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USER'S MANUAL 990-057 
Revision K, May 2004

 

 
 
 
 

Use with Firmware Release V1.19 or higher 

 
 

MODEL HF2 

2 kHz HIGH FREQUENCY 

RESISTANCE WELDING POWER SUPPLY 

 
 

MODEL NUMBER 

STOCK NUMBER 

HF2/230 1-264-03 

HF2/380   

1-264-03-01 

HF2/460 1-264-03-02 

HF2/208   

1-264-03-03 

HF2S/230 1-265-03 

HF2S/380   

1-265-03-01 

HF2S/460 1-265-03-02 

HF2S/208 1-265-03-03 

 

Units with the built-in Weld Sentry Option also require User's Manual No. 990-291 

 
 
 
 
 
 
 
 

WARNING 

Please be sure to read all personnel and equipment 
safety precautions noted in this manual. 

Summary of Contents for HF2/230

Page 1: ...MBER STOCK NUMBER HF2 230 1 264 03 HF2 380 1 264 03 01 HF2 460 1 264 03 02 HF2 208 1 264 03 03 HF2S 230 1 265 03 HF2S 380 1 265 03 01 HF2S 460 1 265 03 02 HF2S 208 1 265 03 03 Units with the built in...

Page 2: ...9 95 Reorganize manual into chapters C None 1 96 Amend to Firmware V1 17 or higher D None 2 96 Update cover stock numbers E None 4 97 Amend to Firmware V1 19 or higher F 17472 6 98 1 Remove existing...

Page 3: ...e Avenue P O Box 5033 Monrovia CA 91017 7133 Telephone 626 303 5676 FAX 626 358 8048 E mail info unitekmiyachi com NOTICE Unitek Miyachi Corporation may be released from all warranty obligations if re...

Page 4: ...eld Head Connections 2 5 Weld Sentry Option 2 5 Help Screen Languages 2 5 CHAPTER 3 WELDING SYSTEM SET UP 3 1 Welding System Set Up Guide 3 1 General Programming Instructions 3 1 Unitek Peco Force Fir...

Page 5: ...Inputs and Outputs 4 3 Power 4 3 Fuses F1 and F2 4 3 Sensing Port 4 3 Sensing Port Connector Pin Assignments 4 4 Output 4 4 Foot Switch Connector 4 5 Single Level Foot Switch 4 5 Two Level Foot Switc...

Page 6: ...4 Weld Graph Program State 5 4 Alphanumeric Program State 5 5 Output Relays 5 6 Relay 1 Dual Air Head Operation 5 7 CHAPTER 6 ADVANCED WELDING FUNCTIONS 6 1 Weld Functions 6 1 Basic Weld 6 2 Weld Repe...

Page 7: ...ergy Limit Monitor Programming 8 5 CHAPTER 9 RS 485 DATACOM 9 1 Description 9 1 RS485 Serial Port Connections 9 2 Datacom Software Installation 9 2 F1 Setup 9 4 F2 Collect Data 9 5 F3 Erase Data 9 5 F...

Page 8: ......

Page 9: ...ality The user can program the HF2 using a graphical or numerical interface The Weld Graph Program Mode Figure 1 1 emulates many of the popular word processing programs by using the front panel cursor...

Page 10: ......

Page 11: ...tern for the HF2 Weld Control Figure 2 2 shows the cooling airflow pattern for the HF2 Weld Transformer Figure 2 1 HF2 Weld Control Air Flow Pattern Figure 2 2 HF2 Weld Transformer Air Flow Pattern HF...

Page 12: ...ower line voltage Use the following table to select the correct power line circuit breaker and wire gauge size To minimize peak power losses use single unbroken wire lines Note To minimize peak power...

Page 13: ...1 TR 7 5 68 1 TR 4 000 4 000 4 000 4 000 1 300 1 100 950 825 460 4 5 14 3 44 1 TR 12 1 52 1 TR 10 5 60 1 TR 9 2 68 1 TR 4 000 4 000 4 000 4 000 1 300 1 100 950 825 X11 4000A 230 15 5 10 7 10 0 52 1 TR...

