Unitek HF2/230 User manual

USER'S MANUAL 990-057
Revision K, May 2004
Use with Firmware Release V1.19 or higher
MODEL HF2
2 kHz HIGH FREQUENCY
RESISTANCE WELDING POWER SUPPLY
MODEL NUMBER STOCK NUMBER
HF2/230 1-264-03
HF2/380 1-264-03-01
HF2/460 1-264-03-02
HF2/208 1-264-03-03
HF2S/230 1-265-03
HF2S/380 1-265-03-01
HF2S/460 1-265-03-02
HF2S/208 1-265-03-03
Units with the built-in Weld Sentry Option also require User's Manual No. 990-291
WARNING
Please be sure to read all personnel and equipment
safety precautions noted in this manual.

MODEL HF2 2kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY
ii 990-057
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
A ENRG-RLSE 3/95 Released original manual.
B None 9/95 Reorganize manual into chapters.
C None 1/96 Amend to Firmware V1.17 or higher.
D None 2/96 Update cover stock numbers
E None 4/97 Amend to Firmware V1.19 or higher.
F 17472 6/98 1. Remove existing calibration procedure and reference User Calibration
Procedure 994-001.
2. Miscellaneous corrections.
3. Remove SAVE error.
G 18951 8/01 1. Include EO# 17693 in manual.
2. Add latest version of Operator Guide.
H 19012 9/01 1. Include EO# 118951 in manual.
2. Add latest version of Operator Guide.
J 19146 1/02 1. Include EO# 19012.
2. Miscellaneous Corrections.
3. Add Appendix F, Quality Resistance Welding Solutions, and Appendix
G, Replacement of Programmed Integrated Circuits.
K 20016 5/04 Updated wire data.

MODEL HF2 2kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY
990-057 iii
FOREWORD
The purpose of this manual is to supply operating, maintenance and service personnel with the
information needed to properly and safely operate, maintain and service the Unitek Peco Model HF2 2
kHz High Frequency Resistance Welding Power Supply.
Should questions arise, or if you have suggestions for improving this manual, please contact:
Unitek Miyachi Corporation
1820 South Myrtle Avenue
P.O. Box 5033
Monrovia, CA 91017-7133
Telephone:[phone]
FAX:[phone]
E-mail: [email protected]
NOTICE
Unitek Miyachi Corporation may be released from all warranty obligations if repairs or modifications
are made by persons other than its own service personnel, or authorized representatives' personnel,
unless such repairs or modifications are specifically authorized in writing by the Unitek Miyachi
Corporation.
WARNING
Contact with voltages present in this power supply may cause serious or fatal injuries. Please read the
manual completely and note all cautions and warnings before attempting to install, operate or maintain
the power supply.

MODEL HF2 2kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY
iv 990-057
CONTENTS
Page
CHAPTER 1: DESCRIPTION............................................................................................................ 1-1
HF2 description........................................................................................................................................ 1-1
CHAPTER 2: GENERAL SET-UP..................................................................................................... 2-1
Required Connections.............................................................................................................................. 2-1
Physical Space Requirements ........................................................................................................... 2-1
HF2 Weld Control Dimensions ........................................................................................................ 2-1
HF2 Weld Transformer Dimensions ................................................................................................2-1
Power Line Voltage, Current, And Wire Size Requirements........................................................... 2-2
Insulation Requirements .................................................................................................................. 2-2
Power Line Fuse Requirements ........................................................................................................ 2-2
HF2 Weld Transformer Electrical Specifications............................................................................. 2-3
HF2 Welding System Maximum Secondary Loop Resistance......................................................... 2-4
HF2 Maximum Secondary Loop Resistance Measurement ............................................................. 2-4
HF2 Weld Control To HF2 Weld Transformer Connections ........................................................... 2-4
HF2 Weld Transformer To Weld Head Connections ....................................................................... 2-5
Weld Sentry Option .......................................................................................................................... 2-5
Help Screen Languages .................................................................................................................... 2-5
CHAPTER 3: WELDING SYSTEM SET-UP ................................................................................... 3-1
Welding System Set-Up Guide................................................................................................................ 3-1
General Programming Instructions.......................................................................................................... 3-1
Unitek Peco Force Fired, Foot Actuated Weld Head System.................................................................. 3-2
Weld Head Set-Up............................................................................................................................ 3-2
Firing Switch Cable Connection....................................................................................................... 3-2
Quick Start Programming Guide ..................................................................................................... 3-2
Unitek Peco Force Fired, Single Air Actuated Weld Head System ........................................................ 3-4
Weld Head Set-Up............................................................................................................................ 3-4
Firing Switch Cable Connection....................................................................................................... 3-4
Weld Head Valve Driver No. 1 Connection ............................................................................................ 3-4
Foot Switch Connection ................................................................................................................... 3-4
Single Air Regulator Adjustment (Model 80 Series) ....................................................................... 3-5
Dual Air Regulator Adjustments (Model 180 And Model 90 Series).............................................. 3-6
Quick Start Programming Guide ...................................................................................................... 3-6
Unitek Peco Force Fired, Dual Air Actuated Weld Head System........................................................... 3-8
General Information.......................................................................................................................... 3-8
HF2 Control, Jumper Modifications................................................................................................. 3-8
Weld Head Set-Up............................................................................................................................ 3-8
Firing Switch Cable Connection....................................................................................................... 3-9

