(626) 358-8048 e-mail: info@amadamiyachi.com Amada Miyachi America is not responsible for any losses due to improper use of this product. The contents of this manual are subject to change without notice. If you have any questions, find any errors/omissions, or if you have suggestions for improving this manual, please contact us.
SAFETY NOTES This instruction manual describes how to operate, maintain and service STA Series AC Controls, and provides instructions relating to their SAFE use. For SAFETY, and to effectively take advantage of the full capabilities of the workstation, please read these instructions before attempting to use the workstation.
CONTENTS Page Revision Record ............................ii Contact Us .............................. iii Safety Notes .............................. iv Chapter 1. Description Section I: Features ..........................1-1 Overview ............................1-1 Standard Features ..........................1-1 Optional Features ..........................1-1 Section II: Major Components ........................ 1-3 Major Components .......................... 1-3 Front Panel Controls and Indicators ....................
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CONTENTS (Continued) Page Section II: Control Set-up ........................2-2 Unpacking ............................2-2 Installation ............................2-2 Mounting the Control ........................2-2 Connecting Electrical Power ......................2-2 Secondary Current Sensing ......................2-3 Placement of Secondary Current Coils ..................2-3 Valve Transformer Wiring Connections .................. 2-3 Cooling Water Hose Connections ....................
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Page Section IV: Monitor Screen ........................3-6 CURR (Weld Current) ........................3-6 COND (Conduction Angle) ......................3-6 VOLTS ............................3-6 FORCE(LBS) ..........................3-6 LO (Low Current Limit) ........................3-6 HI (High Current Limit) ........................3-6 COND. LIMIT (Conduction Angle Limit) ..................3-7 Counts ...
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CONTENTS (Continued) Page CNTRL MODE (Control Mode) .................... 3-13 BIN. SCHED. SELECT (Binary Schedule Select) ..............3-13 FIRING SWITCH ........................3-13 COIL ............................3-13 CONTRAST+/– ........................3-13 NUM VALVES (Number of Valves) ..................3-14 VALVES STATUS ........................ 3-14 MODE ............................ 3-14 MORE (System Value Screen 2) ....................
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Page Chapter 4. Operating Instructions Section I: Introduction ........................... 4-1 Overview ............................4-1 General Operator Safety ........................4-1 Section II: Preparing for Operation ......................4-2 Turning the Equipment ON ......................4-2 Pre-Operational Setup ........................4-3 Section III: Setup Messages ........................4-4 Section IV.
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CONTENTS (Continued) Page Section V. Spare Parts .......................... 5-12 Section VI. Repair ..........................5-13 Section VII. Storage and Shipment ...................... 5-13 Preparation for Storage or Shipment ..................... 5-13 Packing for Storage or Shipment ....................5-13 Appendix A. Technical Specifications ....................A-1 Appendix B.
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LIMITED WARRANTY 1. (a) Subject to the exceptions and upon the conditions set forth herein, Seller warrants to Buyer that for a period of one (1) year from the date of shipment (“Warranty Period”), that such Goods will be free from material defects in material and workmanship.
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(h) Subject to Section 1(e) and Section 1(f) above, with respect to any such Goods during the Warranty Period, Seller shall, in its sole discretion, either: (i) repair or replace such Goods (or the defective part) or (ii) credit or refund the price of such Goods at the pro rata contract rate, provided that, if Seller so requests, Buyer shall, at Buyer’s expense, return such Goods to Seller.
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(6) months after the date of shipment, whichever occurs first. Acceptance Tests: Acceptance Tests (when required) shall be conducted at Amada Miyachi America, Inc., Monrovia, CA, USA (the “Testing Site”) unless otherwise mutually agreed in writing prior to issuance or acceptance of the Acknowledgement.
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Seller further warrants that all Services performed by Seller’s employees will be performed in a good and workmanlike manner. Seller’s sole liability under the foregoing warranty is limited to the obligation to re-perform, at Seller’s cost, any such Services not so performed, within a reasonable amount of time following receipt of written notice from Buyer of such breach, provided that Buyer must inform Seller of any such breach within ten (10) days of the date of performance of such Services.
This manual describes the most common or “typical” components and options. If you have questions about custom items in your Control that are not covered in this manual, contact Amada Miyachi America using the phone, e-mail, or mailing information in the front of this manual.
CHAPTER 1: DESCRIPTION Standard Features Operates on 50Hz or 60Hz, self-detecting, no adjustments needed. Multiple pulse capability. Controlled current ramps. 300, 600, 1200, 1800, or 2200 amp SCRs with constant current control. Water-cooling of the 600A and larger SCR assemblies. ...
CHAPTER 1: DESCRIPTION Section II: Major Components Major Components The following illustrations show a “typical” Control. Your Control may be different due to options that have been installed or to the physical configuration. For example, the LCD Display and operating controls can be factory-installed on the front or on the side of the Control.
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CHAPTER 1: DESCRIPTION STA-100A Series Major Components (Typical) STA SERIES AC CONTROLS 990-351...
CHAPTER 1: DESCRIPTION Front Panel Controls and Indicators All controls and indicators are located on the control panel shown below. The Control Panel Assembly is normally mounted on the access panel, but can also be mounted on the left-hand side of the box on STA-200A through STA-800A Controls.
