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Amada 125ADP Operation Manual

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STORED ENERGY POWER SUPPLY
125/300/1000ADP
 
 
 
 
 
OPERATION MANUAL
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
990-922 Rev G

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  • Page 1 STORED ENERGY POWER SUPPLY 125/300/1000ADP           OPERATION MANUAL                                                   990-922 Rev G...

  • Page 2: Revision Record

      Revision Record    Revision Date Basis of Revision 42027 06/12 None. Original edition. Add Repeat Mode function and 125ADP Ws programming in 42170 09/12 0.1 Ws increments. 42840 10/13 Update to Miyachi America name and logo. 43480 11/14 Updated to Amada Miyachi America name and log.

  • Page 3: Table Of Contents

    Power ............................2-2 Compressed Air and Cooling Water ..................2-3 Input Logic Configuration ....................... 2-3 Section II. 125ADP & 300ADP External Equipment Connections ............2-4 Emergency Stop Switch ......................2-4 Weld Head Connections to Power Supply Terminals .............. 2-5 Foot Pedal-Actuated Weld Head Connection ................2-6 EZ-AIR Weld Head Connections .....................
  • Page 4 Chapter 4. Operating Instructions Section I: Introduction ........................... 4-1 Before You Start ..........................4-1 Pre-Operational Checks ........................4-1 Connections ..........................4-1 Power ............................4-1 Compressed Air ........................4-1 Initial Setup ............................4-2 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922  ...
  • Page 5 Appendix C. System Timing ........................C-1 Appendix D. Communications ......................D-1 Appendix E. The Basics of Resistance Welding ................... E-1 Appendix F. Quality Resistance Welding Solutions: Defining the Optimum Process ......F-1 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922  ...

  • Page 6: Contact Us

    Amada Miyachi America is not responsible for any loss or injury due to improper use of this product. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922  ...

  • Page 7: Safety Notes

     Never perform any welding operation without wearing protective safety glasses. This instruction manual describes how to operate, maintain and service the 125ADP/300ADP/1000ADP Dual Pulse Resistance Welding Power Supplies, 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.
  • Page 8 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY viii 990-922  ...
  • Page 9 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922  ...
  • Page 10 Seller’s own service personnel, or an authorized representative’s personnel, unless such repairs are made with the written consent of Seller in accordance with procedures outlined by Seller.   125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922  ...
  • Page 11 SET FORTH IN SECTION 1(A). Representations and warranties made by any person, including representatives of Seller, which are inconsistent or in conflict with the terms of this warranty, as set forth above, shall not be binding upon Seller.   125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922  ...
  • Page 12 (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.
  • Page 13 Third Party Product, Seller will assist (within reason) Buyer (at Buyer’s sole expense) in obtaining, from the respective third party, any (if any) adjustment that is available under such third party’s warranty. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922 xiii...
  • Page 14  ...

  • Page 15: Chapter 1. Description Section I: Features

    Pulse Resistance Welding Power Supply will simply be called the Power Supply. The 125ADP and 300ADP contain the same set of control features. The 1000ADP has all of the features of the ADP product family except the polarity is fixed and not user settable in weld schedules.

  • Page 16: Display Screens

    , welds within limits display GREEN , and welds out of limits display as indicated below. Pulse 1 & Pulse 2 Limits OFF Pulse 1 Out of Limits / Pulse 2 Within Limits 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 17: Description

     The Power Supply is protected from radio frequency and electromagnetic interference, resulting in reliable operation even in high electrical noise environments. Input switch debounce circuitry eliminates false triggering. Detailed instructions on using these features are located in Chapter 4, Operating Instructions. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 18 The remote schedule feature allows the weld schedules to be selected in automated applications. ADP Power Supplies are designed to operate at either 100-120VAC or 200-240VAC, 50/60 Hz and can be used with manual, user actuated, or air actuated weld heads. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 19: Section Ii: Major Components

    The rear panel connections are discussed in Chapter 2, Installation and Setup. Front Panel Controls The function of each item is described on the following pages. Front Panel Controls (125ADP, 300ADP) 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 20: Up/Down Buttons

    63 schedules to select a desired schedule. The schedule number displays at the lower right corner of the front panel display screen. ● In “editing” mode, these buttons also are used to increase or decrease highlighted values. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 21: Polarity Select

