Unitec Peco HF25A User manual

USER'S MANUAL 990-333
Revision B December 2003
HF25A/HF25D 25kHz HIGH FREQUENCY
DC RESISTANCE WELDING SYSTEM
MODEL NUMBER STOCK NUMBER
HF25A10/240 1-280-02-03
HF25A10/400 1-280-02-04
HF25A10/480 1-280-02-05
HF25DA10/240 1-285-02
HF25DA10/400 1-285-02-01
HF25DA10/480 1-285-02-02

HF25D DC RESISTANCE WELDING SYSTEM
ii 990-333
Copyright © 1998, 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 19826 9/03 None. Original edition.
B 19895 12/03 Updated LVDT Option information.

HF25D DC RESISTANCE WELDING SYSTEM
990-333 iii
CONTENTS
Page
Chapter 1. Description
Section I: Features .................................................................................................................................. 1-1
Section II: Major Components ............................................................................................................... 1-4
Major Components .......................................................................................................................... 1-4
Front Panel Display and Display Controls ......................................................................................1-4
Display ..................................................................................................................................... 1-5
Display Controls ....................................................................................................................... 1-6
SCHEDULE Selector Key ................................................................................................ 1-6
Weld Period Selector Keys ............................................................................................... 1-6
Time/Energy Selector Keys .............................................................................................. 1-6
Front Panel Data Entry and Mode Controls ............................................................................. 1-7
Key Pad .................................................................................................................................... 1-7
Numeric Keys .................................................................................................................... 1-7
Up/Down Keys .................................................................................................................. 1-7
Mode Key ................................................................................................................................. 1-7
RUN Key ........................................................................................................................... 1-7
MENU Key ....................................................................................................................... 1-7
Control Keys ............................................................................................................................. 1-7
Energy Units Selection Keys ............................................................................................. 1-7
KA .............................................................................................................................. 1-7
V ................................................................................................................................. 1-7
KW ............................................................................................................................. 1-8
Monitor Keys ............................................................................................................................ 1-8
KA ..................................................................................................................................... 1-7
V ..................................................................................................................................... 1-8
KW .................................................................................................................................... 1-8
Resistance (Ω) ................................................................................................................... 1-8
Peak/Average .................................................................................................................... 1-8
LVDT Keys .............................................................................................................................. 1-9
Distance ............................................................................................................................. 1-9
New Electrode ................................................................................................................... 1-9
Quick Cal ........................................................................................................................... 1-9
WELD/NO WELD Switch ....................................................................................................... 1-9
Emergency Stop Switch Operation .......................................................................................... 1-9
Chapter 2. Getting Started
Section I: Planning for Installation ........................................................................................................ 2-1
Space Requirements ......................................................................................................................... 2-1
Utilities ..................................................................................................................................... 2-2
Power ..................................................................................................................................... 2-2
Compressed Air and Cooling Water ......................................................................................... 2-2

