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CHAPTER 2: GETTING STARTED

SERIES 300 FAST RESPONSE WELD HEAD SYSTEM

990-115

2-5

Power Supply and Foot Switch to Weld Head Control Connections

Refer to figure 2-4.

1

Connect the MECHANICAL FIRING SWITCH cable from the power supply to the 350C Weld
Head Control WELD FIRE SWITCH cable.

Connect the power supply CONTROL SIGNALS cable to the 350C Weld head Control CONTROL
SIGNAL OUTPUT connector.

Connect the Foot Switch cable to the 350C Weld Head Control FOOT SWITCH connector.

P OW ER

OFF

C B1

C B2

A CC E S SOR Y

P ORT

DISPLAY

CONT RAST

CONT ROL

SIG NAL

OUTPUT

SERIAL

PORT

W ELD

F IRE

SWITCH

CONT ROL

SIG NAL

INPUT

F OOT

SWITCH

AIR

VALVE 1

DRIVER

AIR

VALVE 2

DRIVER

RS232
SERIAL

PO RT

FOO T

SWITCH

ME C HAN IC A L
FIR IN G

SW IT CH

SEN SIN G

P OR T

OPTI CAL

FI RING

SWITCH

A C C E S S O R Y

P O R T

CONT ROL

SIGNALS

RELAY
OUT PUT

RS485

SERIAL
PO RT

O U T PU T

PO W ER

FUSE

FOOT SW ITCH

350C W ELD HEAD CONTROL

POW ER SUPPLY

Control Signals Cable

W ELD FIRE SW ITCH

CABLE

MECHANICAL FIR ING

SW ITCH CABLE

Figure 2-4. Power Supply Connections

Summary of Contents for 300 Series

Page 1: ...990 115 REV Q ELECTRONIC WELD HEAD CONTROL 300 Series OPERATION MANUAL ...

Page 2: ...0 01 98 Correct output relay contact specifications D 17449 05 98 Bind in Addendum 995 115 Rev A E 17528 06 98 Change equipment part numbers F 17452 07 98 Incorporate the information in Addendum 995 115 Revs A B G 19146 01 02 Change name to Unitek Peco Add 302H Models Reformat manual H 19638 01 03 Add Force accuracy data J 21554 08 07 Change to Miyachi Unitek corporate name Updated Technical Infor...

Page 3: ...enue Monrovia California 91016 Phone 626 303 5676 FAX 626 358 8048 E mail info amadamiyachi 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 Series 300 Fast Response Weld Head System We have made every effort to ensure that the information in this manual is accurate and adequate Should questi...

Page 4: ... workstation Procedures other than those described in this manual or not performed as prescribed in it may expose personnel to electrical hazards After reading this manual retain it for future reference when any questions arise regarding the proper and SAFE operation of the tester Please note the following conventions used in this manual WARNING Comments marked this way warn the reader of actions ...

Page 5: ...ce Requirements 2 1 Series 300 Installation Dimensions 2 1 Linear Actuator Installation 2 2 Basic Installation 2 2 Optional L Stand Installation 2 3 Section II Power Supply Connections 2 4 Power Line Voltage Current and Wire Size Requirements 2 4 Connector Functions 2 4 Welding Transformer to Weld Head Connections 2 4 Power Supply and Foot Switch to Weld Head Control Connections 2 5 Section III Ma...

Page 6: ...down RUN Screen 3 8 The MAIN MENU Screen 3 9 The OPTIONS Selection 3 9 The WELD COUNTER Selection 3 13 The COPY a SCHEDULE Selection 3 13 The SYSTEM SECURITY Selection 3 14 The SYSTEM HELP Selection 3 15 The CALIBRATION Selection 3 15 The RESET to DEFAULTS Selection 3 16 The INSTALLATION Selection 3 17 The Weld to Displacement Feature 3 18 The Importance of Follow Up Force 3 20 Chapter 4 Maintenan...

Page 7: ... Weld Head System with the 350C Weld Head Control Applicable Models 4 6 Equipment Required 4 6 Preliminary Setup 4 6 Procedure 4 6 Appendix A Technical Specifications A 1 Appendix B Weld Head Control Input Output Signals B 1 Appendix C Weld Head Dynamics C 1 Appendix D RS 232 Serial Communications D 1 Index Index 1 ...

