Unitek Peco PHASEMASTER 6 User manual

USER'S MANUAL
No. 990-083
Revision D: January 2002
PHASEMASTER™ 6
DIRECT ENERGY WELDING CONTROL
MODEL NUMBER STOCK NUMBER
PM6 1-237-XX
PM6/115 1-237-XX-01
PM6/230 1-237-XX-02
PM6/100 1-237-XX-03
PM6/460 1-238-XX
AIR
MANUAL
NOWELD
WELD
2LEVEL
1LEVEL
MACHINE
SCR
OFF
ON
RUN SAVEPROGRAM
SCHEDULE
NUMBER POLARITYSQUEEZE CYCLES WELD CYCLES HOLD CYCLES % CURRENT
HEAD
TYPE
FOOTSWITCH
FOOTSWITCH
WELD ABORT
ALARM
PHASEMASTERTM 6
AC WELDING CONTROL

PHASEMASTER™ 6 DIRECT ENERGY WELDING CONTROL
ii 990-083
Copyright © 1998, 2002 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
A16289 4/96 Correct illustration callouts.
B17415 4/98 Correct machine alarm condition A4.
C17521 6/98 Incorporated errata.
D19161 10/01 1. Change name to Unitek Peco™.
2. Update manual.

PHASEMASTER™ 6 DIRECT ENERGY WELDING CONTROL
990-083 iii
FOREWORD
Thank you for purchasing a Unitek Peco™ Phasemaster™ 6 .Direct Energy Welding 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 Phasemaster™ 6 .Direct Energy Welding 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.

PHASEMASTER™ 6 DIRECT ENERGY WELDING CONTROL
iv 990-083
SAFETY NOTES
This instruction manual describes how to operate, maintain and service the Phasemaster™ 6 .Direct Energy
Welding 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.

PHASEMASTER™ 6 DIRECT ENERGY WELDING CONTROL
990-083 v
CONTENTS
Revision Record....................................................................................................................... ii
Foreword ........................................................................................................................ iii
Safety Notes ........................................................................................................................ iv
Declaration of Conformity................................................................................... Following Contents
CHAPTER 1: DESCRIPTION ............................................................................................ 1-1
Section I. Features............................................................................................................ 1-1
Features....................................................................................................................... 1-1
Process Definitions....................................................................................................... 1-2
Sequence Welding Function................................................................................... 1-2
Weld Schedule....................................................................................................... 1-2
Remote Weld Schedule Selection........................................................................... 1-2
Run State............................................................................................................... 1-3
Program State........................................................................................................ 1-3
Section II. Major Components.......................................................................................... 1-4
Front Panel Description................................................................................................ 1-4
Front Panel Keys and Switch................................................................................. 1-4
Indicators and Displays .......................................................................................... 1-5
Rear Panel................................................................................................................... 1-7
CHAPTER 2: GETTING STARTED.................................................................................. 2-1
Section I. Planning for Installation...................................................................................... 2-1
Location...................................................................................................................... 2-1
Power Line .................................................................................................................. 2-1
Welding Cables............................................................................................................ 2-3
Output Cable ......................................................................................................... 2-3
Initiation Switch Connection................................................................................... 2-3
Firing Switch.......................................................................................................... 2-3
Optical Firing Switch.............................................................................................. 2-3
Installing Air Actuated Weld Heads........................................................................ 2-4
Air Valve Driver..................................................................................................... 2-5
Footswitch................................................................................................................... 2-6
1-Level Footswitch................................................................................................ 2-6
2-Level Footswitch................................................................................................ 2-6
Footswitch Weld Abort.......................................................................................... 2-6
Replace Cover....................................................................................................... 2-8
External Inputs Connections ................................................................................... 2-8

