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CHAPTER 1:  SYSTEM DESCRIPTION 

 

875DP/500DP/500HV DUAL PULSE 

RESISTANCE WELDING POWER SUPPLIES 

1-4 

990-290

 

 

x

The foot switch weld abort safety feature causes the power supply to abort the welding process if the 
operator releases the footswitch, on an air actuated system, before the end of the welding sequence. 

 

x

The line failure turndown safety feature discharges the capacitor bank when input power is interrupted. 

 

x

The 875DP is protected from radio frequency interference and electromagnetic interference to ensure 
reliable operation even in high electrical noise environments.  Input switch debounce circuitry eliminates 
false triggering.

 

 
 

 

 

Summary of Contents for 500DP

Page 1: ...257 XX 02 875DP 100 1 253 XX 03 875DPS 100 1 257 XX 03 500DP 1 251 XX 500DPS 1 255 XX 500DP 208 1 251 XX 01 500DPS 208 1 255 XX 01 500DP 230 1 251 XX 02 500DPS 230 1 255 XX 02 500DP 100 1 251 XX 03 500DPS 100 1 255 XX 03 500HV 1 252 XX 500HVS 1 256 XX 500HV 208 1 252 XX 01 500HVS 208 1 256 XX 01 500HV 230 1 252 XX 02 500HVS 230 1 256 XX 02 500HV 100 1 252 XX 03 500HVS 100 1 256 XX 03 Units with th...

Page 2: ...e written authorization of Miyachi America Corporation Printed in the United States of America Revision Record Revision EO Date Basis of Revision A 17280 12 19 97 1 Correct clarify calibration procedures 2 Add operating features B 17678 11 3 98 Specify output load for HV500 Models C 18578 11 14 00 1 Add Declaration of Conformity 2 Add tolerance to pulse output voltage 3 Clarify operation of relay ...

Page 3: ...yrtle Avenue P O Box 5039 Monrovia California 91016 Phone 626 256 4128 FAX 626 303 5396 E mail info miyachiamerica com The purpose of this manual is to supply operating and maintenance personnel with the information needed to properly and safely operate and maintain the 875DP 500DP 500HV Dual Pulse Resistance Welding Power Supply We have made every effort to ensure that the information in this man...

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

Page 5: ...nical Firing Switch 2 4 Optical Firing Switch 2 4 3 Wire Firing Switches 2 4 Air Actuated Weld Head Connections 2 5 Air Valve Driver 2 6 Non Unitek Peco Air Actuated Weld Heads 2 7 Air Actuated Weld Heads without Force Firing Switches 2 7 Second Air Head 2 7 Footswitch 2 7 1 Level Footswitch 2 7 2 Level Footswitch 2 8 Remote Schedule Selection 2 8 Relay Outputs 2 8 Interconnection Diagram 2 9 CHAP...

Page 6: ...Energy 5 7 Polarity 5 7 Weld Strength Profiles 5 8 Destructive Testing 5 8 Electrode Maintenance 5 9 CHAPTER 6 PROCESS DEFINITIONS AND WELD FUNCTIONS Power Supply States 6 1 RUN State 6 1 STANDBY State 6 2 PROGRAM State 6 2 MENU State 6 3 HELP State 6 4 NO WELD State 6 4 FIRE State 6 4 Weld Function Field 6 4 Basic Function 6 5 Repeat Function 6 6 Rollspot Function 6 7 CHAPTER 7 MAINTENANCE Modifi...

Page 7: ...mber at Power Up A 8 Utilities A 8 Information A 8 Weld Functions A 9 Head Type A 9 Squeeze Line A 9 Cool Time A 9 Hold Time A 9 Footswitch Type A 10 FOOTSWITCH Connector A 10 Footswitch Weld Abort Feature A 10 Footswitch Weld Abort On A 10 Footswitch Weld Abort Off A 11 Firing Switch Type A 11 Firing Circuit A 11 Switch Debounce Time A 11 Mechanical Firing Switch Cable A 11 Optical Firing Switch ...

Page 8: ...y Stop A 17 Charge Process Inhibit A 18 Remote Weld Schedule Selection A 18 Binary Schedule Selection Code A 19 Relay Outputs A 20 Accessory Port A 21 Input Output Cable Connectors and Fusing A 22 Input Line Power A 22 Circuit Breakers A 22 Fuses A 22 Power Input Connector A 22 Front Panel Switches A 23 Microprocessor CPU A 23 Display A 23 Cooling A 24 Physical Characteristics A 25 Index Index 1 ...

Page 9: ...essure 4 5 4 5 Weld Head Configuration Jumper Selection 4 6 5 1 Effects of Excessive or Insufficient Heat Time and Pressure 5 2 5 2 Typical Weld Strength Profile 5 8 7 1 Line Voltage and Capacitor Bank Jumpering 7 3 7 2 100 VAC Line Voltage Configuration 7 4 7 3 115 VAC Line Voltage Configuration 7 5 7 4 208 VAC Line Voltage Configuration 7 6 7 5 230 VAC Line Voltage Configuration 7 7 A 1 875DP Re...

