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Amada HF28/240 Operation Manual

Dc resistance welding system
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DC RESISTANCE WELDING SYSTEM
HF28
 
 
 
 
 
 
 
 
OPERATION MANUAL
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
990-372 REV E
 

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Summary of Contents for Amada HF28/240

  • Page 1               DC RESISTANCE WELDING SYSTEM HF28                 OPERATION MANUAL                                 990-372 REV E  ...

  • Page 2: Revision Record

    Copyright © 1998 -- 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.    Printed in the United States of America.      Revision Record    Revision Date Basis of Revision 20409 06/05 None. Original edition.

  • Page 3: Table Of Contents

    CONTENTS Page Revision Record ............................ii Contents ............................iii Contact Us ............................. viii Safety Notes ............................ix Declaration Of Conformity .........................x Warranty ............................xi Chapter 1. Description Section I. Features ..........................1-1 Section II. Major Components ....................... 1-3 Major Components .......................... 1-3 Front Panel Display and Display Controls ..................

  • Page 4: Contents

    CONTENTS (Continued) Page Power ............................. 2-2 Compressed Air and Cooling Water ....................2-2 Section II: Setup ............................. 2-3 Connections to External Equipment ....................2-3 Rear Panel Components and Connectors ..................2-3 Weld Head Connections ........................2-4 Foot Pedal-Actuated Weld Head Connection .................. 2-6 EZ-AIR Weld Head Connections ....................
  • Page 5 Page Setup 3 ........................... 3-12 Do Test Weld .......................... 3-12 Always ..........................3-12 Ask ..........................3-12 Section III. Operational States ......................3-13 No Weld State ..........................3-13 Menu State ........................... 3-13 Test State ........................... 3-13 Run State ........................... 3-14 Weld State ........................... 3-15 Monitor State ..........................
  • Page 6 CONTENTS (Continued) Page Chapter 5. Operating Instructions Section I: Introduction ........................... 5-1 Before You Start ..........................5-1 Pre-Operational Checks ........................5-1 Connections ..........................5-1 Power ............................. 5-1 Compressed Air ........................5-1 Initial Setup ............................. 5-2 Section II. Operation ..........................5-3 Single-Pulse Weld Schedule ......................

  • Page 7: Contents (Continued)

    CONTENTS (Continued) Page Appendix A. Technical Specifications ....................A-1 Appendix B. Electrical and Data Connections ..................B-1 Appendix C. Calibration ........................C-1 Appendix D. System Timing ......................D-1 Appendix E. The Basics of Resistance Welding ................E-1 Appendix F. Quality Resistance Welding Solutions: Defining the Optimum Process ....F-1  ...

  • Page 8: Contact Us

    We have made every effort to ensure that the information in this manual is accurate and adequate. Should questions arise, or if you have suggestions for improvement of this manual, please contact us at the above location/numbers. Amada Miyachi America is not responsible for any loss due to improper use of this product.    ...

  • Page 9: Safety Notes

            SAFETY NOTES DANGER  Lethal voltages exist within this unit.   Do not perform any maintenance inside this unit.   Never perform any welding operation without wearing protective safety glasses. This instruction manual describes how to operate, maintain and service the HF28 resistance welding system control, and provides instructions relating to its safe use.
  • Page 10           HF28 DC RESISTANCE WELDING SYSTEM 990-372  ...

  • Page 11: Warranty

    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 12 (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 13 (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 14 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 15: Chapter 1. Description

    CHAPTER 1 Description Section I: Features Features For the rest of this manual, the Miyachi Unitek HF28 High Frequency Resistance Welding System control will simply be referred to as the Control. NOTE: This manual describes HF28 Models manufactured after 1-310-01, 1-310-01-01, 1-310-01-02 June 2005.
  • Page 16 CHAPTER 1: DESCRIPTION  You can program the Control from the front <MAIN MENU> panel, using simplified key clusters and on- 1. SETUP 6. RELAY 2. WELD COUNTERS 7. RESET DEFAULTS screen data fields. A screen MAIN MENU 3. COPY A SCHEDULE 8.

  • Page 17: Section Ii. Major Components

    CHAPTER 1: DESCRIPTION Section II: Major Components Major Components The major components are the front panel, which contains the operator’s controls and indicators, and the rear panel, which contains fuses, circuit breakers and power and signal connectors. The rear panel connections are discussed in Chapter 2.

  • Page 18: Display

    CHAPTER 1: DESCRIPTION Display Liquid Crystal Display (LCD) The Liquid Crystal Display (LCD) on the front panel allows you to locally program the Control with the front panel controls, and read the results of a weld process following its initiation. The LCD has three distinct functions, depending on the active mode of the Control.

  • Page 19: Display Controls

    CHAPTER 1: DESCRIPTION Display Controls There are three display control functions:  Selector Key SCHEDULE  Weld Period Selector Keys  Time/Energy Selector Keys SCHEDULE Key Puts the Control into the weld schedule selection mode. Use the keypad to directly enter a desired weld schedule (refer to Front Panel Data Entry and Mode Controls in this section), then press the key.

  • Page 20: Front Panel Data Entry And Mode Keys

    CHAPTER 1: DESCRIPTION Front Panel Data Entry and Mode Keys Key Pad The keypad consists of the numeric keys and the up/down/left/right keys. Numeric Keys: The numeric keys allow you to:  Enter or modify weld period time and energy values ...

  • Page 21: Monitor Keys

    CHAPTER 1: DESCRIPTION Control Mode Selection Keys. These keys allow you to select the control mode when programming with the (time/energy) selector keys. WELD Pressing the key selects current as the control mode for this schedule. The control will output the current waveform shown on the LCD. Pressing the key selects voltage as the control mode for this schedule.