PHASEMASTER™ 6 DIRECT ENERGY WELDING CONTROL
vi 990-083

PHASEMASTER™ 6 DIRECT ENERGY WELDING CONTROL
990-083 vii
CHAPTER 3: OPERATING INSTRUCTIONS................................................................. 3-1
Section I. Operation.......................................................................................................... 3-1
Power Up.............................................................................................................. 3-1
Select Run or Program State .................................................................................. 3-1
Select Schedule...................................................................................................... 3-1
Change Schedule Parameters ................................................................................. 3-1
Change Parameters for Schedules 1 through 7 ........................................................ 3-3
Copying Information in Schedule 0 to Another Schedule ......................................... 3-4
Alarms ........................................................................................................................ 3-4
SCR Alarm A1 ...................................................................................................... 3-4
Machine Alarm A2................................................................................................. 3-4
Machine Alarm A3................................................................................................. 3-5
Machine Alarm A4................................................................................................. 3-5
Machine Alarm A5................................................................................................. 3-5
Section II. Programmable Options..................................................................................... 3-5
Status Display.............................................................................................................. 3-5
Schedule Protection Feature......................................................................................... 3-6
Line Voltage Compensation Feature............................................................................. 3-6
Line Voltage Compensation Feature On................................................................. 3-7
Line Voltage Compensation Feature Off................................................................. 3-7
Alarm Display.............................................................................................................. 3-7
Change Schedule Protection......................................................................................... 3-8
Schedule Protection Feature On............................................................................. 3-8
Schedule Protection Feature Off............................................................................. 3-8
Section III. Adjusting Weld Heads .................................................................................... 3-9
Adjusting Air Actuated Weld Heads............................................................................. 3-9
Section IV. Developing Weld Schedules............................................................................ 3-11
Resistance Welding Parameters.................................................................................... 3-11
Weld Schedule Development........................................................................................ 3-11
Weld Head Parameters.......................................................................................... 3-12
Welding Transformer Parameters............................................................................ 3-13
PM6 Control Parameters ....................................................................................... 3-14
Making a Weld ............................................................................................................ 3-14
Evaluating the Weld...................................................................................................... 3-15
Weak Weld ........................................................................................................... 3-15
Electrode Sticking.................................................................................................. 3-15
Electrode Force and %CURRENT........................................................................ 3-16
Causes of Imperfect Welds .......................................................................................... 3-16
Polarity.................................................................................................................. 3-16
Output Voltage vs Weld Quality............................................................................. 3-17
Weld Strength Profiles.................................................................................................. 3-19
Destructive Testing....................................................................................................... 3-19

PHASEMASTER™ 6 DIRECT ENERGY WELDING CONTROL
viii 990-083
Evaluate Results........................................................................................................... 3-20
Electrode Maintenance................................................................................................. 3-20
CHAPTER 4: MAINTENANCE......................................................................................... 4-1
Modification and Calibration......................................................................................... 4-1
Cover Removal...................................................................................................... 4-1
Line Voltage Modification...................................................................................... 4-1
Calibration Check........................................................................................................ 4-2
Check Weld/No Weld Switch................................................................................ 4-3
Half Cycle Symmetry............................................................................................. 4-3
Line Count............................................................................................................. 4-3
Memory Initialization.............................................................................................. 4-4
Repair Service ............................................................................................................. 4-4
Telephone Service.................................................................................................. 4-4
Factory Service Repair........................................................................................... 4-4
APPENDIX A: TECHNICAL SPECIFICATIONS............................................................. A-1
Section I. Specifications .................................................................................................... A-1
Line Voltage ................................................................................................................ A-1
50/60 Hz Operation............................................................................................... A-1
Output Current vs Duty Cycle ................................................................................ A-1
Weld Schedules..................................................................................................... A-1
Schedule Protection Feature................................................................................... A-2
Sequence Welding Function................................................................................... A-2
Squeeze Period...................................................................................................... A-2
Weld Period .......................................................................................................... A-2
Weld Current......................................................................................................... A-3
Hold Period........................................................................................................... A-3
Automatic Line Voltage Compensation......................................................................... A-3
Polarity Selection......................................................................................................... A-4
Power Factor Correction............................................................................................. A-4
Head Type................................................................................................................... A-4
Valve Driver ................................................................................................................ A-4
Footswitch................................................................................................................... A-5
Initiation....................................................................................................................... A-5
Footswitch Weld Abort On.......................................................................................... A-5
Footswitch Weld Abort Off.......................................................................................... A-5
Footswitch Weld Abort On/Off.................................................................................... A-6
Alarms ........................................................................................................................ A-6
Alarm Buzzer............................................................................................................... A-6