Page 10: ...ble Title Page 5 1 Recommended Electrode Materials 5 3 5 2 Causes of Imperfect Welds 5 6 7 1 Power Supply Voltage Range Specifications 7 9 A 1 Pulse Characteristics A 2 A 2 Welding Speed A 4 A 3 Binary Codes for Remote Weld Schedule Selection A 19 A 4 Input Power Specifications A 23 ...

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Page 13: ...ch can effectively solve most precision small parts resistance welding problems Its exclusive context sensitive User Help Screens quickly guide the user through even the most complex program Figure 1 1 875DP Dual Pulse Resistance Welding Power Supply W E LD NO W ELD SELEC T SAV E HELP CHNG RUN PRO G MENU C ONT R OL 3 2 1 5 6 4 9 8 7 ENTER 0 D ATA P O W E R O F F 875 DUAL PULSE S TO R E D E N E R G...

Page 14: ...onds The 500HV provides 500 watt seconds and uses an output transformer whose output voltage is double that of the 500DP The 500HV is frequently used in honeycomb welding and or in those applications which use handpieces whose cable lengths exceed 5 feet Except for those specifications which are directly related to energy rating and or output pulse characteristics the 500DP and 500HV are identical...

Page 15: ... schedules except Schedule 0 from changes by unauthorized personnel x Power up schedule selection allows any of the 16 schedules or the last schedule used to be specified as the default power up schedule x The digital display allows operators to set welding energy accurately and quickly x The 875DP is compatible with manually actuated weld heads and air actuated heads with 1 level or 2 level foots...

Page 16: ... releases the footswitch on an air actuated system before the end of the welding sequence x The line failure turndown safety feature discharges the capacitor bank when input power is interrupted x The 875DP is protected from radio frequency interference and electromagnetic interference to ensure reliable operation even in high electrical noise environments Input switch debounce circuitry eliminate...

Page 17: ...work bench approximately 5 inches behind the weld head Use the cables furnished with the weld head to connect the terminals on the back of the weld head to the appropriate terminals on the front of the output transformer Convention is to connect the lower electrode of the weld head or hand piece to the output terminal and the upper electrode to the output terminal of the power supply If the weld h...

Page 18: ...tions securely they must be free from oxidation dirt and or grease see figure 2 2 Figure 2 1 Cable Routing Examples Steel Weld Head Solenoid Cables taped together and routed away from steel structure and electromagnetic field Weld Head Steel Fixture Cables not dressed together and close to steel fixture DON T DO Lower Electrode H older U pper W elding Cable S crew Flat W asher Nut 2 Places Lower W...

Page 19: ...able is used to connect the power supply to the Force Firing Switch in all Unitek Peco Weld Heads and Handpieces D FOOTSWITCH RECEPTACLE Used to connect either a 1 Level or 2 Level Unitek Peco Footswitch Footswitches are only used with air or electrically actuated weld heads E FIRING SWITCH 5 pin receptacle is used to connect the Power Supply to Weld Heads with either a 3 wire Firing Switch or an ...

Page 20: ...ectly to the mating connector of the MECHANICAL FIRING SWITCH located on the rear panel of the power supply Users of manually actuated weld heads which do not have force firing switches must connect the two pins in the mechanical firing switch to an external switch in order to initiate the power supply Air actuated weld heads which do not have force firing switches rely on the squeeze time to ensu...

Page 21: ...ingle regulator installation for a Unitek Peco Series 80 Weld Head Turn the regulator s fully counter clockwise to ensure minimum air pressure Turn on the air supply Repair leaks if necessary All Thinline weld heads are capable of cycling at a rate of 1 weld per second provided that the tubing between pressure regulators and the air cylinder is kept as short as possible Increasing the length of th...

Page 22: ...the power supply Weld heads with 4 pin 24 115 VAC connectors can be plugged directly into the power supply Weld Heads with standard 115 volt plugs NEMA 5 15P require an adapter Unitek Peco Model VDAC Valve Driver Adapter Cable When the connection has been made the power supply will automatically recognize that an air head has been connected Figure 2 4 Typical Solenoid Air Valve Assembly with a Sin...

Page 23: ...ly to the appropriate 24 volt pins of the receptacle on the rear of the power supply Refer to Appendix A under Control Signals for detailed information Footswitch Connect either a 1 Level or 2 Level Footswitch to the FOOTSWITCH receptacle located on the rear panel The power supply will automatically recognize which type Unitek Peco Footswitch has been connected 1 Level Footswitch When the operator...

Page 24: ... be used to provide status timing signals to external devices They can also provide an on closed state during a Run state or if there is an alarm Relay 1 can also be used to control a second 24 VAC air actuated weld head Refer to Air Actuated Weld Head Connections for the appropriate hook up connections and figure 4 5 for appropriate jumper connections Relay 2 can provide a 5 to 50 VDC signal When...

