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

CHAPTER 1: ABOUT YOUR MANUAL
IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES
993-603 REV A: October, 1996 1-3
note them on the Reader Comment Sheet at the back of this manual and drop it in the mail to
us.
If You Need Assistance
There are unique aspects to every installation and application, so your particular needs may
not be covered. If you need further assistance, please contact our sales representative in
your area, or contact the factory directly at:
Unitek Miyachi Corporation
1820 South Myrtle Avenue
Monrovia, California 91017-7133
Telephone: [phone]
Fax: [phone]

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES
993-603 REV A: October, 1996 2-1
IP2PFRON.WPG
Figure 2-1. IP-215A Fine-Spot
Welding Power Supply
CHAPTER 2
ABOUT YOUR EQUIPMENT
Overview
The IP-215A/IP-217A is a high frequency inverter resis-
tance welding power supply designed for fine spot
welding of precision parts. Figure 2-1 shows the physi-
cal characteristics of the 215 Power Supply. The 217
Power Supply is identical except for minor differences
in the front panel key locations.
Simple programming through the front panel controls
and display provides you with a choice of up to three
welding control modes and a variety of welding parame-
ter settings. This versatility brings to your welding
applications reliable and consistent nugget formation,
improved weld quality, and the welding speed required
to work with semi-automated or fully automated equip-
ment.
Performance Features
For a complete listing of the Power Supply’s technical
specifications, please refer to Appendix A. The follow-
ing is a summary of the Power Supply’s performance capabilities.
Feedback Control Modes
Constant Current: Use where welding load resis-
tance is subject to variation, such
as in varying weld forces, weld
piece plating inconsistencies, and
uneven work surfaces. Since this
mode is suitable for all types of
work pieces, always use it when
starting an application.

CHAPTER 2: ABOUT YOUR EQUIPMENT
IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES
2-2 993-603 REV A: October, 1996
Constant Voltage: Use where the electrodes have
relatively high resistance, such as
tungsten electrodes.
Constant Power: Use for cross wire welding and the welding of materials
that are sensitive to heat variation.
Welding Schedules. You can program a welding schedule for up to seven welds.
Alternatively, you can program a start on four only of the seven welding schedules. The welding
schedules control:
Welding heat characteristics
Weld piece cooling time
Control mode selection
Parameter monitoring limits
Welding transformer selection (217 Power Supply only)
Welding Monitors. Built-in performance monitors generate alarm conditions when
preset current, voltage, or power limits are exceed during a weld cycle.
Welding Parameters. Two separate weld current rise and weld periods offer flexible
weld control for multiple applications.
Weld Data Storage. Welcard, a compact data storage unit, collects weld schedule
details. You can recall weld schedules from the Welcard to re-program the Power Supply.
Automation Capability. A signal I/O connector on the rear panel allows integration
with automated production equipment.
Multiple Welding Transformer Selection. The Power Supply has simultaneous
squeeze capability and four channels of transformer selection. With these features, the Power
Supply can be used with an optionally available MA-600A Welding Transformer Selector (see
Figure 2-2) to select up to four different welding transformers to implement sequential welding.
Equipment Description
The Power Supply is delivered fully assembled, together with a shipping kit containing parts that
you will need to install, operate and maintain it. The parts included in the shipping kit are as
follows:
Power Cable
Output (Welding Transformer) Cable

CHAPTER 2: ABOUT YOUR EQUIPMENT
IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES
993-603 REV A: October, 1996 2-3
IP2MA600.WPG
Figure 2-2. Using the Power Supply With Multiple Welding Transformers
Sense Cable
Data I/O Cable
I/O Cable Connector
User’s Manual, Part No. 993-603

IP-215A/217A FINE SPOT WELDING POWER SUPPLIES
993-603 REV A: October, 1996 3-1
CHAPTER 3
GETTING STARTED
Space Requirements
We recommend that you install the Power Supply and its supporting equipment in a well venti-
lated area that is free from excessive dirt and moisture. Other installation considerations are:
The work surfaces must be level, stable, free from vibration, and capable of
supporting the combined weight of the total welding system. The weight of the Power
Supply is:
215 Power Supply 10 Kg (22 lb)
217 Power Supply 13 Kg (28.6 lb)
Allow ample work space around the Power Supply so that it will not be jostled or
struck while welding. The dimensions of the Power Supply are:
215 Power Supply 269 mm (10.5 in.) high, 142 mm (5.5 in.) wide, and 436
mm (17.2 in.) deep
217 Power Supply 269 mm (10.5 in.) high, 172 mm (6.8 in.) wide, and 466
mm (18.3 in.) deep
The atmosphere is free of chemical vapors and particles, and a space of at least 10 cm
(4 in.) is maintained behind the Power Supply for ventilation and air flow.
The Power Supply is far enough from the weld head to avoid contact with weld
splash.
There are no sources of high-frequency energy close by.
NOTE: Be sure that all accessories that you ordered and all items
listed in the shipping kit (see Equipment Description in Chapter 2)
are available, and that the Power Supply shows no sign of damage.
Standard Installation
The standard Power Supply/Welding Transformer installation is shown in Figure 3-1. Depending
on your welding application, you will require an appropriate welding transformer (see Appendix
C).

