Table of Contents
Advertisement
Advertisement
Table of Contents
Related Manuals for Amada 125DP
Summary of Contents for Amada 125DP
- Page 1 STORED ENERGY POWER SUPPLY 125DP OPERATION MANUAL 990-270 Rev J...
- Page 2 Copyright © 2002, 2013, 2014, 2015 Amada Miyachi America The engineering designs, drawings and data contained herein are the proprietary work of Amada Miyachi America and may not be reproduced, copied, exhibited or otherwise used without the written authorization of Amada Miyachi America.
- Page 3 Should questions arise, or if you have suggestions for improvement of this manual, please contact us at the above location/numbers. Amada Miyachi America is not responsible for any loss due to improper use of this product. DUAL PULSE 125 STORED ENERGY RESISTANCE WELDING POWER SUPPLY...
- Page 4 SAFETY NOTES This instruction manual describes how to operate, maintain and service the Dual Pulse 125 Stored Energy Resistance Welding Power Supply, and provides instructions relating to its SAFE use. Procedures described in this manual MUST be performed, as detailed, by QUALIFIED and TRAINED personnel.
-
Page 5: Table Of Contents
CONTENTS CHAPTER 1: SYSTEM DESCRIPTION ................ Section I. Features ......................Section II. System Components ..................Front Panel Description ..................... Front Panel Keys ......................Indicators and Displays ....................Rear Panel ........................CHAPTER 2: GETTING STARTED ................Location ........................Power Line ........................Welding Cables ........................ - Page 6 Change 1st Pulse ....................Change 2nd Pulse ....................Power Up Schedule ....................Copying Information in Schedule 0 to another schedule ........Programming Squeeze Time ................Schedule Protection ON ..................Schedule Protection OFF ..................CHAPTER 4: DEVELOPING WELD SCHEDULES ............ Resistance Welding Parameters ..................Procedure ........................
- Page 7 Circuit Breaker(s) ....................... Power ........................Capacitor Bank......................Line Voltage Regulation .................... Turndown Circuit ....................... Line Failure Turndown ....................Over-Voltage Lockout ....................Charge Lockout Circuit ....................Weld Fire Lockout ..................... Output Pulse Characteristics ..................Welding Speed ......................... Dual Pulse Welding Speed..................Power Cord ........................
- Page 8 Typical Weld Strength Profile ................Line Voltage pins on Control Board ..............Hit Rate of 125 DP with 1500 µF and 750 µF Capacitor Bank ......Repetition Rate, Maximum Continuous welding speed of Model 125DP... 125DP Outline Drawings ..................Tables...
- Page 9 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.
- Page 10 (g) All expendables such as electrodes are warranted only for defect in material and workmanship which are apparent upon receipt by Buyer. The foregoing warranty is negated after the initial use. (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.
- Page 11 (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 12 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.
-
Page 13: Chapter 1: System Description
SYSTEM DESCRIPTION Section I: Features The Miyachi Unitek™ Dual Pulse 125 (125DP) is a stored energy, capacitor discharge, power supply designed to perform precision resistance welding. The circuitry is solid state, microprocessor controlled, with components conservatively rated when used within the maximum specified repetition rates. The charging circuit uses silicon controlled rectifiers in a patented manner which provides high reliability and precise charging intervals. -
Page 14: Section Ii. System Components
CHAPTER 1: SYSTEM DESCRIPTION Section II: System Components Front Panel Description - Used to switch both sides of the incoming power line. POWER SWITCH - Welding current will not flow when this switch is in the NO WELD WELD/NO WELD SWITCH position. -
Page 15: Front Panel Keys
Pulse display can be decreased to 000%. Also used to change Squeeze Time down to a minimum of 0.1 seconds, or 0.0 to disable. Causes the 125DP to enter the PROGRAM State so that the user can change the FIRST PULSE %ENERGY for the current schedule. When already in the... -
Page 16: Indicators And Displays
