Unitec Peco HF25A, HF25D, HF25A10/240, HF25A10/400, HF25A10/480 User Manual
...
USER'S MANUAL 990-333
Revision B December 2003
HF25A/HF25D 25kHz HIGH FREQUENCY
DC RESISTANCE WELDING SYSTEM
MODEL NUMBER STOCK NUMBER
HF25A10/240 1-280-02-03
HF25A10/400 1-280-02-04
HF25A10/480 1-280-02-05
HF25DA10/240 1-285-02
HF25DA10/400 1-285-02-01
HF25DA10/480 1-285-02-02
Copyright © 1998, 2003 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 19826 9/03 None. Original edition.
B 19895 12/03 Updated LVDT Option information.
HF25D DC RESISTANCE WELDING SYSTEM
ii 990-333
CONTENTS
Page
Chapter 1. Description
Section I: Features .................................................................................................................................. 1-1
Section II: Major Components ............................................................................................................... 1-4
Major Components .......................................................................................................................... 1-4
Front Panel Display and Display Controls ......................................................................................1-4
Display ..................................................................................................................................... 1-5
Display Controls ....................................................................................................................... 1-6
SCHEDULE Selector Key ................................................................................................ 1-6
Weld Period Selector Keys ............................................................................................... 1-6
Time/Energy Selector Keys .............................................................................................. 1-6
Front Panel Data Entry and Mode Controls ............................................................................. 1-7
Key Pad .................................................................................................................................... 1-7
Numeric Keys .................................................................................................................... 1-7
Up/Down Keys .................................................................................................................. 1-7
Mode Key ................................................................................................................................. 1-7
RUN Key ........................................................................................................................... 1-7
MENU Key ....................................................................................................................... 1-7
Control Keys ............................................................................................................................. 1-7
Energy Units Selection Keys ............................................................................................. 1-7
KA .............................................................................................................................. 1-7
V ................................................................................................................................. 1-7
KW ............................................................................................................................. 1-8
Monitor Keys ............................................................................................................................ 1-8
KA ..................................................................................................................................... 1-7
V ..................................................................................................................................... 1-8
KW .................................................................................................................................... 1-8
Resistance (Ω) ................................................................................................................... 1-8
Peak/Average .................................................................................................................... 1-8
LVDT Keys .............................................................................................................................. 1-9
Distance ............................................................................................................................. 1-9
New Electrode ................................................................................................................... 1-9
Quick Cal ........................................................................................................................... 1-9
WELD/NO WELD Switch ....................................................................................................... 1-9
Emergency Stop Switch Operation .......................................................................................... 1-9
Chapter 2. Getting Started
Section I: Planning for Installation ........................................................................................................ 2-1
Space Requirements ......................................................................................................................... 2-1
Utilities ..................................................................................................................................... 2-2
Power ..................................................................................................................................... 2-2
Compressed Air and Cooling Water ......................................................................................... 2-2
HF25D DC RESISTANCE WELDING SYSTEM
990-333 iii
Contents (Continued)
Page
Section II: Setup ..................................................................................................................................... 2-3
Connections to External Equipment ................................................................................................ 2-3
Weld Head Connections .................................................................................................................. 2-4
Foot Pedal-Actuated Weld Head Connection .................................................................................. 2-6
Air-Actuated Weld Head Connection .............................................................................................. 2-7
Chapter 3. Using Programming Functions
Section I: Menus .................................................................................................................................... 3-1
Overview ..................................................................................................................................... 3-1
Main Menu ..................................................................................................................................... 3-1
1. Setup .................................................................................................................................... 3-1
2. Weld Counter ....................................................................................................................... 3-2
3. Copy A Schedule ................................................................................................................. 3-2
4. System Security ................................................................................................................... 3-3
1. Schedule Lock .............................................................................................................. 3-3
2. System Lock ................................................................................................................. 3-3
3. Calibration Lock ........................................................................................................... 3-3
5. Communication ................................................................................................................... 3-4
1. Communication Role .................................................................................................... 3-4
