Unitek HF2/230, HF2/380, HF2/460, HF2/208, HF2S/230 User Manual

USER'S MANUAL 990-057
Revision K, May 2004

Use with Firmware Release V1.19 or higher

MODEL HF2

2 kHz HIGH FREQUENCY

RESISTANCE WELDING POWER SUPPLY

MODEL NUMBER STOCK NUMBER

HF2/230 1-264-03

HF2/380 1-264-03-01

HF2/460 1-264-03-02

HF2/208 1-264-03-03

HF2S/230 1-265-03

HF2S/380 1-265-03-01

HF2S/460 1-265-03-02

HF2S/208 1-265-03-03

Units with the built-in Weld Sentry Option also require User's Manual No. 990-291

Please be sure to read all personnel and equipment
safety precautions noted in this manual.

WARNING

1998, 2002 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 ENRG-RLSE 3/95 Released original manual.

B None 9/95 Reorganize manual into chapters.

C None 1/96 Amend to Firmware V1.17 or higher.

D None 2/96 Update cover stock numbers

E None 4/97 Amend to Firmware V1.19 or higher.

F 17472 6/98 1. Remove existing calibration procedure and reference User Calibration

Procedure 994-001.

2. Miscellaneous corrections.

3. Remove SAVE error.

G

H 19012 9/01 1. Include EO# 118951 in manual.

J 19146 1/02 1. Include EO# 19012.

K 20016 5/04 Updated wire data.

18951 8/01

1. Include EO# 17693 in manual.

2. Add latest version of Operator Guide.

2. Add latest version of Operator Guide.

2. Miscellaneous Corrections.

3. Add Appendix F, Quality Resistance Welding Solutions, and Appendix

G, Replacement of Programmed Integrated Circuits.

MODEL HF2 2kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY

ii 990-057

FOREWORD

The purpose of this manual is to supply operating, maintenance and service personnel with the
information needed to properly and safely operate, maintain and service the Unitek Peco Model HF2 2
kHz High Frequency Resistance Welding Power Supply.

Should questions arise, or if you have suggestions for improving this manual, please contact:

Unitek Miyachi Corporation
1820 South Myrtle Avenue
P.O. Box 5033
Monrovia, CA 91017-7133
Telephone:[phone]
FAX:[phone]
E-mail: [e-mail]

NOTICE

Unitek Miyachi Corporation may be released from all warranty obligations if repairs or modifications
are made by persons other than its own service personnel, or authorized representatives' personnel,
unless such repairs or modifications are specifically authorized in writing by the Unitek Miyachi
Corporation.

WARNING

Contact with voltages present in this power supply may cause serious or fatal injuries. Please read the
manual completely and note all cautions and warnings before attempting to install, operate or maintain
the power supply.

MODEL HF2 2kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY

990-057 iii

CONTENTS

Page

CHAPTER 1: DESCRIPTION............................................................................................................ 1-1

HF2 description........................................................................................................................................ 1-1

CHAPTER 2: GENERAL SET-UP..................................................................................................... 2-1

Required Connections.............................................................................................................................. 2-1

Physical Space Requirements ........................................................................................................... 2-1

HF2 Weld Control Dimensions ........................................................................................................ 2-1

HF2 Weld Transformer Dimensions ................................................................................................2-1

Power Line Voltage, Current, And Wire Size Requirements........................................................... 2-2

Insulation Requirements .................................................................................................................. 2-2

Power Line Fuse Requirements ........................................................................................................ 2-2

HF2 Weld Transformer Electrical Specifications............................................................................. 2-3

HF2 Welding System Maximum Secondary Loop Resistance......................................................... 2-4

HF2 Maximum Secondary Loop Resistance Measurement ............................................................. 2-4

HF2 Weld Control To HF2 Weld Transformer Connections ........................................................... 2-4

HF2 Weld Transformer To Weld Head Connections....................................................................... 2-5

Weld Sentry Option .......................................................................................................................... 2-5

Help Screen Languages .................................................................................................................... 2-5

CHAPTER 3: WELDING SYSTEM SET-UP ................................................................................... 3-1

Welding System Set-Up Guide................................................................................................................ 3-1

General Programming Instructions.......................................................................................................... 3-1

Unitek Peco Force Fired, Foot Actuated Weld Head System.................................................................. 3-2

Weld Head Set-Up............................................................................................................................ 3-2

Firing Switch Cable Connection....................................................................................................... 3-2

