Miyachi 875DP User manual

USER'S MANUAL 990-290
Revision D November 2013
875DP/500DP/500HV DUAL PULSE
STORED ENERGY RESISTANCE WELDING
POWER SUPPLIES
Model Stock No. Model Stock No.
875DP 1-253-XX 875DPS 1-257-XX
875DP/208 1-253-XX-01 875DPS/208 1-257-XX-01
875DP/230 1-253-XX-02 875DPS/230 1-257-XX-02
875DP/100 1-253-XX-03 875DPS/100 1-257-XX-03
500DP 1-251-XX 500DPS 1-255-XX
500DP/208 1-251-XX-01 500DPS/208 1-255-XX-01
500DP/230 1-251-XX-02 500DPS/230 1-255-XX-02
500DP/100 1-251-XX-03 500DPS/100 1-255-XX-03
500HV 1-252-XX 500HVS 1-256-XX
500HV/208 1-252-XX-01 500HVS/208 1-256-XX-01
500HV/230 1-252-XX-02 500HVS/230 1-256-XX-02
500HV/100 1-252-XX-03 500HVS/100 1-256-XX-03
Units with the built-in Weld Sentry Option also require User's Manual No. 990-
291.

875DP/500DP/500HV DUAL PULSE
RESISTANCE WELDING POWER SUPPLIES
ii 990-290
Copyright © 1998, 2002, 2013 Miyachi America Corporation
The engineering designs, drawings and data contained herein are the proprietary work of
Miyachi America Corporation and may not be reproduced, copied, exhibited or otherwise
used without the written authorization of Miyachi America Corporation.
Printed in the United States of America.
Revision Record
Revision EO Date Basis of Revision
A 17280 12/19/97
1. Correct/clarify calibration procedures.
2. Add operating features.
B 17678 11/3/98
Specify output load for HV500 Models.
C 18578 11/14/00
1. Add Declaration of Conformity.
2. Add tolerance to pulse output voltage.
3. Clarify operation of relay outputs.
D 19146 01/02
1. Add Unitek Peco™ name
2. Update manual
E 42840 11/13 Update to Miyachi America name and logo.

875DP/500DP/500HV DUAL PULSE
RESISTANCE WELDING POWER SUPPLIES
990-290 iii
FOREWORD
Thank you for purchasing a Unitek Peco™ 875DP/500DP/500HV Dual Pulse Resistance Welding
Power Supply.
Upon receipt of your equipment, please thoroughly inspect it for shipping damage prior to its
installation. Should there be any damage, please immediately contact the shipping company to file a
claim, and notify Miyachi America Corporation at:
Miyachi America
1820 South Myrtle Avenue
P. O. Box 5039
Monrovia, California 91016
Phone: [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 875DP/500DP/500HV Dual Pulse Resistance
Welding Power Supply.
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.
Miyachi America Corporation is not responsible for any loss due to improper use of this product.

875DP/500DP/500HV DUAL PULSE
RESISTANCE WELDING POWER SUPPLIES
iv 990-290
SAFETY NOTES
This instruction manual describes how to operate, maintain and service the 875DP/500DP/500HV Dual
Pulse Resistance Welding Power Supply, and provides instructions relating to its SAFE use. Procedures
described in this manual MUST be performed, as detailed, by QUALIFIED and TRAINED personnel.
For SAFETY, and to effectively take advantage of the full capabilities of the tester, please read these
instruction manuals before attempting to use the workstation.
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 tester.
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.

875DP/500DP/500HV DUAL PULSE
RESISTANCE WELDING POWER SUPPLIES
990-290 v
CONTENTS
Revision Record..................................................................................................................... ii
Foreword ........................................................................................................................ iii
Safety Notes ........................................................................................................................ iv
Declaration of Conformity..................................................................................................... following
x
CHAPTER 1: SYSTEM DESCRIPTION
Applications ..................................................................................................................... 1-1
Features ........................................................................................................................ 1-2
CHAPTER 2: INSTALLATION
Location ........................................................................................................................ 2-1
Power Line ....................................................................................................................... 2-1
Welding Cables................................................................................................................ 2-1
Rear Panel Components................................................................................................... 2-3
Firing Switch Connections............................................................................................... 2-4
Mechanical Firing Switch .......................................................................................... 2-4
Optical Firing Switch................................................................................................. 2-4
3 Wire Firing Switches .............................................................................................. 2-4
Air Actuated Weld Head Connections............................................................................. 2-5
Air Valve Driver ........................................................................................................ 2-6
Non Unitek Peco Air Actuated Weld Heads.............................................................. 2-7
Air Actuated Weld Heads without Force Firing Switches......................................... 2-7
Second Air Head ........................................................................................................ 2-7
Footswitch........................................................................................................................ 2-7
1-Level Footswitch .................................................................................................... 2-7
2-Level Footswitch .................................................................................................... 2-8
Remote Schedule Selection........................................................................................ 2-8
Relay Outputs................................................................................................................... 2-8
Interconnection Diagram ................................................................................................. 2-9
CHAPTER 3: OPERATING CONTROLS AND SCREENS
Operating Controls........................................................................................................... 3-1
Screen Formats................................................................................................................. 3-3
CHAPTER 4: GETTING STARTED
Powering Up .................................................................................................................... 4-1
Adjusting an Air Actuated Weld Head ............................................................................ 4-1

