Home

100dp/300dp dual pulse stored energy resistance welding power

1. D 1 Appendix E Quality Resistance Welding Solutions Defining the Optimum Process E 1 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY iv 990 295 05 Thank you for purchasing Miyachi Unitek Resistance Welding System Control Upon receipt of your equipment please thoroughly inspect it for shipping damage prior to its installation Should there be any damage please immediately contact the shipping company to file a claim and notify Miyachi Unitek at 1820 South Myrtle Avenue P O Box 5033 Monrovia CA 91017 7133 Telephone 626 303 5676 FAX 626 358 8048 e mail info unitekmiyachi com The purpose of this manual is to supply operating and maintenance personnel with the information needed to properly and safely operate and maintain the Miyachi Unitek 100DP and 300DP Resistance Welding System Control We have made every effort to ensure that the information this manual 15 accurate and adequate If you have any questions or if you have suggestions to improve this manual please contact us at the above location numbers Miyachi Unitek Corporation 15 not responsible for any loss due to improper use of this product 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 SAFETY NOTES e Lethal voltages exist within this unit Never perform any maintenance inside this unit e Never perform any welding operation
2. ALARM RELAY RELAY COMMON GROUND 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 B 4 APPENDIX ELECTRICAL AND DATA CONNECTIONS Signal Interface General Description 37 Pin Connector 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 lL _ __ 19 18 17 16 15 14 13 12 11 40 9 8 7 6 5 4 3 2 1 Pinno Description ooo 1 24VDC The total current draw from pins 1 and 19 must not exceed 500 mA Optical firing switch input Not used Firing switch input FS1 Foot switch level 1 input Not used Weld inhibit input Weld counter reset input Program lock input Binary schedule select bit 1 Binary schedule select bit 4 Binary schedule select bit 16 not available on all models Dual weldhead input Weld ready relay output Counter exceeds limit relay output Weld out of limits relay not available on all models Not used Not used 24VDC The total current draw from pins 1 and 19 must not exceed 500 mA Ground Not used Not used FS2 Foot switch level 2 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 B 5 APPENDIX ELECTRICAL AND DATA CONNECTIONS Relay common Ground Two Level Foot Switch Connector Foot Switch Connector Description Chassis Ground Foot 1 to
3. 1 4 Igel gin CC a pirat rises caput 1 7 M 1 7 I mm 1 7 IEmieroeucy Stop WI 1 _____________ LUE 1 7 Chapter 2 Installation and Setup _______ _ _ 2 1 c 2 1 R UTE SN 2 1 nu 2 2 lov i 2 2 Compressed Air and Cooling Water 2 2 Input I 05 ______________ 2 2 videamus 2 3 Connections to External 2 3 ea 2 4 Foot Pedal Actuated Weld Head Connection 2 5 EZAIR Weld Head C OMING 8 san dee emisse 2 6 Chapter 3 Operation DeocHon E eee ee ee ree eer eee 3 1 Boor 3 1 OaE 11 16 lt lt re E 3 1 Aree BO NR 3 1 qo 3 eno vi RS RR 3 Adjust Buzzer ___________88 _ 6 3 1 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990
4. 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 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY E 4 990 295 APPENDIX DEFINING THE OPTIMUM PROCESS R1 amp R7 The electrode resistances affect the conduction of energy and weld heat to the parts and the rate of heat sinking from the parts at the end of the weld R2 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 Bulk Resistances become higher during the weld as the parts are heated If a weld 15 initiated when the contact resistances are still high the heat generated 15 in relation to the level and location of the contact resistances as the materials have not had a chance to fit up correctly It 1s common for the heat generated at the electrode to part and part to part resistances to cause multiple welding problems when welding resistive materials including e Part marking and surface heating Weld splash or expulsion e Electrode sticking e Weak welds Alternately conductive materials can be welded by using high contact resistance and fast heating because their bulk resistance is not high and cannot be relied upon for heat generation I
5. S 2 2 2 Cold Rolled 2 Steel D 14 E 14 14 E 9 2 14 2 14 Paliney 7 2 MATERIAL Steel Dune jw be 14 14 14 2 Cold Rolled Steel i km 2 ew Kovar Gold 2 Kulgrid 2 Plate Kovar Gold 2 Nickel 2 Plate Kovar Gold 2 Silver 11 14 Plate Kovar Gold 2 Stainless Steel 2 Plate 1 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 D 3 APPENDIX D THE BASICS OF RESISTANCE WELDING MATERIAL MATERIAL Steel 2 Cold Rolled 2 Steel 2 Stainless Steel Molybdenum Molybdenum Nichrome Nichrome Nichrome Nichrome Nickel Nickel Nickel Nickel Nickel Copper 2 Cold Rolled 2 Steel Electrode Maintenance Nickel Alloy Nickel Alloy Nickel Alloy Nickel Alloy Nickel Alloy Nickel Alloy Nickel Alloy Nickel Alloy MATERIAL MATERIAL NiSpan C 2 Cold Rolled 2 Steel NiSpan C Stainless Steel 2 NiSpan C NiSpan C Niobium Paliney 7 Paliney 7 2 sie TET TT Cold Rolled Cold Rolled 2 Steel Steel Stainless Steel 2 Stainless Steel 2 Stainless Steel 2 Platinum Cold Rolled Steel Cold Rolled Steel Stainless Steel 2 Titanium Tungsten Tungsten Zinc Depending on use periodic tip resurfacing is required to remove oxides and welding debris from electro
6. weld window for energy time and force This part of weld development 15 critical in order to proceed to a statistical method of evaluation Design of Experiments or Random explosions or unexpected variables will skew statistical data and waste valuable time 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 E 9 APPENDIX DEFINING THE OPTIMUM PROCESS Poor Follow up Sparks Insufficient Force Impact Force Sparks Variation N A lt lt Variation sparks NS No Squeeze No Hold Sparks Hold Variation ea queeze Common welding problems can often be identified in the basic set up of the force energy and time welding profile shown above These problems can lead to weld splash inconsistency and variation contact Unitek Equipment for further information and support What are Screening DOE S The purpose of a Screening DOE 15 to establish the impact that welding and process parameters have on the quality of the weld Quality measurement criteria should be selected based on the requirements of the application A Screening DOE will establish a relative quality measurement for the parameters tested and the variation in the welded result This is important as identifying variation in process 15 critical in establishing the best production settings Typically welded assemblies are assessed for strength of joint and variation in strength A Screening D
7. Press the PULSE 1 button to modify Pulse 1 Hold the button for about 1 second and wait for the LED to turn OFF Stop pressing the button The LED will then flash When the LED 15 flashing the Power Supply is in the edit mode To modify the energy press the A arrow to increase energy or press the V arrow to decrease energy To modify pulse duration press the PULSE SELECT button until the pulse length you want 15 lit underneath the 3 digit energy display NOTE The Very short setting gives the highest peak current and shortest duration for the energy setting The Long setting gives the lowest peak current and longest duration for the energy setting To modify polarity press the POLARITY SELECT button repeatedly until the polarity you want is lit underneath the 3 digit energy display NOTE When ALTERNATING polarity is selected both waveforms will be lit Press the PULSE 1 button to save any changes made To modify the squeeze time press and hold the SQZ button for about 1 second The green LED on the button goes ON and the 6 digit COUNTER display begins to flash While the 6 digit display is flashing press the A arrow to increase squeeze time or press the V arrow to decrease the squeeze time When you get the squeeze time you want press the SQZ button again until 6 digit COUNTER display stops flashing To modify the hold time press and hold the HOLD button for about 1 second The green LED on the button goes ON and t
8. contact Miyachi Unitek for service Calibration value out of The value of the capacitance entered Contact Miyachi Unitek for limits during calibration is out of limits service Memory write error The internal memory writing process Contact Miyachi Unitek for did not complete within 1 second service 3 Firing Switch timeout The firing switch did not close Adjust the weldhead and or within 10 seconds of FS2 closing parts to be welded so that the firing switch closes within 10 seconds of FS2 closing Memory error The values stored in memory have Contact Miyachi Unitek for been corrupted Default values have service been reloaded into the unit 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 4 2 990 295 CHAPTER 4 MAINTENANCE Error Number Error Name Description Troubleshooting Steps 7 Blown fuse The internal fuse in the unit has been 1 Verify that the unit is blown plugged into the correct AC voltage 2 Contact Miyachi Unitek for service Internal communication An error occurred in the internal Contact Miyachi Unitek for error communication between the front service panel and control board Open load detected The resistance of the secondary 1 Verify that the weldhead circuit 18 too high is closed when the unit fires 2 Verify that the weld cables are tightly connected 3 Verify that the electrode is properly installed in the weldhead 4 If the process requires operation with a high secon