Page 14: ...d Cables Figure 2 4 Secondary Resistance Measurement B Shorter length Weld Cables or C Copper Bus Bars to connect the HF2 Weld Transformer to the Weld Head If these suggestions do not work then a diff...

Page 15: ...lectrode Holder so that the lead will not break or move under heavy production operating conditions 6 Do not attach the Firing Switch Cable at this time This procedure is covered in Chapter 3 Weld Sen...

Page 16: ......

Page 17: ...3 4 Unitek Equipment Force Fired Dual Air Actuated Weld Head 3 9 Non Force Fired Single Air or Cam Actuated Weld Head 3 17 Non Force Fired Multiple Air Actuated Weld Heads Not Released General Progra...

Page 18: ...ectrodes in Weld Head Electrode Holders Firing Switch Cable Connection Connect the Weld Head Firing Switch Cable Connector to the matching cable connector on the rear of the HF2 Weld Control Figure 3...

Page 19: ...sufficient to make a good weld 10 Press PROG Use the vertical cursor keys VW to increase the weld CURRENT Use the horizontal cursor keys to increase or decrease the WELD time In this example weld CUR...

Page 20: ...Switch Cable Connector to the matching cable connector on the rear of the HF2 Weld Control Weld Head Valve Driver No 1 Connection Figure 3 2 A single air actuated Weld Head has one Solenoid Valve Dri...

Page 21: ...LD 2 Turn the Power Switch located on the HF2 Weld Control rear panel to ON After a series of power up screens the last RUN screen displayed will appear Press the CHNG key to access the Weld Graph RUN...

Page 22: ...tment Quick Start Programming Guide 1 Press MENU The MAIN MENU screen will appear 2 Select TRANSFORMER MODEL The TRANSFORMER MODEL screen appears 3 Select MULTIPLE HEADS OFF If the display reads ON th...

Page 23: ...cessary to make a good weld Strive to use minimum time and current necessary to make a good weld so that the weld joint heat affected zone will be minimized 11 Up to 128 different weld schedules can b...

Page 24: ...he HF2 Weld Control Locate Jumpers E10 and E11 by looking in the lower right hand corner of the HF2 Weld Control PCB 3 Using a needle nose pliers move Jumpers E10 and E11 from the RELAY position to th...

Page 25: ...ith a rated burst pressure of 250 psi Run separate air lines to each Inlet Air Line Do not split a single 0 25 O D line into two lines or the Weld Heads will not have sufficient air flow to work prope...

Page 26: ...rear panel The HF2 will automatically recognize which model of Unitek Equipment Foot Switch has been connected 2 1 Level Foot Switch The l Level Foot Switch must be fully depressed by the operator Whe...

Page 27: ...ure 3 5 Dual Air Actuated Weld Heads Electrical Connections 1 Set the HF2 Weld Control front panel WELD NO WELD switch to NO WELD 2 Turn the Power Switch located on the HF2 Weld Control rear panel to...

Page 28: ...splay reads ON press CHNG until OFF is displayed 6 Select HEAD 1 X3 4000 230 X3 4000 230 is the default Transformer Model number Press CHNG until the correct Transformer Model that you have purchased...

Page 29: ...raph RUN State 15 Press MENU to return to the MAIN MENU 16 Select COPY A SCHEDULE The COPY SCHEDULE screen will appear 17 Select the last flashing 1 of TO SCHEDULE 1 and use the number keys to change...

Page 30: ...Head Clockwise CW until the HF2 automatic ally returns the Upper Electrode to its up position The lower right hand corner of the display should now show the status message END if you have not released...

Page 31: ...horizontal cursor keys to increase or decrease the WELD time In this example weld CURRENT has been increased to 0 7 KA and WELD time has been increased to 0 5 ms 3 Make additional test welds and then...

