructions 4 2 POW ED otia EUR 4 2 UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 Index 3 INDEX Pre Operational Checks 4 2 O Continued Operation 5 Eq ud 4 11 Automated Welding 4 11 Emergency Stop 4 12 Normal Stop scita tis ais 4 12 Operation 4 11 Re Set after Emergency Stop 4 12 General Operator Safety 4 11 Manual Welding e 4 11 Normal Stop 4 11 Operation 4 11 Programming for Active Part Conditioning sees 4 9 Programming Weld Schedules 4 3 Pulse Weld Schedule 4 6 Enter New Values 4 3 Select Weld Schedule 4 3 Single Pulse Weld Schedule 4 4 Upslope Downslope Weld Schedule 4 5 Pro
91. d trace is displayed on the For PULSE 1 For PULSE 2 LCD NOTE All lower limits apply only to the Pulse 1 and Pulse 2 WELD periods Lower limits do not cover any upslope or downslope periods All upper limits apply to the entire Pulse 1 and Pulse 2 periods including their upslope and downslope periods UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 4 9 CHAPTER 4 OPERATING INSTRUCTIONS Section V Programming For Active Part Conditioning Before you program for Active Part Conditioning make sure you are familiar with these procedures described in this manual Chapter 3 Using UB25 Welding And Monitoring Functions e Chapter 4 Section III Programming Weld Schedules e Chapter 4 Section IV Programming The Weld Monitor 1 Press SCHEDULE button then select a Weld Schedule using eitherthe AW arrows or the numeric keypad 2 Program a single pulse for Constant Power operation Program the power level and weld time to cause slight sticking between the two parts Make a few welds and pull them apart Increase or decrease the power setting until a light tack weld 15 achieved 4 Push the ENERGY button to monitor the waveforms for voltage resistance current and power 5 Push the voltage V key and observe high peak of voltage waveform 5 LO Push the Q MONITOR resistance key and observe the resistance waveform This should appear to begin high then start to drop as a tack weld is made and oxides are removed
92. dix E LCD Display Messages E 1 essences eee nace 1 R lay 1 Clearing Alarm Conditions to Resume Operation E 1 rc dU cu E E 1 Appendix Relay Timing Diagrams F 1 LO t _______ 1 1 cT 2 Oah 2 3 Appendix Repetition Rates G 1 MODEL UB25 LINEAR DC RESISTANCE WELDING CONTROL Xii 990 665 Iritrod ction Maximum Weld Pulse Duration As A Function Of Weld Current Operator Guide Unitek Peco Power Supplies CAUTION This symbol designates an operation which requires qualified technician and User s Manual OPGELET Dit symbool duidt een bediening aan waarvoor een gekwalificeerde technicus en de gebruikershandleiding vereist zijn VARNING Denna symbol indikerar ett arbetsmoment som b r utf ras av en kvalificerad tekniker med hj lp av Anv ndarhandledningen VAARA T m merkki osoittaa toimenpiteen jossa tarvitaan asiantuntevaa teknikkoa ytt sikirjaa ATTENTION Ce symbole d isigne une op ration exigeant un technicien qualifi et le Manuel d utilisation Dieses Symbol kennzeichnet einen Arbeitsgang f r den ein qualifizierter Techniker und ein Benutzerhandbuch erforderlich sind A
93. e 2 Use the numeric keypad to enter the time or use the AW arrows Enter a time between 0 and 99 coo milliseconds We recommend at least 2 milliseconds Program Pulse 2 by repeating Steps 3 through 7 above using the keys for Pulse 2 entering appropriate values for Pulse 2 Press the HOLD key to enter the amount of time for the hold period after the weld Use the numeric keypad to enter the time or use the AW arrows Enter a time between 0 and 999 milliseconds We recommend at least 50 milliseconds UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 4 7 CHAPTER 4 OPERATING INSTRUCTIONS 4 8 Section IV Programming the Weld Monitor Press the SCHEDULE button then select a Weld Schedule using eitherthe X arrows or the numeric keypad Fire the welder and view the output waveform shaded graph on the display Press the ENERGY key to access the MONITOR screen Perform a weld and view the trace of the weld parameter use the E3 E key to view the desired waveform Toggle the Pulse 1 weld time energy selector key to select the upper limit field for the weld period Use the numeric keypad or the X arrows to enter the upper limit value for the Pulse wae 1 weld period The Control can monitor Current from 0 1 2 kiloamps e Voltage from 0 6 5 volts Powerfiom 0 8 0 kilowatts Perform one of the following to program the Pulse 1 monitor limit mode kA Press the kA key to program curren
94. e of the Control in the Top Line of data left side Menu Screens do not display the operational state but the menu itself indicates the Control is in the MENU state The following table describes each of the Control s operational states UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 1 5 CHAPTER 1 DESCRIPTION UB25 Operational States STATE DESCRIPTION NO WELD PROGRAM TEST STANDBY WELD HOLD MONITOR This state indicates the Control is ready to weld and waiting for a start signal Press the RUN key on the front of the Control to put the Control in this state In this state the Control does not deliver weld energy to the weld head heads in order to prevent electrical shock This state is used for cleaning electrodes or adjusting the air regulators on air actuated weld If a start signal is received the Control will execute its programmed weld schedule s but no energy will go to the weld head and the LCD will display WELD SWITCH IN NO WELD POSITION alarm The WELD NO WELD switch toggles the Control between the WELD and NO WELD states In this state the weld time and energy values can be modified and new schedules can be selected From the RUN state press any one of the WELD SELECTOR KEYS to put the Control in the PROGRAM state When a weld schedule is changed the Control has the capability of performing a TEST weld in order to optimize the feedback control loop and produce the fastest rise time minimum
95. e pre wired with two jumpers for the 24V Power signals and a shorted two wire lead for the Emergency Stop Switch connection For connector pin identification and specifications including the 24V Power signals see Appendix B Electrical and Data Connectors NOTE The Control will not function if these plugs are not installed The plug connected to I O Connector A is pre wired with a two wire lead for the Emergency Stop Switch The lead wires are shorted together normally closed and secured with a wire nut PLUG 7T WIRES WIRE NUT gt Emergency Stop Switch Shorting Wires NOTE For clarity the tag attached to the shorting wires containing instructions in several languages is not shown here The tag with the complete text is shown in Appendix B Electrical and Data Connectors You may operate the Control with or without an Operator Emergency Stop Switch For operation without an Emergency Stop Switch leave the two wires of the emergency stop lead shorted together closing the circuit To operate with an Emergency Stop Switch connect a normally closed emergency stop switch across the two wires of the emergency stop lead This switch when actuated opening the circuit will immediately stop the weld cycle and retract the weld head This emergency stop does not require the intervention of the microprocessor To restart the Control after an emergency stop press the RUN key on the front panel Verify that the desired
96. ed during the weld However as the force is increased the contact resistance decreases Lower contact resistance requires additional weld current voltage or power to produce the heat required to form a weld The higher the weld force the greater the weld current voltage power or time required to produce a given weld The formula for amount of heat generated is the square of the weld current I times the workpiece resistance R times the weld time T Welding Parameter Interaction TIME PROBLEM CAUSE PROBLEM CAUSE Parts Overheating Excessive Parts Overheating Excessive Weak Weld Weak Weld Insufficient Nugget Insufficient Nugget Metal Expulsion Metal Expulsion Warping Warping Discoloration Discoloration Electrode Damage Insufficient Electrode Damage Insufficient FORCE PROBLEM CAUSE Parts Overheating Excessive Weak Weld Insufficient Nugget Metal Expulsion Warping Discoloration Electrode Damage Insufficient UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 C 1 APPENDIX THE BASICS RESISTANCE WELDING Interaction of Welding Parameters UB25 LINEAR DC RESISTANCE WELDING CONTROL C 2 990 665 Electrode Selection Correct electrode selection strongly influences how weld heat is generated in the weld area In general use conductive electrodes such as a RWMA 2 Copper alloy when welding electrically resistive parts such as nickel or steel so that the weld heat is generated by the electrical resistan
97. en but they all tell you what action to take how to go to the next menu screen if applicable and how to return to the MAIN MENU Some prompts display NUMBER which means that you should use the numeric keypad to enter the number of a desired function listed on the menu Some prompts display AY which means that you should use the UP or DOWN keys on the front panel to take the next action Other prompts may highlight a specific key which means you should press the key indicated to take the next action When using menu screens you can return to the RUN screen at any time simply by pushing the RUN button on the front panel Setup Menus SETUP menus are accessed in sequence MAIN MENU gt SETUP 1 gt SETUP 2 gt SETUP 3 1 MAIN MENU press 1 to go SETUP 1 to SETUP 1 menu 1 FOOTSWITCH WELD ABORT OFF 2 SWITCH DEBOUNCE TIME 10ms 2 Togotothe SETUP 2 menu press the 3 FIRING SWITCH AUTO v down key 4 INPUT SWITCH SELECT MECH OPEN 5 CONTROL SIGNALS SELECT MECH OPEN NUMBER Select MENU Main menu v Page 2 UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 5 3 CHAPTER 5 SETUP SOFTWARE NOTE The SETUP 2 menu is only SETUP 2 available through the SETUP 1 or SETUP 1 DISPLAY CONTRAST 080 3 menus 2 BUZZER LOUDNESS 030 3 END CYCLE BUZZER OFF 4 UPDATE GRAPH AFTER WELD ON 3 Togotothe SETUP menu press the down key Salact Main
98. epetition rate which can deplete the capacitor bank charge These features are totally independent of Weld Monitor features described in Chapter 3 of this manual Waveform Check ON OFF 1 From the MAIN MENU press 0 to get to the WAVEFORM CHECK menu 2 Pressthe 1 key to toggle WAVEFORM CHECK ON or OFF Stability Check Limit Setting 1 WAVEFORM CHECK menu press the 2 key to access the STABILITY CHECK LIMIT screen 2 Use the numeric keypad to enter the limit This limit is the allowable average deviation from the set point for the weld pulse after the delay period 3 Press MENU to return to the WAVEFORM CHECK menu The STABILITY CHECK LIMIT will display your programmed setting along with deviation readings from the Pulse 1 and Pulse 2 ofthe most recent weld WAVEFORM CHECK 1 WAVEFORM CHECK 2 STABILITY CHECK LIMIT 07 l 3 STABILITY CHECK DLY ms 1 0 msec 4 ENERGY CAPACITY 05 0 5 WELD FIRE LOCKOUT CHRG 95 0 NUMBER Select MENU Main menu STABILITY CHECK LIMIT STABILITY CHECK LIMIT 07 NUMBER Change MENU Previous menu UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 5 7 CHAPTER 5 SETUP SOFTWARE Stability Check Delay Setting 1 From the CHECK menu press the 3 key to access the STABILITY CHECK DLY ms Screen Use the numeric keypad to enter the delay period in milliseconds This period at the
