Unitrol SOFT TOUCH 9381-34WDS/115 User manual
1
SOFT TOUCH for NON-UNITROL
FREQUENCY CONVERTER CONTROLS
9381-34WDS/115, 9381-34WDS/24DC
9381-34YDS/115, 9381-34YDS/24DC
UNITROL ELECTRONICS, INC.
702 LANDWEHR ROAD
NORTHBROOK, IL 60062
847-480-0115
techsupport@unitrol-electronics.com
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.
Having trouble or need answers to your ques-
tions? Unitrol supplies free phone support for
the life of this and all our products.
You can contact us:
By Phone:
Monday - Friday 9:00 - 5:00 CT: 847-480-0115.
By Email:
techsupport@unitrol-electronics.com
By Regular Mail:
Unitrol Electronics, Inc.
Technical Support
702 Landwehr Road
Northbrook, Illinois 60062
4
MODEL NUMBER AND OPTIONS AS CHECKED BELOW
SERIAL NUMBER:
MODEL TYPE VALVE
VOLTAGE
OPTIONS
9181-34BPA
Timed bypass. Includes security lock selec-
tor switch, 2 = LED indicator lights, face-
plate. Closes electrodes under low force,
delays, and brings electrodes to welding
force.
9381-34JB3/PMCO
SOFT TOUCH protecon for the RETRACT
stroke. Supplied to operate PMCO welders
with “li” cylinders. Includes RAM POSI-
TION proximity switch and mounng
bracket
kit. Requires addional eld bracketry to
match welder
9381-34JB3
SOFT TOUCH protecon for RETRACT
stroke on standard cylinders that use for-
ward
pressure to go out of RETRACT. Includes
proximity switch and mounng bracket kit.
Requires addional eld bracketry to
match welder
9381-34F2 FORGE DELAY funcon that connects to
exisng Back Pressure (Bucking Pressure)
regulator.
9181-34LSB
Limit Switch. Allows use of a ram position
or continuity. Includes security lock selec-
tor switch, 2 = LED indicator lights, face-
plate. Does NOT include a proximity switch
or mounting bracket kit. Use with custom-
er-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 additional field bracketry to
match welder. Can be turned off by mov-
ing a jumper on the control board .
9381-34WDS/115 CYLINDER OR DIAPHRAGM
HEAVY WEIGHT RAM 115AC
9381-34WDS/24DC CYLINDER OR DIAPHRAGM
HEAVY WEIGHT RAM 24DC
9381-34YDS/115 CYLINDER OR DIAPHRAGM
LIGHT WEIGHT RAM 115AC
9381-34YDS/24DC CYLINDER OR DIAPHRAGM
LIGHT WEIGHT RAM 24DC
5
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.
6
TABLE OF CONTENTS
1VERIFY YOUR SOFT TOUCH SENSOR BOARD IS CORRECT
2HOW SYSTEM OPERATES
3INSTALLATION, 9181-34W HEAVY WEIGHT SERIES
4INSTALLATION OF SCR DRIVER BOARD
5CONNECTING SCR FIRING CABLE
5CONNECTING CONTROL CABLE
6WIRING CONTROL
7INSTALLING SECONDARY CURRENT PICKUP COIL
8CONTROL CABLE WIRING CHART
9HOOKUP FOR 9381-34WDS/115, 9381-34YDS/115
10 HOOKUP FOR 9381-34WDS/24DC, 9381-34YDS/24DC
11 RETRACT OPTION 9381-34JB3/PMCO
13 RETRACT OPTION 9181-34JB3
15 TIMED DELAY OPTION 9181-34BP
16 DEPTH SWITCH OPTION, 9181-34LSA, 9181-34LSB
18 DEPTH SWITCH OPTION 9181-34LSC
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, BLANK TIME
23 SETTING AND TESTING ELECTRODE CLOSING FORCE
24 SETTING SYSTEM READING SENSITIVITY
25 START-UP PROCEDURE
26 TROUBLE SHOOTING CHART
29 SETTING SYSTEM READING SENSITIVITY
27 BUCKING PRESSURE OPTION 9181-34F2
28 LED INDICATOR LIGHTS
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 various
types of welders. For a Frequency Converter welder, set the four side switches
to the positions shown below.
FOR 115VAC FOR 24VDC
SOLENOID VALVES SOLENOID VALVES
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. If they are not correct, contact Unitrol to swap relays.
2
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 photo be-
low.
HOSE CONNECTION FOR 9181-34W SERIES CONTROL
Note that this system REPLACES the
existing weld solenoid valve.
Connect to point
aer airline oiler
(weld pressure)
Connect to diaphragm
or air cylinder port that
opens the electrodes.
Connect to point between air
lter/water trap and input to
welding pressure regulator
Connect to diaphragm
or air cylinder port
that closes the elec-
trodes.
