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Amada HF-2500A Operation Manual Download Page 147

APPENDIX F:  THE BASICS OF RESISTANCE WELDING 

 

 

HF-2500A HIGH FREQUENCY WELD CONTROL 

990-371 

F-3 

 

MATERIAL 

ELECT 

RWMA 

TYPE 

MATERIAL 

ELECT 

RWMA 

TYPE 

 

MATERIAL 

ELECT 

RWMA 

TYPE 

MATERIAL 

ELECT 

RWMA 

TYPE 

Bronze 

-2, -11 

Nichrome 

-2 

 

Copper 

-14 

Silver 

-11, -14 

Bronze 

-2, -11 

Nickel 

-2 

 

Copper 

-14 

Cold Rolled 
Steel 

-2 

Chromel 

-2 

Chromel 

-2 

 

Copper 

-14 

Stainless Steel 

-2 

Chromel 

-2 

Constantan 

-2 

 

Dumet 

-2 

Dumet 

-2 

Chromel 

-2 

Copel 

-2 

 

Dumet 

-2 

Nichrome 

-2 

Chromel 

-2 

Copper 

-14 

 

Dumet 

-2 

Nickel 

-2 

Chromel 

-2 

Tinned Copper 

-14 

 

Dumet 

-2 

Platinum 

-2 

Chromel 

-2 

Dumet 

-2 

 

Dumet 

-2 

Cold Rolled 
Steel 

-2 

Chromel 

-2 

Nichrome 

-2 

 

Evanohm 

-14 

Copper 

-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 

 

 

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 

 

Karma 

-2 

Karma 

-2 

Copper 

-14 

Copper 

-14 

 

Karma 

-2 

Nickel 

-2 

Copper 

-14 

Dumet 

-2 

 

Karma 

-2 

Platinum 

-2 

Copper 

-14 

Invar 

-2 

 

Kovar, Gold 
Plate 

-2 

Kovar, Gold 
Plate 

-2 

Copper 

-14 

Karme 

-2 

 

Kovar, Gold 
Plate 

-2 

Kulgrid 

-2 

Copper 

-14 

Manganin 

-2 

 

Kovar, Gold 
Plate 

-2 

Nickel 

-2 

Copper 

-14 

Nichrome 

-2 

 

Kovar, Gold 
Plate 

-2 

Silver 

-11, -14 

Copper 

-14 

Nickel 

-2 

 

Kovar, Gold 
Plate 

-2 

Stainless Steel 

-2 

Copper 

-14 

Paliney 7 

-2 

 

Magnesium 

-1 

Magnesium 

-1 

 
 

 

Summary of Contents for HF-2500A

Page 1: ...990 371 REV J HIGH FREQUENCY WELD CONTROL HF 2500A OPERATION MANUAL...

Page 2: ...on Record Revision EO Date Basis of Revision A 20411 03 05 None Original edition B 21590 09 07 Weld Status Codes added to Appendix E Communications C 34461 12 09 Updated technical information specific...

Page 3: ...this manual is to supply operating and maintenance personnel with the information needed to properly and safely operate and maintain the HF 2500A Power Supply We have made every effort to ensure that...

Page 4: ...y 1 6 Weld Period Selector Keys 1 6 Time Energy Selector Keys 1 6 Front Panel Data Entry and Mode Keys 1 6 Key Pad 1 6 Mode Keys 1 7 RUN Key 1 7 MENU Key 1 7 Control Keys 1 7 Control Mode Selection Ke...

Page 5: ...re You Start 3 1 Overview 3 1 Main Menu 3 1 1 Setup 3 1 2 Weld Counter 3 2 3 Copy A Schedule 3 3 4 Calibration 3 3 5 System Security 3 3 1 Schedule Lock 3 4 2 System Lock 3 4 3 Calibration 3 4 6 Commu...

Page 6: ...3 19 Weld Head Applicability 3 20 When To Use Functions 3 20 Weld Schedule Definition 3 21 Weld Sequence Timing 3 21 Welding Applications 3 22 Single Pulse Weld Profile 3 22 Upslope Downslope Weld Pr...