9. shape Polarity heating rate upslope e Observation visual criteria cross section and impact of variables on heat balance 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY E 8 990 295 APPENDIX DEFINING THE OPTIMUM PROCESS Process Perspective What the likely variables 1 a production process How will operators handle and align the parts What tooling or automation will be required How will operators maintain and change the electrodes What other parameters will operators be able to adjust What are the quality and inspection requirements What are the relevant production testing methods and test equipment Do we have adequate control over the quality of the materials Common Problems During this stage of process development it is important to understand that the majority of process problems are related to either materials variation or part to electrode positioning Some examples are shown below Material Control Part To Part Positioning Electrode To Part Positioning The changes detailed above generally result in a change 1 contact resistance and always affect the heat balance of the weld During weld development these common problems must be carefully monitored so as not to mislead the course and productivity of the welding experiments In summary the look see welding experiments should be used to fix further variables from an application and process perspective and also to establish a
10. After the limit is reached the Power Supply will beep each time a weld is made This signals the Operator to take action Pressing this button for about 1 second causes the green LED on the button to go ON and the 6 digit COUNTER display to blink This allows the AV arrows to increase or decrease the LIMIT SET value Pressing this button again saves the setting and stops the 6 digit display from blinking and saves the value This feature is useful for counting weld made on a set of electrodes to determine when to change electrodes When you are using the weld count limit set squeeze time or hold time functions the time in the 6 digit COUNTER display will reset to zero when you press and hold this button for about a second Depending on which button 15 pressed this 6 digit display in the COUNTER section is used to display the number of welds made WELDS the limit that has been set for a set of electrodes LIMIT SET squeeze time SQZ or the hold time HOLD It also displays error codes as described in Chapter 4 Pressing this button causes the green LED on the button to go ON and the 6 digit COUNTER display will show the squeeze time for the current schedule Pressing this button for about 1 second causes the green LED on the button to go ON and the 6 digit COUNTER display to blink This allows the AV arrows to increase or decrease the squeeze time Pressing this button again saves the setting Pressing this b
11. Contaminated weld piece surface Weld Piece Excessive weld time set at 100DP 300DP Sticking plating Warping Excessive weld head force 1 Wrong electrode material tip shape Incompatible weld piece projection Insufficient weld head force design Excessive energy set at 100DP 300DP 2 Incompatible weld piece materials Contaminated electrode surface 2 Wrong electrode tip shape Slow weld head follow up 3 Excessive current energy set at 100DP 300DP Insufficient 1 Insufficient energy set at 100DP 300DP Metal 1 Excessive current energy set at Weld Wrong electrode material tip shape Expulsion 100DP 300DP Nugget Warn mushroomed electrodes 1 Insufficient weld head force Excessively long pulse time set at Slow weld head follow up 100DP 300DP 1 Incompatible weld piece projection 2 Incorrect weld head polarity design 2 Contaminated weld piece surface 2 Contaminated weld piece surface plating plating Incompatible weld piece materials 2 Excessive weld head force Contaminated electrode surface 3 Insufficient weld head force Wrong electrode tip shape 3 Contaminated electrode surface No cover gas on weld piece 3 Incompatible weld piece projection Excessively short weld time set at design 00DP 300DP 3 Slow weld head follow up 4 Incompatible weld piece materials 4 No cover gas on weld piece 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 4 1 CHAPTER 4 MAINTENANCE Cause in orde
12. PROCESS Conclusion The resistance welding process can deliver a reliable and repeatable joining solution for a wide range of metal joining applications Defining the optimum welding process and best production settings can be achieved through a methodical and 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 15 carried out to identify the impact of common variables on the quality and variation of the welded assembly Unitek Equipment frequently uses the Screening DOE tool to establish the impact of key variables and to assist customers with troubleshooting Often the testing described above will provide the information and understanding to predict common failure modes and causes A troubleshooting guide can be requested in the form of a slide rule to assist users in identification of welding problems and likely causes 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY E 12 990 295
13. a relationship between quality and the monitored measurement parameter Criteria for Success Critical parameters should be identified from the list of unfixed variables left from the Screening DOE s A mini experiment may be required establishing reasonable bounds for the combination of parameters to be tested This will prevent void data and wasted time At this stage it 15 useful to record multiple relevant quality measurement or inspection criteria so that a balanced decision can be reached For example 1f part marking and pull strength are the relevant criteria a compromise in ideal setting may be required As with all experiments the test method should be carefully assessed as a potential source of variation and inconsistency Once the optimum parameters have been established in this series of experiments a validation study can be run which looks at the consistency of results over time It is good practice to build in variables such as electrode changes and cleaning as well as equipment set up by different personnel This will ensure that the solution is one that can run in a real production environment Welded assemblies should be tested over time and under real use conditions to ensure that all functional criteria will be met Validation testing 15 usually required to prove the robustness of the process under production conditions 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 E 11 APPENDIX DEFINING THE OPTIMUM
14. average power Automatic turndown upon power interruption circuit 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 A APPENDIX TECHNICAL SPECIFICATIONS oo mem __ Repetition Rate Single Pulse in pulses 100DP 300DP per minute 320 min 750 min 240 min 520 min 170 min 345 min 110 min 240 min 85 min 200 min 75 min 175 min 140 min 120 min 105 min 80 min Rise Times at Max 100DP 300DP Energy Very Short VS 0 6 ms 0 9 ms Short S 0 6 ms 1 0 ms Medium M 0 8 ms 1 5 ms Long L 1 2 ms 1 6 ms Weld schedules Weld pulses per Schedule Watt Second 100DP 1 to 100 Watt Seconds Ws Adjustment Range 300DP 3 to 300 Watt Seconds Ws Polarity Selection Positive Negative or Alternating Hold Time 0 2999 msec Weld Counter 0 999999 Upon Reaching Buzzer sounds after each weld Output relay activates imit Input Debounce Time 32 msec Control Outputs Weld ready 24VAC or 30VDC max 500mA max See Appendix B for Weld end 24VAC or 30VDC max 500mA max details Counter reached limit 24 or 30VDC max 500mA max 24 VDC and return for optical firing switch Environmental Operating Humidity 5 to 95 Non condensing Operating Temperature 5 C to 40 C Ambient Temperature Valve power 24 VAC 1A maximum 24 VDC 1A maximum including any current drawn from pins 1 and 19 of the 37 pin I O connector 100DP 300DP DUAL PULSE RESISTAN
15. finish of the welding process The figure on the right Welding Force shows a typical welding sequence where the force is applied to the parts a Squeeze time is initiated which allows the force to stabilize before the current is fired Squeeze time also allows time for the contact resistances to reduce as the Squeeze Heat Hold materials start to come into closer contact at their interface A hold time 1s initiated after current flows to allow the parts to cool under pressure before the electrodes are retracted from the parts Hold time 15 important as weld strength develops in this period This basic form of weld profile 15 sufficient for the majority of small part resistance welding applications Trigger Force Current Power supply technology selection is based on the requirements of both the application and process In general closed loop power supply technologies are the best choice for consistent controlled output and fast response to changes 1 resistance during the weld for further details comparison see the Unitek Equipment slide rule tool 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 E 7 APPENDIX DEFINING THE OPTIMUM PROCESS Approach to Weld Development The first stage in developing a quality welding process 15 to fix as many of the variables as possible in the welding equipment set up The welding variables can be grouped in the following categories e Material Variables e Process Var
16. in Chapter 3 Operating Instructions NOTE For the rest of this manual the Miyachi Unitek 100DP 300DP Dual Pulse Resistance Welding Power Supply will simply be referred to as the Power Supply Description The Power Supplies are versatile 100 Watt second and 300 Watt second stored energy capacitor discharge dual pulse power supplies which can effectively solve most precision small parts resistance welding problems You can program up to 15 weld schedules and save them in memory A built in schedule protection feature protects weld schedules from unauthorized or inadvertent changes The exclusive charge monitor and firing lockout feature guarantees that weld quality is independent of line voltage fluctuations and the speed at which the power supply 15 operated Dual pulse welding improves weld quality and eliminates weld splash Dual pulse means each weld is performed with two pulses with independent energy levels and independent polarity The first pulse displaces the plating or contamination and reforms the surface so that it 1s in intimate contact with the electrode The second pulse welds the base metals The remote schedule feature allows the Power Supplies to reliably select weld schedules in automated applications The Power Supplies can be used with manual user actuated or air actuated weld heads The units are designed to operate at either 100 120VAC or 200 240VAC 50 60 Hz 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SU
