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Amada Miyachi Unitek STA-100A Operation Manual Download Page 152

INDEX 

 

  

STA SERIES AC CONTROLS 

Index-8 

990-351

 

W 

 
W1 (Weld 1 Time)  ........................................ 3-2 
W2 (Weld 2 Time)  ........................................ 3-3 
Weld    

 .................................................. 1-5 

Weld Count   .................................................. 3-7 
Weld Count Limit  ......................................... 3-7 

 
 
Weld Mode    ................................................ 3-10 
Weld ON/OFF  ..................................... 1-6 , 3-14 
Wire Gauge   

 ...........................................C-2 

Wire Gauges Based on Demand (kVA)  ........C-3 
Wiring Diagram  ............................................ 5-3 

Summary of Contents for Miyachi Unitek STA-100A

Page 1: ...990 351 Rev H AC WELDER STA SERIES OPERATION MANUAL...

Page 2: ...States of America Revision Record Revision EO Date Basis of Revision A 19123 12 01 Initial Release B 19373 7 02 Addition of technical upgrades and features and inclusion of other STA models C 19557 1...

Page 3: ...ntains the AC Main Timer Board SCR Driver Board Control Panel Assembly valve and power transformers SCR assemblies and snubbers and surge resistors Unless ordered otherwise STA 200 Controls contain a...

Page 4: ...ure reference when any questions arise regarding the proper and SAFE operation of the unit Please note the following conventions used in this manual WARNING Comments marked this way warn the reader of...

Page 5: ...1 5 Ready 1 5 Error 1 5 Weld 1 5 Start 1 5 Program Save 1 5 Weld ON OFF 1 6 Data ON OFF 1 6 Cursor 1 6 Schedule 1 6 Valves 1 6 Modes 1 7 Reset 1 7 Monitor 1 7 Stepper 1 7 Programming Lock 1 7 Externa...

Page 6: ...3 1 Section II Schedule Screen 3 2 SCHEDULE 3 2 PROGRAM SAVE 3 2 Links 3 2 SQD Squeeze Delay 3 2 SQZ Squeeze Time 3 2 UP1 Weld 1 Upslope Time 3 2 W1 Weld 1 Time 3 2 DN1 Weld 1 downslope time 3 3 CO c...

Page 7: ...LD COUNT 0 3 8 STEP Step Number 3 8 STEP COUNT 3 8 ELECT VALVE 3 8 STEP COUNT 3 8 ELECT VALVE 3 8 Section VI Mode Screen 3 9 SCHEDULE Schedule Number 3 9 PROGRAM SAVE 3 9 START 3 9 WELD MODE 3 10 Spot...

Page 8: ...F 3 14 LOW LINE ALARM 3 14 AUTO RESET 3 14 ERROR OUTPUT 3 15 SET DEFAULTS 3 15 MASTER CNTL 3 15 UNIT ADDRESS 3 15 System Values Screen 3 3 15 RETRACTION 3 15 Pressure Switch 3 16 Output Force 3 16 Mon...

Page 9: ...Shutdown 4 15 Normal Shutdown 4 15 Chapter 5 Maintenance Section I Precautions 5 1 Section II General Information 5 1 General Maintenance Procedures 5 1 Cooling Maintenance Water Draining 5 1 Fuse Re...

Page 10: ...Electrical And Data Connections B 1 Appendix C SCR Wire Gauge And Circuit Breaker Selection C 1 Appendix D System Timing D 1 Appendix E Cascade Option E 1 Appendix F Valve Expansion Board Option F 1...

Page 11: ...AGE 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 resp...

Page 12: ...ta 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 S...

Page 13: ...s 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 w...

Page 14: ...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...

Page 15: ...d LCD display screen on the STA 200A Control may be installed on the front or side of the Control depending on your space requirements As a result each Control is essentially custom built to your spec...

Page 16: ...the last cycle of each weld only which is useful for welding to a specific resistance A Force Control Force Output Option that can control up to 8 separate user supplied electronic pressure regulator...

Page 17: ...trol Your Control may be different due to options that have been installed or to the physical configuration For example the LCD Display and operating controls can be factory installed on the front or...

Page 18: ...CHAPTER 1 DESCRIPTION STA SERIES AC CONTROLS 1 4 990 351 STA 100A Series Major Components Typical...