Page 7: ...eld Schedule 5 5 Dual Pulse Weld Schedule 5 7 Section III Using the Weld Monitor 5 9 Section IV Active Part Conditioning 5 13 Section V Resistance Set 5 15 Section VI Pre Weld Check 5 17 Section VII W...

Page 8: ...A 1 Appendix B Electrical and Data Connections B 1 Appendix C Calibration C 1 Appendix D System Timing D 1 Appendix E Communications E 1 Appendix F The Basics of Resistance Welding F 1 Appendix G Qual...

Page 9: ...please read these instruction manuals before attempting to use them Procedures other than those described in these manuals or not performed as prescribed in them may expose personnel to electrical bur...

Page 10: ...ds 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 pr...

Page 11: ...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 ha...

Page 12: ...s 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...

Page 13: ...nd 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...

Page 14: ...d 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 select...

Page 15: ...t Conditioning Pre weld Check Weld to Limits Descriptions of the various control modes and process tools are located in Chapter 3 System Configuration and Chapter 4 Introduction to Feedback Modes and...

Page 16: ...sformer saturation and changes in line voltage In addition special power device technology precisely controls the weld energy at both high and low energy levels You can program the Power Supply from t...

Page 17: ...ely program menu items on the Power Supply s Appendix E Communications in this manual lists all of the commands that the Power Supply will respond to and instructions on how to format commands sent to...

Page 18: ...s circuit breakers and power and signal connectors The rear panel connections are discussed in Chapter 2 Installation and Setup Front Panel Display and Display Controls The front panel of the Power Su...

Page 19: ...ts you to View the entire weld schedule profile individual weld periods and weld energy parameters View individual weld parameter program changes as you enter them via the weld period selector keys Vi...

Page 20: ...E 1 and PULSE 2 weld periods select either the bottom line of data or the second to bottom line of data on the screen to be programmed The bottom line of data is weld period time in milliseconds The s...

Page 21: ...urrent as the control mode for this schedule The control will output the current waveform shown on the LCD Pressing the V key selects voltage as the control mode for this schedule The control will out...

Page 22: ...You can also program the power monitor to output an alarm when the limits are exceeded Pressing the key displays the resistance monitor This screen shows the results of the most recent weld The Power...

Page 23: ...s Allow ample workspace around the Power Supply so that it will not be jostled or struck while welding Allow sufficient clearance around both sides and back of the Power Supply for power and signal ca...

Page 24: ...Input power requirements for the Power Supply are as listed below Power Input Specifications HF 2500A Model Input Voltage 50 60 Hz 3 phase Vrms Circuit Breaker Current A rms Copper Wire Gauge 7 stran...

Page 25: ...e connections from the weld head are made at the weld cable terminals on the front panel The pre wired Configuration Plug above is colored red for clarity actual color may vary This plug allows the us...

Page 26: ...2 Connect one end of the second weld cable to the positive welding transformer terminal on the Power Supply 3 Connect the other end of the weld cables to the weld head 4 Attach the voltage sensing cab...

Page 27: ...e either the 1 4 or 1 8 diameter clip as appropriate to the electrode diameter 7 Attach a clip directly to each electrode as shown on the right 8 Put a strain relieve on each voltage sensing lead to i...

Page 28: ...y stop switch across the two leads of the operator emergency stop switch cable This switch when operated open will immediately stop the weld cycle See Appendix B Electrical and Data Connections for ci...

Page 29: ...CHAPTER 2 INSTALLATION AND SETUP HF 2500A HIGH FREQUENCY WELD CONTROL 990 371 2 7 EZ AIR Weld Head Connections AC EZ AIR Weld Head Connection...

Page 30: ...firing switch cable connector to the Power Supply firing switch cable connector 3 Connect a normally closed approved emergency stop switch across the two leads of the operator emergency stop switch c...

Page 31: ...ly front panel to the NO WELD position In this position the Power Supply cannot deliver weld energy but it can control the weld head 9 Set the circuit breaker on the rear panel of the Power Supply to...

