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Amada CD-A Series, Operation Manual

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Amada CD-A Series Operation Manual Download Page 59

CHAPTER 5:  MAINTENANCE 

 

CD-A DUAL PULSE RESISTANCE WELDING POWER SUPPLY 

990-430 

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-mail address listed under 

Contact Us

 in the front of this 

manual. 
 
 

Summary of Contents for CD-A Series

Page 1: ...990 430 Rev C STORED ENERGY POWER SUPPLY CD A OPERATION MANUAL ...

Page 2: ...e weld parameters C 45833 04 20 Update Company Name Amada Weld Tech The following CD A Dual Pulse Resistance Welders are available CD A125A 125WS CD A300A 300WS CD A1000A 1000WS Your New Welder Shipment Contains The Following Items 1 The CD A Control Unit Power Supply 2 User manual 990 430 3 Ship Kit 4 81249 01 4 External current coil CD A1000A only NOTE The CD A1000A will also have an external tr...

Page 3: ...GE MONITOR Light 1 7 WELD NO WELD Switch 1 7 Emergency Stop Switch Operation 1 8 Chapter 2 Installation and Setup Section I Installation 2 1 Unpacking 2 1 Space Requirements 2 1 Utilities 2 2 Power Input Specifications 2 2 Compressed Air and Cooling Water 2 2 Input Logic Configuration 2 2 Section II CD A125A CD A300A External Equipment Connections 2 3 Emergency Stop Switch 2 3 Weld Head Connection...

Page 4: ...S screen 3 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 Section III MENU Screen 3 6 MENU Screen 3 6 Editing the MENU Screen 3 6 Buzzer 3 6 Baud Rate 3 7 Debounce 3 7 Chaining Start 3 7 Chaining End 3 8 Remote 3 8 Language 3 8 Reset Defaults 3 9 Rep...

Page 5: ...t OFF 4 7 Section III Operational Notes 4 8 Repetition Rate 4 8 Automatic Power Turn Down 4 8 Extended Shut down Procedure 4 8 Chapter 5 Maintenance Section I Troubleshooting 5 1 Troubleshooting 5 1 Error Messages 5 2 Section II Maintenance 5 4 Calibration 5 4 Electrode Maintenance 5 4 Parts Replacement 5 4 Section III Repair Service 5 5 Appendix A Technical Specifications A 1 Appendix B Electrica...

Page 6: ... P O Box 5033 Monrovia CA 91017 7133 TELEPHONE 626 303 5676 e mail info amadaweldtech com The purpose of this manual is to provide the information required for proper and safe operation and maintenance of the Amada Weld Tech CD A125A CD A300A and CD A1000A Dual Pulse Resistance Welding Power Supplies We have made every effort to ensure that information in this manual is both accurate and adequate ...

Page 7: ...ower 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 these instruction manuals before attempting to operate weld heads and power supplies Procedures other than those described in these manuals or not performed as prescribed in them may expose personnel t...

Page 8: ...N61000 4 3 EN61000 4 4 EN61000 4 5 EN61000 4 6 EN61000 4 8 EN61000 4 11 EN50581 2012 EU RoHS Manufacturer s Name AMADA WELD TECH Manufacturer s Address 1820 S Myrtle Avenue Monrovia CA 91016 626 303 5676 Equipment Description CD WELDER Equipment Class Insulation Class I Resistance Welding Equipment Model Numbers CD A125A CD A300A I the undersigned hereby declare that the equipment specified above ...

Page 9: ...2 EN61000 4 3 EN61000 4 4 EN61000 4 5 EN61000 4 6 EN61000 4 8 EN61000 4 11 EN50581 2012 EU RoHS Manufacturer s Name AMADA WELD TECH Manufacturer s Address 1820 S Myrtle Avenue Monrovia CA 91016 626 303 5676 Equipment Description CD WELDER Equipment Class Insulation Class I Resistance Welding Equipment Model Numbers CD A1000A I the undersigned hereby declare that the equipment specified above confo...