Quick Start Programming Guide ..................................................................................................... 3-2

Unitek Peco Force Fired, Single Air Actuated Weld Head System ........................................................ 3-4

Weld Head Set-Up............................................................................................................................ 3-4

Firing Switch Cable Connection....................................................................................................... 3-4

Weld Head Valve Driver No. 1 Connection ............................................................................................ 3-4

Foot Switch Connection ................................................................................................................... 3-4

Single Air Regulator Adjustment (Model 80 Series) ....................................................................... 3-5

Dual Air Regulator Adjustments (Model 180 And Model 90 Series).............................................. 3-6

Quick Start Programming Guide ...................................................................................................... 3-6

Unitek Peco Force Fired, Dual Air Actuated Weld Head System........................................................... 3-8

General Information.......................................................................................................................... 3-8

HF2 Control, Jumper Modifications................................................................................................. 3-8

Weld Head Set-Up............................................................................................................................ 3-8

Firing Switch Cable Connection....................................................................................................... 3-9

MODEL HF2 2kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY

iv 990-057

CONTENTS (Continued)

Page

CHAPTER 3: WELDING SYSTEM SET-UP (Continued)

Weld Head Valve Driver Connections .......................................................................................... 3-10

Foot Switch Connection ................................................................................................................. 3-10

Dual Air Regulator Adjustments .................................................................................................... 3-11

Quick Start Programming Guide .................................................................................................... 3-15

Non-Force Fired, Single Air or Cam Actuated Weld Head System............................................... 3-17

LC To HF2 Control Electrical Connections .................................................................................. 3-17

PLC Timing Diagram ..................................................................................................................... 3-18

Quick Start Programming Guide .................................................................................................... 3-18

Non-Force Fired, Multiple Air Actuated Weld Head System ........................................................ 3-20

CHAPTER 4: CONTROLS ................................................................................................................. 4-1

HF2 Weld Control - Front Panel ............................................................................................................ 4-1

HF2 Weld Control - Rear Panel Inputs and Outputs ............................................................................... 4-3

Power ................................................................................................................................................ 4-3

Fuses F1 and F2 ............................................................................................................................... 4-3

Sensing Port ..................................................................................................................................... 4-3

Sensing Port - Connector Pin Assignments .................................................................................... 4-4

Output .............................................................................................................................................. 4-4

Foot Switch Connector .................................................................................................................... 4-5

Single-Level Foot Switch ......................................................................................................... 4-5

Two-Level Foot Switch ............................................................................................................4-5

Firing Switch Operation .......................................................................................................................... 4-6

Mechanical Firing Switch Cable ..................................................................................................... 4-6

Optical Firing Switch Connector ..................................................................................................... 4-6

Mechanical Firing Switch - 3-Wire Connection .............................................................................. 4-6

Opto Coupler Firing Switch - 3-Wire Connection .......................................................................... 4-6

Control Signals Connector ............................................................................................................... 4-7

Control Signals - Pin Assignments .................................................................................................. 4-8

Control Signals - Remote Weld Schedule Selection Input .............................................................. 4-9

Control Signals - Emergency Stop Input ......................................................................................... 4-9

Control Signals - Process Inhibit Input .......................................................................................... 4-10

Control Signals - Output Relays .................................................................................................... 4-10

Relay K1 ........................................................................................................................................ 4-10

Relay K2 ........................................................................................................................................ 4-10

Accessory Port ............................................................................................................................... 4-10

Air Valve 1 and Air Valve 2 Driver Connectors ..................................................................................4-11

Air Valve 1 Driver ......................................................................................................................... 4-11

Air Valve 2 Driver ......................................................................................................................... 4-11

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990-057 v

CONTENTS (Continued)

Page

CHAPTER 5: PROGRAMMING MODES........................................................................................ 5-1

Help Screens ..........................................................................................................................................5-1

Machine States ........................................................................................................................................ 5-1

Weld Graph Run State ............................................................................................................................. 5-1

Basic Weld Monitor Run State ................................................................................................................ 5-2

Alphanumeric Run State.......................................................................................................................... 5-2

No Weld State ......................................................................................................................................... 5-2

Standby State .......................................................................................................................................... 5-2

Alarm State ............................................................................................................................................. 5-3

Fire State ................................................................................................................................................. 5-3

Menu State .............................................................................................................................................. 5-3

Program State .......................................................................................................................................... 5-4