CHAPTER 1: DESCRIPTION Weld ON/OFF When the entry (in the screen) is set to WELD ON/OFF Extended System Values , pressing this pushbutton switch will enable or disable the flow of weld LOCAL current. The green LED lights when current is enabled. When current is disabled, the Control can still sequence through its program and fire valves, but current will not flow.
CHAPTER 1: DESCRIPTION Modes When the pushbutton switch is set to , pressing this pushbutton WELD ON/OFF switch will cause the Mode screen to appear on the display. See Chapter 3 for details of this screen. Reset Pressing this pushbutton switch will reset the Control after a major error signal is received.
CHAPTER 1: DESCRIPTION Cylinder Air Hose Connections If your Control uses Force Control, the air hoses for the Differential Pressure Sensors are located on a panel on the top of the Control. In the example on the right, this Control is equipped with HIGH and LOW fittings for channels 1 and 2.
CHAPTER 1: DESCRIPTION Option Cards Printed circuit boards (“cards”) for STA Series options can be installed in each Control. The STA-100 has a card cage that can accept three option cards. The larger STA-200, -400, and –600 models each have a card cage that can accept four option cards. The STA-800 has two card cages. Option boards can be inserted into a card cage in any order.
CHAPTER 2 INSTALLATION AND SETUP Section I: Planning for Installation Environmental Factors We recommend that you install the Control in a well-ventilated area that is free from excessive dust, weld expulsion, acids, corrosive gasses, salt, moisture, oil, coolant, and contaminants. Allow adequate space around the unit for power and signal cabling runs, water-cooling hose connections, and full length of open front door.
CHAPTER 2: INSTALLATION AND SETUP Section II: Control Set-up Unpacking Unpack the Control from its shipping box. The box also contains a Ship Kit with the components itemized on a packing list within the kit. NOTE: Carefully save and store packing materials for future storage or shipment of the Control. Installation Installation consists of mounting the unit, making power and signal connections, and making cooling water connections.
CHAPTER 2: INSTALLATION AND SETUP Secondary Current Sensing If you ordered Secondary Current sensing, toroidal coil(s) were shipped with the Control, along with cable(s) that attach to the connector(s) on the bottom of the Control box. Place the toroidal coil(s) on the secondary of each weld transformer.
CHAPTER 3 USING STA SERIES CONTROL FUNCTIONS Section I: Overview To ensure accurate, consistent welds, the Control delivers extremely precise pulses of energy to the weld head. Each pulse is comprised of weld-time and weld-energy values pre-programmed by the user. The Control with optional primary or secondary current coils is a closed-loop welding control using internal or external sensors to measure the weld-energy delivered to the weld head.
CHAPTER 3: USING STA SERIES CONTROL FUNCTIONS Section II: Schedule Screen screen consists of the following SCHEDULE SCHEDULE # 01 settings shown on the right. SQD SQZ UP1 W1 DN1 CO UP2 W2 DN2 HLD OFF 060% 000% CH=F1 FORCE=0150Lb ElecValve=01 SCR=1 PLUS 00 ...
CHAPTER 3: USING STA SERIES CONTROL FUNCTIONS – This is the downslope time for weld 1 of the sequence. – This is the cool time between weld 1 downslope and weld 2 upslope in the sequence. – This is the upslope time for weld 2 of the sequence. (See IMPULSE –...
CHAPTER 3: USING STA SERIES CONTROL FUNCTIONS – Copying a schedule ––this includes all functions such as valves, etc.––to another schedule COPY TO # is done by changing the schedule number to the (new) desired schedule number. (It is assumed that the new schedule is not already in use).
CHAPTER 3: USING STA SERIES CONTROL FUNCTIONS Section III: Valves Screen The Valve screen is used to program which SCHEDULE #01 VALVE valves will turn on during a welding schedule. ELECTRODE VALVE 01 (See Appendix D, System Timing for details.) STATUS COUNT The standard unit has four valves, and an 1=ON 00200...
CHAPTER 3: USING STA SERIES CONTROL FUNCTIONS Section IV: Monitor Screen Press the button on the Control Panel to get the Screen. MONITOR MONITOR NOTES: SCHEDULE #00 MONITOR CURR(KA) COND VOLTS FORCE (LBS) These values are the results 00.0 000...
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CHAPTER 3: USING STA SERIES CONTROL FUNCTIONS this FIRE = This field requires installation of the differential pressure input. When this option is installed, field sets the force at which the weldhead will fire. The weld force setting in the schedule screen should match this value.
CHAPTER 3: USING STA SERIES CONTROL FUNCTIONS Section V: Monitor Counts Screen To get the Screen, press the button on the Control Panel, go to COUNTS MONITOR COUNTS MONITOR at the bottom of the screen, highlight the symbol and press the Data + key. SCHEDULE #00 MONITOR COUNTS screen consists of the...
CHAPTER 3: USING STA SERIES CONTROL FUNCTIONS Section VI: Mode Screen Press the button on the Control Panel to get this screen. MODE screen is used to set up various MODE SCHEDULE # 01 MODE parameters used in welding. The Weld Mode START=MAINTAINED screen consists of the settings shown on the...