  • Page 22: Weld/No Weld Switch

    CHAPTER 1: DESCRIPTION Pressing the key displays the power monitor. This screen shows the results of the most recent weld. This screen also allows the operator to set limits that automatically interrupt the weld when they are reached. You can also program the power monitor to output an alarm when the limits are exceeded.

  • Page 23: Chapter 2. Installation And Setup Section I: Installation

    Verify that the Control shows no signs of damage. If it does, please contact the carrier. Also, contact Amada Miyachi America Customer Service immediately at the postal or e-mail address or telephone or FAX number shown in the Foreword of this manual.

  • Page 24: Utilities

    HF28 Model Amps/ AMERICA 3 phase Current (A rms) 7 strands (AWG) (mm) Volts (Vrms) HF28/240 330-096 HF28/400 3.15 330-095 HF28/480 3.15 330-097 Compressed Air and Cooling Water If you require compressed air and cooling water service for the weld head, please refer to the weld head manufacturer’s user’s manual for service specifications.

  • Page 25: Section Ii: Setup

    CHAPTER 2: INSTALLATION AND SETUP Section II: Setup Connections to External Equipment All connections, other than the weld cable connections, between the Control and external equipment are made through the rear panel. Rear Panel Components and Connectors The weld cable connections from the weld head are made at the weld cable terminals on the front panel. HF28 DC RESISTANCE WELDING SYSTEM 990-372...

  • Page 26: Weld Head Connections

    CHAPTER 2: INSTALLATION AND SETUP Weld Head Connections Connect one end of a weld cable to the negative (-) welding transformer terminal on the Control. Connect one end of the second weld cable to the positive (+) welding transformer terminal on the Control.
  • Page 27 CHAPTER 2: INSTALLATION AND SETUP Connect the voltage sensing cable clips that are packed in the shipping kit to the voltage sensing cable leads. Use either the ¼” or 1/8” diameter clip, as appropriate to the electrode diameter. Attach a clip directly to each electrode as shown on the right.

  • Page 28: Foot Pedal-Actuated Weld Head Connection

    CHAPTER 2: INSTALLATION AND SETUP Foot Pedal-Actuated Weld Head Connection 1. Adjust the weld head force adjustment knob to produce 5 units of force, as displayed on the force indicator index. Connect the weld head firing switch cable connector to the Control firing switch cable connector.

  • Page 29: Chapter 5. Operating Instructions

    CHAPTER 2: INSTALLATION AND SETUP Connect a normally closed, approved, emergency stop switch across the two leads of the operator emergency stop switch cable. This switch, when operated (open), will immediately stop the weld cycle. See Appendix B. Electrical and Data Connections for circuit details. Set the switch on the Control front panel to the position.
  • Page 30 CHAPTER 2: INSTALLATION AND SETUP DC EZ-AIR Weld Head Connection Adjust the weld head force adjustment knob to produce 5 units of force, as displayed on the force indicator index. 2. Connect the weld head firing switch cable connector to the Control firing switch cable connector.
  • Page 31 CHAPTER 2: INSTALLATION AND SETUP Refer to the weld head manufacturer user’s manual. Connect the weld head air valve solenoid cable connector to the Control connector. AIR VALVE DRIVER NOTE: This connector supplies 24 VAC power only, and will not drive 115 VAC air valves. 6.

  • Page 32: Non-Ez-Air Weld Head Connections

    CHAPTER 2: INSTALLATION AND SETUP Non-EZ-AIR Weld Head Connections Non-EZ-AIR heads may be connected to the Control as shown below, however you should refer to the manual provided with the weld head you are using for specific instructions. HF28 DC RESISTANCE WELDING SYSTEM 2-10 990-372...

  • Page 33: Chapter 3. System Configuration Section I: Menus

    CHAPTER 3 System Configuration Section I: Menus Before You Start MENU Configuration is simply a matter of selecting various options so the Control will work with all the components of your welding system.  Verify that all connections have been made according to the instructions in Chapter 2, Installation and Setup.

  • Page 34: Weld Counter

    CHAPTER 3: SYSTEM CONFIGURATION SETUP 1 From the screen, press the key. <SETUP, page 2 of 3> 1. DISPLAY CONTRAST SETUP 2 screen is shown on the right with 2. BUZZER LOUDNESS typical settings. 3. END OF CYCLE BUZZER 4. UPDATE GRAPH AFTER WELD 5.

  • Page 35: Copy A Schedule

    CHAPTER 3: SYSTEM CONFIGURATION 3. COPY A SCHEDULE The Control can store (numbered through <COPY SCHEDULE> ) individual weld energy profiles. This COPY SCHEDULE [ 1 ] TO SCHEDULE [2 ] function allows you to copy any weld schedule from one numbered weld schedule to another numbered weld schedule MAIN MENU From the...

  • Page 36: Schedule Lock

    CHAPTER 3: SYSTEM CONFIGURATION 1. Schedule Lock This function prevents unauthorized users from selecting any weld schedule other than the displayed schedule, and from changing any weld energy/time parameters within the weld schedule. 2. System Lock This function prevents unauthorized users from changing any of the options on the main menu. It also prevents unauthorized users from changing weld energy/time parameters within weld schedules 1-99.

  • Page 37: Relay

    CHAPTER 3: SYSTEM CONFIGURATION 6. RELAY MAIN MENU From the , press the <RELAY> RELAY 1. RELAY1:ON OTHER to go to the output state 2. RELAY2:ON ALARM selection menu, shown at the right. The Control has four relays that can provide dry-contact signal outputs under many Number Select an item, RUN or MENU different conditions.