Page 19: ...has occurred Weld Green LED indicator lights when weld is occurring Start Red LED indicator lights to indicate receipt of a start signal Program Save Pressing this pushbutton switch toggles the Contr...

Page 20: ...w works in the reverse direction Whichever arrow is pressed when the cursor enters a field it will automatically position itself at the rightmost position of a numeric field or the leftmost position o...

Page 21: ...III Monitor When the WELD ON OFF pushbutton switch is set to OFF pressing this pushbutton switch will cause the Monitor screen to appear on the display See Chapter 3 for details of this screen Stepper...

Page 22: ...fitting should be connected to the top high pressure side of the cylinder that supplies welding force The LOW fitting is connected to the bottom low pressure side of that same cylinder Make the conne...

Page 23: ...Option boards can be inserted into a card cage in any order No installation hardware is required the cards merely slide into slots A ribbon cable connects each of the option cards together with the la...

Page 24: ......

Page 25: ...including dimensions for the mounting holes are included in Appendix A Technical Specifications Power Requirements Power requirements are 230 or 460 VAC nominal single phase 50 60 Hz See Appendix A Te...

Page 26: ...can be machine mounted using the detachable mounting tabs shipped with the Control All other STA Series Controls are designed for wall or machine mounting using four mounting tabs two with mounting ho...

Page 27: ...he secondary as possible For most accurate measurement do not distort the shape of the toroidal coil Placement of Secondary Current Coils NOTE Unless otherwise ordered Controls are shipped with the Va...

Page 28: ......

Page 29: ...life The Control contains internal software that gives you a great deal of flexibility in the setup and use of your welding system The Control software displays various menu screens on the LCD each co...

Page 30: ...rner of the screen will show the links as a set of three 2 digit numbers 1 First number Previous schedule 2 Second number Current schedule being used shown in brackets SCHEDULE 01 07 03 05 SQD SQZ UP1...

Page 31: ...tions CH Force Output Channel selected Settings include NONE the Force option is not installed and F1 F8 The output for SCR 1 goes through F1 SCR 2 through F2 and so on The F1 F8 option allows the Con...

Page 32: ...hat the new schedule is not already in use By placing the cursor on the symbol next to COPY TO entering the number of schedules beyond this COPY TO and pressing the DATA pushbutton the original schedu...

Page 33: ...rom 00 to 63 Pressing the PROGRAM SAVE pushbutton toggles between the Program and Run Modes Placing the system in the Run Mode automatically saves the currently displayed values for the schedule If an...

Page 34: ...is programmable from 50 to 100 for W1 and W2 A setting of 100 is equivalent to the low monitor being OFF This limit is not applicable in Percent Heat Primary and Percent Heat Secondary modes The Volt...

Page 35: ...than this value and less that a HI limit if programmed for the weld to proceed In order to prevent pressure spikes from inadvertently triggering the weld an initial good reading is followed by a 4 cy...

Page 36: ...D PRESSING THE PROGRAM SAVE KEY SAVES MODIFICATIONS THEN PRESS DESIRED SCREEN BUTTON AFTER SAVING OR PRESS PLUS OR MINUS KEY TO LOSE If no data field has been changed the software will allow control b...

Page 37: ...R SAVING OR PRESS PLUS OR MINUS KEY TO LOSE MODIFICATIONS If no data field has been changed the software shall allow control buttons on the panel to function Entering a new SCHEDULE shall cause the Co...

Page 38: ...rst schedule fired in that succession whether or not that schedule is the first one in the link For instance if schedules 01 through 06 are set up in the link but the weld operation is started with sc...

Page 39: ...al is present See Appendix D for a graphical representation of this weld mode ROLL SPOT MODE optional The roll spot seam mode repeats the weld cycle from SQUEEZE through OFF as long as the start signa...

Page 40: ...to 10 If a schedule number is used more than once it shall have a ERROR printed to the right In the above example schedule 02 has been entered twice The reason for this is that if this schedule number...

Page 41: ...of current sensing coil if any installed HEAT SEC Percent Heat Secondary SEC C C Secondary Constant Current OR HEAT PRI Percent Heat Primary PRI C C Primary Constant Current By placing the cursor at...

Page 42: ...indicates the completion of a stepper It is programmable as either ON or OFF by placing the cursor at the first character of the parameter s value and using the DATA key to toggle between the two sta...