Page 10: ... the Goods within three 3 days of Seller s written notice that the Goods have been delivered to the Shipping Point Buyer shall be responsible for all loading costs including freight and insurance costs and provide equipment and labor reasonably suited for receipt of the Goods at the Shipping Point Seller shall not be liable for any delays loss or damage in transit c Seller may in its sole discreti...

Page 11: ... Buyer has approved credit with Seller Buyer shall pay all invoiced amounts due to Seller within thirty 30 days from the date of Seller s invoice If Seller does not have Buyer s financial information and has not provided pre approved credit terms for Buyer the payment must be made in cash with order or C O D in US dollars If Buyer has approved credit terms the payment may be made by cash with orde...

Page 12: ...e Goods Third Party Products are not covered by the warranty in Section 12 a For the avoidance of doubt SELLER MAKES NO REPRESENTATIONS OR WARRANTIES WITH RESPECT TO ANY THIRD PARTY PRODUCT INCLUDING ANY a WARRANTY OF MERCHANTABILITY b WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE c WARRANTY OF TITLE OR d WARRANTY AGAINST INFRINGEMENT OF INTELLECTUAL PROPERTY RIGHTS OF A THIRD PARTY WHETHER EXPRESS...

Page 13: ...cies and procedures of the applicable government and other competent authorities Buyer will indemnify and hold Seller harmless for any violation or alleged violation by Buyer of such laws rules policies or procedures Buyer shall not transmit export or re export directly or indirectly separately or as part of any system the Goods or any technical data including processes and Services received from ...

Page 14: ...ion and shall be finally settled in accordance with said rules The arbitration shall be conducted before a panel of three arbitrators Each party shall select one arbitrator and the two arbitrators so selected shall select the third arbitrator who shall act as presiding arbitrator Notwithstanding the foregoing if the matter under dispute is 500 000 or less there shall only be one arbitrator who sha...

Page 15: ...nges by unauthorized personnel Dual pulse welding can eliminate weld splash and improve weld quality especially when welding plated materials A peak current monitor displays actual peak current delivered to the weld on each pulse User programmable monitor limits on each pulse can help to detect poor welding conditions Programmable test pulses in conjunction with the INHIBIT SECOND PULSE feature ca...

Page 16: ...implifies use in automated systems The CONTROL SIGNALS connector provides remote control capability for REMOTE WELD INHIBIT REMOTE WELD SCHEDULE SELECTION and REMOTE FIRING The CHAIN SCHEDULE feature allows consecutive schedules to be chained together An advanced charging circuit provides rapid recharging and greater throughput External Emergency Stop function Display Screens Large remarkably intu...

Page 17: ...g 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 compatible with force fired and non force fired weld heads The SQUEEZE and HOLD delay times are adjustable from 0 to 2 999ms and 20 to 2 999ms respectively A built in weld counter allows controlling events based on the number of wel...

Page 18: ...uarantee 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 weld is performed with two pulses with independent energy levels and independent polarity When welding parts with plating or contamination the first pulse can be used to consistently seat the electrodes onto the p...

Page 19: ...he rear panel which contain the circuit breaker power and signal connectors The rear panel connections are discussed in Chapter 2 Installation and Setup Front Panel Controls The function of each item is described on the following pages Front Panel Controls UP DOWN BUTTONS RUN MENU PULSE 2 LIMITS COUNTERS SQUEEZE HOLD WELD NO WELD POLARITY SELECT SAVE PULSE SELECT PULSE 1 CLEAR CHARGE MONITOR PULSE...

Page 20: ...active when the Power Supply is in the editing mode Press this button repeatedly until the pulse duration you want is indicated directly below the 3 digit energy display The front panel display screen shown on the previous page indicates MEDIUM UPSLOPE pulse duration selected for Pulse 1 and MEDIUM UPSLOPE pulse duration selected for Pulse 2 NOTE The VERY SHORT setting provides the shortest durati...

Page 21: ...it Pulse 2 parameters follow the same procedures described for Pulse 1 SQZ HOLD Pressing this button during edit mode causes the editing highlight to move to the SQUEEZE field Pressing this button again moves the highlight to the HOLD field SAVE Pressing this button saves changes made during editing CLEAR Press this button to clear the WELD COUNTER COUNTER LIMIT PULSE 1 PULSE 2 UPPER LOWER LIMIT f...

