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

PHASEMASTER™ 6 DIRECT ENERGY WELDING CONTROL
990-083 1-1
CHAPTER 1
DESCRIPTION
Section I: Features
Features
The Phasemaster™ 6 (PM6) is a single-phase, absolute-count, NEMA type BS2HX, bench mounted,
sequence welding control that has the flexibility to effectively solve most resistance welding problems. The
circuitry used in the PM6 is microprocessor based, convection cooled, with conservatively rated
components. The design ensures safe, repeatable operation in adverse environments. Special precautions
protect against false triggering in high RFI and EMI environments. The PM6 includes power input and
output cables and connectors for easy installation with a Unitek Peco Welding Transformer. It is a multi-
voltage unit designed for operation at 100, 115, 208, or 230 VAC, 50/60 Hz. These models are supplied
with a line cord, suitable connector, and a 30 amp combined circuit breaker/power switch. The PM6/460 is
designed for operation at 220, 380, 415, 440, or 460 VAC. The PM6/460 requires a user supplied circuit
breaker, disconnect and input wiring.
•Cost Effective, Microprocessor Controlled with user friendly programming
•Has the ability to half-cycle weld, a feature critical to the welding of small parts
•Line Voltage Compensation Feature automatically compensates for line voltage
changes of up to ±13% which eliminates the major electrical cause of inconsistent
weld quality
•Stores up to 8 Different Weld Schedules which facilitates multiple applications at a single work
station
•Remote Schedule Selection for ease of automation
•Air Head Capability is a standard feature which allows control of air actuated welding heads
•Digital Display allows operators to set welding current accurately and quickly
•Schedule Protection Feature protects Weld Schedules from changes by unauthorized personnel
•Protected from Radio Frequency Interference and Electro-Magnetic Interference to ensure reliable
operation even in high electrical noise environments
•Multiple Line Voltages -can operate at 100, 115, 208, 230, VAC, 50/60 Hz. or at 460, 440, 415,
380, 220 VAC, 50/60 Hz.

CHAPTER 1: DESCRIPTION
PHASEMASTER™ 6 DIRECT ENERGY WELDING CONTROL
1-2990-083
Process Definitions
Sequence Welding Function
Sequence Welding Function is a term used by the industry to describe this basic welding function.
Sequence Welding, illustrated in figure 1-1, provides the solution for the majority of resistance welding
applications. This function is designed for air actuated weld heads but can also be used with manually
actuated heads. The Squeeze Period allows sufficient time for non-force fired weld heads to close and
apply the required force to the parts before the Weld Period begins. The first level of a two level
initiation switch is used to start the Squeeze Period. The Weld Period cannot start until the Squeeze
Period ends, and the second level of the initiation switch and the force firing switch close. Squeeze has
no meaning with manually operated weld heads.
Weld Schedule
Weld Schedule is all the information required to properly execute a weld function. For purposes of
programming the PM6, a WELD SCHEDULE is: Schedule Number, Polarity, Squeeze Cycles, Weld
Cycles, Hold Cycles and %Current.
Remote Weld Schedule Selection
Automated welding systems can use the Remote Weld Schedule Selection Feature to recall any weld
schedule from the PM6's memory.
Figure 1-1. Sequence Welding Function
WELD
CURRENT
20-99%
WELD
FORCE
RUN SQUEEZE
0-99
cycles
WELD
.5, 0-99
cycles
RUNHOLD
0-99
cycles
START
Air
Only

CHAPTER 1: DESCRIPTION
PHASEMASTER™ 6 DIRECT ENERGY WELDING CONTROL
990-083 1-3
Run State
In this State, the PM6 is ready to make a weld. If it is not executing a weld schedule, it is waiting for
either:
aThe Footswitch to close (Air Actuated Weld Head); or
b The Force Firing Switch to close (Manually Actuated Weld Head).
The user can select, but not change, any weld schedule by using the ?or ?Keys on the Front Panel.
Program State
In this State, the PM6 will allow the user to change and save (write to permanent memory) any weld
schedule.