Page 43: ...the programming on the unit If LOCAL is selected the default the operator will be able to program the unit normally through the buttons on the unit s panel If HOST is set the buttons on the panel wil...

Page 44: ...itoring mode between PEAK and RMS Average Monitored Time This switches the weld monitoring time between W1 W2 Weld 1 and Weld 2 or Last Cycle Only This setting applies to the voltage monitoring option...

Page 45: ...Note that this setting does not control which SCR is to be fired in a weld schedule that is done on the Schedule screen The number of valves displayed on the screen will be either 4 or 12 depending on...

Page 46: ...nels F Force to calibrate F1 is associated with SCR 1 F2 with SCR 2 and so on Lo Psi is highlighted to calibrate Low Pressure Hi Psi is highlighted to calibrate High Pressure 000 FORCE CALIBRATION Psi...

Page 47: ...ogrammable from 01 to 04 or 01 to 12 depending on the valve option selected on the System Wide Values screen SCR This display only field shows the SCR number associated with the selected valve The ass...

Page 48: ......

Page 49: ...trol you must be familiar with the following The principles of resistance welding and the use of programmed weld schedules The location and function of Controls and Indicators For more information see...

Page 50: ...the software installed in the Control If you ever need to contact Amada Miyachi America for technical assistance Customer Support will need to know which version Release number of the software is inst...

Page 51: ...be installed between RETR and RETC inputs on the main board During set up the following symbols indicate which values are controllable and which are presented for information only The symbols are scr...

Page 52: ...VIDED BY TURNS RATIO MUST FALL WITHIN A 50 TO 1500 AMP RANGE ON SYSTEM VALUES SCREEN CHECK THAT THE TURNS RATIO IS VALID IF SO THE FULL CURR VALUE MUST BE BROUGHT WITHIN ACCEPTABLE LIMITS SCHEDULE 01...

Page 53: ...FULL CURR WELD 2 CURRENT MUST BE LESS THAN THIS ADJUST W2 ON THE SCHEDULE SCREEN ACCORDINGLY SCHEDULE 01 WELD 2 CURR PLUS STEP CURR GREATER THAN SYSTEM FULL CURRENT ENTER THE SYSTEM VALUES SCREEN AND...

Page 54: ...ON 5 In Roll Spot Mode optional the motor connected to the valve designated as the Motormove Valve in the schedule moves only during OFF time All other valves are held through the OFF time If OFF tim...

Page 55: ...e values screen for more information on the heat and constant current weld modes 5 Press and enter the weld current or percent heat desired for W2 6 Press to move to the ELECTRODE VALVE and SCR select...

Page 56: ...n of each of these periods 6 Press again and enter the weld current or percent heat desired for W1 See the description of the system wide values screen for more information on the heat and constant cu...

Page 57: ...SQD SQZ UP1 W1 DN1 CO UP2 W2 DN2 HO and OFF In each field use the or keys to change the time desired See Appendix D System Timing for a graphical representation of each of these periods 7 Press again...

Page 58: ...lect the LINKED SCHED field Press the key to select the linked schedule screen 18 In the linked schedule screen use the or keys to select the first schedule you wish to fire in this cascade 19 Press t...

Page 59: ...on on AUTO RESET Major Run Time Error Messages EMERGENCY STOP THE SYSTEM HAS ENCOUNTERED A SERIOUS CONDITION POSSIBLY INVOLVING A SAFETY HAZARD CLEAR THE CONDITION AND PRESS THE RESET BUTTON TO REBOOT...

Page 60: ...SCHEDULE 01 WELD 2 CONDUCTION ANGLE EXCEEDED LIMIT PRESS RESET BUTTON TO RESUME WELDING IF PROBLEM CONTINUES INCREASE THE W2 COND LIMIT AT THE MONITOR SCREEN PRESS RESET BUTTON TO RESUME WELDING COND...

Page 61: ...TOR SCREEN PRESS RESET BUTTON TO RESUME WELDING SCHEDULE 01 WELD 2 CURRENT BELOW LOW LIMIT 1 REPROGRAM WELD 2 CURRENT 2 DECREASE WELD TRANSFORMER RATIO 3 DECREASE W2 LOW LIMIT AT THE MONITOR SCREEN PR...

