Unitrol SOLUTIONi User manual

DIRECTION
BOOK
POWE R FU LLY INTUITIVE

FUNCTION DESCRIPTION RANGE
Weld Programs
Each program is a complete RWMA Schedule including
Forge Delay, Pulsation, and Special Sequences for welding
galvanized steel and other coated metals.
800 Customer Set
100 RWMA Preset
Display Bright blue vacuum uorescent, full alpha/numeric. 80 Characters
Welds Counter Keeps track of welds made. 1-65,500
Parts Counter Keeps track of nished parts made. 1-65,500
Batch Counter Stops welder when batch is completed. 1-999
Master Setup Program Quick setup of system programs using Wizard Tutorial. -
AVC Automatic line voltage compensation.
Maintains welder output with variations of incoming line voltage.
1% Max. Variation
with +/-10% Line Voltage Change
Keyboard Lock Prevents unauthorized changes in welding schedules or setup values. 3 Security Levels
Heat Stepper Computerized curve for welding galvanized steel.
Just enter total welds and last heat % increase. 999 Welds
Tip Force Calculator Displays required pressure regulator setting
needed to produce requested electrode force. 0-99 psi
Line Service Single selector wire to match line voltage.
Keypad entry for line frequency.
115V - 575V
50/60Hz
Dual Program Assigns any weld schedule to one of two initiation inputs. -
Initiation Modes Single level, dual level, anti-tiedown; holding or momentary. -
Low Water Flow Input from external water ow switch. -
Light Curtain Input for light curtain, factory programmed. -
So Touch Function Exclusive UNITROL operator pinch point protection safety system.
Requires So Touch hardware kit. -
SD Slot Copy programs, install programs, modify operating system. -
Anti-tiedown Initiation Requires closing of two hand switches within 1 second to start weld. -
Pressure Transducer*
Starts weld when selected electrode force has been reached.
Locks electrodes on part at end of weld if force exceeds
customer-set limit to prevent cold welds.
0-99 psi
Current Monitor* Compares RMS current to program high/low range.
Locks electrodes closed if out of range. 10KA - 200KA
Constant Current* Accurately provides program-selected secondary current.
Current values are directly entered in amps.
0-200KA
+/-1% Range F.S.
Communication Port* Export of weld results; upload / download schedules. RS-232 or RS-485
Electronic
Pressure Regulator**
Automatically sets pressure regulator to provide
program-selected electrode force. 0-99 psi
* included with SOLUTIONiQC controls ** optional feature
Specication Chart
UNITROL
UNITROL ELECTRONICS, INC.
Northbrook, Illinois
847-480-0115 / [e-mail]
www.unitrol-electronics.com

TABLE OF CONTENTS
INSTALLATION
TROUBLE SHOOTING LED CHARTS
SECTION B: FIRST TIME CONTROL SETUP
SECTION C: PERSONALIZATION
IN PRODUCTION
WELDING SCHEDULES
DIRECT ACCESS CHART
SOLUTION
DIRECTION BOOK
SECTION A:
SECTION D:

SOLUTION INSTALLATION
SECTION A

SOLUTION INSTALLATION
FUNCTION
SECTION
PAGE
NUMBER
UNPACK
A1
1
LOCATION
A2
1
MOUNTING
A3
1
Mounting 9180i, 9180iD, and 9180iL
A3.1
1
Mounting 9180iM
A3.2
1
LINE VOLTAGE CONNECTION
A4
2
POWER CABLE HOLE
A4.1
2
INCOMING POWER connection
A4.2
2
GROUND WIRE
A5
3
Connection of CONTROL WIRES
A6
3
INITIATION and SOLENOID holes
A6.1
3
WIRING 9180iM, 9180iL, and 9180iD
A6.2
4
CONNECTION for all controls
A6.3
4
SCR OVERTEMPERATURE switch
A7
4
TRANSFORMER OVERTEMP switch
A8
5
LOW WATER FLOW switch
A9
5
WATER to SCR CONTACTOR
A10
5
Mounting the REMOTE CONSOLE
A11
6
LOCATION
A11.1
6
BRACKET
A11.2
6
PLUG IN console
A11.3
6
ROUTE CABLE
A11.4
6
CLOSING UP
A11.5
7
LINE VOLTAGE selection
A12
7
HOOKUP DIAGRAM for REMOTE
CONSOLE controls (9180i…)
-
8
HOOKUP DIAGRAM for NON REMOTE
CONSOLE controls (9180iM…,
9180iL…, 9180iD…)
-
10
LED TROUBLE SHOOTING page for
NON REMOTE CONSOLE controls
(9180iM…, 9180iL…, 9180iD…)
-
13
LED TROUBLE SHOOTING page for
REMOTE CONSOLE controls (9180i…)
-
14

