Unitek Miyachi IP-215A User manual

WARNING: Please be sure to read all personnel and
equipment safety precautions noted in this manual.
User's Manual
993-603
Revision A: October, 1996
IP-215A AND IP-217A
FINE SPOT
WELDING POWER SUPPLIES
Model
IP-215A
IP-215A/RS485
IP-217A
IP-217A/RS485
Definition
Standard 50 Amp Power
Supply
50 Amp Power Supply
With RS-485 Data Port
Standard 200 Amp Power
Supply
200 Amp Power Supply
With RS-485 Data Port
Copyright © 1996
Unitek Miyachi Corporation
All Rights Reserved
Prepared by Unitek Miyachi Corporation
1820 South Myrtle Avenue
Monrovia, CA 91017-7133
Phone [phone]
FAX [phone]
TWX [phone]

IP-215A and IP-217A Fine Spot
Welding Power Supplies
User's Manual 993-603, October 1996, Revision A
Unitek Miyachi Corporation
1820 South Myrtle Avenue
Monrovia, CA 91017-7133
Phone [phone]
FAX [phone]
TWX [phone]

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES
993-603 REV A: October, 1996 i
©1996, 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,exhibitedorotherwiseusedwithoutthewrittenauthorizationofUNITEK
MIYACHI CORPORATION.
Printed in the United States of America
REVISION RECORD
Revision EO Date Basis of Revision
A 16785 10/96 Not applicable

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES
iv 993-603 REV A: October, 1996
CAUTIONS
AND
WARNINGS
HIGH VOLTAGE
IS USED IN THE OPERATION OF THIS EQUIPMENT
DEATH ON CONTACT
MAY RESULT IF PERSONNEL FAIL TO OBSERVE THE SAFETY PRE-
CAUTIONS LABELED ON THE EQUIPMENT AND NOTED ON THIS PAGE
Onlya qualifiedtechnician shouldbe allowedto workinside the unit.
Never work on electronic equipment unless there is another person
nearby who is familiar with the operation and hazards on the
equipment and who is competent in administering first aid. The
technician who is aided by operators must warn them about the
hazards.
Whenever possible, shut off the power supply to the equipment
before beginning work on it. When you have shut off power, ground
all parts. Be sure to discharge every capacitor that may hold a
dangerous potential to ground when working inside the equipment.
Do not touch high-voltage connections or 208/230 volt input
connectionswheninstallingoroperatingtheequipment.WARNING:
Do not be misled by the term low voltage. Potentials as low as
50 volts may cause death under adverse conditions.
PLEASE READ THE SAFETY STEPS ON THE NEXT PAGE

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES
993-603 REV A: October, 1996 v
SAFETYSTEPSTOFOLLOWIFSOMEONEISTHEVICTIMOFELECTRICAL
5
SHOCK:
1. Do not try to pull or grab the victim.
2. If possible, turn off the electrical power.
3. If you cannot turn off the electrical power, pull,
push or lift the victim to safety using a dry wooden
pole, a dry rope, or some other non-conductive
material.
4. Send for medical help as soon as possible.
5. When the victim is free of contact with the source
of electrical shock, move the victim away and start
artificial resuscitation.

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES
vi 993-603 REV A: October, 1996
CONTENTS
CHAPTER 1 ABOUT THIS MANUAL
Organization..........................................................1-1
Referencing Conventions ................................................1-2
RelatedManuals ......................................................1-2
HowAreWeDoing? ...................................................1-2
IfYouNeedAssistance ................................................ 1-3
CHAPTER 2 ABOUT YOUR EQUIPMENT
Overview ............................................................ 2-1
PerformanceFeatures................................................... 2-1
WeldingSchedules...............................................2-2
WeldingMonitors ...............................................2-2
WeldingParameters..............................................2-2
WeldDataStorage...............................................2-2
Automation Capability ............................................2-2
EquipmentDescription .................................................2-2
CHAPTER 3 GETTING STARTED
Space Requirements .................................................... 3-1
StandardInstallation ...................................................3-1
MakingaTrialWeld ...................................................3-3
CHAPTER 4 CONTROLS
Rear Panel Components .................................................4-1
Front Panel Components ................................................4-2
Display........................................................4-2
ControlModeStatusIndicators.....................................4-4
SystemStatusIndicators ..........................................4-4
WeldProgramKeyField..........................................4-4
WeldControlKeyField...........................................4-8
WelcardDrive .................................................4-10
POWERCircuitBreaker .........................................4-10

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES
993-603 REV A: October, 1996 vii
CONTENTS (continued)
CHAPTER 5 OPERATING YOUR POWER SUPPLY
Display Screen Data Editing .............................................5-1
SettingtheWeldSchedule...............................................5-3
Monitoring Power Supply Operation .......................................5-4
MonitoringWeldHeatLimits ......................................5-4
WeldCurrent ................................................... 5-4
Current Setting Monitor (IP-217A Only) .............................5-6
MonitoringAveragePulseWidth ...................................5-6
AutomaticPerformanceMonitors ...................................5-7
Selecting the Welding Transformer (217 Power Supply Only) ...................5-8
Selecting the Weld Count ...............................................5-9
SettingControlFeedbackGain ........................................... 5-9
ActivatingtheDataOutputPort ......................................... 5-10
CHAPTER 6 USING THE WELCARD
CareandTreatmentoftheWelcard........................................6-1
WelcardDataRecords .................................................. 6-2
InstallingtheWelcard ..................................................6-2
OperatingWiththeWelcard .............................................6-2
Initializing the Welcard ...........................................6-2
ReferencingtheDirectory .........................................6-3
Copying a Schedule to a Welcard ...................................6-4
Copying a Schedule to the Power Supply .............................6-5
WelcardSystemErrorMessages..........................................6-6
CHAPTER 7 IN CASE OF DIFFICULTY
GeneralKindsofProblems ..............................................7-1
ElectrodeMaintenance .................................................7-1
AdjustingDisplayViewingAngle.........................................7-2
Memory Backup Battery Replacement .....................................7-2
TechnicalAssistance ...................................................7-3