2. I.D. Number .................................................................................................................. 3-5
3. Baud Rate ...................................................................................................................... 3-5
6. Relay .................................................................................................................................... 3-6
7. Calibration ............................................................................................................................ 3-6
8. Reset To Defaults ................................................................................................................ 3-7
1. Reset System Parameters ............................................................................................. 3-7
2. Reset All Schedules ...................................................................................................... 3-7
9. Chain Schedules .................................................................................................................. 3-8
Setup 1 ................................................................................................................................... 3-10
1. Footswitch Weld Abort ..................................................................................................... 3-10
2. Switch Debounce Time ..................................................................................................... 3-10
3. Firing Switch ..................................................................................................................... 3-11
1. Auto ............................................................................................................................ 3-11
2. None ........................................................................................................................... 3-11
3. Remote ....................................................................................................................... 3-11
4. Input Switch Select ............................................................................................................ 3-11
1. Mechanical ................................................................................................................. 3-12
2. OPTO ......................................................................................................................... 3-12
3. PLC ............................................................................................................................. 3-12
5. Control Signals Select ....................................................................................................... 3-13
Setup 2 ................................................................................................................................... 3-13
1. Display Contrast ................................................................................................................ 3-13
2. Buzzer Loudness ............................................................................................................... 3-13
3. End Of Cycle Buzzer ......................................................................................................... 3-13
4. Update Graph After Weld ................................................................................................. 3-14
HF25D DC RESISTANCE WELDING SYSTEM
iv 990-333
Page
Section II. Operational States .............................................................................................................. 3-15
No Weld State ................................................................................................................................ 3-15
Menu State ................................................................................................................................... 3-15
Test State ................................................................................................................................... 3-15
Run State ................................................................................................................................... 3-16
Weld State ................................................................................................................................... 3-17
Monitor State ................................................................................................................................. 3-17
Alarm State ................................................................................................................................... 3-18
Section III. Weld Functions ................................................................................................................. 3-19
Welding Applications .................................................................................................................... 3-19
Weld Head Applicability ............................................................................................................... 3-20
Section IV: Using Weld and Monitor Functions ................................................................................. 3-21
Overview ................................................................................................................................... 3-21
Weld Schedule Definition .............................................................................................................. 3-22
Weld Sequence Timing .................................................................................................................. 3-22
Welding Applications .................................................................................................................... 3-23
Single-Pulse Weld Profile ...................................................................................................... 3-23
Upslope/Downslope Weld Profile .......................................................................................... 3-24
Dual-Pulse Weld Profile ......................................................................................................... 3-24
Section V. Programmable Feedback Modes ........................................................................................ 3-26
Introduction ................................................................................................................................... 3-26
Current Mode ................................................................................................................................. 3-26
Voltage Mode ................................................................................................................................ 3-26
Power Mode ................................................................................................................................... 3-26
Section VI. Weld Monitor .................................................................................................................... 3-27
Introduction ................................................................................................................................... 3-27
Active Part Conditioner (APC) ...................................................................................................... 3-27
How It Works ......................................................................................................................... 3-28
Energy Limits ................................................................................................................................ 3-29
Pre-Weld Check ............................................................................................................................. 3-30
Chapter 4. Operating Instructions
Section I: Before You Start ............................................................................................................. 4-1
Initial Setup: Pre-Operational Checks ..................................................................................... 4-2
Connections ....................................................................................................................... 4-2