Weld Graph Program State ..................................................................................................................... 5-4

Alphanumeric Program State .................................................................................................................. 5-5

Output Relays .......................................................................................................................................... 5-6

Relay 1 - Dual Air Head Operation ........................................................................................................ 5-7

CHAPTER 6: ADVANCED WELDING FUNCTIONS ................................................................... 6-1

Weld Functions ....................................................................................................................................... 6-1

Basic Weld ............................................................................................................................................. 6-2

Weld / Repeat .......................................................................................................................................... 6-3

Quench/Temper ....................................................................................................................................... 6-4

Pre/Postheat ............................................................................................................................................ 6-5

Up/Down Slope ....................................................................................................................................... 6-7

Braze .................................................................................................................................................. 6-8

Rollspot .................................................................................................................................................. 6-9

Seam ................................................................................................................................................ 6-10

Dual Pulse ............................................................................................................................................. 6-11

Pulsation ................................................................................................................................................ 6-13

CHAPTER 7: SPECIAL FEATURES ............................................................................................... 7-1

System Options ....................................................................................................................................... 7-1

Weld Counter .......................................................................................................................................... 7-8

Copy a Schedule ..................................................................................................................................... 7-9

System Security ...................................................................................................................................... 7-9

System Help ......................................................................................................................................... 7-11

Weld Sentry .......................................................................................................................................... 7-11

Calibrate HF2 ........................................................................................................................................ 7-11

Reset to Defaults ................................................................................................................................... 7-11

Installation ............................................................................................................................................. 7-13

Transformer Model ............................................................................................................................... 7-13

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vi 990-057

CONTENTS (Continued)

Page

CHAPTER 8: WELD MONITORING .............................................................................................. 8-1

Basic Weld Monitor General Description................................................................................................ 8-1

Weld Current and Weld Voltage Measurements .................................................................................... 8-2

Data Output Capabilities ......................................................................................................................... 8-2

Weld Monitoring Suggestions ................................................................................................................. 8-2

Basic Weld Monitor Programming.......................................................................................................... 8-3

Energy Limit Monitor General Description............................................................................................. 8-4

Energy Limit Monitor Programming....................................................................................................... 8-5

CHAPTER 9: RS-485 DATACOM .................................................................................................... 9-1

Description ............................................................................................................................................. 9-1

RS485 Serial Port Connections ............................................................................................................... 9-2

Datacom Software Installation................................................................................................................. 9-2

F1:Setup .................................................................................................................................................. 9-4

F2:Collect Data ....................................................................................................................................... 9-5

F3:Erase Data .......................................................................................................................................... 9-5

F4:Exit` ................................................................................................................................................... 9-5

APPENDIX A: TECHNICAL SPECIFICATIONS ........................................................................ A-1

APPENDIX B: RECOMMENDED SPARE PARTS ........................................................................B-1

APPENDIX C: ALARM MESSAGES.................................................................................................C-1

APPENDIX D: HELP SCREEN LANGUAGES ............................................................................. D-1

APPENDIX E: THE BASICS OF RESISTANCE WELDING .........................................................E-1

APPENDIX F: QUALITY RESISTANCE WELDING SOLUTIONS:

DEFINING THE OPTIMUM PROCESS ................................................................................... F-1

APPENDIX G: REPLACEMENT OF PROGRAMMED INTEGRATED CIRCUITS .............. G-1

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

MODEL HF2 2kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY

990-057 vii

CHAPTER 1

DESCRIPTION

The Unitek Peco High Frequency Inverter (HF2) is a 2 KHz, three-phase, state-of-the-art inverter
welding control for joining precision small parts at high speed with controllable rise times using 2 KHz
output pulses superimposed on pure DC welding energy. High speed (250 micro-second) digital
feedback automatically controls weld current, voltage, or power, providing more welding consistency
compared to traditional direct energy (AC) or stored energy (CD) technologies. Microprocessor
technology automatically compensates for changes in workpiece resistance, load inductance, weld
transformer saturation, and ñ 13% changes in line voltage. The HF2 uses IGBT power device
technology for precisely controlling 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 five or more. A selectable weld energy
limiting feature also contributes to repeatable welds and high nugget quality. The user can program the
HF2 using a graphical or numerical interface. The Weld Graph Program Mode (Figure 1-1) emulates
many of the popular word processing programs by using the front panel cursor keys to easily modify any
time period, current, voltage, or power value. The Weld Graph Run Mode (Figure 1-2) gives the user
instant visual feedback on the actual current, voltage or power used to make each weld.