    Press and hold this button for 1 second to display the editing screen. Menu Welding is not allowed when these screens are displayed. Additional Menu instructions for the screen are in Chapter 3, Using Display Screens. Menu 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 22: Limits / Counters

    COUNTER LIMIT fields. Pressing this button discards PULSE 1 & PULSE 2 UPPER & LOWER LIMIT changes made during editing at the prompt: Press to save changes SAVE SAVE to discard. CLEAR 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 23: Charge Monitor Light

    If your work station is not equipped with an , be sure that the conductors of EMERGENCY STOP SWITCH the emergency stop input cable are shorted together as the system will not operate with this loop electrically open. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 25: Chapter 2. Installation And Setup Section I: Installation

    When you unpack the shipping container, be sure that the contents of the shipping kit match the list in Appendix A, Technical Specifications and that you have also received the accessories you ordered. If the Power Supply shows any signs of shipping damage, promptly contact both the carrier and Amada Miyachi America Customer Service. See...

  • Page 26: Utilities

    200-240 1000ADP Compressed Air and Cooling Water If compressed air or cooling water service is required for the weld head, please refer to the weld head manufacturer’s user manual for service specifications. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 27: Input Logic Configuration

    HIGH = TRUE INPUTS which supplies +24VDC to activate, or to enable inputs ON. Detailed instructions for changing the Input Logic Configuration, including electrical schematics, will be found in Appendix B, Electrical and Data Connections. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 28: Section Ii. 125Adp & 300Adp External Equipment Connections

    Rear Panel Components and Connectors 125ADP and 300ADP NOTE: Weld cable connections are made at the front panel for the 125ADP and 300ADP Power Supplies and located on the front panel of the external transformer on the 1000ADP systems.

  • Page 29: Weld Head Connections To Power Supply Terminals

    Connect the other end of the weld cables to the weld head. 5. Install electrodes in the weld head electrode holders. NOTE: If you need additional information about the weld heads, please refer to the manufacturer's user manuals. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 30: Foot Pedal-Actuated Weld Head Connection

    5. Set the active schedule to the minimum energy level of the Power supply. 6. Set the weldhead force to 5 or greater. 7. Smoothly close the weldhead. Verify that the power supply fires. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 31: Ez-Air Weld Head Connections

    NOTE: These instructions describe connection to the Miyachi Unitek EZ-AIR weld head. Non-EZ- AIR heads may be connected to the Power Supply but are not covered in these instructions. For non-EZ- AIR head instructions, refer to the manual provided by the weld head manufacturer. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 32: 24 Vac Ez-Air

    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. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 33 DOWN position, and then send the firing switch signal back to the Power Supply when the preset electrode force is reached. After firing, the upper electrode should ascend smoothly back to the UP position. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 34: Section Iii. 1000Adp External Equipment Connections

    Current Sense Coil. 1000ADP Both of these must be connected to the Power Supply using the rear panel connectors shown below. Rear Panel Connectors for the 1000ADP 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 2-10 990-922...

  • Page 35: Connecting The 1000Adp Transformer

    3. Once the dots are aligned, push the cable into the transformer connector until it stops, then twist counterclockwise until the connectors are secured together. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922 2-11...
  • Page 36 (the end farthest from the opening secured by the Velcro strap) in a fixed position relative to the weld cable. Plug the connector on the current coil cable to the connector on the back of CURRENT SENSE the power supply. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 2-12 990-922...

  • Page 37: Chapter 3. Using Display Screens Section I: Run Screen

    Energy in tenths of watt seconds for energy settings between 1.0 and 10.0 Ws. The energy settings for the 125ADP between 10 and 125 Ws can only be set in whole number increments. The energy settings for the 300ADP and 1000ADP can only be set in whole number increments.