Page 25: ...nhibit Emergency Stop 2 6 2 5 2 4 2 3 2 2 2 1 2 0 Weld schedule select User supplied Programmable Logic Control L1 L2 Initiate Power output Air valve driver 24V AC Return 115V AC Auto sense 1 2 3 4 1 2 1 Firing switch See note 3 See note 2 Weld cables See note 1 See note 4 Weld Head Force firing switch See note 2 Electrodes Air solenoid 24 115V AC Pneumatic input Notes 1 Tie weld cables together 2...

Page 26: ...EENS Operating Controls Figure 3 1 illustrates the layout of the operating controls on the front panel of the 875DP WELD NO WELD S E L E C T SAVE HELP CHNG RUN PRO G MENU C O N T R O L 3 2 1 5 6 4 9 8 7 ENTER 0 D A T A POWER OFF 875 DUAL PULSE STORED ENERGY POWER SUPPLY ON I O Figure 3 1 Front Panel of the 875DP ...

Page 27: ...o move up and down on the screen to select fields In the PROGRAM and MENU states and are used to move to the right and left on the Screen to select fields PROG Causes the Power Supply to enter the PROGRAM state so that you can make changes to Schedules 0 through 15 Press PROGRAM from any screen to return to the PROGRAM screen RUN Causes the Power Supply to exit the PROGRAM state without saving the...

Page 28: ...signify that the data entry you have entered using the keypad is complete KEYPAD Use the 10 numeric keys to enter numeric information is used to enter decimal values WELD NO WELD SWITCH Welding current will not flow when this switch is in the NO WELD position However the control will actuate the weld head and execute the welding sequence Squeeze Weld and Hold This switch must be in the WELD positi...

Page 29: ...EXT 001 AMP SECONDS LOWER UPPER SENTRY 001A 299 1 270 0 310 0 READY Select Schedule RUN RUN Screen with Weld Sentry K SCHEDULE 001 PULSE 1 10 0 PULSE 2 35 0 BASIC WELD POLARITY WIDTH SHORT AIR HEAD 2 L COUNT 00001 NEXT 001 RELAY 1 RUN STATE RELAY 2 ON OFF Select Schedule NO WELD NO WELD Screen P PROGRAM Screen L SCHEDULE 001 NEXT SCH 011 MODE BASIC STEP CNT 0001 POLARITY WIDTH SHORT PULSE 1 PULSE ...

Page 30: ...ON NOTE 1 PRESS MENU TO GO TO MAIN MENU FROM RUN SCREEN OR PROGRAM SCREEN PRESS ENTER TO GO TO NEXT MENU PRESS MENU TO GO TO PREVIOUS MENU NOTE 2 DISPLAY ONLY AND CANNOT CHANGE RUN SCREEN FUNCTION BASIC REPEAT ROLL SPOT POLARITY WIDTH SHORT MEDIUM LONG OFF TIME sec NEXT SCH STEP COUNT 0 99999 SCHEDULE WELD 1 WELD 2 ACCESSED BY PRESSING RUN AT ANY TIME PROGRAM SCREEN SCHEDULE FUNCTION BASIC REPEAT ...

Page 31: ... Schedules 1 through 15 cannot be changed when the system security is PROTECTED If SCHEDULE LOCK is also ON only the schedule displayed can be used to weld To change system security and or turn OFF SCHEDULE LOCK press MENU and select SYSTEM SECURITY NOTE To override the security code refer to Appendix A under Weld Schedules 8 If appropriate change the output relay configuration with the PROGRAM sc...

Page 32: ...se which are printed on the side of the weld head 3 To prevent the power supply from firing until you are ready to weld select NO WELD Remove the workpiece from between or beneath the electrodes 4 Set the force indicator on all Unitek Peco weld heads to 3 For more detailed information on setting up each specific weld head refer to their respective manuals See figures 4 1 and 4 2 for illustrations ...

Page 33: ...od cannot begin until the second level of the foot switch and the force firing switch in the weld head close The power supply will enter a standby state until these conditions are met When the firing force is reached the weld period will start Assuming that an alarm does not occur the welding sequence will continue to completion and the weld head will rise at the end of the hold period If FOOT SWI...

Page 34: ...the upper electrode moves at a reasonable rate and does not impact the workpiece hard enough to damage either the electrode or the workpiece If the flow controls interact readjust the air pressure which controls the pressure on the bottom of the cylinder so that it is identical to that set on the other regulator Then adjust the flow control so that the upper electrode does not slam against the bot...

Page 35: ...If a higher welding force is necessary reset the force indicator on the weld head to a larger number then repeat Steps 9 and 10 12 If a lower welding force is necessary reset the force indicator on the weld head to a smaller number reduce the pressure regulator which controls the air pressure on the top of the air cylinder then repeat Steps 9 and 10 13 If appropriate configure the Weld Sentry Pres...

