Amada HF28/240 User manual

990-372 REV E
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DC RESISTANCE WELDING SYSTEM
HF28
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OPERATION MANUAL
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HF28 DC RESISTANCE WELDING SYSTEM
ii 990-372
Copyright © 1998 -- 2015 Amada Miyachi America
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Theengineeringdesigns,drawingsanddatacontainedhereinaretheproprietaryworkof
AmadaMiyachiAmericaandmaynotbereproduced,copied,exhibitedorotherwise
usedwithoutthewrittenauthorizationofAmadaMiyachiAmerica.
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PrintedintheUnitedStatesofAmerica.
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Revision Record
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Revision EO Date Basis of Revision
A 20409 06/05 None. Original edition.
B 34461 12/09 Updated technical information & specifications.
C 42840 10/13 Updated to Miyachi America name and logo.
D 43480 11/14 Updated to Amada Miyachi America name and logo.
E 43808 8/15 Updated to Amada Miyachi format.
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Important Note
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This manual describes HF28 Models 1-310-01, 1-310-01-01, 1-310-01-02
manufactured after June 2005. These contain significant differences than
earlier models. HF28 models 1-288-01 and 1-288-01-01 manufactured
before June 2005 require a different manual.
To get User’s Manual 990-335 for older HF28 models, order a copy
using the phone number or e-mail address listed under Contact Us on
page viii of this section.
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HF28 DC RESISTANCE WELDING SYSTEM
990-372 iii
CONTENTS Page
Revision Record ........................................................................................................................................ ii
Contents ....................................................................................................................................... iii
Contact Us ..................................................................................................................................... viii
Safety Notes ....................................................................................................................................... ix
Declaration Of Conformity .........................................................................................................................x
Warranty ....................................................................................................................................... xi
Chapter 1. Description
Section I. Features .................................................................................................................................. 1-1
Section II. Major Components ............................................................................................................... 1-3
Major Components .......................................................................................................................... 1-3
Front Panel Display and Display Controls ...................................................................................... 1-3
Display ..................................................................................................................................... 1-4
Display Controls ....................................................................................................................... 1-5
SCHEDULE Key .............................................................................................................. 1-5
Weld Period Selector Keys ............................................................................................... 1-5
Time/Energy Selector Keys .............................................................................................. 1-5
Front Panel Data Entry and Mode Keys .......................................................................................... 1-6
Key Pad .................................................................................................................................... 1-6
Mode Keys ................................................................................................................................ 1-6
RUN Key ........................................................................................................................... 1-6
MENU Key ....................................................................................................................... 1-6
Control Keys .................................................................................................................................... 1-6
Control Mode Selection Keys .................................................................................................. 1-7
kA Key .............................................................................................................................. 1-7
V Key ................................................................................................................................ 1-7
kW Key ............................................................................................................................. 1-7
Monitor Keys ............................................................................................................................ 1-7
kA Key .............................................................................................................................. 1-7
V Key ................................................................................................................................ 1-7
kW Key ............................................................................................................................. 1-8
ΩKey ................................................................................................................................ 1-8
WELD/NO WELD Switch ....................................................................................................... 1-8
Emergency Stop Switch Operation .................................................................................................. 1-8
Chapter 2. Installation and Setup
Section I: Installation ............................................................................................................................. 2-1
Unpacking ..................................................................................................................................... 2-1
Space Requirements ......................................................................................................................... 2-1
Utilities ..................................................................................................................................... 2-2