PHASEMASTER™ 6 DIRECT ENERGY WELDING CONTROL
990-083 ix
Display........................................................................................................................A-7
Front Panel Switches.................................................................................................... A-7
Input/Output Cable Connectors and Fusing................................................................... A-7
Circuit Breakers and Fuses..................................................................................... A-7
Input and Output Cables ........................................................................................ A-8
Firing Switch Cable................................................................................................ A-8
Optical Firing Switch Connector............................................................................. A-8
Footswitch Connector............................................................................................ A-9
Valve Driver Connector ......................................................................................... A-9
External Inputs Connector...................................................................................... A-9
Emergency Stop..................................................................................................... A-10
Remote Weld Inhibit .............................................................................................. A-10
Remote Weld Schedule Selection (PM6)................................................................ A-10
Physical Characteristics................................................................................................ A-11
Section II. UNIPULSE Transformer Specifications and Features ....................................... A-13
Transformer Specifications ........................................................................................... A-13
Transformer Physical Characteristics............................................................................. A-14
Input Connector..................................................................................................... A-14
Forced Air Option................................................................................................. A-15
Maximum Repetition Rate ...................................................................................... A-15
Insulation............................................................................................................... A-15
Transformer Primary Tap Switch............................................................................ A-15
Duty Cycle............................................................................................................. A-15
ILLUSTRATIONS
Figure Title Page
1-1 Sequence Welding Function................................................................................... 1-2
1-2 Phasemaster 6 Front Panel..................................................................................... 1-4
1-3 Phasemaster 6 Rear Panel...................................................................................... 1-7
2-1 Terminal Connection Examples............................................................................... 2-2
2-2 Examples of Cable Routings ................................................................................... 2-2
2-3 Typical Set-up diagram for the PM6 showing both Manually Actuated and Air
Actuated Weld Head connections........................................................................... 2-4
2-4 Typical Solenoid Air Valve Assembly with a Single Regulator.................................. 2-5

PHASEMASTER™ 6 DIRECT ENERGY WELDING CONTROL
x990-083
2-5 Location of Footswitch Weld Abort Jumper on the Input/Output Board .................. 2-7
2-6 Typical Set-up diagram for the PM6 showing connections used in Automated
Systems ................................................................................................................. 2-8
2-7 Remote Heating Schedule Selection via a BCD Coded Digital Thumbwheel
Switch............................................................................................................. 2-9
3-1 Measuring Preset Firing Force of the Weld Head with a Force Gauge ..................... 3-10
3-2 A Graphic Presentation of the Effects of % CURRENT, Time and Pressure on
the Weld................................................................................................................ 3-12
3-3 Test Condition A.................................................................................................... 3-18
3-4 Test Condition B.................................................................................................... 3-18
3-5 Typical Weld Strength Profile ................................................................................. 3-19
4-1 Control Transformer Inside the PM6, Connected for 230V..................................... 4-2
A-1 PM6 Outline Drawing ............................................................................................ A-12
A-2 UNIPULSE Welding Transformers ........................................................................ A-14
Tables
Table Title Page
2-1 Remote Schedule Selection BCD Code.................................................................. 2-9
3-1 Recommended Electrode Materials ........................................................................ 3-13
3-2 Causes of Imperfect Welds .................................................................................... 3-16