  • Page 38: Reset To Defaults

    CHAPTER 3: SYSTEM CONFIGURATION 7. RESET TO DEFAULTS MAIN MENU From the , press the key to go to <RESET TO DEFAULTS> RESET TO DEFAULTS menu, as shown at the 1. RESET SYSTEM PARAMETERS 2. RESET ALL SCHEDULES right. Through this menu, you may reset all 3.

  • Page 39: Reset All Schedules

    CHAPTER 3: SYSTEM CONFIGURATION 2. RESET ALL SCHEDULES Press the key. This will <RESET ALL SCHEDULES?> automatically reset all weld schedule 1. NO parameters to the factory defaults and 2. YES RESET TO return the screen to the DEFAULTS display. MENU Number Select, Page, RUN or MENU...
  • Page 40 CHAPTER 3: SYSTEM CONFIGURATION You can program any of the Control's 99 stored schedules to chain to any other schedule, or back to itself as in the second example above. The chain code becomes part of each weld schedule. You can turn the Chain Schedules feature , or re-program chains, any time you want.

  • Page 41: Setup 1

    CHAPTER 3: SYSTEM CONFIGURATION MENU CHAIN When you finish programming the chain, press the key to return to the SCHEDULES menu. 10 Press the key to toggle between 11 Press the key on the front panel, then use the keys to select the first weld schedule in the chain you want to use.

  • Page 42: Firing Switch

    CHAPTER 3: SYSTEM CONFIGURATION 20, or 30 milliseconds before the weld period can be initiated, thereby avoiding false starts caused by the switch contact bouncing. SETUP 1 From the screen, press the <SWITCH DEBOUNCE TIME> SWITCH DE-BOUNCE key to go to the 1.

  • Page 43: Setup 2

    CHAPTER 3: SYSTEM CONFIGURATION Setup 2 1. Display Contrast SETUP 2 1. From the screen, press the <DISPLAY CONTRAST > DISPLAY CONTRAST key to go to the DISPLAY CONTRAST : 50 % adjustment screen. Use the keys to adjust the screen contrast for comfortable viewing 0 10 in the shop environment.

  • Page 44: Language

    CHAPTER 3: SYSTEM CONFIGURATION 5. Language Press the key to toggle between English and German. All menu items and instructions on the screen will be in the language selected. Setup 3 1. DO TEST WELD In voltage mode, the unit will do a test weld to optimize response to varying weld conditions. Press bring up the following choices: 1) ALWAYS A test weld will be done if:...

  • Page 45: Section Iii. Operational States

    CHAPTER 3: SYSTEM CONFIGURATION Section III. Operational States The Control has seven operational states: NO WELD WELD MENU MONITOR TEST ALARM NO WELD MENU TEST MONITOR WELD You go to the states through the control panel. The ALARM states are functions of the force firing switch and foot switch input states. No Weld State WELD/NO WELD NO WELD...

  • Page 46: Run State

    CHAPTER 3: SYSTEM CONFIGURATION Run State Pressing the key puts the Control in the run state. In the run state, the screen shows a trace that represents your programmed parameters for a given weld schedule. You may select a different weld schedule to be programmed with SCHEDULE key and keypad, or with the up and down arrows.

  • Page 47: Weld State

    CHAPTER 3: SYSTEM CONFIGURATION Weld State WELD Once weld current is flowing, the Control is in the state. You can terminate weld current in five ways:  Remove the first level of a single-level foot switch, assuming weld abort is ON. ...

  • Page 48: Alarm State

    CHAPTER 3: SYSTEM CONFIGURATION Alarm State The Control automatically recognizes many WELD SWITCH alarm conditions. The example IN NO WELD POSITION alarm screen shown at the right is displayed when you attempt to WELD/ NO WELD initiate a weld with the switch NO WELD in the...

  • Page 49: Section Iv. Weld Functions

    CHAPTER 3: SYSTEM CONFIGURATION Section IV. Weld Functions Welding Applications Some welding applications require the use of specialized weld functions. A weld function is a unique heat profile created by weld current, voltage, or power that is applied over a fixed time period, to resistance weld different parts.

  • Page 50: Weld Head Applicability

    CHAPTER 3: SYSTEM CONFIGURATION Weld Head Applicability The weld functions can be used with Miyachi Unitek force fired, manual weld heads; air actuated weld SQUEEZE TIME heads; or Series 300 Weld Heads. is used to allow sufficient time for the electrodes to close and apply the required weld force to the parts before the weld current begins.

  • Page 51: Weld Schedule Definition

    CHAPTER 3: SYSTEM CONFIGURATION Weld Schedule Definition Weld Schedule is the name given to each of 99 separate weld profiles stored in the Control, numbered from 01 to 99. A weld profile is the graphic representation [or waveform] of the numeric weld-time and weld-energy values.

  • Page 52: Welding Applications

    CHAPTER 3: SYSTEM CONFIGURATION Welding Applications Weld Pulse Profile Typical Application Can be used for many of spot-welding applications. Use on flat parts Single-Pulse without plating, or on conductive parts such as those made of copper or brass. Upslope/Downslope should be used for the majority of spot welding Upslope/Downslope applications.

  • Page 53: Upslope / Downslope Weld Profile

    CHAPTER 3: SYSTEM CONFIGURATION Upslope/Downslope Weld Profile Applications  Round or non-flat parts and most resistive materials. Description Upslope allows a gradual application of weld energy which permits the parts to come into better contact with each other reducing the electrode to part contact resistances. Upslope can allow a smaller electrode force to be used, resulting in a cleaner appearance by reducing electrode indentation, material pickup and electrode deformation.
  • Page 54 CHAPTER 3: SYSTEM CONFIGURATION Upslope will also help to displace plating and/or oxides, reduce flashing and spitting, or reduce thermal shock when welding parts containing glass-to-metal seals. In the normal application of dual-pulse, the Pulse 1 weld period provides sufficient heat to displace the plating or oxides, seat the electrodes against the base metals, and force the parts into intimate contact.