99. ers and decimal point A group of three individual keys that program Pulse 2 These keys have the exact same function as the Pulse 1 Keys WELD DOWN LL PULSE 2 UB25 LINEAR DC RESISTANCE WELDING CONTROL 1 10 990 665 CHAPTER 1 DESCRIPTION FUNCTION Press to enter the amount of time for the hold period after the weld To select the value use eitherthe X lt gt up down keys or use the numeric keypad to enter the numbers UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 1 11 CHAPTER 1 DESCRIPTION Numeric Keypad and Operational Controls a BEB y apaan Numeric Keypad and Operational Controls FUNCTION MONITOR LIMITS Monitor Limits a group of two keys that allows you to view monitor data and set limits of welding parameters If the weld exceeds pre set limits the Control can be programmed to initiate alarms and or interrupt welds AVERAGE MONITOR LIMITS ENERGY p PEAK AVERAGE Displays the energy limits monitor allowing you to view the graphic waveform trace of the selected parameter Welding in the MONITOR state allows you to watch and verify welds as they are being made Welding can be automatically interrupted when the programmed limit value of current voltage or power has been reached Using the RELAY MENU screens you can also program relays to provide an output alarm signal when limits are exceeded e Switches dis
100. ewed on the LCD display When PROGRAM is displayed this key is used to set current as the feedback mode for Pulse 1 or Pulse 2 First use the WELD key to highlight the energy field then enter the desired output level with the numeric keypad then press the key to change the feedback mode to current When MONITOR or RUN is displayed in the MONITOR state this key is used to set current as the limit parameter for Pulse 1 or Pulse 2 First use the WELD key to highlight the energy field then enter the desired limit level with the numeric keypad and then press the kA key to change the limit UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 1 13 CHAPTER 1 DESCRIPTION ________________________ _ FUNCTION Continued When MONITOR or RUN 15 displayed in the MONITOR state press the kA key to view the current graph on the LCD display When PROGRAM displayed this key 15 used to set voltage as the feedback mode for Pulse 1 or Pulse 2 First use the WELD key to highlight the energy field then enter the desired output level with the numeric keypad and then press the V key to change the feedback mode to voltage When MONITOR or RUN is displayed in the MONITOR state this key is used to set voltage as the limit parameter for Pulse 1 or Pulse 2 First use the WELD key to highlight the energy field then enter the desired limit level with the numeric keypad and then press the V key to change the limit parameter to voltage When M
101. formation see Chapter 1 of this manual e How to select and use the Control functions for your specific welding applications For more information see Chapter 3 Using UB25 Welding And Monitoring Functions principles of resistance welding and the use of programmed weld schedules For more information see Appendix C The Basics of Resistance Welding For additional information on the welding process see Appendix D Quality Resistance Welding Solutions Defining the Optimum Process UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 44 CHAPTER 4 OPERATING INSTRUCTIONS Section Il Initial Setup Pre Operational Checks Always perform these checks before attempting to operate the Control Connections Verify that the Control has been connected to a manual or air actuated weld head as described in Chapter 2 ofthis manual Verify that the Emergency Stop Switch shorting wires are connected or verify that an Emergency Stop Switch is connected properly Power Verify that power is connected as described in Chapter 2 of this manual Compressed Air If you are using an air actuated weld head verify that compressed air is connected as described in the appropriate sections of your weld head manual Turn the compressed air ON and adjust it according to the instructions in your weld head manual Initial Setup Instructions 1 Adjust the weld head force adjustment knob for a force appropriate for your welding application good
102. gned to identify process variations Reduce the repetition rate See Chapter 5 for programming information See Appendix G for Repetition Rate and Control capability details Normal operation if this function is used See Chapter 4 Operating Instructions for information on WELD STOP Set the WELD NO WELD switch to the Weld position Re program the welding parameters to be within the capability ofthe Control TYPE OF MESSAGE OUT OF LIMITS ALARM OUT OF LIMITS OUT OF LIMITS GENERAL STATUS UB25 LINEAR DC RESISTANCE WELDING CONTROL E 8 990 665 APPENDIX RELAY TIMING DIAGRAMS Introduction Instructions for relay setup are in Chapter 5 Section VI Relay Settings Instructions cover the ON OFF state the SET RELAY TO and the WHEN states WELD END OF WELD ALARM OUT OF LIMITS P1HIGH LIMIT P1LOWLIMIT P2 HIGH LIMIT P2LOWLIMIT The following diagrams show the timing sequence for each relay WHEN state WELD TIME gt ON 0 150 5 gt OFF gt End Of Relay Active Within HOLD Period Weld Cycle Time 5 Milliseconds After Plus 0 150ms Start of SQUEEZE When welding the relay output signal will start within 5 milliseconds after the start of SQUEEZE and will stay energized for 0 150 milliseconds after the end of the HOLD period UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 F 1 APPENDIX RELAY
103. gramming the Weld Monitor 4 7 Operational States 1 5 Operator Maintenance 6 1 Operator Preferences 5 4 Switch Selection ient mtd 5 11 Out Of Limit Alarm Relay F 3 P Parts Replacement 6 6 PID Test Weld 5 17 PLC Switch Selection 5 11 Power Mod aenea n Prec hons 6 1 Precautions CE 8 Pre Operational Checks 4 2 Pre Weld Check 3 11 Programmable Feedback Modes 3 7 MOJE MT m 3 7 Applications eene 3 7 UB25 LINEAR DC RESISTANCE WELDING CONTROL Index 4 990 665 1 ne Muerto 3 7 Power M OUS ritas eiae ena 3 7 Applications 3 7 Description aos dn Gi 3 7 Vollasc Mode 3 7 Applications 3 7 Description 3 7 Programming Active Part Conditioning reines 4 9 Programming Instructions 5 19 Programming Weld Monitor 4 7 Programming Weld Schedules 4 3 Q Quality Resistance Welding Solutions Defining the Optimum Process D 1 R RS 232 CONSOLE B 3 RS 485 Connectors In and Out B 2 Relay Settings 5 19 Relay Timing Diagrams F 1 ic
104. hanges that occur when parts are positioned incorrectly at the weld head In this case the energy limits will prevent blowouts parts damage and electrode damage Limits can be set to terminate the weld if this occurs e stop weld when a sufficient current voltage or power level is reached Using limits in this way ensures a more consistent input of energy which produces consistently good welds Description This function terminates the weld energy during the welding process if pre set weld current voltage or power limits are exceeded In addition to inhibiting the weld the Control has four programmable relay outputs which can be used to trigger alarms to signal operators of weld faults or signal automation equipment to perform pre programmed actions such as stopping the production line so the faulty weld piece can be removed The monitor measures the weld energy parameters during the weld period and compares the measurements against the programmed limits If any of the programmed limits are exceeded the energy limits monitor sets the Control to a state selected from the OUT OF LIMITS ACTION menu In addition the Control s relays can be programmed to trigger alarms or trigger an action in an automated welding system Note When using the energy limits monitor always select a monitor mode that is different from the feedback mode For example e Ifyou are welding in constant current monitor voltage e Ifyou are welding in c
105. he Control NOTE The factory default debounce time is 10 milliseconds ms 1 the SETUP 1 screen SWITCH DEBOUNCE TIME 2 Pressthe 2 key to access the SWITCH DE BOUNCE TIME menu NIIMBRED Galact Dravinue manu 3 Select the required debounce time by pressing the 1 2 3 or 4 key The LCD will automatically return to the SETUP 1 screen and the SWITCH DEBOUNCE TIME line will now reflect your time selection NOTE NONE represents a debounce time of 0 msec Use NONE for interfacing with the Unitek Peco Model 350C Electronic Weld Force Control 4 Press MENU to retum to the MAIN MENU Firing Switch 1 Goto the SETUP 1 screen FIRING SWITCH 2 Pressthe 3 key to get FIRING SWITCH menu Press 1 2 key to select switch type The LCD will automatically return to NUMBER Select MENU Previous menu the SETUP 1 menu with your selection highlighted NOTE e AUTO accepts a single pole double pole or optical firing switch input typically from Unitek Peco weld head Firing switch activation indicates that the weld head has reached the set weld force and is ready for the weld energy sequence including squeeze time to start UB25 LINEAR DC RESISTANCE WELDING CONTROL 5 10 990 665 CHAPTER 5 SETUP SOFTWARE NONE is used when welding with a non force fired weld head With NONE selected footswitch closure activates the 24 Vac Air Valve Driver and initiates the weld energy sequence incl
106. ical display and intuitive weld monitor make understanding the weld and the weld optimization process easy Data output provides the necessary process documentation for critical applications and permits data logging for SPC purposes UB25 LINEAR DC RESISTANCE WELDING CONTROL 1 2 990 665 CHAPTER 1 DESCRIPTION Section Description GNUNITEK MODEL UB25 LINEAR OC RESISTANCE WELDING CONTROL UB25 Front Panel The front panel contains all the controls and indicators necessary to operate the Control You can program the Control using the data input keys and information appearing in the Liquid Crystal Display LCD Descriptions for each button and display are in Section IV of this chapter Controls and Indicators All electrical connectors data connectors and the ON OFF switch are located the rear panel of the Control Connection instructions are described in Chapter 2 Getting Started Complete technical specifications for the Control are listed in Appendix A Technical Specifications Connector pin identification and specifications are listed in Appendix B Electrical And Data Connectors UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 1 3 CHAPTER 1 DESCRIPTION Section Overview Introduction The front panel of the Control contains the Liquid Crystal Display LCD and pushbutton keys Weld Selector Keys Numeric Keypad and Operational Controls Each is described in Section IV Controls And I
107. ill not fill in Metal Expulsion Insufficient current energy set at the Control Wrong electrode material tip shape Worn mushroomed electrodes Insufficient weld time set at the Control Incorrect weld head polarity Misaligned parts Contaminated weld piece surface plating Excessive weld head force Insufficient weld head force Contaminated electrode surface Incompatible weld piece projection design Slow weld head follow up Incompatible weld piece materials No cover gas on weld piece Blown fuse located on internal Bias Power Supply Contact Unitek Peco for support Possible open circuit in the secondary circuit Electrodes did not close properly Possible blown fuse located on internal Capacitor Charging Power Supply Contact Unitek Peco for support Excessive current energy set at the Control Insufficient weld head force Misaligned parts Slow weld head follow up Incompatible weld piece projection design Contaminated weld piece surface plating Incompatible weld piece materials Contaminated electrode surface Wrong electrode tip shape No cover gas on weld piece Excessive weld time set at the Control Misaligned parts UB25 LINEAR DC RESISTANCE WELDING CONTROL 6 4 990 665 CHAPTER 6 USER MAINTENANCE Troubleshooting Chart PROBLEM CAUSE In Order of Probability Weld Piece Discoloration Excessive weld time set at the Control No cover gas on weld piece Excessive current energy set at the Control In