MODEL HF2 2kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY
990-057 v
CONTENTS (Continued)
Page
CHAPTER 3: WELDING SYSTEM SET-UP (Continued)
Weld Head Valve Driver Connections .......................................................................................... 3-10
Foot Switch Connection ................................................................................................................. 3-10
Dual Air Regulator Adjustments .................................................................................................... 3-11
Quick Start Programming Guide .................................................................................................... 3-15
Non-Force Fired, Single Air or Cam Actuated Weld Head System............................................... 3-17
LC To HF2 Control Electrical Connections .................................................................................. 3-17
PLC Timing Diagram ..................................................................................................................... 3-18
Quick Start Programming Guide .................................................................................................... 3-18
Non-Force Fired, Multiple Air Actuated Weld Head System ........................................................ 3-20
CHAPTER 4: CONTROLS ................................................................................................................. 4-1
HF2 Weld Control - Front Panel ............................................................................................................ 4-1
HF2 Weld Control - Rear Panel Inputs and Outputs ............................................................................... 4-3
Power ................................................................................................................................................ 4-3
Fuses F1 and F2 ............................................................................................................................... 4-3
Sensing Port ..................................................................................................................................... 4-3
Sensing Port - Connector Pin Assignments .................................................................................... 4-4
Output .............................................................................................................................................. 4-4
Foot Switch Connector .................................................................................................................... 4-5
Single-Level Foot Switch ......................................................................................................... 4-5
Two-Level Foot Switch ............................................................................................................ 4-5
Firing Switch Operation .......................................................................................................................... 4-6
Mechanical Firing Switch Cable ..................................................................................................... 4-6
Optical Firing Switch Connector ..................................................................................................... 4-6
Mechanical Firing Switch - 3-Wire Connection .............................................................................. 4-6
Opto Coupler Firing Switch - 3-Wire Connection .......................................................................... 4-6
Control Signals Connector ............................................................................................................... 4-7
Control Signals - Pin Assignments .................................................................................................. 4-8
Control Signals - Remote Weld Schedule Selection Input .............................................................. 4-9
Control Signals - Emergency Stop Input ......................................................................................... 4-9
Control Signals - Process Inhibit Input .......................................................................................... 4-10
Control Signals - Output Relays .................................................................................................... 4-10
Relay K1 ........................................................................................................................................ 4-10
Relay K2 ........................................................................................................................................ 4-10
Accessory Port ............................................................................................................................... 4-10
Air Valve 1 and Air Valve 2 Driver Connectors .................................................................................. 4-11
Air Valve 1 Driver ......................................................................................................................... 4-11
Air Valve 2 Driver ......................................................................................................................... 4-11