CHAPTER 3: GETTING STARTED
IP-215A/217A FINE SPOT WELDING POWER SUPPLIES
3-2 993-603 REV A: October, 1996
IP2CONN.WPG
Figure 3-1. Standard Connection Diagram
An installation using multiple welding transformers is shown in Figure 3-2. It is based on the use
of a Model MA-600A Welding Transformer Selector.
CAUTION: Do not connect the AC input voltage cable to the AC power
mains yet.
1. Connect the AC power input cable between the Power Supply AC220V 3 IN connector
and the 220 VAC, 3-phase power source as shown in Figure 3-1.
2. Interconnect the welding transformer and the Power Supply as shown in Figure 3-1. If
your application requires the use of multiple welding transformers, interconnect the
welding transformers with the Power Supply through the Transformer Selector as shown
in Figure 3-2.
3. Connect the Signal I/O cable between the Weld Head and the Power Supply I/O Connect-
or. The factory wiring of the Power Supply I/O connector allows the weld head firing
microswitch to send a single START signal for each operation of the footswitch. For
other START switch selections, please refer to Appendix B.

CHAPTER 3: GETTING STARTED
IP-215A/217A FINE SPOT WELDING POWER SUPPLIES
993-603 REV A: October, 1996 3-3
IP2TRSEL.WPG
Figure 3-2. System Interconnections for Multiple Welding Transformers
4. Connect the Data I/O cable between the Power Supply RS 485 connector and a host
computer if you are using this option.
5. See Figure 3-1. Connect the Power Supply AC power input cable to the AC power mains.
CAUTION: Do not turn on the Power Supply POWER ON/OFF circuit breaker at this
time.
Making a Trial Weld
Making a production weld results from making several trial welds, testing the welds, then adjust-
ing the selected welding parameters each time until you reach production weld quality. The
opera-ting controls and the display are described in Chapter 4. Detailed operating instructions for

CHAPTER 3: GETTING STARTED
IP-215A/217A FINE SPOT WELDING POWER SUPPLIES
3-4 993-603 REV A: October, 1996
selec-ting and editing functions are described in Chapter 5. The following “quick-start” example
weld-ing procedures lead you through a typical weld cycle, from turning on welding system
power to completing a series of trial welds. It is assumed that the weld head that you are using is
connected to the welding transformer(s) according to the manufacturer’s instructions.
1. Set the Power Supply POWER ON/OFF circuit breaker to ON. The display will reflect
the mode and parameters previously set.
2. Adjust the display screen contrast for
optimum viewing, as described in Chapter 7.
3. Press the MODE key to access the Mode
Selection data screen. With the CURSOR
and DATA keys, set the mode selection
fields as follows:
Current monitor (IM) OFF (0)
Voltage monitor (VM) OFF (0)
Power monitor (WM) OFF (0)
Start/End output (MR) OFF (0)
7 schedule start (7S) ON (1)
Panel schedule start (PS) OFF (0)
Program lock (NP) OFF (0)
4. Press the MODE key again to access the
Mode Setting extended data screen.With
the CURSOR and DATA keys, set the
Mode Setting fields as follows:
Transformer: Model number of attached welding transformer
Feedback response (C–GAIN): 0
Data output: OFF
5. Press the WELD SCHED. key to access the
Weld Schedule display screen. With the
CURSOR and DATA keys, set the weld
schedule values as follows:
SCHEDULE: 1
Weld 1 Current Rise Time (R1): 5 ms
Weld 1 Time (W1): 10 ms
Cool Time (CO): 0 ms
Weld 2 Current Rise Time (R2): 0 ms
Weld 2 Time (W2): 0 ms
Control Feedback Mode (I.F.W): Constant Current (I)