Page 36: ...tility menu 17 If you are using a second air actuated weld head a Connect the second air head to Air Valve Driver 2 b There are two jumper headers E10 and E11 located on the lower right hand area of the control printed circuit board Re jumper the headers to the dual air configuration as shown in figure 4 5 c Press MENU and select OPTIONS d Change the weld head type to DUAL AIR e Press PROGRAM and ...

Page 37: ...g Factors Heat ENERGY selected on power supply Time PULSE WIDTH selected on power supply Number of pulses selected on power supply Pressure Electrode firing force set on weld head Surface area of electrode faces The effects of excessive or insufficient heat time and pressure on a weld are illustrated in figure 5 1 You should consider the interaction between these basic welding parameters when deve...

Page 38: ... setting 3 on a Unitek Peco Weld Head Figure 5 1 illustrates the effect of electrode force on the work piece 3 Adjust the air pressure for air operated weld heads HEAT Excessive Insufficient CAUSE PROBLEM Parts Overheating Weak Weld Insufficient Nugget Metal Expulsion Warping Discoloration Electrode Damage PRESSURE Excessive Insufficient CAUSE PROBLEM Parts Overheating Weak Weld Insufficient Nugge...

Page 39: ...old Plated Kovar 2 Dumet 2 Kovar 2 Nichrome 2 Magnesium 1 C R Steel 2 C R Steel 2 Stainless Steel 2 Consil 2 Consil 11 Tinned Copper 14 Beryllium Copper 2 Beryllium Copper 2 Dumet 2 Brass 2 Copper 14 Constantin 2 Constantan 2 Tinned Copper 14 Copper 14 Nickel 2 Tinned Copper 14 C R Steel 2 Iron 2 Stainless Steel 2 Nichrome 2 Nickel 2 Brass 2 11 Brass 2 11 Tinned Brass 14 Copper 14 Copper 14 Bronze...

Page 40: ...dium 2 Iridium 2 Niobium 2 Niobium 2 Platinum 2 Platinum 2 Platinum 2 Iron 2 Iron 2 Paliney 7 2 Paliney 7 2 Karma 2 Karma 2 Nickel 2 Silver 11 Silver 11 Platinum 14 Cadium 13 C R Steel 2 Kovar Gold Plated 2 Gold Plated Kovar 2 Stainless Steel Palladium 2 14 Kulgrid 2 Nickel 2 Cold Rolled Steel 2 C R Steel 2 Silver 11 Stainless Steel 2 Stainless Steel 2 Tantalum 2 Magnesium 1 Magnesium 1 Stainless ...

Page 41: ... Pulse Operation Select pulse width and energy as follows x Pulse Width Short x Energy Pulse 1 10 x Energy Pulse 2 0 Dual Pulse Operation Dual pulse operation can be helpful when welding plated materials materials with heavy oxidation or small wires For these applications start as follows x Pulse Width Short x Energy Pulse 1 5 x Energy Pulse 2 15 NOTE Pulse 1 should be to the energy of the Pulse 2...

Page 42: ...efined specification Electrode Sticking Electrode sticking includes burning sparking and blown welds These problems indicate that either the ENERGY is too high or the electrode force is too low Refer to figure 5 1 Examine the electrode face Resurface it if it is pitted contaminated or burned See Electrode Maintenance later in this chapter Increase electrode force and or decrease ENERGY and save it...

Page 43: ...ly results in a stronger bond Energy is proportional to time and the square of the welding current Polarity Users of stored energy equipment have found that the direction of current flow can have a marked effect on the weld characteristics of some material combinations This effect occurs when welding x Materials with large differences in resistivity such as copper and nickel x Identical materials ...

Page 44: ...gth see figure 5 2 Repeat this procedure for different forces and plot a separate curve for each electrode force Repeat this procedure using the longer pulse width In figure 5 2 Curve C shows the highest pull strengths but the lowest tolerance to changes in weld energy Curve B shows a small reduction in strength but considerably more tolerance to changes in weld energy Weld energy current will var...

Page 45: ...isks to ensure that the electrode faces are smooth and parallel If you don t the rough surface of the electrode face will have a tendency to stick to the work piece or if the faces are not parallel energy will be concentrated at the point of contact and a blowout will result To dress the electrode tip 1 Select NO WELD 2 On air actuated weld heads reduce the air pressure to a value just sufficient ...

Page 46: ...7 of the RUN state screen as shown below a through d to display either a and c graphic below showing the energy of Pulse 1 for a manual or air head or b the status of the output relays or d the status of the Weld Sentry If NO WELD has been selected the legend R U N in the right lower corner will be replaced by NO WELD as shown in b Press CHNG to display different information on Line 6 and Line 7 a...

Page 47: ...to another schedule after a stop command in a chained schedule PROGRAM State In this state the power supply will allow you to change and save write to permanent memory any weld schedule Press PROG to enter the PROGRAM state which is signified by the legend PROGRAM in the lower right hand corner of the screen In those units which include the Weld Sentry option the PROGRAM state also allows you to c...