  • Page 55: Chapter 4. Introduction To Feedback Modes And Monitoring

    CHAPTER 4 Introduction to Feedback Modes and Monitoring Section 1. Programmable Feedback Modes Introduction The feedback mode (current, voltage, power or combo) is one of the selections entered when programming a weld schedule. Programming weld schedules is explained in Chapter 5, Operating Instructions.

  • Page 56: Power Mode

    CHAPTER 4: INTRODUCTION TO FEEDBACK MODES AND MONITORING Power Mode Application  Breaking through surface oxides and plating  Automated applications where part or electrode surface conditions can vary over time. Description This mode precisely varies the weld current and voltage to supply consistent weld energy to the parts.

  • Page 57: Section Ii. Weld Monitoring

    CHAPTER 4: INTRODUCTION TO FEEDBACK MODES AND MONITORING Section II. Weld Monitoring Introduction The Control's feedback sensors not only control weld energy output, but they can also be used to MONITOR monitor each weld. The Control's features allow you to view graphic representations of welds, visually compare programmed welds to actual welds, look at peak or average energy values, set upper and lower limits for welds, and vary the time periods for these limits during the weld pulse.

  • Page 58: Current, Voltage, Power, And Resistance Limits

    CHAPTER 4: INTRODUCTION TO FEEDBACK MODES AND MONITORING Current, Voltage, Power, and Resistance Limits With the screen selected, you can select what you want to monitor by pressing the following = current, = voltage, and = power, and Ω = resistance. These MONITOR keys above: PULSE 1...
  • Page 59 CHAPTER 4: INTRODUCTION TO FEEDBACK MODES AND MONITORING If production parts are plated, there can also be a plating process variation over time resulting in inconsistent welds. These minor material variations are a major cause of process instability, and it is best welding practice to seek to minimize their effect.
  • Page 60 CHAPTER 4: INTRODUCTION TO FEEDBACK MODES AND MONITORING Active Part Conditioning Waveform The use of a current limit monitor for the first pulse enables the pulse to be terminated when a predetermined amount of current flow is achieved. The rise of the current waveform is proof positive that the oxide is breaking down and the parts are fitting up together, ready to weld.
  • Page 61 CHAPTER 4: INTRODUCTION TO FEEDBACK MODES AND MONITORING consistent resistance at the beginning of the second pulse. Depending on the initial resistance, the amount of time required to bring the resistance down will vary from weld to weld. The first pulse, therefore, should be programmed to be much longer than generally required to ensure that the current limit is always reached.
  • Page 62 CHAPTER 4: INTRODUCTION TO FEEDBACK MODES AND MONITORING 4. Weld To A Limit Applications  Parts with narrow weld window  Part-to-part positioning problems  Electrode-to-part positioning problems Function To stop the weld when a sufficient current, voltage, or power level is reached. Using limits in this way ensures a more consistent input of energy, which produces consistently good welds.
  • Page 63 CHAPTER 4: INTRODUCTION TO FEEDBACK MODES AND MONITORING 5. Weld Stop Applications  Part-to-part positioning problems  Electrode-to-part positioning problems Function To detect work piece resistance changes that occur when parts are positioned incorrectly at the weld head. In this case, the energy limits will prevent blowouts, parts damage, and electrode damage. Limits can be set to terminate the weld if this occurs.

  • Page 65: Pre-Operational Checks

    CHAPTER 5 Operating Instructions Section I: Introduction Before You Start Before operating the Control, you must be familiar with the following:  The location and function of Controls and Indicators. For more information, see Chapter 1 of this manual.  How to select and use the Control functions for your specific welding applications.

  • Page 66: Initial Setup

    CHAPTER 5. OPERATING INSTRUCTIONS Initial Setup Adjust the weld head force adjustment knob for a force appropriate for your welding application. A good starting point is the mid-point in the range of the weld head force. WELD/NO WELD NO WELD 2.

  • Page 67: Section Ii. Operation

    CHAPTER 5. OPERATING INSTRUCTIONS Section II. Operation Single-Pulse Weld Schedule key, then select a Weld Schedule using either the  arrows or SCHEDULE Press the the numeric keypad. SQUEEZE Press the key to enter the squeeze time before the weld. Use the numeric keypad to enter the time or use the ...
  • Page 68 CHAPTER 5. OPERATING INSTRUCTIONS COOL Press the key to enter the amount of time for the cool period after Pulse 1. Use the numeric keypad to enter the time or use the  arrows. Enter milliseconds. Program Pulse 2 by repeating Steps 3 through 7 above using the keys for Pulse 2, entering the value 0 in each step.

  • Page 69: Upslope/Downslope Weld Schedule

    CHAPTER 5. OPERATING INSTRUCTIONS Upslope/Downslope Weld Schedule key, then select a Weld Schedule using either the  arrows or SCHEDULE Press the the numeric keypad. SQUEEZE Press the key to enter the squeeze time before the weld. Use the numeric keypad to enter the time or use the ...
  • Page 70 CHAPTER 5. OPERATING INSTRUCTIONS COOL Press the key to enter the amount of time for the cool period after Pulse 1. Use the numeric keypad to enter the time or use the  arrows. Enter milliseconds. Program Pulse 2 by repeating Steps 3 through 7 above using the keys for Pulse 2, entering the value 0 in each step.