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iv 990-333
Contents (Continued)
Page
Section II: Setup ..................................................................................................................................... 2-3
Connections to External Equipment ................................................................................................ 2-3
Weld Head Connections .................................................................................................................. 2-4
Foot Pedal-Actuated Weld Head Connection .................................................................................. 2-6
Air-Actuated Weld Head Connection .............................................................................................. 2-7
Chapter 3. Using Programming Functions
Section I: Menus .................................................................................................................................... 3-1
Overview ..................................................................................................................................... 3-1
Main Menu ..................................................................................................................................... 3-1
1. Setup .................................................................................................................................... 3-1
2. Weld Counter ....................................................................................................................... 3-2
3. Copy A Schedule ................................................................................................................. 3-2
4. System Security ................................................................................................................... 3-3
1. Schedule Lock .............................................................................................................. 3-3
2. System Lock ................................................................................................................. 3-3
3. Calibration Lock ........................................................................................................... 3-3
5. Communication ................................................................................................................... 3-4
1. Communication Role .................................................................................................... 3-4
2. I.D. Number .................................................................................................................. 3-5
3. Baud Rate ...................................................................................................................... 3-5
6. Relay .................................................................................................................................... 3-6
7. Calibration ............................................................................................................................ 3-6
8. Reset To Defaults ................................................................................................................ 3-7
1. Reset System Parameters ............................................................................................. 3-7
2. Reset All Schedules ...................................................................................................... 3-7
9. Chain Schedules .................................................................................................................. 3-8
Setup 1 ................................................................................................................................... 3-10
1. Footswitch Weld Abort ..................................................................................................... 3-10
2. Switch Debounce Time ..................................................................................................... 3-10
3. Firing Switch ..................................................................................................................... 3-11
1. Auto ............................................................................................................................ 3-11
2. None ........................................................................................................................... 3-11
3. Remote ....................................................................................................................... 3-11
4. Input Switch Select ............................................................................................................ 3-11
1. Mechanical ................................................................................................................. 3-12
2. OPTO ......................................................................................................................... 3-12
3. PLC ............................................................................................................................. 3-12
5. Control Signals Select ....................................................................................................... 3-13
Setup 2 ................................................................................................................................... 3-13
1. Display Contrast ................................................................................................................ 3-13
2. Buzzer Loudness ............................................................................................................... 3-13
3. End Of Cycle Buzzer ......................................................................................................... 3-13
4. Update Graph After Weld ................................................................................................. 3-14

HF25D DC RESISTANCE WELDING SYSTEM
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Page
Section II. Operational States .............................................................................................................. 3-15
No Weld State ................................................................................................................................ 3-15
Menu State ................................................................................................................................... 3-15
Test State ................................................................................................................................... 3-15
Run State ................................................................................................................................... 3-16
Weld State ................................................................................................................................... 3-17
Monitor State ................................................................................................................................. 3-17
Alarm State ................................................................................................................................... 3-18
Section III. Weld Functions ................................................................................................................. 3-19
Welding Applications .................................................................................................................... 3-19
Weld Head Applicability ............................................................................................................... 3-20
Section IV: Using Weld and Monitor Functions ................................................................................. 3-21
Overview ................................................................................................................................... 3-21
Weld Schedule Definition .............................................................................................................. 3-22
Weld Sequence Timing .................................................................................................................. 3-22
Welding Applications .................................................................................................................... 3-23
Single-Pulse Weld Profile ...................................................................................................... 3-23
Upslope/Downslope Weld Profile .......................................................................................... 3-24
Dual-Pulse Weld Profile ......................................................................................................... 3-24
Section V. Programmable Feedback Modes ........................................................................................ 3-26
Introduction ................................................................................................................................... 3-26
Current Mode ................................................................................................................................. 3-26
Voltage Mode ................................................................................................................................ 3-26
Power Mode ................................................................................................................................... 3-26
Section VI. Weld Monitor .................................................................................................................... 3-27
Introduction ................................................................................................................................... 3-27
Active Part Conditioner (APC) ...................................................................................................... 3-27
How It Works ......................................................................................................................... 3-28
Energy Limits ................................................................................................................................ 3-29
Pre-Weld Check ............................................................................................................................. 3-30
Chapter 4. Operating Instructions
Section I: Before You Start ............................................................................................................. 4-1
Initial Setup: Pre-Operational Checks ..................................................................................... 4-2
Connections ....................................................................................................................... 4-2
Power ................................................................................................................................. 4-2
Compressed Air ................................................................................................................. 4-2
Initial Setup Instructions ........................................................................................................... 4-2
Section II. Programming Weld Schedules ...................................................................................... 4-3
Introduction .............................................................................................................................. 4-3
Select a Weld Schedule ..................................................................................................... 4-3
Enter New Values .............................................................................................................. 4-3