Power ................................................................................................................................. 4-2
Compressed Air ................................................................................................................. 4-2
Initial Setup Instructions ........................................................................................................... 4-2
Section II. Programming Weld Schedules ...................................................................................... 4-3
Introduction .............................................................................................................................. 4-3
Select a Weld Schedule ..................................................................................................... 4-3
Enter New Values .............................................................................................................. 4-3
HF25D DC RESISTANCE WELDING SYSTEM
990-333 v
Contents (Continued)
Page
Single-Pulse Weld Schedule ..................................................................................................... 4-4
Upslope/Downslope Weld Schedule ........................................................................................4-5
Dual-Pulse Weld Schedule ....................................................................................................... 4-6
Section III. Programming the Weld Monitor .................................................................................. 4-7
Section IV. Programming For Active Part Conditioning ............................................................... 4-9
Section V. Adjusting Monitor Limits ........................................................................................... 4-11
Chapter 5. User Maintenance
Section I: Introduction ........................................................................................................................... 5-1
General Kinds of Problems .............................................................................................................. 5-1
Alarm Messages ............................................................................................................................... 5-1
Section II: Troubleshooting ................................................................................................................... 5-2
Troubleshooting ............................................................................................................................... 5-2
Alarm Messages ............................................................................................................................... 5-3
Section III: Maintenance ........................................................................................................................ 5-9
Electrode Maintenance .................................................................................................................... 5-9
Parts Replacement ........................................................................................................................... 5-9
Section IV: Maintenance ...................................................................................................................... 5-10
Chapter 6. Calibration
Calibration ..................................................................................................................................... 6-1
Calibration Equipment Required ..................................................................................................... 6-1
Calibration Procedure ..................................................................................................................... 6-2
Calibrating the LVDT ...................................................................................................................... 6-4
Appendix A. Technical Specifications ............................................................................................... A-1
Appendix B. Electrical and Data Connections ..................................................................................B-1
Appendix C. System Timing ...............................................................................................................C-1
Appendix D. LVDT Option ................................................................................................................ D-1
Appendix E. Communications ............................................................................................................E-1
Appendix F. The Basics of Resistance Welding ................................................................................F-1
Appendix G. Quality Resistance Welding Solutions: Defining the Optimum Process ................ G-1
HF25D DC RESISTANCE WELDING SYSTEM
vi 990-333
CONTACT US
Thank you for purchasing a Unitek Peco™ Resistance Welding System Control.
Upon receipt of your equipment, please thoroughly inspect it for shipping damage prior to its
installation. Should there be any damage, please immediately contact the shipping company to file a
claim, and notify Unitek Miyachi at:
1820 South Myrtle Avenue
P.O. Box 5033
Monrovia, CA 91017-7133
Telephone: (626) 303-5676
FAX: (626) 358-8048
e-mail: info@unitekmiyachi.com
The purpose of this manual is to supply operating and maintenance personnel with the information
needed to properly and safely operate and maintain the Unitek Peco HF25 Resistance Welding System
Control.
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 contact us at
the above location/numbers.
Unitek Miyachi Corporation is not responsible for any loss due to improper use of this product.
HF25D DC RESISTANCE WELDING SYSTEM
990-333 vii
SAFETY NOTES
DANGER
• Lethal voltages exist within this unit. Do not perform any maintenance
inside this unit.
• Never perform any welding operation without wearing protective safety
glasses.
This instruction manual describes how to operate, maintain and service the HF25 Resistance Welding
System Control, and provides instructions relating to its SAFE use. A separate manual provides similar
information for the Weld Head used in conjunction with the Power Supply. Procedures described in
these manuals MUST be performed, as detailed, by QUALIFIED and TRAINED personnel.
For SAFETY, and to effectively take advantage of the full capabilities of the Weld Head and Power
Supply, please read these instruction manuals before attempting to use them.
Procedures other than those described in these manuals or not performed as prescribed in them, may
expose personnel to electrical, burn, or crushing hazards.
After reading these manuals, retain them for future reference when any questions arise regarding the
proper and SAFE operation of the Power Supply.
Please note the following conventions used in this manual:
WARNING: Comments marked this way warn the reader of actions which, if not followed, might
result in immediate death or serious injury.
CAUTION: Comments marked this way warn the reader of actions which, if not followed, might result
in either damage to the equipment, or injury to the individual if subject to long-term exposure to the
indicated hazard.
HF25D DC RESISTANCE WELDING SYSTEM
viii 990-333
HF25D DC RESISTANCE WELDING SYSTEM
990-333 ix
CHAPTER 1
DESCRIPTION
Section I: Features
Features
For the rest of this manual, the Unitek HF25
High Frequency Resistance Welding System
control will simply be referred to as the Control.
• The Control is a 25 kHz, three-phase, state-
of-the-art inverter power supply for joining
precision small parts at high speed with
controllable rise times. The delivered
welding energy is in the form of DC welding
energy. High speed (50 microsecond)
digital feedback automatically controls weld
current, voltage, or power, providing more
welding consistency compared to traditional
direct energy (AC) or capacitive discharge
(CD) technologies.
• Microprocessor technology automatically
compensates for changes in work piece
resistance, load inductance, weld
transformer saturation, and changes in line
voltage. Special power device technology
precisely controls 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 3 or
more.