Page 8: ...SERIES 300 FAST RESPONSE WELD HEAD SYSTEM viii 990 115 ...

Page 9: ...OPERTY 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 of any Third Party Product Seller will assist within reason Buyer at Buyer s sole expense in obtaining from the respective third party any if any adjustment that is available under such third party s warranty ...

Page 10: ... 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 return such Goods to Seller i THE REMEDIES SET FORTH IN SECTION 1 H SHALL BE BUYER S SOLE AND EXCLUSIVE REMEDY AND SELLER S ENTIRE LIABILITY FOR ANY BREACH OF THE LIMITED WARRANTY SET FORTH IN SECTION 1 A Repres...

Page 11: ...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 Warranty The system is warranted to pass the identical performance criteria at Buyer s site as demonstrated during final Acceptance Testing at the Testing Site during the Warranty Period as provided in the Acknowled...

Page 12: ...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 product whose serial number is altered defaced or removed Remedies With respect to any such Goods during the Warranty Period Seller shall in its sole discretion either repair such Goods or the defective part THE REMED...

Page 13: ...ual any of the Linear Actuator Modules will simply be referred to as the Actuator and any model Electronic Weld Head Control will simply be referred to as the Control unless unique descriptions for specific models are required Performance Features Through two unique features programmable follow up force and weld to displacement the Weld Head System solves critical problems in conventional pneumati...

Page 14: ...portant Features Other important performance features of the Weld Head System are Precise measurement of setdown displacement for each weld provides an indication of weld quality Weld to displacement feature shuts off the power supply when a programmed setdown displacement is reached Over force and hammering are eliminated even at high weld repetition rates Real time graphical display of programme...

Page 15: ...rmer model high frequency resistance welding power supply and a two level foot switch The system equipment is listed in table 1 1 In addition an MK301 in line or MK302 off set stand is available for mounting the Actuator Figure 1 1 Model 301H Linear Actuator Module Typical Figure 1 2 Model 350C Electronic Weld Head Control NOTE For clarity of communication throughout this manual it is assumed you ...

Page 16: ...rce profile program that you select Through the program electrode position can be controlled to within 0 001 in 25μm but measured to within 0 0001 in 2 5μm The weld force and duration can be set to between 1 lb 0 45 kg and 20 lbs 9 kg at a 15 duty cycle Depending on the travel and force profile that you select weld rate can be as high as four per second with no impact force on the weld parts The W...

Page 17: ...larm conditions Graphic screens allow you to fine tune the time follow up force and weld energy relationships Additionally on line help screens allow you to interrogate the system for quick look up information about installation and operation issues NOTE The functions of the key clusters on the HF2 Power Supply and the Weld Head Control are identical So the following descriptions of the key cluste...

Page 18: ...information about any menu option or flashing programmable field Pressing HELP A second time returns you to the original screen state SAVE This key is active only in the PROGRAM state Pressing SAVE saves the changes to the weld schedule that you just entered to the program screen then automatically selects the RUN state Select Keypad This is a cluster of four arrow keys In the RUN state you actuat...

Page 19: ... 350C Electronics Weld Head Control the welding power supply and the welding transformer so that cooling air can flow properly Series 300 Installation Dimensions The dimensions and weight for a complete welding system are listed in table 2 1 Table 2 1 System Installation Dimensions Equipment Width in cm Height in cm Depth in cm Weight lbs kg 350C Weld Head Control 10 5 26 7 8 5 21 6 15 1 38 4 68 0...

Page 20: ...llowing steps 1 Secure the actuator to an adapter plate with four 1 4 20 screws If you are using the above mentioned adapter plate these should be 1 4 20 x 3 4 flat head Phillips screws P N 625 595 2 Secure the adapter plate to a vertical mounting surface using two machine bolts and flat washers The height of the upper electrode holder above the lower electrode holder to be installed in step 3 sho...