SECTION A, PAGE1
SOLUTION INSTALLATION
A1. UNPACK: Carefully unpack system and inspect for damage. Report any
problems to the factory at once. If damage is obvious from outside of carton,
photograph the damage and report to carrier immediately.
A2. LOCATION: Select location for power supply cabinet being sure that the
cabinet door will clear all welder components when open. It is usually an advantage
to locate this cabinet as close to eye level as possible for easy installation and
servicing.
A3. MOUNTING: Select the model number group:
A3.1 FOR 9180i, 9180iD, AND 9180iL, SERIES CONTROLS:
Drill welder to match the four mounting ears mounted to the cabinet. Install cabinet.
A3.2 FOR 9180iM SERIES CONTROLS: Side
mounting brackets are supplied with the system.
a. SIDE MOUNTING: You can mount the control from the left
or right side as desired using the two mounting brackets
supplied with this control. Mount these brackets using the
screws that presently hold the side panel in place per the
photo at the right. Mount cabinet.
b. BOTTOM MOUNTING: Alternately, by drilling holes in the
four foot pads on bottom of this enclosure, you can mount
the control to the top surface of the welder or to a table top.
IT IS IMPORTANT THAT NO METAL CHIPS ENTER ANY OF THE
ELECTRONIC COMPONENTS IN THE CABINET! PROTECT POWER
SUPPLY AND CONTACTOR DURING THE FOLLOWING DRILLING
AND INSTALLATION OPERATIONS. WHEN COMPLETE, REMOVE
ALL CHIPS FROM THIS CABINET BEFORE APPLYING POWER.
Take your time installing this new SOLUTIONicontrol. Be sure that
all connections are tight and that no chips get into the control
components.

SECTION A, PAGE2
SOLUTION INSTALLATION
A4.LINE VOLTAGE CONNECTION:
A4.1 POWER CABLE HOLE: Drill or punch power cable hole either
through the back, side or bottom of the cabinet. Drill or punch a second hole to
handle the return cable to the welder transformer.
When doing any punching or drilling in the control cabinet,
be sure to protect the control components from metal
chips. After drilling or punching holes, be sure that all
filings are fully removed!
A4.2 INCOMING POWER CONNECTION: See the hookup diagram in
the back of this book A that matches your welding control style. Bring two line
voltage wires into the control from the factory source being sure to use conduit and
flexible conduit to match local electrical codes. Consult local codes for proper wire
size. Wire should be sized for at least a 50% duty cycle load.
If your control has a built-in circuit breaker, connect the wires to the top terminals
marked L1 and L2 on the circuit breaker.
If you control does not have built-in circuit breaker, connect one incoming power
wire to the terminal on the SCR contactor marked L1.
For controls in a hinged-door cabinet, connect the second incoming power wire to
the terminal block marked L2.
For controls with M in the model number (screwed-together enclosure), connect the
second power wire directly to one leg of the welding transformer. Include a 16-gage
wire from this junction to be brought into the welding control cabinet and connected
to the small terminal block marked L2.
A good source for selecting the proper wire sized is the RWMA bulletin
#16, charts 1.7.15 and 1.7.16 (www.rwma.org). These charts show the
recommended wire sizes, fuses sizes, and disconnect switch sizes.
Remember that resistance welding transformers require different sizing
of these components than regular power transformers.