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES
vi 993-603 REV A: October, 1996
CONTENTS (continued)
APPENDICES
A TechnicalSpecifications ......................................... A-1
B CableWiringandSignalSpecifications ..............................B-1
C WeldingTransformerSpecifications.................................C-1
D ResistanceWeldingBasics ....................................... D-1
E AlarmMessageList..............................................E-1
F WeldProgrammingSheets ........................................F-1
ALPHANUMERIC SUBJECT INDEX
READER COMMENT SHEET
WARRANTY
ILLUSTRATIONS
2-1 IP-215A Fine Spot Welding Power Supply ............................2-1
2-2 Using the Power Supply With Multiple Welding Transformers ............2-3
3-1 StandardConnectionDiagram......................................3-2
3-2 System Interconnections for Multiple Welding Transformers .............3-3
4-1 Rear Panel Components ........................................... 4-1
4-2 FrontPanelControlsandDisplay ................................... 4-3
6-1 TheWelcardDataStorageSystem ..................................6-1
7-1 FactoryAdjustedDisplayViewing ..................................7-2
7-2 Memory Backup Battery Location ..................................7-3
TABLES
5-1 DisplayDataEntryRanges .....................................5-2
6-1 Welcard Error Messages ........................................6-6

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES
993-603 REV A: October, 1996 1-1
CHAPTER 1
ABOUT THIS MANUAL
This manual is organized to assist you in getting productive quickly with the IP-215A or IP-
217A High Frequency Inverter Welding Power Supply. The simplified information and
instructions in Chapters 1 through 3 will allow you to get the equipment up and running
safely and efficiently, and make basic welds. Chapter 4 explains the operation of the controls
and the display. Chapter 5 and the appendices deal with more advanced welding consider-
ations and procedures.
NOTE: Where the data in this manual is specific to either the IP-215A or the
IP-217A, the data is noted as such. All other data is relevant to both the IP-
215A and the IP-217A.
Organization
This chapter lets you know how to use this manual effectively. The manual contains many
tools to help you find and understand information. The physical, electrical and performance
specifications are listed in Appendix A. Specific subject matter is listed in the Alphanumeric
Subject Index at the back of the manual; the subjects are sorted alphabetically and show
their page number locations in the manual.
Chapter 2 familiarizes you with physical aspects and performance capabilities of your IP-
215A/217A High Frequency Inverter Welding Power Supply.
Chapter 3 provides procedures for setting up the equipment in the workplace and making
your first simple weld. It covers the physical and electrical installation of the IP-
215A/IP217A High Frequency Inverter Power Supply. Details of mounting and applying
AC power to the system are discussed, and a description of the initial power-on actions is
presented. These procedures bring the system up to operational status and lead you through
your first welds.
Chapters 4 and 5 respectively present detailed descriptions of key functions and operating
instructions for the IP-215A/IP-217A High Frequency Inverter Welding Power Supply.
Chapter 6 instructs you in the use of the Welcard data storage system. Finally, Chapter 7
offers courses of action if you run into difficulty with system operation.

CHAPTER 1: ABOUT YOUR MANUAL
IP-215A/217A FINE SPOT WELDING POWER SUPPLIES
1-2 993-603 REV A: October, 1996
Referencing Conventions
For ease of referencing the related components of the IP-215A/IP-217A High Frequency
Inverter Welding Power Supply, here is the way that they will be referred to in the rest of the
narrative in this manual:
IP-215A or IP-217A High Frequency
Inverter Welding Power Supply: Power Supply
IP-215A High Frequency Inverter
Welding Power Supply: 215 Power Supply
IP-217A High Frequency Inverter
Welding Power Supply: 217 Power Supply
Welding Transformers:
Model IT-500A 500 Welding Transformer
Model IT-501A 501 Welding Transformer
Model IT-510A 510 Welding Transformer
Model IT-511A 511 Welding Transformer
Model IT-512A 512 Welding Transformer
Model IT-540A 540 Welding Transformer
Welcard Unit Drive: Welcard Drive
Welcard Unit (the storage medium): Welcard (optional)
The full titles are still used where the components are referenced in a formal sense, such as
in parts lists, or where confusion may result from using the short form of the titles.
Related Manuals
For additional reference support for this manual, the following manual is available from
Unitek Miyachi: Fundamentals of Resistance Welding, Manual No. 990-1-210
How Are We Doing?
We hope you find in this manual all the information you need to integrate the Power Supply
into the Welding System successfully. We have made every effort to present this informa-
tion clearly and concisely. If you have any suggestions for improving the manual, please