MODEL HF2 2kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY
vi 990-057
CONTENTS (Continued)
Page
CHAPTER 5: PROGRAMMING MODES........................................................................................ 5-1
Help Screens .......................................................................................................................................... 5-1
Machine States ........................................................................................................................................ 5-1
Weld Graph Run State ............................................................................................................................. 5-1
Basic Weld Monitor Run State ................................................................................................................ 5-2
Alphanumeric Run State.......................................................................................................................... 5-2
No Weld State ......................................................................................................................................... 5-2
Standby State .......................................................................................................................................... 5-2
Alarm State ............................................................................................................................................. 5-3
Fire State ................................................................................................................................................. 5-3
Menu State .............................................................................................................................................. 5-3
Program State .......................................................................................................................................... 5-4
Weld Graph Program State ..................................................................................................................... 5-4
Alphanumeric Program State .................................................................................................................. 5-5
Output Relays .......................................................................................................................................... 5-6
Relay 1 - Dual Air Head Operation ........................................................................................................ 5-7
CHAPTER 6: ADVANCED WELDING FUNCTIONS ................................................................... 6-1
Weld Functions ....................................................................................................................................... 6-1
Basic Weld ............................................................................................................................................. 6-2
Weld / Repeat .......................................................................................................................................... 6-3
Quench/Temper ....................................................................................................................................... 6-4
Pre/Postheat ............................................................................................................................................ 6-5
Up/Down Slope ....................................................................................................................................... 6-7
Braze .................................................................................................................................................. 6-8
Rollspot .................................................................................................................................................. 6-9
Seam ................................................................................................................................................ 6-10
Dual Pulse ............................................................................................................................................. 6-11
Pulsation ................................................................................................................................................ 6-13
CHAPTER 7: SPECIAL FEATURES ............................................................................................... 7-1
System Options ....................................................................................................................................... 7-1
Weld Counter .......................................................................................................................................... 7-8
Copy a Schedule ..................................................................................................................................... 7-9
System Security ...................................................................................................................................... 7-9
System Help ......................................................................................................................................... 7-11
Weld Sentry .......................................................................................................................................... 7-11
Calibrate HF2 ........................................................................................................................................ 7-11
Reset to Defaults ................................................................................................................................... 7-11
Installation ............................................................................................................................................. 7-13
Transformer Model ............................................................................................................................... 7-13

MODEL HF2 2kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY
990-057 vii
CONTENTS (Continued)
Page
CHAPTER 8: WELD MONITORING .............................................................................................. 8-1
Basic Weld Monitor General Description................................................................................................ 8-1
Weld Current and Weld Voltage Measurements .................................................................................... 8-2
Data Output Capabilities ......................................................................................................................... 8-2
Weld Monitoring Suggestions ................................................................................................................. 8-2
Basic Weld Monitor Programming.......................................................................................................... 8-3
Energy Limit Monitor General Description............................................................................................. 8-4
Energy Limit Monitor Programming....................................................................................................... 8-5
CHAPTER 9: RS-485 DATACOM .................................................................................................... 9-1
Description ............................................................................................................................................. 9-1
RS485 Serial Port Connections ............................................................................................................... 9-2
Datacom Software Installation................................................................................................................. 9-2
F1:Setup .................................................................................................................................................. 9-4
F2:Collect Data ....................................................................................................................................... 9-5
F3:Erase Data .......................................................................................................................................... 9-5
F4:Exit` ................................................................................................................................................... 9-5
APPENDIX A: TECHNICAL SPECIFICATIONS ........................................................................ A-1
APPENDIX B: RECOMMENDED SPARE PARTS ........................................................................B-1
APPENDIX C: ALARM MESSAGES.................................................................................................C-1
APPENDIX D: HELP SCREEN LANGUAGES ............................................................................. D-1
APPENDIX E: THE BASICS OF RESISTANCE WELDING .........................................................E-1
APPENDIX F: QUALITY RESISTANCE WELDING SOLUTIONS:
DEFINING THE OPTIMUM PROCESS ................................................................................... F-1
APPENDIX G: REPLACEMENT OF PROGRAMMED INTEGRATED CIRCUITS .............. G-1
INDEX ............................................................................................................................................ Index-1