108. ime weld force or electrode area 2 Continue increasing weld current voltage or power until any unfavorable characteristic occurs such as sticking or spitting 3 Repeat steps 1 through 3 for different weld forces then create a plot of part pull strength versus weld current voltage or power for different weld forces as shown in the illustration on the next page Typical Weld Strength Profile 4 Repeat steps 1 through 3 using a different but fixed weld time UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 C 7 APPENDIX C THE BASICS RESISTANCE WELDING Typical Weld Strength Profile The picture on the right illustrates a typical weld strength profile The 14 Ib electrode force curve shows the highest pull strengths but the lowest tolerance to changes in weld current voltage or power The 12 Ib electrode force curve shows a small reduction in pull strength but considerably more tolerance to changes in weld energy Weld heat will vary as a result of material variations and electrode wear The 12 Ib electrode force curve is preferred It shows more tolerance to changes in weld current voltage or power and has nearly the same bond strength as the 14 Ib electrode force curve A comparison of weld schedules for several different applications might show that they could be consolidated into one or two weld schedules This would have obvious manufacturing advantages v 2 m 2 a Electrade Force
109. inum and other materials by reducing the cooling rate Annealing is not typically used for welding small parts RUN SQUEEZE UPSLOPE DOWNSLOPE HOLD RUN STATE TIME TIME TME TIME TIME STATE 0 999 meec 0 99 msec 0 99 msec 0 99 msec 0 999 msec lt MAXIMUM eoru WELD CURRENT A OFF WELD lt UP HEAD POSITION lt DOWN Upslope Downslope Weld Profile Dual Pulse Weld Profile Applications Flat to flat parts e Round to round parts e Round to flat small parts that may or may not be plated Description Adding upslope to the front of both weld periods allows a reduction in electrode force this results in a cleaner appearance by reducing electrode indentation material pickup and electrode deformation wu iem com omm Fosa miee m TIME aes 4 MAXIMUM WELD CURRENT A lt n Yt DOWN WELD LL WELD ER PULSE 1 PULSE 2 WELD HEAD POSITION UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 3 5 CHAPTER 3 USING 0825 WELDING FUNCTIONS 3 6 Upslope will also help to displace plating and or oxides reduce flashing and spitting or reduce thermal shock when welding parts containing glass to metal seals In the normal application of dual pulse the Pulse 1 weld period provides sufficient heat to displace the plating or oxides seat the electrodes against the base met
110. ique manu to the SETUP 1 menu Mechanical Switch Normal Open Initiate the Control by closing the mechanical switches Mechanical Switch Normal Closed Initiate the Control by opening the mechanical switches UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 5 11 CHAPTER 5 SETUP SOFTWARE NOTE You will get an INPUT SWITCH ALARM unless you close the Firing Switch and Foot Switch inputs before selecting the Normal Closed option UB25 LINEAR DC RESISTANCE WELDING CONTROL 5 12 990 665 CHAPTER 5 SETUP SOFTWARE OPTO Selection This selection accepts an opto coupler switch for eliminating switch debounce problems 1 the INPUT SWITCH SELECT INPUT SELECT SWITCH menu press 2 to display the opto switch 2 OPTO COLLECTOR NORMAL CLOSED select menu 2 Pressthe 1 or 2 key to select how the input opto switches will initiate the Control The display automatically returns to the 51 Previous menu SETUP 1 menu SWITCH NORMAL OPEN Tum ON the open collector output transistor of the opto isolator to initiate the Control OPTO SWITCH NORMAL CLOSED Tur the open collector output transistor of the opto isolator OFF to initiate the Control NOTE You will get an INPUT SWITCH ALARM unless you close the Firing Switch and Foot Switch inputs before selecting the Normal Closed option PLC Selection This option is used only if you are using an automated welding system This selection acce
111. itical parameters should be identified from the list of unfixed variables left from the Screening DOE S A mini experiment maybe required establishing reasonable bounds for the combination of parameters to be tested This will prevent void data and wasted time At this stage it is useful to record multiple relevant quality measurement or inspection criteria so that a balanced decision can be reached For example if part marking and pull strength are the relevant criteria a compromise in ideal setting maybe required As with all experiments the test method should be carefully assessed as a potential source of variation and inconsistency Once the optimum parameters have been established in this series of experiments a validation study can be run which looks at the consistency of results over time It is good practice to build in variables such as electrode changes and cleaning as well as equipment set up by different personnel to ensure that the solution is one that can run in a real production environment Welded assemblies should be tested over time an under real use conditions to ensure that all functionality criteria will be met Validation testing is usually required to prove the robustness of the process under production conditions Conclusion The resistance welding process can deliver a reliable and repeatable joining solution for a wide range of metal joining applications Defining the optimum welding process and best production settings is not a
112. lds to actual welds look at peak or average energy values set upper and lower limits for welds and make use of these features e Active Part Conditioner e Energy Limits Pre Weld Check Active Part Conditioner APC Application e Displace surface oxides and contamination e Reduce contact resistances before delivering the main weld energy Description In the production environment it is common to see large variations in e Oxide and contamination e Plating thickness and consistency e Shape and fit up e Contact resistances due to varying part fit up In order for a weld to occur the surface oxides and contamination must be displaced to allow proper current flow through the parts Levels of oxide and contamination vary from part to part over time which can have an adverse effect on the consistency of the welding process If production parts are plated there can also be a plating process variation over time resulting in inconsistent welds These minor material variations are a major cause of process instability and it is best welding practice to seek to minimize their effect Active Part Conditioner is designed to cope with material contamination variation and can be programmed to apply the exact power to the parts required to displace oxide or contaminants In addition the Part Conditioner pulse will terminate at a precise current flow preventing the sudden high flow which occurs when the oxide is displaced
113. led on the two I O connectors on the rear panel the plug for Connector is not shown for clarity The Control will function if these plugs are not installed The plug connected to I O Connector is pre wired with a two wire lead for the Emergency Stop Switch For details see Chapter 1 Section V Emergency Stop Switch And 24V Jumpers UB25 LINEAR DC RESISTANCE WELDING CONTROL 24 990 665 2 NOTE Wiring of cables and connectors going to the Control should only be done by qualified service personnel Connector pin identification and specifications for the rear panel connectors are located in Appendix B Electrical And Data Connectors NOTE For clarity illustrations in the rest of this manual do not show the power cable connected to the Control even though the power cable must be connected in order to operate the Control UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 2 5 CHAPTER 2 GETTING STARTED Section IV Setup Manual Weld Head Connections Force Adjustment Knob Force Indicator 7 Set To 5 p Weld Cables m Voltage Sensing Cable Polarity Not Important CAUTIONS 1 Install weld cable washers between the screw heads and cable terminals NOTbetween the cable terminals and Control terminals Dress weld cables together with cable ties to minimize induction loss Manual Weld Head Connections Connect one end of a weld cable t
114. lk Resistances become higher during the weld as the parts are heated If a weld is initiated when the contact resistances are still high the heat generated is in relation to the level and location of the contact resistances as the materials have not had a chance to fit up correctly It is common for the heat generated at the electrode to part and part to part resistances to cause multiple welding problems when welding resistive materials see below Conductive materials can be welded by using high contact resistance and fast heating as their bulk resistance is not high and cannot be relied upon for heat generation Part marking and surface heating Electrode Weld splash or expulsion 2 High Contact e Electrode sticking Resistance Weak welds Electrode If a weld is initiated when both parts and electrodes are fitted up correctly as show on the right the contact resistance is lower and bulk resistance now controls the heat generation This type of weld is achieved with a slower heating rate and normally longer time is preferred for welding resistive materials which can generate heat through their bulk resistance Electrode Electrode DR Better Part to part and electrode to part fit up The contact resistance present at the weld when the power supply is fired has a great impact on the heat balance of a weld and therefore also the heat affected zone UB25 LINEAR DC RESISTANCE WELDING CONT
115. ll not be jostled or struck while welding The work surface must be level stable free from vibration and capable of supporting the combined weight of the total welding system The Control must be far enough from the weld head to avoid contact with weld splash e Assure that there are no sources of high frequency energy close by Dimensions and weight are Height 12 75 324 Width 9 25in 235 mm Depth 23 5in 597 mm Weight 52 Ibs 24 kg Utilities Power requirements will vary depending on your configuration Model UB25 115 volts AC 15 amps Model UB25 230 230 volts AC 10 amps The power cable for the 230 volt version of the Controller the Model UB25 230 is not supplied with a wall connector due to the variety of connectors used by different countries You will need to install the appropriate connector to the Controller power cable before installation and setup The input power wiring diagram is in Appendix B Electrical And Data Connectors UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 2 1 CHAPTER 2 GETTING STARTED If you will require compressed air and cooling water service for the weld head please refer to the weld head manufacturer s user s manual for service specifications UB25 LINEAR DC RESISTANCE WELDING CONTROL 2 2 990 665 2 Section Unpacking As you unpack the shipping container find the Shipping Kit List Verify that