  • Page 38: Editing The Run Screen

    PULSE 2 To edit the same values for Pulse 2, press the button and repeat the procedures for PULSE 2 Pulse 1. SQUEEZE TIME To edit the squeeze time, press the SQZ/HOLD button. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 39: Hold Time

    CLEAR will revert to the original screen. NOTE: Whenever the RUN, MENU buttons are pressed before LIMITS/COUNTERS edited values are saved, the prompt will SAVE appear at the bottom of the screen. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 40: Section Ii: Limits / Counters Screen

    LOWER LIMIT values are both set to zero, the limit function is disabled. PULSE 2 - Limits Limits for Pulse 2 are edited in the same manner as previously described for Pulse 1. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 41: Pulse 1 - Action

    CLEAR 000000. counter limit to will disable the Setting the 000000 output signal available WELD COUNTER RELAY at the rear panel 37-PIN I/O CONNECTOR 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 42 SAVE screen, press the key and the prompt will now appear. To discard all new settings and EDIT SAVE values, and return the system to its previous settings, press the button. CLEAR 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 43: Section Iii: Menu Screen

    This will highlight the buzzer MENU volume for editing. To highlight another field, press and release the button. MENU Use the ▲▼ arrows to change the highlighted values in all fields on the screen. MENU 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 44: Baud Rate

    NOTE: If the schedules that are chained together differ in pulse widths or polarities, a delay of 50 to 350 msec may be required between schedules to switch to the new settings. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 45: Chaining End

    , all serial REMOTE communication commands are active. LANGUAGE Press the button again to select the MENU language ( ENGLISH, ESPAÑOL, DEUTSCH The language on screen will change when this field is saved. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 46: Reset Defaults

    , weld data is FAST WELDING saved to non-volatile memory only when the user presses the button. SAVE See Chapter 4 for more information about the feature. FAST WELDING 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 3-10 990-922...

  • Page 47: Repeat Mode

    REPEAT TIME electrodes and to allow you to reposition the work piece before the entire welding sequence repeats. When is set to , this function is deactivated. REPEAT MODE 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922 3-11...

  • Page 48: Repeat Time

    MODE is the time between the end REPEAT TIME and the start of the next weld HOLD sequence. can range from REPEAT TIME 0.25 seconds. 9.99 REPEAT MODE showing REPEAT TIME 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 3-12 990-922...

  • Page 49: Chapter 4. Operating Instructions Section I: Introduction

    If you are using an air-actuated weld head, verify that compressed air is connected as described in the appropriate sections of your weld head manual. Turn the compressed air ON, and adjust it according to the instructions in your weld head manual. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 50: Initial Setup

    Release the footswitch to release the material. Check the head for smooth operation of the electrodes. When you are ready to perform a weld, be sure to set the switch back to the WELD/NO WELD position. WELD 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 51: Section Ii. Operation

    PULSE 1 screen changes to black, the Power Supply is in the “edit” mode. 4. To modify the energy, press the arrow to increase energy or press the arrow to decrease energy. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 52: Set Peak Current Monitor Limits

    , Pulse 2 is inhibited when Pulse 1 is out of limits. INHIBIT PULSE 2 is selected 5. Use the button to set the upper and lower limits for Pulse 2. PULSE 2 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 53: Set Weld Counter Limits Or Reset The Weld Counter

    6. To set the ending schedule for a weld chain, press the button again. Press the MENU arrows to select the ending schedule. 7. Press the button again to select the field. MENU REMOTE 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 54: Dual Weldhead Operation

    To set this lock, connect pin 27 of the 37 pin connector to the I/O common (pin 28 or pin 32). See Appendix B, Electrical & Data Connections for connection details. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 55: Fast Welding

    In order to assure that all data is saved to non-volatile memory before turning the unit OFF, press the SAVE button. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 56: Section Iii: Operational Notes

    Section III: Operational Notes Repetition Rate The 125ADP, 300 ADP, and 1000 ADP Power Supplies monitor the overall repetition rate and do not accept fire signals that occur at greater rates than listed in Appendix A, Technical Specifications. The 125 ADP does allow for two consecutive welds to be at a faster rate than the .

  • Page 57: Extended Shut-Down Procedure

    2. Set the energy to the maximum level. Example: set the 1000ADP to 999 Watt Seconds. 3. Fire the unit once. 4. Leave the power ON and wait 15 minutes. 5. Program the desired schedule and resume normal operation. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 58  ...