TOP OF CABINET
INSTALL FILTERS ON
BOTTOM OF CABINET
TO EXISTING
RETRACT
VALVE INPUT
FOR
9381-34JB
OPTIONS
TO SCR CONTACTORS
TO WELDING CONTROL
3
HOW THE SYSTEM OPERATES
When the solenoid valve output from the welding control
goes HIGH, this voltage goes to the 9280-TS7 SOFT TOUCH de-
tecon board, terminal #9.
The output terminal #11 (SVL) goes HIGH to turn on solenoid
valve SVL . This closes the electrodes under low force.
Relay K2 iniates the SIMPLICITY control on
the door of the cabinet.
Aer the me set on the TRACE DELAY TIME pushwheels (25
cycles is a good starng me), the SIMPLICITY control starts to
re the new SCR contactor into one primary winding of the
welder transformer connuously at very low heat as set on
the TRACE % pushwheels. 1% is normally a good seng. Note
that this delay allows enough me for the electrodes to close
before starng the ow of current to eliminate sparking.
If the electrodes touch the metal being welded, current will
now ow in the welder’s secondary loop and is detected by
the Rogowski secondary current pickup coil connected to the
9280-TS7 board. This will
1. Turn on SVH to put the welding pressure air on the top of
the welder’s diaphragm or cylinder. At the same me, it
starts a me delay of about 0.1 seconds and then turns on
solenoid SVF that switches pressure on the underside of
the diaphragm or piston to back-up pressure.
2. Energizes relay K1 to stop the SIMPLICITY control from r-
ing the SCR contactor.
3. Close the output relay connected to terminals 6-7 on the
9180-TS7 board to close the second stage or pressure
switch input on the welding control to start the welding
procedure.
SOFT TOUCH PINCH POINT
PROTECTION SYSTEM
FOR INSTALLATION ON NON-UNITROL
3Ø FREQUENCY CONVERTER CONTROLS
4
INSTALLATION OF SCR DRIVER BOARD
This SOFT TOUCH system is supplied with a separate aluminum heat sink with a
high-voltage SCR contactor installed. The SCR contactor is used to drive the
transformer windings operated by exisng SCR-A during the SOFT TOUCH inial
sequence to produce a TRACE signal as explained on page 3.
Mount this panel, using the screws and nuts provided, in a convenient locaon
inside the welder’s enclosure that houses the three SCR contactors . Locate the
panel as close to the SCR contactor as praccal. Wire it per direcons on page 6.
Drill a 7/8” diameter (1/2” knockout) hole in the welding control cabinet and in-
stall one of the strain relief ngs in this kit with the nut inside the enclosure.
Push the 6-wire cable through this strain relief and ghten the nut. Route the
other end of this cable to the SOFT TOUCH enclosure and install it using the sec-
ond strain relief ng.
Connect G1/K1 and G2/K2 to these terminals on the SIMPLICITY control.
Connect the third pair to terminals 5 and 6 on the SIMPLICITY control.
CRITICAL: If cable is shortened, check the pairs by looking on
the white wire in each twisted pair for the pair number (1 one,
2 two, 3 three). Double check by verifying connuity on each
pair. Serious damage can occur if the wires are connected to
the wrong terminals.
4
CABLE PAIR 1
CABLE PAIR 2
CABLE PAIR 3
5
CONNECTING CONTROL CABLES
1. Drill a 7/8” hole in the top panel of the welding control cabinet
and install the supplied strain relief fitting.
2. Route the 10-wire cable from the top of the SOFT TOUCH en-
closure to the welding control and run it through the strain relief
fitting.
3. Trim the cable to allow it to reach the terminals shown in the ta-
ble on the next page. Wire as shown on page 8.
NOTE: Check the Unitrol web site www.unitrol-electronics.com
SUPPORT tab for hookup charts for some popular welding con-
trols. If you do not see your brand and model welding control listed
and cannot figure out how to find the point in the welding control
that are shown on the next page, contact Unitrol for assistance at::
techsupport@unitrol-electronics.com
.
CONNECTING TRACER SCR CONTACTOR
1. Mount the new SCR heat sink assembly in a location near the
existing three SCR contactors inside the existing welding con-
trol enclosure.
2. Drill a 7/8” hole (1/2” electrical knockout) in the welding control
cabinet near this SCR heat sink assembly.
3. Connect the 6-wire control cable coming out of the top of the
SOFT TOUCH into this hole using the strain relief supplied in
the kit.
4. Bring the cable to the terminal on the SCR heat sink that was
installed on the previous page.
5. Cut excess length and strip the outer jacket to expose three 2-
wire pairs. The WHITE wire in each pair is marked 1-one, 2-
two, and 3-three to identify the pair.
