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Unitrol SOLUTIONi Скачать руководство пользователя страница 1

DIRECTION

BOOK

POWERFULLY

INTUITIVE

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Содержание SOLUTIONi

Страница 1: ...DIRECTION BOOK POWERFULLY INTUITIVE...

Страница 2: ...any weld schedule to one of two initiation inputs Initiation Modes Single level dual level anti tiedown holding or momentary Low Water Flow Input from external water flow switch Light Curtain Input fo...

Страница 3: ...CONTENTS INSTALLATION TROUBLE SHOOTING LED CHARTS SECTION B FIRST TIME CONTROL SETUP SECTION C PERSONALIZATION IN PRODUCTION WELDING SCHEDULES DIRECT ACCESS CHART SOLUTION DIRECTION BOOK SECTION A SE...

Страница 4: ...SOLUTION INSTALLATION SECTION A...

Страница 5: ...ON for all controls A6 3 4 SCR OVERTEMPERATURE switch A7 4 TRANSFORMER OVERTEMP switch A8 5 LOW WATER FLOW switch A9 5 WATER to SCR CONTACTOR A10 5 Mounting the REMOTE CONSOLE A11 6 LOCATION A11 1 6 B...

Страница 6: ...ROLS Side mounting brackets are supplied with the system a SIDE MOUNTING You can mount the control from the left or right side as desired using the two mounting brackets supplied with this control Mou...

Страница 7: ...a 50 duty cycle load If your control has a built in circuit breaker connect the wires to the top terminals marked L1 and L2 on the circuit breaker If you control does not have built in circuit breake...

Страница 8: ...e must be connected to the ground stud inside this welding control Look for the stud with the DANGER sign as shown in the photo to the right A6 CONNECTION OF CONTROL WIRING A6 1 INITIATION AND SOLENOI...

Страница 9: ...If switches are PNP solid state check the appropriate section on the HOOK UP DIAGRAM b If you are connecting two hand buttons for anti tiedown initiation there are two choices i Both of the switches...

Страница 10: ...FLOW switch that opens a contact when water flow is low connect this switch to terminals 13 and 14 RT1 RTC Then assign RT1 this input to operate as a WATER FLOW SWITCH by pressing and pressing 5 as d...

Страница 11: ...nput on the keypad A11 2 BRACKET Bolt the U bracket supplied with the console to a secure surface on the welder and mount the console with the two thumb screws supplied Be sure that the location allow...

Страница 12: ...t closely matches your line voltage See photos below for your type of welding control Note Controls shipped to Canada have two black wires connected to the voltage input terminals One will be marked F...

Страница 13: ...HOOK UP DRAWINGS SECTION A PAGE 8 FOR CONTROLS WITH REMOTE CONSOLES PAGE 1 OF 2...

Страница 14: ...HOOK UP DRAWINGS SECTION A PAGE 9 FOR CONTROLS WITH REMOTE CONSOLES PAGE 2 OF 2...

Страница 15: ...HOOK UP DRAWINGS SECTION A PAGE 10 FOR CONTROLS WITH ALL COMPONENTS IN ONE CABINET PAGE 1 OF 3...

Страница 16: ...HOOK UP DRAWINGS SECTION A PAGE 11 FOR CONTROLS WITH ALL COMPONENTS IN ONE CABINET PAGE 2 OF 3...

Страница 17: ...HOOK UP DRAWINGS SECTION A PAGE 12 FOR CONTROLS WITH ALL COMPONENTS IN ONE CABINET PAGE 3 OF 3...

Страница 18: ...TROUBLE SHOOTING DRAWINGS SECTION A PAGE 13 LED TROUBLE SHOOTING DRAWING ALL IN ONE CABINET CONTROLS...

Страница 19: ...TROUBLE SHOOTING DRAWINGS SECTION A PAGE 14 LED TROUBLE SHOOTING DRAWING CONTROLS WITH REMOTE CONSOLES...

Страница 20: ...Unitrol Electronics Inc 702 Landwehr Road Northbrook IL 60062 WEB unitrol electronics com Email techsupport unitrol electronics com...

Страница 21: ...SOLUTIONi FIRST TIME CONTROL SETUP SECTION B...

Страница 22: ...B5 5 8 Entering CYLINDER AREA B6 979 9 FORGE DELAY welders B7 979 9 Entering HEAD WEIGHT B8 979 10 Selecting TYPE OF WELDER B9 979 11 PRESS WELDER B9 1 979 11 ROCKER ARM welder setup B9 2 979 12 Setti...