Page 32: ...FREQUENCY WELD CONTROL 2 10 990 371 Non EZ AIR Weld Head Connections Non EZ AIR heads may be connected to the Power Supply as shown below however you should refer to the manual provided with the weld...

Page 33: ...the menu screens have similar prompts that tell you how to go to a function on the menu and or get to the next menu MAIN MENU 1 SETUP 6 COMMUNICATIONS 2 WELD COUNTERS 7 RELAY 3 COPY A SCHEDULE 8 RESE...

Page 34: ...ade in any weld schedule WELD COUNTERS 1 TOTAL WELDS 0000000 2 OUT OF LIMITS HIGH 000000 3 OUT LIMITS LOW 000000 4 WITHIN LIMITS 000000 Number Select an item RUN or MENU NOTE The Power Supply breaks d...

Page 35: ...key to copy the schedule and exit the screen 6 Press the MENU key to return to the main menu The contents of Weld Schedule 1 will be copied to Weld Schedule 2 overwriting the previous contents of Weld...

Page 36: ...calibration settings NOTE All security options use the same procedure to enter a security code and to turn the security code OFF 1 Press the 1 key to select SCHEDULE LOCK This will bring up the CHANG...

Page 37: ...s various menu screens on the LCD each containing prompts telling you which of the Power Supplies front panel controls to use in order to customize operating parameters set the Power Supply for use in...

Page 38: ...ressing the 3 key will alternately select either RS 232 or RS 485 communications The default selection is RS 232 4 I D Number The host computer may be used to talk with multiple Power Supplies using a...

Page 39: ...1 1 SET RELAY TO ON 2 WHEN ALARM Number Select Page RUN or MENU 4 Press the 2 key to select the WHEN menu shown at the right WHEN 1 ALARM 6 P1LOW 2 OUT OF LIMITS 7 P2HIGH 3 WELD 8 P2LOW 4 END OF WELD...

Page 40: ...Setting System Parameter Default Setting Foot Switch Weld Abort OFF Weld Counters All 0 Switch Debounce Time 10 ms Communication Role CLIENT Firing Switch AUTO Baud Rate 38 4 K Display Contrast 50 ID...

Page 41: ...count creating a chain of schedules that can accommodate a variety of welding needs For example A single work piece requires four welds two weld points require the same weld schedule each of the other...

Page 42: ...EXT 01 0001 01 02 0001 02 03 0001 03 04 0001 04 Scroll SCHEDULE Select MENU 4 Use the Up Down keys on the front panel to scroll vertically through the schedules to highlight the weld count for the sch...

Page 43: ...ic control PLC Any of these switches could be the weld initiation switch in your system setup ON means that the welding process is initiated by closure of the initiation switch and continues to its co...

Page 44: ...ct the required switch type by pressing the 1 2 or 3 key Pressing the numeric keys automatically returns the display to the SETUP 1 screen 1 Auto The Power Supply accepts a single pole double pole or...

Page 45: ...eturn to the SETUP PAGE 2 of 3 screen 3 End Of Cycle Buzzer 1 With the SETUP 2 screen displayed press the 3 key to toggle the end of cycle buzzer ON or OFF This function is normally used with manually...

Page 46: ...mize response to varying weld conditions Press 1 to bring up the following choices 1 ALWAYS A test weld will be done if The voltage level changes The time in any element of the schedule changes If the...

Page 47: ...weld state when adjusting the air regulators on air actuated weld heads Menu State Pressing the MENU key puts the Power Supply in the menu state It brings up menu screens that enable you to select va...

Page 48: ...period was 1 014 volts and the total weld count since the weld counter was last reset is 5 237 The weld profile trace is an analog display of the electrical parameters programmed with the weld period...

Page 49: ...Power Supply detects an out of limits condition it will take one of four actions for PULSE 1 and one of two actions for PULSE 2 depending on the selection made with the MONITOR display as shown at th...

Page 50: ...itoring for a detailed description of monitor and energy limits operation Alarm State The Power Supply automatically recognizes many alarm conditions The example WELD SWITCH IN NO WELD POSITION alarm...