MODEL HF2 2 KHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY
990-057 1-1
CHAPTER 1
DESCRIPTION
The Unitek Peco High Frequency Inverter (HF2) is a 2 KHz, three-phase, state-of-the-art inverter
welding control for joining precision small parts at high speed with controllable rise times using 2 KHz
output pulses superimposed on pure DC welding energy. High speed (250 micro-second) digital
feedback automatically controls weld current, voltage, or power, providing more welding consistency
compared to traditional direct energy (AC) or stored energy (CD) technologies. Microprocessor
technology automatically compensates for changes in workpiece resistance, load inductance, weld
transformer saturation, and ñ 13% changes in line voltage. The HF2 uses IGBT power device
technology for precisely controlling the weld energy at both high and low energy levels.
Easy to use constant weld current, voltage or power feedback ensures repeatable welding and has proven
to extend electrode life in many applications by a factor of five or more. A selectable weld energy
limiting feature also contributes to repeatable welds and high nugget quality. The user can program the
HF2 using a graphical or numerical interface. The Weld Graph Program Mode (Figure 1-1) emulates
many of the popular word processing programs by using the front panel cursor keys to easily modify any
time period, current, voltage, or power value. The Weld Graph Run Mode (Figure 1-2) gives the user
instant visual feedback on the actual current, voltage or power used to make each weld.
Figure 1-1. Program Mode Figure 1-2. Actual Weld Current
The HF2's exclusive, context sensitive, User Help Screens quickly guide the user through even the most
complex program. Each weld schedule can use any one of 10 different Weld Functions, thus matching
the appropriate weld energy profile to the application.
Simple automated welding control is easily accomplished using the BCD Remote Schedule Select
feature. For more complex automation processes, a host computer can use the HF2 Bi-Directional
RS422/RS485 Communications Port to select HF2 Weld Schedules and receive average weld current
and weld voltage data for each weld. Refer to the separate RS-485 Datacom Manual, P/N: 990-058, for
Advanced RS-485 Datacom operation. The 2 KHz operating frequency ensures that the HF2 Weld
Transformers are light weight and compact, providing a significant advantage when they are built into
robotics or automatic machines.

MODEL HF2 2 kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY
990-057 2-1
CHAPTER 2
GENERAL SET-UP
REQUIRED CONNECTIONS
Physical Space Requirements
Unitek Peco recommends that the HF2 Weld Control and HF2 Weld Transformer be installed in a well
ventilated area that is free from excessive dust, acids, corrosive gases, salt and moisture. Allow
sufficient clearance around both sides and back of the HF2 Weld Control and HF2 Weld Transformer so
that cooling air may flow properly. Figure 2-1 shows the cooling airflow pattern for the HF2 Weld
Control. Figure 2-2 shows the cooling airflow pattern for the HF2 Weld Transformer.
Figure 2-1. HF2 Weld Control
Air Flow Pattern
Figure 2-2. HF2 Weld Transformer
Air Flow Pattern
HF2 Weld Control Dimensions
Width (in/cm) Height (in/cm) Depth (in/cm) Weight (lbs/Kg)
10.5 / 26.7 8.5 / 21.5 15.0 / 38.1 42 / 19
HF2 Weld Transformer Dimensions
Model Height (in/cm) Width (in/cm) Depth (in/cm) Weight (lbs/Kg)
X2/2000A 7.0 / 17.6 5.4 / 13.8 11.0 / 28.0 14.3 / 6.5
X3/4000A 7.2 / 18.3 7.2 / 18.3 13.4 / 34.0 28.6 / 13
X5/3000A 7.5 / 18.9 7.2 / 18.3 14.2 / 36.0 31 / 14
X11/4000A 7.5 / 18.9 7.2 / 18.3 17.9 / 45.5 46 / 21
X11/4/460A 7.4 / 18.8 7.2 / 18.3 18.9 / 48.5 55 / 25
X3/4/380A 7.2 / 18.3 7.2 / 18.3 13.4 / 34.0 28.6 / 13
X3/4/460A 7.2 / 18.3 7.2 / 18.3 13.4 / 34.0 28.6 / 13

