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USER'S MANUAL
No. 990-083
Revision D: January 2002

PHASEMASTER™ 6

DIRECT ENERGY WELDING CONTROL

MODEL NUMBER

STOCK NUMBER

PM6

1-237-XX

PM6/115

1-237-XX-01

PM6/230

1-237-XX-02

PM6/100

1-237-XX-03

PM6/460

1-238-XX

AIR

MANUAL

NO WELD

WELD

2 LEVEL

1 LEVEL

MACHINE

SCR

OFF

ON

RUN

SAVE

PROGRAM

SCHEDULE

NUMBER POLARITY

SQUEEZE

CYCLES

WELD

CYCLES

HOLD

CYCLES

% CURRENT

HEAD

TYPE

FOOTSWITCH

FOOTSWITCH

WELD ABORT

ALARM

PHASEMASTER

TM

6

AC WELDING CONTROL

1
2
3
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Summary of Contents for PHASEMASTER 6

Page 1: ...M6 1 237 XX PM6 115 1 237 XX 01 PM6 230 1 237 XX 02 PM6 100 1 237 XX 03 PM6 460 1 238 XX AIR MANUAL NO WELD WELD 2 LEVEL 1 LEVEL MACHINE SCR OFF ON RUN SAVE PROGRAM SCHEDULE NUMBER POLARITY SQUEEZE CY...

Page 2: ...PORATION and may not be reproduced copied exhibited or otherwise used without the written authorization of UNITEK MIYACHI CORPORATION Printed in the United States of America Revision Record Revision E...

Page 3: ...via CA 91017 7133 Telephone 626 303 5676 FAX 626 358 8048 e mail info unitekmiyachi com The purpose of this manual is to supply operating and maintenance personnel with the information needed to prope...

Page 4: ...d 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 burn or crush...

Page 5: ...te 1 3 Section II Major Components 1 4 Front Panel Description 1 4 Front Panel Keys and Switch 1 4 Indicators and Displays 1 5 Rear Panel 1 7 CHAPTER 2 GETTING STARTED 2 1 Section I Planning for Insta...

Page 6: ...PHASEMASTER 6 DIRECT ENERGY WELDING CONTROL vi 990 083...

Page 7: ...on Feature 3 6 Line Voltage Compensation Feature On 3 7 Line Voltage Compensation Feature Off 3 7 Alarm Display 3 7 Change Schedule Protection 3 8 Schedule Protection Feature On 3 8 Schedule Protectio...

Page 8: ...ervice Repair 4 4 APPENDIX A TECHNICAL SPECIFICATIONS A 1 Section I Specifications A 1 Line Voltage A 1 50 60 Hz Operation A 1 Output Current vs Duty Cycle A 1 Weld Schedules A 1 Schedule Protection F...

Page 9: ...n II UNIPULSE Transformer Specifications and Features A 13 Transformer Specifications A 13 Transformer Physical Characteristics A 14 Input Connector A 14 Forced Air Option A 15 Maximum Repetition Rate...

Page 10: ...g Preset Firing Force of the Weld Head with a Force Gauge 3 10 3 2 A Graphic Presentation of the Effects of CURRENT Time and Pressure on the Weld 3 12 3 3 Test Condition A 3 18 3 4 Test Condition B 3...

Page 11: ......

Page 12: ...ion at 220 380 415 440 or 460 VAC The PM6 460 requires a user supplied circuit breaker disconnect and input wiring Cost Effective Microprocessor Controlled with user friendly programming Has the abili...

Page 13: ...t level of a two level initiation switch is used to start the Squeeze Period The Weld Period cannot start until the Squeeze Period ends and the second level of the initiation switch and the force firi...

Page 14: ...d schedule it is waiting for either a The Footswitch to close Air Actuated Weld Head or b The Force Firing Switch to close Manually Actuated Weld Head The user can select but not change any weld sched...