116. m condition occurs you must do the following Take the Corrective Action shown next to the Alarm message in the list of messages 2 Clear the Alarm condition on the Control in order to resume operation Press the RUN key on the front panel of the Control OR Momentarily close the Process Inhibit input on I O Connector on the rear panel No action is required to resume operation if you see either Out of Limits or General Status messages List of Messages The following pages list LCD display messages in alphabetical order UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 E 1 APPENDIX E LCD DISPLAY MESSAGES LCD Display Messages CORRECTIVE ACTION TYPE OF DESCRIPTION IF REQUIRED MESSAGE ACCESS DENIED Operator tried to change a weld Press MENU select System SCHEDULE LOCK schedule or individual weld Security then enter your access code ON parameters to turn off Schedule Lock GENERAL STATUS NOTE Entering a security code of 414 will always unlock the system ACCESS DENIED Operator tried to change Press MENU select System SYSTEM parameters ofan individual weld Security then enter the correct SECURITY ON schedule I O switch functions or access code to turn off the System or GENERAL calibration parameters Calibration Lock protection features STATUS NOTE Entering a security code of 414 will always unlock the system CALIBRATION User entered calibration values Execute the built in calibration RESET TO
117. meric keypad to enter the energy level or use the AW arrows The wao Control output ranges e Current from 0 005 1 000 kiloamps Voltage from 0 100 4 900 volts Power from 0 050 4 900 kilowatts Perform one of the following kA Press the kA key to program current as the feedback mode Press the V key to program voltage as feedback mode el Press the kW key to program power as the feedback mode Press the PULSE 1 DOWNSLOPE key to enter the amount of time for the Weld Pulse 1 downslope Use the numeric keypad or the AW arrows to enter the time Enter a time 9 between O and 99 milliseconds good starting point is 5 milliseconds Press the COOL key to enter amount of time for the cool period after Pulse 1 Use numeric keypad to enter the time or use the AW arrows Enter 0 5 milliseconds Program Pulse 2 by repeating Steps 3 through 7 above using the keys for Pulse 2 entering the value 0 in each step Press the HOLD key to enter the amount of time for the hold period after the weld Use the numeric keypad or the AW arrows Enter a time between 0 and 999 milliseconds We recommend at least 50 milliseconds as weld strength is formed in the hold time UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 CHAPTER 4 OPERATING INSTRUCTIONS Dual Pulse Weld Schedule 10 Press the SCHEDULE button then select a Weld Schedule using eitherthe AW arrows or the
118. miconductors silicon geranium UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 D 1 APPENDIX D DEFINING THE OPTIMUM PROCESS Metals can be resistance welded because they are electrically conductive soften on heating and can be forged together without breaking UB25 LINEAR DC RESISTANCE WELDING CONTROL D 2 990 665 APPENDIX D DEFINING THE OPTIMUM PROCESS Alloys are a mixture of two or more metals as Alloy shown on the right Alloys are normally harder less conductive and more brittle than the parent metal This has bearing on the type of joint one can expect when resistance welding a combination of different metals Metals atoms are naturally attracted to other metal atoms even in different parent materials Metals and alloys will bond together once surface contaminants such as dirt grease and oxides are removed Resistance welding generates heat at the material interface that decomposes the dirt and grease and helps to break up the oxide film The heat generated softens or melts the metal and the applied force brings the atoms on either side into close contact to form the bond The strength of the joint develops as the joint cools and a new structure is formed There are three main types of bonds that can be formed using the resistance welding process Solder or Braze Joint A filler material such as a solder or braze compound is either added during the process or present as a plating or coating Solde
119. n Oogbescherming dragen Augenschutz verwenden Anv ndskyddsglas gon Usare occhiali di protezione K yt silm suojaimia Use culos de prote Porter une protection oculaire Use protecci n para los ojos Unitek Miyachi Corporation 1820 South Myrtle Avenue Monrovia CA 91017 Tel 626 303 5676 FAX 626 358 8048 A Operator Guide Unitek Peco Power Supplies 4 Examine weld terminals de lasterminals na Inspektera svetsterminalerna Tarkista hitsausterminaalit Examiner les bornes de soudure Schwei verbindungen pr fen Esaminare i terminali di saldatura Examine os terminais de soldagem Examine las terminales soldadas 5 Use WELD NO WELD switch to stop weld current from flowing Gebruik de schakelaar WELD NO WELD om de lasstroom te gt gt gt e um stoppen f E ON rae Anv nd omkopplaren WELD NO WELD f ratt koppla fr n OFF WELD svetsstr mmen WELD Katkaise hitsausvirta WELD NO WELD kytkimest H 7 H NO WELD Utiliser l interrupteur WELD NO WELD pour arr ter le passage NO WELD du courant de soudure Der Schwei stromflu wird mit dem Schalter WELD NO WELD angehalten Usare l interruttore WELD NO WELD per interrompere il flusso della corrente di saldatura Use a chave WELD NO WELD para interromper o fluxo da corrente de soldagem Utilice el interruptor de WELD NO WELD para cortar el flujo de la corriente de soldar 7 EMERGENCY STOP Open electrical circuit to retract weld head
120. n method Visual criteria Electrode material and shape Test method other weld joint requirements Power supply variables Energy Time squeeze weld hold UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 D 9 APPENDIX D DEFINING THE OPTIMUM PROCESS At this stage it is good practice to document the welding set up so that it can be referred to later request Unitek Peco Process Audit Worksheet for an example Once the equipment set up has been documented the next stage is to fix as many ofthe process and material variables as possible to reduce variation in the subsequent welding trials The main welding parameters such as energy force and time cannot be fixed at this stage but many of the other variables such as repeatable part positioning should be fixed Initial Welding Trials The Look See Tests Look see welding tests are a series of mini welding experiments designed to provide a starting point for further statistical development of the welding parameters The user should adjust the key welding variables energy force time in order to identify the likely good weld window The mini experiments should also be used to understand the weld characteristics from both application and process perspective Key factors in this understanding are listed on the next page Application Perspective Materials Resistivity melting point thermal mass Shape hardness Heat balance Electrode materials sha
121. ndicators The LCD and the front panel keys are used together when programming and operating the Control Instructions on how to do this are in Chapter 4 Operating Instructions The LCD displays all of the setup programming and operating information for the Control The front panel keys allow you to enter data for programming custom weld schedules customizing the operating parameters of the Control and operating your welding equipment The keys also allow you to program the precise voltage current power and time of each energy pulse into individual weld schedules which may contain one or two weld pulses Weld schedules consist of e Squeeze time before the weld pulse s after the firing input is given e The time and energy for each weld period Cooling time between Pulse 1 and Pulse 2 if two pulses are used Hold time after the welding pulse s You can program and store up to 99 different weld schedules to meet a variety of welding applications LCD Screens MAIN MENU ORM CHECK 5 ey nw S CRAIN SCHEDULES Data Screen Menu Screen LCD Display Screens The LCD displays two types of screens Data screens and Menu screens NOTE The purpose of this section is to describe the content of LCD screens For clarity LCD screens are shown here without the Weld Selector keys located directly under the display UB25 LINEAR DC RESISTANCE WELDING CONTROL 1 4 990 665 CHAPTER 1 DESCRIPTION Menu
122. nenne atat tna eaae sanae 7 3 Section M Calibration Procedur 7 4 Appendix A Technical Specifications 1 ________ ___ 1 Mechanical Mar acteristics bem 3 Environmental Characteristics RAIS 3 3 3 Appendix B Electrical And Data Connectors B 1 1 Voltage Sense M 1 Ius 485 And RS 485 CUL 2 3 4 VO SICA Interface B B 6 25 Pin Mating Plug With Emergency Stop Shorting Wires For I O Connector A B 8 25 Pin Mating Plug With Internal Jumpers For I O Connector B B 8 Air Valve Driver 24V 1 QOe Y 9 Firing Switch B 9 was sd M _ B 10 AC Input Power nici M N B 11 Weld Terminals EE Ea B 12 Appendix C The Basics Of Resistance Welding C 1 Resistance Parameters C 1 Welding Parameter Interaction T H C 1 El
123. o the negative weld terminal on the Control Connect one end of the second weld cable to the positive weld terminal on the Control Connect the other end of the two weld cables to the weld head Dress the weld cables together with cable ties to minimize induction losses A N Attach the voltage sensing cable connector to VOLTAGE SENSE INPUT connector UB25 LINEAR DC RESISTANCE WELDING CONTROL 2 6 990 665 2 6 Install electrodes weld head electrode holders 7 Attach voltage sensing cables to the screws on the electrode holders as shown SENSING CABLE TERMINAL VOLTAGE SENSING CABLE CABLE TIE SENSING CABLE TERMINAL Voltage Sensing Cable Installation 8 Using a cable tie as a strain relieve attach each voltage sensing lead to its corresponding electrode holder so that the lead terminals will not break away under heavy production operating conditions 9 Connectthe Firing Switch cable connector from the Control to the firing switch cable connector from the weld head UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 2 7 CHAPTER 2 GETTING STARTED Air Actuated Weld Head Connections If you are using an air actuated weld head you will need to make the following two connections in addition to the manual weld head connections Weld Cables To Foot Switch Mm Sensing Cable Polarity Not Important Weld CAUTIONS W
124. ocedures 4 TEST SERIAL PORT 7 Atthe screen prompt press the 2 key for YES to confirm that you want to reset calibration Y NUMBER Select MENU Previous menu 8 From the PRE CALIBRATION screen press the 2 key to start the sequence of onscreen calibration instructions 9 The next screen is CALIBRATION SHUNT which requires you to enter the actual value of the 4 000 micro ohm shunt the value is printed on the exterior of the shunt Enter the value using the numeric keypad then go to the next screen NOTE The prompts at the bottom of the screen that tell you how to go to the next screen may vary from screen to screen To go to the next screen press the key indicated by the prompt 10 Follow the instructions on the calibration screens Each screen will show you the desired energy output value for that calibration step Use the oscilloscope to measure the output then use the keys to adjust the Control output to the correct average value UB25 LINEAR DC RESISTANCE WELDING CONTROL 7 4 990 665 11 12 13 14 990 665 CHAPTER 7 CALIBRATION 25 0 5 5 Sampie 7 2 00 5 7 T 48V 9 Apr 2001 10 52 34 Oscilloscope Display of Average Output NOTE Some screens will tell you to fire the Control 5 times when setting the Monitor others will tell you to keep firing until the desired value is reached You must wait a minimum of 2 seconds between firing pulses for c