17. is to regularly re grind electrode tip surfaces and shapes in a certified machine shop Parts Replacement Below 15 a list of the replacement parts for the Control items listed are a quantity of 1 each WARNING Only qualified technicians should perform internal adjustments or replace parts Removal of the unit cover could expose personnel to high voltage and may void the warranty Overvoltage Protection Fuse F1 330 197 Power PCB 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 4 4 990 295 CHAPTER 4 MAINTENANCE Section Ill Repair Service If you have problems with your Control that you cannot resolve please contact our service department at the address phone number or e mail address listed under Contact Us 1 the front of this manual 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 4 5 APPENDIX Technical Specifications NOTE The specifications listed in this appendix may be changed without notice 10 8 inches 275 mm 900p AL PULSE Ei Weight 300DP 66 165 30 kg 100DP 37 165 17kg Input line voltage 85 138 VAC 50 or 60 Hz 180 264 500r60Hz Overvoltage Detection Internal fuse Input VA 1300 VA Max demand Charge circuit type Switched mode Weld Capacitor Charge 430 V max Voltage Weld Capacitance As required to achieve Output Energy Output Energy 100DP 100Ws Max per pulse 300DP 300Ws Voltage turndown 50W
18. verified 5 Setthe circuit breaker on the rear panel of the Power Supply to the ON position 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 2 5 CHAPTER 2 INSTALLATION AND SETUP EZ AIR Weld Head Connections NOTE These instructions describe connection to the Miyachi Unitek EZ AIR weld head Non EZ AIR heads be connected to the Power Supply but are not covered in these instructions For 22 AIR head instructions refer to the manual provided with the specific weld head FORCE ADJUSTMENT KNOB FORCE INDICATOR Set to 5 EZ AIR SHOP AIR amm WELD HEAD MIYACHI i WELD HEAD CABLE EMERGENCY STOP SWITCH FOOT SWITCH m REAR PANEL 1 Adjust the weld head force adjustment knob to produce 5 units of force as displayed on the force indicator index 2 Connect the weld head firing switch cable connector to the Power Supply firing switch cable connector 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 2 6 990 295 CHAPTER 2 INSTALLATION AND SETUP 3 Connect a normally closed approved EMERGENCY STOP SWITCH across the two leads of the operator emergency stop switch cable This switch when operated open will immediately stop the weld cycle and retract the weld head See Appendix B Electrical and Data Connections for circuit details 4 Connect a Model FS2L or FS1L Foot Switch to the Power Supply FOOT SWITCH c
19. 222 5 MANUAL 990 295 22 MIYACHI Revision B June 2007 100DP 300DP DUAL PULSE STORED ENERGY RESISTANCE WELDING POWER SUPPLIES Model Stock No 100DP 115 1 293 01 100DP 230 1 293 01 01 300DP 115 1 294 01 300DP 230 1 294 01 01 Copyright 2005 Miyachi Unitek Corporation The engineering designs drawings and data contained herein are the proprietary work of Miyachi Unitek Corporation and may not be reproduced copied exhibited or otherwise used without the written authorization of Miyachi Unitek Corporation Printed in the United States of America Revision Record 20633 12 05 None Original edition 21448 6 07 Added open load detection feature 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 5 606 11 A 7 vi Chapter 1 Description SOn o cone cats ae 1 1 a UY 1 1 lh uui e ___ _6 68____ ___ _ 6___ 8 1 2 Section IE S O E A OE 1 4 NGO 1 3 Front Panel Display and Display Controls 1 3 Schedule Number and C hain aei RE AE 1 4 Energy and Pulse Indicators Pulse Edit Buttons Up Down Buttons
20. 295 CONTENTS Continued Page Chapter 3 Operation Continued MORET 3 2 0 ___________8_ 3 3 We UGS cee E EEEN E 3 3 Modify Weld Schedules 3 3 the CDOS NR ___6_ _6 __ 3 4 cng var 3 4 en 3 5 Head OP r gt ______ ____ _ ___ 3 5 LOCK ee of cemetary 3 5 DCIS MINS LOCE EC 3 5 Chapter 4 Maintenance DECHOB TONDE OOIE ee ee ee ee ne AEE E ee ee ee ee 4 MTG WONG ditare ENT 4 1 TL 4 2 Scc on UL 4 4 on eee Re ene eee on ee oon ee 4 4 PES CUS Maintenance Pest to 4 4 Parts 4 4 DeeHon INS 4 5 Appendix A Technical Specifications 1 Appendix B Electrical and Data Connections 1 Appendix C System Timing 1 Appendix D The Basics of Resistance Welding
21. CE WELDING POWER SUPPLY A 2 990 295 APPENDIX A TECHNICAL SPECIFICATIONS Ship Kit Contents 1 37 pin mating connector with hood 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 XXX A 3 APPENDIX B Electrical and Data Connections Section Electrical Connection Input Power As described in Chapter 2 you need to supply an AC power cord The female end of the power cable is IEC 320 C13 standard plug The length of the cord and the male end are as required in your local installation Connect the Power Supply power cable to a 1 phase 50 60Hz power source The voltage range for each model is set at the factory If you wish to change the operating voltage of your unit please contact Miyachi Unitek Corporation for the required components and installation instructions See CONTACT US in the front of this manual for contact information AN CAUTION Be sure that the AC power is the correct voltage for your Power Supply model 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 B 1 APPENDIX ELECTRICAL AND DATA CONNECTIONS Section Il External Input Outputs Input Logic Configuration The unit is shipped from the factory configured for LOW TRUE INPUTS This is a common set up when using a switch closure to ground to activate or to turn an input ON The unit can also be configured for HIGH TRUE INPUTS This is a common set up for using a PLC or other external device to supply 24VDC to activate o
22. NO WELD Emergency Stop Switch Operation If your work station is equipped with an EMERGENCY STOP SWITCH connected to the emergency stop connection of the Control operate the switch to immediately stop the welding process All power to the air valves and power circuits will be disconnected The 6 digit display will show E STOP To resume operation reset the EMERGENCY STOP SWITCH to the normal position 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 1 7 2 Installation and Setup Section Installation Unpacking The Power Supply 15 shipped to you completely assembled together with the accessories you ordered and a shipping kit The contents of the shipping kit 1s listed in Appendix A Technical Specifications sure that the contents of the shipping kit match the Shipping Kit List and that you have received the accessories that you ordered Verify that the Power Supply shows signs of damage If it does please contact the carrier Also contact Miyachi Unitek Customer Service at the address phone number or e mail address listed under Contact Us in the front of this manual Space Requirements e Allow ample workspace around the Power Supply so that it will not be jostled or struck 4 9 4 inches gt while welding 240 mm e Allow sufficient clearance around both sides and back of the Power Supply for power and signal cabling runs e Install the Power Supply in a well ven
23. OE tests the high low settings of a parameter and will help establish 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 The DOE promotes understanding of many variables in a single experiment and allows the user to interpret results thus narrowing the variables for the next level of statistical analysis If many variables are still not understood multiple Screening DOE s may be required Unitek Equipment provides a simple Screening DOE tool that is run in Excel and is sufficient for the majority of possible applications contact Unitek Equipment for details Sophisticated software 1s also available from other vendors designed specifically for this purpose 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY E 10 990 295 APPENDIX DEFINING THE OPTIMUM PROCESS Criteria for Success Before running the series of experiments the user must establish an acceptable window for energy time and force thus preventing voided results It is common practice to include one or all of the above variables in a Screening DOE This is only recommended if sufficient understanding has been established for the other
24. PPLY 1 2 990 295 CHAPTER 1 DESCRIPTION Section Major Components Major Components The major components are the front panel which contains the operator s controls and indicators and the rear panel which contains fuses circuit breakers and power and signal connectors The rear panel connections are discussed in Chapter 2 Installation and Setup Front Panel Display and Display Controls The front panel of the Control below shows controls and indicators The function of each item 15 described on the following pages SCHEDULE ENERGY UP DOWN NUMBER INDICATORS BUTTONS CHAIN BUTTON __ A LIGHTED INDICATORS Ss PULSE EDIT BUTTON WELDS BUTTON E e LIMIT SET BUTTON PULSE SELECT BUTTON 1 7 POLARITY BUTTON CLEAR BUTTON CD iii COUNT INDICATOR SQUEEZE BUTTON HOLD BUTTON k CHARGE MONITOR INDICATOR ______ momong WELD TERMINALS E 2 MIYACHI UNITEK WELD WELD 1000 DUAL PULSE SWITCH STORED EMEROY POWER SUPPLY Front Panel Controls 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 1 3 CHAPTER 1 DESCRIPTION Schedule Number and Chain Switch The 2 digit LED displays which welding schedule 15 selected for use The CHAIN SCH 1 2 button will chain Schedule 1 and Schedule 2 together meaning welding pulses will alternate between these two schedules The green lig
