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Amada 1000ADP, Operation Manual

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APPENDIX E:  THE BASICS OF RESISTANCE WELDING 

 

 

125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 

E-2 

990-922 

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 resistance of the parts and the 
contact resistance between the parts.  Use resistive electrodes such as RWMA-13 (Tungsten) and 
RWMA-14 (Molybdenum) to weld conductive parts such as copper and gold because conductive parts 
do not generate much internal heat so the electrodes must provide external heat.  Use the following 
Electrode Selection Table for selecting the proper electrode materials. 

 

MATERIAL

 

ELECT 

RWMA 

TYPE

 

MATERIAL

 

ELECT 

RWMA 

TYPE

 

 

MATERIAL

 

ELECT 

RWMA 

TYPE

 

MATERIAL

 

ELECT 

RWMA 

TYPE

 

Alumel -2 

Alumel -2 

 

Beryllium 
Copper 

-2 

Cold Rolled 
Steel 

-2 

Alumel -2 

Chromel 

-2 

 

Beryllium 
Copper 

-2 Stainless 

Steel 

-2 

Alumel -2 

Dumet  -2 

 

Brass 

-2, -14 

Brass 

-2, -14 

Aluminum -1 

Aluminum -1 

 

Brass 

-2, -14 

Tinned Brass 

-14 

Aluminum -1 

Aluminum 
Alloys 

-1 

 

Brass -2, 

-14 

Consil  -2 

Aluminum -1 

Cadmium 

Plating 

-1 

 

Brass -2, 

-14 

Constantan 

-2 

Aluminum -1 

Tinned 

Brass 

-14 

 

Brass -2, 

-14 

Copper -14 

Aluminum -1 

Tinned 

Copper 

-14 

 

Brass 

-2, -14 

Tinned Copper 

-14 

Aluminum -1 

Gold Plated 
Dumet 

-2 

 

Brass -2, 

-14 

Dumet  -2 

Aluminum -1 

Gold Plated 
Kovar 

-2 

 

Brass -2, 

-14 

Nichrome 

-2 

Aluminum -1 

Kovar 

-2 

 

Brass -2, 

-14 

Nickel  -2 

Aluminum -1 

Magnesium -1 

 

Brass 

-2, -14 

NiSpan C 

-2 

Aluminum -1 

Cold Rolled 
Steel 

-2 

 

Brass -2, 

-14 

Paliney 

7 

-2 

Aluminum -1 

Stainless 

Steel 

-2 

 

Brass 

-2, -14 

Silver 

-11, -14 

Beryllium 
Copper 

-2 

Beryllium 
Copper 

-2 

 

Brass -2, 

-14 

Cold Rolled 
Steel 

-2 

Beryllium 
Copper 

-2 Brass 

-2, 

-14 

 

Brass 

-2, -14 

Stainless Steel 

-2 

Beryllium 
Copper 

-2 Copper 

-14 

 

Bronze 

-2, -11 

Bronze 

-2, -11 

Beryllium 
Copper 

-2 Tinned 

Copper  -14 

 

Bronze 

-2, -11 

Tinned Copper 

-14 

Beryllium 
Copper 

-2 Nickel 

-2 

 

Bronze -2, 

-11 

Iron 

-2 

Summary of Contents for 1000ADP

Page 1: ...990 922 Rev G STORED ENERGY POWER SUPPLY 125 300 1000ADP OPERATION MANUAL...

Page 2: ...Ws programming in 0 1 Ws increments C 42840 10 13 Update to Miyachi America name and logo D 43480 11 14 Updated to Amada Miyachi America name and log E 43808 07 15 Updated to Amada format F 44033 01 1...

Page 3: ...COUNTERS 1 8 Pulse 1 Pulse 2 1 8 SQZ HOLD 1 8 SAVE 1 8 CLEAR 1 8 CHARGE MONITOR Light 1 9 WELD NO WELD Switch 1 9 Emergency Stop Switch Operation 1 9 Chapter 2 Installation and Setup Section I Install...

Page 4: ...4 LIMITS COUNTERS Screen 3 4 Edit the LIMITS COUNTERS Screen 3 4 Pulse 1 Upper Limit 3 4 Pulse 1 Lower Limit 3 4 Pulse 2 Limits 3 4 Pulse 1 Action 3 5 Reset Weld Counter 3 5 Edit Counter Limit 3 5 Se...

Page 5: ...rational Notes 4 8 Repetition Rate 4 8 Automatic Power Turn Down 4 8 Open Load Protection 4 8 Extended Shut down Procedure 4 9 Chapter 5 Maintenance Section I Troubleshooting 5 1 Troubleshooting 5 1 E...