Page 32: ...welds 13 Press SAVE to save the updated Schedule 2 14 Press W to select SCH 001 BASIC WELD 15 Press PROGRAM once to select the Alphanumeric PROGRAM screen for Schedule 1 16 Select NEXT 001 Change 001...

Page 33: ...m Relay 1 and Relay 2 reference Chapter 5 Programming Modes Output Relays 3 For a complete description on how to use the RS 485 Datacom feature reference Chapter 9 RS 485 Datacom 4 All weld schedules...

Page 34: ...Start Programming Guide 1 Set the HF2 Weld Control front panel WELD NO WELD switch to NO WELD 2 Turn the Power Switch located on the HF2 Weld Control rear panel to ON After a series of power up scree...

Page 35: ...IONS 2 screen 10 Select WELD HEAD TYPE AUTO Press CHNG until the MANUAL option appears Note FOOTSWITCH TYPE AUTO will automatically change to NONE 11 Select FOOTSWITCH WELD ABORT ON Press CHNG until t...

Page 36: ...minimized 18 Up to 128 different weld schedules can be created and saved To manually recall any specific weld schedule press the up or down vertical arrow keys until the desired schedule number appea...

Page 37: ...ion Use the to enter decimal values KEYPAD Use the numeric keys to change weld schedules without the need to use the keys For example pressing 1 0 will recall weld schedule 10 In the RUN State press t...

Page 38: ...t the PROGRAM State and return to the RUN State SAVE has no function in the RUN State MENU In either the RUN or PROGRAM States press MENU to provide a menu list of user options which are common to all...

Page 39: ...roperly apply power to the HF2 Weld Control FUSES F1 F2 Refer to Chapter 2 Power Line Fuse Requirements for complete specifications for Power Line Fuse sizes SENSING PORT The Sensing Port contains bot...

Page 40: ...k Secondary Weld Voltage Measurement Return 12 Black Weld Transformer Select Line 3 For MA 600 13 Black Weld Transformer Thermo Switch Return 14 Black Future Expansion 15 Red Future Expansion 16 Red 2...

Page 41: ...onnector to initiate the welding process The emitter of the opto coupler must be connected to Pin 4 3 When using a non Unitek Peco Foot Switch connect Pin 2 to Pin 3 Two Level Foot Switch Figure 4 4 1...

Page 42: ...re The Firing Switch Connector is a 2 pin Amphenol 80 MC2FI Unitek P N 520 011 with strain relief that mates with an Amphenol 80 MC2M Unitek P N 520 001 Pin 2 is Digital Ground 2 Connect a Unitek Mode...

Page 43: ...er Firing Switch and outputs are designed to be used with a Programmable Logic Control PLC see Figure 4 8 or a Host Computer in automated environments 2 When an external chain control box is connected...

Page 44: ...Remote Weld Schedule Selection Control Line 21 CCB input Schedule Up increment number 3 Input PLC input Remote Weld Schedule Selection Control Line 22 CCB input Reset set schedule to power up schedule...

Page 45: ...box in place of the PLC a semi automatic chain weld schedule can be used to control the remote schedule select lines through the Control Signals Connector in accordance with the following table Pin No...

Page 46: ...process sequence to start Relay K1 Figure 4 10 1 Connect a 24 to 115 VAC voltage source and PLC load to Pins 8 and 15 on the Control Signals Connector Maximum relay current is limited to 250 ma 2 Rel...

Page 47: ...2 Driver outputs Figure 4 11 115 VAC Weld Head Solenoid Air Valve 1 Driver Figures 4 11 and 4 12 The output of Air Valve 1 Driver is 12 VA at 115 or 24 volts VAC The HF2 Weld Control automatically ap...

Page 48: ......

Page 49: ...right horizontal cursor key 3 To return to the first page of help information press the left horizontal cursor key Machine States The HF2 Weld Control has eight Machine States RUN NO WELD STANDBY ALAR...

