Unitek Unibond ii Manual

Manual No. 990-050

Revision A: February 2001

OPERATION, MAINTENANCE AND

SERVICE MANUAL

FOR THE

UNIBOND®II

CONSTANT POWER/CONSTANT VOLTAGE

POWER SUPPLY AND METER ACCESSORY

Model UB2 Stock No. 1-191-02

Model UB2/100 Stock No. 1-191-02-01

Model UB2/230 Stock No. 1-191-02-04

Model UBM Stock No. 10-266-01

Unitek Miyachi Corporation

UNIBOND®II POWER SUPPLY

ii 990-050

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 17848 6/99 Re-format and correct publication.

UNIBOND®II POWER SUPPLY

990-050 iii

FOREWORD

Thank you for purchasing a Unitek Equipment®power supply.

Upon receipt of your system, please thoroughly inspect it for shipping damage prior to

installation. Should there be any damage, immediately contact the shipping company to file

a claim, and notify us at:

Unitek Equipment

1820 South Myrtle Avenue

P.O. Box 5033

Monrovia, CA 91017-7133

Phone: (626) 303-5676

FAX: (626) 358-8048

e-mail: [email protected]

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 Unitek

Equipment's Unibond II Power Supply and Meter Accessory.

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

Unitek Equipment is not responsible for any losses due to improper use of this product.

UNIBOND®II POWER SUPPLY

iv 990-050

SAFETY NOTES

This instruction manual describes how to operate, maintain and service the

Unibond II Power Supply, and provides instructions relating to it's SAFE use.

Procedures described in this manual MUST be performed as detailed by

QUALIFIED and TRAINED personnel.

For SAFETY, and to effectively take advantage of the full capabilities of the

power supply, please read this instruction manual thoroughly before

attempting to use the power supply.

Procedures other than those described in this manual or not performed as

prescribed in this manual, may expose personnel to electrical hazards.

After reading this manual, retain it for future reference when any questions

arise regarding the proper and SAFE operation of the power supply.

WARNING:

High Voltage: Lethal electrical voltage exist inside the power supply. Take

appropriate precautions when making calibration adjustments with the cover

removed.

Protective Goggles: When performing any welding operations, always wear

protective goggles.

Design Integrity: Do not modify the power supply without prior written

approval from Unitek Equipment.

Maintenance. Before performing any user maintenance or servicing the

power supply, please read Chapters 4 and 5, respectively.

Use appropriate tools, such as strippers and pressure connection tools, for

terminating and connecting cables, being careful not to nick wire conductors.

UNIBOND®II POWER SUPPLY

990-050 v

Contents

Revision Record................................................................................................................................. ii

Foreword............................................................................................................................................ iii

Safety Notes....................................................................................................................................... iv

Chapter 1: System Description...................................................................................................... 1-1

Section I: System Features ...................................................................................................... 1-1

Description............................................................................................................................. 1-1

Features............................................................................................................................ 1-1

Physical Description ........................................................................................................ 1-1

Optional Meter Assembly................................................................................................ 1-2

Section II: Specifications and Functional Description ............................................................. 1-3

Feedback Modes .................................................................................................................... 1-3

Output .................................................................................................................................... 1-3

Rise Time ............................................................................................................................... 1-3

Maximum Output Current...................................................................................................... 1-3

Maximum Secondary Loop Resistance ................................................................................. 1-3

Repetition Rate ...................................................................................................................... 1-4

Line/Load Regulation ............................................................................................................ 1-4

Accuracy ................................................................................................................................ 1-4

Voltage Feedback Mode ........................................................................................................ 1-4

Voltage + Current Feedback Mode........................................................................................ 1-4

How it Works................................................................................................................... 1-5

Weld Resistance Compensation............................................................................................. 1-7

Weld Fire Lockout Feature .................................................................................................... 1-7

Overload Protection Feature .................................................................................................. 1-7

Section III: Controls and Indicators........................................................................................... 1-8

Meter Accuracy...................................................................................................................... 1-10

Section IV: General Considerations........................................................................................... 1-11

Output Circuit ........................................................................................................................ 1-12

How the Feedback Loop Determines Output Impedance...................................................... 1-13

Chapter 2: Getting Started ............................................................................................................ 2-1

Unpacking.............................................................................................................................. 2-1

Connections and Set-up ......................................................................................................... 2-1

Connecting the Unibond II for Proper Line Voltage ....................................................... 2-1

Connect the Output Transformer ..................................................................................... 2-1

UNIBOND®II POWER SUPPLY

vi 990-050

Install Weld Head and Optics .......................................................................................... 2-1

Connect Remote Sensing Cable and Firing Cable........................................................... 2-1

Connect Power Cables ..................................................................................................... 2-2

Chapter 3: Operating Instructions................................................................................................ 3-1

Section I: Operating Precautions............................................................................................. 3-1

Section II: Preparing for Operation .......................................................................................... 3-1

Section III: Operating Functions................................................................................................ 3-1

Parallel Gap Welding............................................................................................................. 3-1

Variables for Parallel Gap Welding....................................................................................... 3-1

Gap................................................................................................................................... 3-1

Force ................................................................................................................................ 3-1

Area of Electrode Face .................................................................................................... 3-1

Pulse Duration.................................................................................................................. 3-1

Electrode Materials .......................................................................................................... 3-2

Finding the Correct Parameters ............................................................................................. 3-2

Printed Circuit Board Trace Repair – Considerations ........................................................... 3-8

Melting the Laminate....................................................................................................... 3-9

Printed Circuit Board Trace Repair ....................................................................................... 3-9

Chapter 4: User Maintenance........................................................................................................ 4-1

Section I: Maintenance Precautions ........................................................................................ 4-1

Section II: Maintenance Procedures ......................................................................................... 4-1

Electrode Maintenance .......................................................................................................... 4-1

Chapter 5: Service Procedures ...................................................................................................... 5-1

Section I: Service Precautions................................................................................................. 5-1

Section II: Calibration Procedures............................................................................................ 5-1

Calibration ............................................................................................................................. 5-1

Setup ................................................................................................................................ 5-1

Adjusting Pulse Width ..................................................................................................... 5-3

Improper Setting Indicator............................................................................................... 5-3

Check High Voltage Supply ............................................................................................ 5-3

Check Output Stage Bias ................................................................................................. 5-3

Check Output Pulse ......................................................................................................... 5-4

Check the Overload Indicator .......................................................................................... 5-4

Calibrating the Model UBM Meter Accessory................................................................ 5-4

Checking Resistance of the Weld Head........................................................................... 5-5

Section III: Troubleshooting ...................................................................................................... 5-6

Troubleshooting ..................................................................................................................... 5-6

UNIBOND®II POWER SUPPLY

990-050 vii

Section IV: How to Reach Us .................................................................................................... 5-6

Technical Assistance.............................................................................................................. 5-6

Appendix A: Technical Specifications .......................................................................................... A-1

Specifications......................................................................................................................... A-1

Index.................................................................................................................................................. Index-1