Page 51: ...weld energy amplitudes for the weld period segments you can program an appropriate weld schedule profile to perform the above applications Typical applications and recommended weld schedule profiles a...

Page 52: ...ead closes Manual Weld Heads For manually actuated weld heads SQUEEZE TIME begins when the force firing switch closes Using SQUEEZE TIME is optional depending on the welding process you have developed...

Page 53: ...les may be programmed for single pulse upslope downslope or dual pulse operation Weld schedules may also use special monitoring features of the Power Supply such as Energy Limit Active Part Conditione...

Page 54: ...ot flat spring steel parts or heavily plated or oxidized parts Dual Pulse Use for spot welding parts with plating First pulse can be used to displace plating or oxides and the second pulse to achieve...

Page 55: ...sed to displace plating and or oxides reduce flashing and spitting or reduce thermal shock when welding parts containing glass to metal seals Downslope annealing assists in the grain refinement of cer...

Page 56: ...weld current is typically greater than the Pulse 1 weld current by a factor of 3 as the first pulse significantly reduces the resistance of the interface between the parts The only use for the downsl...

Page 57: ...ckness without affecting weld quality Set monitoring limits on voltage Voltage Mode Application Ideal for welding round or non flat parts Description This mode controls the voltage across the work pie...

Page 58: ...vary the time periods for these limits during the weld pulse These limits can be used for several purposes Common uses for out of limits welds are to stop a weld or to trigger a relay to remove parts...

Page 59: ...ngle pulse must be in the same units such as kW Process Tools These tools are proven methods to use the monitor and limit functions described above in order to achieve specific results There are five...

Page 60: ...ed in their ability to deal with varying levels of part contamination and oxide If constant current feedback were used the power supply would ramp the voltage to very high levels in order to achieve c...

Page 61: ...s used when parts vary in initial resistance due to Shape and part fit up Very small parts Resistance Set is very similar to APC except that there are applications where you do not want a high voltage...

Page 62: ...ead If a part is missing or misaligned you do not want the machine to weld because the result would be an unacceptable weld and or damaged electrodes When using a Pre Weld Check Pulse 1 should be very...

Page 63: ...e faulty weld piece can be removed The monitor measures the weld energy parameters during the weld period and compares the measurements against the programmed limits If any of the programmed limits ar...

Page 64: ...signal automation equipment to perform pre programmed actions such as stopping the production line so the faulty weld piece can be removed In the profile above the weld current is exceeding the select...

Page 65: ...tion 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 S...

Page 66: ...2 Set the WELD NO WELD switch on the Power Supply front panel to the NO WELD position In this position the Power Supply will operate the weld head without producing weld energy NOTE When you are read...

Page 67: ...0 and 99 milliseconds 5 Press the PULSE 1 WELD key again to highlight the middle line of the LCD to enter weld energy Use the numeric keypad to enter the energy level or use the arrows The Power Supp...

Page 68: ...or use the arrows Enter 0 5 milliseconds 9 Program Pulse 2 by repeating Steps 3 through 7 above using the keys for Pulse 2 entering the value 0 in each step 10 Press the HOLD key to enter the amount...

Page 69: ...nds 5 Press the PULSE 1 WELD key again to highlight the middle line of the LCD to enter weld energy Use the numeric keypad to enter the energy level or use the arrows The Power Supply output ranges ar...

Page 70: ...or use the arrows Enter 0 5 milliseconds 9 Program Pulse 2 by repeating Steps 3 through 7 above using the keys for Pulse 2 entering the value 0 in each step 10 Press the HOLD key to enter the amount...

Page 71: ...1 WELD key again to highlight the middle line of the LCD to enter weld energy Use the numeric keypad to enter the energy level or use the arrows The Power Supply output ranges are Current from 0 1 2 4...

Page 72: ...a time between 0 and 99 milliseconds We recommend at least 2 milliseconds 9 Program Pulse 2 by repeating Steps 3 through 7 above using the keys for Pulse 2 entering appropriate values for Pulse 2 10...

