Miyachi Unitek UP-100A User manual

USER'S MANUAL 990-801
Revision A March 2003
AC WELDING POWER SUPPLY
UP-100A
OPERATION MANUAL
CONTENTS
1. Special Precautions................. 1-1 to 3
2. Features.................................. 2-1
3. Name and Functions of
Each Section .......................... 3-1 to 5
4. Connection.............................. 4-1
5. Before the Operation ............... 5-1 to 4
6. Basic Operation....................... 6-1 to 11
7. Stepper-Up Function ............... 7-1 to 4
8. Detail Settings (SET2 Screen) . 8-1 to 6
9. Replacing the Battery .............. 9-1
10. Interface.................................. 10-1 to 11
11. Time Chart .............................. 11-1 to 6
12. Troubleshooting....................... 12-1 to 5
13. Specifications .......................... 13-1 to 9
14. Outline .................................... 14-1 to 2
15. Schedule Table........................ 15-1 to 3
WELD
MENU
RESET
READY START GOOD CAUTION N.G
SET 1 SET 2
SCHEDULE NO. CURR.1 CURR.2 PULSATION SOLENOID
UP2
10010000 00010
WELDING POWER SUPPLY
MEA- 100A
KEY LOCK
DWNW2SQ UP1 W1 CO HLD
10 0.95 kA 1.0 0 kA 00
UNITEK PECO

Copyright © 2003 Unitek Miyachi Corporation
The engineering designs, drawings and data contained herein
are the proprietary work of UNITEK MIYACHI CORPORATION
and may not be reproduced, copied, exhibited or otherwise
used without the written authorization of UNITEK MIYACHI
CORPORATION.
Printed in the United States of America.
REVISION RECORD
Revision EO Date Basis of Revision
A 19703 3/03 Original Release.

UP-100A
1. Special Precautions
1-1
1. Special Precautions
(1) Safety Precautions
Before using, read "Safety precautions" carefully
to understand the correct method of use.
These precautions are shown for safe use of our
products and for prevention of damage or
injury to operators or others. Be sure to read
each of them, since all of them are important
for safety.
The meaning of the words and symbols is as
follows.
These symbols denote
"prohibition".
They are warnings about actions
out of the scope of the
warranty of the product.
These symbols denote actions
which operators must take.
Each symbol with a triangle
denotes that the content gives
ti f DANGER WARNING
Denotes operations and practices that
may imminently result in serious injury or
Denotes operations and practices that
may result in serious injury or loss of life
Denotes operations and practices that may
result in personal injury or damage to the
Do not touch the inside of the Power Supply unnecessarily
Since very high voltages are applied to the inside of this Power Supply, it is very
dangerous to touch it unnecessarily. You may touch it only when you replace the
battery.
When inspecting the inside of the Power Supply, be sure to turn off the Main
Breaker of the Power Supply and wait for at least 3 minutes. (For details, see 9.
Replacing the Battery.)
Never disassemble, repair or modify the Power Supply
These actions can cause electric shock and fire. Consult Unitek Miyachi Corp. or
your distribution for inspection and repair.
NC
A
UTIO
!
DANGER
!
D
A
NGER
!
WARNING
!

UP-100A
1. Special Precautions
1-2
Do not put your hands between the electrodes
When welding, keep your fingers and hands away from the electrodes.
Do not touch any welded part or electrodes during welding and just after
welding finished
The welded part of a workpiece, electrodes and arm are very hot.
Do not touch them; otherwise you may be burnt.
Ground this Power Supply
If the Power Supply is not grounded, you may get an electric shock when fault
occurs, or electricity leaks.
Apply Single-Phase, 200/220/230/240/380/400/460/480
VAC power supply
Application of a voltage out of the specified range can cause fire and electric
shock.
Connect the specified cables securely
Cables of insufficient current capacities and loose connections can cause fire and
electric shock.
Do not damage the power cable and connecting cables
Do not tread on, twist or tense any cable. The power cable and connecting
cables may be broken, and that can cause electric shock and fire. If any part
needs to be repaired or replaced, consult Unitek Miyachi Corp. or your distributor.
Stop the operation if any trouble occurs
Continuous operation after occurrence of a trouble such as burning smell,
abnormal sound, abnormal heat, smoke, etc. can cause electric shock and fire. If
such a trouble occurs, immediately consult Miyachi Technos Corp. or your
distributor.
Persons with pacemakers must stay clear of the welding machine
A person who uses a pacemaker must not approach the welding machine or walk
around the welding shop while the welding machine is in operation, without being
permitted by his/her doctor. The welding machine generates a magnetic field and
has effects on the operation of the pacemaker while it is turned on.
Protective gear must be worn
WARNING
!