HF25D Front Panel
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CHAPTER 1: DESCRIPTION
• You can program the Control from the front
panel, using simplified key clusters and on-
screen data fields. A MAIN MENU screen
allows you select all of the system setup
options for working with inputs from
external equipment.
• The RUN screen allows you to easily modify
any time period, current, voltage, or power
value.
<MAIN MENU>
1. SETUP 5.
COMMUNICATION
2. WELD COUNTER 6. RELAY
3. COPY A SCHEDULE 7. CALIBRATION
4. SYSTEM SECURITY 8. RESET TO
DEFAULTS
NUMBER Select an item
Run Screen
• The
MONITOR screen provides instant visual
feedback on the actual current, voltage, or
power used to make each weld. It permits
you to program adjustable limits for both
weld pulses.
Monitor Screen
• Rear-mounted RS-232 and RS-485 connectors allow for remote programming, weld schedule
selection, and data logging for SPC purposes. The Control has communication and data options
that allows you to connect a single Control, or multiple Controls, to a printer or a computer in
order to:
− Compile, store, view, and print weld history data for detailed analysis.
− Remotely program weld schedules on the Control(s).
− Remotely program menu items on the Control(s).
However, to enable the Control to perform these functions, you must install the software from the
optional HF25 Advanced Serial Datacom Communications Interface Kit, commonly referred to as
"the Datacom kit," in a host computer.
Appendix E, Communications in this manual lists all of the commands that the Control will respond
to, and instructions on how to format commands sent to the Control so it will respond properly.
HF25D DC RESISTANCE WELDING SYSTEM
1-2 990-333
CHAPTER 1: DESCRIPTION
• The Control has a Linear Variable Differential Transformer (LVDT) option that allows the
user to:
− Measure Initial Part Thickness
− Measure Final Part Thickness
− Measure displacement during welding
− Stop the weld energy after a programmable displacement is reached.
Programmable relay outputs are also provided with this option. For details see Appendix D, LVDT
option.
• The design of the Control is directed toward compactness, lightweight, operational simplicity, and
ease of repair. Metric hardware is used throughout the chassis to facilitate international servicing
and repair.
• The 25 kHz operating frequency ensures that the integral welding transformer is light and compact.
The input/ output connector box on the rear panel is easily removable for replacement by quick-
connect signal I/O cabling, facilitating interface with automation systems.
I/O Connector Box (Rear Panel)
HF25D DC RESISTANCE WELDING SYSTEM
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CHAPTER 1: DESCRIPTION
Section II: Major Components
Major Components
The major components are the front panel, which contains the operator’s controls and indicators, and the
rear panel, which contains fuses, circuit breakers and power and signal connectors. The rear panel
connections are discussed in Chapter 2.
Front Panel Display and Display Controls
The front panel of the Control below shows controls and indicators. The function of each item is
described on the following pages.
HF25D DC RESISTANCE WELDING SYSTEM
1-4 990-333
Front Panel Controls
CHAPTER 1: DESCRIPTION
Display
Liquid Crystal Display (LCD)
The Liquid Crystal Display (LCD) on the front panel allows you to locally program the Control with the
front panel controls, and read the results of a weld process following its initiation.
The LCD has three distinct functions, depending on the active mode of the Control. In the run mode, the
display permits you to:
• View the entire weld schedule profile, individual weld periods, and weld energy parameters.
• View individual weld parameter program changes as you enter them via the weld period
selector keys.
• View completed weld feedback data and use the data to modify the weld schedule.
In the menu mode, the display presents system setup options for you to select. In the monitor mode, the
display is your means of programming the energy limits monitor and viewing actual out of limit
conditions.
HF25D DC RESISTANCE WELDING SYSTEM
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CHAPTER 1: DESCRIPTION
Display Controls
There are three display control functions:
• SCHEDULE Selector Key
• Weld Period Selector Keys
• Time/Energy Selector Keys
SCHEDULE Key
Weld Period Selector Keys
Select individual weld periods and weld energy fields in the weld schedule profile for programming.
See Front Panel Data Entry and Mode Controls.
Time/Energy Selector Keys
Puts the Control into the weld schedule selection mode. Use the
keypad to directly enter a desired weld schedule (refer to Front Panel
Data Entry and Mode Controls in this section), then press the RUN
key.
