Unitrol 9181-34YB/115 User manual

1
SOFT TOUCH for NON-UNITROL CONTROLS
9181-34YB/115, 9181-34WB/115
9181-34YB/24DC, 9181-34WB/24DC
9181-34YM/115, 9181-34YM/24DC
9181-34WM/115, 9181-34WM/24DC
9181-34YM/24AC, 9181-34WM/24AC
9181-34YB/24AC, 9181-34WB/24AC
UNITROL ELECTRONICS, INC.
702 LANDWEHR ROAD
NORTHBROOK, ILLINOIS 60062
[e-mail]
847-480-0115

2

3
Thank you for purchasing this Unitrol SOFT
TOUCH system. It is designed to protect your
resistance welder operator from serious elec-
trode pinch point injury. Please let us know if
there are any questions or problems with the
installation or use of this product. You can con-
tact us:
By Phone:
Monday - Friday 9:00 - 5:00 CT: 847-480-0115.
By Email:
[e-mail]
By Regular Mail:
Unitrol Electronics, Inc.
Technical Support
702 Landwehr Road
Northbrook, Illinois 60062

4

5
MODEL NUMBER AND OPTIONS AS CHECKED BELOW
SERIAL NUMBER:
CHECK MODEL
WELDER TYPE
AND
HARDWARE
RAM TYPE VALVE
VOLTAGE
9181-34WB/115 1Ø AC
INCLUDES A
SNUBBER
AND
2=MUFFLERS
HEAVY WEIGHT 115AC
9181-34YB/115 LIGHT WEIGHT, ROCKER ARM
9181-34WB/24DC HEAVY WEIGHT 24VDC
9181-34YB/24DC LIGHT WEIGHT, ROCKER ARM
9181-34WB/24AC HEAVY WEIGHT 24VAC
9181-34YB/24AC LIGHT WEIGHT, ROCKER ARM
9181-34WM/115
MFDC
(INVERTER)
INCLUDES
2=MUFFLERS
HEAVY WEIGHT 115VAC
9181-34YM/115 LIGHT WEIGHT, ROCKER ARM
9181-34WM/24DC HEAVY WEIGHT 24VDC
9181-34YM/24DC LIGHT WEIGHT, ROCKER ARM
9181-34WM/24AC HEAVY WEIGHT 24VAC
9181-34YM/24AC LIGHT WEIGHT, ROCKER ARM
OPTIONS
9181-34BPA
Timed bypass. Includes security lock selector switch, 2 = LED
indicator lights, faceplate. Closes electrodes under low force,
delays, and brings electrodes to welding force.
9181-34JA
Retract Kit. Includes HEAD DOWN proximity switch and
mounting bracket kit. May require additional field bracketry
to match welder
9181-34JB
Retract option without proximity switch. For use with weld-
ers that have separate RETRACT and WELD INITIATION
switches.
9181-34LSA
Limit Switch. Allows use of ram position or continuity. In-
cludes RAM POSITION proximity switch and mounting brack-
et kit. May require additional field bracketry to match weld-
er. Includes security lock selector switch, 2 = LED indicator
lights, faceplate
9181-34LSB
Limit Switch. Allows use of a ram position or continuity. In-
cludes security lock selector switch, 2 = LED indicator lights,
faceplate. Does NOT include a proximity switch or mounting
bracket kit. Use with customer-supplied PNP proximity
switch.
9181-34LSC
Limit Switch used as a redundancy with continuity. Always in
operation and not keylock selected. Includes RAM POSITON
proximity switch and mounting bracket kit. May require addi-
tional field bracketry to match welder. Can be turned off by
moving a jumper on the control board inside the locked cabi-
net.
9181-34FRL-1/2 ½” NPT Filter, regulator, lubricator with inter block for pilot
line. With air gauge. Not needed if existing regulator is good.
9181-34FRL-3/4 ¾” NPT Filter, regulator, lubricator with inter block for pilot
line. With air gauge. Not needed if existing regulator is good.