CHAPTER 2: GENERAL SETUP
MODEL HF2 2 kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY
2-2 990-057
Power Line Voltage, Current, and Wire Size Requirements
WARNING: The HF2 Weld Control and HF2 Weld Transformer are assembled at the factory for
operation at a specific input power line voltage. Serious damage can result if these units are used on
different voltage other than the voltage for which they are wired. The HF2 weld transformer input
voltage must match the HF2 weld control power line voltage.
Use the following table to select the correct power line circuit breaker and wire gauge size. To
minimize peak power losses, use single unbroken wire lines. Note: To minimize peak power losses,
Unitek Peco recommended wire gauge sizes exceed the USA National Electrical Code
recommendations.
3-Phase Service
Voltage (RMS)
3-Phase Service Breaker
Current (RMS)
Copper Wire Gauge Size
(AWG)
208V to 230V 50A AWG 8 @ 133 strands
380V to 460V 30A AWG 10 @ 105 strands
Insulation Requirement
Oil-resistant synthetic rubber rated at 90°C and 600V.
Power Line Fuse Requirements
Service Voltage Fuse Size: F1, F2 Unitek Peco P/N
208, 230, 380 3AG, 440 V, 2 A 330-071
460 3AG, 500 V, 2 A 330-100

CHAPTER 2: GENERAL SETUP
MODEL HF2 2 kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY
990-057 2-3
HF2 Weld Transformer Electrical Specifications
Model Input Volts
(Rms) Input kva (Rms) Duty Cycle ( %) Peak Open Ckt Output Voltage Peak Output Max. (Amps) Max Sec
Resist. (μΩ)
X3/4/380A 380 9 6 6.5 4,000 500
X3/4/460A 460 9 6 6.5 4,000 500
X3/4000A 230 9 6 6.5 4,000 500
X9/6000A 230 19 6 9.3 (32:1 TR) 4,900 500
X11/4/460A 380 4 5 11.8 (44:1 TR)
10.0 (52:1 TR)
8.6 (60:1 TR)
7.5 (68:1 TR)
4,000
4,000
4,000
4,000
1,300
1,100
950
825
460 4 5 14.3 (44:1 TR)
12.1 (52:1 TR)
10.5 (60:1 TR)
9.2 (68:1 TR)
4,000
4,000
4,000
4,000
1,300
1,100
950
825
X11/4000A 230 15 5 10.7
10.0 (52:1 TR)
8.6 (60:1 TR)
8.7
8.8
8.9
4,000
4,000
4,000
1,300
1,100
TRANSFORMER SPECIFICATION NOTES:
1For the Model X11/4/460A, turns ratios
(TR) are selectable by a switch on the
transformer rear panel.
2HF2 Weld Control Input voltage selection
must be jumpered at E12 on the HF2 Weld
PCB as shown in Figure 2-3. E12 is
located at the center of the PCB left edge.
3Maximum weld time at Maximum Short
Circuit Current is 50 milliseconds.
Figure 2-3. Voltage Jumpers

CHAPTER 2: GENERAL SETUP
MODEL HF2 2 kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY
2-4 990-057
HF2 Welding System Maximum Secondary Loop Resistance
To use the HF2 Weld Control and HF2 Weld Transformer system to its maximum capability, the
Maximum Secondary Loop Resistance must not exceed the values listed in the preceding table.
Exceeding these maximums will produce a "FEEDBACK RANGE EXCEEDED" alarm.
HF2 Maximum Secondary Loop Resistance Measurement (Figure 2-4)
1Connect a four terminal micro-ohmmeter
as shown in Figure 2-4.
2Put the parts to be welded between the
electrodes.
3Measure the total loop resistance which
includes both Weld Cables, Weld Head,
Electrodes, and parts.
4If the total loop resistance exceeds the
table value, use:
A) Larger diameter Weld Cables Figure 2-4. Secondary
Resistance Measurement
B) Shorter length Weld Cables, or
C) Copper Bus Bars to connect the HF2 Weld Transformer to the Weld Head. If these
suggestions do not work, then a different Weld Transformer Model may be required.
CAUTION: For product safety, the system power cable and all inter-unit cabling should be as short as
possible, and be dressed so that all cables stay separated.
HF2 Weld Control to HF2 Weld Transformer Connections (Figure 2-5)
The HF2 Weld Control must always be connected
to the HF2 Weld Transformer as shown in Figure 2-
5, regardless of what Weld Head System is used.
1Connect the HF2 Weld Control POWER
Cable to the line voltage source as
specified in Chapter 2, Power Line
Voltage, Current, and Wire Size
Requirements.
2Connect the HF2 Weld Control OUTPUT
Cable to the matching connector on the
HF2 Weld Transformer.
3Connect the HF2 Weld Control SENSING
PORT Cable to the matching connector on
the HF2 Weld Transformer.