6. Connect pair 1 and pair 2 cables to four terminals on the SCR
heat sink as shown on page 6. Be sure that the black and
white wires for each pair are connected exactly as shown with
the white wires going to the G1S and G2S terminals, and the
black wires going to K1S and K2S. The third pair is not used.
6
7—8 terminals
for SCR over-
tempt switch
POWER CONNECTION OF TRACER PULSE SCR CONTACTOR
1. Connect the upper lug wire to terminal A1 on SCR A. This will add one
extra wire to the terminal.
2. Connect the lower lug wire to terminal A2 on SCR A. This will add one
extra wire to the terminal.
SCR-A
A1
A2
7
INSTALLING SECONDARY PICKUP COIL
Put the secondary current pickup coil band around the
lower electrode arm as shown in this photo:
The band opens at the buckle for easy installation.
Note that the buckle is approximately at the bottom and
that the coil is as far out of the way as possible so that
it is not contacted by parts being welded. If desired, use
a cable tie to secure the band to the lower arm.
Plug the other end of the cable into the socket located
on the right side of the SOFT TOUCH enclosure. Wrap
excess cable and tie to make a clean and secure instal-
lation.
8
WIRING CONTROL
CONTROL CABLE WIRING CHART
WIRE COLOR
TS7
TERM
CONNECT IN WELDING CONTROL
FOR
24VDC MODELS
9381-34WDS/24DC
9381-34YDS/24DC
CONNECT IN WELDING
CONTROL FOR
115VAC MODELS
9381-34WDS/115
9381-34YDS/115
BLACK 1100VAC L - 240VAC1115VAC L
WHITE 2100VAC N - 240VAC1115VAC N
RED/BLACK ST. 6INIT. PERMISSION2INIT. PERMISSION1
RED 7INIT. PERMISSION2INIT. PERMISSION1
FOR CONTROLS FOR CONTROLS
SWITCHED WITH SWITCHED WITH
+24VDC 3 0VDC 4
BLUE 14 24VDC 0V24VDC + 115VAC = NOT USED
24VAC = 24VAC L
WHITE/BLACK ST. 23 24VDC +24VDC 0V 115VAC = NOT USED
24VAC = 24V N
ORANGE 9* WELD CONTROL SOLENOID VALVE
OUTPUT4
115VAC L SOLENOID
VALVE DRIVER
OUTPUT
GREEN - GROUND STUD GROUND STUD
GREEN/BLACK ST. 18 5
TH RETRACT OPTIONS 9381ONLY WIUSED -N34JA A
1.
2.
3.
4.
5.
FOOTNOTES:
CAUTION: INCORRECT CONNECTION WILL CAUSE SEVERE DAMAGE.
#23.
terminal #23 voltage should be same as the voltage between terminals #14
-
When the RETRACT valve is turned on by the welding control, terminal 18 to
ifapplicable) solenoid valve.
Welding controls that use
0VDC to operate the welding (and RETRACT
applicable) solenoid valve.
Welding controls that use
+24VDC to operate the welding (and RETRACT if
on the TS7 sensor board.
with FOOTSWITCH second stage. These wires connect to a dry contact relay
INIT. PERMISSION
is either a PRESSURE SWITCH input terminal or in series
is 100V
-
240VAC.
LINE VOLTAGE: For 24VDC valve systems
only, voltage on black/white wires
RETRACT
ON
SIGNAL 5
RETRACT
ON
SIGNAL
D 938-34JB
9
INSTALLATION
HOOK-UP DRAWING FOR
9381-34WDS/115, 9381-34YDS/115
24VDC 24VDC
RED
RED/BLACK
115VAC
LINE
SVL
SVH
ORANGE TIP DRESS
BLACK
WHITE
WELDING
TRANSFORMER
115V
NEUTRAL
10
INSTALLATION
HOOK-UP DRAWING
9181-34WDS/24VDC, 9181-34YDS/24DC
24VDC 24VDC
RED
RED/BLACK
115VAC
LINE
SVL
SVH
ORANGE
TIP DRESS SWITCH
WELDING
TRANSFORMER
115V
NEUTRAL
WHITE/BLACK STRIPE
BLUE
BLACK
WHITE
11
OPTIONAL RETRACT WITH SOFT TOUCH
9381-34JB3/PMCO & 9381-34JB3
The RETRACT function starts when the RETRACT switch is closed and
latched. This can be either the first stage of a 3-stage footswitch, or a
separate footswitch. This option protects against pinch point injury when
bringing the electrodes from fully open RETRACT position to the WORK posi-
tion (small space between electrodes). The option includes a PNP proximity
switch that is adjusted to go high when the retract cylinder is fully bottomed put-
ting the electrodes in the (small opening) WORK position.