Page 48: ...ree sub screens OPTIONS 1 OPTIONS 2 and OPTIONS 3 SCHEDULE 000 FUNCTION BASIC POLARITY WIDTH SHORT PULSE 1 PULSE 2 ENERGY 010 0 036 0 RELAY 1 RUN STATE RELAY 2 OFF OFF Select CHNG Change PROGRAM MAIN MENU OPTIONS WELD SENTRY WELD COUNTERS CALIBRATE 875DP COPY A SCHEDULE RESET TO DEFAULTS SYSTEM SECURITY INSTALLATION SYSTEM HELP Select then ENTER OPTIONS 1 DISPLAY UNITS ENERGY POWER UP SCHEDULE LAS...

Page 49: ...ess HELP from the RUN state information on the function of the power supply keys will be displayed as illustrated below Typical HELP screens If there is more than one page of Help the number of pages will be displayed in the upper right hand corner Use or to move from page to page Press HELP to return to the previous state NO WELD State The WELD NO WELD switch is in the NO WELD position The power ...

Page 50: ... a 2 level foot switch closes and after the firing switch in the head closes It includes the time required to recharge the capacitor bank for the second pulse In AC welding a hold period is usually included as part of a basic weld function It allows the electrodes to cool the work piece However the energy level of the power supply is not sufficient to require a hold period so it has been omitted f...

Page 51: ...is confirmed in real time in the RUN state Repeat Function This function provides an automatic repeat of the weld sequence for simple automated air actuated applications It is ideal for volume production which requires a single schedule NOTE Repeat can only be used with an air actuated weld head You should specify the off time so that it is sufficient to allow the weld head to open the electrodes ...

Page 52: ... required for all subsequent spots Weld 2 in the sequence Rollspot cannot be used in a chain Dual pulse and or Footswitch Weld Abort OFF are not permitted in Rollspot The PROGRAM State Screen for the Rollspot Weld Function In the rollspot application shown on the above screen the welds would not overlap if the rotational speed of the wheel exceeded 0 25 inches second assuming a spot which is 1 16 ...

Page 53: ...cover to perform calibration or modifications Use the following procedure 1 Set the front panel POWER switch to OFF 2 Disconnect the power supply from its power source 3 Remove the top two screws on each side of the cover 4 Loosen the bottom two screws on each side and lift the cover straight upwards To disconnect the right half of the capacitor bank from the left half refer to figure 7 1 and proc...

Page 54: ...0 60 Hz To reconfigure the line power input circuitry proceed as follows 1 Set the front panel POWER switch to OFF 2 Remove the cover 3 Select the schematic of the primary circuit for the required voltage figures 7 2 through 7 5 Check the connections and reconfigure the following components x Jumpers E3 and E4 located in the top center area of the control printed circuit board x Bead Pins BP1 BP12...

Page 55: ...power supply housing refer to figure 7 1 4 Install the correct circuit breaker Refer to Appendix A under Input Output Cable Connections and Fusing 5 Install the line cord plug appropriate to your line voltage supply 6 Change all labels and tags so that they indicate the correct line voltage 7 Replace the cover Figure 7 1 Line Voltage and Capacitor Bank Jumpering ...

Page 56: ...BP2 BP3 BP4 BP5 BP6 BP7 R1 R2 4 300 W 4 300 W 0 1mfd 0 1mfd 1 2 3 4 5 R3 R4 4 300 W 4 300 W TRIAC BP8 BP1 BP12 BP11 BP10 BP9 F1 0 75A E1 E3 102 204V 115 230V E2 E4 102 204V 115 230V 102 115V 204 230V 204 230V 102 115V 100VAC 7 6 4 3 1 2 4 1 2 3 E3 T1 E4 Figure 7 2 100 VAC Line Voltage Configuration ...

Page 57: ...BP2 BP3 BP4 BP5 BP6 BP7 R1 R2 4 300 W 4 300 W 0 1mfd 0 1mfd 1 2 3 4 5 R3 R4 4 300 W 4 300 W TRIAC BP8 BP1 BP12 BP11 BP10 BP9 F1 0 75A E1 E3 102 204V 115 230V E2 E4 102 204V 115 230V 102 115V 204 230V 204 230V 102 115V 115VAC 7 6 4 1 3 2 4 1 3 2 T1 E3 E4 Figure 7 3 115 VAC Line Voltage Configuration ...

Page 58: ...P2 BP3 BP4 BP5 BP6 BP7 R1 R2 4 300 W 4 300 W 0 1mfd 0 1mfd 1 2 3 4 5 R3 R4 4 300 W 4 300 W TRIAC BP8 BP1 BP12 BP11 BP10 BP9 F1 0 75A E1 E3 102 204V 115 230V E2 E4 102 204V 115 230V 102 115V 204 230V 204 230V 102 115V 208 VAC 7 6 4 1 3 2 4 1 3 2 T1 E4 E3 Figure 7 4 208 VAC Line Voltage Configuration ...