  • Page 71: Dual-Pulse Weld Schedule

    CHAPTER 5. OPERATING INSTRUCTIONS Dual-Pulse Weld Schedule key, then select a Weld Schedule using either the  arrows or SCHEDULE Press the the numeric keypad. SQUEEZE Press the key to enter the squeeze time before the weld. Use the numeric keypad to enter the time or use the ...
  • Page 72 CHAPTER 5. OPERATING INSTRUCTIONS COOL Press the key to enter the amount of time between Pulse 1 and Pulse 2. Use the numeric keypad to enter the time or use the  arrows. Enter a time between milliseconds. We recommend at least 2 milliseconds. Program Pulse 2 by repeating Steps 3 through 7 above using the keys for Pulse 2, entering appropriate values for Pulse 2.

  • Page 73: Section Iii. Using The Weld Monitor

    CHAPTER 5. OPERATING INSTRUCTIONS Section III. Using the Weld Monitor The Control allows you to adjust extremely precise limits for the amount of energy and weld time. Like all welding processs development, you’ll need to make several test welds, and view the waveforms and limits of actual welds in order to “fine tune”...
  • Page 74 CHAPTER 5. OPERATING INSTRUCTIONS key, then select a Weld Schedule using either the  arrows SCHEDULE Press the or the numeric keypad. Fire the welder and view the output waveform (shaded graph) on the display. MONITOR From the keys section on the front panel, press the key to view the desired waveform.
  • Page 75 CHAPTER 5. OPERATING INSTRUCTIONS  PART CONDITIONER (Stop PULSE1) stops Pulse 1 immediately after upper or lower energy limits are exceeded, but allows Pulse 2 to fire. This function will not operate if both pulses are joined without a cool time. NOTE: See Section IV, Programming For Active Part Conditioning.
  • Page 76 CHAPTER 5. OPERATING INSTRUCTIONS NOTE: All lower limits apply only to the Pulse 1 and Pulse 2 WELD periods. Lower limits do not cover any upslope or downslope periods. All upper limits apply to the entire Pulse 1 and Pulse 2 periods, including their upslope and downslope periods. Set an using the procedures in Chapter 4, Using Feedback UPPER LIMIT...

  • Page 77: Section Iv. Active Part Conditioning

    CHAPTER 5. OPERATING INSTRUCTIONS Section IV. Active Part Conditioning key, then select a Weld Schedule using either the  arrows SCHEDULE Press the or the numeric keypad. Program a single pulse for Constant Power operation. Program the power level and weld time to cause slight sticking between the two parts.
  • Page 78 CHAPTER 5. OPERATING INSTRUCTIONS Try welds with varying oxide (clean and dirty). The power supply terminates the first pulse when your programmed current is reached. A clean part will reach the current limit sooner and the pulse will terminate early. A dirty part will require more time before the oxide is broken down and current can flow.

  • Page 79: Resistance Set

    CHAPTER 5. OPERATING INSTRUCTIONS Section V. Resistance Set NOTE: The Resistance Set tool is very similar to the Active Part Conditioning tool. The difference is that the first pulse is programmed as all Upslope for Resistance Set, where it is programmed as all Weld Time (Square Wave) for Active Part Conditioning.
  • Page 80 CHAPTER 5. OPERATING INSTRUCTIONS NOTE: For more details on this process, see Resistance Set in Chapter 4, Using Feedback Modes and Weld Monitoring. Since different levels of resistance require different amounts of time to reach the current limit, return to the screen and extend the programmed weld time (usually double the time works).

  • Page 81: Pre-Weld Check

    CHAPTER 5. OPERATING INSTRUCTIONS Section VI. Pre-Weld Check Note: The Pre-Weld Check function is used to detect misaligned or missing parts before the weld is performed. Therefore, the Pre-Weld Check function should only be programmed after the welding schedule has been developed. The welding schedule includes the time and energy settings as well as the electrode force required to produce strong, consistent welds.
  • Page 82 CHAPTER 5. OPERATING INSTRUCTIONS Try making welds with only one part present. Also try making welds with misaligned parts. Observe that the power supply terminates the weld during the first pulse as soon as the voltage limits are reached. If the voltage limits are not being reached with these conditions present, return to the voltage monitor screen and adjust the limits accordingly.

  • Page 83: Weld To A Limit

    CHAPTER 5. OPERATING INSTRUCTIONS Section VII. Weld To A Limit NOTE: The Weld to a Limit function is used to stop the weld when a specific current, voltage, or power level, sufficient to produce good welds, is reached. Using limits in this way ensures a more consistent input of energy, which produces consistently good welds for some applications.
  • Page 84 CHAPTER 5. OPERATING INSTRUCTIONS Return to the RUN screen and increase the weld time by 1-2 ms. Make several welds and verify that the upper voltage limit is reached for every weld, and the weld pulse stops before the end of the programmed weld Weld to a Limit Waveform time.

  • Page 85: Weld Stop

    CHAPTER 5. OPERATING INSTRUCTIONS Section VIII. Weld Stop NOTE: The Weld Stop function is similar to the Pre-Weld Check function, as both are used to detect missing or misaligned parts. Both functions are used to stop the weld when a specific current, voltage, or power level is reached.
  • Page 86 CHAPTER 5. OPERATING INSTRUCTIONS Press the voltage V key to save the setting as a lower voltage limit. Make several more welds and verify that under normal circumstances, the limits are not reached and the welds are not aborted. If the limits are reached under normal welding conditions, adjust the levels and times of the upper and lower voltage limits accordingly.

  • Page 87: Section Ix. Programming Relays

    CHAPTER 5. OPERATING INSTRUCTIONS Section IX. Programming Relays MAIN MENU 1. From the , press the <RELAY> RELAY 1. RELAY1:ON ALARM to go to the output state 2. RELAY2:ON ALARM selection menu, shown at the right. The Control has four relays that can provide dry-contact signal outputs under many Number Select an item, RUN or MENU different conditions.