CHAPTER 2: GENERAL SETUP
MODEL HF2 2 kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY
990-057 2-5
HF2 Weld Transformer to Weld Head Connections (Figure 2-6)
1Connect the Upper Weld Cable to the
Positive Terminal on the HF2 Weld
Transformer.
2Connect the Lower Weld Cable to the
Negative Terminal on the HF2 Weld
Transformer.
3Attach the Voltage Sensing Cable
connector to the HF2 Weld Transformer
INPUT connector.
4Attach each lead at the opposite end of
the Voltage Sensing Cable to each
Electrode Holder. Note: Polarity is not
important.
Figure 2-6. HF2 Weld Transformer to
Weld Head Connections
5Strain relief each Voltage Sensing lead to its corresponding Electrode Holder so that the lead
will not break or move under heavy production operating conditions.
6Do not attach the Firing Switch Cable at this time. This procedure is covered in Chapter 3.
Weld Sentry Option
A small tag displaying the message WELD SENTRY INSTALLED will be attached to the front panel of
the HF2 Weld Control if the optional Weld Sentry Module has been installed. Refer to the separate
Weld Sentry User's Manual, 990-291 for Weld Sentry operation.
The Built-in Weld Sentry Module can be added to the HF2 Weld Control after purchase by ordering the
HF2 Weld Sentry Module, P/N 3-130-01-01.
Help Screen Languages
Integrated circuit chip U2 on the Main printed circuit board varies in memory capacity according to the
help screen languages available. Refer to Appendix D for special jumpering instructions relative to the
installation of IC chip U2.

MODEL HF2 2 kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY
990-057 3-1
CHAPTER 3
WELDING SYSTEM SET-UP
Welding System Set-Up Guide
To complete the welding system installation, select the welding system that best matches your Weld
Head configuration using the Welding System Set-Up Guide listed below:
Welding System Set-Up Guide Page
Unitek Equipment Force Fired, Foot Actuated Weld Head 3-2
Unitek Equipment Force Fired, Single Air Actuated Weld Head 3-4
Unitek Equipment Force Fired, Dual Air Actuated Weld Head 3-9
Non-Force Fired, Single Air or Cam Actuated Weld Head 3-17
Non-Force Fired, Multiple Air Actuated Weld Heads Not Released
General Programming Instructions
The following nomenclature and symbols will be used for programming the HF2 Weld Control:
1Press and release HF2 Weld Control front panel keys that are enclosed by [ ] symbols.
2Use the vertical cursor keys [ ] in conjunction with the horizontal cursor keys [ ] to
select or highlight a requested Menu Option, followed by the [ENTER] key.
3Words shown in UPPER CASE ITALIC letters indicate flashing Menu Options on the HF2
Weld Control LCD Display.

CHAPTER 3: WELDING SYSTEM SET-UP
MODEL HF2 2 kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY
3-2 990-057
UNITEK EQUIPMENT FORCE FIRED,
FOOT ACTUATED WELD HEAD SYSTEM
Weld Head Set-up
1Adjust the Weld Head Force Adjust
Knob to produce 5 units of force as
displayed on the Force Indicator. For a
complete description of force control
and its effect on the welding process,
please refer to your Weld Head manual.
2Install electrodes in Weld Head
Electrode Holders.
Firing Switch Cable Connection
Connect the Weld Head Firing Switch Cable
Connector to the matching cable connector
on the rear of the HF2 Weld Control. Figure 3-1. Firing Switch Cable Connection
Quick Start Programming Guide
1Set the HF2 Weld Control front panel
WELD/NO WELD switch to NO
WELD.
2Turn the circuit breaker switch located
on the HF2 Weld Control rear panel to
ON. After a series of power up screens,
the last RUN screen displayed will
appear. Press the [CHNG] key to access
the Weld Graph RUN screen for the
BASIC WELD Function.
3Press [MENU]. The MAIN MENU
screen will appear.