These two switches, one for each of the PULSE 1 and PULSE 2 weld
periods, select either the bottom line of data or the second-to-bottom
line of data on the screen to be programmed. The bottom line of data
is weld period time in milliseconds. The second-to-bottom line is
Weld Energy, in the units selected by the energy units selection keys.
See Front Panel Data Entry and Mode Controls.
HF25D DC RESISTANCE WELDING SYSTEM
1-6 990-333
CHAPTER 1: DESCRIPTION
Front Panel Data Entry and Mode Keys
Key Pad
The keypad consists of the numeric keys and the up/down keys.
Numeric Keys: The numeric keys allow you to:
• Enter or modify weld period time and energy values
• Enter or modify monitor and limit values
• Directly recall a specific weld schedule.
To use the numeric keypad, you must first select a time/energy weld period key or
the schedule key.
Up/Down Keys: The up/down keys allow you to increment (up) or decrement
(down) numeric values on the display, to change states, such as OFF to ON (up)
or ON to OFF (down); and to scroll the schedule number up and down while in
the run mode.
Mode Keys. The mode keys consist of the RUN key and the MENU key.
RUN Key: Sets the Control to the operating mode.
MENU Key: You access the menu screen with this key. Menu items control
system parameters such as setup and weld counter operation. Refer to Menus in
Chapter 3, Section II for details of the functions accessible through that screen.
Control Keys
Energy Units Selection Keys. These keys allow you to select the control mode when programming
with the
WELD (time/energy) selector keys.
Pressing the kA key selects current as the control mode for this schedule. The
control will output the current waveform shown on the LCD.
Pressing the V key selects voltage as the control mode for this schedule. The
control will output the voltage waveform shown on the LCD.
HF25D DC RESISTANCE WELDING SYSTEM
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CHAPTER 1: DESCRIPTION
NOTE: Selecting the voltage feedback mode requires you to make a test weld
when the voltage or weld pulse time is changed. The test weld optimizes the
Control feedback performance. The weld status message TEST disappears after
the internal control parameters are optimized.
Pressing the kW key selects power as the control mode for this schedule. The
control will output the power waveform shown on the LCD.
Monitor Keys
These keys allow you to view the results of the last weld and to set the limits of the welding parameters
beyond which the energy limits monitor terminate the weld and/or initiate alarms.
Pressing the kA key displays the current monitor. This screen shows the results of
the most recent weld. This screen also allows the operator to set limits that
automatically interrupt the weld when they are reached. You can also program
the current monitor to output an alarm when the limits are exceeded.
Pressing the V key displays the voltage monitor. This screen shows the results of
the most recent weld. This screen also allows the operator to set limits that
automatically interrupt the weld when they are reached. You can also program
the voltage monitor to output an alarm when the limits are exceeded.
Pressing the kW key displays the power monitor. This screen shows the results of
the most recent weld. This screen also allows the operator to set limits that
automatically interrupt the weld when they are reached. You can also program
the power monitor to output an alarm when the limits are exceeded.
Pressing the Ω key displays the resistance monitor. This screen shows the results
of the most recent weld.
Pressing this key selects either peak welding energy or average welding energy to
be monitored by the energy limits monitors.
HF25D DC RESISTANCE WELDING SYSTEM
1-8 990-333
LVDT Keys
Pressing DISTANCE displays the displacement monitor. This screen shows the
results of the most recent weld. This screen also allows the operator to set limits
that automatically interrupt the weld when they are reached. You can also
program the power monitor to output an alarm when the limits are exceeded
Pressing NEW ELECTRODE allows the operator to reset the zero point for distance
measurement. This is useful when electrodes are changed and the new electrode
may be slightly longer or shorter than the old one.
Pressing QUICK CAL enters the displacement calibration routine. This routine sets
a new zero point for the distance measurement and calibrates the measurement.
WELD/NO WELD Switch
CHAPTER 1: DESCRIPTION
When the switch is in the WELD position, the programmed weld sequence can
initiate weld energy.
When you set this switch to the NO WELD position, no weld current can flow.
However, the Control can execute a complete weld sequence. This function is
required to adjust the weld head prior to operation.