Software Version Number. The 125DP will then go to the RUN State and display the last Schedule saved in memory. ENERGY DISPLAY - Indicates Energy setting for the currently displayed schedule number. -
Page 17: Rear Panel
AIR VALVE DRIVER - Provides either 24 or 115 volts (AC) to Miyachi Unitek Air Actuated Weld Heads. MECHANICAL FIRING SWITCH - 5 foot cable is used to connect the 125DP to the Force Firing Switch in all Miyachi Unitek Weld Heads and Handpieces. -
Page 19: Chapter 2: Getting Started
This power supply was wired for a specific voltage which was marked on the line cord during the manufacturing process. The standard 125DP is wired for 115 VAC. Re-connection for operation at another voltage may be made by a qualified technician. Refer to Chapter 5 - Calibration and Modifications. -
Page 20: Welding Cables
CHAPTER 2: GETTING STARTED Welding Cables Position the 125DP on the work bench approximately 5 inches behind the weld head. Use the cables which are furnished with the weld head to connect the terminals on the back of the weld head to the appropriate terminals on the transformer. -
Page 21: Firing Switch
Figure 2-3. Examples of Cable Routings Firing Switch Connect the Mechanical Firing Switch located on the rear panel of the 125DP to the mating connector of a Miyachi Unitek weld head or handpiece. Miyachi Unitek weld heads are force fired, instructions for... -
Page 22: Installing Air Actuated Weld Heads
CHAPTER 2: GETTING STARTED Installing Air Actuated Weld Heads Solenoid valve/regulator assemblies which are not mounted on the weld head should be located as close as possible to the weld head. Use the shortest air lines possible to obtain the fastest mechanical response. -
Page 23: Air Valve Driver
Miyachi Unitek Air Actuated Weld Heads with 4-pin 24 volt plugs manufactured prior to 1991, require a jumper connection. Pin 4 must be jumpered to Pin 2 so that the 125DP can recognize that an Air Head is connected. Refer to Appendix A - Specifications. -
Page 24: 2-Level Footswitch
CHAPTER 2: GETTING STARTED 2-Level Footswitch When a 2-Level Footswitch is pressed to the first level, the weld head will close and apply force to the workpiece. At this point, if the operator does not press further (harder) and actuate the second Level, the Footswitch can be released so that the workpiece can be re-positioned. -
Page 25: Pulse Width Changes
PARALLEL connection results in a SHORT Pulse. The SERIES connection results in a LONG Pulse. The amplitude of the Long Pulse is approximately two-thirds that of the Short Pulse. Refer to Chapter 6. Most welding applications use the Short Pulse. The 125DP is shipped from the factory connected for the Short Pulse. -
Page 26: Replace Cover
CHAPTER 2: GETTING STARTED Replace Cover After performing all internal selections, replace cover and screws and tighten securely. After verifying that all necessary installation and modification procedures have been completed, connect the line cord to the proper power outlet. External Inputs Options A 9-pin, sub-miniature "D"... - Page 27 CHAPTER 2: GETTING STARTED Figure 2-8. Remote Schedule Selection via BCD Coded Switches NOTE: If only a single schedule is to be executed, it is not necessary to close Charge Inhibit each time the power supply fires. Input Pin Numbers 1 (2 2 (2 3 (2...
-
Page 29: Chapter 3: Operating Instructions
Indicator is always lit in the RUN State, the 2nd Pulse Indicator will only light when a 2nd Pulse %Energy has been set. Welding is done in the RUN State. The 125DP will always power up in the RUN state with the last Schedule saved displayed. DUAL PULSE 125... -
Page 30: Select Schedule
ENERGY result in a flashing error message of Press [RUN] to clear the error code. to set the Energy Level of the 1ST Pulse. When the key is released the 125DP will Press ENERGY charge the capacitor bank to the %ENERGY displayed. The amount of energy used to make the weld is determined by the %ENERGY. -
Page 31: Welding Rate
For this reason the Force Firing Switch, located in the Welding Head, must close AFTER the capacitors reach the correct level. If the Force Firing Switch closes BEFORE the 125DP is properly charged, the Lockout Circuit will ignore the Firing Switch and a weld will not be made. -
Page 32: Section Ii. Operation
Schedules which are saved are remembered even if the power is switched to OFF. Schedules 0 through 7 can be saved. After the Schedule has been saved the 125DP will automatically re-enter the RUN State. NOTE: After entering the RUN state the capacitors will begin to charge to the PROGRAMMED level. -