  • Page 59: Section I. Troubleshooting

    1. Insufficient weld head force design Sticking Warping 2. Excessive energy setting 2. Incompatible weld piece materials 2. Contaminated electrode surface 2. Wrong electrode tip shape 3. Slow weld head follow-up 3. Excessive current/energy setting 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 60 The unit did not reach this 2) If the error persists, new, lower energy value within 15 contact Amada Miyachi seconds. America for service. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 61 The resistance of the secondary Open load detected is properly installed in circuit is too high. the weldhead If the process requires operation with a high secondary circuit resistance, contact Amada Miyachi America for assistance 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 62: Calibration

    Calibration Calibration must be performed by factory-trained and qualified personnel. If your Power Supply needs calibration, contact your local Amada Miyachi America service representative, or contact our service department at the address, phone number, or e-mail address listed under in the front of this Contact Us manual.

  • Page 63: Section Iii. Repair Service

    If you have problems with your power Supply that you cannot resolve, please contact our service department at the address, phone number, or e-mail address listed under in the front of this Contact Us manual. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 65: Appendix A. Technical Specifications

    Description Item 125ADP (Control Unit) 300ADP (Control Unit) 1000ADP (Control Unit) Dimensions 125ADP 44 lbs ( 20kg )  300ADP 69 lbs ( 31 kg ) Weight 1000ADP control unit 29 lbs ( 13kg ) 1000ADP (Transformer) Dimensions Weight 135 lbs (61 kg)
  • Page 66 52/min 100 Ws 47/min 175/min 125 Ws 45/min 150 Ws 140/min 200 Ws 120/min 225 Ws 105/min 250 Ws 65/min 300 Ws 80/min 500 Ws 35/min 750 Ws 17/min 1000 Ws 10/min 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 67 6.0 ms inductance. Duration measured at 10% of Medium 2.5 ms 8.0 ms 8.4 ms 2.8 ms 8.2 ms peak currents. Long 3.9 ms 11.2 ms 11.7 ms 4.7 ms 12.2 ms 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 68 APPENDIX A: TECHNICAL SPECIFICATIONS Description Item  125ADP -- 1 to 125 Watt Seconds (Ws) in 0.1 Ws increments for 1.0 10.0 Ws, otherwise 1 Ws increments. Watt Second Adjustment Range 300ADP -- 3 to 300 Watt Seconds (Ws) in one Ws increments 1000ADP –...

  • Page 69: Appendix B. Electrical And Data Connections

    As described in Chapter 2, Installation & Setup, a 115V power cord is supplied. The female end of the power cable is an IEC-320-C13 standard plug. Connect the Power Supply power cable to a 1-phase, 50/60Hz power source. The nominal voltage can be either 100/120V or 200/240V. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 70 DC voltage. This configuration is made with one jumper. To convert to DC output, remove the cover of the unit and locate jumper . Move it to the HEAD2 position as shown below. TOP VIEW (Cover Removed) 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 71 LOW = TRUE To reconfigure all other inputs (Binary schedule select lines, weld inhibit, etc.) for , move HIGH = TRUE jumper to the position as shown in the photograph. HIGH = TRUE 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 72 Miyachi Unitek heads with this feature. In operation, an optical switch connects pin 3 to pin 20 to initiate firing. Neither of these pins should be used for any other purpose since they connect to internal, non-isolated points in the unit. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 73 Miyachi Unitek heads with this feature. In operation, an optical switch connects pin 3 to pin 20 to initiate firing. Neither of these pins should be used for any other purpose since they connect to internal, non-isolated points in the unit. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 74 Weld out of limits relay Not used Not used +24VDC. The total current draw from pins 1 and 19 must not exceed 500 mA. Ground Not used Not used FS2 (Foot switch level 2) 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 75 Relay common Ground RS-232 Connections (As seen from the back of the power supply) DESCRIPTION No Connection. RS-232 Transmit. RS-232 Receive. No Connection. Signal Ground. No Connection. No Connection. No Connection. No Connection. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 76 I/O Signal Interface General Description on page B-3. The mating connector is an AMP type 206429-1, using cable clamp AMP type 206358-2. The two male pins used are Amp type 66361-2. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 77 The Weld Head Connector combines all the inputs and outputs necessary to connect a plug-and-play EZ- AIR Miyachi Unitek weld head. If PLC or other means of trigger is used, refer to the I/O Signal Interface General Description on page B-3. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 78 Power Supply. If you choose not use an Emergency Stop an electrical short is required between cable leads for the Power Supply to be functional. Switch, 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY B-10 990-922...