Emergency Stop Switch Operation
If your work station is equipped with an emergency stop switch (connected to the emergency stop
connection of the Control), operate the switch to immediately stop the welding process. All power to
the air valves and power circuits will be disconnected. To restart the Control, you must press the RUN
key on the front panel.
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CHAPTER 2
INSTALLATION AND SETUP
Section I: Installation
Unpacking
The Control is shipped to you completely assembled, together with the accessories you ordered and a
shipping kit. The contents of the shipping kit, available accessories, and contents of the Datacom Kit are
listed in Appendix A, Technical Specifications. Be sure that the accessories that you ordered have been
packed and the contents of the shipping kit and Datacom kit are as listed.
Verify that the Control shows no signs of damage. If it does, please contact the carrier. Also, contact
Unitek Miyachi Customer Service immediately at the postal or e-mail address or telephone or FAX
number shown in the Foreword of this manual.
Space Requirements
We recommend that the Control be installed in a well-ventilated area that is free from excessive dust,
acids, corrosive gases, salt and moisture. Other installation considerations are:
• Allow sufficient clearance around both sides and back of the Control for power and signal
cabling runs.
• Allow ample workspace around the Control so that it will not be jostled or struck while
welding. The dimensions of the Control are:
Height: 12.8 in. (325 mm)
Width: 9.0 in. (229 mm)
Depth: 18.0 in. (457 mm)
• The work surface must be level, stable, free from vibration, and capable of supporting the
combined weight of the total welding system. The weight of the Control is 62 lbs. (28 kg).
• The Control must be far enough from the weld head to avoid contact with weld splash.
• There are no sources of high-frequency energy close by.
HF25D DC RESISTANCE WELDING SYSTEM
990-333 2-1
CHAPTER 2: INSTALLATION AND SETUP
Utilities
Power
Because of the different electrical requirements for the countries in which the Control is used, the
Control is shipped without a power cable connector. The required connections for your power cable
connector are described in Appendix B, Electrical and Data Connections. Input power requirements for
the Control are as listed below.
Power Input Specifications
Input Voltage,
HF25 Model
HF25A10/240 240 25 10 2.5 6.3 330-096
HF25A10/400 400 20 10 2.5 3.15 330-095
HF25A10/480 480 13 10 2.5 3.15 330-097
50-60 Hz,
3 phase
(Vrms)
Ckt Brkr
Current (A rms)
Copper Wire
Gauge,
7 strands (AWG)
Wire Dia
(mm)
Fuses F1, F2
Amps/
Volts
Unitek Peco
P/N
Compressed Air and Cooling Water
If you require compressed air and cooling water service for the weld head, please refer to the weld head
manufacturer’s user’s manual for service specifications.
HF25D DC RESISTANCE WELDING SYSTEM
2-2 990-333
CHAPTER 2: INSTALLATION AND SETUP
Section II: Setup
Connections to External Equipment
All connections, other than the weld cable connections, between the Control and external equipment are
made through the rear panel.
Rear Panel Components
The weld cable connections from the weld head are made at the weld cable terminals on the front panel.
HF25D DC RESISTANCE WELDING SYSTEM
990-333 2-3
CHAPTER 2: INSTALLATION AND SETUP
Weld Head Connections
1. Connect one end of a weld cable to the negative (-) welding transformer terminal on the
Control.
2. Connect one end of the second weld cable to the positive (+) welding transformer terminal on
the Control.
3. Connect the other end of the weld cables to the weld head.
4. Attach the voltage sensing cable connector to the VOLTAGE SENSE INPUT connector.
5. Install electrodes in the weld head electrode holders.
NOTE: If you need additional information about the weld heads, please refer to their user’s
manuals.
HF25D DC RESISTANCE WELDING SYSTEM
2-4 990-333
6. Connect the voltage sensing cable clips
that are packed in the shipping kit to the
voltage sensing cable leads. Use either the
¼” or 1/8” diameter clip, as appropriate to
the electrode diameter.
7. Attach a clip directly to each electrode as
shown on the right.
8. Put a strain relieve on each voltage sensing
lead to its corresponding electrode holder
so that the lead clips will not break away
under heavy operating conditions.
NOTE: Do not attach the firing
switch, foot switch or
STOP
cables at this time.