Page 62: ...SSAGE ONLY LOW LINE VOLTAGE WAS DETECTED CHECK LINE VOLTAGE AND PRESS RESET KEY TO CONTINUE HIGH LINE VOLTAGE ADVISORY MESSAGE ONLY HIGH LINE VOLTAGE WAS DETECTED CHECK LINE VOLTAGE AND PRESS RESET KE...

Page 63: ...YSTEM HAS ENCOUNTERED A SERIOUS CONDITION POSSIBLY INVOLVING A SAFETY HAZARD CLEAR THE CONDITION AND PRESS THE RESET BUTTON TO REBOOT After clearing the emergency condition you must Assure that FS1 an...

Page 64: ......

Page 65: ...uctors Never use paint thinner benzene or acetone to clean the exterior of the Control Use a dry cloth or if it is heavily soiled use a cloth moistened with a mild detergent or alcohol Section II Gene...

Page 66: ...5A FNM 150 24VAC 500 VA 30A FNM 30 Principles of Operation Input power L1 and L2 enters the Control L1 is applied through the optional circuit breaker and optional primary current sensor to the SCRs a...

Page 67: ...has the basic controls for the operation of four user programmable valves If more valves are required an optional Valve Expansion Card can be added to control the additional valves An optional key lo...

Page 68: ...CHAPTER 5 MAINTENANCE STA SERIES AC CONTROLS 5 4 990 351...

Page 69: ...ata Connections for a detailed listing of I O signals AC Timer Main Board Connector Locations 3 If present disconnect the following optional cable connectors from the indicated headers on the circuit...

Page 70: ...Card to J16 and the 26 wire ribbon cable from the same circuit board to J5 7 Reconnect the six I O plugable terminal strips to the board J6 J7 J8 J12 J13 and J14 See Appendix B Electrical and Data Co...

Page 71: ...range and gray XF red and X2 black 2 While supporting the transformer remove the four 10 32 x 3 8 Phillips head screws 10 split lock washers and 10 flat washers that secure the transformer to the Cont...

Page 72: ...from the SCR connected to J2 Eight wire cable connector from AC Timer Main Board or Cascade Board to J1 SCR Drive Board Connector Locations 4 Remove the four 6 32x3 8 Phillips head screws spring lock...

Page 73: ...or from the AC Timer Main Board connected to J2 Optional 2 wire cable connector from the control panel key switch to J3 Control Panel Assembly Connector Locations 3 Install or re install the circuit b...

Page 74: ...4 Slide the current sensor from the orange cable 5 Install or re install the primary current sensor by sliding the sensor onto the orange cable from L1 bus bar 6 Connect the orange cable to the circui...

Page 75: ...cooling water hoses going to the SCR assembly OFF NOTE Place a container beneath the Control to catch water draining from the SCR assembly and the cooling water hoses 2 Disconnect the cooling water ho...

Page 76: ...a Part Number AC Timer Main Board A1 4 35255 01 Control Panel Assembly A3 4 35259 01 Fuse 2A SB FNM 2 330 130 Fuse 3A SB FNM 3 330 141 Fuse 10A SB FNM 10 330 142 Fuse 15A SB FNM 15 330 117 Cascade Boa...

Page 77: ...disconnecting input LINE cables 1 Open the Control door and disconnect all line and load wires 2 Disconnect all signal wires 3 If a secondary current sensor is used disconnect the signal cable from t...

Page 78: ......

Page 79: ...Pa maximum 104 F 40 C maximum In addition Water temperature should be no less than existing dew point for ambient air approximately 70 F 21 C Water shall have a pH of 7 0 8 0 Maximum impurity contents...

Page 80: ...d 95 of full current Responds by end of second cycle to input voltage fluctuations 3 of set point for fluctuation of 10 of power source voltage Internal current transformer Whole cycle symmetrical by...

Page 81: ...APPENDIX A TECHNICAL SPECIFICATIONS STA SERIES AC CONTROLS 990 351 A 3 Outline Drawings NOTE Measurements are in inches mm STA 100A AC Control...

Page 82: ...APPENDIX A TECHNICAL SPECIFICATIONS STA SERIES AC CONTROLS A 4 990 351 STA 200A AC Control Control...