Page 59: ...BP2 BP3 BP4 BP5 BP6 BP7 R1 R2 4 300 W 4 300 W 0 1mfd 0 1mfd 1 2 3 4 5 R3 R4 4 300 W 4 300 W TRIAC BP8 BP1 BP12 BP11 BP10 BP9 F1 0 75A E1 E3 102 204V 115 230V E2 E4 102 204V 115 230V 102 115V 204 230V 204 230V 102 115V 230VAC 7 6 4 1 3 2 4 1 3 2 T1 E4 E3 Figure 7 5 230 VAC Line Voltage Configuration ...

Page 60: ...or equivalent Pre Calibration Procedures Calibration is performed using the instructions displayed on the screen and the HELP messages The procedure consists of verifying power supply voltages and capacitor bank values and adjusting five trimpots on the control printed circuit board As each trimpot adjustment is performed it must be displayed on the screen with the cursor positioned next to the in...

Page 61: ...if you are only performing a calibration check 5 Turn R12 and R36 fully counter clockwise 6 Turn R108 R97 and R104 to mid range 7 Press ENTER to display the calibration screen Entering Capacitor Bank Values Press ENTER to display the next calibration screen and follow the instructions on that screen Adjustment Potentiometers Seven trimpots are located on the control printed circuit board These adj...

Page 62: ...kout Circuit g Malfunction or improper adjustment of the Overvoltage Protection Lockout Circuit h Defective circuit breaker i Miscellaneous short circuits or mis connection of the pulse transformer or the control board x Test the Triac by removing U1 on the Control Board This should switch the Triac OFF and no current should flow If it does not turn off replace the Triac x Test all diodes for shor...

Page 63: ... Factory Service Repair Miyachi America provides a repair service for both warranty and non warranty repairs Call the Customer Service Department at the telephone number shown in the Foreword of this manual for a Return Material Authorization number All equipment to be returned to Miyachi America for repair must be shipped PREPAID Please include information concerning the type of problem you are e...

Page 64: ...tts stand by Capacitor Bank The 875DP consists of 28 capacitors which total 10 500 μF 5 at 20 C The Capacitor Bank for the 500DP and 500HV consists of 16 capacitors which total 6000 μF 5 The capacitors are grouped in banks of four capacitors At full rating the Capacitor Banks are operated at 408 volts The following features are related to the capacitor bank Output Pulse Characteristics Pulse width...

Page 65: ... 5 ms 7 8 V 8 6 V Weld Fire Lockout Output of the error amplifier inhibits the firing circuit during the charge and turndown intervals This helps prevent poor welds caused by firing the power supply before the capacitor bank is properly charged or discharged Line Voltage Regulation Maintains voltage on the capacitor bank within 0 25 of setting for a 13 change from the nominal rated line voltage Tu...

Page 66: ...rity Selection Positive and negative polarity can be achieved by reversing the cables which connect the Output Transformer to the weld head Polarity sets the initial direction of the weld current flow through the workpiece This feature is useful for welding applications which are sensitive to the direction of weld current flow because of dissimilar materials and or materials with thickness ratios ...

Page 67: ...71 55 51 75 60 56 40 36 100 40 42 30 27 Conditions 25qC Ambient Nominal Line Voltage 60 Hz In dual pulse operation the repetition rate or hit rate for each individual pulse may be calculated as follows RR1 First Pulse Rep Rate Hit Rate RR2 Second Pulse Rep Rate Hit Rate Calculate RR 1 2 Rep Rate Hit Rate for dual pulse operation RR1 RR2 RR 1 2 RR1 RR2 For example if wired for the 10 500 μF Capacit...

Page 68: ...Sentry software not installed Typical at nominal line voltage Typical at low line voltage Minimum at low line voltage Minimum at nominal line voltage 20 40 50 60 80 100 120 140 Figure A 1 875DP Repetition Rate 10 500 μF Figure A 2 875DP Hit Rate 10 500 μF 0 25 50 75 100 125 150 175 1 3 4 2 5 6 7 8 9 10 20 30 40 50 60 70 8090100 Percent Energy Maximum Repetition Rate Welds Minute Model 875DP Power ...

Page 69: ...P Power Supply maximum intermittent repetition rate Weld Sentry software not installed Typical at nominal line voltage Minimum at nominal line voltage Minimum at low line voltage Typical at low line voltage Figure A 4 500DP Hit Rate 6000 μF 0 50 100 150 200 250 1 3 4 2 5 6 7 8 9 10 20 30 40 50 60 70 8090100 Percent Energy Maximum Repetition Rate Welds Minute Model 500DP Power Supply maximum contin...

Page 70: ...hedule i Status of Relay 1 e Step Count j Status of Relay 2 Weld Schedules 1 through 15 can be protected from unauthorized or inadvertent changes by Unitek Peco s System Security Feature When the System Security is Protected Schedule 0 is the only schedule which can be modified NOTE If the security code is lost Select SYSTEM SECURITY from the main menu Switch the WELD SWITCH to NO WELD press SAVE ...