Figure 1-1. Program Mode Figure 1-2. Actual Weld Current

The HF2's exclusive, context sensitive, User Help Screens quickly guide the user through even the most
complex program. Each weld schedule can use any one of 10 different Weld Functions, thus matching
the appropriate weld energy profile to the application.

Simple automated welding control is easily accomplished using the BCD Remote Schedule Select
feature. For more complex automation processes, a host computer can use the HF2 Bi-Directional
RS422/RS485 Communications Port to select HF2 Weld Schedules and receive average weld current
and weld voltage data for each weld. Refer to the separate RS-485 Datacom Manual, P/N: 990-058, for
Advanced RS-485 Datacom operation. The 2 KHz operating frequency ensures that the HF2 Weld
Transformers are light weight and compact, providing a significant advantage when they are built into
robotics or automatic machines.

MODEL HF2 2 KHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY

990-057 1-1

CHAPTER 2

GENERAL SET-UP

REQUIRED CONNECTIONS

Physical Space Requirements

Unitek Peco recommends that the HF2 Weld Control and HF2 Weld Transformer be installed in a well
ventilated area that is free from excessive dust, acids, corrosive gases, salt and moisture. Allow
sufficient clearance around both sides and back of the HF2 Weld Control and HF2 Weld Transformer so
that cooling air may flow properly. Figure 2-1 shows the cooling airflow pattern for the HF2 Weld
Control. Figure 2-2 shows the cooling airflow pattern for the HF2 Weld Transformer.

Figure 2-1. HF2 Weld Control

Air Flow Pattern

HF2 Weld Control Dimensions

Width (in/cm) Height (in/cm) Depth (in/cm) Weight (lbs/Kg)

10.5 / 26.7 8.5 / 21.5 15.0 / 38.1 42 / 19

HF2 Weld Transformer Dimensions

Model Height (in/cm) Width (in/cm) Depth (in/cm) Weight (lbs/Kg)

X2/2000A 7.0 / 17.6 5.4 / 13.8 11.0 / 28.0 14.3 / 6.5

X3/4000A 7.2 / 18.3 7.2 / 18.3 13.4 / 34.0 28.6 / 13

X5/3000A 7.5 / 18.9 7.2 / 18.3 14.2 / 36.0 31 / 14

X11/4000A 7.5 / 18.9 7.2 / 18.3 17.9 / 45.5 46 / 21

X11/4/460A 7.4 / 18.8 7.2 / 18.3 18.9 / 48.5 55 / 25

X3/4/380A 7.2 / 18.3 7.2 / 18.3 13.4 / 34.0 28.6 / 13

X3/4/460A 7.2 / 18.3 7.2 / 18.3 13.4 / 34.0 28.6 / 13

Figure 2-2. HF2 Weld Transformer

Air Flow Pattern

MODEL HF2 2 kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY

990-057 2-1

CHAPTER 2: GENERAL SETUP

Power Line Voltage, Current, and Wire Size Requirements

WARNING: The HF2 Weld Control and HF2 Weld Transformer are assembled at the factory for

operation at a specific input power line voltage. Serious damage can result if these units are used on
different voltage other than the voltage for which they are wired. The HF2 weld transformer input
voltage must match the HF2 weld control power line voltage.

Use the following table to select the correct power line circuit breaker and wire gauge size. To
minimize peak power losses, use single unbroken wire lines. Note: To minimize peak power losses,
Unitek Peco recommended wire gauge sizes exceed the USA National Electrical Code
recommendations.

3-Phase Service

Voltage (RMS)

208V to 230V 50A AWG 8 @ 133 strands

380V to 460V 30A AWG 10 @ 105 strands

Insulation Requirement

Oil-resistant synthetic rubber rated at 90°C and 600V.