Page 21: ... 5 Install the assembly to a horizontal work surface that provides firm non deflectional support using two T slot nuts P N 465 208 M8 1 25 x 50mm studs P N 625 578 5 16 flat washers P N 755 044 and M8 nuts P N 465 208 contained in the Ship Kit 6 Adjust the height of the upper electrode holder above the lower electrode holder to allow for no more than 1 06 in 27mm of upper electrode travel 7 Adjust...

Page 22: ... Circuit Breaker and Wire Size Recommendations Service Voltage RMS Circuit Breaker Current RMS Copper AWG Wire Gauge Outside Wire Dia in mm 115 15 Amps 12 0 083 2 208 to 230 6 Amps 12 0 083 2 Connector Functions The functions and pin assignments of the connector on the rear panel of the 350C Weld Head Control are described in Appendix B Welding Transformer to Weld Head Connections Refer to figure ...

Page 23: ... the Foot Switch cable to the 350C Weld Head Control FOOT SWITCH connector POWER OFF CB1 CB2 A CCE S SORY P ORT DISPLAY CONTRAST CONTROL SIGNAL OUTPUT SERIAL PORT W ELD FIRE SWITCH CONTROL SIGNAL INPUT FOOT SWITCH AIR VALVE 1 DRIVER AIR VALVE 2 DRIVER RS232 SERIAL PORT FOOT SWITCH ME CHANICA L FIRING SW IT CH SEN SIN G P OR T OPTICAL FIRING SWITCH A C C E S S O R Y P O R T CONTROL SIGNALS RELAY OU...

Page 24: ...ess the ENTER key The words shown in UPPER CASE ITALIC letters or overlaid with shading indicate flashing menu options on the display screens Electrode Installation Install the appropriate electrodes in the Weld Head electrode holders Your choice of electrodes depends on your specific welding applications but keep in mind the following considerations Use a flat electrode face for most applications...

Page 25: ...ntially less than 1 inch 25 mm the default settings for the UPST and SRCH positions will be different than those shown Also the Linear Actuator head moves to the upstop position UPST specified by the initial positioning schedule NOTE The head may run into the limits of inward travel as determined during the automatic self test cycle If it does a message appears on the lowest alarm line of the scre...

Page 26: ...er electrodes to reach the workpieces Enter the UPST value of 0 27 inch as follows 1 Assuming that the default alphanumerical RUN screen is still accessed Step 2 of the power up Weld Head Control procedure in the previous section press the PROG key to access the alphanumerical PROGRAM screen NOTE Instructions for selecting parameters on the screen and entering values are annotated on the instructi...

Page 27: ...options allow you to save the new UPST and SRCH positions to the weld schedule SAVE go to the run mode and save the new UPST and SRCH positions to Schedule 000 RUN or cancel the changes ENTER Power Supply Power Up and Initialization To turn on the Power Supply and set initial conditions proceed as follows 1 Set the Power Supply front panel WELD NO WELD switch to NO WELD 2 Set the circuit breaker l...

Page 28: ... change WELD HEAD TYPE to MANUAL and SWITCH DEBOUNCE TIME to 0ms 9 Press RUN to return to the graphical RUN screen Step 2 Making Test Welds with Round to Round or Round to Flat Stock To arrive at the point where you make a successful first weld will require you to make several test welds using identical weld pieces each time for true process control You should make the first test welds with low en...

Page 29: ... piece surface and trigger the weld cycle 4 If a partial weld has taken place peel the welded materials apart A satisfactory weld will show residual material pulled from one material to the other The default WELD time of 1ms and the default CURRENT of 0 5kA as shown on the Power Supply graphical RUN screen will probably not be sufficient to make a good weld or any weld Also weld force will need to...

Page 30: ...w the 000 setdown reference line and a weld nugget has formed between the two workpieces The relationship of the follow up force profile and the electrode setdown trace is important Its center must be fairly well aligned with the center of the setdown curve If there is misalignment you can adjust the delay of the follow up force profile with the actual setdown curve 8 Press PROG to access the Weld...

Page 31: ...for round to flat or round to round stock The only difference is in the appearance of the setdown trace in the Weld Head Control graphical set down screen where the setdown trace will always be initially in the positive direction above the 0000 setdown line This is because when weld energy is first applied to flat stock expansion of the stock forces the electrode upward until melting and electrode...