Page 71: ...ystem Security Status c Reset Default Parameters b Copy a Schedule d Set Weld Counter Information Information on the following subjects is available to the operator from the main menu a Calibration d Description of Relay Outputs b Installation e Description of Control Signals c Description of Keyboard f Description of Valve Outputs Default System Parameters are a Head Type Auto g Power Up Schedule...

Page 72: ... to Pin 2 the power supply assumes that a manual head is being used The power supply determines whether it is connected to an air or manual head whenever it enters the RUN state The options menu can be programmed to override the automatic selection feature Squeeze Time For air head operation squeeze time is the delay from the footswitch closure until the start of the weld period For manual head op...

Page 73: ...tswitch connector FOOTSWITCH Connector The FOOTSWITCH connector is a 4 pin Amphenol 91 PC4F Unitek Peco PN 550 006 that mates with an Amphenol 91 MC4M Unitek Peco PN 520 009 Connect Pin 3 to Pin 4 on a user supplied 1 level footswitch This connector is wired as follows Pin Description 1 Chassis Ground 2 Footswitch Level 1 or Single Level Footswitch 3 Footswitch Level 2 4 Common Footswitch Weld Abo...

Page 74: ...cal firing switch either of which should be connected to the OPTICAL FIRING SWITCH connector eliminates switch bounce which causes false triggering and should be used when the welding speed exceeds 1 5 welds per second Firing Circuit The firing circuit requires external contact closure or low logic level for firing Internal filtering prevents premature firing due to radio frequency interference Th...

Page 75: ...ure A 5 It mates with an AMP Assembly consisting of an AMP 212437 3 Plug 212435 7 Ferrule and 212 800 1 Strain Relief The connector is wired as follows Pin Description Shell Shield 1 Switch Normally Closed 2 Switch Common 3 Switch Normally Open 4 5 VDC 5 Switch Common Initiation Switch Manual Head Operation If the power supply is connected to a manual head the initiation switch is the force firing...

Page 76: ...al fields for both STEP COUNT and NEXT SCHEDULE STEP COUNT and NEXT SCHEDULE are used to chain schedules together Step Count STEP COUNT is a weld counter which counts down to 0 Any number from 00001 to 99999 can be entered as a step count When the step count reaches 0 the schedule will change as specified by the NEXT SCHEDULE If a weld sequence is not completed and or the WELD NO WELD switch is se...

Page 77: ... cover End Of Cycle Buzzer ON OFF This feature is normally used with manual heads ON means that an audible signal will be given at the end of each weld sequence as a signal to the operator to release the footpedal The end of cycle buzzer is controlled from the options menu Key Click Whenever a key is pressed a click sound is generated Weld Counter A seven digit weld counter automatically increment...

Page 78: ...did not stay closed during the weld sequence or did not close within 10 seconds after the 1 level footswitch or the second level of a 2 level footswitch closed Air Valve Driver The air valve driver provides power to control the solenoid of an air actuated weld head The power supplies can sequentially operate two separate air actuated weld heads using two receptacles on the rear panel AIR VALVE DRI...

Page 79: ...the rear panel are AMP P N 206430 1 Unitek Peco PN 550 062 The mating plug is an AMP 206429 1 Unitek Peco PN 520 107 which uses a cable clamp AMP 206358 2 Unitek Peco PN 245 084 Air Valve Driver 1 is wired as follows Pin Description 1 24 VAC 2 115 and 24 VAC return 3 115 VAC 4 Air head sensing externally connected to Pin 2 NOTE Connect Pin 2 to Pin 4 on a non Unitek Peco air actuated weld head Con...

Page 80: ... Remote Weld Schedule Selection Control Line 21 3 Remote Weld Schedule Selection Control Line 22 4 Remote Weld Schedule Selection Control Line 23 5 No Connection 6 Relay 2 Input 7 No Connection 8 Relay 1 Input 9 Process and Charge Inhibit 10 Emergency Stop 11 Signal and Chassis Ground 12 No Connection 13 RELAY 2 Return 14 No Connection 15 RELAY 1 Return Emergency Stop Emergency stop or any other e...

Page 81: ...cond commutation pulse has ended The line must then be opened before the next schedule can be executed Charge inhibit can also be used instead of RUN to remotely clear any error stop alarm Short Pin 9 to Pin 11 momentarily and immediately open the short to clear the alarm Remote Weld Schedule Selection Refer to figure A 6 To use this feature connect the seven control lines from a user supplied nor...

Page 82: ... 0 0 1 10 0 1 0 1 11 1 1 0 1 12 0 0 1 1 13 1 0 1 1 14 0 1 1 1 15 1 1 1 1 Binary Schedule Selection Code To select a schedule connect the pin s corresponding to the schedule number to Pin 11 The schedules listed below are selected using the pin indicated by the 1 marked under the pin number To select any other schedule number select the schedule numbers whose sum equals the desired schedule then co...