25. RUE INPUTS This is used for a switch closure to ground to activate or to turn an input ON The unit can also be configured for HIGH TRUE INPUTS which is commonly used for a PLC or other external device to supply 24VDC to activate or to turn an input ON Instructions for changing this configuration including electrical schematics are in Appendix B 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 2 2 990 295 CHAPTER 2 INSTALLATION AND SETUP Section Il Setup Connections to External Equipment All connections other than the weld cable connections between the Power Supply and external equipment are made through the rear panel FOOT AIR SWITCH VALVE WELD HEAD CONNECTOR DRIVE CONNECTOR FIRING SWITCH CONNECTOR CABLE EMERGENCY STOP SWITCH CONNECTOR CABLE 37 PIN DATA CONNECTOR CIRCUIT BREAKER ON OFF SWITCH AC POWER CONNECTOR Rear Panel Components and Connectors NOTE The weld cable connections from the weld head are made at the weld cable terminals on the front panel 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 2 3 CHAPTER 2 INSTALLATION AND SETUP Weld Head Connections WELD TERMINALS WELD CABLES CAUTIONS 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 Connect one end of a weld cable to the
26. SE SELECT button and wait for the counter display to show BUZZ 2 Use the AV arrows to adjust the buzzer loudness from 0 to 4 3 When you get the loudness you like press PULSE SELECT on the front panel to accept the change and return to normal operation 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 3 1 CHAPTER 3 OPERATING INSTRUCTIONS Initial Setup 1 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 2 Adjust the weld head force adjustment knob for a force appropriate for your welding application A good starting point 15 the mid point 1 the range of the weld head force 3 When you are ready to perform a weld be sure to set the WELD NO WELD switch back to the WELD position 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 3 2 990 295 CHAPTER 3 OPERATING INSTRUCTIONS Section Il Operation Using Existing Weld Schedules 2 Use the AV arrows to select the weld schedule you want to use Press the WELD NO WELD switch to the WELD position Begin welding using your normal procedures NOTE Welding will be performed using the values for the schedule you selected until you select a new schedule Modify Weld Schedules l 2 3 10 11 Press the WELD NO WELD switch to the NO WELD position Use the AV arrows to select the weld schedule you want to modify
27. WELD INHIBIT INPUT WELD COUNT RESET INPUT PROGRAM LOCK INPUT BINARY 1 BINARY 4 BINARY 16 Advanced Unit ONLY DUAL HEAD INPUT WELD READY RELAY COUNTER LIMIT RELAY OUT OF LIMIT RELAY Advanced unit ONLY 24V 500mA max shared with pin 1 GROUND Typical Isolated Input Sw BAK FAULT RESET INPUT SCHEDULE LOCK INPUT COMMON BINARY 2 BINARY 8 BINARY 32 Advanced unit ONLY WELD END RELAY _ ALARM RELAY RELAY COMMON GROUND 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 B 3 APPENDIX ELECTRICAL AND DATA CONNECTIONS Configuration for High True Inputs PLC or 24V to Activate Inputs m USER SIDE UNIT SIDE gt 24V 500mA max shared with pin 19 OPTO FOOTSWITCH INPUT FIRE FS1 WELD INHIBIT INPUT WELD COUNT RESET INPUT PROGRAM LOCK INPUT BINARY 1 BINARY 4 BINARY 16 Advanced Unit ONLY DUAL HEAD INPUT WELD READY RELAY COUNTER LIMIT RELAY __ OUT OF LIMIT RELAY Advanced unit ONLY 24V 500mA max shared with pin 1 GROUND Typical Isolated Input FAULT RESET INPUT SCHEDULE LOCK INPUT COMMON BINARY 2 BINARY 8 BINARY 32 Advanced unit ONLY WELD END RELAY
28. aced 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 1s preferred for round wire and a 45 degree peel test for sheet stock 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 D 5 APPENDIX D THE BASICS OF RESISTANCE WELDING Weld Strength Profiles Creating a weld strength profile offers the user a scientific approach to determining the optimum set of welding parameters and then displaying these parameters in a graphical form Start at a low weld current voltage or power making five or more welds then perform pull tests for each weld Calculate the average pull strength Increase weld current voltage or power and repeat this procedure Do not change the weld time weld force or electrode area 2 Continue increasing weld current voltage or power until any unfavorable characteristic occurs such as sticking or spitting 3 Repeat steps 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 Stren
29. activate Foot Switch Level 1 connect to pin 4 Foot 2 to activate Foot Switch Level 2 connect to pin 4 24COM When you press the foot switch to the first level the Power Supply energizes the air actuated weld head This causes the upper electrode to descend and apply force to the weld pieces If you release the foot switch before pressing it to the second level the Power Supply will automatically return the upper electrode to its UP position so that you may re position the weld pieces If you do not release the foot switch at the first level and proceed to the second level the force firing switch in the weld head will close Weld current will flow and the Power Supply will automatically return the upper electrode to its UP position 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 B 6 APPENDIX ELECTRICAL AND DATA CONNECTIONS Standard Air Valve Driver Output Connector Air Valve Driver 24 VAC Connector Description 24VAC for solenoid HEAD 1 Switched 24V common The air valve driver output 24V is initiated when Foot Switch Level 1 is initiated If a PLC or other means of trigger 1s used refer to the O Signal Interface General Description on page B 3 The mating connector is an AMP type 206429 1 using cable clamp AMP type 206358 2 The two male pins used are Amp type 66361 2 Weld Head Connector Weld Head Connector OOO EN HEAD 1 switched 24V common for sol
30. application and process variables that can impact quality Users should first try to screen out all common application and process variables that require further exploration from the results of the look see mini experiments and then include the three key welding variables energy force and time Several Screening DOE s may be required Results should be interpreted carefully Typically one would look for the highest result in terms of quality with the least variation A Screening DOE provides only a measurement that indicates the relative importance of a parameter and not the ideal setting Factorial DOE s should be used to establish the correct or best setting for a parameter once many of the other variables have been screened and fixed This is also the time to assess the measurement accuracy and consistency of the test method and procedure Variation in test method can invalidate the test and lead to misinterpretation of results What are Factorial DOE s The purpose of a Factorial DOE 1s to narrow in on the optimal setting for a particular parameter This method is generally used when the critical or main key variables have been identified and we need to establish the best settings for the process A factorial DOE may also give an indication as to how wide the acceptable weld window 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
31. be used to count the number of welds during a particular shift or work day After the limit is reached the Power Supply will beep each time weld 15 made This signals the Operator to take action Press the LIMIT SET button and wait for the green LED on the button to go ON When it does the 6 digit COUNTER display will show the limit set for the number of welds made To change the LIMIT SET number press this button for about 1 second and wait for the 6 digit display to flash When it flashes you can then press the A V arrows to increase or decrease the number of welds for LIMIT SET To accept the changes press the LIMIT SET button again and the LED will stop flashing To exit the editing mode without accepting changes press any other button on the front panel 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 3 4 990 295 CHAPTER 3 OPERATING INSTRUCTIONS Chain Schedules 1 amp 2 1 Use the AV arrows to select weld Schedule 1 and Schedule 2 in order to verify that each schedule displays the values you want to use If not follow the Modify Weld Schedules procedures above 2 After you have verified that Schedule 1 and Schedule 2 are correct press and hold the CHAIN SCH 1 2 button for about 1 second and verify that the green light on the switch is ON The CHAIN SCH 1 2 button will chain Schedule 1 and Schedule 2 together meaning welding pulses will alternate between these two schedules The green ligh
32. d 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 MATERIALI ELECT MATERIAL RWMA TYPE 1 Aluminum Alloys 1 Cadmium Plating x Alumel Alumel Aluminum Aluminum Aluminum Aluminum 1 Tinned Copper 1 Gold Plated Dumet 1 Gold Plated Kovar 1 Cold Rolled Steel 1 Stainless Steel 2 Beryllium 2 Copper 2 Tinned Copper Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Beryllium Copper Beryllium Copper Beryllium Copper 2 2 2 1 1 1 14 14 2 2 2 1 14 Beryllium 14 Copper Beryllium 2 Copper 2 2 14 2 14 2 2 2 2 2 2 2 14 2 2 14 Cold Rolled Steel 2 2 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY D 2 990 295 MATERIAL Bronze Bronze Chromel Chromel Chromel Chromel Chromel Chromel Chromel Chromel Consil Consil Consil Constantan Constantan Constantan Constantan Constantan Constantan Copper Copper Copper Copper Copper Copper Copper Copper 2 11 2 11 NO 2 20 2 2 NO APPENDIX D THE BASICS OF RESISTANCE WELDING MATERIAL Nichrome 2 2 2 2 20 14 14 2 2 NO NO 2
33. d interface thus preventing the formation of harmful alloys that could form brittle compounds that are easily fractured Remember that in a solid state joint the metals are only heated to 70 80 of their respective melting points resulting in less thermal stress during heating and subsequent joint cooling 1 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 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY E 2 990 295 APPENDIX DEFINING THE OPTIMUM PROCESS Consider the Material Properties The important material properties to be considered in the resistance welding process are e Electrical and thermal conductivity e Melting point Plating and coating Oxides e Hardness The figure below illustrates the variance in resistivity and melting points for some of the more common materials used in micro resistance welding today Ti 6Al 4V OFF Scale Nichrome 800 Group 600 TN Resistivity Stainless Steels nano ohm 304 316 etc Group Ti 400 Group Br Pt Ir ee eee i Steel Nb Bro ii Ni Pt Al Ag T W 500 1000 1500 2000 2500 3000 350 Melting Point The materials can be grouped into three common categories The types of joints achievabl