UP-100A
1. Special Precautions
1-3
(2) Precautions for Handling
Install this Welding Power Supply on a firm, level, horizontal surface. If it is inclined,
malfunction may result.
Do not install this Welding Power Supply in the following :
¾Damp places where humidity is higher than 90%,
¾Hot or cold places where temperatures are above 45 deg C or below 0 deg C,
¾Places near a high-frequency noise source,
¾Places where chemicals are handled,
¾Places where water will be condensed, and
¾Dusty places.
Clean the outside of the Welding Power Supply with a soft, dry cloth or one wet with a
little water. If it is very dirty, use diluted neutral detergent or alcohol. Do not use paint
thinner, benzene, etc., since they can discolor or deform the Welding Power Supply.
Do not put a screw, a coin, etc., in the Welding Power Supply, since they can cause a
malfunction.
Operate the Welding Power Supply according to the method described in this
operation manual.
Operate the switches and buttons carefully by hand. If they are operated roughly or
with the tip of a screwdriver, a pen, etc., this will cause malfunction or damage.

UP-100A
1. Special Precautions
1-4

UP-100A
2. Features
2-1
2. Features
The UP-100A is a single-phase AC resistance-welding power supply designed for fine spot
welding. The control method can be selected from secondary constant-current control and
power supply voltage fluctuation compensation control. The UP-100A realizes high quality
welding, so it is suitable for small size precise welding.
Four welding current control systems are currently available for the UP-100A. Select the
control system best suited to the particular workpiece.
[Multicycle Welding + Secondary Constant-Current Control]
Returns welding current feedback to the control at each half-cycle, using the toroidal coil.
The control makes adjustments based on this feedback to maintain a constant current,
compensating for voltage fluctuation and workpiece load variances.
[Multicycle Welding + Power Supply Voltage Fluctuation Compensation Control]
Monitors and compensates for power supply voltage fluctuation to maintain a constant
current. Compensation begins from the first half-cycle.
[Single-Cycle Welding + Power Supply Voltage Fluctuation Compensation Control]
Permits the flow of one cycle current only. You can set the first half wave and the second
half wave separately. Compensation begins with the first half wave.
[Half-Cycle Welding + Power Supply Voltage Fluctuation Compensation Control]
Permits the flow of one half-cycle current only. The direction of the current is inverted
with each current flow.
Current Monitor Function Provided
This function allows you to check the current at every welding. Also, a fault message is
displayed when the current range has been preset and the current is out of range.
Automatic Maximum Current Setting
The highest optimum current is automatically set through test welding. (This setting is
then retained in memory even when the power supply is turned off. However, it is reset
when another test welding is performed.)

UP-100A
2. Features
2-2

UP-100A
3. Name and Functions of Each Section
3-1
3. Name and Functions of Each Section
(1) Front Panel
N. Display Panel
This LCD panel is used to monitor various UP-100A functions.
Indicates various settings and weld measurement results.
A [READY] Lamp
Lights when the UP-100A is ready to supply a welding current.
This lamp is synchronized with Terminal 12 ([READY]) of the I/O Terminal Strip
on the rear panel.
This lamp lights when the following conditions are met:
yThe [WELD] lamp on the panel is on.
yThe [WELD ON/OFF] signal on the rear panel terminal block is on.
yNo trouble has occurred.
WELD
MENU
RESET
READY START GOOD CAUTION N.G
SET 1 SET 2
SCHEDULE NO. CURR.1 CURR.2 PULSATION SOLENOID
UP2
10010000 00010
WELDING POWER SUPPLY
MEA- 100A
KEY LOCK
DWNW2SQ UP1 W1 CO HLD
10 0.95 kA 1.0 0 kA 00
‡@
‡A
‡B
‡C
‡D
‡G
‡H
‡J
‡K
‡J
‡E
‡F
‡I
‡L
‡M
N

