Amada UB25 User manual

990-665 REV J
LINEAR DC RESISTANCE WELDING CONTROL
UB25
OPERATION MANUAL

MODEL UB25 LINEAR DC RESISTANCE WELDING CONTROL
ii 990-665
Copyright © 2002 – 2021 AMADA WELD TECH
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 18653 5/01 Original Release.
B 18860 5/01 Technical changes.
C 19146 2/02 Technical changes.
D 42840 10/13 Updated to Miyachi America name and logo.
E 43480 12/14 Updated to Amada Miyachi America name and logo.
F 43838 01/16 Updated to Amada Miyachi America format.
G 44640 05/17 Removed Reference to Weldstat Software
H 45829 04/20 Update Company Name (Amada Weld Tech) + Misc corrections
J 46300 04/21 Add EU Disposal Statement + Miscellaneous Updates

MODEL UB25 LINEAR DC RESISTANCE WELDING CONTROL
990-665 iii
FOREWORD
Thank you for purchasing an AMADA WELD TECH - UB25 Linear DC Welding Power Supply / 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 WELD TECH INC.
1820 South Myrtle Avenue
Monrovia, CA 91016
Telephone: [phone]
FAX: [phone]
e-mail: [e-mail]
The purpose of this manual is to supplyoperating, maintenance and service personnel with the information
needed to properly and safely operate, maintain and service the UB25 Linear DC Welding Control.
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.
Should questions arise, or if you have suggestions for improvement of this manual, please contact us at
the phone number or address above.
AMADA WELD TECH is not responsible for any loss or injury due to improper use of this product.

MODEL UB25 LINEAR DC RESISTANCE WELDING CONTROL
iv 990-665
Table of Contents Page
Chapter 1. Description .........................................................................................................................1-1
Section I. Introduction ....................................................................................................................1-1
Features ..................................................................................................................................... 1-1
Applications ..............................................................................................................................1-2
Section II. Description ....................................................................................................................1-3
Section III. Overview ......................................................................................................................1-4
Introduction .............................................................................................................................. 1-4
LCD Screens ............................................................................................................................. 1-4
Menu Screens .................................................................................................................................1-5
Data Screens ...................................................................................................................................1-5
Alphanumeric Data ................................................................................................................... 1-5
Operational States .....................................................................................................................1-5
Graphed Data ............................................................................................................................1-7
Section IV. Controls and Indicators ................................................................................................1-8
Introduction .............................................................................................................................. 1-8
Liquid Crystal Display (LCD) and Weld Selector Keys ..........................................................1-8
Numeric Keypad and Operational Controls ...........................................................................1-10
Section V. Emergency Stop Switch and 24v Jumpers ..................................................................1-13
Section VI. Related Publications ..................................................................................................1-14
Chapter 2 Getting Started ....................................................................................................................2-1
Section I: Planning For Installation ................................................................................................ 2-1
Space Requirements .................................................................................................................2-1
Utilities .....................................................................................................................................2-1
Section II: Unpacking .....................................................................................................................2-2
Section III: Electrical and Data Connections ..................................................................................2-3
Section IV. Setup ............................................................................................................................2-4
Manual Weld Head Connections ..............................................................................................2-4
Air-Actuated Weld Head Connections......................................................................................2-6
Relay, Data, And Communication Connections .......................................................................2-6
Chapter 3. Using UB25 Welding and Monitoring Functions ...........................................................3-1
Section I: Introduction .................................................................................................................... 3-1
Section II: Weld Schedules .............................................................................................................3-2
Definition ..................................................................................................................................3-2
Weld Sequence Timing ............................................................................................................ 3-2
Welding Applications ...............................................................................................................3-3
Weld Head Applicability ..........................................................................................................3-3
Single-Pulse Weld Profile ........................................................................................................3-4
Applications ......................................................................................................................3-4
Description ........................................................................................................................3-4