Power Line Fuse Requirements

Service Voltage Fuse Size: F1, F2 Unitek Peco P/N

3-Phase Service Breaker

Current (RMS)

Copper Wire Gauge Size

(AWG)

208, 230, 380 3AG, 440 V, 2 A 330-071

460 3AG, 500 V, 2 A 330-100

MODEL HF2 2 kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY

2-2 990-057

CHAPTER 2: GENERAL SETUP

HF2 Weld Transformer Electrical Specifications

Model Input Volts

(Rms)

X3/4/380A 380 9 6 6.5 4,000 500
X3/4/460A 460 9 6 6.5 4,000 500
X3/4000A 230 9 6 6.5 4,000 500
X9/6000A 230 19 6 9.3 (32:1 TR) 4,900 500

Input kva

(Rms)

Duty Cycle ( %) Peak Open Ckt

Output Voltage

Peak Output

Max. (Amps)

Max Sec

Resist. (μΩ)

X11/4/460A 380 4 5 11.8 (44:1 TR)

10.0 (52:1 TR)

8.6 (60:1 TR)

7.5 (68:1 TR)

X11/4000A 230 15 5 10.7

460 4 5 14.3 (44:1 TR)

12.1 (52:1 TR)

10.5 (60:1 TR)

9.2 (68:1 TR)

10.0 (52:1 TR)

8.6 (60:1 TR)

8.7

8.8

8.9

TRANSFORMER SPECIFICATION NOTES:

1 For the Model X11/4/460A, turns ratios

(TR) are selectable by a switch on the
transformer rear panel.

2 HF2 Weld Control Input voltage selection

must be jumpered at E12 on the HF2 Weld
PCB as shown in Figure 2-3. E12 is
located at the center of the PCB left edge.

4,000
4,000
4,000
4,000

4,000
4,000
4,000
4,000

4,000
4,000
4,000

1,300
1,100

950
825

1,300
1,100

950
825

1,300
1,100

3 Maximum weld time at Maximum Short

Circuit Current is 50 milliseconds.

MODEL HF2 2 kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY

990-057 2-3

Figure 2-3. Voltage Jumpers

CHAPTER 2: GENERAL SETUP

HF2 Welding System Maximum Secondary Loop Resistance

To use the HF2 Weld Control and HF2 Weld Transformer system to its maximum capability, the
Maximum Secondary Loop Resistance must not exceed the values listed in the preceding table.
Exceeding these maximums will produce a "FEEDBACK RANGE EXCEEDED" alarm.

HF2 Maximum Secondary Loop Resistance Measurement (Figure 2-4)

1 Connect a four terminal micro-ohmmeter

as shown in Figure 2-4.

2 Put the parts to be welded between the

electrodes.

3 Measure the total loop resistance which

includes both Weld Cables, Weld Head,
Electrodes, and parts.

4 If the total loop resistance exceeds the

table value, use:

A) Larger diameter Weld Cables

Figure 2-4. Secondary

Resistance Measurement

B) Shorter length Weld Cables, or

C) Copper Bus Bars to connect the HF2 Weld Transformer to the Weld Head. If these

suggestions do not work, then a different Weld Transformer Model may be required.

CAUTION: For product safety, the system power cable and all inter-unit cabling should be as short as
possible, and be dressed so that all cables stay separated.

HF2 Weld Control to HF2 Weld Transformer Connections (Figure 2-5)

The HF2 Weld Control must always be connected
to the HF2 Weld Transformer as shown in Figure 2­5, regardless of what Weld Head System is used.

1 Connect the HF2 Weld Control POWER

Cable to the line voltage source as
specified in Chapter 2, Power Line

Voltage, Current, and Wire Size
Requirements.

2 Connect the HF2 Weld Control OUTPUT

Cable to the matching connector on the
HF2 Weld Transformer.

3 Connect the HF2 Weld Control SENSING

PORT Cable to the matching connector on
the HF2 Weld Transformer.

MODEL HF2 2 kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY

2-4 990-057

CHAPTER 2: GENERAL SETUP

HF2 Weld Transformer to Weld Head Connections (Figure 2-6)

1 Connect the Upper Weld Cable to the

Positive Terminal on the HF2 Weld
Transformer.

2 Connect the Lower Weld Cable to the

Negative Terminal on the HF2 Weld
Transformer.

3 Attach the Voltage Sensing Cable

connector to the HF2 Weld Transformer
INPUT connector.

4 Attach each lead at the opposite end of

the Voltage Sensing Cable to each
Electrode Holder. Note: Polarity is not
important.

5 Strain relief each Voltage Sensing lead to its corresponding Electrode Holder so that the lead

will not break or move under heavy production operating conditions.