Page 83: ...al components and where they are located see Chapter 1 Description Make sure you know where the power connection points are See Page B 2 Electrical Power Connections Make sure you know the appropriate...

Page 84: ...gauge wire from there to H4 of the valve transformer 4 Connect the Control to the appropriate power source 230 V or 460 V using the appropriate wire gauge for your power requirements See Appendix C 5...

Page 85: ...put Output Control Signals With the exception of the valve outputs all output signals are isolated contact relays Valve outputs may be either 115 VAC standard or 24 VAC Input signals are referenced to...

Page 86: ...APPENDIX B ELECTRICAL AND DATA CONNECTIONS STA SERIES AC CONTROLS B 4 990 351 Input Output Control Signals...

Page 87: ...T setting set on the Weld Mode screen determines whether this signal will be sent MT1 MTC Step End Output Output signal indication stepper is completed Once this output is on the unit can no longer be...

Page 88: ...ral Purpose Input 2 Unused BP1 BP2 BP4 BP8 BP16 BP32 Binary Input 1 2 4 8 16 32 These are the binary inputs for weld schedule selection See Appendix D for the I O Binary Input schedule There are two B...

Page 89: ...l power to the valve solenoid connected across those connections Output is limited to 1 amp per channel Valve Expansion Board Optional J2A J2B N L VAL5 N L VAL6 N L VAL7 N L VAL8 Valve Output 5 Neutra...

Page 90: ......

Page 91: ...r than effective 100 RMS current based on NEC table Circuit breaker is determined by a Trip current being the lowest specified unit at least 1 25 times the maximum RMS current normalized to 100 of the...

Page 92: ...Wire Gauge 195 2 0 225 3 0 260 4 0 290 250 320 300 350 350 380 400 Ampacity AWG Wire Gauge 430 500 475 600 520 700 535 750 555 800 585 900 615 1000 Table C 3 Wire Gauge Based on Ampacity 240V AC Main...

Page 93: ...x XLw AWG Cu 10 42 2 880E 01 8 640E 01 2 758E 00 8 15 63 1 920E 01 5 760E 01 1 839E 00 6 20 83 1 440E 01 4 320E 01 1 379E 00 4 30 125 9 600E 02 2 880E 01 9 195E 01 3 50 208 5 760E 02 1 728E 01 5 517E...

Page 94: ...4 150 313 7 680E 02 2 304E 01 7 356E 01 2 160 333 7 200E 02 2 160E 01 6 896E 01 2 175 365 6 583E 02 1 975E 01 6 305E 01 1 200 417 5 760E 02 1 728E 01 5 517E 01 1 250 521 4 608E 02 1 382E 01 4 414E 01...

Page 95: ...tart Holding Two Stage Operation FS1 FS2 Sched SQD SQZ UP1 W1 DN1 CO UP2 W2 DN2 HO Maintained Start START signals FS1 FS2 need only be held through SQD START signals FS1 FS2 must be held through SQZ S...

Page 96: ...APPENDIX D SYSTEM TIMING STA SERIES AC CONTROLS D 2 990 351 Continuous Seam Weld...

Page 97: ...enoid Valve Electrode Force SQD SQZ UP1 W1 CO UP2 W2 HO OFF All modes are program mable from 0 to 99 cycles Notes 1 FS1 and FS2 are debounced for 30 70 ms upon opening and closing 2 The microprocessor...

Page 98: ...APPENDIX D SYSTEM TIMING STA SERIES AC CONTROLS D 4 990 351 Spot Welding...

Page 99: ...hed modes One stage footswitch shown The first impulse is a W2 period only The second and following impulses are a CO period followed by a W2 period First Impulse Second Impulse Third Impulse CO W2 CO...

Page 100: ...ched B Sched C Sched A Initiation required for each schedule in link Each schedule may be pulsed latched or maintained Chained Initiation required only once at beginning Control defaults to first sche...

Page 101: ...Schedule 16 Schedule 17 Schedule 18 Schedule 19 Schedule 20 Schedule 21 Schedule 22 Schedule 23 Schedule 24 Schedule 25 Schedule 26 Schedule 27 Schedule 28 Schedule 29 Schedule 30 Schedule 31 Schedul...

Page 102: ......

Page 103: ...ect the 8 wire cable connector from each of the SCR Driver Boards connected to J4 SCR1 through J7 SCR4 as required 3 Disconnect the 2 wire power connector from J8 4 Slide the card out of the card cage...