Page 22: ...d power circuits Additionally an EMERGENCY STOP status display message will appear near the bottom of the display screen To resume operation reset the EMERGENCY STOP SWITCH to the normal position which will automatically return the system to RUN mode NOTE During the 20 second startup period when the Power Supply is first turned ON an activation of the Emergency Stop will interrupt 24V power to the...

Page 23: ...ufficient 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 CD A125A CD A300A CD A1000A Allow a minimum of 1 inch space on each side and 2 inches in the rear CD A1000A Weld Transformer Allow a minimum of 1 inch on all sides of the transformer The work surface must be level stable free from vib...

Page 24: ...upply are as listed below Model Input Voltage 50 60 Hz Single phase VRMS Circuit Breaker Current ARMS Copper Wire Gauge 7 strands AWG Wire Diameter mm All CD A Models 100 120 15 14 1 6 200 240 10 14 1 6 Compressed Air and Cooling Water If compressed air or cooling water service is required for the weld head please refer to the weld head manufacturer s user manual for service specifications Input L...

Page 25: ...mpliant normally closed EMERGENCY STOP SWITCH across the two leads of the emergency stop switch connector cable When this switch is opened the weld cycle will immediately stop See Appendix B Electrical and Data Connections for circuit details NOTE For operation without an EMERGENCY STOP SWITCH verify that the two conductors of the emergency stop cable are shorted together as the system will not op...

Page 26: ...ve welding transformer terminal on the Power Supply or external transformer for a CD A1000A 4 Connect the other ends of the weld cables to the weld head 5 Install electrodes in the weld head electrode holders NOTE If you need additional information about the weld heads please refer to the manufacturer s user manuals CAUTIONS 1 Install weld cable washers between the screw heads and cable terminals ...

Page 27: ... leads of the emergency stop switch connector 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 5 Set the ON OFF switch on the rear panel of the Power Supply to the ON position 6 Set the active schedule to the minimum energy level of the Power supply 7 Set the weldhead force to 5 un...

Page 28: ...perated open will immediately stop the weld cycle and retract the weld head See Appendix B Electrical and Data Connections for circuit details 7 Set the ON OFF switch on the rear panel of the Power Supply to the ON position 8 Set the active schedule to the minimum energy level of the Power supply 9 Set the weldhead force to 5 units of force or greater as displayed on the force indicator index 10 P...

Page 29: ...ion to the Amada Weld Tech EZ AIR weld head Non EZ AIR heads may be connected to the Power Supply but are not covered in these instructions For non EZ AIR head instructions refer to the manual provided by the weld head manufacturer EMERGENCY STOP SWITCH PNEUMATIC AIR SUPPLY WELD HEAD CABLE WELD HEAD EZ AIR FORCE ADJUSTMENT KNOB FORCE INDICATOR Set to 5 FOOT SWITCH REAR PANEL ...

Page 30: ...e weld head firing switch cable connector to the Power Supply firing switch cable connector 4 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 cycle and retract the weld head See Appendix B Electrical and Data Connections for circuit details PNEUMATIC AIR ...

Page 31: ...et the 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 activate the weld head 11 Set the ON OFF switch on the rear panel of the Power Supply to the ON position 12 Press the foot switch part way to actuate the first level switch The weld head upper electrode should descend smoothly to the DOWN positi...

Page 32: ... A300A described in Section II however there are three notable exceptions The CD A1000A uses a separate external Weld Transformer The CD A1000A uses a separate external Current Sense Coil The CD A1000A uses an external Pulse Selection Cable All three of these must be connected to the Power Supply using the rear panel connectors shown below Rear Panel Connectors for the CD A1000A CURRENT SENSE CONN...

Page 33: ...e Selection Cable on to the Pulse Selection Connector 3 Connect the Transformer Cable Connector on to the Transformer Connector Align the RED dot on the transformer cable connector to the RED dot on the transformer connector Once the RED dots are aligned push the cable into the transformer connector until it stops then twist counterclockwise until the connectors are secured together Transformer Co...