Page 6: ...e Avenue P O Box 5033 Monrovia CA 91017 7133 TELEPHONE 626 303 5676 e mail info amadamiyachi com The purpose of this manual is to provide the information required for proper and safe operation and mai...

Page 7: ...power supply Procedures described in these manuals must be performed as detailed by qualified and trained personnel For safety and to effectively take advantage of their full capabilities please read...

Page 8: ...125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY viii 990 922...

Page 9: ...125ADP 300ADP 1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 922 ix...

Page 10: ...LECTUAL PROPERTY RIGHTS OF A THIRD PARTY WHETHER EXPRESS OR IMPLIED BY LAW COURSE OF DEALING COURSE OF PERFORMANCE USAGE OF TRADE OR OTHERWISE Notwithstanding the foregoing in the event of the failure...

Page 11: ...er i repair or replace such Goods or the defective part or ii credit or refund the price of such Goods at the pro rata contract rate provided that if Seller so requests Buyer shall at Buyer s expense...

Page 12: ...Terms and conditions for Additional Acceptance Tests either at Seller s or Buyer s facility shall be mutually agreed in writing prior to issuance or acceptance of the Acknowledgement Performance Warr...

Page 13: ...anted only for defect in material and workmanship which are apparent upon receipt by Buyer The foregoing warranty is negated after the initial use No warranty made hereunder shall extend to any produc...

Page 14: ......

Page 15: ...ated weld heads The Power Supply provides repeatable process control and protection from weld schedule changes by unauthorized personnel Dual pulse welding can eliminate weld splash and improve weld q...

Page 16: ...le selection simplifies use in automated systems The CONTROL SIGNALS connector provides remote control capability for EMERGENCY STOP REMOTE WELD INHIBIT and REMOTE WELD SCHEDULE SELECTION The CHAIN SC...

Page 17: ...operators to set welding energy accurately and quickly The Power Supply is compatible with both manually and air actuated weld heads with 1 level or 2 level foot switches The Power Supply is compatib...

Page 18: ...features guaranteed accurate energy output independent of line voltage fluctuations and or process speed Dual pulse welding improves weld quality and can eliminate weld splash Dual pulse means each we...

Page 19: ...mponents are the front panel which contains operator controls and indicators and the rear panel which contains fuses circuit breakers power and signal connectors The rear panel connections are discuss...

Page 20: ...ons The UP and DOWN buttons have two functions During normal operation up and down buttons are used to scroll through the 63 schedules to select a desired schedule The schedule number displays at the...

Page 21: ...ay screen shown on the previous page indicates MEDIUM UPSLOPE pulse duration selected for Pulse 1 and MEDIUM pulse duration selected for Pulse 2 NOTE The VERY SHORT setting provides the shortest durat...

Page 22: ...se width and polarity for Pulse 1 may now be edited To accept changes press the SAVE button To exit editing mode without accepting changes press the front panel RUN button then at the SAVE prompt pres...

Page 23: ...EEZE HOLD delay parameters prior to actual welding Emergency Stop Switch Operation If your work station has an EMERGENCY STOP SWITCH connect it to the cable provided at the rear panel of the unit When...

Page 24: ......

Page 25: ...eration Allow sufficient clearance around the sides and back of the Power Supply to allow for connecting cables Allow enough ventilation space so the Power Supply does not overheat 125ADP 300ADP Allow...

Page 26: ...ong mains connector and replace it with an approved mains power connector for the country in which the unit is to be used The required connections for your power cable connector are described in Appen...

Page 27: ...ompatible with switch closures to ground for activation or to enable an input function ON The unit can also be configured for HIGH TRUE INPUTS which is commonly used with a PLC or other external devic...

Page 28: ...the 125ADP and 300ADP Power Supplies and located on the front panel of the external transformer on the 1000ADP systems Emergency STOP Switch Connect an agency compliant normally closed EMERGENCY STOP...

Page 29: ...ransformer terminal on the Power Supply or external transformer for a 1000ADP 3 Connect one end of the second weld cable to the positive welding transformer terminal on the Power Supply or external tr...

Page 30: ...r 3 Connect a normally closed agency compliant EMERGENCY STOP SWITCH across the two leads of the emergency stop switch connector cable This switch when operated open will immediately stop the weld cyc...

Page 31: ...AIR Weld Head Connections 24 VDC EZ AIR NOTE These instructions describe connection to the Miyachi Unitek EZ AIR weld head Non EZ AIR heads may be connected to the Power Supply but are not covered in...

Page 32: ...nits 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 a normally closed agency compl...

