Amada HF2 User manual

990-057 REV S
INVERTER WELDING POWER SUPPLY
HF2/HF2S
OPERATION MANUAL

2 KHZ INVERTER WEDLING POWER SUPPLY
ii 990-057

1998 – 2021 AMADA WELD TECH INC.
The engineering designs, drawings and data contained herein are the proprietary work of
AMADA WELD TECH and may not be reproduced, copied, exhibited or otherwise used
without the written authorization of AMADA WELD TECH.
Printed in the United States of America.
REVISION RECORD
Revision EO Date Basis of Revision
A ENRG-RLSE 03/95 Released original manual.
B None 09/95 Reorganize manual into chapters.
C None 01/96 Amend to Firmware V1.17 or higher.
D None 02/96 Update cover stock numbers
E None 04/97 Amend to Firmware V1.19 or higher.
F 17472 06/98
1. Remove existing calibration procedure and reference User Calibration
Procedure 994-001.
2. Miscellaneous corrections.
3. Remove SAVE error.
G 18951 08/01 1. Include EO# 17693 in manual.
2. Add latest version of Operator Guide.
H 19012 09/01 1. Include EO# 118951 in manual.
2. Add latest version of Operator Guide.
J 19146 01/02
1. Include EO# 19012.
2. Miscellaneous Corrections.
3. Add Appendix F, Quality Resistance Welding Solutions, and Appendix
G, Replacement of Programmed Integrated Circuits.
K 20016 05/04 Updated wire data.
L N/A N/A N/A
M 42009 06/12 Updated to Miyachi Unitek format and updated RS-
485 connection
information.
N 42840 10/13 Updated to Miyachi America name and logo.
P 43479 11/14 Updated to Amada Miyachi America name and logo.
Q 43808 08/15 Updated to Amada Miyachi America format.
R 45804 04/20 Update Company Name (Amada Weld Tech)
S 46311 04/21 See ECO for Details

2 KHZ INVERTER WEDLING POWER SUPPLY
990-057 iii
FOREWORD
Thank you for purchasing an AMADA WELD TECH - HF2 - 2kHz High Frequency Inverter Welding
Power Supply. For the rest of this manual, the HF2 will be referred to simply as the Power Supply.
Upon receipt of your equipment, please thoroughly inspect it for shipping damage prior to its installation.
Should there be any damage, please immediately contact the shipping company to file a claim, and notify
us at:
AMADA WELD TECH INC.
1820 South Myrtle Avenue
Monrovia, CA 91017-7133
Telephone: [phone]
FAX: [phone]
e-mail: [e-mail]
The purpose of this manual is to provide the information required for proper and safe operation and
maintenance of the AMADA WELD TECH - HF2 - 2kHz High Frequency Inverter Welding Power
Supply.
We have made every effort to ensure that the information in this manual is both accurate and adequate.
The contents of this manual are subject to change without notice. Should questions arise, or if you have
suggestions for improvement of this manual, please contact us at the above location/numbers.
AMADA WELD TECH is not responsible for any loss or injury due to improper use of this product.
The contents of this manual apply to the following models:
AMADA WELD TECH
Model AWTA P/N
HF2/230 1-264-0x
HF2/280 1-264-0x-01
HF2/460 1-264-0x-02
HF2/208
1-264-0x-03
HF2S/230 1-265-0x
HF2S/380 1-265-0x-01
HF2S/460 1-265-0x-02
HF2S/208 1-265-0x-03

2 KHZ INVERTER WEDLING POWER SUPPLY
iv 990-057
CONTENTS
Page
CHAPTER 1: DESCRIPTION
HF2 description........................................................................................................................................1-1
CHAPTER 2: GENERAL SET-UP
Required Connections..............................................................................................................................2-1
Physical Space Requirements...........................................................................................................2-1
HF2 Welding Power Supply Dimensions.........................................................................................2-1
HF2 Welding Transformer Dimensions ...........................................................................................2-1
Power Line Voltage, Current, and Wire Size Requirements............................................................2-2
Insulation Requirements ..................................................................................................................2-2
Power Line Fuse Requirements........................................................................................................2-2
HF2 Welding Transformer Electrical Specifications ....................................................................... 2-3
HF2 Welding System Maximum Secondary Loop Resistance......................................................... 2-4
HF2 Maximum Secondary Loop Resistance Measurement .............................................................2-4
HF2 Welding Power Supply to HF2 Welding Transformer Connections........................................2-4
HF2 Welding Transformer to Weld Head Connections................................................................... 2-5
Weld Sentry Option.......................................................................................................................... 2-5
Help Screen Languages ....................................................................................................................2-5
CHAPTER 3: WELDING SYSTEM SET-UP
Welding System Set-Up Guide................................................................................................................3-1
General Programming Instructions..........................................................................................................3-1
AMADA WELD TECH Force Fired, Foot Actuated Weld Head System..............................................3-2
Weld Head Set-Up............................................................................................................................ 3-2
Firing Switch Cable Connection....................................................................................................... 3-2
Quick Start Programming Guide .....................................................................................................3-2
AMADA WELD TECH Force Fired, Single Air Actuated Weld Head System.....................................3-4
Weld Head Set-Up............................................................................................................................ 3-4
Firing Switch Cable Connection....................................................................................................... 3-4
Weld Head Valve Driver No. 1 Connection.....................................................................................3-4
Foot Switch Connection ................................................................................................................... 3-4
Single Air Regulator Adjustment (TL-080B Series Weld Heads) ................................................... 3-5
Dual Air Regulator Adjustments (TL-180B Weld Heads)...............................................................3-6
Quick Start Programming Guide...................................................................................................... 3-6