Page 73: ...tual weld waveform The LOWER LIMIT line is shorter because it only includes the WELD portion of the waveform If the line of either limit crosses the weld energy waveform the Power Supply can trigger a...

Page 74: ...de 5 Toggle the Pulse 1 weld time energy selector key to select the lower limit field for the weld period Enter the lower limit value for the Pulse 1 weld period NOTE In order for a Pulse 1 lower limi...

Page 75: ...s will bring up the PULSE 2 OUT OF LIMITS ACTION screen This screen allows you to select the action that the Power Supply will take if the Pulse 2 upper or lower limits are exceeded You PULSE 2 OUT OF...

Page 76: ...of time deleted on each end of the limit the limit will appear to move horizontally across the screen This allows PULSE 1 MONITOR LIMITS 1 LOWER LIMIT IGNORE 1ST 0 0 ms 2 LOWER LIMIT IGNORE LAST 2 5 m...

Page 77: ...tance has stabilized and the parts have come into closer contact 6 Push RUN and optimize the energy and time setting of Pulse 1 constant power to provide an adequate tack weld and also a current wavef...

Page 78: ...art will reach the current limit sooner and the pulse will terminate early A dirty part will require more time before the oxide is broken down and current can flow 12 Program your second welding pulse...

Page 79: ...oltage waveform 4 From the MONITOR keys section on the front panel press the resistance key and observe the resistance waveform This should appear to begin high then start to drop as a tack weld is ma...

Page 80: ...for the current to rise and reach the limit even with wide variations in initial resistance 11 The power supply terminates the first pulse when your programmed current is reached A low resistance par...

Page 81: ...first pulse peak voltage readings from weld to weld 4 Press the Pulse 1 weld key to highlight the upper limit field for the weld period Use the numeric keypad to enter the upper limit value for the P...

Page 82: ...voltage limits are reached If the voltage limits are not being reached with these conditions present return to the voltage monitor screen and adjust the limits accordingly You may also have to adjust...

Page 83: ...press the kA current V voltage kW power and resistance keys and observe the resulting waveforms NOTE You can toggle between PEAK and AVERAGE readings by pressing the PEAK AVERAGE key 4 Press the kA cu...

Page 84: ...d of the programmed weld time Weld to a Limit Waveform 11 Make several more welds and inspect them for consistency of weld quality and or weld strength NOTE When using the Weld to a Limit function alw...

Page 85: ...m the MONITOR keys section on the front panel press the kA current V voltage kW power and resistance keys and observe the resulting waveforms NOTE You can toggle between PEAK and AVERAGE readings by p...

Page 86: ...4 Try making welds with only one part present Also try making welds with misaligned parts Observe that the power supply terminates the weld as soon as the voltage limits are reached If the voltage lim...

Page 87: ...F open RELAY 1 1 SET RELAY TO ON 2 WHEN ALARM Number Select Page RUN or MENU 4 Press the 2 key to select the WHEN menu shown at the right WHEN 1 ALARM 6 P1LOW 2 OUT OF LIMITS 7 P2HIGH 3 WELD 8 P2LOW 4...

Page 88: ......

Page 89: ...Correct weld energy and time is set at the Power Supply The equipment is set up properly All electrical connections are tight Electrode alignment allows flush contact with the weld pieces Electrodes a...

Page 90: ...at HF 2500A 2 Contaminated electrode surface 3 Slow weld head follow up Weld Piece Warping 1 Excessive weld time set at HF 2500A 1 Excessive weld head force 1 Incompatible weld piece projection design...

Page 91: ...parameters Press MENU select System Security then enter your access code to turn off System Security NOTE Entering a security code of 280 will always unlock the system CALIBRATION RESET TO DEFAULT Use...

Page 92: ...s properly connected to the electrodes or electrode holder NOTE Polarity is not important for the cable connection CURRENT 1 GREATER THAN UPPER LIMIT Actual weld current is greater than the user set U...

Page 93: ...d cable length Reduce the total electrical resistance by increasing the weld cable diameter Check cable and weld head connections Verify that all three phases from the input power lines are functionin...