6
WARRANTY
Unitrol Electronics provides a 5-year limited warranty to cover all of this SOFT TOUCH sys-
tem. The warranty periods are determined using the date the new control was originally
shipped from Unitrol Electronics. All warranty coverage is FOB Northbrook. Illinois.
This warranty, except for exclusions shown herein covers the following items:
DURING YEAR #1: All parts (exclusive of fuses) that fail due to manufacturing defects.
Necessary labor to repair control that has failed due to manufacturing defects.
DURING YEAR #2: 80% cost of all parts (exclusive of fuses).
80% cost of necessary labor to repair control that has failed due to manufacturing defects.
DURING YEAR #3: 60% cost of all parts (exclusive of fuses).
60% cost of necessary labor to repair control that has failed due to manufacturing defects.
DURING YEAR #4: 40% cost of all parts (exclusive of fuses).
40% cost of necessary labor to repair control that has failed due to manufacturing defects.
DURING YEAR #5:
20% cost of all parts (exclusive of fuses).
20% cost of necessary labor to repair control that has failed due to manufacturing defects.
EXCLUSIONS TO WARRANTY
Any expense involved with repair of control by other than Unitrol Electronics personnel that
has not been authorized in advance and in writing by an officer of Unitrol Electronics.
All costs for freight, to and from Unitrol Electronics, are excluded from this warranty
All field service labor, travel expense, and field living expenses associated with field service
are excluded from this warranty.
No coverage, parts or labor, is offered for components that have failed on control not being
used as specified in Unitrol Electronics published literature, technical sheets, and this direction
book.
No warranty coverage will be made on controls that are being used contrary to specifications,
that were mechanically or electronically altered by customer or installer, or that were physical-
ly damaged after shipment from Unitrol Electronics.
Damages to a control by lightning, flood, or mechanical damage are excluded from this war-
ranty.
Unitrol Electronics assumes no liability for damage to other equipment or injury to personnel
due to a failure in the Unitrol Electronics control.
Unitrol Electronics shall not be responsible for any consequential damages of whatever kind.
Expenses involving alteration or installation of a Unitrol Electronics control are not covered in
this warranty.
NO OTHER UNITROL ELECTRONICS INC. WARRANTY, WRITTEN OR
IMPLIED, COVERS THIS CONTROL UNLESS IN WRITING AND SIGNED
BY AN OFFICER OF UNITROL ELECTRONICS, INC. PRIOR TO SHIP-
MENT OF PRODUCT.

7
1VERIFY YOUR SOFT TOUCH SENSOR BOARD IS CORRECT
2HOW SYSTEM OPERATES
3INSTALLATION, 9181-34W HEAVY WEIGHT SERIES
4INSTALLATION, 9181-34Y LIGHT WEIGHT SERIES
5WIRING CONTROL: CONNECTING SIGNAL PICKUP WIRES
6CONNECTING THE SNUBBER
6CONNECTING CONTROL CABLE
7CONTROL CABLE WIRING CHART
8ELECTRICAL HOOKUP, 9181-34WB/115, 9181/34YB/115
9ELECTRICAL HOOKUP, 9181-34WB/24DC,9181/34YB/24DC
10 ELECTRICAL HOOKUP, 9181-34WB/24AC,9181/34YB/24AC
11 ELECTRICAL HOOKUP, 9181-34WM/115, 9181/34YM/115
12 ELECTRICAL HOOKUP,9181-34WM/24DC,9181/34YM/24DC
13 ELECTRICAL HOOKUP,9181-34WM/24AC,9181/34YM/24AC
14 RETRACT OPTION 9181-34JA
16 RETRACT OPTION 9181-34JB
18 TIMED BYPASS OPTION 9181-34BP
19 PNEUMATIC HOOKUP, 9181-34Y LIGHT WEIGHT
20 PNEUMATIC HOOKUP, 9181-34W HEAVY WEIGHT
21 ADJUSTING SOFT TOUCH VALVES
22 SETTING MAXIMUM DETECT TIME SWITCHES
22 TESTING ELECTRONIC SYSTEM
23 STARTUP PROCEDURE
24 TESTING ELECTRODE CLOSING FORCE
25 TROUBLE SHOOTING CHART
26 LED INDICATOR LIGHTS
TABLE OF CONTENTS

8

1
VERIFY YOUR SOFT TOUCH SENSOR BOARD IS CORRECT
The SOFT TOUCH sensor board can be configured in several
ways. Before turning power on, check to be sure that the
mode and valve voltage matches your welder.
1. TYPE OF WELDING CONTROL. This board can be set to
operate either a 1ØAC welder or an MFDC (inverter) welder.
This is done by pushing the three switches on the lower left
corner to a position to match your welding control.
FOR 1ØAC WELDERS FOR MFDC (inverter) WELDERS
2. SOLENOID VALVE VOLTAGE. Be sure that the two tall
relays, K2 and K3, show the same voltage on the top printing
as the solenoid voltage of your welding control.
FOR 115VAC FOR 24VDC
SOLENOID VALVES SOLENOID VALVES

2
HOW THE SYSTEM OPERATES
When the solenoid valve output from the welding control goes HIGH,
this voltage goes to the 9280-TS6 SOFT TOUCH detecon board, terminal
#9.
The output terminal #11 (SVL) goes HIGH to turn on solenoid valve SVL.
For 9181-34WB systems, this closes the welding electrodes under gravi-
ty force with low force bucking pressure (ADVANCE) acng on the under-
side of the cylinder piston to counterbalance part of the ram dead
weight.
For 9181-34YB systems, this closes the welding electrodes under low
force using low air pressure on the forward port of the welder cylinder.
The 9280-TS6 board checks input at terminals #4 and #5 to see if the
voltage signal drops a minimum value indicang that the electrodes have
made contact on a conducng material (connuity detected).
If this contact is NOT sensed within the maximum me seng on
the board’s DIPswitches, the output terminal #11 (SVL) will go
LOW and drop out solenoid valve SVL to open the electrodes.
If this contact IS sensed within the maximum me seng:
Terminal #11 (SVL) will connue to be HIGH
Terminal #13 (SVH) will go HIGH
Solenoid valve SVH will be turned ON to start high electrode
pressure, and relay K4 on this board will close to start the weld-
ing sequence
The contact across terminals #6 and #7 on the TS2 board close
to tell the welding control to start the welding sequence.
SOFT TOUCH PINCH POINT
PROTECTION SYSTEM
FOR INSTALLATION ON NON-UNITROL
1Ø AC and MFDC WELDING CONTROLS