  • Page 89: Chapter 6. Maintenance

    CHAPTER 6 MAINTENANCE Section I. Introduction General Kinds of Problems It has been our experience that most resistance welding power supply ‘problems’ are caused by lack of material control, process control and electrode tip surface maintenance. The problems that you might encounter fall into two groups: ...

  • Page 90: Section Ii. Troubleshooting

    CHAPTER 6: MAINTENANCE Section II. Troubleshooting Troubleshooting Problem Cause (in order of probability) Problem Cause (in order of probability) Electrode 1. Excessive current/energy set at HF28 Electrode 1. Excessive current/energy set at HF28 Damage Sparking 1. Excessive or insufficient weld head 1.

  • Page 91: Alarm Messages

    CHAPTER 6: MAINTENANCE Problem Cause (in order of probability) Problem Cause (in order of probability) Weld Piece 1. Excessive weld time set at HF28 Weld Piece 1. Excessive weld time set at HF28 Over- Discoloration 2. Excessive current/energy set at HF28 1.
  • Page 92 CHAPTER 6: MAINTENANCE Alarm Message Description Corrective Action CURRENT 1 Actual weld current is greater than the Reset the Upper Limit for Weld1 to a larger GREATER THAN user set Upper Limit value for Weld1. value. UPPER LIMIT CURRENT 2 Actual weld current is greater than the Reset the Upper Limit for Weld2 to a larger GREATER THAN...
  • Page 93 CHAPTER 6: MAINTENANCE Alarm Message Description Corrective Action FIRING DIDN’T The Firing Switch on a Miyachi Unitek Press RUN and readjust the air pressure to the CLOSE IN 10 air actuated weld head did not activate Miyachi Unitek air actuated weld head. SECONDS within 10 seconds after the Foot Switch was initially activated.
  • Page 94 CHAPTER 6: MAINTENANCE Alarm Message Description Corrective Action NO WELD Cable connecting the Control and Power Verify installation of the welding TRANSFORMER PCB’s is open. transformer/rectifier module connections. DETECTED Cable connecting the Power PCB to the Weld Transformer is open. POWER 1 Actual weld power is greater than the Weld splash can cause the actual weld power to...
  • Page 95 CHAPTER 6: MAINTENANCE Alarm Message Description Corrective Action SYSTEM User programmed the HF28 to CAUTION: Be careful when using the MENU PARAMETERS ARE automatically reset all I/O and other default features. There is no way to restore a RESET system parameters to their factory set default action.
  • Page 96 CHAPTER 6: MAINTENANCE Alarm Message Description Corrective Action WELD STOP - The user set Upper Limit value has been This is a MONITOR LIMITS feature activated LIMIT REACHED exceeded and automatically terminated by the selecting the ENERGY key, then the weld energy. programming the Upper Limit values for Weld1 and Weld2.

  • Page 97: Section Iii. Maintenance

    Below is a list of the replacement parts for the Control. All items listed are a quantity of 1 each. WARNING: Only qualified technicians should perform internal adjustments or replace parts. Removal of the unit cover could expose personnel to high voltage and may void the warranty. Amada Miyachi America Part Description Location...

  • Page 98: Section Iv. Repair Service

    CHAPTER 6: MAINTENANCE Section III. Repair Service If you have problems with your Control 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. HF28 DC RESISTANCE WELDING SYSTEM 6-10 990-372...

  • Page 99: Appendix A. Technical Specifications

    Power Input Power Line ....................50-60 Hz, 3 phase Input Voltage Range at Maximum Output Current HF28/240 ....................... 216-264 VAC at 25A HF28/400 ....................... 360-440 VAC at 20A HF28/480 ....................... 432-528 VAC at 13A Input kVA (Demand) ................30 kVA max at 3% duty cycle Output Power at 12% Duty Cycle and a Combined PULSE 1 and PULSE 2 Pulse Width of 50 ms ........
  • Page 100 APPENDIX A. TECHNICAL SPECIFICATIONS Performance Capabilities Number of Weld Schedules ........................100 Programmable Weld Periods: Squeeze ..........................0 - 999 ms Upslope 1 ..........................0 - 99 ms Weld 1 ...........................0 - 99 ms Downslope 1 ..........................0 - 99 ms Cool ...........................0 - 99 ms Upslope 2 ..........................0 - 99 ms Weld 2 ...........................0 - 99 ms Downslope 2 ..........................0 - 99 ms...
  • Page 101 APPENDIX A. TECHNICAL SPECIFICATIONS Input Signals NOTE: Except where parenthetically noted below, all input signals accept 5 to 24 VDC, normally open or normally closed, positive or negative logic. Inputs are optically isolated. Firing Switch Initiation: 1-level foot switch, 2-level foot switch or opto firing switch. DB15 Control Signals: Remote weld schedule select, process inhibit .