CHAPTER 1: DESCRIPTION
PHASEMASTER™ 6 DIRECT ENERGY WELDING CONTROL
1-4990-083
Section II: Major Components
Front Panel Description
Front Panel Keys and Switch
The eight keys and one switch on the Front Panel, shown in figure 1-2, are identified as follows:
KEY/
SWITCH DESCRIPTION
WELD/ Welding current will not flow when this switch is in the NO WELD position, however
NO WELD the control will actuate the weld head and execute the welding sequence (Squeeze, Weld
and Hold). This switch must be in the WELD position in order to make a weld.
NOTE: Instructions to "Select [WELD] or [NO WELD]" mean that you are to
place this switch in either the WELD or the NO WELD position, whichever is
indicated inside the brackets.
? ?In RUN State, changes ([?] increases and [?] decreases) the SCHEDULE NUMBER
which is displayed.
In PROGRAM State, changes ([?] increases and [?] decreases) the value of whichever
parameter is flashing.
Figure 1-2. Phasemaster 6 Front Panel
AIR
MANUAL
NO WELD
WELD
2 LEVEL
1 LEVEL
MACHINE
SCR
OFF
ON
RUN SAVEPROGRAM
SCHEDULE
NUMBER POLARITY SQUEEZE CYCLES WELD CYCLES HOLD CYCLES % CURRENT
HEAD
TYPE
FOOTSWITCH
FOOTSWITCH
WELDABORT
ALARM
PHASEMASTERTM 6
AC WELDING CONTROL

CHAPTER 1: DESCRIPTION
PHASEMASTER™ 6 DIRECT ENERGY WELDING CONTROL
990-083 1-5
PROGRAMCauses the PM6 to enter the PROGRAM State so that the user can make changes to
Schedules 0 through 7.
? ?In PROGRAM State, used to select the parameter to the right (?) or left (?) of the
parameter which is flashing.
RUN Causes the PM6 to exit the PROGRAM State without saving the changed schedule. The
changed schedule will become Schedule 0 and will NOT be written to permanent
memory. If no changes are made to the schedule, then it will not be transferred to
Schedule 0. Welding is done in the RUN State.
SAVE In the PROGRAM State, saves (writes) any schedule to permanent memory. The PM6
will then exit the PROGRAM State and return to RUN State. This key has no function
in the RUN State.
NOTE: Instructions to "press [ ]", mean that you are to press the key described
inside the brackets. For example: "Press [PROGRAM]" means press the key
labeled PROGRAM. Press [?/?] or [?/?] means press either the ?or the ?(?
or ?) key, whichever is appropriate.
Indicators and Displays
SCHEDULE NUMBER DISPLAY -Indicates the currently selected Schedule Number. Press [?/?] in
either the RUN or PROGRAM State to select Schedules 0 through 7. When the power is switched to
ON, the PM6 will go to the RUN State and display the last Schedule saved in memory.
FORCE FIRING SWITCH INDICATOR -The red decimal point, next to the SCHEDULE NUMBER,
will light when the Force Firing Switch in the weld head closes. This feature is a useful convenience
when setting the electrode firing force.
POLARITY DISPLAY -Indicates the Polarity of the Welding Current. Press [?/?] in the PROGRAM
State to select: Positive indicated by [+]; Negative (reverse) indicated by [)]; Alternate indicated by [±].
SQUEEZE CYCLES -Indicates the time, in number of cycles of the AC power source, which must
elapse before the welding current starts to flow. SQUEEZE CYCLES is used for Air Operated Weld
Heads only. This display will be blank if a Manual Weld Head is connected. The Squeeze period
allows sufficient time for non-force fired air heads to close and apply the required force to the
workpiece. SQUEEZE time can be set from 0 to 99 cycles in 1 cycle increments. Since all Unitek Peco
Weld Heads are "force fired", Squeeze time is usually set to 0.
WELD CYCLES -Indicates the time, in number of cycles of the AC power source, during which
welding current will flow. WELD time can be set to either 0.5 (one-half cycle) or from 1 to 999 cycles
in 1 cycle increments. Set the Weld Period to the shortest time which produces a consistently acceptable
weld.
HOLD CYCLES -Indicates the time, in number of cycles of the AC power source, after the end of the
Weld Period for which an air actuated weld head will continue to apply force to the workpiece. HOLD
CYCLES is used for Air Operated Weld Heads only. This display will be blank if a Manual Weld Head
is connected. The HOLD Period provides time for either brazing alloy or the weld nugget, in the case of
welds which take more than 10 cycles, to solidify. HOLD Time can be set from 0 to 99 cycles in 1 cycle
increments. HOLD Time has no meaning when used with a Manual Head.