Page 34: ...onitoring accuracy use tie wraps to secure the loop end of the current coil the end farthest from the opening secured by the Velcro strap in a fixed position relative to the weld cable 5 Plug the connector of the current coil cable to the CURRENT SENSE connector on the back of the power supply WELD TRANSFORMER CD A1000A WELD HEAD WELD CABLES CURRENT SENSING COIL CURRENT SENSE CONNECTOR WELD TERMIN...

Page 35: ...n the WELD COUNTER and process monitor indicate how many welds have been completed since the weld counter was reset and what percentage of those welds were within programmed limits indicated both numerically and graphically The GREEN bar on the screen above indicates 95 of welds are within limits the RED portion of the bar shows 5 of welds are outside limits The CD A125A allows programmed values f...

Page 36: ...ues in WHITE as shown on the right Use the arrows PULSE WIDTH and POLARITY SELECT buttons to change the values for Pulse 1 To change the energy value for Pulse 1 use the arrows NOTE Pulse Polarity and Upslope are not user settable in CD A1000A PULSE 2 To edit the same values for Pulse 2 press the PULSE 2 button and repeat the procedures for Pulse 1 SQUEEZE TIME To edit the squeeze time press the S...

Page 37: ...ave not edited 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 appears at the bottom of the screen Press SAVE to save changes CLEAR to discard The system will revert to the original screen NOTE Whenever the RUN MENU or LIMITS COUNTERS buttons are presse...

Page 38: ... 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 the PULSE 1 button until the upper limit parameter is highlighted Use the arrows to set the limit to the desired value Use the CLEAR button to enter a value of zero PULSE 1 Lower Limit Press and release the ...

Page 39: ...000 NOTE The weld counter value can not be changed using the arrows EDIT COUNTER LIMIT From the LIMITS COUNTERS edit screen press and release the LIMITS COUNTERS button until the COUNTER LIMIT field is highlighted Press the arrows to set a desired limit value or use the CLEAR key to reset to the limit to 000000 Setting the counter limit to 000000 will disable the WELD COUNTER RELAY output signal a...

Page 40: ...Editing the MENU Screen Press and hold the MENU button to enter the MENU edit mode The screen will turn black when you are in edit mode Press the MENU button to sequence through all of the menu selections When a menu option is highlighted it can be changed To change the value use the arrows The first menu item is BUZZER This field sets the overall buzzer volume 1 4 where the value 4 is the loudest...

Page 41: ...ns where a PLC communicates with the unit CHAINING START Press the MENU button again 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 the system returns to the CHAINING START schedule Whenever a schedule within a chain is selected the chain will start a...

Page 42: ...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 REMOTE is set to ON all serial communication commands are active LANGUAGE Press the MENU button again to select the language ENGLISH ESPAÑOL DEUTSCH The language on screen will change when this field is saved ...

Page 43: ...re closed and held down and then the Force Firing Switch in the Air Actuated Weld Head closes sending a fire signal Note Weld Mode set to FS1 FS2 FSW When REPEAT MODE is used with a Non Force Fired Air Actuated Weld Head Weld Mode set to FS1 FS2 the Squeeze SQZ Period must be used to allow sufficient time for the electrodes to close and apply the required weld force to the parts before the Weld Pe...

Page 44: ...the weld head to open the electrodes and to allow you to reposition the work piece before the entire welding sequence repeats When REPEAT MODE is set to OFF this function is deactivated REPEAT MODE showing REPEAT TIME Note Weld Mode set to FS1 FS2 for the timing shown below RUN STATE SQZ HOLD REPEAT TIME SQZ HOLD REPEAT TIME RUN STATE WELD WELD UP UP DOWN WELD HEAD POSITION ...

Page 45: ...he valves Each option is defined below FS1 FS2 FSW Foot Switch 1 and Foot Switch 2 and Firing Used with two level foot switches and air actuated weld heads with force firing switch such as the Amada Thinline series Weld Heads Weld Head descends upon activation of FS1 weld begins when FS2 and FSW inputs are received FS1 FS2 FootSwitch 1 and Foot Switch 2 Used with two level foot switch and non forc...

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Page 47: ...mation 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 the Power Supply Connections Verify the Power Supply is connected to a manual or air actuated weld head as described in Chapter 2 Installation Setup in this manual Verify the EMERGENCY STOP SWITCH connector ca...