34. dary circuit resistance contact Miyachi Unitek for assistance 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 4 3 4 Section Il Maintenance Calibration Calibration must be performed by factory trained and qualified personnel If your Power Supply needs calibration contact your local Miyachi Unitek service representative or contact our service department at the address phone number or e mail address listed under Contact Us in the front of this manual 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 increasing weld current density thus cooling the weld Try replacing the electrodes The rough surface of a worn electrode tip tends to stick to the work pieces So periodic tip resurfacing dressing 1s required to remove pitting oxides and welding debris from the electrode You should limit cleaning of an electrode on the production line to using a 400 600 grit electrode polishing disk If you must clean a badly damaged tip with a file you must use a polishing disk after filing to ensure the electrode faces are smooth The best method of preventing electrode problems
35. de to part contact area 3 Use the Force Adjustment Knob on the Weld Head to set the Firing Force and adjust an Air Actuated Weld Head 4 Program a weld schedule then make your first weld Always observe safety precautions when welding and wear safety glasses For a complete procedure on making welds refer to Operating Instructions 5 Use pliers to peel the welded materials apart A satisfactory weld will show residual material pulled from one material to the other Tearing of base material around the weld nugget indicates a material failure NOT a weld failure Excessive electrode sticking and or spitting should define a weld as unsatisfactory and indicates that too much weld current voltage power or time has been used 6 Ifthe parts pull apart easily or there 1s little or no residual material pulled the weld is weak Increase the weld time in 1 msec increments Increase weld current voltage or power if a satisfactory weld achieved using 10 msec of weld time NOTE Actual weld strength 15 user defined specification 7 Polarity as determined by the direction of weld current flow can have a marked effect on the weld characteristics of some material combinations This effect occurs when welding materials with large differences in resistivity such as copper and nickel or when welding identical materials with thickness ratios greater than 4 to 1 The general rule 1s that the more resistive material or the thinner material should be pl
36. des Cleaning of electrodes on production line should be limited to use of 400 600 grit electrode polishing disks For less critical applications a file can be used to clean a badly damaged tip However after filing polishing disks should then be used to ensure that the electrode faces are smooth If this 15 not done the rough surface of the electrode face will have a tendency to stick to the work piece 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY D 4 990 295 APPENDIX D THE BASICS OF RESISTANCE WELDING Weld Schedule Development Developing a weld schedule is a methodical procedure which consists of making sample welds and evaluating the results The first weld should be made at low energy settings Adjustments are then made to each of the welding parameters one at a time until a successful weld 15 made 1 Install the correct electrodes in the electrode holders on the Weld Head See the preceding Table for electrode material recommendations 2 Usea flat electrode face for most applications Use a domed face if surface oxides are a problem If either of the parts is a wire the diameter of the electrode face should be equal to or greater than the diameter of the wire If both parts are flat the face should be at least one half the diameter of the electrodes Pencil point electrodes cause severe electrode sticking to the parts unexplained explosions and increase the weld heat substantially because of the reduced electro
37. e within each of the main groups are detailed below Group 1 Conductive Metals Conductive metals dissipate heat and it can be difficult to focus heat at the interface A solid state joint is therefore preferred Typically resistive electrode materials are used to provide additional heating 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 E 3 APPENDIX DEFINING THE OPTIMUM PROCESS Group 1 Resistive Metals It 15 easier to generate and trap heat at the interface of resistive metals and therefore it 15 possible to form both solid state and fusion welds depending on time and temperature Upslope can reduce contact resistances and provide heating in the bulk material resistance Group 11 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 Group Solid State Solid State Solid State Copper W Mo electrodes Projection on Group I Fine projections on Group Group Il Solid State or Fusion Solid state or braze of II Steel on III Projection on III Group Solid State Moly Basic Principles R2 Contact Resistance Resistance Bulk Resistance
38. enoid PIN 47 PIN 5 PIN 8 EN 24V OUT 24VDC for solenoid acom o o O VOLT COM T AIRHEAD s The Weld Head Connector combines all the inputs and outputs necessary to connect a plug and play EZ AIR Miyachi Unitek weld head If PLC or other means of trigger is used refer to the O Signal Interface General Description on page B 3 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 7 APPENDIX ELECTRICAL AND DATA CONNECTIONS Operator Emergency Stop Cable Switch Input Function You must connect a normally closed single pole switch across both cable leads otherwise the Power Supply cannot be turned ON Use the switch during Power Supply operation as an Emergency Stop Switch When operated opened it will immediately halt the weld process Connections Connect an approved normally closed emergency stop switch across the 2 foot 61 cm operator Emergency Stop Switch cable When the switch is operated opened it de energizes all power outputs from the Power Supply 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 B 8 APPENDIX System Timing Basic Weld Operation Air Head System with Two Level Foot Switch Definitions 11 D1 D2 SQZ Pulse 1 COOL Pulse 2 HOLD FOOT switch L_ LEVEL 1 WELD FORCE FOOT SWITCH 1 LEVEL 2 FIRING lo SWITCH WELDING CURRENT p1 p2 souEEzE PULSE1 cooL PULSE2 HOLD Dela
39. er If the unit were allowed to fire repeatedly into an open load it could cause internal circuits to overheat and be damaged In order to prevent this potential failure mode the unit has an overload protection feature When an open load is detected by the unit the firing circuit 15 quickly turned OFF and the unit will display ERR 12 in the 6 digit display The threshold for detecting an open load is typically about 15 milliohms If your application requires operation with a secondary circuit that exceeds this resistance please contact Miyachi Unitek for assistance 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 3 6 990 295 CHAPTER 4 Maintenance Section Troubleshooting Troubleshooting Cause in order of probability Cause in order of probability Electrode Excessive energy set at 100DP 300DP Electrode Excessive energy set at 100DP 300DP Damage 1 Excessive or insufficient weld head Sparking force Insufficient weld head force Slow weld head follow up l Wrong electrode tip shape Incompatible weld piece projection 2 Contaminated weld piece surface esign plating Contaminated weld piece surface plating 1 1 1 1 4 1 2 Excessively short pulse time set at 1 Wrong electrode tip shape 100DP 300DP gt 1 2 2 Excessively short pulse time set at 2 Wrong electrode material 00DP 300DP 2 Contaminated electrode surface Wrong electrode material Contaminated electrode surface Electrode 1
40. f a weld 15 initiated when both parts and electrodes are fitted up correctly the contact resistance 15 lower and bulk resistance now controls the heat generation This type of weld 15 achieved with a slower heating rate and normally longer time 15 preferred for welding resistive materials which can generate heat through their bulk resistance The contact resistances present at the weld when the power supply is fired have a great impact on the heat balance of a weld and therefore the heat affected zone 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 E 5 APPENDIX DEFINING THE OPTIMUM PROCESS The figure below shows a weld that is fired The figure shows a weld that is initiated when the early on 1 the weld sequence when the contact resistance is lower in this example we are contact resistance 15 still quite high using bulk resistance to generate our weld heat Contact Resistance Contact Resistance Resistance Weld Pulse Resistanc Weld Pulse Bulk Resistance Bulk Resistance Time Heat Affected Zone NOTE Larger nuggets are possible with longer weld times when using bulk resistance In general conductive materials benefit from a faster heating rate as the higher contact resistances assist heat generation in the weld Resistive materials benefit from slower heating rates which allow the contact resistances to reduce significantly Bulk resistances therefore become the major source f