Page 32: ......

Page 33: ...shown in figure 3 1 during the weld cycle The circled numbers refer you to the step numbers in weld head cycle table 3 1 When doing manual welding the two level Foot Switch FS2L allows you to move the electrode between the upstop UPST position and the search SRCH position as often as you need before completing the weld with setdown STDN This way you can carefully align the materials to be welded d...

Page 34: ...r Supply is initiated and follow up force delay timer DLY is started You must set the switch debounce time in the Power Supply to 0 msec 6 DLY time is expired Force rapidly increases from the WELD force to the follow up FWUP force Force change occurs in about 1 millisecond and remains at the FWUP force level for the programmed FWUP time duration Round to round or round to flat parts collapse set d...

Page 35: ...he related on line help screen will appear to give you more information about setting the upstop position To return to the set upstop screen press HELP again Press RUN to return to the alphanumerical RUN screen A Closer Look at the PROGRAM Screens Press the PROG key to enter the program mode Repeatedly pressing the PROG key cycles the display through five programming screens Each screen is updated...

Page 36: ...PROGRAM Screen The search SRCH position is the location where the head stops on its way down to allow the user to accurately align the materials to be welded Typically this position is set up so the electrodes are just above the weld material Upon entering this screen the head is positioned in the SRCH position You use the keys to lower the head or program the SRCH position directly using the nume...

Page 37: ... on this screen refer to Weld to Displacement Feature at the end of this chapter Press ENTER to select the UPPER or LOWER setdown limit alarms or the WELD STOP displacement for the weld to displacement feature Set the limit and stop line values with the keys Note that the LOWER setdown limit must be programmed before the UPPER limit Press the CHNG key to remove either limit lines or weld stop disp...

Page 38: ...mp up and the FWUP force impulse The programmed force is shown as a line graph and the actual force is shown as a filled in graph after the weld cycle is repeated The force is shown on the vertical axis and the time is shown on the horizontal axis The total time duration of the SQZ and WELD periods is indicated in the lower right corner After a weld cycle is completed the peak FWUP force is indica...

Page 39: ...e to 0 000 where the electrodes touch each other TIME SRCH Rate at which the head moves between search position and where the electrode touches the weld material FAST 0 5 inches 12 7 mm second MED 0 1 inches 2 5 mm second SLOW 0 05 inches 1 3 mm second POSITION SRCH Search height position is relative to 000 0 where the electrodes touch each other TIME SQZ Time duration for force to build up to the...

Page 40: ...wer Supply start signal is terminated The displayed time is normally less than the programmed WELD time period If the weld to displacement feature is not programmed the displayed time is equal to the programmed WELD time period Refer to Weld to Displacement Feature toward the end of this chapter for details of the weld to displacement feature The final setdown displacement is listed alphanumerical...

Page 41: ...and OPTION 3 Most of these programmed options allow you to modify how an external input such as a foot switch interfaces with the Weld Head Control Output relay options allow you to interface the Weld Head Control with an external computer or Programmable Logic Control PLC 1 From the MAIN MENU screen select OPTIONS The OPTIONS 1 screen appears Five option items appear as shown POWER UP SCHEDULE Th...

Page 42: ...re is identical to the RELAY 1 ON CONDITION 2 Press More Options to access the submenu of options on the OPTIONS 2 screen FOOTSWITCH WELD ABORT Select ON or OFF with the CHNG key This option controls how the Weld Head Control interfaces with a foot switch or a force firing switch Either or both switches may be defined as the initiation switch The ON selection means the welding process is initiated...

Page 43: ...material by the time the electrodes are 0 005 inch apart the weld cycle aborts and a warning message appears on the alphanumeric RUN screen Press MENU to return to the MAIN MENU screen or press RUN to return to the weld graphical RUN screen 3 Press More Options to access the submenu of options on the OPTIONS 3 screen SELF CHECK DURING BOOT UP When you set this option to OFF the self checking proce...