CHAPTER 3: USING STA SERIES CONTROL FUNCTIONS – This control selects one of six welding modes: WELD MODE – This is the basic default weld. Spot Weld Mode – When this mode is being used, the entire weld cycle from through Repeat Mode Squeeze...
CHAPTER 3: USING STA SERIES CONTROL FUNCTIONS (optional) - The continuous seam mode repeats the weld cycle from CONT SEAM MODE COOL through as long as the start signal is present. See Appendix D for a graphical WELD2 representation of this weld mode. ...
CHAPTER 3: USING STA SERIES CONTROL FUNCTIONS Section VII: Linked Schedules Screen To get this screen, go to the screen, highlight and press the button on LINKED SCHED. , MODE DATA + the Control Panel. This screen shows all linked schedules, their SCHD CURR WELD CNT WELD MODE current weld counts, weld modes, and an error 01.
CHAPTER 3: USING STA SERIES CONTROL FUNCTIONS Section VIII: System Values Screens System Values Screen 1 To get this screen, go to the screen, MODE SYSTEM VALUES SCREEN 1 highlight and press System Values Screen 1 , FULL CURR=10KA COIL=01X button on the Control Panel.
CHAPTER 3: USING STA SERIES CONTROL FUNCTIONS This control will select the number of valves in the system. It is pre-set to either 4 or 12, NUM VALVES – depending on the valve option implemented in this unit. – This control allows the operator to select the screen, discussed in VALVES STATUS Valve Status...
CHAPTER 3: USING STA SERIES CONTROL FUNCTIONS When , the error signal will light the Error LED indicator but this error signal AUTO RESET will be reset by the next signal. If the function is turned on, a Fault output Start ERROR OUTPUT will occur.
CHAPTER 3: USING STA SERIES CONTROL FUNCTIONS = This turns the function . When this function is turned Pressure Switch Pressure Switch ON, a weld will not proceed until both the footswitch input and the pressure switch inputs are closed. If this input does not close in approximately 5 seconds, the unit gives a “Pressure Switch Alarm”...
CHAPTER 3: USING STA SERIES CONTROL FUNCTIONS Section IX: System Valve Status Screen To get this screen, go to the , highlight and press VALVES STATUS. , SYSTEM VALUES SCREEN 1 button on the Control Panel. DATA + screen allows the operator to view the weld count used in the function.
CHAPTER 3: USING STA SERIES CONTROL FUNCTIONS Section X: Force Calibration Screen To get to this screen, go to the , highlight FORCE CALIBRATION , SYSTEM VALUES SCREEN 3 press the button on the Control Panel. DATA + screen allows the operator to calibrate the pressure used in both the FORCE CALIBRATION FORCE (Differential Pressure) functions.
CHAPTER 3: USING STA SERIES CONTROL FUNCTIONS Section XI. Stepper Screen screen allows information to be Stepper VALVE NUM=01 programmed to maintain weld results despite SCR #1 STEPPER=OFF COUNT HEAT% COUNT HEAT% gradual degradation of the weld electrodes. This 0000 FIXED 6 0000 100%...
Chapter 4 OPERATING INSTRUCTIONS Section I: Introduction Overview This Chapter tells you how to turn the Control ON, use menu screens to customize operating parameters, match the Control to your welding system, and how to operate the Control. This chapter is divided into the following sections: ...
STA SERIES RESISTANCE WELDING SYSTEM installed in the Control. If you ever need to AMADA MIYACHI AMERICA contact Amada Miyachi America for technical MONROVIA, CALIFORNIA assistance, Customer Support will need to know COPYRIGHT 2014, ALL RIGHTS RESERVED which version (“Release”) number of the...
CHAPTER 4: OPERATING INSTRUCTIONS Pre-Operational Setup NOTES: If your unit is equipped with a lock, the key must be inserted and turned to the PROGRAMMING ON position before any program changes can be made. If your weldhead does not have a retraction switch to control this function, a jumper must be installed between RETR and RETC inputs on the main board.
You may receive one of the following messages during set-up of the Control. The message tells you what corrective action should be taken. If you cannot correct the action by performing these instructions, contact your Amada Miyachi America representative. SCHEDULE 01 WELD 1 CURRENT LESS THAN 20% OF SYSTEM FULL CURRENT.
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CHAPTER 4: OPERATING INSTRUCTIONS SCHEDULE 01 W1 AND W2 TIMES ARE SET TO ZERO PRESS PROGRAM/SAVE KEY TO ACCEPT, THEN DESIRED SCREEN BUTTON AFTER SAVING. OR PRESS SCHEDULE KEY TO VIEW OR CHANGE THESE TIMES MODIFIED SCHEDULE NOT SAVED. PRESSING THE PROGRAM/SAVE KEY SAVES MODIFICATIONS, THEN PRESS DESIRED SCREEN BUTTON AFTER SAVING.
CHAPTER 4: OPERATING INSTRUCTIONS Section IV: Operation Turn power ON, either from the internal circuit breaker or the external, customer-supplied circuit breaker or power contactor. After waiting for the internal self-test, and presentation of the introductory screens, the Control Panel will present the Schedule Screen. During this period, all LEDs will light briefly as an indication that they are working.