41. f the weld sequence that 1s start of SQZ Maximum DELAY time is 40 msec SQZ Squeeze time Selectable range is 0 to 2999 ms Pulse 1 The timing of this weld pulse depends upon the pulse length programmed the energy setting and the impedance of the secondary circuit COOL This time is not programmable by the user It depends upon the energy level of the second pulse and ranges from 20 to 670 msec If no second pulse is programmed this time period is skipped Pulse 2 The timing of this weld pulse depends upon the pulse length programmed the energy setting and the impedance of the secondary circuit HOLD Hold time Selectable range 15 0 to 2999 ms NOTE The firing switch signal needs to be at least 50 msec duration for the unit to recognize it 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY C 2 990 295 APPENDIX D The Basics Of Resistance Welding Resistance Welding Parameters Resistance welding heat 15 produced by passing electrical current through the parts for a fixed time period The welding heat generated 15 a function of the magnitude of the weld current the electrical resistance of the parts the contact resistance between the parts and the weld force applied to the parts Sufficient weld force is required to contain the molten material produced during the weld However as the force 15 increased the contact resistance decreases Lower contact resistance requires additional weld current voltage or power to produce t
42. gth Profile 4 Repeat steps through 3 using a different but fixed weld time Typical Weld Strength Profile The picture on the right illustrates a typical weld strength profile The 14 Ib electrode force curve 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 1s 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 uU 2 TA 2 Electrode Force 30 40 50 BU 70 BO 90 100 Energy watt seconds Typical Weld Strength Profile 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY D 6 990 295 Quality Resistance Welding Solutions Defining the Optimum Process Introduction A quality resistance welding solution both meets the application objectives and produces stable repeatable results in a production environment In defining the optimum process the user must approach the application methodica
43. he 6 digit COUNTER display begins to flash 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 3 3 CHAPTER 3 OPERATING INSTRUCTIONS 12 13 14 15 16 While the 6 digit display is flashing press the A arrow to increase hold time or press the V arrow to decrease the hold time When you get the hold time you want press the HOLD button again until the 6 digit COUNTER display stops flashing To modify the settings for Pulse 2 press the Pulse 2 button Hold the button for about 1 second and wait for the LED to turn OFF Stop pressing the button The LED will then flash When the LED is flashing the Power Supply is in the edit mode Repeat steps 4 through 6 to program the settings for Pulse 2 To accept the changes press the Pulse 2 button again and the LED will stop flashing To exit the editing mode without accepting changes press clear or any other button on the front panel Using the WELDS Counter Press this button for about 1 second and wait for the green LED on the button to ON When it does the 6 digit COUNTER display will show the total number of welds the Power Supply has made since the last time it was reset to zero To reset this counter press the CLEAR button for about second and the 6 digit display will reset to zero Using LIMIT SET This feature is useful for counting weld made on a set of electrodes to determine when to change electrodes This feature can also
44. he 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 RT the square of the weld current I times the workpiece resistance R times the weld time T Welding Parameter Interaction PROBLEM CAUSE PROBLEM Parts Overheating Excessive Parts Overheating Weak Weld f Weak Weld Insufficient Nugget Insufficient Nugget Metal Expulsion eS Metal Expulsion Warping Warping Discoloration Discoloration a Electrode Damage Insufficient Electrode Damage Insufficient FORCE PROBLEM CAUSE Parts Overheating A Excessive Weak Weld E Insufficient Nugget gt Metal Expulsion Warping Discoloration Electrode Damage insufficient Interaction of Welding Parameters 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 D 1 APPENDIX D THE BASICS OF RESISTANCE WELDING Electrode Selection Correct electrode selection strongly influences how weld heat 1s generated in the weld area In general use conductive electrodes such as RWMA 2 Copper alloy when welding electrically resistive parts such as nickel or steel so that the weld heat is generated by the electrical resistance of the parts and the contact resistance between the parts Use resistive electrodes such as RWMA 13 Tungsten and RWMA 14 Molybdenum to weld conductive parts such as copper an
45. ht on this switch will be ON when the chain function 15 10 use Welding will continue repeating between these schedules until you press the CHAIN SCH 1 2 button again and the green light on the button goes OFF Welding will then continue from a single schedule Energy and Pulse Indicators e Pulse Edit Buttons e UP DOWN Buttons V Ws The 3 digit LED displays the energy for each pulse in Watt seconds Ws Ws When in the edit mode this display will flash until editing is 3 complete PULSE and POLARITY indicators These displays will light up to indicate which pulse length and polarity has been selected for each pulse Press either of these buttons for approximately 1 second to put the Power Supply into the edit mode This enables you to modify the settings for each weld schedule Press the Pulse 1 button and wait for the LED to flash When the LED flashes you can change the energy pulse length and polarity for Pulse 1 To accept the changes press the Pulse 1 button again and the LED will stop flashing To exit the editing mode without accepting changes press the clear button or any Pulse 2 other button on the front panel Press the Pulse 2 button and follow the same procedures to modify Pulse 2 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 1 4 990 295 PULSE SELECT g very stiorr vs IN 8 N tone Weld Cou
46. iables Base material Tooling level of automation Plating Repetition rate Size Part positioning Shape Maintenance electrode cleaning e Weld Head amp Mechanical Variables e Quality Requirements A Force squeeze hold Pull strength Actuation method Visual criteria Electrode material and shape e Power Supply Variables Energy Time squeeze weld hold Test method other weld joint requirements The first stage in developing a quality welding process 15 to fix as many of the variables as possible in the welding equipment set up Welding variables can be grouped in the following categories Initial Welding Trials The Look See Tests Look see welding tests are a series of mini welding experiments designed to provide a starting point for further statistical development of the welding parameters The user should adjust the key welding variables energy force time in order to identify the likely good weld window Close visual inspection of the weld parts will promote better understanding of the heating characteristics of the application The mini experiments should also be used to understand the weld characteristics from both application and process perspective Key factors in this understanding are as follows Application Perspective e Materials Resistivity melting point thermal mass shape hardness surface properties e Heat balance Electrode materials
47. lly and consider many variables In this article we will look at the following key stages and principles to be considered when defining the optimum resistance welding process e Materials and their properties e Basic resistance welding principles e Weld profiles e Approach to development e Common problems e Use of screening DOE s e Use of factorial DOE s Resistance Welding A Material World The first consideration designing a quality welding solution 15 the properties of the materials to be joined and the quality requirements of the desired welded joint At this stage it 1s 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 Plastics polymers PVC teflon e Semiconductors silicon geranium Of these only metals can be resistance welded because they are electrically conductive soften on heating and can be forged together without breaking 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 E 1 APPENDIX DEFINING THE OPTIMUM PROCESS Alloys are a mixture of two or more metals An alloy is normally harder less conductive and more brittle than the parent metal which has bearing on the type of joint one can expect when resistance welding a combination of different metals Alloy Metals atoms are nat
48. n ascend smoothly back to the UP position 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 2 7 3 Operating Instructions Section Introduction Before You Start Before operating the Control you must be familiar with the following The location and function of Controls and Indicators For more information see Chapter 1 of this manual The principles of resistance welding and the use of programmed weld schedules For more information see AppendixD The Basics of Resistance Welding For additional information on the welding process see AppendixE Quality Resistance Welding Solutions Defining the Optimum Process Pre Operational Checks Always perform these checks before attempting to operate the Control Connections Verify that the Control has been connected to a manual or air actuated weld head as described in Chapter 2 of this manual Verify that the 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 Adjust Buzzer Loudness NOTE This can only be done when the Power Supply is being powered up 1 Press the POLARITY SELECT button followed by the PUL
49. negative welding transformer terminal on the Power Supply 2 Connect one end of the second weld cable to the positive welding transformer terminal on the Power Supply 3 Connect the other end of the weld cables to the weld head 4 Install electrodes in the weld head electrode holders NOTES e Do not attach the firing switch foot switch or EMERGENCY STOP cables at this time e If you need additional information about the weld heads please refer to their user s manuals 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 24 990 295 CHAPTER 2 INSTALLATION AND SETUP Foot Pedal Actuated Weld Head Connection FORCE REAR PANEL ADJUSTMENT KNOB FORCE INDICATOR Set to 5 WELD HEAD EENUS SWITCH CABLE Adjust the weld head force adjustment knob to produce 5 units of force as displayed on the force indicator index 2 Connect the weld head firing switch cable connector to the Power Supply firing switch cable connector 3 Connect normally closed approved EMERGENCY STOP SWITCH across the two leads of the operator emergency stop switch cable This switch when operated open will immediately stop the weld cycle See Appendix B Electrical and Data Connections for circuit details 4 Setthe WELD NO WELD switch on the Power Supply front panel to the NO WELD position In this position the Power Supply cannot deliver weld energy but the firing switch connection can be