Page 44: ...bs or to AUTO by pressing the CHNG key AUTO is the default setting When set to AUTO the material search force will change according to the search SRCH rate setting of the selected weld schedule see table 3 2 With the SRCH rate set to FAST or MED the force will be 3 lbs When SRCH is set to SLOW the force will be 2 lbs NOTE You will not be able to set a weld force lower than the MATERIAL SEARCH FORC...

Page 45: ...e with the numerical keys and press ENTER 3 Press MENU to return to the MAIN MENU screen or press RUN to return to the weld graphical RUN screen The COPY a SCHEDULE Selection All Weld Head Control weld schedules can be easily copied from one weld schedule to another by using the COPY A SCHEDULE option listed under the MAIN MENU 1 From the MAIN MENU select COPY A SCHEDULE The COPY SCHEDULE Screen w...

Page 46: ...les select SCHEDULE LOCK OFF and use CHNG to select ON When ON is selected all other weld schedules are locked out and cannot be used for welding 4 Press ENTER to enable System Security SECURITY STATUS will now display PROTECTED 5 Press MENU to return to the MAIN MENU screen or press RUN to return to the weld graphical RUN screen 6 To unlock the Weld Head Control return to the SYSTEM SECURITY scre...

Page 47: ...Weld Head Control to OFF WARNING Be sure to observe the instructions given in Step 2 If you do not perform Step 2 or you perform it improperly you could be seriously injured Up to 230 VAC could be present in the chassis area 2 Disconnect the AC input power to the Weld Head Control 3 Remove the Weld Head Control Cover WARNING Be extremely careful when reconnecting the input power Up to 230 VAC coul...

Page 48: ...To Defaults feature allows you to reset all system parameters or all weld schedules to their original factory default settings NOTE You will not reset the weld counter 1 From the MAIN MENU screen select RESET TO DEFAULTS The RESET DEFAULTS screen will appear 2 Select RESET SYSTEM PARAMETERS and press ENTER The RESET SYSTEM PARAMETERS PROCEED Option line appears 3 Press CHNG to change NO to YES to ...

Page 49: ...ATION Selection The installation option provides narrative no illustrations instructions about how to set up the Weld Head Control At the MAIN MENU screen press ENTER to select this option Then press for each new page of instructions The best procedure is to follow the instructions in Chapter 2 Getting Started in this manual System Parameters Default System Parameters Default Power Up Schedule Las...

Page 50: ...curs at the right point in the weld cycle Here is a check list to ensure that the Power Supply and the Weld Head Control are synchronized for the weld to displacement function it assumes that the units are interconnected as described in Chapter 2 Program the weld function and weld energy as follows 1 Set the switch debounce option to 0ms This eliminates the time delay between receipt of the start ...

Page 51: ...is the SETDOWN displacement just starts to change rapidly 6 Experiment with WELD time WELD force FWUP time FWUP force DLY time and Power Supply energy until you achieve the desired weld and setdown displacement NOTE Do not experiment with Power Supply time 7 Access the graphical setdown PROGRAM screen and select the WELD STOP feature Using the keys move the weld stop line to just above the final s...

Page 52: ...is proportional to the weld head force This means that for low force welds or for welds that require a lot of follow up acceleration such as wire to foil or cross wire welds conventional weld heads have a fundamental limit to their follow up performance The Series 300 Weld Head System however uses an electromagnetic linear actuator to develop the weld force A user programmed force impulse FWUP acc...

Page 53: ...tion Reading this chapter will speed up the process General Kinds of Problems NOTE It has been our experience that 99 of all weld head and resistance welding power supply problems are caused by lack of material control process control and electrode tip surface maintenance The problems that you might encounter fall into two groups Soft The problem is transient and you can correct it by re calibrati...

Page 54: ...s greater than the programmed lower limit 1 Reprogram a lower lower setdown limit 2 Replace the weld material 3 Troubleshoot the Welding Power Supply ERROR WELD ABORTED Foot switch did not stay actuated during the weld cycle Actuate the foot switch again FOLLOW UP TIME TOO SMALL Time entered was below the minimum value allowed Reprogram the follow up time to be at least the 1ms minimum FOLLOW UP T...