Page 15: ...tch must be in the WELD position in order to make a weld NOTE Instructions to Select WELD or NO WELD mean that you are to place this switch in either the WELD or the NO WELD position whichever is indi...

Page 16: ...a useful convenience when setting the electrode firing force POLARITY DISPLAY Indicates the Polarity of the Welding Current Press in the PROGRAM State to select Positive indicated by Negative reverse...

Page 17: ...ng the Footswitch This Feature is considered by many to be a safety requirement in non tooled systems Footswitch Weld Abort is turned OFF by connecting a jumper on the PM6 s Input Output Board With a...

Page 18: ...rce Firing Switch in all Unitek Peco Weld Heads and Handpieces OPTICAL FIRING SWITCH RECEPTACLE Used to connect the PM6 to Weld Heads with either a 3 wire Firing Switch or an optical switch assembly E...

Page 19: ...nches 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 Refer t...

Page 20: ...re foot could result in losses of up to 65 figure 2 1 Lower Electrode Holder Upper Welding Cable Screw Flat Washer Nut 2 Places Lower Welding Cable Note Attach both welding cables on the same side of...

Page 21: ...the PM6 Users of Manually Actuated Weld Heads which do not have force firing switches must connect the two pins in the Firing Switch Cable to an external switch in order to initiate the PM6 Users of A...

Page 22: ...that the system will be operated in a clean environment Once every six months or every 1 million operations whichever occurs first place two or three drops of light machine oil in the top of the air c...

Page 23: ...eco Model VDAC24P P N 10 304 01 Valve Driver Adapter Cable When the connection has been made the PM6 will automatically recognize that an Air Head has been connected Users of Air Actuated Weld Heads w...

Page 24: ...ompleted If the FOOTSWITCH WELD ABORT Option has been set to OFF the welding process will continue to its conclusion regardless of the position of the Footswitch once the Preset Firing Force has been...

Page 25: ...r source c LOOSEN the four screws which secure the cover and lift the cover straight up to remove it When the Footswitch Weld Abort option is ON the two pins at the top of the I O board are open A jum...

Page 26: ...30A 50 60 Hz 1 HOT COM GND BLK WHT GRN POWER EXTERNAL INPUTS INB GND 4 7 WELD INHIBIT USER SUPPLIED PROGRAMMABLE LOGIC CONTROL FOOTSWITCH GND LEVEL 2 4 1 INITIATE AIR VALVE DRIVER 24VAC 24 115 RTN 11...

Page 27: ...shorting across Pins 6 7 8 or 9 and the appropriate pins coded to the BCD binary coded decimal pattern shown in table 2 1 and figure 2 7 Table 2 1 Remote Schedule Selection BCD Code Input Pin Numbers...

Page 28: ...normally open contacts of a user supplied switch to Pin 4 of the EXTERNAL INPUTS connector The second wire can be connected to Pins 6 7 8 or 9 To use the EMERGENCY STOP Feature connect one wire from...

Page 29: ...EEZE WELD HOLD or CURRENT Press RUN to enter the RUN State Welding is done in the RUN State Select Schedule Press RUN if any of the numeric fields are flashing Press to select any Schedule Number from...

Page 30: ...the RUN State none of the numeric fields will be flashing A weld can be made with the modified schedule Welding can be done in the PROGRAM State in Schedule 0 For example Switch the Circuit Breaker to...

Page 31: ...un State or b Press RUN and transfer all of the parameters to Schedule 0 in the PM6 s temporary memory and automatically return to the Run State In the RUN State none of the numeric fields will be fla...

Page 32: ...for at least 1 second g The SCHEDULE NUMBER will change from 0 to a blank h Continue to press SAVE and use to select another Schedule Number i Release SAVE when the desired Schedule number is display...

Page 33: ...hitting the Downstop before sufficient force has been applied to the workpiece to actuate the Force Firing Switch Either adjust downstop or increase the length of the upper electrode Sometimes this c...