  • Page 79: Appendix C. System Timing

    This time is not programmable by the user. It depends upon the energy level of the second COOL pulse, and ranges from 20 to 670 ms on the 125ADP and 300 ADP. It can range up to 1.5 seconds on the 1000ADP. If no second pulse is programmed, this time period is skipped.
  • Page 80 This time is not programmable by the user. It depends upon the energy level of the second pulse, and ranges from 20 to 670 ms on the 125ADP and 300 ADP. It can range up to 1.5 seconds on the 1000ADP. If no second pulse is programmed, this time period is skipped.
  • Page 81 OUT OF LIMITS ranges from 100 to 250 msec. Delay time from the end of time until the relay turns On. HOLD COUNTER EXCEEDS LIMIT This is from 125 to 250 msec. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 83: Appendix D. Communications

    The host must be set to the same baud rate as the unit.  For a microprocessor-based conversion (such as the Edgeport USB converter from Inside Outside Networks), the host computer should be running the Windows operating system. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 84 When you issue a command to the ADP, you need to wait for the response before you issue the next command. This waiting period should be at least 250 msec. The ADP should respond within this timeout. VARIABLE: italics. RANGE OF PARAMETERS: low_end - high_end (separated by hyphen). 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 85 Reset Weld Counter (zero = 1) 1 Byte WELD LIMIT “CS” Set Weld Limit Value. 6 Bytes LOAD “LR” Read None, Returns current schedule number 0 Bytes “LS” Set 01-63 = Sets active schedule 2 Bytes 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 86 (0=Off, 1= On) 1 Byte REMOTE (0=Off, 1= On) 1 Byte CHAINING START, (0=Off, 01-63) 2 Bytes CHAINING END (0=Off, 01-63) 2 Bytes 9 Bytes Total ------------------------------------------------------------------------- rate 0=9600, 1=19.2 k, 2=38.4 k Baud 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 87 Returns the rear panel status in HEX. 1 Byte Dual Weld Head 1 Bit Weld Inhibit 1 Bit Schedule Lock 1 Bit Program Lock 1 Bit Emergency Stop 1 Bit 1 Bit 1 Bit Fire Switch 1 Bit 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 88 (0=Off, 1= On) 1 Byte REMOTE (0=Off, 1= On) 1 Byte CHAINING START, (0=Off, 01-63) 2 Bytes CHAINING END (0=Off, 01-63) 2 Bytes 9 Bytes Total ------------------------------------------------------------------------- rate 0=9600, 1=19.2 k, 2=38.4 k Baud 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 89 P1 Lower Limit, 4 Bytes P1 Action (action) 1 Byte P2 Upper Limit 4 Bytes P2 Lower Limit 4 Bytes 19 Bytes Total ------------------------------------------------------------------------- action 0 = NONE, 1 = INHIBIT P2 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 90 22 hex (in decimal 84 + 67 + 48 + 54 + 48 + 48 + 48 + 48 + 48 + 53 = 546. 546 / 256 = 2.13. Therefore the check sum is 546 – (256*2) = 34 decimal or 22 hex. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 91 Reset an Error Schedule (Read) Schedule (Set) Read Weld Counter Read Good & Bad Counters Read Weld Count Limit Rear Panel Status Read Status of last weld Read the Type System (Read System (Set) 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 93: Appendix E. The Basics Of Resistance Welding

    RT -- the square of the weld current [ I ] times the workpiece resistance [ R ] times the weld time [ T ]. Welding Parameter Interaction Interaction of Welding Parameters 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 94 -2, -14 Brass -2, -14 Stainless Steel Copper Beryllium Copper Bronze -2, -11 Bronze -2, -11 Copper Beryllium Tinned Copper Bronze -2, -11 Tinned Copper Copper Beryllium Nickel Bronze -2, -11 Iron Copper 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 95 Kovar, Gold Copper Karme Kulgrid Plate Kovar, Gold Copper Manganin Nickel Plate Kovar, Gold Copper Nichrome Silver -11, -14 Plate Kovar, Gold Copper Nickel Stainless Steel Plate Copper Paliney 7 Magnesium Magnesium 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 96 If this is not done, the rough surface of the electrode face will have a tendency to stick to the work piece. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 97 Fatigue tests and radiography have also been used. Of these methods torsional shear is preferred for round wire and a 45-degree peel test for sheet stock. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 98 Typical Weld Strength Profile A comparison of weld schedules for several different applications might show that they could be consolidated into one or two weld schedules. This would have obvious manufacturing advantages. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 99: Appendix F. Quality Resistance Welding Solutions: Defining The Optimum Process

