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USER'S MANUAL
Revision D
875DP/500DP/500HV DUAL PULSE
STORED ENERGY RESISTANCE WELDING
Model
875DP
875DP/208
875DP/230
875DP/100
500DP
500DP/208
500DP/230
500DP/100
500HV
500HV/208
500HV/230
500HV/100
Units with the built-in Weld Sentry Option also require User's Manual No. 990-
291.
990-290
November 2013
POWER SUPPLIES
Stock No.
1-253-XX
1-253-XX-01
1-253-XX-02
1-253-XX-03
1-251-XX
1-251-XX-01
1-251-XX-02
1-251-XX-03
1-252-XX
1-252-XX-01
1-252-XX-02
1-252-XX-03
Model
875DPS
875DPS/208
875DPS/230
875DPS/100
500DPS
500DPS/208
500DPS/230
500DPS/100
500HVS
500HVS/208
500HVS/230
500HVS/100
Stock No.
1-257-XX
1-257-XX-01
1-257-XX-02
1-257-XX-03
1-255-XX
1-255-XX-01
1-255-XX-02
1-255-XX-03
1-256-XX
1-256-XX-01
1-256-XX-02
1-256-XX-03
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Summary of Contents for Miyachi 875DP
- Page 1 USER'S MANUAL 990-290 Revision D November 2013 875DP/500DP/500HV DUAL PULSE STORED ENERGY RESISTANCE WELDING POWER SUPPLIES Model Stock No. Model Stock No. 875DP 1-253-XX 875DPS 1-257-XX 875DP/208 1-253-XX-01 875DPS/208 1-257-XX-01 875DP/230 1-253-XX-02 875DPS/230 1-257-XX-02 875DP/100 1-253-XX-03 875DPS/100 1-257-XX-03 500DP 1-251-XX...
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Page 2: Revision Record
Copyright © 1998, 2002, 2013 Miyachi America Corporation The engineering designs, drawings and data contained herein are the proprietary work of Miyachi America Corporation and may not be reproduced, copied, exhibited or otherwise used without the written authorization of Miyachi America Corporation. -
Page 3: Foreword
Should questions arise, or if you have suggestions for improvement of this manual, please contact us at the above location/numbers. Miyachi America Corporation is not responsible for any loss due to improper use of this product. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES... -
Page 4: Safety Notes
SAFETY NOTES This instruction manual describes how to operate, maintain and service the 875DP/500DP/500HV Dual Pulse 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
Remote Schedule Selection..................Relay Outputs........................Interconnection Diagram ....................CHAPTER 3: OPERATING CONTROLS AND SCREENS Operating Controls......................Screen Formats......................... CHAPTER 4: GETTING STARTED Powering Up ........................Adjusting an Air Actuated Weld Head ................875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290... - Page 6 Basic Function ......................Repeat Function ......................Rollspot Function....................... CHAPTER 7: MAINTENANCE Modification and Calibration................... Cover Removal ......................Line Voltage Changes....................Calibration........................Troubleshooting ....................... 7-10 Repair Service........................7-11 Telephone Service...................... 7-11 Factory Service Repair....................7-11 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 7 Step Count........................A-13 Next Schedule ......................A-13 Audible Buzzer ........................ A-14 End of Cycle Buzzer ON/OFF................... A-14 Key Click ........................A-14 Weld Counter ........................A-14 Alarms ........................A-15 Air Valve Driver ......................A-15 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 8 Circuit Breakers ......................A-22 Fuses ........................A-22 Power Input Connector ....................A-22 Front Panel Switches......................A-23 Microprocessor CPU......................A-23 Display ........................A-23 Cooling ........................A-24 Physical Characteristics ....................A-25 Index-1 Index............................875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES viii 990-290...
- Page 9 115 VAC Line Voltage Configuration..............208 VAC Line Voltage Configuration..............230 VAC Line Voltage Configuration..............875DP Rep Rate with 10500 μF Capacitor Bank ..........875DP Hit Rate with 10500 μF Capacitor Bank ..........500DP Rep Rate with 6000 μF Capacitor Bank ..........