50. nter and Setup Pulse Select CHAPTER 1 DESCRIPTION The UP and DOWN buttons have two functions During normal operation these are used to scroll up or down through the schedule numbers in order to select a schedule The schedule number displayed in the 2 digit LED 1s the schedule selected for welding In the editing mode these buttons will increase or decrease the values in the PULSE 1 and PULSE 2 energy WELDS or LIMIT SET displays This button is only active when the Power Supply is in the editing mode Press this button repeatedly until the pulse duration you want 15 lit underneath the 3 digit energy display As shown below the MEDIUM M pulse duration 1s selected NOTE The VERY SHORT VS setting gives the highest peak current and shortest duration for the energy setting The LONG L setting gives the lowest peak current and longest duration for the energy setting 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 1 5 CHAPTER 1 DESCRIPTION Pressing this button causes the green LED on the button to go ON and the 6 digit COUNTER display will show the total number of welds the Power Supply has made since the last time it was reset to zero This feature can be used to count the number of welds during a particular shift or work day Pressing this button causes the green LED on the button to go ON and the 6 digit COUNTER display will show the LIMIT SET for the number of welds made
51. onnector 5 Refer to the weld head manufacturer user s manual Connect the weld head air valve solenoid cable connector to the Power Supply AIR VALVE DRIVER connector 6 Connect a properly filtered air line to the air inlet fitting on the weld head Use 0 25 inch O D by 0 17 inch I D plastic hose with a rated burst pressure of 250 psi Limit the length of the air line to less than 40 in 1 m or electrode motion will be very slow NOTE Use a lubricator only with automated installations 7 Turn on the air system and check for leaks 8 Setthe WELD NO WELD switch on the Power Supply front panel to the NO WELD position In this position the Power Supply cannot deliver weld energy but it can Power Supply the weld head 9 Setthe circuit breaker on the rear panel of the Power Supply to the ON position 10 Press the foot switch to actuate the first level The weld head upper electrode should descend smoothly to the DOWN position When it reaches the down position release the foot switch and proceed to Step 12 If it does not descend smoothly proceed to Step 11 11 Adjust the weld head down speed knob and repeat Step 10 until the upper electrode descends smoothly 12 Press the foot switch all the way down to close both levels The weld head upper electrode should descend smoothly to the DOWN position and send the firing switch signal back to the Power Supply when the preset electrode force 1s reached The upper electrode should the
52. or heat generation The heat affected zone is also much smaller in this case producing a weld with less variation The following figure shows the three stages of heat generation for resistive materials in a fusion weld In the first stage the heat is focused in the part to part and electrode to part contact areas since contact resistance is high relative to bulk resistance In the second stage contact resistance decreases as the electrodes seat better to the parts Less heat is generated in the electrode to part contact areas and a greater amount of heat 15 generated in the parts as the bulk resistance increases In the third stage the bulk resistance becomes the dominant heat generating factor and the parts can reach their bonding temperature at the part to part interface The stages of heat generation for conductive materials will be similar to that of resistive materials but there will be less heat generated in the bulk resistance due to the conductivity of the materials 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY E 6 990 295 APPENDIX DEFINING THE OPTIMUM PROCESS Bonding temperature of materials different for solid state vs Fusion welds TEMPERATURE Weld Profiles The basic welding profile or schedule consists of a controlled application of energy and force over time Precision power supplies control the energy and time and therefore heating rate of the parts The weld head applies force from the start to
53. ows Schedule 1 and Schedule 2 to be chained together e Schedule protection and system security features protects weld schedules from changes by unauthorized personnel 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 1 1 CHAPTER 1 DESCRIPTION e The schedule lock feature allows you to restrict welding to one selected weld schedule e The digital display allows operators to set welding energy accurately and quickly e The Power Supply is compatible with manually actuated weld heads and air actuated heads with 1 level or 2 level foot switches e The Power Supply is compatible with force fired and non force fired weld heads Squeeze delay time is adjustable from 0 to 2 999 seconds e A built in weld counter allows you to control events which are a function of the number of welds made e The firing circuit uses single pole double pole or optical firing pressure switches e The energy monitor and lockout helps prevent poor welds caused by firing the power supply before the capacitor bank is properly charged or discharged e The line failure turndown safety feature discharges the capacitor bank when input power is interrupted e The Power Supply is protected from radio frequency interference and electromagnetic interference resulting in reliable operation even in high electrical noise environments Input switch debounce circuitry eliminates false triggering Detailed instructions on using these features are located
54. r of probability Cause in order of probability Weld Piece Excessive energy set at 100DP 300DP Weld Piece No cover gas on weld piece id Insufficient weld head force Discoloration 2 Excessive energy set at 100DP 300DP eating Incompatible weld piece materials Insufficient weld head force Wrong electrode material tip shape Contaminated weld piece surface plating Contaminated electrode surface Wrong electrode material tip shape Contaminated electrode surface Error Codes The Control displays the following error codes 1 the 6 digit counter display The error codes are in the format ERR 01 ERRO2 and so on To clear an error code press and hold the CLEAR button for 2 seconds Error descriptions and typical troubleshooting steps are shown below 1 Error Number Error Name Description Troubleshooting Steps 1 Capacitor Discharge timeout The energy setting in the weld 1 Turn off the unit and schedule was reduced or the wait 30 seconds Turn schedule number was changed to a on the unit and see if the schedule with a lower energy setting error disappears The unit did not reach this new lower energy value within 15 seconds 2 If the error persists contact Miyachi Unitek for service Capacitor Charge timeout The capacitors did not reach the 1 Verify that the AC line programmed energy level within 500 voltage 15 within limits id 2 Ifthe AC voltage 15 within limits and the error persists
55. r to turn an input ON This configuration is accomplished by changing two jumpers To replace the footswitch and firing switch with PLC or other 24VDC TRUE SIGNALS remove the cover of the unit and locate jumper P6 Move it to the HIGH TRUE position as shown below Note that this position is only used 1f Miyachi Unitek footswitch and weldhead firing switch connections are replaced by 24VDC TRUE INPUTS If a Miyachi Unitek mechanical footswitch and standard weldhead firing switch are used this jumper should remain in the LOW TRUE position To reconfigure all other inputs Binary schedule select lines weld inhibit etc for HIGH TRUE move jumper P7 to the HIGH TRUE position as shown in the photograph TOP VIEW Cover Removed tl JUMPER puel P7 P6 3 byor T jj 2 seme MN D Y v s 5 WI alg Jr E J BINARY INPUTS FOOT SWITCH h il t X FRONT HIGH TRUE 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 B 2 APPENDIX ELECTRICAL AND DATA CONNECTIONS Configuration for Low True Inputs Switch Closure to Activate Inputs USER SIDE UNIT SIDE 24V 500mA max shared with pin 19 OPTO FOOTSWITCH INPUT FIRE FS1
56. t on this switch will remain ON while the chain function is in use The control will switch to Schedule 1 3 Press the WELD NO WELD switch to the WELD position 4 Begin welding using your normal procedures Welding will continue repeating between these schedules until you press and hold the CHAIN SCH 1 2 button again for about second until the green light on the button goes OFF Dual weldhead operation 1 Follow the procedure above to chain Schedule 1 and Schedule 2 together 2 Connect weldhead 1 to the 4 pin Standard Air Valve Driver Output Connector 3 Connect Weldhead 2 to the 8 pin Weld Head Connector 4 Connect the Dual Weldhead Input pin 13 on the 37 pin connector to the I O common pin 32 on the 37 pin connector 5 Schedule 1 will then use weldhead 1 and schedule 2 will use weldhead 2 These two heads and schedules will fire alternately with the FS input Programming Lock The programmed values of the 15 schedules can be locked so that no changes are possible To set this lock connect pin 9 of the 37 pin connector to the I O common See Appendix B for connection details Note that the schedule numbers can still be changed but the values stored in each schedule cannot be changed Schedule Lock The programmed values of the 15 schedules and the schedule number itself can be locked so that no changes are possible To set this lock connect pin 27 of the 37 pin connector to the I O common See Appendix B for connec