CHAPTER 1: DESCRIPTION
PHASEMASTER™ 6 DIRECT ENERGY WELDING CONTROL
1-6990-083
%CURRENT -Indicates the percentage of the maximum current which will flow during each half-cycle
of the Weld Period. %CURRENT can be set from 20 to 99% in 1% steps. Welding quality will
improve if %CURRENT is set between 65% and 85%.
HEAD TYPE -Indicates whether an Air or Manual Head is connected to the PM6. This determination
is made when power is first applied to the PM6, therefore any change in status after the Circuit Breaker
is switched to ON will not be recognized.
FOOT SWITCH -Indicates whether a 1 or 2-Level Footswitch is connected to the PM6. Footswitches
are used with Air Actuated Weld Heads. If an Air Head is connected but no Footswitch has been
connected, the 2-Level Indicator will light by default. The determination is made when power is first
applied to the PM6, therefore any change in status after the Circuit Breaker is switched to ON will not
be recognized.
FOOT SWITCH WELD ABORT -Indicates the status of this feature. When the Footswitch Weld
Abort indicator is "ON", the operator can abort the welding sequence at any time by releasing the
Footswitch. This Feature is considered by many to be a safety requirement in non-tooled systems.
Footswitch Weld Abort is turned "OFF" by connecting a jumper on the PM6's Input/Output Board.
With a Manual Head this feature is always ON regardless of the position of the jumper.
ALARM -Indicates that either an SCR or MACHINE ALARM condition is present. A 5 second Alarm
Buzzer will sound when an ALARM Indicator lights.
SCR ALARM -Indicates that the PM6's output SCR's are defective. The output SCR's control
the flow of current to the welding transformer. "SEE A1" will appear in the display.
MACHINE ALARM -Indicates an alarm condition referenced by an Alarm Code in the Display
Fields. "SEE" appears in the WELD CYCLE Field, the Alarm Code appears in the HOLD
CYCLE Field. Alarm Codes are as follows: Machine Alarms will be erased from the display as
soon as the alarm condition is corrected or whenever [PROGRAM] is pressed. (Later model
PM6's also accept [RUN] to clear an error.)
A2 -Emergency Stop signal was received from the user's equipment.
A3 -The Footswitch remained closed at the end of the weld sequence preventing the PM6
from entering the RUN State.
A4 -The Force Firing Switch in the Weld Head did not close within 10 seconds after the
Footswitch closed.
A5 -SAVE was pressed but the Schedule was not properly stored in Memory.