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CONTENTS (Continued) Page
Power ..................................................................................................................................... 2-2
Compressed Air and Cooling Water ................................................................................................ 2-2
Section II: Setup ..................................................................................................................................... 2-3
Connections to External Equipment ................................................................................................ 2-3
Rear Panel Components and Connectors ......................................................................................... 2-3
Weld Head Connections .................................................................................................................. 2-4
Foot Pedal-Actuated Weld Head Connection .................................................................................. 2-6
EZ-AIR Weld Head Connections .................................................................................................... 2-7
Non-EZ-AIR Weld Head Connections .......................................................................................... 2-10
Chapter 3. System Configuration
Section I: Menus .................................................................................................................................... 3-1
Before You Start .............................................................................................................................. 3-1
Overview ..................................................................................................................................... 3-1
Main Menu ..................................................................................................................................... 3-1
1. Setup .................................................................................................................................... 3-1
2. Weld Counter ....................................................................................................................... 3-2
3. Copy A Schedule ................................................................................................................. 3-3
4. Calibration ........................................................................................................................... 3-3
5. System Security ................................................................................................................... 3-3
1. Schedule Lock .............................................................................................................. 3-4
2. System Lock ................................................................................................................. 3-4
3. Calibration ................................................................................................................... 3-4
6. Relay .................................................................................................................................... 3-5
7. Reset To Defaults ................................................................................................................ 3-6
1. Reset System Parameters ............................................................................................. 3-6
2. Reset All Schedules ...................................................................................................... 3-7
3. Reset Schedule Limits .................................................................................................. 3-7
8. Chain Schedules .................................................................................................................. 3-7
Setup 1 ..................................................................................................................................... 3-9
1. Footswitch Weld Abort ................................................................................................ 3-9
2. Switch Debounce Time .............................................................................................. 3-10
3. Firing Switch .............................................................................................................. 3-10
Setup 2 ................................................................................................................................... 3-11
1. Display Contrast ................................................................................................................ 3-11
2. Buzzer Loudness ............................................................................................................... 3-11
3. End Of Cycle Buzzer ......................................................................................................... 3-11
4. Update Graph After Weld ................................................................................................. 3-11
5. Language ........................................................................................................................... 3-12

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Page
Setup 3 ................................................................................................................................... 3-12
Do Test Weld .......................................................................................................................... 3-12
Always ............................................................................................................................. 3-12
Ask .................................................................................................................................. 3-12
Section III. Operational States ............................................................................................................. 3-13
No Weld State ................................................................................................................................ 3-13
Menu State ................................................................................................................................... 3-13
Test State ................................................................................................................................... 3-13
Run State ................................................................................................................................... 3-14
Weld State ................................................................................................................................... 3-15
Monitor State ................................................................................................................................. 3-15
Alarm State ................................................................................................................................... 3-16
Section IV. Weld Functions ................................................................................................................. 3-17
Welding Applications .................................................................................................................... 3-17
Weld Head Applicability ............................................................................................................... 3-18
When To Use Functions ................................................................................................................ 3-18
Weld Schedule Definition .............................................................................................................. 3-19
Weld Sequence Timing .................................................................................................................. 3-19
Welding Applications .................................................................................................................... 3-20
Single-Pulse Weld Profile ...................................................................................................... 3-20
Upslope / Downslope Weld Profile ........................................................................................ 3-21
Dual-Pulse Weld Profile ......................................................................................................... 3-21
Chapter 4. Introduction to Feedback Modes and Monitoring
Section I. Programmable Feedback Modes ........................................................................................... 4-1
Introduction ..................................................................................................................................... 4-1
Current Mode ................................................................................................................................... 4-1
Voltage Mode .................................................................................................................................. 4-1
Power Mode ..................................................................................................................................... 4-2
Section II. Weld Monitoring .................................................................................................................. 4-3
Introduction ..................................................................................................................................... 4-3
PEAK and AVERAGE MONITORING ......................................................................................... 4-3
Current, Voltage, Power, and Resistance Limits ............................................................................. 4-4
Process Tools ................................................................................................................................... 4-4
1. Active Part Conditioner (APC) ........................................................................................... 4-4
2. Resistance Set ...................................................................................................................... 4-6
3. Pre-Weld Check ................................................................................................................... 4-7
4. Weld To A Limit ................................................................................................................. 4-8
5. Weld Stop ............................................................................................................................ 4-9