125. ol is a closed loop welding control using internal and external sensors to measure the weld energy delivered to the weld head Weld energy feedback instantly goes to the Control s logic circuits that actively correct the pulse to compensate for any variation in part resistance The Control also has several monitor functions that give you remarkable control over the welding and production process Together these features ensure precise consistent welds higher productivity a lower rejection rate and longer electrode life Before operating the Control it is important to know how to match the Control s capabilities to specific weld applications This chapter provides Weld Feedback and Monitor details in the following sections e Weld Schedules Single Pulse Upslope Downslope Dual Pulse e Programmable Feedback Modes e Weld Monitor Active Part Conditioner Energy Limits Pre Weld Check Chapter 4 Operating Instructions contains the step by step instructions on how to program each of the functions above UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 3 1 CHAPTER 3 USING 0825 WELDING FUNCTIONS Section Il Weld Schedules Definition Weld Schedule is the name given to each of 99 separate weld profiles stored in the Control numbered from 01 gt 99 A weld profile is the graphic representation or waveform of the numeric weld time and weld energy values NOTE There is an additional weld schedule numbered
126. on chosen a TEST WELD will be performed any time the schedule s feedback mode is changed to voltage or power If or kW keys are pressed when the energy level field is selected highlighted in PROGRAM state the Control will treat this as if the feedback mode was changed and do a TEST WELD whether the feedback mode was actually changed or not Changes to monitor settings such as energy limits and actions do not cause the Control to perform a TEST WELD UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 5 19 CHAPTER 5 SETUP SOFTWARE The DO TEST WELD options are IF REQUIRED The Control will only do a Test Weld when the feedback mode is changed to voltage or power as described above ASK The Control will do a Test Weld when the feedback mode 15 changed to voltage or power as described above The Control will also prompt the operator if a Test Weld should be done TEST WELD MENU NO RUN YES when time values voltage levels or power levels are changed on the schedule ALWAYS The Control will do a Test Weld when the feedback mode is changed to voltage or power as described above The Control will also do a Test Weld when time values voltage levels or power levels are changed on the schedule 1 From the SETUP 3 menu screen press DO TEST WELD the 1 key to access the DO TEST A screen 2 Press the 1 2 3 key to select the desired option The display will automatically return to the SETUP 3
127. onstant voltage monitor current e Ifyou are welding in constant power monitor current or voltage UB25 LINEAR DC RESISTANCE WELDING CONTROL 3 10 990 665 CHAPTER 3 USING 0825 WELDING FUNCTIONS Example 1 Energy Limit Weld Termination Example 1 In the profile above the weld current is exceeding the selected upper limit before the end of the welding cycle The spike in the current waveform indicates that parts were misplaced In this case the operator has selected the option to terminate the weld energy under this condition so the energy limits monitor terminates the Pulse 1 weld and inhibits the Pulse 2 weld if it had been programmed Example 2 Sufficient Current Level Example 2 In the profile above the weld current limit is at a sufficient level to get a good weld Pre Weld Check Application Detect Misaligned or Missing parts Function This is used to see if parts are misaligned or missing before a welding pulse is delivered to the weld head part is missing or misaligned you do want the machine to weld because the result would be an unacceptable weld and or damaged electrodes Pre Weld Check is similar to Energy Limits however in this case Pulse 1 should be very short 1 2 milliseconds and the current should be low about 1096 of the Pulse 2 current Pulse 1 should be used as a measurement pulse and should perform a weld UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 3 11 C
128. or lower energy limits are exceeded but allows Pulse 2 to fire This function will not operate if both pulses are joined without a cool time NOTE See Active Part Conditioner in Chapter 3 8 After making your selection the display will automatically retum to the monitor screen 9 Program the upper and lower limits for Pulse 2 by repeating Steps 4 through 6 above using the keys for Pulse 2 entering appropriate values for Pulse 2 NOTE The monitor limit mode current voltage or power for Pulse 2 can be different than the monitor limit mode for Pulse 1 Press the HOLD period key This PULSE 2 OUT OF LIMITS ACTION will bring up the PULSE 2 OUT ao OF LIMITS ACTION screen 2 STOP DURING PULSE 2 This screen allows you to select the action that the Control will take if the Pulse 2 upper or lower limits are calant MERT mans exceeded You have two choices NONE takes no action if upper or lower energy limits are exceeded STOP DURING PULSE 2 stops PULSE 2 immediately after upper or lower energy limits are exceeded 14 After you have made your selection the display will automatically return to the MONITOR screen NOTE The Control adds dotted lines to the appropriate graph to show the programmed limits UPPER And LOWER UPPER And LOWER The screen on the right shows how the Limits for PULSE 1 Limits for PULSE 2 Limits and Alarm actions appear when Alarm Action Alarm Action an actual wel
129. ork pieces So periodic tip resurfacing dressing is required to remove pitting oxides and welding debris from the electrode You should limit cleaning of an electrode on the production line to using a 600 grit silicon carbide electrode polishing disk If you must clean a badly damaged tip with a file you must use a polishing disk after filing to ensure the electrode faces are smooth The best method of preventing electrode problems is to regularly re grind electrode tip surfaces and shapes in a certified machine shop Parts Replacement There are no replaceable parts for the Control other than the protection fuse for the 24 volt Air Valve Driver Fuse DESCRIPTION LOCATION 3 A 125 V Slow Blow Rear Panel WARNING e Only qualified technicians should perform internal adjustments or replace parts Removal ofthe unit cover could expose personnel to high voltage Removal of the unit cover may void the warranty UB25 LINEAR DC RESISTANCE WELDING CONTROL 6 6 990 665 CHAPTER 7 CALIBRATION Section Introduction Overview Calibration instructions are displayed on the series of screens displayed on the Control s LCD There are only two Calibrations sefups or equipment connections After you connect the Control to the calibration equipment as instructed follow the instructions shown on each LCD screen While some of the instructions may appear slightly different the procedures are essentially the same It takes ap
130. p or process can affect the energy delivered Refer to the Troubleshooting Chart in Chapter 6 Limits should be set by qualified by personnel and are designed to identify process variations TYPE OF MESSAGE GENERAL STATUS GENERAL STATUS GENERAL STATUS OUT OF LIMITS OUT OF LIMITS OUT OF LIMITS APPENDIX E LCD DISPLAY MESSAGES MESSAGE VOLTAGE 2 LOWER THAN LOWER LIMIT WELD FIRE LOCKOUT WELD STOP LIMIT REACHED WELD SWITCH IN NO WELD POSITION WELD TIME TOO SMALL LCD Display Messages DESCRIPTION Actual weld voltage is less than the user set Lower Limit value for Pulse 2 A weld was initiated before the capacitor bank charge reached the required level as programmed in the WAVEFORM CHECK menu Default value for WELD FIRE LOCKOUT is 90 charge Reducing this value with high energy levels or longer weld times could exceed the capacity of the Control The user set Upper Limit value has been reached and the weld energy has been terminated User has tried to activate the Control with the WELD NO WELD Switch in the No Weld Position The user has attempted to program zero for all upslope weld and downslope time periods CORRECTIVE ACTION IF REQUIRED Determine the cause ofthe low voltage Changes to the welding setup or process can affect the energy delivered Refer to the Troubleshooting Chart in Chapter 6 Limits should be set by qualified by personnel and are desi
131. p the electrodes closed on the parts after weld current has terminated to provide additional heat sinking or parts cooling The weld strength is formed during the hold period UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 3 3 CHAPTER 3 USING 0825 WELDING FUNCTIONS Single Pulse Weld Profile Applications e Flat parts that do not have any plating or heavy oxides Conductive parts made of copper or brass Description Single Pulse is a term used by the industry to describe the simplest heat profile used for many resistance spot welding applications WELD TIME 0 99 msec Single Pulse Weld Profile Upslope Downslope Weld Profile Applications Round or non flat parts and most resistive materials Description Upslope allows a gradual application of weld energy which permits the parts to come into better contact with each other reducing the electrode to part contact resistances Upslope can allow a smaller electrode force to be used resulting in a cleaner appearance by reducing electrode indentation material pickup and electrode deformation It can also be used to displace plating and or oxides reduce flashing and spitting or reduce thermal shock when welding parts containing glass to metal seals UB25 LINEAR DC RESISTANCE WELDING CONTROL 3 4 990 665 CHAPTER 3 USING 0825 WELDING FUNCTIONS Downslope annealing assists in the grain refinement of certain heat treatable steels and prevents cracking in alum
132. panel of the Control are grouped in two clusters Liquid Crystal Display LCD and Weld Selector Keys e Numeric Keypad and Operational Controls Various functions of the Control may require the use of buttons or keys from each cluster This section describes each button and key on the front panel Descriptions are given in the order they appear on the front panel from left to right and from the top of the panel to the bottom Step by step instructions on how to use the controls and indicators are in Chapter 4 Operating Instructions Operating Instructions will list the buttons and keys in the sequential order necessary to perform each task Liquid Crystal Display LCD And Weld Selector Keys LIQUID CRYSTAL DISPLAY LCD SCHEDULE lt lt SELECTOR KEY WELD SELECTOR KEYS lt lt Time Periods eque UP WNO SOM OM UP DONI MOLD Energy Levels puise 1 emas LCD and Weld Selector Keys Press to view and select a Weld Schedule After pressing the SCHEDULE SCHEDULE key you can use eitherthe X up down keys on the front panel to scroll through the 99 stored Weld Schedules or use the numeric keypad to enter the two digit number of the desired schedule Weld Selector Keys A group of nine keys used to program the time periods and energy levels for each complete weld schedule UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 1 9 CHAPTER 1 DESCRIPTION Press to enter the squeeze time before the wel
133. pe Polarity heating rate upslope Observation visual criteria cross section and impact of variables on heat balance Process Perspective What are the likely variables in a production process How will operators handle and align the parts What tooling or automation will be required How will operators maintain and change the electrodes What other parameters will operators are able to adjust What are the quality and inspection requirements What are the relevant production testing methods and test equipment Do we have adequate control over the quality of the materials UB25 LINEAR DC RESISTANCE WELDING CONTROL D 10 990 665 APPENDIX D DEFINING THE OPTIMUM PROCESS Common Problems During this stage of process development it is important to understand that the majority of process problems are related to either materials variation or part to electrode positioning Some examples are shown below Material Control Part To Part Positioning Electrode To Part Positioning The changes detailed above generally result in a change in contact resistance and always affect the heat balance ofthe weld During weld development these common problems must be carefully monitored so as not to mislead the course and productivity of the welding experiments In summary the look see welding experiments should be used to fix further variables from an application and process perspective and also to establish a weld window for energy time