CHAPTER 4: OPERATING INSTRUCTIONS Spot Welds To change the information in the schedule screen the control must be in mode. From PROGRAM the schedule screen press the button so that the red indicator is off and PROGRAM/SAVE READY the green indicator is on.
CHAPTER 4: OPERATING INSTRUCTIONS Continuous Seam Weld (Optional on all STA Models) To change the information in the schedule screen the control must be in . From the PROGRAM schedule screen, press the button so that the red indicator is off and PROGRAM/SAVE READY the green...
CHAPTER 4: OPERATING INSTRUCTIONS Cascading (Requires Multiple SCRs) To change the information in the schedule screen the control must be in . From the PROGRAM schedule screen press the button so that the red indicator is OFF and PROGRAM/SAVE READY the green indicator is ON.
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This sets the first schedule in the chain. To help the user PROGRAM/SAVE follow which schedules are Linked together, Amada Miyachi America has provided an easy to understand Help-Link. The -Link is located in the upper right-hand corner of the Help screen and displays the schedules that are Linked to the schedule that is displayed.
You may receive one of the following error messages during set-up or operation of the Control. The message tells you what corrective action should be taken. If you cannot correct the action by performing these instructions, contact your Amada Miyachi America representative. Major errors require pressing button or giving a signal to the input to clear the error.
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CHAPTER 4: OPERATING INSTRUCTIONS SCHEDULE 01 WELD 1 CURRENT EXCEEDED HIGH LIMIT. 1. REPROGRAM WELD 1 CURRENT. 2. INCREASE WELD TRANSFORMER RATIO. 3. INCREASE W1 HIGH LIMIT AT THE MONITOR SCREEN. PRESS RESET BUTTON TO RESUME WELDING. SCHEDULE 01 WELD 1 CONDUCTION ANGLE EXCEEDED LIMIT. PRESS RESET BUTTON TO RESUME WELDING.
CHAPTER 4: OPERATING INSTRUCTIONS CHANGED FROM RUN MODE TO PROGRAM MODE IN THE MIDDLE OF A WELD, OR TURNED OFF WELD CURRENT DURING A WELD. WELD WAS ABORTED. PRESS RESET BUTTON, THEN RESTART THE WELD FROM THE BEGINNING. Minor Run-Time Error Messages SCHEDULE 01 WELD 1 CURRENT BELOW LOW LIMIT.
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CHAPTER 4: OPERATING INSTRUCTIONS *** LOW LINE VOLTAGE *** *** ADVISORY MESSAGE ONLY *** LOW LINE VOLTAGE WAS DETECTED. CHECK LINE VOLTAGE AND PRESS RESET KEY TO CONTINUE. *** HIGH LINE VOLTAGE *** *** ADVISORY MESSAGE ONLY *** HIGH LINE VOLTAGE WAS DETECTED. CHECK LINE VOLTAGE AND PRESS RESET KEY TO CONTINUE *** SCALE CURRENT ERROR ***...
CHAPTER 4: OPERATING INSTRUCTIONS Section VI: Shutdown Emergency Shutdown In an emergency, you may perform an emergency shutdown by hitting the Emergency ************ EMERGENCY STOP ************ Stop Switch. Weld power will be immediately THE SYSTEM HAS ENCOUNTERED A SERIOUS shut down, the valve outputs will turn off, and CONDITION, POSSIBLY INVOLVING A you will get the emergency shutdown message SAFETY HAZARD.
Other than as indicated in Appendix K, Circuit Modification for External Transformer Thermostat, do not modify the unit without prior written approval from Amada Miyachi America. Use the appropriate tools for terminating the connecting cables, being careful not to nick the wire conductors.
The fuse size will depend on which transformer has been ordered. See table 4-1 for appropriate fuse selection. Valve Transformer Fuse Selection Transformer Rating Fuse Size Amada Miyachi America Part Number 115VAC, 150 VA FNM-2 115VAC, 250 VA FNM-3...
CHAPTER 5: MAINTENANCE Your Control may have Primary Current sensing, Secondary Current sensing, or no current sensing. The valve transformer is wired and jumpered based on the input voltage. The output of the transformer is applied to the AC Timer Main Board for application to the valves. Two chassis-mounted power transformers break down the input voltage to the various voltages required in the main board and the Control.
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CHAPTER 5: MAINTENANCE STA SERIES AC CONTROLS 990-351...
CHAPTER 5: MAINTENANCE Section III. Standard Components Replacement AC Timer Main Board Disconnect the following To Valve Expansion To SCR Drive cable connectors from the Board J1 Board J1 indicated headers on the circuit board: Two wire cable from the valve transformer T3 connected to J9.
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CHAPTER 5: MAINTENANCE Remove the nine 6-32x3/8 Phillips head screws and nine #6 flat nylon washers that secure the circuit board to the Control and remove the board. Install or re-install the circuit board with nine 6-32x3/8 Phillips head screws and nine #6 flat nylon washers, being careful not to over-tighten the screws and damage the circuit board.
CHAPTER 5: MAINTENANCE Power Transformer T1 Disconnect the transformer cable connector from AC Timer Main Board connector J17. While supporting the transformer with one hand, remove the two screws and lock washers. Install re-install the transformer by supporting it with one hand while attaching it to the side of the card cage with two screws and lock washers.
