Amada ST-100A User manual

990-351 Rev K
AC WELDER
ST-100A
ST-200A
OPERATION MANUAL
RESISTANCE WELDING. SOLVED.
4943 Driscoll Road ¥ Warrensville Heights, OH 44146 USA ¥ www.WSIWELD.com
844-WSI-WELD ¥ [phone]

ST-100A / ST-200A AC CONTROL
ii
Copyright © 2001 - 2021 AMADA WELD TECH INC.
The engineering designs, drawings and data contained herein are the proprietary work of AMADA WELD
TECHand 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 19123 12/01 Initial Release
B 19373 07/02 Addition of technical upgrades and features and inclusion of other
STA models.
C 19557 11/02 Inclusion of all STA Controls, and software upgrade to version 3.0.
D 20369 03/05 Updated technical information.
E 21467 07/07 Updated Schematics.
F 42840 10/13 Updated to Miyachi America name and logo.
G 43479 11/14 Updated to Amada Miyachi America name and logo.
H 43808 08/15 Updated to Amada Miyachi format, deleted obsolete models.
J 45836 04/20 Update Company Name (Amada Weld Tech), Update Model
Numbers + Update Input Voltage Requirement
K 46317 05/21 See ECO for Details
4943 Driscoll Road ¥ Warrensville Heights, OH 44146 USA ¥ www.WSIWELD.com
844-WSI-WELD ¥ [phone]

ST-100A / ST-200A AC CONTROL
iii
FOREWORD
Thank you for purchasing an AMADA WELD TECH, ST-100A / ST-200A - AC Control / Power Supply.
This unit is a component of a larger resistance welding system. Upon receipt, please inspect it thoroughly
for shipping damage before you install it. If there is any damage, contact the shipping company
immediately to file a claim, and notify us at:
AMADA WELD TECH INC.
1820 South Myrtle Avenue
Monrovia, CA 91016-7133
Telephone: [phone]
FAX: [phone]
e-mail:[e-mail]
We have made every effort to ensure that the information in this manual is accurate and adequate. The
contents of this manual are subject to change without notice. If you have any questions, find any
errors/omissions, or if you have suggestions for improving this manual, please contact us.
About This Equipment
The ST-100A / 200A consists of a cabinet which contains; (1) an AC Main Timer Board, (2) SCR Driver
Board, (3) Control Panel Assembly, (4) valve + power transformers, (5) SCR assemblies + snubbers and
(6) surge resistors. Unless ordered otherwise, ST-200A also contains a circuit breaker that disconnects
when the front panel is opened. Four tabs on the rear panel provide convenient mounting of the unit.The
ST-100A / 200A provides the user with all of the controls for establishing all weld modes and timing.
Control options include a Valve Expansion Board, communication capability, voltage monitoring,
electronic pressure regulator control, force monitoring and either primary current sensor or input
connector(s) for secondary current sensor(s).
AMADA WELD TECH is not responsible for any loss or injury due to improper use of this product.
This manual covers the following models:
Original Model Name
Original P/N
Current Model Name
Current P/N
STA-100A
1-1-xxxx-xx-01
ST-100A
1-1-xxxx-xx-01
STA-200A
1-2-xxxx-xx-01
ST-200A
1-2-xxxx-xx-01
4943 Driscoll Road ¥ Warrensville Heights, OH 44146 USA ¥ www.WSIWELD.com
844-WSI-WELD ¥ [phone]

4943 Driscoll Road ¥ Warrensville Heights, OH 44146 USA ¥ www.WSIWELD.com
844-WSI-WELD ¥ [phone]
ST-100A / ST-200A AC CONTROL
iv
CONTENTS
Page
Chapter 1. Description
Section I: Features .................................................................................................................................. 1-1
Overview .......................................................................................................................................... 1-1
Standard Features ............................................................................................................................. 1-2
Optional Features ............................................................................................................................. 1-2
Section II: Major Components ................................................................................................................ 1-3
Major Components .......................................................................................................................... 1-3
Front Panel Controls and Indicators ................................................................................................ 1-5
LCD Display ............................................................................................................................. 1-5
Ready ........................................................................................................................................ 1-5
Error .......................................................................................................................................... 1-5
Weld ......................................................................................................................................... 1-5
Start ........................................................................................................................................... 1-5
Program/Save ........................................................................................................................... 1-5
Weld ON/OFF .......................................................................................................................... 1-6
– Data + ON | OFF ................................................................................................................... 1-6
Schedule ................................................................................................................................... 1-6
Valves ....................................................................................................................................... 1-6
Modes ....................................................................................................................................... 1-6
Reset ......................................................................................................................................... 1-6
Monitor ..................................................................................................................................... 1-6
Stepper ...................................................................................................................................... 1-6
Cursor ....................................................................................................................................... 1-7
Programming Lock ................................................................................................................... 1-7
External Connectors ......................................................................................................................... 1-8
Cylinder Air Hose Connections ....................................................................................................... 1-9
Internal Access ................................................................................................................................. 1-9
Option Cards .................................................................................................................................. 1-10
Electrical Connections ................................................................................................................... 1-10
Chapter 2. Installation and Setup
Section I: Planning for Installation ........................................................................................................ 2-1
Environmental Factors ..................................................................................................................... 2-1
Space and Mounting Requirements ................................................................................................. 2-1
Power Requirements ........................................................................................................................ 2-1
Cooling Water Requirements ......................................................................................................... 2-1
Section II: Power Supply Set-up ............................................................................................................ 2-2
Unpacking ........................................................................................................................................ 2-2
Installation ....................................................................................................................................... 2-2
Mounting the Power Supply ............................................................................................................ 2-2
Connecting Electrical Power ........................................................................................................... 2-2