Page 34: ...CHAPTER 3 OPERATING INSTRUCTIONS PHASEMASTER 6 DIRECT ENERGY WELDING CONTROL 3 6 990 083...

Page 35: ...hed to ON Schedule 0 is the only schedule which can be modified When Schedule Protection is switched to OFF any schedule can be modified and saved to permanent memory Refer to Change Schedule Protecti...

Page 36: ...age Compensation Feature can be switched to OFF using the following procedure a Select NO WELD b Select Schedule 0 c Press SAVE and at the same time d The PM6 should display L C O F F Alarm Display As...

Page 37: ...CHAPTER 3 OPERATING INSTRUCTIONS PHASEMASTER 6 DIRECT ENERGY WELDING CONTROL 990 083 3 9...

Page 38: ...nel who are not authorized to make Schedule Changes Change Schedule Protection Schedule Protection Feature On Weld Schedules 1 through 7 can be protected from unauthorized or inadvertent changes by sw...

Page 39: ...uence will continue to completion and the weld head will rise at the end of the hold period If Footswitch Weld Abort is ON releasing the Footswitch at any time during the welding sequence will termina...

Page 40: ...both flow controls as necessary Resist the temptation to increase the downspeed by increasing the regulator setting since this increases the force applied to the workpiece by the electrodes If a highe...

Page 41: ...ing Factors Heat Primary Tap Setting of Welding Transformer Secondary Tap Connections of Welding Transformer CURRENT selected on PM6 Time WELD CYCLES selected on PM6 Pressure Electrode Firing Force se...

Page 42: ...e 3 2 illustrates the effect of electrode force on the work piece 3 Adjust the air pressure for air operated weld heads See Chapter 3 Section III Adjusting Weld Heads HEAT Excessive Insufficient CAUSE...

Page 43: ...inned Copper 14 Consil 11 Iridium 2 Niobium 2 Titanium 2 Constantan 2 Iron 2 NiSpan C 2 Tungsten 2 Copper 14 Karma 2 Platinum 2 Zinc 14 Dumet 2 Kovar 2 Paliney 7 2 Electrode Face Use a flat electrode...

Page 44: ...and WELD on the PM6 2 Position the parts between the electrodes 3 Press the footpedal or footswitch to initiate the Welding Sequence When weld current flows the red pilot lamp on the UNIPULSE Transfo...

Page 45: ...s 90 If you still have not obtained a satisfactory weld use the next Highest Primary or Secondary Tap on the Welding Transformer When the PrimaryTap is at the highest step and if the transformer has s...

Page 46: ...trength Increased force requires higher energy but usually results in a stronger bond Energy is proportional to time and the square of the welding current Causes of Imperfect Welds Table 3 2 lists the...

Page 47: ...lding Transformer Figures 3 3 and 3 4 show two extreme conditions A and B which can be used to weld two resistive workpieces such as Nickel to Nickel Test Condition A shows the use of the HIGH 3 Prima...

Page 48: ...with a short burst of current which results in b large temperature deviations around the average temperature HEAT COOL VOLTAGE 38VRMS Figure 3 4 Test Condition B C O O L 2 9 VR M S H E A T COOL HEAT...

Page 49: ...lectrode force Repeat this procedure using the longer pulse width In figure 3 5 Curve C shows the highest pull strengths but the lowest tolerance to changes in weld energy Curve B shows a small reduct...

Page 50: ...have obvious manufacturing advantages Electrode Maintenance Depending on use periodic tip resurfacing is required to remove oxides and welding debris from electrodes Select NO WELD On air actuated wel...

Page 51: ...to OFF 2 Disconnect the PM6 from its power source 3 Remove the top two screws on each side of the cover 4 Loosenthe bottom two screws on each side and lift the cover straight upwards Line Voltage Modi...

Page 52: ...erform the following procedure With the power OFF select NO WELD Press both SAVE and RUN Hold both keys down while power is turned ON Do not release the keys until the self test display reads as follo...