SECTION A, PAGE3
SOLUTION INSTALLATION
A5. GROUND WIRE:
Do not operate this resistance welder without a
proper ground wire and connection.The ground wire must
be a separate wire that comes into the control through the same
conduit as the two power wires. Grounding cannot be from a conduit
connection.
The ground wire has to be sized to handle a MINIMUM
of 50% of the amperage-carrying capacity of the two
main power wires coming into this control.
The ground wire must be connected to the ground stud
inside this welding control. Look for the stud with the
DANGER sign as shown in the photo to the right.
A6. CONNECTION OF CONTROL WIRING:
A6.1 INITIATION AND SOLENOID HOLES: Drill or punch access holes
to handle the foot pedal or palm buttons, limit switches, and solenoid valves. These
should be at a convenient location in the bottom or back of the cabinet. Install liquid
tight or approved cable through appropriate box connectors.
When doing any punching or drilling in the control cabinet,
be sure to protect the control components from metal
chips. After drilling or punching holes, be sure that all
filings are fully removed!

SECTION A, PAGE4
SOLUTION INSTALLATION
A6.2 WIRING 9180iM, 9180iL, and
9180iD series CONTROLS: Remove the
four outer screws on the control face plate. Lift the
white faceplate up slightly and carefully rotate the
front panel from the top to expose the wiring
terminals. A bracket is provided to prevent the
panel from going more than 900as shown in the
photo to the right. Connect wires in this position.
This will make wire installation easier, and be sure
that the panel will be able to rotate outward in the
future should service be required.
A6.3 CONNECTION FOR ALL CONTROLS: Connect foot pedal, palm
buttons, or machine contacts per HOOK-UP DIAGRAM in the back of this book A.
a. If limit switch, pressure switch, and/or transformer thermostat is used, connect
per HOOK-UP DIAGRAM. If switches are PNP solid-state, check the
appropriate section on the HOOK-UP DIAGRAM.
b. If you are connecting two hand buttons for anti-tiedown initiation, there are two
choices:
i. Both of the switches have to have two NORMALLY OPEN contacts and
are wired per the HOOKUP-DIAGRAM.
ii. If your switches do NOT have two NORMALLY OPEN contacts, connect
them to a Unitrol part #9181-56 ANTI-TIEDOWN INTERFACE. If this
board was not ordered with this control it can be easily field installed for
this purpose.
c. If any of these are not being used, install jumpers as shown on the HOOK-UP
DIAGRAM. These jumpers are normally installed at the factory.
A7. SCR CONTACTOR OVERTEMPERATURE SWITCH: This
surface thermostat switch has been factory installed. It will open if the temperature of
the cooling block on the SCR contactor exceeds the switch setting. At that time the
control will display:
No operation of the control is possible until
this switch input has been closed.
SCR OVERTEMPERATURE

SECTION A, PAGE5
SOLUTION INSTALLATION
A8. TRANSFORMER OVERTEMPERATURE SWITCH: If your
welder transformer has a thermostat that opens on temperature rise, remove the
factory jumper and connect it to terminals #3 and #4. Before connecting, be sure that
the contact is CLOSED. Some of these switches are used for turning on cooling
water solenoid valves and close on temperature rise.
When this input is opened, the display will show:
No operation of the control is possible until this switch input has been closed.
A9. LOW WATER FLOW SWITCH: If you have a WATER FLOW switch
that opens a contact when water flow is low, connect this switch to terminals #13 and
#14 (RT1 –RTC). Then assign RT1 this input to operate as a WATER FLOW
SWITCH by pressing:
and pressing 5 as directed. When the
weld is started, if this input is open, the
display will flash:
No operation of the control is possible until this switch input has been closed.
A10. WATER TO SCR CONTACTOR: If your control has a WATER-
COOLED SCR CONTACTOR, connect water hoses to the ¼” NPT fittings. Direction
(in/out) is not important as long as this control does not have a built-in WATER
FLOW safety switch. If it does have a WATER FLOW safety switch, observe the IN
and OUT labels on the water ports.
TRANSFORMER OVERTEMP
WATERFLOW sw.is open
open open
9
8
7
9
3
ENTER
STEP