Page 55: ...sition with the CALIBRATE selection on the MAIN MENU SAVE ERROR Weld Head Control could not save the weld schedule Contact your authorized service agent for technical assistance SCHEDULE LOCKED System is protected and the schedule is locked Unlock the schedule as follows 1 At the MAIN MENU access the SYSTEM SECURITY selection 2 Enter your security code and change SCHEDULE LOCK to OFF SEARCH POSITI...

Page 56: ... Try replacing the electrode The rough surface of a worn electrode tip tends to stick to the workpieces So periodic tip resurfacing dressing is required to remove pitting oxides and welding debris from the electrode You should limit cleaning of an electrode tip on the production line to using a 400 600 grit electrode polishing disk If you must clean a badly damaged tip with a file be sure that the...

Page 57: ...repair parts for the 301H and 302H Linear Actuators Table 4 2 301H and 302H Linear Actuator Module Repair Parts List Amada Miyachi America P N Description Application 4 33274 01 Flexure 301H and 302H 4 33967 02 Electrode Holder Upper 301H 4 33474 01 Electrode Holder Handle Clamp 301H 4 33712 02 Electrode Holder 302H Technical Assistance If you need further technical assistance please contact eithe...

Page 58: ...n and allow the Weld Head Control and all test equipment to warm up for 15 minutes prior to calibrating the system Procedure 1 Set the POWER switch on the rear panel of the Weld Head Control to the OFF position 2 Disconnect the AC input power to the Weld Head Control 3 Remove the Weld Head Control cover 4 Reconnect the AC input power to the Weld Head Control and set the POWER switch to the ON posi...

Page 59: ...ust potentiometer R51 to set the indicator bar to center scale or zero Notice there is a 4 digit number just to the right of the word Calibrate For best accuracy adjust this reading to 0000 2 11 Press right arrow key Move the voltmeter lead to test point TP2 Adjust potentiometer R11 for a reading of 0 00 VDC 1mV on the voltmeter 12 Press right arrow key Adjust potentiometer R3 for a reading of 2 0...

Page 60: ... 14 kg If the force gauge reading is out of tolerance press RUN to exit and restart calibration from step 5 of this procedure If the reading is within tolerance press right arrow key and continue 20 Use the up and down arrow keys to adjust the force gauge reading to 2lb 0 2lb 0 91 kg 0 09 kg 21 Press right arrow key No more adjustments are necessary Remove the force gauge from between the electrod...

Page 61: ...e Current Weld Current Input max Control Signals 100 115 208 230 VAC single phase 50 60 Hz 10A rms 100 115 VAC 5A rms 208 230 VAC 5 kA Refer to Appendix B Operational Force Displacement Setdown Position Overshoot Rate Stroke max Electrode Holders 301H 302H Response Rate 50 000 lbs sec 22 680 kg sec Rating RMS 7 8 lbs 3 53 kg Weld and Hold 20lbs 0 to 9 07 kg Impulse 50 lbs 0 to 22 68 kg Resolution ...

Page 62: ......

Page 63: ...SERIES 300 FAST RESPONSE WELD HEAD SYSTEM 990 115 B 1 APPENDIX B WELD HEAD CONTROL INPUT OUTPUT SIGNALS ...

Page 64: ...50C Weld Head Control are shown in figure B 1 The functions of the connectors are as follows ACCESSORY PORT 25 pin D type connector to accommodate future expansion SERIAL PORT 25 pin D type connector transmits weld force and weld displacement data using RS 485 protocol to a user data logging device or host computer Refer to Appendix D and the Series 350 Serial Communications Interface Manual No 99...

Page 65: ... the weld cycle Lower central cable with right angle connector Conducts command signals to and feedback signals from the Linear Actuator Right bottom corner cable Power mains input CONTROL SIGNAL INPUT Connector The CONTROL SIGNAL INPUT connector interfaces with a Programmable Logic Control PLC or host computer for operation in an automated environment As shown in figure B 2 the connector accommod...

Page 66: ...rnal 1k ohm pull up to 5V and are active low See figure B 3 1 20 Binary remote schedule select bit 1 input 1 2 21 Binary remote schedule select bit 2 input 2 3 22 Binary remote schedule select bit 3 input 4 4 23 Binary remote schedule select bit 4 input 8 12 24 Binary remote schedule select bit 5 input 16 5 25 Binary remote schedule select bit 6 input 32 14 26 Binary remote schedule select bit 7 i...