Page 104: ......

Page 105: ...ard Maintenance Replacement 1 Disconnect the 26 pin ribbon cable connector from the AC Timer Main Board connected to J3 2 Disconnect the 2 wire cable connector from the AC Timer Main Board connected t...

Page 106: ...AC Timer Main Board to J1 7 Reconnect the I O plugable terminal strips to the board J2A and J2B 8 Slide the card into the card cage Valve Expansion Board Optional J2A J2B N L VAL5 N L VAL6 N L VAL7 N...

Page 107: ...art at the end of the weld Voltage Monitor Board Specifications Voltage Measurement Range 10 to 9 99 volts Accuracy 2 of full scale Operation Voltage Monitor functions are described in Chapter 3 Using...

Page 108: ......

Page 109: ...Chapter 3 Using STA Series Control Functions For accurate back pressure readings the electronic pressure regulator attached to this board must be set to have an association of 0 10V 0 100 psi Calibrat...

Page 110: ...rodes 5 Let the force stabilize then check the force on the force gauge Press the WELD ON button to release the weldhead Enter the number of pounds under Lo Psi on the LCD screen 6 Select Hi Psi on th...

Page 111: ...ables from J1 and the force output cables from J2 and J3 on the Force Output Board as required 3 Slide the card out of the card cage 4 Reconnect the force input cables from J1 and the force output cab...

Page 112: ......

Page 113: ...ressure Board cycles of squeeze delay time may be needed in order to prevent premature triggering due to the pressure spikes The Pressure Control Option will trigger an alarm if correct pressure is no...

Page 114: ...rd into other Pressure Boards in any sequence The channel number is fixed and will not change until it is reprogrammed Calibration 1 From the SYSTEM VALUES SCREEN 3 turn DIFF PRESSURE ON 2 Go to FORCE...

Page 115: ...ut Option is installed press the WELD ON button on the Control Panel to close the electrodes If the force output option is not installed press the WELD On button to close the electrodes Set the air pr...

Page 116: ...hoses 2 Unplug the Pressure Board s from the Force Board If you are using multiple Pressure Boards disconnect them in order to remove replace install specific boards NOTE If you are using a new board...

Page 117: ...t weld history data for detailed analysis Check the status of the Control s Remotely program weld schedules on the Control s Serial Communications Board Remotely program menu items on the Control s Re...

Page 118: ...mputer hardware and operating system needed to achieve that level of performance depends upon the RS 485 adapter or converter box used For a microprocessor based conversion such as the Edgeport USB co...

Page 119: ...80 bytes per second Electrical noise on the communications lines will further reduce this capacity Shielded cables are recommended Several commands require the Control to be in HOST mode for the Contr...

Page 120: ...optional BINARY data Multiple binary byte ordering MSB LSB cksum 2 BYTES This is a two charter ASCII HEX string calculated from the sum of all fields except soh cksum and eot Then masked with 0xFF eo...

Page 121: ...1 Byte RESET RX Set Reset an Error and Returns STATUS 0 Bytes REMOTE RM Set 0 Local 1 Remote 1 Byte LOAD LR Read none 0 Bytes LS Set The schedule to become active 1 Byte COUNTER CS Set Schedule to Res...

Page 122: ...ime 2 Bytes WELD1 Weld Time 2 Bytes DOWN1 Down Slope Time 2 Bytes COOL Cool Time 2 Bytes UP2 Up Slope Time 2 Bytes DOWN2 Down Slope Time 2 Bytes HOLD Hold Time 2 Bytes OFF Off Time 2 Bytes HEAT 1 0 10...

Page 123: ...duction limit 1 1 Byte ANGLE LIMIT 2 Conduction limit 2 1 Byte LIMIT Weld Count limit 2 Bytes START start value 1 Byte MODE weld mode 1 Byte LOP Low Pressure Limit 0 9999 2 Bytes HIP High Pressure Lim...

Page 124: ...P 8 COUNT 3 Bytes STEP 9 COUNT 3 Bytes STEP 10 COUNT 3 Bytes 0 9999 50 200 32 Bytes Total NOTE COUNT 2 Bytes 1 Byte VALVE VR Read Schedule 1 Byte VALVE VS Set SCHEDULE 1 Byte ELECTRODE VALVE 1 Byte VA...