UP-100A
3. Name and Functions of Each Section
3-2
B [KEY LOCK] Lamp
If this lamp is lit, the schedules or other settings cannot be edited.
However, you can still change screens and the schedule no. using the [MENU]
key, and change functions using NP on the SET2 screen (See 8. (2) ).
C [START] Lamp
Indicates the status of Terminal 28 ([START(1ST)]) of the I/O Terminal Strip on
the rear panel.
Lights when the start signal is input.
D [GOOD] Lamp
Lights when the current is within the monitor range after welding (See 6. (2)).
This lamp is synchronized with Terminals 17 and 18 ([GOOD]) of the I/O
Terminal Strip on the rear panel.
E [CAUTION] Lamp
Lights if the items set to 0 on #4–#7 of the SET2 screen are troubled (See 8.
(2) ). Detailed information on the problem is provided on the display panel.
The lamp is synchronized with Terminal 10 ([CAUTION]) of the I/O Terminal
Strip on the rear panel.
F [NG] Lamp
Lights if the items set to 1 on #4–#7 of the SET2 screen are troubled (See 8.
(2) ). Detailed information on the problem is provided on the display panel.
The lamp is synchronized with Terminals 15 and 16 ([NG]) of the I/O Terminal
Strip on the rear panel.
G [WELD] Lamp
This lamp is one of the three conditions to light the [READY] lamp. Lights when
the [WELD] key is pressed.
If the lamp is turned off, a sequence test can be performed without a welding
current.
H [WELD] Key
Turns on the [WELD] lamp. To turn off the lamp, the key must be pressed for at
least a second.
I [RESET] Key
Turns off an [NG] or [CAUTION] output.
The key does not work until the cause of the problem has been rectified.
J [CURSOR] Key
Used to move the cursor.

UP-100A
3. Name and Functions of Each Section
3-3
K [MENU] Key
Used to move from the MENU screen to another screen or to return to the
MENU screen from the SET screen. For the SET screen, see 5. and 8.
yTo move to the SET1 screen, simultaneously press the [ ] key and the
[MENU] key. Press both for at least a second.
yTo move to the SET2 screen, simultaneously press the [ ] key and the
[MENU] key. Press both for at least a second.
L [+] Key
Changes the number selected by the cursor. Press this key repeatedly to
increase the value.
M [-] Key
Changes the number selected by the cursor. Press this key repeatedly to
decrease the value.

UP-100A
3. Name and Functions of Each Section
3-4
(2) Rear Panel
I/O Terminal Strip
Terminal strip for signals, including the [START] and [NG] signals.
For details, see 10. Interface.
Toroidal Coil Connector
This serves as the input connector for the secondary current detection signal.
Connect the toroidal coil (sold separately) to this connector when the secondary
constant-current control is selected, or if the power supply voltage fluctuation
compensation control is selected and the welding current monitor is in use.
Power Cable Connecting Terminal
Connect the power cable (sold separately) to this terminal for welding.
The other end of the power cable is connected to a single-phase power supply
for welding.
Circuit Breaker
Supplies or shuts off power to the UP-100A.
Raise the handle to turn the circuit breaker on and to supply welding power to
the UP-100A.
ON
PE
COIL






Remove thecircuit
breakercover


UP-100A
3. Name and Functions of Each Section
3-5
Lower the handle to turn off the circuit breaker and to shut off welding power to
the UP-100A.
Output Terminal Block
The output cable (sold separately) is connected to this block.
The other end of the cable is connected to the input terminal of the welding
transformer.
Power Cable Inlet
Pass the power cable through this inlet to connect the cable to the power cable
connecting terminal.
Grounding Terminal
Be sure to ground the UP-100A to prevent electric shock.

UP-100A
3. Name and Functions of Each Section
3-6

UP-100A
4. Connection
4-1
4. Connection
The illustration below shows the UP-100A connected to a typical weld head, and a typical welding
transformer.
Connect the wire to theterminalhavinga frequency that matches the welding power supply
‚P
ON
PE
COIL
MEA-100A
MH-21A
Connecting Cable
Connecting Cable
Connect to
No.27 and 28
on the I/O signal
terminal strip.
MT-510A
‚t ‚u
‚o‚n‚v‚d‚q‚n‚t‚s
‚Q
19
21
25 26
Troidal
Coil
COM 50Hz 60Hz
AC200V IN
Connect the
green wire to
Remove the
terminal cover
Connect the green wire to
Secondary Cable
Connect the green cable to the PE.
Grounding
Green
Single- phase
welding power supply
27 28
Check that the wires and
cables are connected to the correct locations.
Wrong wiring can lead to
malfunctions.
(All of the following
components except the
MEA- 100A are sold
separately.)
Start Cable

UP-100A
4. Connection
4-2

UP-100A
5. Before the Operation
5-1
5. Before the Operation
(1) Screen Configuration
MENU Screen
Press the [MENU] key to select the desired screen. The screens are cycled like this:
Welding schedule setting screen
Current monitor display screen
Current monitor range setting screen
Total count display screen
Step count setting screen
Stepper-up current up rate setting screen
Stepper-up display screen
These seven screens are called the MENU screens.
SET Screen
There is the SET screen for detail settings in addition to the MENU screen. The SET
screen is divided into two general screens, the SET1 screen and the SET2 screen.
To display the SET1 screen, press the [MENU] key
and the [ ] key simultaneously for at least a
second.
To display the SET2 screen, press the [MENU] key
and the [ ] key simultaneously for at least a
second.
Also, the SET1 screen has #1 and #2 screens, and
the SET2 screen has #1 to #7 screens.
The number is displayed at the upper left side on
the screen (See the circle in figure below.)
When screen is switched to the SET screen, the #1
screen is always displayed first.
   