- Page 10 Recommended Electrode Materials ..............Causes of Imperfect Welds .................. Power Supply Voltage Range Specifications ............Pulse Characteristics .................... Welding Speed ..................... Binary Codes for Remote Weld Schedule Selection ........... A-19 Input Power Specifications .................. A-23 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
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Page 13: Chapter 1: System Description
SYSTEM DESCRIPTION Applications The 875DP (figure 1-1) is a versatile, 875 watt-second stored energy, capacitor discharge, dual pulse power supply which can effectively solve most precision, small parts, resistance welding problems. Its exclusive, context sensitive, User Help Screens quickly guide the user through even the most complex program. -
Page 14: Features
Feature allows the 875DP to reliably select weld schedules in automated applications. The 875DP can be used with manual, user actuated, or air actuated weld heads. The 875DP is a multi-voltage unit designed for operation at 100, 115, 208, or 230 VAC, 50/60 Hz. Features Multi-function, microprocessor control with 16 discrete weld schedules provides repeatable process control and is compatible with air or manually actuated weld heads. - Page 15 The digital display allows operators to set welding energy accurately and quickly. The 875DP is compatible with manually actuated weld heads and air actuated heads with 1-level or 2- level footswitches. The 875DP is compatible with force fired and non-force fired weld heads. Squeeze (delay) time adjustable from 0 to 9.9 seconds.
- Page 16 The line failure turndown safety feature discharges the capacitor bank when input power is interrupted. The 875DP is protected from radio frequency interference and electromagnetic interference to ensure reliable operation even in high electrical noise environments. Input switch debounce circuitry eliminates false triggering.
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Page 17: Chapter 2: Installation
6 cable and 20% for No. 2 cable. To reduce energy losses, follow these recommendations: Route cables so that they do not surround magnetic materials such as air solenoids, tooling, or steel weld heads (see figure 2-1). 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290... - Page 18 I nsta ll fla t w ash e r u n de r s c re w h e a d, n o t w e ld in g c a b le te rm ina l Figure 2-2. Terminal Connection Examples 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
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Page 19: Rear Panel Components
FOOT SWITCH FIRING CABLE Figure 2-3. Rear Panel of the 875DP/500DP/500HV CIRCUIT BREAKER(S) - is used to protect the incoming power line. INPUT POWER CABLE - 5 foot cable is terminated with the appropriate 115 or 230 volt plug. The standard plug for the 115 VAC power supply a NEMA 5-15P rated for 15 amps. -
Page 20: Firing Switch Connections
Users of weld heads with single pole, double throw, 3-wire pressure switches should also use the OPTICAL FIRING SWITCH connector. The power supply will automatically detect that the system is using a 3-wire switch if Pin 2 is low at power-up. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290... -
Page 21: Air Actuated Weld Head Connections
Once every six months or every 1 million operations, whichever occurs first, remove the top flow control valve and place two drops of light machine oil in the top of the air cylinder. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290... -
Page 22: Air Valve Driver
Weld Heads with standard 115 volt plugs (NEMA 5-15P) require an adapter, Unitek Peco Model VDAC, Valve Driver Adapter Cable. When the connection has been made, the power supply will automatically recognize that an air head has been connected. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290... -
Page 23: Non Unitek Peco Air Actuated Weld Heads
If the FOOTSWITCH WELD ABORT option has been set to OFF, the welding process will continue to its conclusion, regardless of the position of the footswitch, once the preset firing force has been applied to the workpiece by the upper electrode of the weld head. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290... -
Page 24: 2-Level Footswitch
If scheduled to be closed during any successive periods, it will not open at the end of the first period, but will remain closed during both (or all) periods for which it is scheduled to be closed. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290... -
Page 25: Interconnection Diagram
CHAPTER 2: INSTALLATION Interconnection Diagram Figure 2-5. 875DP Equipment Interconnection Diagram 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290... -
Page 26: Chapter 3: Operating Controls And Screens
CHAPTER 3 OPERATING CONTROLS AND SCREENS Operating Controls Figure 3-1 illustrates the layout of the operating controls on the front panel of the 875DP. POWER D A T A C O N T R O L W ELD M ENU... - Page 27 In the PROGRAM state, pressing this key saves (writes) any schedule to permanent memory. The Power Supply will then exit the PROGRAM state and return to the RUN state. This key has no function in the RUN state. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
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Page 28: Screen Formats