CHAPTER 5: MAINTENANCE Disconnect the blue wire from the SCR and the black wire from copper bus bar L1. Loosen the clamp screw that secures the snubber and remove it. Install or re-install the snubber by slipping it into the clamp and tightening the clamp screw. Reconnect the black wire to copper bus bar L1 and the blue wire to the SCR.
CHAPTER 5: MAINTENANCE Control Panel Assembly To replace the Control Panel Assembly remove the four screws securing the protective cover plate over the Control Panel Assembly and remove the plate. Disconnect the following cable connectors from the indicated headers on the circuit board: ...
CHAPTER 5: MAINTENANCE Section IV. Optional Components Replacement NOTE: Each of the following options is described in a separate Appendix. Each Appendix contains descriptions, maintenance procedures, and other information. (See Table of Contents.) Optional Primary Current Sensor To replace the primary current sensor, disconnect the two-wire (white and gray) connector from the mating connector of the two-wire (black and red) jumper cable (which is connected to the AC Timer Main Board connector J1).
CHAPTER 5: MAINTENANCE Optional Key Lock To replace the key lock, disconnect the two-wire cable from connector J3 of the Control Panel Assembly. Unscrew the nut on the rear of the switch. Install a new key lock (or re-install the old one if it is being used) by sliding it into the double “D”...
CHAPTER 5: MAINTENANCE Section V. Spare Parts Below is a list of frequently required spare parts, which can be obtained by contacting your Amada Miyachi America representative. Additional parts are available by contacting Amada Miyachi America using the phone, e-mail, or mailing information in the front of this manual.
CHAPTER 5: MAINTENANCE Section VI. Repair If you have problems with your unit that you cannot resolve, please contact our service department at the address, phone number, or e-mail address indicated in the Foreword of this manual. Section VII. Storage and Shipment Preparation for Storage or Shipment WARNING: Be sure all power is removed from the Control before disconnecting input (LINE) cables.
APPENDIX A TECHNICAL SPECIFICATIONS Specifications Maximum Number Model Size Weight of SCRs 18” H 10” W 10” D STA-100 35-50 lbs (depends on options) (457mm x 254mm x 25.4mm) 30” H x 25.4” W x 12” D 110-140 lbs (depends on options) STA-200 (762mm x 645mm x 305mm ) ITEMS...
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APPENDIX A: TECHNICAL SPECIFICATIONS ITEMS SPECIFICATIONS Regulation Percent Heat Mode Control Speed Responds by end of second cycle to input voltage fluctuations. 3% of set point for fluctuation of 10% of power source voltage Accuracy Constant Current – Primary Monitor Internal current transformer Control Algorithm Whole cycle (symmetrical) by cycle...
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APPENDIX A: TECHNICAL SPECIFICATIONS Outline Drawings NOTE: Measurements are in inches (mm). STA-100A AC Control STA SERIES AC CONTROLS 990-351...
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APPENDIX A: TECHNICAL SPECIFICATIONS STA-200A AC Control Control STA SERIES AC CONTROLS 990-351...
APPENDIX B ELECTRICAL AND DATA CONNECTIONS Section I. Electrical Connections WARNING: The installer must make electrical connections in accordance to all applicable codes. NOTES: Make sure you are familiar with the Control’s internal components and where they are located (see Chapter 1, Description).
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APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Chassis AC Timer Ground Main Board Point Circuit Breaker Expansion Boards T3 Valve Transformer H2-1 H2-2 Terminal Block SCR Assemblies H1-1 H1-2 Typical Electrical Power Connections Connect the control to the weld transformer using the appropriate wire gauge for your requirements.
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APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Section II. Input/Output Signal Connections Connect the input/output (I/O) signals as shown in the connection diagram on the following page (B-4), Input/Output Control Signals. With the exception of the valve outputs, all output signals are isolated contact relays. Valve outputs may be either 115 VAC (standard) or 24 VAC.
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APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Input/Output Control Signals STA SERIES AC CONTROLS 990-351...
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APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Input/Output Signal Descriptions EMO – Emergency Stop A disconnect signal from an external Emergency Stop switch, across these two pins will cause an immediate termination of the welding operation. Control power remains on. When the emergency stop switch is released and the reset button is pressed, the Control will automatically re-boot and then be ready for operation.
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APPENDIX B: ELECTRICAL AND DATA CONNECTIONS further input is required. In the case of a two-level footswitch, the valves will be activated on the first level, and the schedule will commence from the beginning on the second level. FS2 – Foot Switch Stage 2 Input This signal starts the weld schedule.
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APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Optional Valve Expansion Board VAL5 VAL6 VAL7 VAL8 VAL9 VAL10 VAL11 VAL12 Valve Expansion Board (Optional) Valve Expansion Board Output Signals VAL5, N & L through VAL12, N & L – Valve Output 5 Neutral and Line through Valve Output 12 Neutral and Line Output signals to drive up to eight additional valves.
APPENDIX C SCR, WIRE GAUGE, AND CIRCUIT BREAKER SELECTION Basis for SCR, Wire Gauge, and Circuit Breaker Selection SCR size is determined as the larger size needed to support a) machine rated kVA b) machine demand kVA The maximum demand current an SCR can handle is conservatively assumed equal to 2.5 X rated current (at the 50% duty cycle).