1. Install the PNP proximity switch using the starter bracket kit in this option.
Modify as necessary to work with your welder. The proximity switch has to
be blocked when the ram is down in the WORK (small opening) position.
This will put 24VDC into terminal 26.
2. Wire the PNP proximity switch as shown below.
3. Move the double RETRACT jumper plug to
the RETRACT (upper) position as shown.
This is located near the top center of the
board.
-24IS
LEDS
31 30 29 28 27 26 25 24
RETR.
FOOT
SWITCH
HEAD
DOWN
LIM. SW
ELECTR.
CLOSED
LIM. SW
SELECT
SWITCH
INPUT
P-N-P
BROWN P-N-P
BLACK P-N-P
BLUE
-24IS
+24IS
BROWN
PNP BLACK
BLUE
RETRACT HEAD
DOWN PROX.
SWITCH
12
OPTIONAL RETRACT WITH SOFT TOUCH
9381-34JB3/PMCO & 9381-34JB3
(continued)
3. Typical welders have the RETRACT solenoid valve operated
from the welding control. If this matches your welder, skip to the
next page.
If this signal is not available (unusual), you can connect wiring
from either a 3-stage or 1-stage latching footswitch as shown be-
low.
3- STAGE FOOTSWITCH:
TOP: LATCHING RETRACT SWITCH
MIDDLE: STAGE 1 WELDING
BOTTOM: STAGE 2 WELDING
-24IS
LEDS
31 30 29 28 27 26 25 24
RETR.
FOOT
SWITCH
HEAD
DOWN
LIM. SW
ELECTR.
CLOSED
LIM. SW
SELECT
SWITCH
INPUT
P-N-P
BROWN P-N-P
BLACK P-N-P
BLUE
-24IS
+24IS
See bottom of page 14 for PNEUMATIC
HOOKUP for this option.
1 - STAGE RETRACT LATCHING-
FOOTSWITCH
13
This hook-up on this page is for RETRACT that uses
RETRACT VOLTAGE from the welding control.
OPTIONAL RETRACT WITH SOFT TOUCH
9381-34JB3/PMCO & 9381-34JB3
GREEN/BLACK STRIPE WIRE:
FOR controls that operate 115VAC solenoid valves: Wire that is con-
nected to original RETRACT solenoid valve, 115V L (not neutral)
FOR controls that operate 24DC solenoid valves: Wire that went to
original RETRACT solenoid control + voltage.
SVRH
17 18 19 20 21 22 23
RETRACT
VALVE
ON
RETRACT
LOW PRES.
RETRACT
HIGH
PRES.
SVC SVR SVC SVL SVC SVH
VALVE
SUPPLY
SVC
FACTORY WIRED TO RETRACT HIGH PRES. VALVE
WHITE/BLACK STRIPE WIRE:
For controls that operate 115VAC solenoid valves: Connect to 115V N.
For controls that operate 24DC solenoid valves: Connect to 0V (GND).
Leave the exist RETRACT solenoid valve in place
and wired to the original welding control terminals.
14
OPTIONAL RETRACT WITH SOFT TOUCH
9381-34JB3/PMCO & 9381-34JB3
(continued)
PLUMBING: Connect hoses from the input port on the existing RETRACT
SOLENOID to the bulkhead on the SOFT TOUCH enclosure as shown below.
ADJUST the RETRACT BUCKING REGULATOR until the electrodes close
with less than 50 pounds of force. Follow the rotation symbol on the drawing
below that matches your SOFT TOUCH model.
CAUTION: On 9381-34JB3 (rocker arm welders), changing the OPENING
PRESSURE regulator will require changing the RETRACT BUCKING PRES-
SURE regulator to keep the force below 50 pounds.
EXISTING RETRACT SOLENOID VALVE.
MUST BE EXTERNALLY PILOTED OR
DIRECT ACTION.
1
3
22
SET WHITE PADDLE
TO READ 3-NC
FROM THIS SIDE
TO RETRACT
VALVE INPUT
1
3
SVRL
NEW 3-WAY
SOLENOID VALVE
RETRACT BUCKING
REGULATOR
DIAPHRAGM HEAD
SVRH
TO LINE AIR IN
EXT. PILOT
CYLINDER HEAD
1
3
SVRL
2
1
3
SVRH
TO RETRACT
VALVE INPUT
2
SET WHITE PADDLE-
TO READ 3-NO
FROM THIS SIDE
EXT. PILOT
IMPORTANT: CONNECT COIL WIRES
AND SET WHITE PADDLE TO MATCH
TYPE OF WELDER HEAD
PLUMBING FOR 9381-34JB3/PMCO
PLUMBING FOR 9381-34JB3
EXISTING RETRACT
SOLENOID VALVE
TO LINE AIR IN
RETRACT BUCKING PRESSURE
RETRACT BUCKING PRESSURE
This manual suits for next models
3
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