Illustrated below is the information displayed in RUN, PROGRAM, NO WELD, HELP and MAIN MENU screens. Note that the 875DP operational state is displayed at the bottom right corner of the operation screens. Figure 3-2 shows the detailed sequence of the screens. - Page 29 Switching status of output relays Pulse width of Weld Pulses 1 and 2 Run state with NO WELD switch ON Next schedule number (1-15) in chain Typical multi-page help screen Present state of power supply 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 30 ADJUST E TO 408V AT CapBank ADJUST R108 TO cw/ccw/CORRECT ADJUST R97 TO 0V• • 5 mV AT TP4 ADJUST R12 AT U3 Pin 14 INSTALLATION HELP Figure 3-2. Screen Flow Chart 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
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Page 31: Chapter 4: Getting Started
Alarm messages will be erased from the display as soon as the alarm condition is corrected or when [PROG] is pressed. Refer to Appendix A under Control Signals to remotely clear alarms. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290... - Page 32 4 Set the force indicator on all Unitek Peco weld heads to 3. For more detailed information on setting up each specific weld head, refer to their respective manuals. See figures 4-1 and 4-2 for illustrations of typical air actuated systems. Figure 4-1. Typical Solenoid Air Valve System with Dual Regulators 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 33 If FOOT SWITCH WELD ABORT is ON, releasing the foot switch at any time during the welding sequence will terminate the sequence. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 34 Firing Switch in the head closes, the screen on the power supply will no longer display STANDBY. Re- adjust both flow controls, as necessary. Figure 4-3. Measuring Preset Firing Force of the Weld Head with a Force Gauge 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 35 13 If appropriate, configure the Weld Sentry. Press [MENU], select WELD SENTRY followed by SYSTEM SETUP. 14 If appropriate, configure the Weld Sentry print options, relay outputs, and communications options. Set the Weld Sentry clock for the correct time and date. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 36 Press [PROGRAM] and move the Figure 4-5. Weld Head Configuration Jumper cursor to the RELAY 1 field. Selection Press [CHNG] until AIR HEAD 2 is displayed. g Press [SAVE] to store the changes. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 37 Developing a weld schedule is a methodical procedure consisting of making sample welds and evaluating the results. You should make the first weld at low energy settings. Then, you make adjustments to each of the parameters one at a time until a successful weld is made. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 38 3 on a Unitek Peco Weld Head. Figure 5-1 illustrates the effect of electrode force on the work piece. 3 Adjust the air pressure for air operated weld heads. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 39 Tinned Copper Nichrome Dumet Nickel Nichrome Paliney 7 Nickel Silver NiSpan C C.R. Steel Paliney 7 Stainless Steel Silver C.R. Steel Dumet Dumet Stainless Steel Nichrome Nickel Bronze Bronze Platinum C.R. Steel 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 40 Stainless Steel Stainless Steel Tungsten Molybdenum Molybdenum Nickel Tantalum Tantalum Tungsten Titanium Titanium Nichrome Nichrome Nickel Tungsten Tungsten C.R. Steel Rhenium Stainless Steel Zinc Zinc Nickel Nickel C.R. Steel Stainless Steel Tantalum Tungsten 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 41 %ENERGY in increments of 5% until the parts begin to weld. If you are using dual pulse operation, increase Pulse 2 in increments of 5% and change the energy of Pulse 1 to maintain the ½ to ratio. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 42 Too High Too Large Too Short Blow Holes Too High Too Low Too Small Too Long Expulsion Burned, Pitted Too High Too Low. Poor Too Short or Cracked Requires Maintenance Electrodes Maintenance 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 43 (-) electrode. CAUTION: If weld schedules are chained together, do NOT change polarity. All schedules in the chain must have the same polarity or the relay contacts may be damaged. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 44 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. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 45 3 Place the polishing disks between the electrodes and actuate the footpedal or footswitch to bring the electrodes into light contact with the polishing disk. Move the polishing disk in a rotary motion. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES...
- Page 46 READY STATE Line 6 Line 7 Select Schedule NO WELD Select Schedule ) RUN State Showing Pulse 1 Energy Level. (b) NO WELD State showing Relay Manual Head using Basic Weld Function. Status. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 47 PROGRAM in the lower right-hand corner of the screen. In those units which include the Weld Sentry option, the PROGRAM state also allows you to change the measurement unit, the limits related to the Weld Sentry program, and the other parameters associated with the Weld Sentry. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 48 FOOTSWITCH TYPE : AUTO HOLD TIME :0.00 sec FOOTSWITCH WELD ABORT : ON FIRING SWITCH : 2-WIRE SWITCH DEBOUNCE TIME : 10 msec Select, CHNG Change More Options Select, CHNG Change More Options 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 49 There are two versions of the basic and rollspot functions: one for an air actuated weld head and the other for a manually actuated weld head. The repeat function only applies to an air actuated weld head. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES...