Page 33: Power Up Schedule
Now use ENERGY Press The change made to Schedule 1 has been transferred to Schedule 0 and the 125DP is in the RUN State, ready to make a weld. Schedule 1 has remained unchanged. Example continued: to select Schedule 1. Notice that the parameters for Schedule 1 are as SCHEDULE they were before the 86% Energy entered. -
Page 34: Programming Squeeze Time
(the first Level of a 1-Level Footswitch or the second Level of a 2-Level Footswitch). See Chapter 2, Installing Air Actuated Weld Heads. After the Squeeze Time has elapsed the 125DP will fire. It is not necessary to make a Firing Switch connection when using Squeeze Time. -
Page 35: Schedule Protection On
CHAPTER 3: OPERATING INSTRUCTIONS NOTE: This section of this manual contains instructions which should not be made available to operators or personnel who are not authorized to make Schedule Changes. Schedule Protection ON When Schedule Protection is turned ON, all Schedules except Schedule 0 are protected from accidental or unauthorized changes. -
Page 37: Chapter 4: Developing Weld Schedules
Heat %ENERGY selected on 125DP Time PULSE WIDTH selected on 125DP. Number of pulses selected on 125DP. Pressure Electrode firing force set on weld head. Surface area of electrode faces. The interaction between the three basic welding parameters should be considered when developing a Weld Schedule. -
Page 38: Procedure
CHAPTER 4: DEVELOPING WELD SCHEDULES HEAT TIME PROBLEM CAUSE PROBLEM CAUSE Parts Overheating Excessive Parts Overheating Excessive Weak Weld Weak Weld Insufficient Nugget Insufficient Nugget PULSE Metal Expulsion Metal Expulsion ENERGY WIDTH Warping Warping Discoloration Discoloration Electrode Damage Insufficient Electrode Damage Insufficient PRESSURE PROBLEM... -
Page 39: Number Of Pulses
If both workpieces are flat, the face should be at least one-half the diameter of the electrodes. In any event, "pencil point" electrodes reduce the overall quality of the welding process. 125DP POWER SUPPLY - Parameters: PULSE WIDTH, %ENERGY, NUMBER OF PULSES Select SHORT pulse width. -
Page 40: Evaluate The Weld
If the weld is satisfactory, make numerous welds, using the exact physical set-up which is planned for the production line, to determine if the process is repeatable. Then you should properly document your Weld Schedule and COPY Schedule 0 to one of the 125DP's permanent Schedules (1 - 7). See Chapter 3. -
Page 41: Electrode Force And %Energy
CHAPTER 4: DEVELOPING WELD SCHEDULES Table 4-1. Causes of Imperfect Welds Electrode Problem Energy Time Force Size Weak Weld Too Low Too High Too Large Too Short Blow Holes. Too High Too Low Too Small Too Long Expulsion. Burned, Pitted Too Low. -
Page 42: Evaluate Results
CHAPTER 4: DEVELOPING WELD SCHEDULES Weld strength profiles are graphic presentations of the varying effects of %ENERGY, electrode force and weld strength. Make 3 or 4 welds after at the previous settings. Perform pull tests and plot the results. Continue to plot points until any unfavorable characteristic occurs, such as sticking or spitting. Repeat this procedure at different Electrode Forces. - Page 43 CHAPTER 4: DEVELOPING WELD SCHEDULES Depending on use, periodic tip resurfacing is required to remove oxides and welding debris from electrodes. Select [NO WELD]. On air actuated weld heads, reduce the air pressure to a value just sufficient to lower the upper electrode arm. Cleaning of electrodes on production line should be limited to use of #400-600 grit electrode polishing disks.
-
Page 45: Chapter 5: Maintenance
CHAPTER 5 MAINTENANCE Modification and Calibration Unless you are a skilled technician, we suggest you telephone the Amada Miyachi America Repair Department at the telephone number shown in the Foreword of this manual for advice before attempting calibration and/or modification. -
Page 46: Calibration
Figure 5-1. Line Voltage pins on Control Board Calibration The 125DP should not require any regular adjustments. Use the following procedure as a guideline to check the calibration. Care should be taken not to make unnecessary adjustments. Do not hesitate to call the Amada Miyachi America Repair Department with any questions. - Page 47 CHAPTER 5: MAINTENANCE Push the Switch to OFF, disconnect BP13 or BP14 and remove U5. Push the POWER POWER Switch to ON again. NOTE: Before proceeding, allow unit to warm up for a minimum of 5 minutes. ▲, and the 4.