2 KHZ INVERTER WEDLING POWER SUPPLY
990-057 v
CONTENTS (Continued) Page
CHAPTER 3: WELDING SYSTEM SET-UP (Continued)
AMADA WELD TECH Force Fired, Dual Air Actuated Weld Head System .......................................3-7
General Information..........................................................................................................................3-7
Power Supply, Jumper Modifications............................................................................................... 3-7
Weld Head Set-Up............................................................................................................................ 3-8
Firing Switch Cable Connection....................................................................................................... 3-9
Weld Head Valve Driver Connections ............................................................................................3-9
Foot Switch Connection ................................................................................................................... 3-9
Dual Air Regulator Adjustment......................................................................................................3-10
Quick Start Programming Guide.................................................................................................... 3-14
Non-Force Fired, Single Air or Cam Actuated Weld Head System...............................................3-16
PLC to Power Supply Electrical Connections ...............................................................................3-16
PLC Timing Diagram.....................................................................................................................3-17
Quick Start Programming Guide ....................................................................................................3-17
CHAPTER 4: CONTROLS
Power Supply Front Panel ......................................................................................................................4-1
Power Supply - Rear Panel Inputs and Outputs....................................................................................... 4-3
Power................................................................................................................................................ 4-3
Fuses F1, 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 Switch ............................................................................................................4-5
Firing Switch Operation ..........................................................................................................................4-6
Mechanical Firing Switch Cable .....................................................................................................4-6
Optical Firing Switch Connector .....................................................................................................4-6
Mechanical Firing Switch - 3-Wire Connection ..............................................................................4-7
Opto-coupler Firing Switch - 3-Wire Connection ........................................................................... 4-7
Control Signals Connector ...............................................................................................................4-7
Control Signals - Pin Assignments ..................................................................................................4-8
Control Signals - Remote Weld Schedule Selection Input .............................................................. 4-9
Control Signals - Emergency Stop Input .........................................................................................4-9
Control Signals - Process Inhibit Input ............................................................................................ 4-9
Control Signals - Output Relays ....................................................................................................4-10
Relay K1 ........................................................................................................................................ 4-10
Relay K2 ........................................................................................................................................ 4-10
Accessory Port ...............................................................................................................................4-10
Air Valve 1 and Air Valve 2 Driver Connectors .................................................................................. 4-11
Air Valve 1 Driver ......................................................................................................................... 4-11
Air Valve 2 Driver ......................................................................................................................... 4-11

2 KHZ INVERTER WEDLING POWER SUPPLY
vi 990-057
CONTENTS (Continued) Page
CHAPTER 5: PROGRAMMING MODES
Help Screens ..........................................................................................................................................5-1
Machine States ........................................................................................................................................5-1
Weld Graph Run State............................................................................................................................. 5-1
Basic Weld Monitor Run State................................................................................................................5-2
Alphanumeric Run State..........................................................................................................................5-2
No Weld State ......................................................................................................................................... 5-2
Standby State ..........................................................................................................................................5-2
Alarm State ............................................................................................................................................. 5-3
Fire State .................................................................................................................................................5-3
Menu State ..............................................................................................................................................5-3
Program State .......................................................................................................................................... 5-4
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
Weld Functions .......................................................................................................................................6-1
Basic Weld .............................................................................................................................................6-2
Weld / Repeat ..........................................................................................................................................6-3
Quench/Temper .......................................................................................................................................6-4
Pre/Postheat ............................................................................................................................................ 6-5
Up/Down Slope .......................................................................................................................................6-7
Braze .................................................................................................................................................. 6-8
Rollspot ..................................................................................................................................................6-9
Seam ................................................................................................................................................6-10
Dual Pulse .............................................................................................................................................6-12
Pulsation ................................................................................................................................................6-13
CHAPTER 7: SPECIAL FEATURES
System Options .......................................................................................................................................7-1
Weld Counter ..........................................................................................................................................7-8
Copy a Schedule .....................................................................................................................................7-9
System Security ......................................................................................................................................7-9
System Help .........................................................................................................................................7-11
Weld Sentry ..........................................................................................................................................7-11
Calibrate the Power Supply ..................................................................................................................7-11
Reset to Defaults ...................................................................................................................................7-11
Installation .............................................................................................................................................7-13
Transformer Model ...............................................................................................................................7-13