Page 83: ... be made during this 120 millisecond period and or while the charge inhibit line is grounded Alarm stop conditions can also be cleared remotely by toggling the charge inhibit line Relay Outputs Two output relays can be used to provide status timing signals to external devices They can also provide an on closed state during a Run state or if there is an alarm Relay 1 can also be used to control a s...

Page 84: ... first period but will remain closed during both or all periods for which it is scheduled to be closed The 24 to 115 VAC input and output for Relay 1 are Pins 8 and 15 respectively of the CONTROL SIGNALS connector The 5 to 50 VDC input and output for Relay 2 are Pins 6 and 13 respectively You must supply the voltage source and in each case the ungrounded side of the AC power source for Relay 1 The...

Page 85: ...ts specified in table A 4 Circuit Breakers Circuit breakers are used to protect the incoming power line The circuit breakers may need to be replaced if the power supply is reconnected for a different line voltage see table A 4 Fuses A amp fuse F1 is located near the top center of the control printed circuit board The power supply is shipped wired for 115 VAC unless otherwise specified Power Input ...

Page 86: ... electro statically shielded 8 row by 40 column rear lit liquid crystal cold cathode display A contrast level adjustment potentiometer can be accessed through a hole in the right side of the cover The energy display accuracy is 0 5 The resolution of the display ranges from 0 1 to 0 6 energy depending upon the amount of energy selected Energy can be displayed in either watt seconds or of 875 500 fo...

Page 87: ... 60 Hz power The air inlet is underneath the unit and exhaust is through the rear panel No restriction to air flow should be closer than 2 inches to the sides and rear of the power supply Do not place the power supply on a soft pad or on any other surface which could block the air inlets on the bottom of the housing Do not allow the power supply to sit on surfaces which are covered with heavy dirt...

Page 88: ...sions include any protrusions Height 12 5 inches 31 8 cm Width 16 5 inches 41 9 cm Depth 16 inches 40 6 cm Weight 69 pounds 31 5 kg 500DP 500HV 77 pounds 35 kg 875DP WE LD NO W ELD S E L E C T SAVE HELP CHNG RUN PROG MENU C O N T R O L 3 2 1 5 6 4 9 8 7 ENTER 0 D A T A POWER OFF 875 DUAL PULSE STORED ENERGY POWER SUPPLY FRONT SIDE 16 5 12 5 16 5 Figure A 9 875DP Physical Dimensions ...

Page 89: ... and 875DP Welding Transformers NOTE Dimensions include any protrusions 500DP 500HV 875DP Height 12 inches 30 5 cm 14 25 inches 36 2 cm Width 9 inches 22 9 cm 9 inches 22 9 cm Depth 10 inches 25 4 cm 10 inches 25 4 cm Weight 79 pounds 36 kg 121 pounds 55 kg 875 UNIPULSE Figure A 10 Physical Characteristics 500DP 500HV and 875DP Welding Transformers ...

Page 90: ...lve driver 2 6 A 15 Control signals A 16 Footswitch 2 7 Mechanical firing switch 2 4 Non Unitek Peco air actuated weld heads 2 7 C continued Optical firing switch 2 4 Second air head 2 7 Controls front panel 3 1 CONTROL SIGNALS connector A 16 Cool time definition A 9 Cooling 875DP A 24 Cover removal 7 1 CPU microprocessor A 23 D Debounce time switch A 11 Declaration of Conformity following CE Oper...

Page 91: ...16 K Key click A 14 L Line power input 2 1 A 22 Line voltage changes 7 2 Locating system for installation 2 1 M Main menu information A 8 Main menu utilities A 8 Maintenance Electrodes 5 9 Power supply 7 2 Manual Revision Record ii Mechanical firing switch connections 2 4 MENU state 6 3 Microprocessor CPU A 23 Modification 7 1 N Next schedule A 13 NO WELD state 6 4 O Operating controls 3 1 A 21 Op...

Page 92: ...counter A 14 Weld schedule A 6 Welding speed A 4 Squeeze time definition A 9 STANDBY state 6 2 States 875DP FIRE 6 4 HELP 6 4 MENU 6 3 NO WELD 6 4 PROGRAM 6 2 RUN 6 1 STANDBY 6 2 S continued Step count A 13 Sticking electrodes 5 6 Switch debounce time A 11 System Default parameters A 8 Features 1 2 Location considerations 2 1 T Technical specifications A 1 Telephone repair service 7 11 Testing des...

Page 93: ...ontinued Specifications A 6 Weld Sentry options and utilities A 7 Weld strength profiles 5 8 Welding 5 5 Welding cable installation 2 1 Welding considerations 5 1 Welding parameters 5 1 Welding schedule specifications A 6 Welding speed specifications A 3 Wiring diagram interconnection 2 9 ...

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