Страница 23: ...i control will tell you what to do next You don t need any codes or printed sheets to get you back into production Whenever you see pay extra attention to the idea shown This symbol will tell you that...

Страница 24: ...splay above Pushing will let you use that setup program Pushing will skip that setup program and go to the next setup program Pushing or will exit out of the MASTER SETUP PROGRAM And if you went too f...

Страница 25: ...YES 979 SETUP for TIP FORCE CALCULATOR and TIP FORCE WINDOW SELECT YES SKIP NO Maximum AIR PRESSURE VARIATION 00 PSI After entering data Press YES Area of CYLINDER is 00 0 SQUARE INCHES After enterin...

Страница 26: ...4 inside diameter cylinder AREA 785 X 4 X 4 785 16 12 56 square in For welders with a CYLINDER AREA less than 99 9 square inches skip to B5 AIR CYLINDER INSIDE DIAMETER INCHES AREA of CYLINDER SQUARE...

Страница 27: ...up program press 7 times The display will show Press one time and then press one time The display will show MASTER SETUP PROGRAM YES YES NO CYLINDER AREA RANGE Is 0 99 9 SQUARE IN Want to change PUSH...

Страница 28: ...e directions on the following pages to enter the proper number for AREA of CYLINDER TYPICAL PRESS WELDER WITH A STANDARD SINGLE PISTON AIR CYLINDER ON TOP OF WELDER TYPICAL PRESS WELDER WITH A STANDAR...

Страница 29: ...cylinders on this type of welder look similar to the MULTI PISTON air cylinder welders but include a separate oil reservoir to feed hydraulic fluid into the welder cylinder If your welder uses an OHMA...

Страница 30: ...verage of the welder s rocker arm system In the picture to the right the calculation would be ELECTRODE FORCE CYLINDER AREA X AIR PRESSURE X A B The CYLINDER AREA is the number as listed in the SINGLE...

Страница 31: ...culated as Effective AREA of CYLINDER TIP FORCE AIR PRESSURE EXAMPLE The chart on the welding gun specification sheet shows 688 pounds at 80psi The calculation will be effective AREA of CYLINDER 688 8...

Страница 32: ...ot have this FORGE DELAY system installed on your welder leave the value at 00 Press and the display will show If you disconnect the air coming into the welder and the electrodes do not close by gravi...

Страница 33: ...r your hand held unit does not have any accuracy in the low range you can use a digital UPS scale Put a 14 gage or thicker sheet of steel on top and bottom of the scale to prevent the electrodes from...

Страница 34: ...will be calculated as the air pressure times this number It will then exit out to the next setup program EXAMPLE If the display showed and the air pressure regulator is set for 60psi then the force be...

Страница 35: ...center of the rocker arm pin Press and the display will show Enter DIMENSION B in the photo This is the dimension from the center of the rocker arm pin to the centerline of the electrode holder Press...

Страница 36: ...c Voltage Compensation AVC This function will maintain the RMS voltage going into the welder transformer within a 1 window for a line voltage variation of 10 Press 5 times The display shows Press and...

Страница 37: ...seline for the Automatic Voltage Compensation system has been set B10 1 TURNING OFF AVC If the control is not holding steady welding current the AVC function can be turned OFF to see if this system is...

Страница 38: ...eld sequence Even if you have the Unitrol SOFT TOUCH system installed or have a properly installed light curtain system leaving the control in the HOLDING INITIATION mode will allow the operator to op...

Страница 39: ...Press The display will show Most package transformers are WOUND CORE style These are transformers with metal casings on the outside of the transformer Other transformers do not have metal casings on t...

Страница 40: ...welder was known when the control was built at Unitrol the CURRENT MONITORING settings were made to this control prior to shipment from Unitrol This will be shown on the serial number page of at the f...

Страница 41: ...UP TO 20 10KA 4 25 TO 75 25KA 3 80 TO 150 50KA 2 OVER 150 100KA 1 If the maximum current number is shown on the display press to exit out of this program If the maximum current number on the display...

Страница 42: ...QC REMOTE CONSOLE 1 Remove the blue back plate on the remote console 2 Locate the 4 position DIPswitch as shown in the photo 3 Pull the switch finger that matches the desired MAXIMUM CURRENT RANGE cha...

Страница 43: ...above 3 Look down between the two circuit boards and locate the 4 position DIPswitch at the top between the front of the circuit board and the inside of the white metal faceplate 4 Push the switch fi...

Страница 44: ...an also be used for all welding sequences If you want to use only heat settings in percent and not use the CONSTANT CURRENT feature of this control exit out of this FIRST TIME CONTROL SETUP section Yo...