MODEL UB25 LINEAR DC RESISTANCE WELDING CONTROL
990-665 v
Table of Contents (Continued)
Page
Upslope/Downslope Weld Profile Applications ......................................................................3-4
Applications ......................................................................................................................3-4
Description ........................................................................................................................3-4
Dual-Pulse Weld Profile ...........................................................................................................3-5
Applications ......................................................................................................................3-5
Description ........................................................................................................................3-5
Section III. Programmable Feedback Modes .................................................................................. 3-7
Introduction .............................................................................................................................. 3-7
Current Mode ............................................................................................................................3-7
Applications ......................................................................................................................3-7
Description ........................................................................................................................3-7
Voltage Mode ...........................................................................................................................3-7
Applications ......................................................................................................................3-7
Description ........................................................................................................................3-7
Power Mode .............................................................................................................................. 3-7
Applications ......................................................................................................................3-7
Description ........................................................................................................................3-7
Section IV. Weld Monitor ..............................................................................................................3-8
Introduction .............................................................................................................................. 3-8
Active Part Conditioner (APC) ................................................................................................3-8
Applications ......................................................................................................................3-8
Description ........................................................................................................................3-8
How It Works ....................................................................................................................3-9
Instructions ......................................................................................................................3-10
Energy Limits .........................................................................................................................3-10
Applications ....................................................................................................................3-10
Description ......................................................................................................................3-10
Pre-Weld Check ...................................................................................................................... 3-12
Application ......................................................................................................................3-12
Function ...........................................................................................................................3-12
Chapter 4, Operating Instructions .....................................................................................................4-1
Section I: Introduction .................................................................................................................... 4-1
Section II: Initial Setup ................................................................................................................... 4-2
Pre-Operational Checks ............................................................................................................4-2
Connections .......................................................................................................................4-2
Power ................................................................................................................................. 4-2
Compressed Air .................................................................................................................4-2
Initial Setup Instructions ...........................................................................................................4-2
Section III. Programming Weld Schedules ....................................................................................4-3
Introduction .............................................................................................................................. 4-3

MODEL UB25 LINEAR DC RESISTANCE WELDING CONTROL
vi 990-665
Table of Contents (Continued)
Page
Select a Weld Schedule ......................................................................................................... 4-3
Enter New Values ..............................................................................................................4-3
Single-Pulse Weld Schedule ..................................................................................................... 4-4
Upslope/Downslope Weld Schedule ........................................................................................4-5
Dual-Pulse Weld Schedule ....................................................................................................... 4-6
Section IV. Programming the Weld Monitor .................................................................................4-7
Section V. Programming For Active Part Conditioning .................................................................4-9
Section VI. Operation ...................................................................................................................4-11
General Operator Safety ......................................................................................................... 4-11
Manual Welding ..................................................................................................................... 4-11
Operation .........................................................................................................................4-11
Normal Stop ....................................................................................................................4-11
Automated Welding ................................................................................................................4-11
Operation .........................................................................................................................4-11
Normal Stop ....................................................................................................................4-12
Emergency Stop ..............................................................................................................4-12
Re-Set After Emergency Stop .........................................................................................4-12
Chapter 5, Setup Software ..................................................................................................................5-1
Section I: Introduction .................................................................................................................... 5-1
Overview .................................................................................................................................. 5-1
Section II. How to Use Menu Screens ............................................................................................5-2
Main Menu ............................................................................................................................... 5-2
Setup Menus ............................................................................................................................. 5-2
Section III. Operator Preferences ...................................................................................................5-4
Display Contrast .......................................................................................................................5-4
Buzzer Loudness ......................................................................................................................5-4
End of Cycle Buzzer .................................................................................................................5-4
Update Graph after Weld ..........................................................................................................5-5
Buzzer On Weld Stop ............................................................................................................... 5-5
Section IV. System Settings ...........................................................................................................5-6
Waveform Check and Weld Fire Lockout ................................................................................5-6
Waveform Check ON/OFF ............................................................................................... 5-6
Stability Check % Limit Setting ........................................................................................5-6
Stability Check Delay Setting ...........................................................................................5-7
Energy Capacity % Limit Setting ......................................................................................5-7
Weld Fire Lockout Charge % Setting ...............................................................................5-8
Footswitch Weld Abort ............................................................................................................ 5-8
Switch Debounce Time ............................................................................................................ 5-9
Firing Switch ............................................................................................................................5-9