SECTION A, PAGE6
SOLUTION INSTALLATION
BE SURE THAT THE PIPE FITTING THAT YOU THREAD INTO THESE
PORTS IS NON-METALLIC. IT CAN BE PVC OR NYLON. ANY
METALLIC FITTING (GALVANIZED, BRASS, ETC.) PUT INTO THESE
PORTS CAN EVENTUALLY CAUSE A HOLE IN THE WATER-
COOLED JACKET THAT WILL FLOOD THE CONTROL WITH WATER
AND DESTROY THE SYSTEM. WARRANTY IS VOID IF METALLIC
FITTINGS ARE INSTALLED IN THESE PORTS!
If your control does NOT have a remote console
as shown in the photo below, skip to A12.
A11. MOUNTING THE REMOTE CONSOLE:
A11.1 LOCATION: Select a location on the welder
to mount the remote console. Ideally this should be at
eye level and close enough for easy data input on the
keypad.
A11.2 BRACKET: Bolt the U bracket supplied with
the console to a secure surface on the welder and mount
the console with the two ¼” thumb screws supplied. Be
sure that the location allows the console to swing both
ways.
A11.3 PLUG IN CONSOLE: Plug the cable into
the socket at the back of the remote. HAND tighten the
two jack screws.
DO NOT TIGHTEN THESE SCREWS WITH A SCREWDRIVER
OR PLIERS. EXCESS FORCE WILL BREAK THE SOCKET
FASTENER AND VOID THE WARRANTY!
A11.4 ROUTE CABLE: Route this remote console cable to the power
supply cabinet and push the excess cable into the large compression fitting supplied
on the cabinet top. Be sure that there is enough of a loop at the console to allow full
movement of the console. Tighten strain relief fitting.
SKIP
U bracket mounted to console.
Notice that the top of the
bracket has the threaded insert.

SECTION A, PAGE7
SOLUTION INSTALLATION
A11.5 CLOSING UP: Secure all wires inside power supply cabinet and check
to be sure that connections are made correctly and that no loose strands of wire are
at any terminal point. If you have rotated the control out of the enclosure earlier,
carefully rotate it back and secure with the original four screws.
A12. LINE VOLTAGE SELECTION: If your line voltage was known to
Unitrol when this control was manufactured, it was factory connected to match that
voltage.
BEFORE TURNING POWER ON, verify that this was done correctly.
Check to see if the YELLOW wire on power supply terminal is connected to
a terminal that most closely matches your line voltage. See photos below for
your type of welding control.
Note: Controls shipped to Canada have two black wires connected to the
voltage input terminals. One will be marked F2. This goes to the F2 terminal.
IF THE ACTUAL LINE VOLTAGE IS MORE THAN 20% HIGHER THAN THE
TERMINAL MARKING, PERMANENT DAMAGE CAN OCCUR TO THE SYSTEM.
DAMAGE CAUSED BY OVERVOLTAGE IS NOT COVERED BY WARRANTY.
For 400V –412V line voltages, set the yellow wire on the 380V terminal.
SUPPORT: If you have any doubts when installing this control, contact UNITROL
technical support 9:00 –5:00 central time, M-F. We want to be sure that your
installation goes smoothly!
By phone: [phone] By Email: [e-mail]
CONTROLS WITH REMOTE CONSOLE
EXAMPLE IN THIS PHOTO IS SET FOR
460V.
CONTROLS ALL IN ONE ENCLOSURE
EXAMPLE IN THIS PHOTO IS SET FOR
460V.

HOOK-UP DRAWINGS
SECTION A, PAGE8
FOR CONTROLS WITH REMOTE CONSOLES, PAGE 1 OF 2.

HOOK-UP DRAWINGS
SECTION A, PAGE9
FOR CONTROLS WITH REMOTE CONSOLES, PAGE 2 OF 2.

HOOK-UP DRAWINGS
SECTION A, PAGE10
FOR CONTROLS WITH ALL COMPONENTS IN ONE CABINET, PAGE 1 OF 3.

HOOK-UP DRAWINGS
SECTION A, PAGE11
FOR CONTROLS WITH ALL COMPONENTS IN ONE CABINET, PAGE 2 OF 3.

HOOK-UP DRAWINGS
SECTION A, PAGE12
FOR CONTROLS WITH ALL COMPONENTS IN ONE CABINET, PAGE 3 OF 3.

TROUBLE SHOOTING DRAWINGS
SECTION A, PAGE13
LED TROUBLE SHOOTING DRAWING, ALL IN ONE CABINET CONTROLS

TROUBLE SHOOTING DRAWINGS
SECTION A, PAGE14
LED TROUBLE SHOOTING DRAWING, CONTROLS WITH REMOTE CONSOLES

Unitrol Electronics, Inc.
702 Landwehr Road
Northbrook, IL. 60062
WEB: unitrol-electronics.com
Email: [e-mail]