2 KHZ INVERTER WEDLING POWER SUPPLY
990-057 vii
CONTENTS (Continued) Page
CHAPTER 8: WELD MONITORING
Basic Weld Monitor General Description................................................................................................ 8-1
Weld Current and Weld Voltage Measurements ....................................................................................8-2
Data Output Capabilities .........................................................................................................................8-2
Weld Monitoring Suggestions .................................................................................................................8-2
Basic Weld Monitor Programming..........................................................................................................8-3
Energy Limit Monitor General Description............................................................................................. 8-4
Energy Limit Monitor Programming.......................................................................................................8-5
APPENDIX A: TECHNICAL SPECIFICATIONS ........................................................................ A-1
APPENDIX B: RS-485 CONNECTION ............................................................................................B-1
APPENDIX C: RECOMMENDED SPARE PARTS .......................................................................C-1
APPENDIX D: ALARM MESSAGES................................................................................................ D-1
APPENDIX E: HELP SCREEN LANGUAGES ..............................................................................E-1
APPENDIX F: REPLACEMENT OF PROGRAMMED INTEGRATED CIRCUITS ...............F-1
APPENDIX G: THE BASICS OF RESISTANCE WELDING........................................................ G-1
APPENDIX H: QUALITY RESISTANCE WELDING SOLUTIONS:
DEFINING THE OPTIMUM PROCESS ........................................................................... H-1

2 KHZ INVERTER WEDLING POWER SUPPLY
viii 990-057
SAFETY NOTES
General
This instruction manual describes the operation and maintenance of the Power Supply and
provides instructions relating to its safe use. Procedures described in this manual must be
performed as detailed by Qualified and Trained personnel.
For Safety, and to effectively take advantage of the full capabilities of the Power Supply,
please read this instruction thoroughly before attempting to use it.
After reading this manual, retain it for future reference when any questions arise regarding
the proper and safe operation of the Power Supply.
Operation
Procedures other than those described in this manual or not performed as prescribed in this
manual, may expose personnel to electrical shock or DEATH.
When operating any welder, always wear appropriate personal protective gear.
Maintenance/Service
Use the appropriate tools for terminating the connecting cables, being careful not to nick
the wire conductors.
Do not modify the Power Supply without prior written approval from AMADA WELD
TECH.
DANGER
DEATH ON CONTACT may result if personnel fail to observe the safety
precautions labeled on the equipment and noted in this manual.
Contact with high voltages present in this Power Supply may cause serious
or fatal injuries. Please read the manual completely and note all cautions and
warnings before attempting to install, operate or maintain the Power Supply.
WARNING
Always wear safety glasses when welding to avoid eye injuries.

2 KHZ INVERTER WEDLING POWER SUPPLY
990-057 ix
SAFETY PRECAUTIONS
•These precautions are given for safe use of
the Power Supply and for prevention of
injury to operators or others.
•Be sure to read each of the instructions, as
they are all important for safe operation.
•The meanings of the words and symbols
are as follows:
DANGER
DO NOT TOUCH THE INSIDE OF THE
POWER SUPPLY UNNECESSARILY.
High Voltages are present
inside the Power Supply Enclosure. Do not touch the inside of
the
Power Supply unnecessarily with the power turned ON. You may receive an electric
shock. When inspecting the inside of the
Power Supply, be sure to turn the power source
OFF and push and hold the DISCHARGE switch until the CHARGE light goes OFF.
NEVER DISASSEMBLE, REPAIR, OR MODIFY THE
POWER SUPPLY.
These actions can cause electric shock and fire. Do
not do anything other than the
ma
intenance described in the Operator Manual.

2 KHZ INVERTER WEDLING POWER SUPPLY
x 990-057
WARNING
Do NOT put your hands or fingers between the electrodes.
When welding, keep your hands and fingers away from the electrodes.
Do NOT touch any welded part or electrode during, or just after welding.
The welded parts and electrodes are very hot. If you touch them you will be burned.
Ground the equipment.
If the equipment is not grounded, you may get an electric shock.
Use a ground fault breaker.
Use a ground fault breaker to prevent an electric shock.
Only use specified cables.
A cable with insufficient capacity or loose connections can cause electric shock or fire.
Do NOT use a damaged power cable, connecting cables, or plugs.
Do not step on, twist, or tense any cable. The power cable and connecting cables may be
damaged which can cause electric shock, short circuit, or fire. If any part needs to be repaired
or replaced, consult AMADA WELD TECH or your distributor.
Stop operation if any trouble occurs.
If you detect a burning smell, abnormal sounds, abnormal heat, smoke, etc., turn power OFF
immediately to prevent fire or electric shock. Contact AMADA WELD TECH or your distributor
for help.
People with pacemakers MUST stay away from the Power Supply.
When the Power Supply is operating, it generates a magnetic field, which adversely affects
pacemakers. People who use a pacemaker must not approach the Power Supply, or walk
around the welding shop while the Power Supply is operating, unless their medical doctor
has deemed it safe to do so.
Wear protective gear.
Put on protective gear such as protective gloves, long sleeved jacket, and leather apron to
avoid being burned.