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APPENDIX C: SCR, WIRE GAUGE, AND CIRCUIT BREAKER SELECTION Wire Gauge For specific wire gauge needed to support ampacity, use the Equivalent Continuous Current and refer to NFPA 70 National Electric Code table 310-16. The table for 90°C insulated copper wire at 30°C ambient temperature is reproduced here for reference only.
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APPENDIX C: SCR, WIRE GAUGE, AND CIRCUIT BREAKER SELECTION Wire Gauges Based on Demand (kVA) For wire gauge needed to support a maximum of 5% voltage drop, consult table C-4. The information herein is based on NFPA70 National Electric Code table 9 in Chapter 9. The calculations are based on a 30% power factor and 100 foot power cable run.
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APPENDIX C: SCR, WIRE GAUGE, AND CIRCUIT BREAKER SELECTION Wire Gauge Based on Demand 480V AC Mains Demand kVA Max Z AWG (Cu) 1.152E+00 3.456E+00 1.103E+01 7.680E-01 2.304E+00 7.356E+00 5.760E-01 1.728E+00 5.517E+00 3.840E-01 1.152E+00 3.678E+00 2.304E-01 6.912E-01 2.207E+00 1.536E-01 4.608E-01 1.471E+00 1.152E-01 3.456E-01...
APPENDIX D SYSTEM TIMING Input and Output Timing Signals Figure B-1 shows the timing signals for the pulsed, latched, and maintained start signals. Table B-1 is the binary input for the schedules. Pulsed Start (Standard Two-Stage Operation) START signals (FS1 + FS2) need only be held through SQD.
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APPENDIX D: SYSTEM TIMING Continuous Seam Weld STA SERIES AC CONTROLS 990-351...
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APPENDIX D: SYSTEM TIMING All modes are program- mable from 0 to 99 cycles. Current Repeats as long as FS is active Motormove Valve Solenoid Valve Electrode Force SQD SQZ UP1 Notes: FS1 and FS2 are debounced for 30-70 ms upon opening and closing. The microprocessor requires up to 70 ms of calculation time upon closure of FS1 and 50 ms of calculation of FS2.
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APPENDIX D: SYSTEM TIMING Spot Welding STA SERIES AC CONTROLS 990-351...
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APPENDIX D: SYSTEM TIMING Current Electrode Valve Solenoid Valve Electrode Force FS1* First Impulse** Second Impulse** Third Impulse** SQD SQZ UP1 W1 CO UP2 W2 *See Chapter 3 for description of Maintained, Pulsed, and Latched modes. One-stage footswitch shown. **The first impulse is a W2 period only. The second and following impulses are a CO period followed by a W2 period. Notes: FS1 and FS2 are debounced for 30-70 ms upon opening and closing.
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APPENDIX D: SYSTEM TIMING Linked Schedules Sched A Sched B Sched C Sched A Successive Initiation required for each schedule in link. Each schedule may be pulsed, latched, or maintained. Sched A Sched B Sched C Sched A Chained Initiation required only once at beginning. Control defaults to first schedule start signal for all linked schedules.
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APPENDIX E CASCADE BOARD OPTION Description The Cascade Board gives the Control the ability to operate up to four SCRs instead of just one. The STA-600 and STA-800 use two Cascade Boards in order to operate up to six and eight SCRs respectively.
APPENDIX F VALVE EXPANSION BOARD OPTION Description The Valve Expansion Board gives the Control the ability to drive up to eight additional valves. Each set of connections provides 115 VAC (standard) or 24 VAC (optional) power to the valve solenoid connected across those connections.
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APPENDIX F: VALVE EXPANSION BOARD OPTION VAL5 VAL6 VAL7 VAL8 VAL9 VAL10 VAL11 VAL12 Valve Expansion Board (Optional) Valve Expansion Board Output Signals NOTES: VAL5, N & L through VAL12, N & L – Valve Output 5 Neutral and Line through Valve Output 12 Neutral and Line.
APPENDIX G VOLTAGE MONITOR BOARD OPTION Description The Voltage Board gives the Control the ability to compare weld voltage against pre- programmed high and low limits. This board allows you to monitor either peak or average (RMS) voltage. You can also select when the voltage is monitored, either during both weld periods (excluding up/downslope) or during the last cycle only.
APPENDIX H FORCE CONTROL OPTION Description The Force Control (Force Output) Option can control up to 8 electronic pressure regulators. Output Force is programmed in lbs using front panel controls. Once the Operator programs the Output Force, the Control converts this to the correct voltage to be sent to the electronic pressure regulator in order to get the desired force.
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APPENDIX H: FORCE CONTROL OPTION Operation Use the buttons on the *** FORCE CALIBRATION *** Control panel to highlight the valve (All Force Entries in Pounds) Channel-----------------Valve Channel-----------------Valve number for the channel to be calibrated. # Lo-Psi Hi-Psi Lo-Psi Hi-Psi Press to put the unit PROGRAM/SAVE...