134. play between peak welding energy and average AVERAGE welding energy readings Data is displayed in the top data line on the LCD Press to Increment increase or decrement decrease numeric values on the display Scroll the weld schedule numbers up and down UB25 LINEAR DC RESISTANCE WELDING CONTROL 1 12 990 665 CHAPTER 1 DESCRIPTION Numeric Keypad Enter or modify weld period time and energy values Enter or modify monitor and limit values Directly recall a specific weld schedule Select menu items when MENU screens are displayed Press to insert a decimal point into the time and energy values you enter Press to display the version number of the Control software and other pertinent information about the Control Press to return to the RUN state or to clear alarms When using any MENU screen press this key to exit the menu Press to display the MENU screen Chapter 4 Operating Instructions describes how to use the different MENU options C When in the MONITOR state press to view the resistance waveform of the MONITOR last weld The resistance waveform and values are provided as a reference and are designed to provide an illustration of the resistance change during the weld NOTE The kA V and kW keys are used to e the feedback mode for Pulse 1 and Pulse 2 in the weld schedule e Set feedback parameters for upper and lower monitor limits e Select the monitor mode to be vi
135. ppendix E LCD Display Messages The relay signal will switch when the Control senses that the Pulse 2 energy is lower than the programmed lower limit It will start 0 150 milliseconds after the end of HOLD and will stay energized until the OUT OF LIMITS alarm state is cleared by pressing the RUN button or at the start of the next weld refer to Appendix E LCD Display Messages Use the numeric keypad to enter the number of your choice Press the MENU key two times to return to the RELAY screen UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 CHAPTER 5 SETUP SOFTWARE 7 Repeat Steps 2 through 6 to program the other relays as needed 8 Press MENU to return to the MAIN MENU UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 5 23 CHAPTER 5 SETUP SOFTWARE Section VII Special Functions Copy A Schedule 1 From MAIN MENU press the 3 key COPY SCHEDULE to get COPY SCHEDULE COPY SCHEDULE 1 TO SCHEDULE 1 Screen NOTE There are two fields in the COPY SCHEDULE screen These fields determine which schedule will be copied source and which schedule will be overwritten destination Both fields initially contain the number of the schedule most recently displayed NUMBERS followed by SCHEDULE Use the numeric keypad to enter the number of the source schedule Press the schedule key to select the destination schedule number field Use the numeric keypad to enter the number of the destination schedule
136. proximately one hour to calibrate the Control if working by yourself faster with an assistant Once you are familiar with the calibration process it will become faster and easier to do After performing these procedures the Control will store the calibration values in RAM where they will be used as standards for the operational welding parameters NOTE Only authorized personnel should perform this procedure Calibration Equipment Required This equipment is required for calibration 2 weld cables No 2 0 1 ft 30 cm long PN 2 0 12 4 000 micro ohm coaxial shunt resistor accurate to 0 5 Source for shunt resistor Model K 1000 2 150 Watts Mod 004 T amp M Research Products Inc Telephone 505 268 0316 139 Rhode Island Street NE E Mail www tandmresearch com Albuquerque New Mexico 87108 Calibration Kit PN 4 35914 01 Filter Special Calibration Cable PN 4 35913 01 Standard BNC Cable Digital oscilloscope Tektronix 724 or equivalent 2 wire normally open switch for weld initiation mating connector PN 520 011 The waveforms displayed on the oscilloscope screen will vary from pulse to pulse To calibrate the Control adjust the energy output to the average value of each pulse displayed on the oscilloscope UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 7 1 CHAPTER 7 CALIBRATION Calibration Points The term Calibration Points refers to the
137. pts 24 Vdc from a PLC as a source for activating the Firing Switch and Foot Switch inputs For detailed electrical interface information on these input switch selections see Appendix B Electrical And Data Connectors 1 From the INPUT SWITCH SELECT INPUT SWITCH SELECT menu press the 3 key to display the PLC select menu NOTE PLC TURN ON initiates the Control from a PLC source by changing the PLC voltage from 24 Vdc NHMREB Salant Mani to 0 Vdc PLC 24VDC TURN ON initiates the Control from a PLC source by changing the PLC voltage from 0 Vdc to 24 Vdc NOTE You will get an INPUT SWITCH ALARM unless you have 0 Vdc on the Firing Switch and Foot Switch inputs before selecting the 24 Vdc Turn On option 2 PLC 24VDC TURN ON 2 Pressthe 1 or 2 key to select how the PLC input switches will initiate the Control The display automatically returns to the SETUP 1 menu UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 5 13 CHAPTER 5 SETUP SOFTWARE Control Signals Select This option selects the type of external switch to be used by the Schedule Selection Process Inhibit and ISTOP inputs and how these switches are activated 4 From the SETUP 1 menu press 5 for CONTROL SIGNALS SELECT the CONTROL SIGNALS SELECT menu Follow the INPUT SWITCH SELECT instructions on previous two pages the procedures are identical for CONTROL SIGNALS SELECT Press MENU to return to the MAIN MENU
138. red joints are typically achieved at temperatures less than 400 C and brazed joints such as Sil Phos materials melt at temperatures above 400 C Solid State Joint A solid state joint can be formed when the materials are heated to between 70 80 of their melting point Fusion Joint A fusion joint can be formed when both metals are heated to their melting point and their atoms mix Many micro resistance welding challenges involve joining dissimilar metals in terms of their melting point electrical conductivity and hardness A solid state joint can be an ideal solution for these difficult joining challenges There is no direct mixing of the two materials across the weld interface thus preventing the formation of harmful alloys that could form brittle compounds that are easily fractured In a solid state joint the metals are only heated to 70 80 of their respective melting points This means that the materials are less thermally stressed during heating and subsequent joint cooling in comparison to a fusion weld As there is no real melting of the materials in a solid state joint there is less chance of weld splash or material expulsion A weld nugget can still be achieved with a solid state joint UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 D 3 APPENDIX D DEFINING THE OPTIMUM PROCESS Consider the Material Properties The important material properties to be considered in the resistance welding process are as follows
139. rol UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 B 11 APPENDIX B ELECTRICAL AND DATA CONNECTORS Foot Switch PIN 1 CHASSIS GROUND PIN 4 24V GND PIN 2 IFOOT1 PIN 3 IFOOT2 FOOT SWITCH CONNECTOR SPECIFICATIONS MAX SIGNAL VOLTAGE cyrRENT COMMENTS 2 IFOOTI Digital 24V 10mA I Foot switch SW1 Level 1 normally open open UB25 LINEAR DC RESISTANCE WELDING CONTROL B 12 990 665 APPENDIX B ELECTRICAL AND DATA CONNECTORS AC Input Power Connection GROUND NEUTRAL AC INPUT POWER CONNECTION SPECIFICATIONS CNN ame et 7 7 UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 B 13 APPENDIX ELECTRICAL AND DATA CONNECTORS Weld Terminals 3 lt POSITIVE WELD TERMINAL La NEGATIVE WELD TERMINAL WELD TERMINAL SPECIFICATIONS TERMINAL MAXIMUM VOLTAGE MAXIMUM CURRENT COMMENTS de 0825 LINEAR DC RESISTANCE WELDING CONTROL B 14 990 665 APPENDIX THE BASICS RESISTANCE WELDING Resistance Welding Parameters Resistance welding heat is produced by passing electrical current through the parts for a fixed time period The welding heat generated is a function of the magnitude of the weld current the electrical resistance of the parts the contact resistance between the parts and the weld force applied to the parts Sufficient weld force is required to contain the molten material produc
140. see mini experiments and then include the three key welding variables energy force and time Several Screening DOE S maybe required Results should be interpreted carefully Typically one would look for the highest result in terms of quality with the least variation A Screening DOE provides only a measurement that indicates the relative importance of a parameter and not the ideal setting Factorial DOE S should be used to establish the correct or best setting for a parameter once many of the other variables have been screened and fixed This is the time to also assess the measurement accuracy and consistency of the test method and procedure Variation in test method can invalidate the test and can lead to misinterpretation of results UB25 LINEAR DC RESISTANCE WELDING CONTROL D 12 990 665 APPENDIX D DEFINING THE OPTIMUM PROCESS What are Factorial DOE S The purpose of a Factorial DOE is to narrow in on the optimal setting for a particular parameter This method is generally used when the critical or main key variables have been identified and we need to establish the best settings for the process A factorial DOE may also give an indication as to how wide the acceptable weld window is in relation to quality requirements We recommend data be gathered from a monitoring perspective so that this can provide a starting point for establishing a relationship between quality and the monitored measurement parameter Criteria for Success Cr
141. starting point is the mid point in the range of the weld head force 2 Set the WELD NO WELD switch on the Control front panel to the NO WELD position In this position the Control will operate the weld head without producing weld energy NOTE When you are ready to perform a weld be sure to set this switch back to the WELD position 3 Turn the ON OFF switch on the rear panel of the Control to the ON position The default RUN screen will be displayed You will use this screen to enter welding parameters 0000000 0 300 0 300 150 1 0 1 0 1 0 1 0 1 0 1 0 1 0 058 ms UB25 LINEAR DC RESISTANCE WELDING CONTROL 4 2 990 665 990 665 CHAPTER 4 OPERATING INSTRUCTIONS Default RUN Screen UB25 LINEAR DC RESISTANCE WELDING CONTROL 4 3 CHAPTER 4 OPERATING INSTRUCTIONS Section Ill Programming Weld Schedules Introduction The Control comes with 99 factory installed weld schedules numbered from 01 through 99 Each schedule 15 set to the same preset value and looks like the display on the right See Chapter 3 Using UB25 Welding And Monitoring Functions for descriptions of the features available in weld schedules PROGRAM 1 150 1 0 1 0 1 0 1 0 1 0 1 0 1 0 058 ms The process of Programming a weld schedule consists of e Select a weld schedule e Enter new values in the selected schedule NOTE For reference and convenience you might want to keep a written list of your programmed