Page 94: ...ARE RESET User programmed the HF 2500A to automatically reset all 100 weld schedules to their factory set default values CAUTION Be careful when using the MENU default features There is no way to res...

Page 95: ...r of the weld cables Reset the Lower Limit for Weld2 to a smaller value VOLTAGE SELECTION PLUG IS MISSING The Voltage Selection Plug on the Weld Transformer is missing or improperly connected Verify t...

Page 96: ...must use a polishing disk after filing to ensure the electrode faces are smooth The best method of preventing electrode problems is to regularly re grind electrode tip surfaces and shapes in a certifi...

Page 97: ...ned PULSE 1 and PULSE 2 Pulse Width of 50 ms 6 0 kW max Maximum Output Current 2400 A Max Peak Output Voltage at Max Peak Output Current 5 2 V Duty Cycle at Max Peak Output Current 3 Max Load Resistan...

Page 98: ...d Single Valve Air or Cam Actuated Force Fired EZ Air Kit Plug and Play 24VDC EZ AIR weld head SL 300A 320A Electronic Weldheads Weld Energy Limits Monitoring Weld Pre Check Mode Inhibit second weld p...

Page 99: ...mputer Voltage Weld voltage signal for voltage feedback operation 0 to 10 volt peak Weld Head Plug and play connector with Firing and Foot switch inputs Voltage Sense input and 24VDC Air Valve Driver...

Page 100: ......

Page 101: ...by a set of two jumper plugs One jumper plug is installed on power connector J23 located on the center chassis plate The other jumper plug P22 plugs into welding transformer cable connector J22 The j...

Page 102: ...d in the Ship Kit Complete connection information is in Section III I O Configuration Before fabricating I O cables you should be familiar with the physical characteristics of the Power Supplies I O c...

Page 103: ...rt and use screw terminal wire connections so no soldering is required Each pin of this connector has a tab on top as shown below When you fabricate I O cables according to the configuration instructi...

Page 104: ...on For other configuration methods please refer to Modification of I O Configuration on page B 6 Input Section Example This unit employs bi directional opto isolators which allow the user to configure...

Page 105: ...APPENDIX B ELECTRICAL AND DATA CONNECTIONS HF 2500A HIGH FREQUENCY WELD CONTROL 990 371 B 5 I O Signal Interface General Description...

Page 106: ...tive 10 WELD_ABORT Weld Abort Input 11 FIRE 1 Fires unit 12 24COM NEGATIVE of internal 24 VDC power supply 13 WELD NO_WELD Weld No Weld Input Functions as a weld enable 14 Not active Not active 15 I O...

Page 107: ...33 RELAY_1 Relay 1 output dry contact programmable Contact rating 24 VDC AC 1 amp 34 RELAY_1R 35 RELAY_2 Relay 2 output dry contact programmable Contact rating 24 VDC AC 1 amp 36 RELAY_2R 37 RELAY_3...

Page 108: ...ocks which can be independently configured SCHEDULE INPUTS Common Input Pin Number I O COMMON WELD ABORT 10 WELD NO WELD 13 SCHEDULE 0 20 24 SCHEDULE 1 21 25 SCHEDULE 2 22 26 SCHEDULE 4 23 27 SCHEDULE...

Page 109: ...LD CONTROL 990 371 B 9 Configuration for Common Input Connections Dry Contact Input Common Positive Input External Power Common Negative Input External Power Common Positive Input Internal Power NOTE...

Page 110: ...plug on Pins 11 20 allows the use of the AMADA WELD TECH 2 level footswitch directly If a PLC or other means of trigger is used refer to the I O Signal Interface General Description on page B 3 Foot...

Page 111: ...eld Head Connector combines all the inputs and outputs necessary to connect a plug and play EZ AIR AMADA WELD TECH weld head Using the supplied Configuration plug on Pins 11 20 allows the use of the A...

Page 112: ...e firing switch cable connector is a 2 pin Amphenol 80 MC2F1 Pt 520 008 It mates with the weld head firing switch connector which is a 2 Pin Amphenol 80 MC2M Pt 520 001 connector Firing Switch Connect...