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APPENDIX H: FORCE CONTROL OPTION Maintenance/Replacement Disconnect the serial cable connector (26-pin ribbon cable) connected to J10 on the Force Board. Disconnect the force input cables from J1 and the force output cables from J2 and J3 on the Force Output Board as required. Slide the card out of the card cage.
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APPENDIX I PRESSURE MONITORING OPTION Description The Pressure Control Option (Force Input) uses differential pressure sensors on up to eight channels. You may use this feature in a Force- Firing function (welds only when correct pressure is reached), or as a pressure monitor to see if air pressure reached (or exceeded) the desired range.
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APPENDIX I: PRESSURE CONTROL OPTION Channel Number Setup Each Pressure Board is manually assigned to a specific channel at the factory using the dipswitch on each board. If you are replacing a Pressure Board(s), you will have to set each one to a different channel.
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APPENDIX I: PRESSURE CONTROL OPTION Place a force gauge between the electrodes. If the force output option is installed, press the button on the WELD ON Control Panel to close the electrodes. NOTE: In FORCE CALIBRATION mode, the Control will not send weld current to the electrodes.
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APPENDIX I: PRESSURE CONTROL OPTION Maintenance/Replacement Label the air hoses from the Pressure Board(s) you want to remove. Note the location on the board and label them appropriately. Hoses cannot be switched! Remove the hoses. Unplug the Pressure Board(s) from the Force Board. If you are using multiple Pressure Boards, disconnect them in order to remove/replace/install specific boards.
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Appendix J Communications Option Section I. Description An optional circuit card gives the Control the ability to communicate with a host computer or with automation control systems. The communications option uses either RS-232 to connect one control to one host or RS-485 multi- drop architecture to connect up to 30 controls to one host on a single channel.
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APPENDIX J: COMMUNICATION OPTION RS-485 / RS-232 Operation The STA Communications Option card can be used for RS-232 or RS-485 protocol. The wiring of the external 9-pin connector is determined by the internal serial connector supplied at time of purchase. The connectors shown on the right are from the cables that go between the external 9- pin connector on the Control and the Communications Board.
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APPENDIX J: COMMUNICATION OPTION A good guideline is that on a line free of electrical noise, the number calculated above must remain less that 70% of the theoretical maximum capacity (26,880 bytes per second). Electrical noise on the communications lines will further reduce this capacity. Shielded cables are recommended. Several commands require the Control to be in HOST mode for the Control to accept them.
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APPENDIX J: COMMUNICATION OPTION Section II. Communications Protocol and Commands Communication External Protocol Each external command will be formatted as follows: <soh> <@> <cmd> <cnt> <data> <cksum> <eot>. Definition of Command Elements <soh> 1 BYTE The data packet will start with a SOH (start of header 0x01) character . <@>...
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APPENDIX J: COMMUNICATION OPTION Host Originated Command Set These are commands sent by the host computer, via the RS-485/RS-232 port to the STA. NAME COMMAND DATA SIZE TYPE “TY” Read none 0 Bytes REPORT “RR” Read Retransmission = 0x0FF 1 Byte RESET “RX”...
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APPENDIX J: COMMUNICATION OPTION NAME COMMAND DATA SIZE MONITOR “MR” Read Read Schedule # 1 Byte MONITOR “MS” Set Set SCHEDULE # 1 Bytes HIGH1C # High current #1% 2 Bytes HIGH2C # High current #2% 2 Bytes LOW1C # Low current #1% 2 Bytes LOW2C #...
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APPENDIX J: COMMUNICATION OPTION NAME COMMAND DATA SIZE SYSTEM “YR” Read none 0 Bytes SYSTEM “YS” Set MAX VALVES # 1 Byte MAX SCRS 1 Byte TURNS RATIO (1:1 - 200:1) 1 Byte 87 DEGREE DELAY {ON=1 | OFF=0} 1 Byte RESET {ON=1 | OFF=0} 1 Byte...
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APPENDIX J: COMMUNICATION OPTION NAME COMMAND DATA SIZE FORCE “PR” Read None 0 Bytes FORCE “PS” Set P1 MIN CALIBRATE #, (0-9999) 2 Bytes P1 MAX CALIBRATE #, 2 Bytes P2 MIN CALIBRATE #, 2 Bytes P2 MAX CALIBRATE #, 2 Bytes P3 MIN CALIBRATE #, 2 Bytes...
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APPENDIX J: COMMUNICATION OPTION STA Originated Response Command Set These are commands returned by the STA, via the RS-485/RS-232 port. NAME COMMAND DATA SIZE TYPE “TY” Read "STA", Release # and Revision # 12 Bytes Example: "STA 01.21 AB" COUNT “CT”...
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APPENDIX J: COMMUNICATION OPTION NAME COMMAND DATA SIZE REPORT “RR” Read Schedule # 1 Byte Status 4 Bytes pulse Current 2 Bytes pulse Pressure 2 Bytes 1st pulse Angle 2 Bytes 2nd pulse Current 2 Bytes 2nd pulseVoltage 2 Bytes 2nd pulsePressure 2 Bytes 2nd pulse Angle...