  • Page 103: Appendix B. Electrical And Data Connections

    APPENDIX B Electrical and Data Connections Electrical Connection As described in Chapter 2, you need to supply a connector for the Control input power cable (see diagram below). Connect the Control power cable to a 3-phase, 50/60Hz power source. The voltage range for each model is set at the factory by a set of two jumper plugs.
  • Page 104 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS DB15 I/O Connector I/O Control Signal Interface Input/Output Control Signals Signal Name Description SCHEDULE 0 Binary Schedule input terminals, used for schedule selection SCHEDULE 1 Binary Schedule input terminals, used for schedule selection SCHEDULE 2 Binary Schedule input terminals, used for schedule selection SCHEDULE 4 Binary Schedule input terminals, used for schedule selection...
  • Page 105 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Signal Name Description 24COM NEGATIVE of internal 24 VDC power supply SCHEDULE 8 Binary Schedule input terminals, used for schedule selection RELAY_2R Return of RELAY_2 NOT ACTIVE RELAY_1R Return of RELAY_1 Two-Level Foot Switch Connector When you press the foot switch to the first level, the Control energizes the air actuated weld head.
  • Page 106 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Standard Air Valve Driver Output Connector The air valve driver output (24VAC) is initiated when Foot Switch Level 1 is initiated. Using the supplied Configuration plug on Pins 11 – 20 allows the use of the Miyachi Unitek 2-level footswitch directly.
  • Page 107 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Weld Head Connector The Weld Head Connector combines all the inputs and outputs necessary to connect a plug-and-play EZ-AIR Miyachi Unitek weld head Weld Head Connector Description HEAD_1 switched 24V common 24V_OUT 24VDC for solenoid 24COM FIRE_1 VOLT_IN...
  • Page 108 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Force Firing Switch Cable Input Function The force-firing switch input to the Control from the weld head signals that the selected pressure has been applied to the weld pieces. Note that a mechanical firing switch is subject to contact bounce, which can cause false weld starts.
  • Page 109 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Timing Diagram BCD Welding Schedule Selection Scheme Weld Bit 2 Bit 2 Bit 2 Bit 2 Bit 2 Bit 2 Bit 2 Schedule Pin 1 Pin 2 Pin 3 Pin 4 Pin 12 Pin 5 Pin 14 5-98 BCD progression from 5 to 98...
  • Page 110 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Relay Outputs Function Two mechanical relays on the control board can be independently programmed to supply alarm or weld status contact signal outputs. You can access the programming function through the main menu, as described in Chapter 3.

  • Page 111: Appendix C Calibration

    APPENDIX C Calibration Section I. Calibrating the Control Overview The Control is calibrated by the software, using inputs from a calibration setup during a weld process. Following a few calibration inputs, the Control will adjust itself and store the calibration values in RAM, where they will be used as standards for the operational welding parameters.
  • Page 112 APPENDIX C: CALIBRATION Calibration Procedure Initial Calibration Setup Connect the calibration setup to the <MAIN MENU> Control as shown. 1. SETUP 6. RELAY 2. WELD COUNTERS 7. RESET DEFAULTS Turn the Control ON. 3. COPY A SCHEDULE 8. CHAIN SCHEDULES 4.
  • Page 113 APPENDIX C: CALIBRATION The first calibration screen is the screen. If you are qualified to CAUTION <CALIBRATION SHUNT> proceed with the calibration press continue. Shunt value 0987.6 μΏ The next page is for the CALIBRATION . This screen asks for the actual SHUNT Number change ...

  • Page 115: Appendix D. System Timing

    APPENDIX D System Timing Basic Weld Operation: Air Head System with Two-Level Foot Switch Definitions Delay time from Foot Switch Level 1 closure to Weld Force start. Maximum delay time is 1 ms plus switch debounce time. Switch debounce time can be set to none, 10, 20, or 30 ms with the menu screen.
  • Page 116 APPENDIX D: SYSTEM TIMING Basic Weld Operation: Manual Head System with Firing Switch Operation Definitions DELAY Delay time from firing switch closure to the start of the weld sequence (that is, start of ). Maximum time is 2 ms, plus switch debounce time. DELAY Squeeze time.
  • Page 117 APPENDIX D: SYSTEM TIMING Basic Weld Operation: System with Remote Firing Switch NOTE: The firing switch mode is selected under the Setup 1 menu. Definitions DELAY Delay time from Remote Schedule Select Signal ON to the start of the weld sequence (that is, start of time is 23 ms.
  • Page 118 APPENDIX D: SYSTEM TIMING Basic Weld Operation: Air Head System with Two-Level Foot Switch Definitions Delay time from Foot Switch Level 1 closure to Weld Force start. Maximum delay time is 1 ms plus switch debounce time. Switch debounce time can be set to none, 10, 20, or 30 ms with the menu screen.

  • Page 119: Appendix E. The Basics Of Resistance Welding

    APPENDIX E The Basics of Resistance Welding Resistance Welding Parameters Resistance welding heat is produced by passing electrical current through the parts for a fixed time period. The welding heat generated is a function of the magnitude of the weld current, the electrical resistance of the parts, the contact resistance between the parts, and the weld force applied to the parts.
  • Page 120 APPENDIX E: THE BASICS OF RESISTANCE WELDING Electrode Selection Correct electrode selection strongly influences how weld heat is generated in the weld area. In general, use conductive electrodes such as a RWMA-2 (Copper alloy) when welding electrically resistive parts such as nickel or steel so that the weld heat is generated by the electrical resistance of the parts and the contact resistance between the parts.
  • Page 121 APPENDIX E: THE BASICS OF RESISTANCE WELDING ELECT ELECT ELECT ELECT MATERIAL MATERIAL MATERIAL MATERIAL RWMA RWMA RWMA RWMA TYPE TYPE TYPE TYPE Bronze -2, -11 Nichrome Copper Silver -11, -14 Bronze -2, -11 Nickel Copper Cold Rolled Steel Chromel Chromel Copper Stainless Steel...
  • Page 122 APPENDIX E: THE BASICS OF RESISTANCE WELDING ELECT ELECT ELECT ELECT MATERIAL MATERIAL MATERIAL MATERIAL RWMA RWMA RWMA RWMA TYPE TYPE TYPE TYPE Molybdenum Nickel NiSpan C NiSpan C Molybdenum Tungsten NiSpan C Cold Rolled Steel Nichrome Nichrome NiSpan C Stainless Steel Nichrome Nickel...
  • Page 123 APPENDIX E: THE BASICS OF RESISTANCE WELDING Weld Schedule Development Developing a weld schedule is a methodical procedure, which consists of making sample welds and evaluating the results. The first weld should be made at low energy settings. Adjustments are then made to each of the welding parameters one at a time until a successful weld is made.
  • Page 124 APPENDIX E: THE BASICS OF RESISTANCE WELDING Weld Strength Profiles Creating a weld strength profile offers the user a scientific approach to determining the optimum set of welding parameters and then displaying these parameters in a graphical form. Start at a low weld current, voltage, or power, making five or more welds, then perform pull tests for each weld.