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Contents (Continued)
Page
Single-Pulse Weld Schedule ..................................................................................................... 4-4
Upslope/Downslope Weld Schedule ........................................................................................ 4-5
Dual-Pulse Weld Schedule ....................................................................................................... 4-6
Section III. Programming the Weld Monitor .................................................................................. 4-7
Section IV. Programming For Active Part Conditioning ............................................................... 4-9
Section V. Adjusting Monitor Limits ........................................................................................... 4-11
Chapter 5. User Maintenance
Section I: Introduction ........................................................................................................................... 5-1
General Kinds of Problems .............................................................................................................. 5-1
Alarm Messages ............................................................................................................................... 5-1
Section II: Troubleshooting ................................................................................................................... 5-2
Troubleshooting ............................................................................................................................... 5-2
Alarm Messages ............................................................................................................................... 5-3
Section III: Maintenance ........................................................................................................................ 5-9
Electrode Maintenance .................................................................................................................... 5-9
Parts Replacement ........................................................................................................................... 5-9
Section IV: Maintenance ...................................................................................................................... 5-10
Chapter 6. Calibration
Calibration ..................................................................................................................................... 6-1
Calibration Equipment Required ..................................................................................................... 6-1
Calibration Procedure ..................................................................................................................... 6-2
Calibrating the LVDT ...................................................................................................................... 6-4
Appendix A. Technical Specifications ............................................................................................... A-1
Appendix B. Electrical and Data Connections ..................................................................................B-1
Appendix C. System Timing ...............................................................................................................C-1
Appendix D. LVDT Option ................................................................................................................ D-1
Appendix E. Communications ............................................................................................................E-1
Appendix F. The Basics of Resistance Welding ................................................................................ F-1
Appendix G. Quality Resistance Welding Solutions: Defining the Optimum Process ................ G-1

HF25D DC RESISTANCE WELDING SYSTEM
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CONTACT US
Thank you for purchasing a Unitek Peco™ Resistance Welding System Control.
Upon receipt of your equipment, please thoroughly inspect it for shipping damage prior to its
installation. Should there be any damage, please immediately contact the shipping company to file a
claim, and notify Unitek Miyachi at:
1820 South Myrtle Avenue
P.O. Box 5033
Monrovia, CA 91017-7133
Telephone: [phone]
FAX: [phone]
e-mail: [email protected]
The purpose of this manual is to supply operating and maintenance personnel with the information
needed to properly and safely operate and maintain the Unitek Peco HF25 Resistance Welding System
Control.
We have made every effort to ensure that the information in this manual is accurate and adequate.
Should questions arise, or if you have suggestions for improvement of this manual, please contact us at
the above location/numbers.
Unitek Miyachi Corporation is not responsible for any loss due to improper use of this product.

HF25D DC RESISTANCE WELDING SYSTEM
viii 990-333
SAFETY NOTES
DANGER
•Lethal voltages exist within this unit.Do not perform any maintenance
inside this unit.
•Never perform any welding operation without wearing protective safety
glasses.
This instruction manual describes how to operate, maintain and service the HF25 Resistance Welding
System Control, and provides instructions relating to its SAFE use. A separate manual provides similar
information for the Weld Head used in conjunction with the Power Supply. Procedures described in
these manuals MUST be performed, as detailed, by QUALIFIED and TRAINED personnel.
For SAFETY, and to effectively take advantage of the full capabilities of the Weld Head and Power
Supply, please read these instruction manuals before attempting to use them.
Procedures other than those described in these manuals or not performed as prescribed in them, may
expose personnel to electrical, burn, or crushing hazards.
After reading these manuals, retain them for future reference when any questions arise regarding the
proper and SAFE operation of the Power Supply.
Please note the following conventions used in this manual:
WARNING: Comments marked this way warn the reader of actions which, if not followed, might
result in immediate death or serious injury.
CAUTION: Comments marked this way warn the reader of actions which, if not followed, might result
in either damage to the equipment, or injury to the individual if subject to long-term exposure to the
indicated hazard.

HF25D DC RESISTANCE WELDING SYSTEM
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