Page 48: ... 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 head force 4 Press the foot switch to activate the first level switch and clamp the material Check the head for suitable clamping pressure Release the footswitch to release the material Check the head for smooth...

Page 49: ...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 Welding will be performed using values of the schedule selected until you select a new schedule Modifying Weld Schedules 1 Press the WELD NO WELD switch to the NO WELD position 2 Use the arrows to select the wel...

Page 50: ...ress 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 SAVE button to save any changes made To exit editing mode without accepting changes press the RUN button on the front panel which will activate the SAVE prompt then press CLEAR to discard changes Set Peak Current Monitor Limits Refer to Appendix A regarding repetition ra...

Page 51: ...gain The COUNTER LIMIT field will be highlighted Press the CLEAR button to set this to zero or use the or arrows to change the value 4 Press the SAVE button to save changes To exit editing mode without accepting changes press RUN to activate the SAVE PROMPT then press CLEAR on the front panel to discard changes Set MENU Entries The MENU screen contains set up and configuration values that apply to...

Page 52: ...nnect Weldhead 2 to the 4 pin Standard Air Valve Driver Output Connector 2 Connect Weldhead 1 to the 8 pin Weld Head Connector 3 Connect the Dual Weldhead Input pin 13 on the 37 pin connector to the I O common pin 28 or 32 on the 37 pin connector 4 Schedule 1 will then use Weldhead 1 and schedule 2 will use Weldhead 2 These two heads and schedules will fire alternately with the Footswitch input Do...

Page 53: ...e weld data Schedule data and Counter data into Non Volatile memory whenever the input power is interrupted When cycling power from the ON to OFF to ON position a 3second pause should be observed when turning the power back on If this pause is not incorporated the unit may come on with a white display If a white display occurs at any time perform the power cycle with the 3 second pause to correct ...

Page 54: ...o 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 secon...

Page 55: ... materials 2 Wrong electrode tip shape 3 Excessive current energy setting Insufficient Weld Nugget 1 Insufficient energy setting 1 Wrong electrode material tip shape 1 Worn mushroomed electrodes 2 Excessively long pulse time setting 2 Incorrect weld head polarity 2 Contaminated weld piece surface plating 2 Excessive weld head force 3 Insufficient weld head force 3 Contaminated electrode surface 3 ...

Page 56: ...condition has occurred and the unit has locked out the fire mode 1 Cycle the input power to disengage lock out 2 If the error persists contact Amada Weld Tech for service 3 Firing Switch not closed within 10 seconds The firing switch did not close within 10 seconds of FS2 closing Adjust the weldhead and or parts to be welded so that the firing switch closes within 10 seconds of FS2 closing 4 5 6 7...

Page 57: ... 18 19 20 21 Internal Communication Errors Various internal Errors Power off then power on If the error persists contact Amada Weld Tech for service 22 Check Input Switch Status Input switch Active unexpectedly Resolve Switch Condition 23 Check Weld Mode Setting Weld Mode is not set for the input switch being used Use correct switch or change the Weld Mode setting ...

Page 58: ...g current to maintain the same weld heat the electrode tip has probably increased in surface area mushroomed effectively decreasing weld current density thus cooling the weld Try replacing the electrodes The rough surface of a worn electrode tip tends to stick to the work pieces So periodic tip resurfacing dressing is required to remove pitting oxides and welding debris from the electrode You shou...

Page 59: ...G POWER SUPPLY 990 430 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 mail address listed under Contact Us in the front of this manual ...

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Page 61: ...e changed without notice Item Description Dimensions CD A125A Power Supply CD A300A Power Supply CD A1000A Power Supply Weight Power Supply CD A125A 44 lbs 20kg CD A300A 69 lbs 31 kg CD A1000A control unit 29 lbs 13kg CD A1000A Transformer Dimensions Weight Transformer 135 lbs 61 kg 10 26 260 6 15 25 387 4 14 76 375 0 8 0 203 2 14 3 363 2 9 0 228 6 ...