-
Page 48: Troubleshooting
CHAPTER 5: MAINTENANCE Troubleshooting If the circuit breaker trips repeatedly, one of the following is probably the cause: a) Overload - Exceeding the duty cycle. b) Lockup of the output SCR, Q6 (switches ON, but not OFF). c) Shorting of the charging Triac Q1. d) Charge shunting SCR, Q2, shorted or locked ON. -
Page 49: Repair Service
Repair Service Telephone Service Call the Amada Miyachi America Repair Department at the telephone number shown in the Foreword of this manual. Before calling, please obtain the model number and serial number from the identification plate on the rear panel. -
Page 51: Appendix A: Technical Specifications
APPENDIX A TECHNICAL SPECIFICATIONS Stored Energy Rating 0.75 to 125 watt-seconds (joules). Energy Display The accuracy of the display is 0.5%. The resolution of the display ranges from 0.1% to 0.6% energy, depending upon the amount of energy selected. Line Voltage Table A-1. -
Page 52: Capacitor Bank
APPENDIX A: TECHNICAL SPECIFICATIONS Capacitor Bank The full bank of four capacitors total 1500 µF ±5% at 20º C. Four capacitors are grouped in two banks of two capacitors. At full rating, the Capacitor Banks are operated at 408 volts. The Pulse Width characteristics as well as the Hit Rate and Repetition Rate can be changed by disconnecting one-half of the Capacitor Bank. -
Page 53: Output Pulse Characteristics
APPENDIX A: TECHNICAL SPECIFICATIONS Output of the error amplifier inhibits the firing circuit during the charge and turndown intervals. This helps prevent poor welds caused by firing the power supply before the capacitor bank is properly charged or discharged. Firing Circuit Requires external contact closure or low logic level for firing. - Page 54 Percent Full Energy (welds/min) (welds/min) (welds/min) (welds/min) Under 2% 100% Conditions: 25C Ambient, Nominal Line Voltage, 60 Hz. Figure A-1. Hit Rate of 125DP with 1500 μF and 750 μF Capacitor Bank DUAL PULSE 125 STORED ENERGY RESISTANCE WELDING POWER SUPPLY 990-270...
-
Page 55: Dual Pulse Welding Speed
APPENDIX A: TECHNICAL SPECIFICATIONS Figure A-2. Repetition Rate, Maximum Continuous welding Speed of Model 125DP Dual Pulse Welding Speed The Repetition Rate or Hit Rate for Dual Pulse operation may be calculated as follows: Refer to table A-3 or figures A-1 and A-2. -
Page 56: Power Cord
APPENDIX A: TECHNICAL SPECIFICATIONS Calculate RR Rep Rate (Hit Rate) for dual pulse operation. (1+2), ) (RR = welds/minute (1+2) + RR For example, with a 1500 μf capacitor bank, if the energy level of Pulse 1 is 25% and Pulse 2 is 75%, the repetition rate for the dual pulse weld would be: (85) (52) = 32.2 welds/min. -
Page 57: Cooling
Muffin type fan, 115V, 50/60 Hz. Air inlet is underneath the unit, exhaust is to the left. No restriction to air flow should be closer than two inches to the side of the 125DP. Do not place the rear lefthand corner of the power supply in a corner in such a manner that the exhaust air will recirculate. -
Page 58: Physical Characteristics
APPENDIX A: TECHNICAL SPECIFICATIONS Shorting Pin 4 to Pin 5 will close the Charge Inhibit Line, and prevent recharging of the Capacitor Bank while a weld schedule is being selected. This line must be closed immediately after the power supply fires, before the 60 ms commutation pulse has ended. - Page 59 APPENDIX A: TECHNICAL SPECIFICATIONS Figure A-3. 125DP Outline Drawing DUAL PULSE 125 STORED ENERGY RESISTANCE WELDING POWER SUPPLY 990-270...
-
Page 61: Index
Footswitch ........2-5, A-6 Installation instructions ......2-1 Controls, front panel ......1-3 Interconnection wiring diagram .... 2-9 Cooling, 125DP........A-7 Cover, replace ........2-8 Jumper selection of weld heads .... 4-6, A-15 Declaration of Conformity ....following CE Operator Guide Dimensions ........... - Page 62 Power requirements ......A-1 Troubleshooting ........5-4 Power line, input ........2-1 Turning power on ......... 1-2 Power supply (125DP) parameters ..4-3 Powering up ........3-1 Profiles, weld strength ......4-6 PROGRAM state ........3-4 Voltage changes, line ......A-2 Voltage range specifications ....
- Page 63 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 64 AMADA MIYACHI AMERICA, INC. 1820 South Myrtle Ave., Monrovia, CA 91016, U.S.A. TEL. +1‐626‐303‐5676 FAX. +1‐626‐358‐8048 ...
Need help?
Do you have a question about the 125DP and is the answer not in the manual?
Questions and answers