875DP/500DP/500HV DUAL PULSE
RESISTANCE WELDING POWER SUPPLIES
vi 990-290
CHAPTER 5: OPERATING INSTRUCTIONS
Successful Welding.......................................................................................................... 5-1
Resistance Welding Parameters....................................................................................... 5-1
Weld Schedule Development........................................................................................... 5-1
Weld Head Parameters............................................................................................... 5-2
Power Supply Parameters .......................................................................................... 5-5
Making a Weld................................................................................................................. 5-5
Evaluating the Weld......................................................................................................... 5-6
Weak Weld................................................................................................................. 5-6
Electrode Sticking...................................................................................................... 5-6
Causes of Imperfect Welds .............................................................................................. 5-6
Electrode Force and %Energy ................................................................................... 5-7
Polarity....................................................................................................................... 5-7
Weld Strength Profiles..................................................................................................... 5-8
Destructive Testing .......................................................................................................... 5-8
Electrode Maintenance..................................................................................................... 5-9
CHAPTER 6: PROCESS DEFINITIONS AND WELD FUNCTIONS
Power Supply States ........................................................................................................ 6-1
RUN State .................................................................................................................. 6-1
STANDBY State........................................................................................................ 6-2
PROGRAM State....................................................................................................... 6-2
MENU State............................................................................................................... 6-3
HELP State................................................................................................................. 6-4
NO WELD State ........................................................................................................ 6-4
FIRE State.................................................................................................................. 6-4
Weld Function Field ........................................................................................................ 6-4
Basic Function ........................................................................................................... 6-5
Repeat Function ......................................................................................................... 6-6
Rollspot Function....................................................................................................... 6-7
CHAPTER 7: MAINTENANCE
Modification and Calibration........................................................................................... 7-1
Cover Removal .......................................................................................................... 7-1
Line Voltage Changes................................................................................................ 7-2
Calibration.................................................................................................................. 7-8
Troubleshooting ............................................................................................................... 7-10
Repair Service.................................................................................................................. 7-11
Telephone Service...................................................................................................... 7-11
Factory Service Repair............................................................................................... 7-11

875DP/500DP/500HV DUAL PULSE
RESISTANCE WELDING POWER SUPPLIES
990-290 vii
APPENDIX A: TECHNICAL SPECIFICATIONS
Type Power Supply.......................................................................................................... A-1
Power Requirements ........................................................................................................ A-1
Capacitor Bank................................................................................................................. A-1
Output Pulse Characteristics...................................................................................... A-1
Weld Fire Lockout ..................................................................................................... A-2
Line Voltage Regulation............................................................................................ A-2
Turndown Circuit....................................................................................................... A-2
Line Failure Turndown .............................................................................................. A-2
Over-Voltage Lockout ............................................................................................... A-3
Charge Lockout Circuit.............................................................................................. A-3
Polarity Selection............................................................................................................. A-3
Welding Speed ................................................................................................................. A-3
Weld Schedules................................................................................................................ A-7
Weld Schedule Definition.......................................................................................... A-7
Options ........................................................................................................................ A-7
Schedule Number at Power-Up ................................................................................. A-8
Utilities ........................................................................................................................ A-8
Information ...................................................................................................................... A-8
Weld Functions ................................................................................................................ A-9
Head Type........................................................................................................................ A-9
Squeeze Line.............................................................................................................. A-9
Cool Time .................................................................................................................. A-9
Hold Time .................................................................................................................. A-9
Footswitch Type............................................................................................................... A-10
FOOTSWITCH Connector ........................................................................................ A-10
Footswitch Weld Abort Feature....................................................................................... A-10
Footswitch Weld Abort On........................................................................................ A-10
Footswitch Weld Abort Off ....................................................................................... A-11
Firing Switch Type .......................................................................................................... A-11
Firing Circuit.............................................................................................................. A-11
Switch Debounce Time.............................................................................................. A-11
Mechanical Firing Switch Cable................................................................................ A-11
Optical Firing Switch Connector ............................................................................... A-12
Initiation Switch............................................................................................................... A-12
Manual Head Operation............................................................................................. A-12
Air Head Operation.................................................................................................... A-12
Chain Schedules Feature.................................................................................................. A-13
Step Count.................................................................................................................. A-13
Next Schedule ............................................................................................................ A-13
Audible Buzzer ................................................................................................................ A-14
End of Cycle Buzzer ON/OFF................................................................................... A-14
Key Click ................................................................................................................... A-14
Weld Counter................................................................................................................... A-14
Alarms ........................................................................................................................ A-15
Air Valve Driver .............................................................................................................. A-15