Page 33: ...witch on the Power Supply front panel to the NO WELD position In this position the Power Supply cannot deliver weld energy but it can activate the weld head 9 Set the ON OFF switch on the rear panel o...

Page 34: ...al connections for the 1000ADP are identical to those for the 125ADP and 300ADP described in Section II however there are two notable exceptions The 1000ADP uses a separate external Weld Transformer T...

Page 35: ...rmer 1 Locate the connector at the top rear of the 1000ADP external transformer 2 Align the RED dot on the transformer cable connector to the RED dot on the transformer connector 3 Once the RED dots a...

Page 36: ...wo weld cables you can use either the or cable For best weld monitoring accuracy use tie wraps to secure the loop end of the current coil the end farthest from the opening secured by the Velcro strap...

Page 37: ...rent monitor results for the last weld completed are displayed in the middle of the screen The number of the currently active weld schedule is displayed at the lower right corner In the lower middle o...

Page 38: ...own on the right Use the arrows PULSE WIDTH and POLARITY SELECT buttons to change the values for Pulse 1 To change the energy values for Pulse 1 press and hold the PULSE 1 button for about 1 second an...

Page 39: ...any values press the RUN button to return to the blue RUN screen To discard edited values and restore previously saved values press the RUN key The system will respond with the SAVE prompt which appe...

Page 40: ...OUNTERS button for about 1 second to enter edit mode When editing on the LIMITS COUNTERS screen use the arrows to increment the values of a highlighted parameter PULSE 1 Upper Limit Press and release...

Page 41: ...T WELD COUNTER From the LIMITS COUNTERS edit screen press and release the LIMITS COUNTERS button until the weld counter field is highlighted Press the CLEAR key to clear the weld counter to 000000 NOT...

Page 42: ...VE settings you may recover original system settings including the weld counter values by pressing the CLEAR key at the SAVE 1 To activate the SAVE prompt from the EDIT screen press the RUN key and th...

Page 43: ...creen Press the MENU button momentarily to display this screen Editing the MENU Screen Press and hold the MENU button to enter the MENU edit mode This will highlight the buzzer volume for editing To h...

Page 44: ...gain to edit the starting value for a weld chain In chaining all schedules from CHAINING START to CHAINING END are welded one time and in numeric order When the last schedule in the chain is completed...

Page 45: ...he MENU button again to highlight the REMOTE selection When this is set to OFF serial communication commands to read data are active but commands to change programs and settings are not active When RE...

Page 46: ...save changes To discard changes press RUN to activate the SAVE PROMPT and at the prompt press CLEAR to discard changes After saving or discarding new settings the display will revert to the original s...

Page 47: ...s before the Weld Period begins Weld current begins when the Squeeze Period ends and a fire signal is received During this whole operation both levels of a two level Foot Switch must remain closed to...

Page 48: ...ELDING POWER SUPPLY 3 12 990 922 REPEAT TIME A time other than 0 must be set if REPEAT MODE is set to ON The REPEAT TIME is the time between the end of HOLD and the start of the next weld sequence REP...

Page 49: ...al information on the welding process see Appendix F Quality Resistance Welding Solutions Defining the Optimum Process Pre Operational Checks Always perform these checks before attempting to operate t...

Page 50: ...he Power Supply to the ON position 3 Adjust the weld head force adjustment knob for a force appropriate for your welding application A good starting point is the mid point in the range of the weld hea...

Page 51: ...mplete Using Existing Weld Schedules 1 Use the arrows to select the weld schedule you desire 2 Press the WELD NO WELD switch to the WELD position 3 Begin welding using your normal procedures NOTE Weld...

Page 52: ...the arrow to decrease hold time 9 To modify the settings for Pulse 2 press and hold the Pulse 2 button to enter edit mode 10 Repeat steps 4 through 6 to program the settings for Pulse 2 11 Press the S...

Page 53: ...ange the Weld Counter value 3 To change the COUNTER LIMIT field press the LIMITS COUNTERS button again The COUNTER LIMIT field will be highlighted Press the CLEAR button to set this to zero or use the...

Page 54: ...O common pin 28 or pin 32 See Appendix B Electrical Data Connections for connection details 1 Connect weldhead 2 to the 4 pin Standard Air Valve Driver Output Connector 2 Connect Weldhead 1 to the 8...

Page 55: ...atile memory after 200 welds have been accumulated The unit will take approximately 30 milliseconds to save the data and will ignore fire signals during this time When the Power Supply is turned OFF a...

Page 56: ...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 d...

Page 57: ...P unit has been turned off and non operational for a period of 3 months or longer an extended warm up sequence is recommended 1 Turn the unit ON 2 Set the energy to the maximum level Example set the 1...