Страница 45: ...your particular welder B14 3 DOING THE LEARN CURVE 1 Press The display will show If your welder does NOT have a TAP SWITCH PUSH If your welder HAS a TAP SWITCH press and enter the total number of tap...

Страница 46: ...equested welding current quickly and accurately c 9 Close the initiation foot switch or hand switches and KEEP THEM CLOSED The electrodes will close on the metal and the display will show The SOLUTION...

Страница 47: ...series of pulses and then display 12 This sequence will continue until the control has done a LEARN CURVE for all TAP SWITCHES Set TRANSF TAP to 2 Place metal between ELECTRODES and then Close INITIAT...

Страница 48: ...SOLUTION PERSONALIZATION SECTION C...

Страница 49: ...ment C4 7 EHR relay operation C4 1 7 FAULT relay operation C4 2 8 FAULT RESET mode C5 982 8 KEYPAD INITIATE fault reset mode C5 1 9 KEYPAD KEYLOCK fault reset mode C5 2 9 FAULT RELAY mode C6 985 9 CLO...

Страница 50: ...re making more than 1 weld per part and want to count FINISHED parts enter the number of WELDS on each PART and then press If you want to only count WELDS leave 000 and press C1 1 SETTING BATCH COUNTE...

Страница 51: ...lder will continue to operate and after each weld will display This indicated that there are 437 more parts to make before the control will stop After the last weld is made for the last part in the ba...

Страница 52: ...CTION STANDARD FULL MANAL FULL AUTO Review WELDING PROGRAM DATA YES NO NO Change WELDING PROGRAM DATA NO NO NO Select NEW WELDING PROGRAM YES NO NO Change welding mode SINGLE NO WELD or REPEAT YES YES...

Страница 53: ...in place of opening the keylock To select a security code press The display will show Press and the display will show Enter a 3 digit number and then press PROGRAM 9 9 7 9 9 Bypass keylock Security c...

Страница 54: ...DARD KEYBOARD LOCK mode and you try to enter a welding program the display will show Enter the security code and press You will be able to view and change anything in the PROGRAM If you do not know th...

Страница 55: ...even if the keypad is locked Each time you push the WELD HEAT will increase by 1 Each time you push the WELD HEAT will decrease by 1 To use this feature and set and limits Press The display will show...

Страница 56: ...he control has a relay that can be jumper selected to be used in one of two ways C4 1 EHR End Of Hold OPERATION When the J3 jumper is in the EHR position the relay will close at the end of every weld...

Страница 57: ...GE out of 10 variation from baseline Faults in any of these three categories can close a FAULT relay for a selectable time and can also stop the welding sequence if so desired You can also set the SOL...

Страница 58: ...et a fault If you push every time one of the three faults is detected the electrodes will stay closed To release and reset the fault do one of the following 1 If the KEYLOCK is in the OPEN position pr...

Страница 59: ...or other control system to recognize the closure To adjust this time press The display will show If you want to change the default 30 cycles 1 2 second press and the display will show Enter the desir...

Страница 60: ...ENT MONITOR The SOLUTIONi control can use the CURRENT MONITORING system in three ways 1 Just display the WELDING CURRENT at the end of each weld 2 Display the WELDING CURRENT at the end of a weld and...

Страница 61: ...ed after each weld and the control will compare it to the HIGH CURRENT LIMIT and LOW CURRENT LIMIT in the welding program If the measured average RMS welding current in a weld goes above the HI CUR LI...

Страница 62: ...can be assigned to operate in several ways To select how you want this output to operate press The display will show Press and the display shows C10 1 FORGE DELAY This function is useful when welding...

Страница 63: ...ear in all welding programs FORGE DELAY time starts at the beginning of the WELD TIME If your welding program uses PULSATION this FORGE DELAY TIME starts at the beginning of the last WELD IMPULSE C10...

Страница 64: ...full welding force on the electrodes Push and the display will show the rest of the choices C10 3 CLAMP DELAY Press 4 and the display will show Push to use this mode This is useful for operations tha...

Страница 65: ...ELDER IF THIS JUMPER IS NOT IN THE ON POSITION C10 4 TURN ON WITH LEVEL 2 Press 5 and the display will show In this mode the SV0 output will turn ON only after the second level of the FOOT SWITCH is c...

Страница 66: ...PERSONALIZATION The display will show Push to keep the control in FULL CYCLE HEAT COUNT mode If you push the control will show and exit out FULL CY HEAT COUNT Want to change Push the YES or NO button...