ST-100A / ST-200A AC CONTROL
v
CONTENTS (Continued)
Page
Secondary Current Sensing .............................................................................................................. 2-3
Placement of Secondary Current Coils ..................................................................................... 2-3
Valve Transformer Wiring Connections .................................................................................. 2-3
Cooling Water Hose Connections ................................................................................................... 2-3
Input / Output Signal Connections .................................................................................................. 2-3
Chapter 3. Using ST-100A / ST-200A Control Functions
Section I: Overview ............................................................................................................................... 3-1
Section II: Schedule Screen ................................................................................................................... 3-2
SCHEDULE # ................................................................................................................................ 3-2
PROGRAM/SAVE .......................................................................................................................... 3-2
Links ............................................................................................................................................ 3-2
SQD (Squeeze Delay) ...................................................................................................................... 3-2
SQZ (Squeeze Time) ....................................................................................................................... 3-2
UP1 (Weld 1 Upslope Time) ........................................................................................................... 3-2
W1 (Weld 1 Time) ........................................................................................................................... 3-3
DN1 (Weld 1 downslope time) ........................................................................................................ 3-3
CO (cool time) ................................................................................................................................. 3-3
UP2 (Weld 2 Upslope Time) ........................................................................................................... 3-3
W2 (Weld 2 Time) ........................................................................................................................... 3-3
DN2 (Weld 2 downslope Time) ...................................................................................................... 3-3
HLD –hold time ............................................................................................................................... 3-3
OFF ............................................................................................................................................ 3-3
CURRENT SETTING ..................................................................................................................... 3-3
CONTROL MODE .......................................................................................................................... 3-3
CH (Force Output Channel) ............................................................................................................. 3-3
FORCE ........................................................................................................................................... 3-3
ElecValve (Valve Associated with Electrode) ................................................................................ 3-3
SCR # (SCR Number) ..................................................................................................................... 3-3
IMPULSE (Quantity of Weld 2 Operations) ................................................................................... 3-3
COPY TO # – Copying a schedule ................................................................................................. 3-4
Section III: Valves Screen ..................................................................................................................... 3-5
SCHEDULE # ................................................................................................................................. 3-5
PROGRAM/SAVE .......................................................................................................................... 3-5
ELECTRODE VALVE .................................................................................................................... 3-5
STATUS .......................................................................................................................................... 3-5
COUNT ............................................................................................................................................ 3-5
Section IV: Monitor Screen ................................................................................................................... 3-6
CURR (Weld Current) ..................................................................................................................... 3-6
COND (Conduction Angle) ............................................................................................................. 3-6
VOLTS ............................................................................................................................................ 3-6
FORCE(LB.) .................................................................................................................................... 3-6
4943 Driscoll Road ¥ Warrensville Heights, OH 44146 USA ¥ www.WSIWELD.com
844-WSI-WELD ¥ [phone]