Page 113: ...C Timing Diagram BCD Welding Schedule Selection Scheme Weld Schedule No Bit 20 Sch 0 Bit 21 Sch 1 Bit 22 Sch 2 Bit 23 Sch 4 Bit 24 Sch 8 Bit 25 Sch 16 Bit 26 Sch 32 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 2 0...

Page 114: ...y alarm or weld status contact signal outputs You can access the programming function through the main menu as described in Chapter 3 The events that you can program for each relay and their timing di...

Page 115: ...ameters CAUTION Only authorized personnel should perform this procedure Calibration Equipment Required The required equipment for the setup is as follows 2 weld cables No 2 0 1ft 30 cm long Pt 2 0 BB1...

Page 116: ...OUNTERS 7 RELAY 3 COPY A SCHEDULE 8 RESET DEFAULTS 4 CALIBRATION 9 CHAIN SCHEDULES 5 SYSTEM SECURITY Number Select an item 4 Press 1 for HF 2500A CALIBRATION which will bring up the CAUTION screen on...

Page 117: ...top cover and enter the shunt value which is stamped on the copper conductor connected to the transformer Press to continue 8 The next two screens are 1 CALIBRATE D A HIGH and 2 CALIBRATE D A LOW Foll...

Page 118: ......

Page 119: ...nu screen D1 Delay time from Weld Force start to Firing Switch closure Maximum D1 time is 10 seconds If the firing switch does not close within 10 seconds the message FIRING SWITCH DIDN T CLOSE IN 10...

Page 120: ...start of the weld sequence that is start of SQZ Maximum DELAY time is 2 ms plus switch debounce time SQZ Squeeze time Selectable range is 0 to 999 ms UP Up slope time Selectable range is 0 0 to 99 0...

Page 121: ...e from Remote Schedule Select Signal ON to the start of the weld sequence that is start of SQZ DELAY time is 23 ms SQZ Squeeze time Selectable range is 0 to 999 ms UP Up slope time Selectable range is...

Page 122: ...ng Switch closure Maximum D1 time is 10 seconds If the firing switch does not close within 10 seconds the message FIRING SWITCH DIDN T CLOSE IN 10 SECONDS will be displayed D2 Delay time from Firing S...

Page 123: ...I Communications Protocol and Commands Using these codes users can write customized software for controlling all functions of the welding power supply and interfacing the unit to automation control sy...

Page 124: ...nverter box used For a microprocessor based conversion such as the Edgeport USB converter from Inside Outside Networks the host computer should be at least a Pentium II 233 running Windows 98 Windows...

Page 125: ...baud rate selected on the unit This capacity is not an issue on RS 232 channels A good guideline is that on a line free of electrical noise the number calculated above must remain less than 70 of the...

Page 126: ...vertical bar indicates one OR another of choices presented REQUIRED OPTIONAL PARAMETERS enclosed in brackets one or more allowed used in the SET parameter zero allowed in the READ parameter RANGE OF P...

Page 127: ...State Any Description Requests the Power Supply to erase all the weld reports Command SYNC crlf lf Control State Any Description Provides synchronization of the commands The Power Supply returns SYNC...

Page 128: ...er from 0 to 99 There must be a space between LOAD and schedule_number Command COUNTERS READ SET TOTAL HIGH LOW GOOD crlf lf Control State Any Description Requests the Power Supply to return the Power...

Page 129: ...list of valid literal substitutions for the parameter_name and value variables ENG1 FEEDBACK1 ENG2 FEEDBACK 2 SQUEEZE UP1 WELD1 DOWN1 COOL UP2 WELD2 DOWN2 HOLD RINDEX1 RINDEX2 EINDEX1 EINDEX2 weld_ene...

Page 130: ...arameter_name value crlf lf Control State Any except while welding Description Provides control over the basic weld monitor settings of the Power Supply schedule When used with the READ keyword the ba...

Page 131: ...le welding Description Provides control over the Power Supply schedule parameters for relay settings When used with the READ keyword the relay settings of the currently loaded schedule are returned se...