142. sufficient weld head force Contaminated weld piece surface plating Wrong electrode material tip shape Contaminated electrode surface Weld Piece Over heating Excessive weld time set at the Control Excessive current energy set at the Control Misaligned parts Insufficient weld head force Incompatible weld piece materials Wrong electrode material tip shape Contaminated electrode surface Weld Piece Warping Excessive weld time set at the Control Excessive weld head force Incompatible weld piece projection design Incompatible weld piece materials Wrong electrode tip shape Excessive current energy set at the Control Technical Assistance If you need further technical assistance please contact either your authorized service agent or Unitek Miyachi by telephone or FAX or at the postal or e mail addresses shown in the Foreword of this manual UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 6 5 CHAPTER 6 USER MAINTENANCE Electrode Maintenance When a welding schedule has been suitable for a particular welding application over many welds but poor quality welds are now resulting electrode deterioration could be the problem If you need to increase welding current to maintain the same weld heat the electrode tip has probably increased in surface area mushroomed effectively decreasing weld current density thus cooling the weld Try replacing the electrodes The rough surface of a worn electrode tip tends to stick to the w
143. t as the limit mode Press V key to program voltage as limit mode Press kW key to program power as the limit mode Toggle the Pulse 1 weld time energy selector key to select the lower limit field for the weld period Enter the lower limit value for the Pulse 1 weld period NOTE In order for a Pulse lower limit to be programmed you must first program a Pulse 1 upslope in the weld schedule The lower limit mode current voltage or power will automatically be the same as the upper limit mode programmed in Step 5 Press the COOL weld period key E FUESE COUT OF CIMITS ACTION cox This will bring up the PULSE 1 2 STOP DURING PULSE 1 OUT OF LIMITS ACTION screen 3 INHIBIT PULSE 2 This screen allows you to select the action that the Control will take if the Pulse 1 upper or lower limits are MENT Provine mani exceeded You have four choices 4 STOP PULSE 1 ALLOW PULSE 2 e NONE takes no action if upper or lower energy limits are exceeded e STOP DURING PULSE 1 stops the weld immediately during Pulse 1 and prevents Pulse 2 from firing if applicable UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 CHAPTER 4 OPERATING INSTRUCTIONS INHIBIT PULSE 2 stops the weld at the end of Pulse 1 and prevents Pulse 2 from firing This function will not operate if both pulses are joined without a cool time STOP PULSE 1 ALLOW PULSE 2 stops Pulse 1 immediately after upper
144. t the Control Contaminated weld piece surface plating Wrong electrode material Contaminated electrode surface UB25 LINEAR DC RESISTANCE WELDING CONTROL 6 2 990 665 CHAPTER 6 USER MAINTENANCE Troubleshooting Chart PROBLEM CAUSE In Order of Probability Electrode Sparking Electrode Sticking EMERGENCY STOP message is displayed on the LCD and fans all stop but the Emergency Stop Switch is not activated Excessive current energy set at the Control Insufficient weld head force Slow weld head follow up Incompatible weld piece projection design Misaligned parts Contaminated weld piece surface plating Wrong electrode tip shape Wrong electrode material Contaminated electrode surface Contaminated weld piece surface plating Wrong electrode material tip shape Insufficient weld head force Excessive current energy set at the Control Misaligned parts Excessive weld time set at the Control Contaminated electrode surface Slow weld head follow up Blown fuse located on internal Power Distribution amp Fan Controller Board Contact Unitek Peco for support UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 CHAPTER 6 USER MAINTENANCE Troubleshooting Chart PROBLEM CAUSE In Order of Probability Insufficient Weld Nugget LCD Display is blank fans are still operational LCD is operational the Control will attempt to fire but no energy is provided to the weld and the graphs in the RUN screen w
145. ta on the keypad you will see the graph change as you program new data When you have entered all the data you will see the completed waveform Shaded Graph After each weld is performed the LCD displays a white shaded graph showing the waveform of the actual weld pulse The LCD now displays both graphs together allowing you to visually compare the line graph to the shaded graph to see if the weld was completed properly The actual weld energy delivered shaded graph is dependent on the load resistance including cables the weld head and parts to be welded A missing area of the shaded graph indicates that the Control is not able to deliver the programmed energy most likely due to the load resistance If the front part of the shaded graph 15 missing the load resistance is not allowing the Control to instantly deliver the programmed energy You can compensate for this by using the upslope feature when programming a weld schedule see UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 1 7 CHAPTER 1 DESCRIPTION Chapter 3 Using UB25 Welding And Monitoring Functions Chapter 4 Operating Instructions The data lines on the LCD may also display alarm messages showing that the weld was inhibited stopped or terminated and the reason why the action was taken UB25 LINEAR DC RESISTANCE WELDING CONTROL 1 8 990 665 CHAPTER 1 DESCRIPTION Section IV Controls and Indicators Introduction The Controls and Indicators on the front
146. tain and service the UB25 Linear DC Welding Control We have made every effort to ensure that the information in this manual is accurate and adequate Should questions arise or if you have suggestions for improvement of this manual please contact us at the above location numbers Unitek Miyachi is not responsible for any loss due to improper use of this product SAFETY NOTES This instruction manual describes how to operate and maintain the UB25 Linear DC Welding Control and provides instructions relating to its SAFE use Procedures described herein MUST be performed as detailed by QUALIFIED and TRAINED personnel For SAFETY and to effectively take advantage of the full capabilities of the workstation please read this instruction manual before attempting to use the UB25 Linear DC Welding Control 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 unit 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
147. tance Group lll Refractory Metals Refractory metals have very high melting points and excess heating can cause micro structural damage A solid state joint is therefore preferred The chart below gives some guidance on the type of joint that can be expected and design considerations required when joining materials from the different groups Group Group Il Group Ill Group Solid State Solid State Solid State Copper W Mo electrodes Projection on Group I Fine projections on Group III Group Il Solid State or Fusion Solid state or braze of II Steel Projection Solid State Moly Basic Principles Contact Resistance Resistance Bulk Resistance Time The figure above shows the key resistances in a typical opposed resistance weld and the relationship between contact resistances and bulk resistances over time during a typical resistance weld UB25 LINEAR DC RESISTANCE WELDING CONTROL D 6 990 665 APPENDIX D DEFINING THE OPTIMUM PROCESS R1 amp R7 The electrode resistances affect the conduction of energy and weld heat to the parts and also the rate of heat sinking from the parts at the end of the weld R2 RA amp R6 The electrode to part and part to part Contact Resistances determine the amount of heat generation in these areas The contact resistances decline over time as the parts achieve better fit up R3 amp R5 The metal Bu
148. tay energized until the OUT OF LIMITS alarm state is cleared by pressing the RUN button or at the start of the next weld P1 HIGH LIMIT The relay signal will switch when the Control senses that the Pulse 1 energy is higher than the programmed upper limit It will start 0 150 milliseconds after the end of HOLD and will stay energized until the OUT OF LIMITS alarm state is cleared by pressing the RUN button or at the start of the next weld P1LOW LIMIT The relay signal will switch when the Control senses that the Pulse 1 energy is lower than the programmed lower limit It will start 0 150 milliseconds after the end of HOLD and will stay energized until the OUT OF LIMITS alarm state is cleared by pressing the RUN button or at the start of the next weld P2 HIGH LIMIT The relay signal will switch when the Control senses that the Pulse 2 energy is higher than the programmed upper limit It will start 0 150 milliseconds after the end of HOLD and will stay energized until the OUT OF LIMITS alarm state is cleared by pressing the RUN button or at the start of the next weld e P2LOWLIMIT The relay signal will switch when the Control senses that the Pulse 2 energy is lower than the programmed lower limit It will start 0 150 milliseconds after the end of HOLD and will stay energized until the OUT OF LIMITS alarm state is cleared by pressing the RUN button or at the start of the next weld UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 F 3
149. ter than the UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 C 5 APPENDIX C THE BASICS RESISTANCE WELDING diameter of the wire If both parts are flat the face should be at least one half the diameter of the electrodes Pencil point electrodes cause severe electrode sticking to the parts unexplained explosions and increase the weld heat substantially because of the reduced electrode to part contact area 3 Usethe Force Adjustment Knob on the Weld Head to set the Firing Force and adjust an Air Actuated Weld Head UB25 LINEAR DC RESISTANCE WELDING CONTROL C 6 990 665 APPENDIX THE BASICS RESISTANCE WELDING Program a weld schedule then make your first weld Always observe safety precautions when welding and wear safety glasses For a complete procedure on making welds refer to Chapter 4 Operating Instructions Use pliers to peel the welded materials apart A satisfactory weld will show residual material pulled from one material to the other Tearing of base material around the weld nugget indicates a material failure NOT a weld failure Excessive electrode sticking and or spitting should define a weld as unsatisfactory and indicates that too much weld current voltage power or time has been used If the parts pull apart easily or there is little or no residual material pulled the weld is weak Increase the weld time in 1 msec increments Increase weld current voltage or power if a satisfactory weld achieved
150. the Emergency Stop Input pins 15 and 16 SPOWER have an internal jumper between them The external wires are provided so the user can connect to an Emergency Stop Switch Opening the connection will cause the Control to initiate an Emergency Stop The LCD will display Emergency Stop Operator Activated and a beep will sound An Emergency Stop will disable all power outputs To reset the condition the switch connection must be closed and the RUN key must be pushed on the front panel to reset the Control Users should verify that the weld Schedule is correct If not reset to the correct schedule if necessary PLUG SHORTING WIRES WIRE NUT An instruction tag is attached to the shorting wires with a cable tie Instructions are printed on the front and back of the tag in several languages full text below EMERGENCY STOP ARRET D URGENCE Open electrical circuit to retract weld head Ouvrez le circuit lectrique pour retirer la t te de soudure DESCONECCION DE EMERGENCIA NOODSTOP Abra el circuito el ctrico para retraer la cabeza de Open het elektrische circuit om de laskop terug te trekken soldadura N DSTOPP PARADA DE EMERG NCIA ppna den elektriska kretsen dra tillbaka Abrir o circuito el trico para tirar a da maquina svetstr den ARRESTO D EMERGENZA NOT AUSSCHALTER Interrompere l alimentazione per risalita testa W rd den elektrischen Kreis ffen der Schweifskopf