ST-100A / ST-200A AC CONTROL
vi
CONTENTS (Continued)
Page
LO (Low Current Limit) .................................................................................................................. 3-6
HI (High Current Limit) .................................................................................................................. 3-6
FIRE ............................................................................................................................................ 3-7
Counts (MONITOR COUNTS Screen) ...................................................................................... 3-7
Section V: Monitor Counts Screen ........................................................................................................ 3-8
SCHEDULE # (Schedule number) .................................................................................................. 3-8
WELD COUNT ............................................................................................................................... 3-8
WELD COUNT LIMIT ................................................................................................................... 3-8
SET WELD COUNT = 0 ................................................................................................................. 3-8
STEP # (Step Number) .................................................................................................................... 3-8
STEP COUNT ................................................................................................................................. 3-8
ELECT. VALVE ............................................................................................................................. 3-8
Section VI: Mode Screen ....................................................................................................................... 3-9
SCHEDULE # (Schedule Number) ................................................................................................ 3-9
PROGRAM/SAVE .......................................................................................................................... 3-9
START ............................................................................................................................................ 3-9
WELD MODE .............................................................................................................................. 3-10
Spot Weld Mode ..................................................................................................................... 3-10
Repeat Mode ........................................................................................................................... 3-10
Successive Mode .................................................................................................................... 3-10
Chaining Mode ....................................................................................................................... 3-10
LINKED SCHED ....................................................................................................................... 3-11
Section VII: Linked Schedules Screen ................................................................................................ 3-12
Reference Number ......................................................................................................................... 3-12
SCHD .......................................................................................................................................... 3-12
CURR WELD CNT (Weld Counts for Schedule) ......................................................................... 3-12
WELD MODE ............................................................................................................................... 3-12
ERROR .......................................................................................................................................... 3-12
Section VIII: System Values Screens .................................................................................................. 3-13
System Values Screen 1 ................................................................................................................. 3-13
FULL CURR. (Full Current) .................................................................................................. 3-13
MAX # OF SCR (SCRs in Control) ....................................................................................... 3-13
TURNS RATIO ...................................................................................................................... 3-13
CNTRL MODE (Control Mode) ............................................................................................ 3-13
BIN. SCHED. SELECT (Binary Schedule Select) ................................................................ 3-13
FIRING SWITCH .................................................................................................................. 3-13
COIL ....................................................................................................................................... 3-13
CONTRAST+/– ...................................................................................................................... 3-13
NUM VALVES (Number of Valves)...................................................................................... 3-14
VALVES STATUS ................................................................................................................ 3-14
MODE .................................................................................................................................... 3-14
MORE (System Value Screen 2) ............................................................................................ 3-14
4943 Driscoll Road ¥ Warrensville Heights, OH 44146 USA ¥ www.WSIWELD.com
844-WSI-WELD ¥ [phone]

4943 Driscoll Road ¥ Warrensville Heights, OH 44146 USA ¥ www.WSIWELD.com
844-WSI-WELD ¥ [phone]
ST-100A / ST-200A AC CONTROL
vii
CONTENTS (Continued)
Page
System Values Screen 2 ................................................................................................................. 3-14
87° DELAY (ON or OFF) ...................................................................................................... 3-14
END OUTPUT ....................................................................................................................... 3-14
STEP END OUTPUT ............................................................................................................. 3-14
WELD ON/OFF ..................................................................................................................... 3-14
LOW LINE ALARM ............................................................................................................. 3-14
AUTO RESET ........................................................................................................................ 3-14
ERROR OUTPUT .................................................................................................................. 3-15
SET DEFAULTS .................................................................................................................... 3-15
HOST CNTL .......................................................................................................................... 3-15
UNIT ADDRESS .................................................................................................................... 3-15
System Values Screen 3 ................................................................................................................. 3-15
RETRACTION ....................................................................................................................... 3-15
Pressure Switch ...................................................................................................................... 3-16
Force Calibration .................................................................................................................... 3-16
Output Force ........................................................................................................................... 3-16
Monitored Volts .............................................................................................................. 3-16
Monitored Time ............................................................................................................... 3-16
DIF Pressure ........................................................................................................................... 3-16
Back Pressure ......................................................................................................................... 3-16
Screen 2 ............................................................................................................................... 3-16
Section IX. System Valve Status Screen ............................................................................................. 3-17
VALVE (Valve Numbers) ...................................................................................................... 3-17
CNT (Weld Count) ................................................................................................................. 3-17
RESET (Reset Count to Zero) ................................................................................................ 3-17
SCR (SCR Used With Each Valve) ........................................................................................ 3-17
Section X: Force Calibration Screen .................................................................................................... 3-18
Section XI. Stepper Screen .................................................................................................................. 3-19
VALVE NUM ............................................................................................................................... 3-19
SCR# (SCR Number) ................................................................................................................... 3-19
STEPPER (ON/OFF) .................................................................................................................... 3-19
COUNT .......................................................................................................................................... 3-19
HEAT% ......................................................................................................................................... 3-19
Chapter 4. Operating Instructions
Section I: Introduction ........................................................................................................................... 4-1
Overview .......................................................................................................................................... 4-1
General Operator Safety .................................................................................................................. 4-1
Section II: Preparing for Operation ........................................................................................................ 4-2
Turning the Equipment ON ............................................................................................................. 4-2
Pre-Operational Setup ...................................................................................................................... 4-3