Page 50: ...essing CHNG will cause the display screen to change from the Basic Weld Monitor RUN screen if this option has been set to ON to the Alphanumeric RUN screen Pressing CHNG again will return the HF2 Weld...

Page 51: ...vel Foot Switch b removing the second level of a two level Foot Switch or c shorting the Emergency Stop Control Signals Input Pin 10 to Pin 11 Completion of the Firing State is indicated by momentary...

Page 52: ...uated Weld Head is connected to the HF2 Weld Control Squeeze Time allows sufficient time for a non force fired Weld Head to apply the required weld force to the work pieces Squeeze Time is not normall...

Page 53: ...URRENT value displayed in the upper left hand corner will automatically scroll during this change process In this example weld CURRENT has been increased to 0 7 kA and WELD time has been increased to...

Page 54: ...s are displayed Both relays can be activated in the SQUEEZE WELD and HOLD periods Press CHNG to select ON In this example RELAY 1 will turn on during the WELD period 4 There are four more RELAY 1 opti...

Page 55: ...Refer to Chapter 3 Unitek Peco Force Fired Dual Air Actuated Weld Head System for complete instructions to set up and operate two sequential action Air Actuated Weld Heads 2 When MENU OPTIONS 2 WELD...

Page 56: ......

Page 57: ...tion Weld Function Pre Prog Schedule Typical Application BASIC WELD 001 Make single spot welds on simple flat parts without plating WELD REPEAT 002 Make multiple semi automatic spot welds using an ope...

Page 58: ...the electrodes to close and apply the required weld force to the parts before the Weld Period begins Weld current begins when the Squeeze Period ends and both levels of a two level Foot Switch are clo...

Page 59: ...the required weld force to the parts before the Weld Period begins Weld current begins when the Squeeze Period ends and both levels of a two level Foot Switch are closed When Weld Repeat is used with...

Page 60: ...e Weld Period weld current by a factor of two or three since the first bond significantly reduces the resistance of the interface between the parts Another use for Quench Temper is to control grain re...

Page 61: ...schedule 003 is pre programmed at the factory for Quench Temper operation The HF2 Weld Control automatically recognizes the presence of a Manually or Air Actuated Weld Head before the first weld is m...

Page 62: ...Switch in the Air Actuated Weld Head closes When Pre Postheat is used with a Non Force Fired Air Actuated Weld Head the Squeeze SQZ Period must be used to allow sufficient time for the electrodes to c...

Page 63: ...ds weld current begins when both levels of a two level Foot Switch are closed and the Force Firing Switch in the Air Actuated Weld Head closes When Up Downslope is used with a Non Force Fired Air Actu...

Page 64: ...s Figure 16 Braze Braze can be used with Unitek Peco Force Fired Manual or Air Actuated Weld Heads For Manually Actuated Weld Heads weld current begins when the Force Firing Switch closes For Force Fi...

Page 65: ...onjunction with an automatic parts feeder are used to make a Rollspot weld Because of the weld current shunting effect after the first weld set the Weld2 Period weld current greater than Weld1 by a fa...

Page 66: ...ammed at the factory for Rollspot operation The HF2 Weld Control automatically recognizes the presence of a Manually or Air Actuated Weld Head before the first weld is made Figure 6 20 Rollspot Weld G...

Page 67: ...e the Weld Period begins Weld current begins when the Squeeze Period ends and both levels of a two level Foot Switch are closed Weld Current flows as long as all switches remain closed Hold Period has...

Page 68: ...t bond significantly reduces the resistance of the interface between the parts The only use for the Down Slope Period following the Weld2 Period is to control grain refinement in brittle parts by slow...

Page 69: ...that uses an Air Actuated Weld Head press to scroll the program screen to the right to access the Down and Hold periods Figure 6 27 Dual Pulse Alphanumeric Run Screen PULSATION Figure 6 28 Pulsation a...

Page 70: ...an be used to automatically keep the electrodes closed on the parts after weld current has terminated for the purpose of providing additional heat sinking or parts cooling Squeeze and Hold Periods hav...

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