Figure 2-6. HF2 Weld Transformer to

Weld Head Connections

6 Do not attach the Firing Switch Cable at this time. This procedure is covered in Chapter 3.

Weld Sentry Option

A small tag displaying the message WELD SENTRY INSTALLED will be attached to the front panel of
the HF2 Weld Control if the optional Weld Sentry Module has been installed. Refer to the separate
Weld Sentry User's Manual, 990-291 for Weld Sentry operation.
The Built-in Weld Sentry Module can be added to the HF2 Weld Control after purchase by ordering the
HF2 Weld Sentry Module, P/N 3-130-01-01.

Help Screen Languages

Integrated circuit chip U2 on the Main printed circuit board varies in memory capacity according to the
help screen languages available. Refer to Appendix D for special jumpering instructions relative to the
installation of IC chip U2.

MODEL HF2 2 kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY

990-057 2-5

CHAPTER 3

WELDING SYSTEM SET-UP

Welding System Set-Up Guide

To complete the welding system installation, select the welding system that best matches your Weld
Head configuration using the Welding System Set-Up Guide listed below:

Welding System Set-Up Guide Page

Unitek Equipment Force Fired, Foot Actuated Weld Head 3-2

Unitek Equipment Force Fired, Single Air Actuated Weld Head 3-4

Unitek Equipment Force Fired, Dual Air Actuated Weld Head 3-9

Non-Force Fired, Single Air or Cam Actuated Weld Head 3-17

Non-Force Fired, Multiple Air Actuated Weld Heads Not Released

General Programming Instructions

The following nomenclature and symbols will be used for programming the HF2 Weld Control:

1 Press and release HF2 Weld Control front panel keys that are enclosed by [ ] symbols.

2 Use the vertical cursor keys [ ] in conjunction with the horizontal cursor keys [ ] to

select or highlight a requested Menu Option, followed by the [ENTER] key.

3 Words shown in UPPER CASE ITALIC letters indicate flashing Menu Options on the HF2

Weld Control LCD Display.

MODEL HF2 2 kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY

990-057 3-1

CHAPTER 3: WELDING SYSTEM SET-UP

UNITEK EQUIPMENT FORCE FIRED,

FOOT ACTUATED WELD HEAD SYSTEM

Weld Head Set-up

1 Adjust the Weld Head Force Adjust

Knob to produce 5 units of force as
displayed on the Force Indicator. For a
complete description of force control
and its effect on the welding process,
please refer to your Weld Head manual.

2 Install electrodes in Weld Head

Electrode Holders.

Firing Switch Cable Connection

Connect the Weld Head Firing Switch Cable
Connector to the matching cable connector
on the rear of the HF2 Weld Control.

Quick Start Programming Guide

1 Set the HF2 Weld Control front panel

WELD/NO WELD switch to NO
WELD.

Figure 3-1. Firing Switch Cable Connection

2 Turn the circuit breaker switch located

on the HF2 Weld Control rear panel to
ON. After a series of power up screens,
the last RUN screen displayed will
appear. Press the [CHNG] key to access
the Weld Graph RUN screen for the
BASIC WELD Function.

3 Press [MENU]. The MAIN MENU

screen will appear.

MODEL HF2 2 kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY

3-2 990-057

CHAPTER 3: WELDING SYSTEM SET-UP

4 Select  TRANSFORMER MODEL.

The TRANSFORMER MODEL screen
appears.

5 Select MULTIPLE HEADS: OFF. If

the display reads ON, then press
[CHNG] until OFF is displayed.

6 Select HEAD 1 : X3/4000-230.

X3/4000-230 is the default Transformer
Model number. Press [CHNG] until
the correct Transformer Model that you
have purchased appears.

7 Press [RUN] to return to the Graphical RUN screen.

8 Set the HF2 Weld Control front panel WELD/NO WELD switch to WELD.

9 Make a test weld by pressing on the Weld Head foot actuator until the HF2 Weld Control fires.

The default WELD time of 1 ms and the default CURRENT of 0.5 kA may not be sufficient to
make a good weld.

10 Press [PROG]. Use the vertical cursor

keys [VW] to increase the weld
CURRENT. Use the horizontal cursor
keys [ ] to increase or decrease the
WELD time. In this example, weld
CURRENT has been increased to 0.7
kA and WELD time has been increased
to 5ms.

11 Press [SAVE] to save your program. You are now back in the Weld Graph RUN State.

12 Make additional test welds and then reprogram WELD time and weld CURRENT as necessary

to make a good weld. Try to use the minimum time and current necessary to make a good weld
so that the weld joint heat affected zone will be minimized.