CHAPTER 1: DESCRIPTION
PHASEMASTER™ 6 DIRECT ENERGY WELDING CONTROL
990-083 1-7
Rear Panel
The Rear Panel components, shown in figure 1-3, are identified as follows:
CIRCUIT BREAKER -is used as a circuit breaker and power switch.
FUSE -is used to protect the internal Control Boards and the Valve Driver Circuit. See Appendix A for
fuse ratings.
POWER CABLE -5 foot cable is terminated with the appropriate 230 or 115 volt plug.
OUTPUT CABLE -5 foot cable is used to connect the PM6 to Unitek Peco Welding Transformers.
FIRING SWITCH CABLE -5 foot cable is used to connect the PM6 to the Force Firing Switch in all
Unitek Peco Weld Heads and Handpieces.
OPTICAL FIRING SWITCH RECEPTACLE -Used to connect the PM6 to Weld Heads with either a 3-
wire Firing Switch or an optical switch assembly.
EXTERNAL INPUTS -9-pin, sub-miniature "D" connector used for Remote Schedule Selection,
Emergency Stop and Weld Inhibit.
FOOTSWITCH RECEPTACLE -Used to connect either a 1-Level or 2-Level Unitek Peco Footswitch.
Footswitches are only used with air or electrically actuated weld heads.
AIR VALVE DRIVER -Provides either 24 or 115 volts (AC) to Unitek Peco Air Actuated Weld Heads.
Model VDAC24P (10-304-01) adapter is used to connect standard 115V plugs.
Figure 1-3. Phasemaster 6 Rear Panel
FUSE
EXTERNAL
INPUTS
FIRING
SWITCH
OPTICAL
FIRING
SWITCH
VALVE
DRIVER
FOOT
SWITCH CB1
F1
OUTPUT POWER

PHASEMASTER™ 6 DIRECT ENERGY WELDING CONTROL
990-083 2-1
CHAPTER 2
GETTING STARTED
Section I. Planning for Installation
Location
Install the power supply in a well-ventilated area that is free from dirt and moisture. Allow sufficient
clearance around the sides and rear of the unit so that cooling air may flow properly. Position the PM6 as
close as practical to the weld head.
Power Line
CAUTION: Do not connect the line cord at this time.
This control was wired for the specific input line voltage marked on the line cord at the factory. The
standard PM6 unit is wired for 230 VAC. Reconnection for operation at another voltage may be made by a
qualified technician. Refer to Chapter 4 under Modifications and Calibration.
Welding Cables
Position the PM6 on the workbench approximately 5 inches behind the weld head. Use the cables furnished
with the weld head to connect the terminals on the back of the weld head to the appropriate terminals on the
front of the output transformer. Refer to Appendix A, Transformer Specifications.
For proper cable connections and to reduce energy losses follow these recommendations:
aUse the #6AWG Welding Cables, or #2AWG if the cables are more than 12
inches long. The diameter of the cables should be as large as practical.
b Use the shortest possible Welding Cables. It is not uncommon to have losses up to
50% per foot for #6AWG cable and 20% for #2AWG cable.
cBolt terminals together, DO NOT place washers between the terminals of the
transformer and the terminals of the cables. Tighten connections securely, they must
be free from oxidation, dirt and/or grease. See figure 2-1.
d Route cables so that they do not surround magnetic materials such as air solenoids,
tooling, or steel weld heads. The cable routing and weld head design should be such

CHAPTER 2: GETTING STARTED
PHASEMASTER™ 6 DIRECT ENERGY WELDING CONTROL
2-2990-083
that the secondary loop does not encompass magnetic materials (steel) and/or is not
encompassed by any magnetic material. See figure 2-2.
eTape cables together to minimize the inductive losses. A separation of weld cables
surrounding an area of one square foot could result in losses of up to 65% (figure 2-1).
Lower Electrode
Holder
Upper Welding Cable
Screw, Flat
Washer, Nut
(2 Places)
Lower Welding Cable
Note: Attach both welding cables on the same side of the weld head.
Install flat washer under
screw head, not welding
cable terminal
Cap Head Screw and
Flat Washer
Figure 2-1. Terminal Connection Examples
Weld Head
Air
DON'T
Steel
Weld
Head
Solenoid
(Steel)
Cables Taped Together
DO
Weld Head
Steel
Cables
DON'T
Non-
Magnetic
Material
Solenoid
(Steel)
DO
Figure 2-2. Examples of Cable Routings