Page 58: ......

Page 59: ...d electrode surface Electrode Sparking 1 Excessive energy setting 1 Insufficient weld head force 1 Slow weld head follow up 1 Incompatible weld piece projection design 1 Contaminated weld piece surfac...

Page 60: ...ld time set at 125DP 300DP Weld Piece Over heating 1 Excessive energy setting 2 Insufficient weld head force 3 Incompatible weld piece materials 3 Wrong electrode material tip shape 4 Contaminated ele...

Page 61: ...complete within 1 second Contact Amada Miyachi America for service 6 Memory error The values stored in memory have been corrupted Default values have been reloaded into the unit Contact Amada Miyachi...

Page 62: ...ease 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...

Page 63: ...WELDING POWER SUPPLY 990 922 5 5 Section III Repair Service If you have problems with your power Supply that you cannot resolve please contact our service department at the address phone number or e...

Page 64: ......

Page 65: ...cations NOTE The specifications listed in this appendix may be changed without notice Item Description 125ADP Control Unit 300ADP Control Unit 1000ADP Control Unit Dimensions Weight 125ADP 44 lbs 20kg...

Page 66: ...P 300Ws 1000ADP 999Ws Voltage turndown circuit 50W average power Automatic turndown upon power interruption Weld schedules 63 Weld pulses per Schedule 2 Repetition Rate Pulses per minute Energy 125ADP...

Page 67: ...Ws 17 min 1000 Ws 10 min NOTE The Hit Rates for the 300ADP and 1000ADP are the same as their Repetition Rates Rise Times at Max Energy into a 1 milliohm load with very low inductance No Upslope With...

Page 68: ...eze Time 0 2999 msec Hold Time 0 2999 msec Weld Counter 0 999999 Action Upon Reaching Limit Buzzer sounds after each weld Output relay activates Input Debounce Time Approximately 32 msec Control Outpu...

Page 69: ...ions Section I Electrical Connection Input Power As described in Chapter 2 Installation Setup a 115V power cord is supplied The female end of the power cable is an IEC 320 C13 standard plug Connect th...

Page 70: ...ting Air Valve Driver 2 to DC output The unit is shipped from the factory configured for 24VAC output on Air Valve Driver 2 This output can be configured to provide DC voltage This configuration is ma...

Page 71: ...N 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 P7 Move it...

Page 72: ...ate Inputs Default Configuration CAUTION Damage may result from improper connection of these pins The optical firing switch is intended for use only on Miyachi Unitek heads with this feature In operat...

Page 73: ...to Activate Inputs CAUTION Damage may result from improper connection of these pins The optical firing switch is intended for use only on Miyachi Unitek heads with this feature In operation an optica...

Page 74: ...iring switch input 3 Not used 4 Firing switch input 5 FS1 Foot switch level 1 input 6 Not used 7 Weld inhibit input 8 Weld counter reset input 9 Program lock input 10 Binary schedule select bit 1 11 B...

Page 75: ...mmon 29 Binary schedule select bit 2 30 Binary schedule select bit 8 31 Binary schedule select bit 32 32 I O common 33 Weld end relay output 34 Alarm relay output 35 Not used 36 Relay common 37 Ground...

Page 76: ...lly 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...

Page 77: ...ch Connections The firing switch cable is 5 feet long Type 2 C 600 volt cable containing two shielded twisted pair 22 AWG stranded leads The firing switch cable connector is a 2 pin Amphenol Type 80 M...

Page 78: ...d opened it will immediately halt the weld process and de energize all ADP outputs Connections You must connect the Emergency Stop Switch Cable leads otherwise the Power Supply will not function Conne...

Page 79: ...is 0 to 2999 ms Typical accuracy is 0 10 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...

Page 80: ...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 ms on the 125ADP and 300 ADP It can...

Page 81: ...ulse 2 is greater than the energy required for Pulse 1 of the next weld the unit will discharge the capacitor bank to the proper energy level The end of weld relay will be delayed until the proper ene...

Page 82: ......

Page 83: ...ed in Section II Communications Protocol and Commands Using these codes users can write customized software for controlling all functions of the welding control and interfacing the unit to automation...

Page 84: ...LSB cksum 2 BYTES This is a two charter ASCII HEX string calculated from the sum of all bytes except stx cksum and etx Then masked with 255 0xFF etx 1 BYTE This terminates the transmission End of text...

Page 85: ...SET RX Set None Reset an Error 0 Bytes WELD TC Read None Returns the current weld counter 0 Bytes COUNTER TG Read None Returns Good and Bad Weld counts 0 Bytes LIMITS TL Read None Returns Weld count L...