Page 62: ...tomatic turndown upon power interruption Weld schedules 63 Weld pulses per Schedule 2 Repetition Rate without monitoring Pulses per minute Energy CD A125A CD A300A CD A1000A 3 Ws 836 min 4 Ws 586 min 5 Ws 708 min 10 Ws 554 min 408 min 120 min 20 Ws 425 min 25 Ws 281 min 40 Ws 313 min 50 Ws 204 min 91 min 60 Ws 261 min 75 Ws 167 min 80 Ws 227 min 100 Ws 201 min 145 min 65 min 125 Ws 173 min 150 Ws ...

Page 63: ...5 Ws 103 min 80 Ws 95 min 100 Ws 87 min 95 min 125 Ws 86 min 150 Ws 84 min 200 Ws 84 min 225 Ws 72 min 250 Ws 66 min 300 Ws 52 min 500 Ws 35 min 750 Ws 17 min 1000 Ws 10 min NOTE The Hit Rates for the CD A300A and CD A1000A are the same as their Repetition Rates Rise Times at Max Energy into a 1 milliohm load with very low inductance No Upslope With Upslope CD A125A CD A300A CD A1000A CD A125A CD ...

Page 64: ...D A300A 3 to 300 Watt Seconds Ws in 1 Ws increments CD A1000A 10 to 999 Watt Seconds Ws in 1 Ws increments Polarity Selection Positive Negative or Alternating on CD A125A CD A300A only Squeeze Time 0 2 999 msec Hold Time 20 2 999 msec Weld Counter 0 999999 Action Upon Reaching Limit Buzzer sounds after each weld Output relay activates Input Debounce Time Approximately 30 msec Control Outputs See A...

Page 65: ...er Cord is supplied The female end of the power cable is an IEC 320 C13 standard plug Connect the Power Supply power cable to a single phase 50 60Hz power source The nominal voltage can be either 100 120V or 200 240V Power Input Specifications Model Input Voltage 50 60 Hz Single phase VRMS Circuit Breaker Current ARMS Copper Wire Gauge 7 strands AWG Wire Diameter mm All CD A 100 120 15 14 1 6 200 ...

Page 66: ...m an improper connection The optical firing switch input can only be used with Amada Weld Tech heads that have this feature In operation an optical switch connects between pin 2 and pin 20 to initiate firing Neither of these pins should be used for any other purpose since they connect to internal non isolated points in the unit 3 Not used 4 Firing switch input Input must be held active for at leas...

Page 67: ...also possible to Reset the relay using the Fault Relay input Pin 26 17 18 Not used 19 24VDC The total current draw from pins 1 and 19 must not exceed 500mA 20 Ground 21 22 Not used 23 FS2 Foot switch level 2 Input must be held active for at least 50ms 24 FSI FS2 Fire Common I O common for FS1 FS2 FSW inputs 25 Not used 26 Fault reset input When activated for 50ms will reset any I O relay fault Exc...

Page 68: ...ELECTRICAL AND DATA CONNECTIONS CD A DUAL PULSE RESISTANCE WELDING POWER SUPPLY B 4 990 430 Connection Example Inputs configured for sinking Low True Inputs Switch Closure to Activate Inputs Default Configuration ...

Page 69: ...PPENDIX B ELECTRICAL AND DATA CONNECTIONS CD A DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 430 B 5 Connection Example Inputs configured for sourcing High True Inputs Switch Closure to Activate Inputs ...

Page 70: ... by connecting it to Fire Common When the footswitch is depressed the weld head moves into position and applies force to the weld pieces After the Squeeze delay the Weld Current will flow and the Power Supply will automatically return the upper electrode to its UP position when the weld schedule is complete Two Level Footswitch When using a two level footswitch connect position 1 1st position betw...

Page 71: ...t is initiated when the footswitch is depressed during the 1st position At this time the upper electrode on the Weld Head will descend and apply force to the weld pieces The Valve Driver mating connector is a TE Connectivity 206429 1 connector Pt 520 107 206358 5 backshell Pt 245 084 1 66103 8 terminals Pt 253 001 Weld Head Connector Weld Head Connector Pin Description 1 HEAD_1 switched 24V common...