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CONTENTS (Continued) Page
Chapter 5. Operating Instructions
Section I: Introduction ........................................................................................................................... 5-1
Before You Start .............................................................................................................................. 5-1
Pre-Operational Checks ................................................................................................................... 5-1
Connections .............................................................................................................................. 5-1
Power ..................................................................................................................................... 5-1
Compressed Air ........................................................................................................................ 5-1
Initial Setup ..................................................................................................................................... 5-2
Section II. Operation .............................................................................................................................. 5-3
Single-Pulse Weld Schedule ............................................................................................................ 5-3
Upslope/Downslope Weld Schedule ............................................................................................... 5-5
Dual-Pulse Weld Schedule .............................................................................................................. 5-7
Section III. Using the Weld Monitor ..................................................................................................... 5-9
Section IV. Active Part Conditioning .................................................................................................. 5-13
Section IV. Resistance Set ................................................................................................................... 5-15
Section VI. Pre-Weld Check ................................................................................................................ 5-17
Section VII. Weld To A Limit ............................................................................................................. 5-19
Section VIII. Weld Stop ....................................................................................................................... 5-21
Section IX. Programming Relays ......................................................................................................... 5-23
Chapter 6. Maintenance
Section I. Introduction ......................................................................................................................... 6-1
General Kinds of Problems .............................................................................................................. 6-1
Alarm Messages ............................................................................................................................... 6-1
Section II. Troubleshooting ................................................................................................................... 6-2
Troubleshooting ............................................................................................................................... 6-2
Alarm Messages ............................................................................................................................... 6-3
Section III. Maintenance ........................................................................................................................ 6-9
Electrode Maintenance .................................................................................................................... 6-9
Parts Replacement ........................................................................................................................... 6-9
Section IV. Repair Service ................................................................................................................... 6-10

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CONTENTS (Continued) Page
Appendix A. Technical Specifications ............................................................................................... A-1
Appendix B. Electrical and Data Connections ..................................................................................B-1
Appendix C. Calibration .....................................................................................................................C-1
Appendix D. System Timing .............................................................................................................. D-1
Appendix E. The Basics of Resistance Welding ................................................................................E-1
Appendix F. Quality Resistance Welding Solutions: Defining the Optimum Process .................F-1
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HF28 DC RESISTANCE WELDING SYSTEM
viii 990-372
CONTACT US
Thank you for purchasing a Miyachi Unitek™ Resistance Welding System Control.
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 Miyachi America
1820 South Myrtle Avenue
P.O. Box 5033
Monrovia, CA 91017-7133
Telephone: [phone]
FAX: [phone]
e-mail: [email protected]
The purpose of this manual is to supply operating and maintenance personnel with the information
needed to properly and safely operate and maintain the Miyachi Unitek™ HF28 Resistance Welding
System Control.
We have made every effort to ensure that the information in this manual is accurate and adequate.
Should questions arise, or if you have suggestions for improvement of this manual, please contact us at
the above location/numbers.
Amada Miyachi America is not responsible for any loss due to improper use of this product.
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HF28 DC RESISTANCE WELDING SYSTEM
990-372 ix
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SAFETY NOTES
DANGER
Lethal voltages exist within this unit.Donotperformanymaintenanceinsidethisunit.
Never perform any welding operation without wearing protective safety glasses.
This instruction manual describes how to operate, maintain and service the HF28 resistance welding
system control, and provides instructions relating to its safe use. A separate manual provides similar
information for the weld head used in conjunction with the power supply. Procedures described in these
manuals must be performed, as detailed, by qualified and trained personnel.
For safety, and to effectively take advantage of the full capabilities of the weld head and power supply,
please read 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 crushing hazards.
After reading these manuals, retain them for future reference when any questions arise regarding the
proper and safe operation of the power supply.
Please note the following conventions used in this manual:
WARNING: Comments marked this way warn the reader of actions which, if not followed, might
result in immediate death or serious injury.
CAUTION: Comments marked this way warn the reader of actions which, if not followed, might result
in either damage to the equipment, or injury to the individual if subject to long-term exposure to the
indicated hazard.
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HF28 DC RESISTANCE WELDING SYSTEM
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