MODEL UB25 LINEAR DC RESISTANCE WELDING CONTROL
990-665 vii
Table of Contents (Continued)
Page
Input Switch Select .................................................................................................................5-10
Mechanical Selection ......................................................................................................5-10
OPTO Selection ...............................................................................................................5-11
PLC Selection ..................................................................................................................5-11
Control Signals Select ............................................................................................................ 5-12
Weld Counter Functions .........................................................................................................5-12
System Security ...................................................................................................................... 5-13
Calibration ..............................................................................................................................5-14
Chain Schedules ..................................................................................................................... 5-14
Section V. PID Test Weld Setup ..................................................................................................5-17
Overview ................................................................................................................................ 5-17
Do Test Weld Options ............................................................................................................5-17
Ignore First/Last .....................................................................................................................5-18
Section VI. Relay Settings ............................................................................................................5-19
Function .................................................................................................................................. 5-19
Programming Instructions ...................................................................................................... 5-19
Section VII. Special Functions .....................................................................................................5-21
Copy a Schedule .....................................................................................................................5-21
Reset Defaults .........................................................................................................................5-21
Reset System Parameters ................................................................................................ 5-23
Reset All Schedules .........................................................................................................5-23
Section VIII. Communication and Data ....................................................................................... 5-24
Requirements ..........................................................................................................................5-24
Communication ...................................................................................................................... 5-24
I.D. Number ............................................................................................................................5-25
Baud Rate ...............................................................................................................................5-25
Chapter 6. User Maintenance .............................................................................................................6-1
Section I. Precautions .....................................................................................................................6-1
Section II. Operator Maintenance ...................................................................................................6-1
Section III. Troubleshooting ...........................................................................................................6-1
General Kinds of Problems ......................................................................................................6-1
Alarm Messages .......................................................................................................................6-2
Troubleshooting ........................................................................................................................6-2
Technical Assistance ................................................................................................................6-5
Electrode Maintenance ............................................................................................................. 6-6
Parts Replacement ....................................................................................................................6-6

MODEL UB25 LINEAR DC RESISTANCE WELDING CONTROL
viii 990-665
Page
Chapter 7. Calibration ......................................................................................................................... 7-1
Section I. Introduction ....................................................................................................................7-1
Overview .................................................................................................................................. 7-1
Calibration Equipment Required ..............................................................................................7-1
Calibration Points .....................................................................................................................7-2
Section II. Calibration Equipment Setup ........................................................................................7-3
Section III. Calibration Procedure ..................................................................................................7-4
Appendix A. Technical Specifications ............................................................................................... A-1
Appendix B. Electrical and Data Connectors ...................................................................................B-1
Appendix C. The Basics of Resistance Welding ................................................................................C-1
Appendix D. Quality Resistance Welding Solutions Defining the Optimum Process .................. D-1
Appendix E. LCD Display Messages ..................................................................................................E-1
Appendix F. Relay Timing Diagrams .................................................................................................F-1
Appendix G. Repetition Rates ........................................................................................................... G-1