Page 53: ...ed in the Squeeze Cycles window while the corresponding sign is displayed in the Polarity window The range of allowed values for Symmetry Calibration is from 2 to 2 0 2 If the Symmetry Calibration doe...

Page 54: ...will automatically enter the Run State Repair Service Telephone Service Call our Repair Department at the telephone number shown in the Foreword of this manual Before calling please obtain the model...

Page 55: ...input wiring 50 60 Hz Operation The PM6 is a dual frequency control whose microprocessor automatically compensates for 50 or 50 Hz operation Output Current vs Duty Cycle Duty cycle is defined as the p...

Page 56: ...cycles Squeeze Period Squeeze Time is measured as the number of cycles of the AC power source which must elapse after the 1st Level of the Footswitch closes Squeeze Time can be set from 0 to 99 cycle...

Page 57: ...he electrodes are not water cooled and where the Weld Time is less than 5 or 10 cycles In these applications Hold Time allows the electrodes to cool the workpiece HOLD Time can be set from 0 to 99 cyc...

Page 58: ...egardless of the power factor of the load Without this feature the welding current would change with the position of the cables and or whenever a magnetic workpiece was placed between the electrodes H...

Page 59: ...the Valve Driver which causes the upper electrode of the weld head to apply force as determined by the air regulator connected to the top of the air cylinder on the head to the workpiece and b to star...

Page 60: ...CHINE ALARM When lit this indicator together with the word SEE which will appear in the WELD CYCLE Field and the following messages which appear in the HOLD CYCLE Field provide the user with the follo...

Page 61: ...h switch is listed in Chapter 1 The function of the WELD NO WELD Switch is to inhibit Welding when it is placed in the NO WELD position This switch is a mechanical switch whose state is not dependent...

Page 62: ...e Color Description A 1 Black Output from SCR to H1 Side of Output Transformer C 2 White L2 Side of Input Power Line and H2 Side of Output Transformer B Green Chassis ground Firing Switch Cable Firing...

Page 63: ...receptacle that mates with an AMP 206429 1 520 1 107 plug that uses an AMP 206358 2 245 1 084 cable clamp Connect Pin 2 to Pin 4 on a non Unitek Peco Air Actuated Head The connector is wired as follow...

Page 64: ...ed until the short is removed Remote Weld Inhibit This input has the same function as the WELD NO WELD Switch on the Front Panel Shorting Pin 4 on the External Input Connector to Pins 6 7 8 or 9 inhib...

Page 65: ...4 1 0 1 5 0 1 1 6 1 1 1 7 1 Switch Closure MICROPROCESSOR CPU MC6805 with 4 00 MHz clock RAM 256 bytes Random Access Memory EPROM 4K bytes Electrically Programmable Read Only Memory EEPROM 2K bytes E...

Page 66: ...990 083 Figure A 1 PM6 Outline Drawing AIR MANUAL NO WELD WELD 2LEVEL 1LEVEL MACHINE SCR OFF ON RUN SAVE PROGRAM SCHEDULE NUMBER POLARITY SQUEEZE CYCLES WELD CYCLES HOLD CYCLES CURRENT HEAD TYPE FOOTS...

Page 67: ...ULSE Transformer specifications and characteristics Transformer Specifications Model Primary Voltage volts Input KVA Duty Cycle Taps Output Voltage volts rms Short CKT Current amps 3 8 50 Prim Sec X2...

Page 68: ...0 Width in cm 6 5 16 5 6 6 16 8 7 0 17 8 7 5 19 1 Depth in cm 11 0 27 9 9 6 24 4 14 0 35 6 14 0 35 6 Weight lb kg 20 0 9 1 60 0 27 3 90 0 40 9 95 0 43 2 Input Connector Input Connector is an Amphenol...

Page 69: ...ould not exceed 4 2 at full output which translates to one weld cycle at 99 heat during a 12 cycle period Insulation Insulation is Class 130 rated 180 C Transformer Primary Tap Switch The Tap Switch l...

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