Page 125: ...ytes Valve 2 SCR Count 5 Bytes Valve 3 SCR Count 5 Bytes Valve 4 SCR Count 5 Bytes Valve 5 SCR Count 5 Bytes Valve 6 SCR Count 5 Bytes Valve 7 SCR Count 5 Bytes Valve 8 SCR Count 5 Bytes Valve 9 SCR C...

Page 126: ...IRING SWITCH 0 2Stage 1 1Stage 1 Byte SEAM WELD seam mode 1 Byte WELD ON OFF LOCAL 0 REMOTE 1 1 Byte LOW LINE ALARM ON 1 OFF 0 1 Byte Master Control 0 Local 1 Host 1 Byte RETRACTION 0 MAINTAINED 1 PUL...

Page 127: ...MIN CALIBRATE 2 Bytes P4 MAX CALIBRATE 2 Bytes P5 MIN CALIBRATE 2 Bytes P5 MAX CALIBRATE 2 Bytes P6 MIN CALIBRATE 2 Bytes P6 MAX CALIBRATE 2 Bytes P7 MIN CALIBRATE 2 Bytes P7 MAX CALIBRATE 2 Bytes P8...

Page 128: ...TY Read STA Release and Revision 12 Bytes Example STA 01 21 AB COUNT CT Read Reports Stored 1 Byte COUNTER CS Set ACK OR NAK 0 Bytes COPY CP Set ACK OR NAK 0 Bytes LOAD LR Read The active schedule 1...

Page 129: ...t 4 Bytes Total number of reports cnt 30 Bytes Total SCHEDULE DS Set ACK OR NAK 0 Bytes SCHEDULE DR Read SCHEDULE 1 Byte SQD Squeeze Delay 2 Bytes SQZ Squeeze Time 2 Bytes UP1 Up Slope Time 2 Bytes WE...

Page 130: ...Limit 0 9999 2 Bytes HIP High Pressure Limit 2 Bytes VOLTHIW1 W1 High Volt Limit 0 00 9 99 2 Bytes VOLTLOW1 W1 Low Volt Limit 2 Bytes VOLTHIW2 W2 High Volt Limit 2 Bytes VOLTLOW2 W2 Low Volt Limit 2 B...

Page 131: ...umber error Minor Error Bit Pattern the following bits are set to 1 when their associated error condition exists Bit 0 Weld 1 current low Bit 1 Weld 2 current low Bit 2 Step count too high Bit 3 Setup...

Page 132: ...ogramming screen 27 Weld 1 current plus stepper value exceeds full current screen 28 Weld 2 current plus stepper value exceeds full current screen 29 Emergency Stop screen 30 Thermostat over temperatu...

Page 133: ...line voltage screen 56 High line voltage screen 57 Current scaling error 58 Not used 59 Continuous seam weld enabled mode screen 60 Roll spot weld enabled mode screen 61 Schedule number error screen 6...

Page 134: ...es STEP 9 COUNT 3 Bytes STEP 10 COUNT 3 Bytes 0 9999 50 200 33 Bytes Total NOTE COUNT 2 Bytes 1 Byte VALVE VS Set ACK OR NAK 0 Bytes VALVE VR Read SCHEDULE 1 Byte ELECTRODE VALVE 1 Byte VALVE 1 ON 1 O...

Page 135: ...Bytes Valve 2 SCR Count 5 Bytes Valve 3 SCR Count 5 Bytes Valve 4 SCR Count 5 Bytes Valve 5 SCR Count 5 Bytes Valve 6 SCR Count 5 Bytes Valve 7 SCR Count 5 Bytes Valve 8 SCR Count 5 Bytes Valve 9 SCR...

Page 136: ...FIRING SWITCH 0 2Stage 1 1Stage 1 Byte SEAM WELD seam mode 1 Byte WELD ON OFF LOCAL 0 REMOTE 1 1 Byte LOW LINE ALARM ON 1 OFF 0 1 Byte MASTER CONTROL 0 Local 1 Host 1 Byte RETRACTION 0 MAINTAINED 1 PU...