Страница 67: ...SOLUTION IN PRODUCTION SECTION D...

Страница 68: ...G ON the transducer D5 2 996 10 Checking TIP FORCE D5 3 996 11 Checking AIR PRESSURE D5 4 996 11 Using PRESSURE TRANSDUCER D5 996 10 Setting effective CYLINDER AREA D5 1 996 10 TURNING ON the PRESSURE...

Страница 69: ...YING AN EXISTING WELDING PROGRAM If PROGRAM IS READY is shown some data is already in this PROGRAM number Press if you want to check this PROGRAM or make changes Press and another number if you want t...

Страница 70: ...isplay shows the proper value S SQUEEZE TIME 00CY WELD TIME 00 CY WELD HEAT 00 MOD WELD HEAT 00 You can move through a WELDING PROGRAM in many ways Push this button quickly and the will move down to t...

Страница 71: ...ues for each line and then push or HOLD TIME 00 CY SQUEEZE TIME 00CY WELD TIME 00 CY WELD HEAT 00 MOD WELD HEAT 00 SQUEEZE TIME WELD TIME HOLD TIME ELECTRODE FORCE RESISTANCE WELDING CURRENT RESISTANC...

Страница 72: ...closed Push When the foot pedal is closed the control will mechanically go through one sequence without passing any welding heat It will repeat this sequence if the foot pedal remains closed with REP...

Страница 73: ...NSDUCER in the QC control and you use the transducer per the directions further down in these directions putting anything in SQUEEZE TIME or INITIAL SQUEEZE will just increase the time it takes to mak...

Страница 74: ...function using the sequence above as a guide First heat sequence Non heat time after the end of PREHEAT PREHEAT TIME 00CY PREHEAT 00 COOL AFTER PREHT 00 SQUEEZE TIME PREHEAT UPSLOPE WELD TIME QUENCH T...

Страница 75: ...E TIME 00CY Start USLOPE at 00 PULSATION is handy to use when welding thick metal 120 or thicker Divide the number of weld cycles found on a welding chart for this thickness by 5 and Set PULSATION COO...

Страница 76: ...n operating the control in CONSTANT CURRENT mode Enter the desired force between electrodes See SETTING TIP FORCE CALCULATOR SYSTEM in section B2 for information on this function If your control has Q...

Страница 77: ...ve pushed these buttons to trim the WELD HEAT the original WELD HEAT that was set in this welding program will not be changed But the next line will show the current value of WELD HEAT being used This...

Страница 78: ...ING THE TRANSDUCER ON Press The display will show OR Press if the TRANSDUCER is OFF is shown Press if TRANSDUCER is OFF is shown Use of this DIFFERENTIAL PRESSURE TRANSDUCER will eliminate the need fo...

Страница 79: ...he display will show The number displayed represents the calculated TIP FORCE D5 4 CHECKING AIR PRESSURE Press and the display will show Check TIP FORCE PRESS the YES or NO button YES Check TIP FORCE...

Страница 80: ...red by the transducer Press and the SOLUTIONi control will reset and be ready to weld If your control does NOT have the letters QC in the model number skip to the next section 5 5 USING THE PRESSURE T...

Страница 81: ...ansducer function is turned on To do this press The display will show OR If it shows ON press If it shows OFF press 6 Press 7 When you push the foot switch or hand buttons to make a weld the SOLUTIONi...

Страница 82: ...ULE 1 Press The display will show 2 Press and the display will show If you want to weld LOW CARBON STEEL CRS press The RWMA welding schedules are good starting points They assume that the proper elect...

Страница 83: ...anged later if it is not correct for the range of current needed for this part Set the pressure regulator to the PSI shown on the display and make a sample weld Thinnest metal 00GA After entering data...

Страница 84: ...splay will show 00 for the WELD HEAT To make a starting weld set WELD HEAT to 50 make a test weld and start increasing the WELD HEAT until you reach the desired weld quality D6 3 TAP FAULT FUNCTION If...

Страница 85: ...t show this phrase If you do NOT have a transformer TAP SWITCH on your welder you can ignore this recommendation D6 4 TURNING OFF TAP FAULT FUNCTION If you do not want this TAP SWITCH warning system p...

Страница 86: ...unit is installed on your air system in full replacement of the existing mechanical WELDING PRESSURE REGULATOR It should be located AFTER the filter and before the oiler 7 2 OPERATION Each welding pro...

Страница 87: ...Unitrol Electronics Inc 702 Landwehr Road Northbrook IL 60062 WEB unitrol electronics com Email techsupport unitrol electronics com...

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