ST-100A / ST-200A AC CONTROL
viii
CONTENTS (Continued)
Page
Section III: Setup Messages .................................................................................................................... 4-4
Section IV. Operation ............................................................................................................................ 4-6
Spot Welds ....................................................................................................................................... 4-7
Continuous Seam Weld ................................................................................................................... 4-8
Cascading (Multiple SCRs) ............................................................................................................. 4-9
Section V: Operational Messages ........................................................................................................ 4-11
Major Run-Time Error Messages .................................................................................................. 4-11
Minor Run-Time Error Messages .................................................................................................. 4-13
Section VI: Shutdown .......................................................................................................................... 4-15
Emergency Shutdown .................................................................................................................... 4-15
Normal Shutdown .......................................................................................................................... 4-15
Chapter 5. Maintenance
Section I: Precautions ............................................................................................................................ 5-1
Section II: General Information ............................................................................................................. 5-1
General Maintenance Procedures .................................................................................................... 5-1
Cooling Maintenance – Water Draining .......................................................................................... 5-1
Fuse Replacement ............................................................................................................................ 5-2
Principles of Operation .................................................................................................................... 5-2
Wiring Diagram ............................................................................................................................... 5-3
Section III. Standard Components Replacement ................................................................................... 5-5
AC Timer Main Board ..................................................................................................................... 5-5
Power Transformer T1 ..................................................................................................................... 5-7
Power Transformer T2 ..................................................................................................................... 5-7
Valve Transformer, T3 .................................................................................................................... 5-7
Surge Resistors ............................................................................................................................... 5-7
Snubber ............................................................................................................................................ 5-8
SCR Drive Board ............................................................................................................................. 5-8
Control Panel Assembly .................................................................................................................. 5-9
Section IV. Optional Components Replacement ................................................................................. 5-10
Optional Primary Current Sensor .................................................................................................. 5-10
Optional Secondary Current Sensor Connector ............................................................................. 5-10
Optional Key Lock ........................................................................................................................ 5-11
Optional SCR Assembly, 600,1200, 1800, and 2200 Amp ........................................................... 5-11
Section V. Spare Parts .......................................................................................................................... 5-12
Section VI. Repair ................................................................................................................................ 5-13
Section VII. Storage and Shipment ...................................................................................................... 5-13
Preparation for Storage or Shipment ............................................................................................. 5-13
Packing for Storage or Shipment ................................................................................................... 5-13
4943 Driscoll Road ¥ Warrensville Heights, OH 44146 USA ¥ www.WSIWELD.com
844-WSI-WELD ¥ [phone]

ST-100A / ST-200A AC CONTROL
ix
CONTENTS (Continued)
Page
Appendix A. Technical Specifications ............................................................................................... A-1
Appendix B. Electrical And Data Connections .................................................................................B-1
Appendix C. SCR, Wire Gauge, And Circuit Breaker Selection ....................................................C-1
Appendix D. System Timing .............................................................................................................. D-1
Appendix E. Cascade Board Option ..................................................................................................E-1
Appendix F. Valve Expansion Board Option ....................................................................................F-1
Appendix G. Voltage Monitor Board Option ................................................................................... G-1
Appendix H. Force Control Option.................................................................................................... H-1
Appendix I. Pressure Monitoring Option............................................................................................I-1
Appendix J. Communications Option .................................................................................................J-1
Appendix K. Circuit Modification for External Transformer Thermostat .................................. K-1
Appendix L. Default Initializations ....................................................................................................L-1
4943 Driscoll Road ¥ Warrensville Heights, OH 44146 USA ¥ www.WSIWELD.com
844-WSI-WELD ¥ [phone]

ST-100A / ST-200A AC CONTROL
x
SAFETY NOTES
This instruction manual describes how to operate, maintain and service the ST-100A / ST-200A AC
Control / Power Supply, and provides instructions relating to its SAFE use.
For SAFETY, and to effectively take advantage of the full capabilities of this Power Supply, please read
these instructions before attempting to use the equipment.
Procedures other than those described in this manual or not performed as prescribed in it, may expose
personnel to electrical hazards.
After reading this manual, retain it for future reference when any questions arise regarding the proper and
SAFE operation of the unit.
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.
WARNINGS
HIGH VOLTAGE is used in the operation of this equipment.
DEATH ON CONTACT may result if personnel fail to observe the
safety precautions labeled on the equipment and noted in this manual.
WHEN WELDING alwayswear safety glasses.
Disposal
Properly handle and dispose of used materials.
For the disposal of electronic waste please contact AMADA WELD TECH.
4943 Driscoll Road ¥ Warrensville Heights, OH 44146 USA ¥ www.WSIWELD.com
844-WSI-WELD ¥ [phone]