    Ceramic (alumina, sand)  Plastics/polymers (PVC, teflon)  Semiconductors (silicon, geranium) Of these, only metals can be resistance welded because they are electrically conductive, soften on heating, and can be forged together without breaking. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 100 As there is no real melting of the materials in a solid-state joint, there is less chance of weld splash or material expulsion. A weld nugget can still be achieved with a solid-state joint. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 101 Conductive metals dissipate heat and it can be difficult to focus heat at the interface. A solid- state joint is therefore preferred. Typically, resistive electrode materials are used to provide additional heating. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 102 Bulk Resistance Time The figure above shows the key resistances in a typical opposed resistance weld and the relationship between contact resistances and bulk resistances over time, during a typical resistance weld: 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 103 The contact resistances present at the weld when the power supply is fired have a great impact on the heat balance of a weld and, therefore, the heat affected zone. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 104 The stages of heat generation for conductive materials will be similar to that of resistive materials, but there will be less heat generated in the bulk resistance due to the conductivity of the materials. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 105 (for further details comparison see the Miyachi Unitek “slide rule” tool). 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 106 Materials: Resistivity, melting point, thermal mass, shape, hardness, surface properties.  Heat balance: Electrode materials, shape, Polarity, heating rate (upslope).  Observation: visual criteria, cross section, and impact of variables on heat balance. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...

  • Page 107: Common Problems

    This part of weld development is critical in order to proceed to a statistical method of evaluation (Design of Experiments or “DOEs”). Random explosions or unexpected variables will skew statistical data and waste valuable time. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922...
  • Page 108 If many variables are still not understood, multiple Screening DOE’s may be required. Amada Miyachi America provides a simple Screening DOE tool that is run in Excel® and is sufficient for the majority of possible applications (contact Amada Miyachi America for details).
  • Page 109 Welded assemblies should be tested over time and under real use conditions to ensure that all functional criteria will be met. Validation testing is usually required to prove the robustness of the process under production conditions. 125ADP/300ADP/1000ADP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-922 F-11...
  • Page 110 Welding problems can more easily be identified and solved if sufficient experimental work is carried out to identify the impact of common variables on the quality and variation of the welded assembly. Amada Miyachi America frequently uses the Screening DOE tool to establish the impact of key variables and to assist customers with troubleshooting.
  • Page 111     http://www.amy.amada.co.jp/e/    AMADA MIYACHI AMERICA, INC. 1820 South Myrtle Ave., Monrovia, CA 91016, U.S.A.  TEL. +1‐626‐303‐5676  FAX. +1‐626‐358‐8048               http://amadamiyachi.com  AMADA MIYACHI CO., LTD. 200, Ishida, Isehara‐shi, Kanagawa 259‐1196, Japan    AMADA MIYACHI KOREA CO., LTD. 28, Dongtanhana 1‐gil, Hwaseong‐si, Gyeonggi‐do, 445320, Korea  TEL. +82‐31‐8015‐6810  FAX. +82‐31‐8003‐5995  AMADA MIYACHI SHANGHAI CO., LTD. Room01,15th Floor, SML Center, No.610 Xujiahui Road, Huangpu District, Shanghai 200025, China  TEL. +86‐21‐6448‐6000  FAX. +86‐21‐6448‐6550    AMADA MIYACHI EUROPE GmbH Lindberghstrasse 1, DE‐82178 Puchheim, Germany  TEL. +49‐89‐839403‐0  FAX. +49‐89‐839403‐10    AMADA MIYACHI TAIWAN CO., LTD.
  • Page 112                                                                   AMADA MIYACHI AMERICA, INC.     1820 South Myrtle Ave., Monrovia, CA 91016, U.S.A.     TEL. +1‐626‐303‐5676  FAX. +1‐626‐358‐8048  ...

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