EMERGENCY
CHAPTER 2: INSTALLATION AND SETUP
HF25D DC RESISTANCE WELDING SYSTEM
990-333 2-5
CHAPTER 2: INSTALLATION AND SETUP
Foot Pedal-Actuated Weld Head Connection
1. Adjust the weld head force adjustment knob to produce 5 units of force, as displayed on the
force indicator index.
2. Connect the weld head firing switch cable connector to the Control firing switch cable
connector.
3. Adjust the weld head force adjustment knob to produce 5 units of force, as displayed on the
force indicator index.
4. Connect the weld head firing switch cable connector to the Control firing switch cable
connector.
5. Adjust the weld head force adjustment knob to produce 5 units of force, as displayed on the
force indicator index.
6. Connect the weld head firing switch cable connector to the Control firing switch cable
connector.
7. Connect a normally closed, approved, emergency stop switch across the two leads of the
operator emergency stop switch cable. This switch, when operated (open), will immediately
stop the weld cycle. See Appendix B. Electrical and Data Connections for circuit details.
8. Set the
position, the Control cannot deliver weld energy, but it can control the weld head.
WELD/NO WELD switch on the Control front panel to the NO WELD position. In this
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CHAPTER 2: INSTALLATION AND SETUP
9. Set the circuit breaker on the rear panel
of the Control to the ON position. The
default
You will use this screen to enter
welding parameters. See Chapter 3,
Using Weld Functions and Chapter 4,
Operating Instructions.
RUN screen will be displayed.
Air-Actuated Weld Head Connections
1. Adjust the weld head force adjustment knob to produce 5 units of force, as displayed on the
force indicator index.
2. Connect the weld head firing switch cable connector to the Control firing switch cable
connector.
3. Connect a normally closed, approved, emergency stop switch across the two leads of the
operator emergency stop switch cable. This switch, when operated (open), will immediately
stop the weld cycle and retract the weld head. See Appendix B. Electrical and Data
Connections for circuit details.
4. Connect a Model FS2L Foot Switch to the Control FOOT SWITCH connector.
HF25D DC RESISTANCE WELDING SYSTEM
990-333 2-7
CHAPTER 2: INSTALLATION AND SETUP
5. Refer to the weld head manufacturer user’s manual. Connect the weld head air valve solenoid
cable connector to the Control AIR VALVE DRIVER connector.
NOTE: This connector supplies 24 VAC power only, and will not drive 115 VAC air valves.
6. Connect a properly filtered air line to the air inlet fitting on 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. Limit the length of the air
line to less than 40 in. (1 m) or electrode motion will be very slow.
NOTE: Use a lubricator only with automated installations.
7. Turn on the air system and check for leaks.
8. Set the
WELD/NO WELD switch on the Control front panel to the NO WELD position. In this
position, the Control cannot deliver weld energy, but it can control the weld head.
9. Set the circuit breaker on the rear panel
of the Control to the ON position. The
default
RUN screen will be displayed.
See Chapter 3, Using Weld Functions
and Chapter 4, Operating Instructions.
10. Turn the air regulator clockwise to produce 10 psi on the air regulator pressure gauge.
11. Press the foot switch all the way down to close both levels, and hold the foot switch down.
When the weld head upper electrode rises to the UP position, release the foot switch. Proceed
to Step 13. If it does not rise to the UP position, proceed to Step 12.
12. Increase air pressure in 5 psi increments and repeat Step 11 until the upper electrode rises to the
UP position.
13. Press the foot switch to actuate the first level. The weld head upper electrode should descend
smoothly to the DOWN position. When it reaches the down position, release the foot switch
and proceed to Step 15. If it does not descend smoothly, proceed to Step 14.
14. Adjust the weld head down speed control knob and repeat Step 13 until the upper electrode
descends smoothly.
15. Press the foot switch to actuate the first level and set the upper electrode to the DOWN
position. Release the foot switch and verify that upper electrode holder does not impact the UP
home position.
16. Repeat Step 15, adjusting the weld head up speed control knob until the upper electrode holder
does not impact at the UP home position.