Page 86: ...short 1 Short 2 Medium 3 Long weld polarity 0 Positive 1 Negative 2 Alternating Note The SS Set commands for PULSE1 PULSE2 POLARITY1 and POLARITY2 do not apply to the 1000ADP LIMITS MR Read Schedule...

Page 87: ...s counters 12 Bytes LIMITS TL Read Weld count Limit 6 Bytes COUNT RC Read Returns of stored welds 4 Bytes REMOTE RM Set ACK OR NAK 1 Byte WELD ZERO CR Set ACK OR NAK 1 Byte WELD LIMIT CS Set ACK OR NA...

Page 88: ...emory error 6 Internal EEPROM values corrupted Default values loaded 7 Power board fuse blown 8 Communication error between control board and front panel 9 Exiting Edit mode 10 Emergency Stop EMO inpu...

Page 89: ...ytes PULSE1 weld length 1 Byte PULSE2 weld length 1 Byte POLARITY1 weld polarity 1 Byte POLARITY2 weld polarity 1 Byte UP Up Slope 0 Off 1 On 1 Byte 21 Bytes Total weld length 0 Very short 1 Short 2 M...

Page 90: ...heck sum 255 Here it is only 1 If the check sum was 9C4 hex 2500 decimal Then n 2500 256 9 7 Using only the hole number n 9 The final check sum is 2500 256 9 196 decimal or 0xC4 hex A better way is to...

Page 91: ...t LR Read current schedule LS Set active schedule MR Monitor Limits Read MS Monitor Limits Set RC Number of reports stored RM Set Remote RR Read Report RX Reset an Error SR Schedule Read SS Schedule S...

Page 92: ......

Page 93: ...he weld force applied to the parts Sufficient weld force is required to contain the molten material produced during the weld However as the force is increased the contact resistance decreases Lower co...

Page 94: ...TYPE MATERIAL ELECT RWMA TYPE MATERIAL ELECT RWMA TYPE Alumel 2 Alumel 2 Beryllium Copper 2 Cold Rolled Steel 2 Alumel 2 Chromel 2 Beryllium Copper 2 Stainless Steel 2 Alumel 2 Dumet 2 Brass 2 14 Bras...

Page 95: ...pper 14 Chromel 2 Cold Rolled Steel 2 Gold 14 Gold 14 Consil 2 Consil 2 Gold 14 Kovar 2 Consil 2 Tinned Copper 14 Hastalloy 2 Titanium 2 Consil 2 Dumet 2 Inconel 2 Inconel 2 Constantan 2 Constantan In...

Page 96: ...old Rolled Steel 2 Tantalum 2 Nickel Alloy 2 Nickel Alloy 2 Stainless Steel 2 Stainless Steel 2 Nickel Alloy 2 Tinned Brass 14 Stainless Steel 2 Tungsten 2 Nickel Alloy 2 Beryllium Copper 2 Tantalum 2...

Page 97: ...rs 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...

Page 98: ...nt 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 Typical Weld...

Page 99: ...asic resistance welding principles Weld profiles Approach to development Common problems Use of screening DOE s Use of factorial DOE s Resistance Welding A Material World The first consideration in de...

Page 100: ...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 ab...

Page 101: ...ed in micro resistance welding today The materials can be grouped into three common categories The types of joints achievable within each of the main groups are detailed below Group I Conductive Metal...

Page 102: ...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 grou...

Page 103: ...t up correctly It is common for the heat generated at the electrode to part and part to part resistances to cause multiple welding problems when welding resistive materials including Part marking and...

Page 104: ...f 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 b...

Page 105: ...llows time for the contact resistances to reduce as the materials start to come into closer contact at their interface A hold time is initiated after current flows to allow the parts to cool under pre...

Page 106: ...ix 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 ar...

Page 107: ...ocess problems are related to either materials variation or part to electrode positioning Some examples are shown below The changes detailed above generally result in a change in contact resistance an...

Page 108: ...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 pa...

Page 109: ...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 a...

Page 110: ...vide 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...

Page 111: ...chheim Germany TEL 49 89 839403 0 FAX 49 89 839403 10 AMADA MIYACHI TAIWAN CO LTD Rm 5 2F No 9 Dehui St Zhongshan Dist Taipei 10461 Taiwan R O C TEL 886 2 2585 0161 FAX 886 2 2585 0162 AMADA MIYACHI V...

Page 112: ...AMADA MIYACHI AMERICA INC 1820 South Myrtle Ave Monrovia CA 91016 U S A TEL 1 626 303 5676 FAX 1 626 358 8048...

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