3
INSTALLATION
Note that this system REPLACES the
existing weld solenoid valve.
1. Mount the control in a convenient location using the four
mounting tabs on the back of the box.
2. Remove hoses from the existing welding solenoid valve.
This solenoid valve will not be used with this this control.
3. Connect hoses from the control to the air cylinder as
shown in the photos below and the next page. Choose the
photo that matches your control model.
HOSE CONNECTION FOR 9181-34W SERIES CONTROLS
Connect to air cylinder port
that opens the electrodes.
Connect to air cylinder port
that closes the electrodes.
BOTTOM OF CABINET
Install two airline muers
supplied with this unit.
Connect to point aer airline
oiler (weld pressure)
BOTTOM OF CABINET
Connect to point between air
lter/water trap and input to
welding pressure regulator

4
BOTTOM OF CABINET
HOSE CONNECTION FOR 9181-34Y SERIES CONTROLS
Note that this system REPLACES the existing weld solenoid valve.
Connect to air cylinder port
that closes the electrodes.
Connect to air cylinder port
that opens the electrodes.
Connect to point aer airline
lubricator (weld pressure)
Install two airline muers
supplied with this unit.
Connect to point between air
lter/water trap and input to
welding pressure regulator

5
WIRING CONTROL
CONNECTING SIGNAL PICKUP WIRES
1. Connect the two blue wires from the bottom of the box to
the upper and lower secondary pad on the welding trans-
former or any point close to the pad. See photos below for
suggested areas for various types of welders.

6
WIRING CONTROL
(CONTINUED)
CONNECTING SNUBBER
2. : For 9181-34WB… and 9181-34YB… models, Connect
blue snubber cylinder in this kit across the SCR contactor
per the HOOK-UP drawing and typical photos below. It
does not matter which wire from the snubber connects to
which side of the SCR contactor.
NOTE: If the welding control already has a snubber or a
resistor in series with a capacitor wired across the SCR
contactor, remove it. There should only be the new blue
snubber installed across the SCR contactor.
CONNECTING CONTROL CABLE
3. Route the black multi-wire cable from the top of the SOFT
TOUCH enclosure to the welding control.
4. Install the supplied strain relief fitting in the welding control
and bring cable into the control.
5. Trim the cable to allow it to reach the terminals shown in the
table on the next page. Wire as shown.

7
WIRE COLOR
CONNECT IN
WELDING CONTROL
FOR 24VDC MODELS
9181-34WB/24DC 9181
-34WM/24DC
9181-34YB/24DC
9181-34YM/24DC
CONNECT IN
WELDING CONTROL
FOR 115VAC MODELS
9181-34WB/115
9181-34WM/115
9181-34YB/115
9181-34YM/115
TS6
TERM
BLACK 115VAC L 115VAC L
1
WHITE 115VAC N 115VAC N
2
RED/BLACK STRIPE INITIATION INITIATION
6
RED 7INITIATION INITIATION
BLUE 24VDC + NOT USED
14
WHITE/BLACK
STRIPE
24VDC 0V NOT USED
23
ORANGE
24VDC + SOLENOID
VALVE DRIVER
OUTPUT*
115VAC L SOLENOID
VALVE DRIVER
OUTPUT*
9*
GREEN GROUND STUD GROUND STUD
-
WIRING CONTROL
(CONTINUED)
CONTROL CABLE WIRING CHART
*BE SURE THAT THE ORANGE WIRE IS CONNECTED TO THE WELDING CON-
TROL TERMINAL THAT ORIGINALLY SUPPLIED EITHER 115V L (HIGH) OR
24VDC+ TO THE WELD SOLENOID VALVE.
SEVERE DAMAGE CAN OCCUR IF THIS IS NOT WIRED CORRECTLY.

8
INSTALLATION
HOOK-UP DRAWING
9181-34WB/115, 9181-34YB/115

9
INSTALLATION
HOOK-UP DRAWING
9181-34WB/24VDC, 9181-34YB/24DC

10
INSTALLATION
HOOK-UP DRAWING
9181-34WB/24VAC, 9181-34YB/24AC

11
INSTALLATION
HOOK-UP DRAWING
9181-34WM/115, 9181-34YM/115

12
INSTALLATION
HOOK-UP DRAWING
9181-34WM/24VDC, 9181-34YM/24DC