151. time usually double the time works This will ensure that there will be enough time for the current to rise and reach the limit even with heavily oxidized parts Try welds with varying oxide clean and dirty The power supply terminates the first pulse when your programmed current is reached A clean part will reach the current limit sooner and the pulse will terminate early A dirty part will require more time before the oxide is broken down and current can flow Program your second welding pulse as 30 Peak 6 447KA 9820051 normal to achieve a strong weld Constant voltage is recommended for round parts and constant current for flat parts An 5755 1 3r 37 2900 E a a upslope may be required to restrict the 9 6 5 0 0 0 2 9 5 0 1 0 6 9 current flow early in second pulse and avoid weld splash UB25 LINEAR DC RESISTANCE WELDING CONTROL CHAPTER 4 OPERATING INSTRUCTIONS Section Operation General Operator Safety ALWAYS wear safety goggles and other appropriate safety equipment when you are performing a welding operation Manual Welding Operation 1 Verify that all components of your welding system have been properly connected and turned ON 2 Verify that all welding components are operating properly and ready for use 3 Venfy that you have programmed the Control with all necessary schedules for your welding application 4 Setthe WELD NO WELD switch on the front panel to the WEL
152. tion 3 5 Single Pulse Weld Profile 3 4 Applications 24 3 4 Description 3 4 Upslope Downslope Weld Profile Applications 3 4 DeSonpltlon 3 4 Welding Applications 3 3 Weld Head Applicability 3 3 Weld Sequence Timing 3 2 Weld Selector Keys eese entren tt rn sts tois 1 8 Weld Sequence Timing 3 2 Weld Strength Profiles C 5 Weld Strength Testing C 5 Weld Terminals B 12 Welding Applications 3 3 Welding Parameter Interaction C 1 UB25 LINEAR DC RESISTANCE WELDING CONTROL Index 8 990 665 INDEX UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 Index 9
153. to the MONITOR state The LCD will show the actual trace of energy of the last weld performed You can also view the peak or average energy value for each weld pulse as selected by pressing the PEAK AVERAGE key If a start signal is received while in the MONITOR state the Control will execute the programmed weld schedule and the waveform trace UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 CHAPTER 1 DESCRIPTION UB25 Operational States STATE DESCRIPTION will update with the new weld data The operational state will then read RUN and the LCD screen will show the monitored data The Control automatically goes into an alarm state when it recognizes any alarm condition these are described in detail in Appendix E LCD Display Messages Pressing the MENU key puts the Control in the MENU state which displays the MAIN MENU on the LCD A series of menu and sub menu screens enable you to change the Control s operating parameters see Chapter 4 Operating Instructions Graphed Data Line Graph Programmed Weld 000 amp A O18 2 0 40 20 18 28 48 20 001 Line Graph Programmed Weld 1009 Peak 1030 0000114 E a e 000kA 20 40 20 10 20 40 20 Shaded Graph Actual Weld Graphed Data Line Graph When you enter data to program a weld schedule the Control automatically draws the data in graphic form a line graph or waveform of a programmed weld schedule As you enter da
154. tothe SETUP 1 screen 2 Pressthe 1 key to toggle between FOOTSWITCH WELD ABORT ON and FOOTSWITCH WELD ABORT OFF STATE PREFERRED APPLICATION FUNCTION Human operated welding stations Allows you to abort the weld process by where the operator holds parts releasing the foot switch used with an air actuated weld head Will also terminate the welding sequence if the footswitch is opened before the firing switch 15 initiated welding stations Also for human level footswitch and firing switches have both operated stations where tooling holds been closed the welding sequence will the parts and where the welding continue to its conclusion regardless of sequence can be initiated with a single footswitch or firing switch position momentary start pulse Computer or PLC controlled Once the footswitch second level of a two 3 Keep pressing the MENU key on the front panel to return to the MAIN MENU UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 5 9 CHAPTER 5 SETUP SOFTWARE Switch Debounce Time The contacts of mechanical firing switches bounce when they close The switch debounce time function allows you to specify that the initiation switch contacts must remain closed for 10 20 or 30 milliseconds before the weld period can be initiated thereby avoiding false starts caused by the switch contact bouncing In addition to the debounce time there is a delay of no greater than 2 5ms before the start signal 1s recognized by t
155. tting or reduce repetition rate See OUT OF Chapter 5 for programming LIMITS MESSAGE CHK VOLTAGE CABLE amp SECONDARY CKT COOL TIME ADDED FOR DIFFERENT FEEDBACK COOL TIME MINIMUM CURRENT 1 GREATER THAN UPPER LIMIT CURRENT 1 LOWER THAN LOWER LIMIT CURRENT 2 GREATER THAN UPPER LIMIT UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 APPENDIX E LCD DISPLAY MESSAGES LCD Display Messages DESCRIPTION No electrode voltage measurement was made Possible open circuit The Control automatically added Cool Time to the schedule because Pulse 1 and Pulse 2 feedback modes are different or Pulse 1 and Pulse 2 energy levels are different The operator programmed a cool time smaller than required Actual weld current is greater than the user set Upper Limit value for Pulse 1 Actual weld current is less than the user set Lower Limit value for Pulse 1 Actual weld current is greater than the user set Upper Limit value for Pulse 2 CORRECTIVE ACTION IF REQUIRED Check that a closed secondary circuit 15 present when the Control fires Verify that the Voltage Sense Cable is properly connected to the electrodes or electrode holder NOTE Polarity is not important for the cable connection If message persists possible blown internal fuse on Capacitor Charging Power Supply contact Unitek Peco for support Normal operation Increase setting Determine the cause of the high current
156. u M M F 2 BOT 2 1 Qut DI Elis aou Dieci Enn NEHME ERE F 3 Weld MUn F 1 Relay Data and Communication Connections d 2 7 Repetition Rates G 1 Introduction rre bite eroe G 1 Maximum Weld Pulse Duration As A Function of Weld Current G 2 Re Set After Emergency Stop 4 12 Reset All Schedules 5 23 Reset Default 5 21 Reset System Parameters 5 23 Resistance Welding Parameters C 1 Revision Record ises ose ree inet efe ii UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 Index 5 INDEX S Reset System Parameters 5 23 Safety Notes iv Select A Weld Schedule 4 3 SOLID 2 4 Air Actuated Weld Head Connections 2 6 Manual Weld Head Connections 2 4 Relay Data and Communication Connections 2 7 Setup Menus 5 2 Setup Software 5 1 Communication and Data 5 24 Baud Bale 5 25 Single Pulse Weld Profile 3 4 Communication esee 5 24 ID 5 25 ROI GIGAS 5 24 Setup Software Continued How to Use Menu Screens 5 2 5 2 Setup Menus 5 2 Operator Preferen
157. uding squeeze time Sufficient squeeze time must be programmed in the weld schedule to allow the weld head to close and the weld force to stabilize before the weld current starts NOTE In addition to the debounce time there is a delay of no greater than 2 5ms before the start signal is recognized by the Control REMOTE be used in automated applications or when using a PLC to control the weld head The weld energy sequence is initiated via the Remote Schedule Select input lines which also select the weld schedule number Refer to Appendix B Electrical And Data Connectors for I O connector pin connections and specifications 3 Press MENU to return to the MAIN MENU Input Switch Select Selects the type of external switch to be used by the Firing Switch and Foot Switch inputs and how these switches are activated 1 Go to the SETUP 1 menu INPUT SELECT SWITCH 2 Press 4 for INPUT SWITCH SELECT menu NUMBER Select MENU Previous menu Mechanical Selection This selection accepts dry contact single or double pole switch or reed relay devices This is the factory default setting and will run Unitek Peco weld heads 1 From INPUT SWITCH SELECT INPUT SELECT SWITCH menu press 1 for the mechanical switch 2 MECHANICAL SWITCH NORMAL CLOSED select menu 2 Pressthe 1 or 2 key to select how the input mechanical switches will initiate the Control The display automatically returns coloct_ MENTI Prav
158. ufacturer s Address Equipment Description Equipment Class Model Numbers 55011 Class A Group 2 ENS0082 2 1995 EN61000 4 2 EN61000 4 3 EN61000 4 4 EN61000 4 5 EN61000 4 6 EN61000 4 8 EN61000 4 11 Unitek Miyachi 1820 S Myrtle Ave Monrov a CA 91017 626 303 5676 Linear DC Welder ISM Class A Group 2 UB 25 I the undersigned hereby declare that the equipment specified above conforms to the above Directive s and Standard s CHAPTER 1 DESCRIPTION Section Introduction Features The UB25 Linear DC Welding Control is a Resistance Welding Control For the rest of this manual the UB25 will be referred to simply as the Control The Control has the following features Programming of time in 10 increments minimum provides shorter weld times less part deformation longer electrode and greater weld strength with more part ductility e Built in Liquid Crystal Display LCD shows a graphical trace of weld current voltage power and resistance plus alphanumeric peak and average values Up to 99 individual Weld Schedules sometimes referred to as weld profiles can be programmed and stored Weld schedules can be used individually or in sequence with others using the chain schedules function You can also use schedule 00 as a scratch pad for developing schedules Easy to set limits establish process window for acceptable quality e Weld limits and user programmable rel
159. w rd POIS zur ck gezogen Avaa virtapiiri vetaaksesi hitsauspaan takaisin Emergency Stop Switch Instruction Tag 25 Pin Mating Plug With Internal Jumper I O Connector B This connector should be attached to I O Connector B when it 15 shipped from the factory This plug has internal jumper between pins 11 and 12 UB25 LINEAR DC RESISTANCE WELDING CONTROL B 8 990 665 APPENDIX B ELECTRICAL DATA CONNECTORS NOTE In order to operate both mating plugs must be attached to the connectors I O cables wired for the proper jumpers must be attached to the Control UB25 LINEAR DC RESISTANCE WELDING CONTROL 990 665 B 9 APPENDIX ELECTRICAL AND DATA CONNECTORS Air Valve Driver 24V PIN 22 24V ac RETURN PIN 1 HEAD 95 PIN 4 USED NOT USED AIR VALVE DRIVER CONNECTOR SPECIFICATIONS MAX MAX SIGNAL VOLTAGE CURRENT COMMENTS ww me L5 qwe 1 1 1 4 jw Air valve drive return Firing Switch PIN 2 IFIRE PIN 1 24VGND FIRING SWITCH CONNECTOR SPECIFICATIONS SIGNAL nx m mios NAME VOLTAGE current 5 0825 LINEAR DC RESISTANCE WELDING CONTROL B 10 990 665 APPENDIX B ELECTRICAL DATA CONNECTORS NOTE In addition to the debounce time there is a delay of no greater than 2 5ms before the start signal is recognized by the Cont

UB25 Cover+Front Matter [Rev C] -- 1-02

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