Operator Guide – AMADA WELD TECH Power Supplies
CAUTION! This symbol designates an operation which requires a
qualified
technician and User's Manual
OPGELET! Dit symbool duidt een bediening aan waarvoor een gekwalificeerde technicus en de gebruikershandleiding vereist zijn
VARNING! Denna
symbol indikerar ett arbetsmoment som br utfras av en kvalificerad tekniker med hjlp av
Anv
ndarhandledningen
VAARA! T
mmerkki osoittaa toimenpiteen, jossa tarvitaan asiantuntevaa teknikkoa sekkyttksikirjaa
ATTENTION! Ce symbole d
isigne une opration exigeant un technicien qualifiet le Manuel d'utilisation
Dieses Symbol kennzeichnet einen Arbeitsgang, f
r den ein qualifizierter Techniker und ein Benutzerhandbuch erforderlich sind
ATTENZIONE! Questo simbolo indica un'operazione ch
e richiede un tecnico qualificato ed il manuale dell'utente
¡CUIDADO! Este s
mbolo indica uma operao que requer um tcnico qualificado e o Manual do Usurio
¡PRECAUCI
N! Este smbolo designa una operacin que requiere un tcnico competente y el Manual del usuario
1.
Install power supply system
Installeer het voedingssysteem
Installera kraftaggregatsystemet
Asenna voimanlhdejrjestelm
Installer le systme d'alimentation 1ectrique
Das Elektroenergieversorgungssystem installieren
Installazione del sistema d'alimentazione elettrico
Instale o sistema de fonte de alimento
Instale el sistema de fuente de alimentacin
2.
Refer all program or setting changes to a qualified technician
Alle programma
- of instellingswijzigingen moeten door een gekwalificeerd technicus
H
nvisa alla program- och instllningsndringar till en kvalificerad tekniker
Anna kaikki ohjelman tai asetusten muutokset asiantuntevan teknikon suoritettaviksi
Confier toutes les modifications de programme ou de r
glages un technicien qualifi
S
mtliche Programm - oder Einstellungsnderungen mssen einem qualifizierten Techniker

berlassen werden
Rivolgersi ad un tecnico qualificato per tutti i cambiamenti di programma di impostazione
Consuite um t
cnico qualificado quanto a qualquer alterao de programa ou ajuste
Comfiele a un t
cnico competente todos los cambios de programas o ajustes
3.
Use eye protection
Oogbescherming dragen Augenschutz verwenden
Anvnd skyddsglasgon Usare occhiali di protezione
Kytsilmsuojaimia Use culos de proteo
Porter une protection oculaire Use proteccin para los ojos
AMADA WELD TECH INC.
1820 South Myrtle Avenue •Monrovia CA 91016
Tel: [phone] •FAX: [phone]

Operator Guide – AMADA WELD TECH Power Supplies
4.
Examine weld terminals
Kijk de lasterminals na
Inspektera svetsterminalerna
Tarkista hitsausterminaalit
Examiner les bornes de soudure
Schweiverbindungen prfen
Esaminare i terminali di saldatura
Examine os terminais de soldagem
Examine las terminales soldadas
5.
Use WELD/NO WELD switch to stop weld current from flowing
Gebruik de schakelaar WELD/NO WELD om de lasstroom te
stoppen
Anv
nd omkopplaren WELD/NO WELD fr att koppla frn
svetsstr
mmen
Katkaise hitsausvirta
WELD/NO WELD - kytkimest
Utiliser l'interrupteur WELD/NO WELD pour arr
ter le
passage du courant de soudure
Der Schwei
stromfluwird mit dem Schalter WELD/NO WELD angehalten
Usare l'interruttore WELD/NO WELD per interrompere il flusso della corrente
di saldatura
Use a chave WELD/NO WELD para interromper o fluxo da corrente de soldagem
Utilice el interruptor de WELD/NO WELD para cortar el flujo de la corriente de soldar
EMERGENCY STOP -Open electrical circuit to retract weld head
NOODSTOP
- Open het elektrische circuit om de laskop terug te trekken.
N
DSTOPP - ppna den elektriska kretsen fr att dra tillbaka svetstrden.
H
TKYTKIN POIS - Avaa virtapiiri vetksesi hitsauspn takaisin.
ARRET D'URGENCE
- Ouvrez le circuit lectrique pour retirer la tte de soudure.
NOT AUSSCHALTER
- Wrd den elektrischen Kreis ffnen, der Schweikopf w
rd
zur
ck gezogen.
EMERGENZA DISINSERITA
- Aprire il circuito elettrico per ritrarre la testa della
saldatura.
DESCONE
O DE EMERGNCIA - Abra o circuito eltrico para retrair a cabea da
soldadura.
DESCONECCION DE EMERGENCIA
- Abra el circuito elctrico para retraer la cabeza
de soldadura.
AMADA WELD TECH INC.
1820 South Myrtle Avenue •Monrovia CA 91016
Tel: [phone] •FAX: [phone]