Page 67: ...ROL SIGNAL INPUT connector to prevent a new welding process from beginning No welding process can be initiated until the switch closure has been removed The emitter of the opto coupler must be connected to pin 11 Output Relays Output relays K1 and K2 see figure B 4 can be used to provide status or timing signals to a Programmable Logic Control PLC or host computer When used for status signals the ...

Page 68: ...tical schedule number on the power supply On the UB25 Power Supply the schedule must be separately set on the power supply See table B 2 for the connector pin assignments Table B 2 CONTROL SIGNAL OUTPUT Connector Pin Assignments Pin Signal Name Function 1 20 Binary remote schedule select bit 1 input 1 2 21 Binary remote schedule select bit 2 input 2 3 22 Binary remote schedule select bit 3 input 4...

Page 69: ...ons for the two level FS2L Foot Switch are shown schematically in figure B 5 The pin assignments are listed in table B 3 When the foot switch is pressed to the first level the Weld Head Control energizes the weld head causing the Upper Electrode to descend to the search position If you release the foot switch before you press the foot switch to the second level the Weld Head Control will automatic...

Page 70: ...OT SWITCH Connector Pin Assignments Pin No Signal Function 1 Chassis Chassis ground 2 1 Level Foot switch level 1 input Internal 10 k ohm pull up to 5V When grounded head moves to SRCH position 3 2 Level Foot switch level 2 input Internal 10 k ohm pull up to 5V When grounded head completes weld cycle 4 Com DC common ...

Page 71: ... 115 C 1 APPENDIX C WELD HEAD DYNAMICS This appendix describes graphically and textually the dynamics of the Series 300 Actuator during a weld cycle The explanation should be useful to those who are tasked to install set up and operate the system ...

Page 72: ...t flows through the electrodes and the weld material 5 After a short period the weld material softens or melts 6 The net force on the electrodes is now no longer 0 zero The reaction force provided by the weld material decreases because the material has softened Now the electrodes start to move into the weld material This movement called follow up compresses the weld material until the reaction for...

Page 73: ...d head weighs 1 4 lbs 636 grams In order for the weld head to execute the required motion shown in the diagram while maintaining a weld force of 4 lbs 1 81 kilograms on the weld material the applied force must be increased to 1 81 22 0 63 15 7 kg or 4 22 1 4 34 8 lbs A spring driven weld head is adjusted to provide the weld force needed to create the right heat balance at the weld joint If a sprin...

Page 74: ...p and Adjusting the follow up force magnitude and duration FWUP to maintain the proper force on the weld material while the electrode is moving As a general guide for programming FWUP multiply 2 5 lbs per each 0 001 inch 44 6 Kg millimeter of electrode displacement then add this new constant to the weld force value Use the combined total as the new programmed follow up force For example Given Exis...

Page 75: ...SERIAL PORT Connections Refer to figure D 1 The RS 232 SERIAL PORT connector is a standard 25 pin female D Sub connector This connector will mate with any standard 25 pin male D Sub connector such as the Amada Miyachi America P N 250 479 connector 250 027 connector shell Connect an RS 232 cable between your host computer COM1 or COM2 ports and the Weld Head Control serial data port Parameter Descr...

Page 76: ...aight through RS 232 cable to the Weld Head Control SERIAL PORT connector 7 Set the printer or PC communication parameters in accordance with the parameters listed in table D 1 8 The Weld Head Control will now automatically send out weld data for each weld Weld Data Output Format The data fields in the weld data report packet are organized as follows weld_count schedule_number thickness setdown we...

Page 77: ...d signal Resolution is 0 1 milliseconds weld_status Status of the weld An example of a weld data print out is 17 0 0 005 0 0004 10 0 where 17 weld count 0 weld schedule number 0 005 material thickness of 0 005 inch 0 0004 setdown of 0 0004 inch 10 weld time of 10 0 milliseconds 0 weld status of 0 which is good ...

Page 78: ......

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Page 80: ...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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