Page 137: ...P4 MIN CALIBRATE 2 Bytes P4 MAX CALIBRATE 2 Bytes P5 MIN CALIBRATE 2 Bytes P5 MAX CALIBRATE 2 Bytes P6 MIN CALIBRATE 2 Bytes P6 MAX CALIBRATE 2 Bytes P7 MIN CALIBRATE 2 Bytes P7 MAX CALIBRATE 2 Bytes...

Page 138: ...l cable connector coming from the external 9 pin connector from J3 3 Slide the card out of the card cage 4 Install or re install the circuit board by sliding it into the card cage 5 Reconnect the 26 p...

Page 139: ...terminals 2 Mount the relay socket and perform the following wiring procedure a On one of the SCR thermostats locate the red wire tagged 5 b Cut the wire and splice on two extension wires long enough...

Page 140: ......

Page 141: ...will set all settings to those shown in table E 1 This may require you to reset certain settings such as Control Mode to allow the Control to operate as you ordered it Default Initializations Setting...

Page 142: ...VALVES 04 Weld Mode Status MODE SPOT 87 Delay 87 DELAY ON End Output END OUTPUT ON Step End STEP END ON Weld On Off WELD ON OFF LOCAL Low Line Alarm LOW LINE VOLTAGE ALARM ON Auto Reset AUTO RESET OF...

Page 143: ...PER Initialization Stepper STEPPER OFF Step 1 Count COUNT 250 Step 2 Count COUNT 400 Step 3 Count COUNT 600 Step 4 Count COUNT 800 Step 5 Count COUNT 1000 Step 6 Count COUNT 1200 Step 7 Count COUNT 14...

Page 144: ......

Page 145: ...ons Protocol and Commands J 4 Communication External Protocol J 4 Definition of Command Elements J 4 Host Originated Command Set J 5 STA Originated Response Command Set J 12 Unit Responses to External...

Page 146: ...tch input B 6 PULLUP Pullup Voltage B 6 RETR Retraction Input B 5 RTVAL N L Retraction Valve Output Neutral and Line B 5 SPR1 SPR1C Weld On Off Status B 5 SR1 Step Reset Input B 6 VAL5 N L through VAL...

Page 147: ...KED SCHED 3 11 Linked Schedules Screen 3 12 Links 3 2 LO Low Current Limit 3 6 LOW LINE ALARM 3 13 M Maintenance Procedures 5 1 J 21 Major Components 1 3 Air Hose Connections 1 8 Electrical Connection...

Page 148: ...5 10 Optional SCR Assembly 600 1200 1800 and 2200 Amp 5 11 Optional Secondary Current Sensor Connector 5 10 Optional Valve Expansion Board B 7 Outline Drawings A 3 Output Force 3 16 P Planning for Ins...

Page 149: ...SQZ Squeeze Time 3 2 SR1 Step Reset Input B 6 STA Originated Response Command Set J 12 Standard Components Replacement 5 5 AC Timer Main Board 5 5 Control Panel Assembly 5 9 Power Transformer T1 5 7...

Page 150: ...ction Angle Limit 3 6 Counts MONITOR COUNTS Screen 3 6 CURR Weld Current 3 6 FORCE LBS 3 6 HI High Current Limit 3 6 LO Low Current Limit 3 6 VOLTS 3 6 Monitor Counts Screen 3 7 ELECT VALVE 3 7 ELECT...

Page 151: ...L 3 15 SET DEFAULTS 3 15 STEP END OUTPUT 3 14 UNIT ADDRESS 3 15 WELD ON OFF 3 14 System Values Screen 3 3 15 Back Pressure 3 16 Monitored Time 3 16 Monitored Volts 3 16 Output Force 3 16 Pressure Swit...

Page 152: ...C CONTROLS Index 8 990 351 W W1 Weld 1 Time 3 2 W2 Weld 2 Time 3 3 Weld 1 5 Weld Count 3 7 Weld Count Limit 3 7 Weld Mode 3 10 Weld ON OFF 1 6 3 14 Wire Gauge C 2 Wire Gauges Based on Demand kVA C 3 W...

Page 153: ...chheim Germany TEL 49 89 839403 0 FAX 49 89 839403 10 AMADA MIYACHI TAIWAN CO LTD Rm 5 2F No 9 Dehui St Zhongshan Dist Taipei 10461 Taiwan R O C TEL 886 2 2585 0161 FAX 886 2 2585 0162 AMADA MIYACHI V...

Page 154: ...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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