  • Page 125: Appendix F. Quality Resistance Welding Solutions: Defining The Optimum Process

    APPENDIX F Quality Resistance Welding Solutions: Defining the Optimum Process Introduction A quality resistance welding solution both meets the application objectives and produces stable, repeatable results in a production environment. In defining the optimum process the user must approach the application methodically and consider many variables. In this article we will look at the following key stages and principles to be considered when defining the optimum resistance welding process: ...
  • Page 126 APPENDIX F: DEFINING THE OPTIMUM PROCESS Alloys are a mixture of two or more metals. An alloy is normally harder, less conductive, and more Alloy brittle than the parent metal which has bearing on the type of joint one can expect when resistance Metal A welding a combination of different metals.
  • Page 127 APPENDIX F: DEFINING THE OPTIMUM PROCESS Consider the Material Properties The important material properties to be considered in the resistance welding process are:   Electrical and thermal conductivity Melting point  Oxides  Plating and coating  Hardness The figure below illustrates the variance in resistivity and melting points for some of the more common materials used in micro resistance welding today.
  • Page 128 APPENDIX F: DEFINING THE OPTIMUM PROCESS  Group II – Resistive Metals It is easier to generate and trap heat at the interface of resistive metals and therefore it is possible to form both solid state and fusion welds depending on time and temperature. Upslope can reduce contact resistances and provide heating in the bulk material resistance.
  • Page 129 APPENDIX F: DEFINING THE OPTIMUM PROCESS R1 & R7 The electrode resistances affect the conduction of energy and weld heat to the parts and the rate of heat sinking from the parts at the end of the weld. R2, R4 & R 6 The electrode-to-part and part-to-part “Contact Resistances” determine the amount of heat generation in these areas.
  • Page 130 APPENDIX F: DEFINING THE OPTIMUM PROCESS The figure below shows a weld that is fired The figure shows a weld that is initiated when the early on in the weld sequence when the contact resistance is lower; in this example, we are contact resistance is still quite high.
  • Page 131 APPENDIX F: DEFINING THE OPTIMUM PROCESS Weld Profiles The basic welding profile (or schedule) consists of a controlled application of energy and force over time. Precision power supplies control the energy and time and therefore heating rate of the parts. The weld head applies force from the start to finish of the welding process.
  • Page 132 APPENDIX F: DEFINING THE OPTIMUM PROCESS Approach to Weld Development The first stage in developing a quality welding process is to fix as many of the variables as possible in the welding equipment set up. The welding variables can be grouped in the following categories: ...
  • Page 133 APPENDIX F: DEFINING THE OPTIMUM PROCESS Process Perspective  What are the likely variables in a production process?  How will operators handle and align the parts?  What tooling or automation will be required?  How will operators maintain and change the electrodes? ...
  • Page 134 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 135 APPENDIX F: DEFINING THE OPTIMUM PROCESS Criteria for Success Before running the series of experiments, the user must establish an acceptable window for energy, time, and force, thus preventing voided results. It is common practice to include one or all of the above variables in a Screening DOE.
  • Page 136 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 137 Index Active Part Conditioner (APC) ......4-4 Declaration Of Conformity ........ix Active Part Conditioning ........5-13 Description ............1-1 Alarm Messages ........... 6-1, 6-3 Features ............1-1 Alarm State ............3-16 Major Components ......... 1-3 Always ............3-12 Control Keys ..........1-6 Application Perspective ........
  • Page 138 INDEX Factorial DOE’s ..........F-11 ....4-3 PEAK & AVERAGE MONITORING Features ............1-1 Process Tools ..........4-4 Firing Switch ............3-10 Active Part Conditioner (APC) .... 4-4 Foot Pedal-Actuated Weld Head Connection ..2-6 Pre-Weld Check ........4-7 Footswitch Weld Abort ........3-9 Resistance Set ........
  • Page 139 INDEX Basic Principles ..........F-4 ............1-8 Ω Common Problems ......... F-9 Operating Instructions .......... 5-1 Criteria for Success ......F-10, F-11 Active Part Conditioning ....... 5-13 Factorial DOE’s ..........F-11 Introduction ............. 5-1 Initial Welding Trials ........F-8 Before You Start ........5-1 Application Perspective ......
  • Page 140 INDEX S (Continued) Setup 2 ............3-11 Display Contrast ......... 3-11 Setup 3 ............3-12 End Of Cycle Buzzer ......3-11 Single-Pulse Weld Profile ........3-22 Language ..........3-12 Single-Pulse Weld Schedule ......... 5-3 Update Graph After Weld ....3-11 Solder or Braze Joint ...........
  • Page 141 INDEX Weld Counter ............3-2 Weld Stop ..........4-9, 5-21 Weld Functions ........... 3-17 Weld Strength Profiles ......... E-6 Weld Head Applicability ........3-18 Weld Strength Testing ......... E-6 Weld Head Connections ........2-4 Weld To A Limit ........4-8, 5-19 Weld Monitoring ..........
  • Page 143     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 144                                                                   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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