13 Up to 128 different weld schedules can be created and saved. To recall any specific weld

schedule, press the up or down vertical arrow keys [VW] until the desired schedule number
appears on the display screen. A faster technique for recalling a specific schedule is to input
the Schedule number using the number keys.

MODEL HF2 2 kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY

990-057 3-3

CHAPTER 3: WELDING SYSTEM SET-UP

UNITEK EQUIPMENT FORCE FIRED,

SINGLE AIR ACTUATED WELD HEAD SYSTEM

Weld Head Set-up (Figure 3-2)

1 Adjust the Weld Head Force Adjust

Knob to produce 5 units of force as
displayed on the Force Indicator. For a
complete description of force control
and its effect on the welding process,
please refer to your Weld Head manual.

2 Install electrodes in Weld Head

Electrode Holders.

3 Connect a properly filtered air line to

the Inlet Air Line on the Weld Head Air
Valve Driver Solenoid assembly which
is located on the back of 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. A lubricator should
only be used with automated
installations. Turn on the air system and check for leaks.

Firing Switch Cable Connection (Figure 3-2)

Figure 3-2. Single Air Actuated

Weld Head Connections

Connect the Weld Head Firing Switch Cable Connector to the matching cable connector on the rear of
the HF2 Weld Control.

Weld Head Valve Driver No. 1 Connection (Figure 3-2)

A single air actuated Weld Head has one Solenoid Valve Driver Cable for automatic actuation and
timing control by the HF2 Weld Control. The HF2 Weld Control will automatically recognize the
solenoid voltage of the Weld Head. Connect the 4 pin black plastic connector on the cable to the
matching Air Valve 1 Driver connector located on the HF2 Weld Control rear panel.

Foot Switch Connection (Figure 3-2)

1 Connect a Model FS1L, 1-Level, or a Model FS2L, 2-Level Foot Switch to the FOOT

SWITCH connector located on the HF2 rear panel. The HF2 will automatically recognize
which model of Unitek Equipment Foot Switch has been connected.

2 1-Level Foot Switch - The l-Level Foot Switch must be fully depressed by the operator. When

the Foot Switch closes, the HF2 energizes the Air Actuated Weld Head, causing the Upper
Electrode to descend and apply force to the parts. If the Foot Switch is released before the
Weld Head applies the Preset Firing Force, the HF2 will automatically return the Upper
Electrode to its up position.

MODEL HF2 2 kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY

3-4 990-057

CHAPTER 3: WELDING SYSTEM SET-UP

3 2-Level Foot Switch - When a 2-Level Foot Switch is pressed to the first level, the HF2

energizes the Air Actuated Weld Head, causing the Upper Electrode to descend and apply force
to the parts. If the Foot Switch is released before the operator presses the Foot Switch to the
second level, the HF2 will automatically return the Upper Electrode to its up position so that
the parts can be repositioned. Once the second level has been reached and the Force Firing
Switch in the Weld Head has closed, Weld Current will flow and the HF2 will automatically
return the Upper Electrode to its up position.

Single Air Regulator Adjustment (Model 80 Series Weld Heads - Figure 3-2)

1 Set the HF2 Weld Control front panel

WELD/NO WELD switch to NO WELD.

2 Turn the Power Switch located on the

HF2 Weld Control rear panel to ON.
After a series of power up screens, the
last RUN screen displayed will appear.
Press the [CHNG] key to access the Weld
Graph RUN screen for the BASIC
WELD function.

3 Turn the Air Regulator Clockwise (CW)

to produce 10 psi on the Pressure Gauge.

4 Press and hold the Foot Switch

completely down to close all switch
levels. The lower right hand corner of
the display should show the status
message  STANDBY .

5 Continuing turning the Air Regulator

Clockwise (CW) until the HF2
automatically returns the Upper Electrode
to its "up position". The lower right hand
corner of the display should now show
the status message  END  if you have
not released the Foot Switch. Release the
Foot Switch.

6 Note: You have 10 seconds to make the

Air Regulator adjustment or a buzzer
alarm will sound and the HF2 will
automatically return the Upper Electrode
to its up position. The status message
changes from  STANDBY  to 
ALARM FIRING SWITCH . Press
[RUN] to clear the alarm and then repeat
steps 4 and 5.

MODEL HF2 2 kHz HIGH FREQUENCY RESISTANCE WELDING POWER SUPPLY

990-057 3-5