HF25D DC RESISTANCE WELDING SYSTEM
2-8 990-333
USING PROGRAMMING FUNCTIONS
Overview
CHAPTER 3
Section I: Menus
You program the Control through the MAIN
MENU
screen and its sub-menus. You go to the
MAIN MENU screen by pressing the MENU key on
the front panel of the Control.
All of the menu screens have similar prompts
that tell you how to go to a function on the menu
1. SETUP 5. COMMUNICATION
2. WELD COUNTER 6. RELAY
3. COPY A SCHEDULE 7. CALIBRATION
4. SYSTEM SECURITY 8. RESET TO DEFAULTS
9. CHAIN SCHEDULES
NUMBER Select an item
MAIN MENU
and/or get to the next menu.
• At the NUMBER Select an item prompt, use the numeric keypad to select one of the functions on
the menu.
• Press the down keys to go to the next or previous menu. Each additional menu gives you
choices for additional functions.
• Press the MENU key to return to the main menu.
Main Menu
1. SETUP
From the MAIN MENU screen, press 1 to go to the
SETUP 1 screen.
The SETUP 1 screen is shown on the right with
typical settings.
1. FOOTSWITCH WELD ABORT : ON
2. SWITCH DEBOUNCE TIME : 10 ms
3. FIRING SWITCH : NORMAL
4. INPUT SWITCH SELECT : MECH OPEN
5. CONTROL SIGNALSEL ECT : MECH OPEN
NUMBER Select, MENU Main menu, W Page 2
<SETUP 1>
From the SETUP 2 screen, go to the SETUP 1
screen then press the key.
The SETUP 2 screen is shown on the right with
typical settings.
HF25 DC RESISTANCE WELDING SYSTEM
990-333 3-1
<SETUP 2>
1. DISPLAY CONTRAST : 075%
2. BUZZER LOUDNESS : 015%
3. END OF CYCLE BUZZER : OFF
4. UPDATE GRAPH AFTER WELD : ON
NUMBER Select, MENU Main menu, VPage 1
CHAPTER 3: USING PROGRAMMING FUNCTIONS
2. WELD COUNTER
1. From the MAIN MENU, press the 2 key
to go to the WELD COUNTERS screen.
The total welds counter increments each
time a weld is made in any weld
schedule.
1. TOTAL WELDS : 0000000
2. OUT OF LIMITS HIGH : 000000
3. OUT LIMITS LOW : 000000
4. WITHIN LIMITS : 000000
NUMBER Select, MENU Previous menu
<WELD COUNTERS>
NOTE: The Control breaks down the weld count into three additional categories, as
determined by the energy limits monitor: rejects due to higher than programmed weld energy,
rejects due to lower than programmed weld energy, and the number of acceptable welds.
2. To select the weld counters, press the 1, 2, 3 or 4 key to select the desired weld counter.
The example to the right shows the TOTAL WELDS screen.
3. To reset the counter, press the 0 key.
4. To input a preset number, use the
numeric keys.
5. If you accidentally reset the wrong
counter, press the period (.) key. The
original count will reappear. Press the
MENU key to return to the MAIN MENU
1. TOTAL WELDS : 0017429
NUMBER Change, . Restore, MENU Menu
WELD COUNTER>
screen.
3. COPY A SCHEDULE
The Control can store 99 (numbered 1 through
99) individual weld energy profiles. This
function allows you to copy any weld schedule
from one numbered weld schedule to another
numbered weld schedule
1. From the
go to the
MAIN MENU, press the 3 key to
COPY SCHEDULE screen.
2. Using the numeric keys, enter 1 in the
source schedule number field.
3. Press the
SCHEDULE key to select the
destination schedule number field.
4. Using the numeric keys, enter
2 in the
COPY SCHEDULE [ 1 ] TO SCHEDULE [2 ]
NUMBERS followed by SCHEDULE
COPY SCHEDULE [ 1 ] TO SCHEDULE [2 ]
NUMBERS followed by SCHEDULE
COPY SCHEDULE
COPY SCHEDULE
destination schedule number field.
5. Press the SCHEDULE key to copy the schedule and exit the screen.
6. Press the
MENU key to return to the main menu. The contents of Weld Schedule 1 will be
copied to Weld Schedule 2, overwriting the previous contents of Weld Schedule 2.
HF25 DC RESISTANCE WELDING SYSTEM
3-2 990-333
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