Page 72: ... shielded 22awg twisted wires and is terminated with a 2 pin Amphenol Type 80 MC2F connector Pt 520 011 This connector mates with the weld head firing switch connector Pt 520 001 Firing Switch Connector Pin Description 1 FIRE COMMON Pin 24 of the 37 pin I O Connector 2 FIRE Pin 4 of the 37 pin I O Connector Operator Emergency Stop Cable Switch Input Function The Emergency Stop Cable Switch Input o...

Page 73: ...S CD A DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990 430 B 9 RS 232 Connections PIN DESCRIPTION 1 No Connection 2 RS 232 Transmit 3 RS 232 Receive 4 No Connection 5 Signal Ground 6 No Connection 7 No Connection 8 No Connection 9 No Connection ...

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Page 75: ...whichever is greater 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 670ms on the CD A125A and CD A300A or up to 1 500ms on the CD A1000A If no second pulse is programmed this time peri...

Page 76: ...OOL This time is not programmable by the user It depends upon the energy level of the second pulse and ranges from 20 to 670ms on the CD A125A and CD A300A It can range up to 1 500ms on the CD A1000A If no second pulse is programmed this time period is skipped Changing pulse widths or polarities may result in longer cool times than if no changes are made to these parameters Pulse 2 The timing of t...

Page 77: ... 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 energy level is reached D5 Duration of the END OF WELD relay This is from 100 to 125ms D6 Delay time from the end of the weld pulse until the OUT OF LIMITS relay turns on This time can be up to 300ms D7 Dela...

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Page 79: ...ction 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 control systems RS 232 Serial Connector Information RS 232 settings Baud Rate 9600 19 2k and 38 4k Baud Data bits 8 Stop bit 1 Parity None NOTES The host must be set to the same baud rate as the unit For a mi...

Page 80: ...m 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 0x03 The CD A will respond with a Negative Acknowledge Command NK when an error is encountered in response to a command The format and reasons follow stx NK cnt err cksum etx Where err 1 2 3 NO SOH BAD check...

Page 81: ... 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 Limit 0 Bytes COUNT RC Read None Returns of stored welds 0 Bytes REPORT RR Read Request 1 6 or Retransmission F 1 Byte READ ORDER N new O Old 1 Byte 2 Bytes Total REMOTE RM Set 0 Local 1 Remote 1 Byte WELD ZERO CR Set Reset Weld Counter ze...

Page 82: ...tive 2 Alternating Note The SS Set commands for PULSE1 PULSE2 POLARITY1 and POLARITY2 do not apply to the CD A1000A LIMITS MR Read Schedule 2 Bytes LIMITS MS Set SCHEDULE 2 Bytes P1 Upper Limit 4 Bytes P1 Lower Limit 4 Bytes P1 Action action 1 Byte P2 Upper Limit 4 Bytes P2 Lower Limit 4 Bytes 19 Bytes Total action 0 NONE 1 INHIBIT P2 SYSTEM YR Read none 0 Bytes SYSTEM YS Set BAUD RATE rate 1 Byte...

Page 83: ...s 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 NAK 1 Byte LOAD LS Set ACK OR NAK 1 Byte LR Read The active schedule 2 Bytes REPORT RR Read Schedule 1 to 63 2 Bytes Weld Status 0 Good 1 Out of Limits 1 Byte 1st pulse Current 3 Bytes 2nd pulse Current 3 Bytes Weld Numb...

Page 84: ... values loaded 7 Power board fuse blown 8 Communication error between control board and front panel 9 Exiting Edit mode 10 Emergency Stop EMO input is open 11 Invalid Chaining start or end value 12 Last Weld was out of Limits SYSTEM YS Set ACK OR NAK 1 Byte SYSTEM YR Read BAUD RATE rate 1 Byte DEBOUNCE 0 None 1 30ms 1 Byte BUZZER 0 Off 1 2 3 4 loud 1 Byte FAST WELD 0 OFF 1 ON 1 Byte WELD MODE 0 FS...