57. tilated area that 1s free from excessive dust acids corrosive gases salt and moisture 10 8 inches 275 mm e Other installation considerations The work surface must be level stable free from vibration and capable of supporting the combined weight of the total welding system The weight of the Power Supply is 66 lbs 30 kg The Power Supply must be far enough from the weld head to avoid contact with weld splash Make sure there are no sources of high frequency energy close by 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 2 1 CHAPTER 2 INSTALLATION AND SETUP Utilities Power Because of the different electrical requirements for the countries in which the Power Supply is used the Power Supply is shipped without a power cable connector The required connections for your power cable connector are described in Appendix B Electrical and Data Connections Input power requirements for the Power Supply are as listed below Power Input Specifications Input Voltage Copper Wire 50 60 Hz Ckt Brkr Gauge Wire Dia 3 phase Vrms Current A rms 7 strands AWG mm Compressed Air and Cooling Water 15 100DP 230 10 15 0 If you require compressed air and cooling water service for the weld head please refer to the weld head manufacturer s user s manual for service specifications Input Logic Configuration The unit 1s shipped from the factory configured for LOW T
58. tion details 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 3 5 CHAPTER 3 OPERATING INSTRUCTIONS Section 3 Operational Notes Repetition Rate The user must maintain the repetition rate of the unit at or below that listed in Appendix A Short burst of 2 or 4 welds may be fired at a more rapid pace but the number of welds per minute listed must not be exceeded Automatic Power Turn Down The user must limit the power dissipated the automatic turn down circuit to the 50W limit listed in Appendix A Rapid firing of different schedules with significantly different energy level can exceed this limit To calculate the total power dissipated in this circuit 1 Determine how many times one minute the schedule will change from a higher energy to a lower energy 2 Add up the total Watt seconds of energy decrease in one minute 3 Divide this number by 60 to determine the average Watts of power dissipated Example If there are 12 schedule changes per minute where the programmed energy decreases from 300Watt seconds to 100Watt seconds the total change is 2400 Watt seconds per minute Dividing by 60 gives a resultant value of 40 Watts Watt seconds per second equals Watts which is within the capability of the unit Open Load Protection When the unit is fired with an open secondary circuit the energy from the capacitor bank 1s not delivered to the weld Instead it is absorbed by the internal circuitry of the weld
59. urally attracted to other Metal B metal atoms even in different parent materials Metals and alloys will bond together once surface contaminants such as dirt grease and oxides removed Resistance welding generates heat at the material interface which decomposes the dirt and grease and helps to break up the oxide film The resultant heat softens or melts the metal and the applied force brings the atoms on either side into close contact to form the bond The strength of the joint develops as it cools and a new structure 15 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 15 either added during the process or present as a plating or coating Soldered joints are typically achieved at temperatures less than 400 C and brazed joints such as Sil Phos materials melt at temperatures above 400 C Solid State Joint A solid state joint can be formed when the materials are heated to between 70 80 of their melting point Fusion Joint A fusion joint can be formed when both metals are heated to their melting point and their atoms mix Many micro resistance welding challenges involve joining dissimilar metals in terms of their melting points electrical conductivity and hardness A solid state joint can be an ideal solution for these difficult applications there is no direct mixing of the two materials across the wel
60. utton causes the green LED on the button to go ON and the 6 digit COUNTER display will show the hold time for the current schedule Pressing this button for about 1 second causes the green LED on the button to go ON and the 6 digit COUNTER display to blink This allows the AV arrows to increase or decrease the hold time Pressing this button again saves the setting 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 1 6 990 295 CHAPTER 1 DESCRIPTION Polarity Select This button is only active when the Power Supply is in the editing mode Press POLARITY this button repeatedly until the polarity you want is lit underneath the 3 digit SELECT energy display As shown below positive polarity is selected NOTE When ALTERNATING polarity is selected both waveforms below will be lit A t v ALTERNATING Charge Monitor CHARGE MONITOR When the green light is lit the capacitors are fully charged and ready to weld The light will turn on a short time after a weld is completed If the WELD NO WELD switch is in the OFF position the CHARGE MONITOR light will not be lit WELD NO WELD Switch When the switch is in the WELD position the programmed weld sequence can initiate weld energy When you set this switch to the NO WELD position no weld current can flow However the Control can execute a complete weld sequence This function is used to adjust the weld head prior to operation
61. welding energy and weld head timing Multi function microprocessor control provides repeatable process control and 15 compatible with air or manually actuated weld heads Facilitates multiple applications at a single work station and protects weld schedules from changes by unauthorized personnel e Dual pulse welding eliminates weld splash Improves weld quality especially when welding plated materials e Alternating polarity allows the user to set up a pulse to change from positive to negative polarity each time the welder 15 fired This allows the user to equalize the wear between two electrodes in many parallel gap welding 2277 AINJA LI processes VY MIYACHI OST DP ES lt e Two air valve drivers are provided to sequentially control two separate air operated 100DP D UAL 11 1 9 weld heads if desired As shipped STORED ENERGY POWER SUPPLY Valve Driver 1 15 configured to drive a 24 l VAC weld head but can be reconfigured to drive a 24VDC weld head instead Air Valve Driver 2 can only drive a 24VDC weld head e Three relays provide signals for when the unit is ready to weld when a weld is completed and when the weld counter has reached its preset limit e Remote schedule selection simplifies use in automated systems A CONTROL SIGNALS connector accepts remote control signals for Emergency Stop Remote Weld Inhibit and Remote Weld Schedule Selection e The chain schedule feature all
62. without wearing protective safety glasses This instruction manual describes how to operate maintain and service the 100DP and 300DP Resistance Welding Power Supplies and provides instructions relating to its safe use A separate manual provides similar information for the weld head used 1 conjunction with the power supply Procedures described 1n these manuals must be performed as detailed by qualified and trained personnel For safety and to effectively take advantage of the full capabilities of the weld head and power supply please read these instruction manuals before attempting to use them Procedures other than those described in these manuals or not performed as prescribed 1 them may expose personnel to electrical or burn hazards After reading these manuals retain them for future reference when any questions arise regarding the proper and safe operation of the power supply Please note the following conventions used in this manual WARNING Comments marked this way warn the reader of conditions which might result in immediate death or serious injury CAUTION Comments marked this way warn the reader of conditions which might result in either damage to the equipment or injury to the individual 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY vi 990 295 1 Description Section Features Features The Miyachi Unitek 100DP 300DP Dual Pulse Resistance Welding Power Supply precisely controls
63. y time from Foot Switch Level 1 closure to Weld Force start Maximum delay time is 40 ms Delay time from Weld Force start to Firing Switch closure Maximum D1 time 15 10 seconds If the firing switch does not close within 10 seconds the message FIRING SWITCH DIDN T CLOSE IN 10 SECONDS will be displayed Delay time from Firing Switch closure and Foot Switch Level 2 closure to squeeze time SQZ Maximum D2 time is 40 ms Squeeze time Selectable range is 0 to 2999 ms The timing of this weld pulse depends upon the pulse length programmed the energy setting and the impedance of the secondary circuit This time is not programmable by the user It depends upon the energy level of the second pulse and ranges from 20 to 670 msec If no second pulse is programmed this time period is skipped The timing of this weld pulse depends upon the pulse length programmed the energy setting and the impedance of the secondary circuit Hold time Selectable range 15 0 to 2999 ms NOTE The inputs signals FSI FS2 and firing switch need to be at least 50 msec duration for the unit to recognize them 100DP 300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 295 C 1 APPENDIX SYSTEM TIMING Basic Weld Operation Manual Head System with Firing Switch Operation REMOTE FIRING ee SWITCH WELDING CURRENT DELAY SQUEEZE PULSE1 COOL PULSE2 HOLD Definitions DELAY Delay time from firing switch closure to the start o

100dp/300dp dual pulse stored energy resistance welding power

Contents

Download Pdf Manuals

Related Search

Related Contents