Page 132: ...iables LIGHT light_value LCD contrast LOUDNESS loudness_value Buzzer Loudness BUZZER OFF ON end of cycle buzzer DISPLAY PEAK AVG Display mode SWSTATE switch_state Input Switch Type CTSTATE switch_stat...

Page 133: ...n the SET keyword is used the host may invoke an error identified by error_number When the DISPLAY keyword is used an error condition can be created with any message desired The length of the error me...

Page 134: ...tion Returns HF25 1 00 A 37250 for the first release of an HF 2500A Command COUNT number crlf lf Control State Any Description Returns the number of weld data available in Power Supply The total numbe...

Page 135: ...data an integer number in unit of A Command VOLTAGE number_of_data crlf data crlf data crlf data crlf lf Control State Any Description Returns the Voltage waveform data of the last weld First field i...

Page 136: ...data An integer number in unit of mOhms Command SYNC crlf lf Control State Any Description The Power Supply return SYNC command back to the host computer when the SYNC command is received from the ho...

Page 137: ...s sent to the host computer the Power Supply does not erase the weld data sent to the host from the weld data buffer You must use the REPORT ERASE command to erase weld data from the weld buffer unit_...

Page 138: ...IT CONTROL SIGNALS ACTIVATED 12 LOW BATTERY 13 NO CURRENT READING 14 NO VOLTAGE READING 15 LOAD RESISTANCE TOO HIGH 16 NO WELD TRANSFORMER DETECTED 17 WELD SWITCH IN NO WELD POSITION 18 CHECK VOLTAGE...

Page 139: ...0 39 ACCESS DENIED SYSTEM SECURITY ON 40 ILLEGAL SECURITY CODE ENTERED 41 NOT USED 42 NOT USED 43 NOT USED 44 NOT USED 45 NOT USED 46 NOT USED 47 ACCESS DENIED SCHEDULE LOCK ON 48 NOT USED 49 NOT USED...

Page 140: ...PPER LIMIT 76 POWER2 LOWER LIMIT 77 RESISTANCE2 UPPER LIMIT 78 RESISTANCE2 LOWER LIMIT 79 INHIBIT 2ND PULSE 80 WELD STOP LIMIT REACHED 81 SYSTEM ERROR BUS ERROR 82 SYSTEM ERROR SOFTWARE INTERRUPT 83 S...

Page 141: ...gy_index crlf lf Control State Any Description Reports the settings of the currently loaded Power Supply schedule parameters The schedule_number variable identifies which schedule is currently loaded...

Page 142: ...nto a table of resistance vs energy PID tables used for the last weld energy index is the index value into a PID energy vs PID values table used for the last weld Command MONITOR schedule_number crlf...

Page 143: ...xtended_condition_value crlf ACTIVE4 HIGH LOW crlf CONDITION4 condition_value crlf SUBCOND4 extended_condition_value crlf lf condition_value ALARM LIMITS WELD END P1HI P1LOW P2HI P2LOW extended_condit...

Page 144: ......

Page 145: ...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 resistan...

Page 146: ...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 Aluminu...

Page 147: ...l 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 Kulgri...

Page 148: ...el 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 Ni...

Page 149: ...elded materials apart A satisfactory weld will show residual material pulled from one material to the other Tearing of base material around the weld nugget indicates a material failure NOT a weld fail...

Page 150: ...ge or power for different weld forces as shown in the illustration below Typical Weld Strength Profile 4 Repeat steps 1 through 3 using a different but fixed weld time Typical Weld Strength Profile Th...

Page 151: ...e 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 qual...

Page 152: ...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 Soli...

Page 153: ...sistance 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 m...

Page 154: ...int 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 Gro...

Page 155: ...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 heatin...

Page 156: ...ion 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...

Page 157: ...d 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 pa...

Page 158: ...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...

Page 159: ...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 affec...

Page 160: ...e 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...

Page 161: ...ed 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 wel...

Page 162: ...tantial 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...

Page 163: ...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 AMA...

Page 164: ...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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