CHAPTER 3: WELDING SYSTEM SET-UP
MODEL HF2 2 kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY
990-057 3-3
4Select  TRANSFORMER MODEL.
The TRANSFORMER MODEL screen
appears.
5Select MULTIPLE HEADS: OFF. If
the display reads ON, then press
[CHNG] until OFF is displayed.
6Select HEAD 1 : X3/4000-230.
X3/4000-230 is the default Transformer
Model number. Press [CHNG] until
the correct Transformer Model that you
have purchased appears.
7Press [RUN] to return to the Graphical RUN screen.
8Set the HF2 Weld Control front panel WELD/NO WELD switch to WELD.
9Make a test weld by pressing on the Weld Head foot actuator until the HF2 Weld Control fires.
The default WELD time of 1 ms and the default CURRENT of 0.5 kA may not be sufficient to
make a good weld.
10 Press [PROG]. Use the vertical cursor
keys [VW] to increase the weld
CURRENT. Use the horizontal cursor
keys [ ] to increase or decrease the
WELD time. In this example, weld
CURRENT has been increased to 0.7
kA and WELD time has been increased
to 5ms.
11 Press [SAVE] to save your program. You are now back in the Weld Graph RUN State.
12 Make additional test welds and then reprogram WELD time and weld CURRENT as necessary
to make a good weld. Try to use the minimum time and current necessary to make a good weld
so that the weld joint heat affected zone will be minimized.
13 Up to 128 different weld schedules can be created and saved. To recall any specific weld
schedule, press the up or down vertical arrow keys [VW] until the desired schedule number
appears on the display screen. A faster technique for recalling a specific schedule is to input
the Schedule number using the number keys.

CHAPTER 3: WELDING SYSTEM SET-UP
MODEL HF2 2 kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY
3-4 990-057
UNITEK EQUIPMENT FORCE FIRED,
SINGLE AIR ACTUATED WELD HEAD SYSTEM
Weld Head Set-up (Figure 3-2)
1Adjust the Weld Head Force Adjust
Knob to produce 5 units of force as
displayed on the Force Indicator. For a
complete description of force control
and its effect on the welding process,
please refer to your Weld Head manual.
2Install electrodes in Weld Head
Electrode Holders.
3Connect a properly filtered air line to
the Inlet Air Line on the Weld Head Air
Valve Driver Solenoid assembly which
is located on the back of the Weld
Head. Use 0.25 inch O.D. by 0.17 inch
I.D. plastic hose with a rated burst
pressure of 250 psi. A lubricator should
only be used with automated
Figure 3-2. Single Air Actuated
Weld Head Connections
installations. Turn on the air system and check for leaks.
Firing Switch Cable Connection (Figure 3-2)
Connect the Weld Head Firing Switch Cable Connector to the matching cable connector on the rear of
the HF2 Weld Control.
Weld Head Valve Driver No. 1 Connection (Figure 3-2)
A single air actuated Weld Head has one Solenoid Valve Driver Cable for automatic actuation and
timing control by the HF2 Weld Control. The HF2 Weld Control will automatically recognize the
solenoid voltage of the Weld Head. Connect the 4 pin black plastic connector on the cable to the
matching Air Valve 1 Driver connector located on the HF2 Weld Control rear panel.
Foot Switch Connection (Figure 3-2)
1Connect a Model FS1L, 1-Level, or a Model FS2L, 2-Level Foot Switch to the FOOT
SWITCH connector located on the HF2 rear panel. The HF2 will automatically recognize
which model of Unitek Equipment Foot Switch has been connected.
21-Level Foot Switch - The l-Level Foot Switch must be fully depressed by the operator. When
the Foot Switch closes, the HF2 energizes the Air Actuated Weld Head, causing the Upper
Electrode to descend and apply force to the parts. If the Foot Switch is released before the
Weld Head applies the Preset Firing Force, the HF2 will automatically return the Upper
Electrode to its up position.