875DP/500DP/500HV DUAL PULSE
RESISTANCE WELDING POWER SUPPLIES
viii 990-290
Air Valve Driver 1 ..................................................................................................... A-15
Air Valve Driver 2 ..................................................................................................... A-16
Air Valve Driver Receptacles .................................................................................... A-16
Control Signals Connector............................................................................................... A-16
Emergency Stop ......................................................................................................... A-17
Charge (Process) Inhibit ............................................................................................ A-18
Remote Weld Schedule Selection.............................................................................. A-18
Binary Schedule Selection Code................................................................................ A-19
Relay Outputs................................................................................................................... A-20
Accessory Port ................................................................................................................. A-21
Input/Output Cable Connectors and Fusing..................................................................... A-22
Input Line Power........................................................................................................ A-22
Circuit Breakers ......................................................................................................... A-22
Fuses ........................................................................................................................ A-22
Power Input Connector .............................................................................................. A-22
Front Panel Switches........................................................................................................ A-23
Microprocessor CPU........................................................................................................ A-23
Display ........................................................................................................................ A-23
Cooling ........................................................................................................................ A-24
Physical Characteristics ................................................................................................... A-25
Index...................................................................................................................................... Index-1

875DP/500DP/500HV DUAL PULSE
RESISTANCE WELDING POWER SUPPLIES
990-290 ix
ILLUSTRATIONS
Figure Title Page
1-1 875DP Dual Pulse Resistance Welding Power Supply........................................ 1-1
2-1 Cable Routing Examples...................................................................................... 2-2
2-2 Terminal Connection Examples........................................................................... 2-2
2-3 Rear Panel Components....................................................................................... 2-3
2-4 Typical Solenoid Air Valve Assembly with a Single Regulator ......................... 2-6
2-5 875DP Equipment Interconnection Diagram....................................................... 2-9
3-1 Front Panel Controls ............................................................................................ 3-1
3-2 Screen Flow Chart................................................................................................ 3-5
4-1 Typical Solenoid Air Valve System with Dual Regulators ................................. 4-2
4-2 Typical Solenoid Air Valve System with a Single Regulator.............................. 4-3
4-3 Measuring Preset Firing Force of the Weld Head with a Force Gauge ............... 4-4
4-4 Results of Excessive Air Pressure........................................................................ 4-5
4-5 Weld Head Configuration Jumper Selection ...................................................... 4-6
5-1 Effects of Excessive or Insufficient Heat, Time and Pressure............................. 5-2
5-2 Typical Weld Strength Profile ............................................................................. 5-8
7-1 Line Voltage and Capacitor Bank Jumpering...................................................... 7-3
7-2 100 VAC Line Voltage Configuration................................................................. 7-4
7-3 115 VAC Line Voltage Configuration................................................................. 7-5
7-4 208 VAC Line Voltage Configuration................................................................. 7-6
7-5 230 VAC Line Voltage Configuration................................................................. 7-7
A-1 875DP Rep Rate with 10500 μF Capacitor Bank ................................................ A-5
A-2 875DP Hit Rate with 10500 μF Capacitor Bank ................................................. A-5
A-3 500DP Rep Rate with 6000 μF Capacitor Bank .................................................. A-6
A-4 500DP Hit Rate with 6000 μF Capacitor Bank ................................................... A-6
A-5 Pin Numbers as Viewed from the Rear Panel...................................................... A-12
A-6 Jumper Selection for Air Valve Driver Control................................................... A-16
A-7 CONTROL SIGNALS Connector ....................................................................... A-17
A-8 Remote Schedule Selection with a Remote Binary Switch ................................. A-20
A-9 875DP Physical Dimensions................................................................................ A-25
A-10 500DP Physical Dimensions................................................................................ A-26

875DP/500DP/500HV DUAL PULSE
RESISTANCE WELDING POWER SUPPLIES
x 990-290
TABLES
Table Title Page
5-1 Recommended Electrode Materials ..................................................................... 5-3
5-2 Causes of Imperfect Welds .................................................................................. 5-6
7-1 Power Supply Voltage Range Specifications ...................................................... 7-9
A-1 Pulse Characteristics ............................................................................................ A-2
A-2 Welding Speed ..................................................................................................... A-4
A-3 Binary Codes for Remote Weld Schedule Selection ........................................... A-19
A-4 Input Power Specifications .................................................................................. A-23