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APPENDIX J: COMMUNICATION OPTION NAME COMMAND DATA SIZE MONITOR “MS” Set <ACK> OR <NAK> 0 Bytes MONITOR “MR” Read SCHEDULE # 1 Byte HIGH1C # High current #1 % 2 Bytes LOW1C # Low current #1 % 2 Bytes HIGH2C # High current #1 % 2 Bytes LOW2C #...
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APPENDIX J: COMMUNICATION OPTION Major Error Bit Pattern – the following bits are set to 1 when their associated error condition exists. Bit 0 Emergency Stop Bit 1 Over temperature Bit 2 No current Bit 3 Mode change error Bit 4 Shorted SCR Bit 5 Weld 1 current high...
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APPENDIX J: COMMUNICATION OPTION Active Screen Number (Continued) Duplicate starting schedules in link lists screen Schedule programming screen Not used Hidden screen Copy schedule screen System valve screen – 4 valve option System valve screen – 12 valve option Full current error screen Weld 1 current greater than full current error screen Weld 2 current greater than full current error screen Weld 1 current less than 20% of full current screen...
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APPENDIX J: COMMUNICATION OPTION Active Screen Number (Continued) Seam weld simplified schedule screen – constant current modes Seam weld simplified schedule screen – %heat modes SCR shorted screen List of boards installed screen Low line voltage screen High line voltage screen Current scaling error Not used Continuous seam weld enabled mode screen...
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APPENDIX J: COMMUNICATION OPTION NAME COMMAND DATA SIZE SYSTEM “YS” Set <ACK> OR <NAK> 0 Bytes SYSTEM “YR” Read MAX VALVES # 1 Byte MAX SCRS 1 Byte TURNS RATIO (1:1 - 200:1) 1 Byte 87 DEGREE DELAY { ON=1 | OFF=0} 1 Byte RESET { ON=1 | OFF=0}...
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APPENDIX J: COMMUNICATION OPTION NAME COMMAND DATA SIZE FORCE “PS” Set <ACK OR NAK> 0 Bytes FORCE “PR” Read P1 MIN CALIBRATE #, (0-9999) 2 Bytes P1 MAX CALIBRATE #, 2 Bytes P2 MIN CALIBRATE #, 2 Bytes P2 MAX CALIBRATE #, 2 Bytes P3 MIN CALIBRATE #, 2 Bytes...
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Section III. Maintenance Remove/Replace the Communications Board Disconnect the twenty-six pin ribbon cable connector from the AC Timer Main Board connected to J2. Disconnect the serial cable connector (coming from the external 9-pin connector) from J3. Slide the card out of the card cage. Install or re-install the circuit board by sliding it into the card cage.
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APPENDIX K CIRCUIT MODIFICATION FOR EXTERNAL TRANSFORMER THERMOSTAT External Transformer Thermostat Connection The following procedure will enable you to connect an external transformer thermostat to the Control such that it will monitor that thermostat the same as the SCR thermostat. WARNING: Lethal voltages are present in the unit.
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APPENDIX L DEFAULT INITIALIZATIONS The Table below lists the settings that are initially loaded into the Control software. Note that some of these settings may not still be so set when you receive your equipment. During final testing in our Quality Assurance department certain settings, such as , may be altered to test the Control Mode...
APPENDIX L. DEFAULT INITIALIZATIONS Screen Indication Setting Name Default (May vary between screens) SYSTEM WIDE VALUES Initialization Full Current FULL CURR. Maximum Number of SCRs MAX # OF SCR Turns Ratio TURNS RATIO 053:1 Control Mode CNTRL MODE %HEAT Binary Schedule Selected BIN.
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APPENDIX L: DEFAULT INITIALIZATIONS Screen Indication Setting Name Default (May vary between screens) MONITOR Initialization (Continued) Weld 2 High Current Limit W2 - HIGH Weld 2 Low Current Limit W2 - LOW Weld 2 Conduction Angle Limit W2 – COND. LIMIT STEPPER Initialization Stepper STEPPER...
Index AC Timer Main Board ........5-5 Communications Protocol and Air Hose, Cylinder, Connections ....1-8 Commands ..........J-4 AUTO RESET ..........3-14 Communication External Protocol .. J-4 Definition of Command Elements ... J-4 Host Originated Command Set ..J-5 STA Originated Response Back Pressure ..........
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INDEX Data + ON | OFF ........... 1-6 VAL5, N & L through VAL12, N & L B-7 Default Initializations ........L-1 Electrical Connections ......1-9, B-1 Definition of Command Elements ....J-4 Electrode Valve (Electrode Valve Number) . 3-5 Delay, 87°...
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INDEX General Information ........5-1 Maintenance Procedures ...... 5-1, J-21 Cooling Maintenance – Water Draining 5-1 Major Components ........1-3 Fuse Replacement ........5-2 Air Hose Connections ......1-8 General Maintenance Procedures ..5-1 Electrical Connections ......1-9 Principles of Operation ......5-2 External Connectors .......
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INDEX NUM VALVES (Number of Valves) ..3-14 Planning for Installation ........ 2-1 NW1 – Weld On/Off Input ......B-6 Cooling Water Requirements ....2-1 Normal Shutdown ........4-15 Environmental Factors ......2-1 Power Requirements ......2-1 Space and Mounting Requirements ..2-1 Power, +24V ..........B-6 Operating Instructions ........
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