For details of the SET1 screen, see 5. (3) and (4).
For details of the SET2 screen, see 8. Detail Settings.
MENU screen (7 screens)
SET2 screen (7 screens)
SET1 screen (2 screens)
Ordinary
(4 screens)
Stepper-Up
(7 screens)

UP-100A
5. Before the Operation
5-2
(2) Control Method and Welding Current Cycle Settings
Follow the procedure described below and set the control method and welding current cycle
according to the specific application after the UP-100A is installed.
(Secondary constant-current control is factory-set on shipment.)
To display the SET2 screen, press the [MENU] key simultaneously and the [ ] key for at
least a second. (For details of the SET2 screen, see 8. Detail Settings.)
     
    
Change the value under CC (arrow above) to select a desired control method and welding
current cycle.
Setting Control Method Welding Current
Cycle
0 Secondary constant-current control Multi cycle welding
1 Power supply voltage fluctuation
compensation control Multi cycle welding
2 Power supply voltage fluctuation
compensation control Single cycle welding
3 Power supply voltage fluctuation
compensation control Half cycle welding
After changing, press the [MENU] key to go to the schedule setting screen.
(3) Maximum Current Setting
The maximum current is set in one of two ways described below:
A: To set the maximum current of the welding machine directly
To display the SET1 screen, press the [MENU] key simultaneously and the [ ] key for at
least a second. When screen is switched to the SET screen, the #1 screen is always
displayed first.
   
Move the cursor to and set the maximum current of the welding machine. Setting
range is 0.5 to 9.9kA.
Caution: Read this manual carefully before modifying any of the above settings
other than CC.

UP-100A
5. Before the Operation
5-3
B: To set the maximum current automatically, from the measurement of actual welding
If the maximum current of the welding machine is unknown, set the maximum current
automatically with the automatic setting function.
Connect the toroidal coil (sold separately) to the UP-100A.
To display the #1 of the SET1 screens, press the [MENU] key simultaneously and the
[ ] key for at least a second.
   
Decrease the value of below 0.5kA to indicate “***kA”, the automatic maximum current
setting function is enabled.
   
   
The initial settings are shown above. Edit the settings according to the specific welding
machine in use.
Description Setting Range
a
Squeeze time.
The set squeeze time must be longer than the actual
squeeze time. (HLD (hold time) will equal SQ (squeeze
time).)
00–99 cycles
b Weld time.
The set weld time must be the actual weld time. 00–99 cycles
c
The set current must be 60% to 90% of the actual welding
current in order to prevent the damage to the UP-100A
caused by overcurrent.
0.20–9.99kA
d Weld Force number. Select the welding machine for which
you want to set the maximum current automatically.
SOL1
SOL2
Close Terminal 28 ([START(1ST)]) of the I/O Terminal Strip on the rear panel.
After test welding is complete, the display will revert to the screen shown in .
The screen shows the maximum current set automatically.
Caution: When the value is set to lower than 0.5, "∗∗∗" will be displayed and the
the maximum current will be set automatically.
For details, see next page.
Caution: The value set by the automatic setting function is an approximation.
Sometimes the value is differrent from an actual maximum current. Do
not use this function other than the setting of the maximum current.

UP-100A
5. Before the Operation
5-4
If the display does not revert to the screen, repeat test welding until the screen returns.
(To measure the maximum current, welding must be performed for 6 cycles.)
(4) Contrast Setting
Adjusts the LCD contrast.
To display the SET1 screen, press the [MENU] key simultaneously and the [ ] key for at
least a second.
   
Move the cursor to and change to the #2 screen.
The #2 LCD CONTRAST screen is displayed.
  

Change the value indicated by arrow to select one of 16 contrast levels.
The lower the value is, the darker the LCD is.
‘<<>>’ at the bottom line indicates the current contrast level.
Caution: Moving to another screen during the automatic maximum current setting
will interrupt the setting process.