Page 85: ...SE1 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 23 Bytes Total weld length 0 Very short 1 Short 2 Medium 3 Long weld polarity 0 Positive 1 Negative 2 Alternating MONITOR MS Set ACK OR NAK 1 Byte MONITOR MR Read SCHEDULE 2 Bytes P1 Upper Limit 4 Bytes P1 Lower Limit 4 Bytes P1 Action action 1 Byte P2 Upper ...

Page 86: ... 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 take the final check sum and AND it with 255 0x0FF In hex taking the final check sum 0x9C4 and ANDing it with 0xFF 0xC4 or in decimal 2500 AND 255 196 EXAMPLE 2 Now we wish to find out how many welds are sto...

Page 87: ...ad 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 Set TC Read Weld Counter TG Read Good Bad Counters TL Read Weld Count Limit TR Rear Panel Status TS Read Status of last weld TY Read the Type YR System Read YS System Set ...

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Page 89: ...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 contact resistance requires additional weld current voltage or power to produce the heat required to form a weld The higher the weld force the greater the weld current voltage power or time required to produce ...

Page 90: ...TERIAL 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 A...

Page 91: ... 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 Inconel 2 Kulgrid 2 Constantan 2 Copper 14 Invar 2 Invar 2 Constantan 2 Tinned Copper 14 Iridium 2 Iridium 2 Constantan 2 Iron 2 Iridium 2 Platinum 2 Constantan 2 Nichrome 2 Iron 2 Iron 2 Constantan 2 Nickel 2...

Page 92: ...led 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 Tantalum 2 Nickel Alloy 2 Consil 2 Titanium 2 Titanium 2 Nickel Alloy 2 Tinned Copper 14 Tungsten 2 Tungsten 2 Nickel Alloy 2 Nichrome 2 Tungsten 2 henium 2 Nickel Alloy 2 Nickel 2 Zinc 14 Zinc 14 Nickel Al...

Page 93: ...ld 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 If the parts pull apart easily or there is little or no residual materia...

Page 94: ...ltage 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 Strength Profile The picture on the right illustrates a typical weld strength profile The 14lb electrode force curve shows the highest pull strengths but the lowest tolerance to changes in weld current vol...

Page 95: ...sistance 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 designing a quality welding solution is the properties of the materials to be joined and the quality requirements of the desired welded joint At this stage it is worthwhile to review the way the resistance wel...

Page 96: ...uring 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 the...

Page 97: ...cro 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 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 heat...

Page 98: ...ate 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 I Group II Group III Group I Copper Solid State W Mo electrodes Solid State Projection on Group I Solid State Fine projections on Group III Group II Steel Solid State or Fusion Solid state or braze o...

Page 99: ...rectly 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 surface heating Weld splash or expulsion Electrode sticking Weak welds Alternately conductive materials can be welded by using high contact resistance and fast heating because their bulk resistance is not hig...

Page 100: ...eneration 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 is generat...

Page 101: ...s fired Squeeze time also allows 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 pressure before the electrodes are retracted from the parts Hold time is important as weld strength develops in this period This basic form of weld profile is sufficient for th...

Page 102: ...any 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...

Page 103: ...oblems 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 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 th...

Page 104: ...ests 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 co...

Page 105: ...lly used when the critical or main key variables have been identified and we need to establish the best settings for the process A factorial DOE may also give an indication as to how wide the acceptable weld window is in relation to quality requirements We recommend data be gathered from a monitoring perspective so that this can provide a starting point for establishing a relationship between qual...

Page 106: ...t in weld development will ensure a stable welding process and provide a substantial return in quality and long term consistency Welding problems can more easily be identified and solved if sufficient experimental work is carried out to identify the impact of common variables on the quality and variation of the welded assembly Amada Weld Tech frequently uses the Screening DOE tool to establish the...

Page 107: ...E 82178 Puchheim Germany TEL 49 89 839403 0 FAX 49 89 839403 68 AMADA WELD TECH 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 VIETNAM CO LTD 469 Ha Huy Tap Road Yen Vien Gia Lam Ha Noi Vietnam TEL 84 4 6261 4583 FAX 84 4 6261 4584 AMADA THAILAND CO LTD Asia Industrial Estate Suvarnabhumi AIES 88 41 Moo 4 Khlongsuan Bangbo...

Page 108: ...AMADA WELD TECH 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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