- Page 50 There are two output relays which you can use to provide status signals to external devices. You can also use Relay 1 to control a second air actuated weld head or to signal an alarm condition. When used for status signals, these relays can be independently programmed to close: 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 51 PULSE 2 ENERGY :010.0% 030.0% 0.25 sec RELAY 1 RELAY 2 :ALARM Select PROGRAM The PROGRAM State Screen for the Repeat Function. NOTE: The OFF Period is only used with this function. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 52 0.25 inches/second, assuming a spot which is 1/16 inch long, because the recharge time was approximately 0.050 seconds (refer to Appendix A under Welding Speed) and the cool time was set to 0.250 seconds. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 53 CHAPTER 7 MAINTENANCE Modification and Calibration Unless you are a skilled technician, we suggest you telephone the Miyachi America Repair Department at the telephone number shown in the Foreword of this manual for advice before attempting calibration and/or modification. WARNING: Contact with voltages present in this power supply may cause serious or fatal injuries.
- Page 54 Jumpers E3 and E4, located in the top center area of the control printed circuit board. Bead Pins BP1-BP12 and Terminals E1 and E2, located along the top edge of the control printed circuit board. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 55 4 Install the correct circuit breaker. Refer to Appendix A under Input/Output Cable Connections and Fusing. 5 Install the line cord plug appropriate to your line voltage supply. 6 Change all labels and tags so that they indicate the correct line voltage. 7 Replace the cover. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 56 4 • • , 300 W 4 • • , 300 W 0.1mfd • • • • TRIAC 102/115V 102/204V • • BP12 204/230V BP11 115/230V 204/230V BP10 102/115V 102/204V 0.75A • 115/230V Figure 7-2. 100 VAC Line Voltage Configuration 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 57 4• • , 300 W 4• • , 300 W 0.1mfd • • • • TRIAC 102/115V 102/204V • • BP12 204/230V BP11 115/230V 204/230V BP10 102/115V 102/204V 0.75A • 115/230V Figure 7-3. 115 VAC Line Voltage Configuration 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 58 4• • , 300 W 4• • , 300 W 0.1mfd • • • • TRIAC • 102/115V 102/204V • BP12 204/230V BP11 115/230V 204/230V BP10 102/115V 102/204V • 115/230V Figure 7-4. 208 VAC Line Voltage Configuration 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 59 4 • • , 300 W 4 • • , 300 W 0.1mfd • • • • TRIAC • 102/115V 102/204V • BP12 204/230V BP11 115/230V 204/230V BP10 102/115V 102/204V • 115/230V Figure 7-5. 230 VAC Line Voltage Configuration 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 60 The power supply should not require any regular adjustments. Use the following procedure as a guideline to check the calibration. Take care not to make unnecessary adjustments; however, if any components or software are replaced, check the calibration. Do not hesitate to call the Miyachi America Repair Department with any questions.
- Page 61 The potentiometers and their specific functions are: R 108 Calibrate Display R 104 Reference Adjustment R 97 Offset Adjustment R 135 Alarm Volume E Out R 36 R 131 Display Contrast R 12 Overvoltage Adjustment 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 62 WARNING: Do not discharge the capacitor bank by shorting it directly to ground. The stored energy could be sufficient to melt the shorting tool in an explosive manner. After making any repairs and checking the results, replace the cover and tighten all screws. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 7-10...
- Page 63 CHAPTER 7: MAINTENANCE Repair Service Telephone Service Call the 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 64 The Model 500DP and 500HV are rated 3.0 to 500 watt-seconds. Power Requirements LINE VOLTAGE is single phase 100, 115, 208, or 230 volts, 50/60 Hz. The 875DP, 500DP and 500HV use approximately 3300 watts, initially during charging, and 50 watts stand-by.
- Page 65 The turndown circuit deadband is approximately 0.6% of full scale voltage. Line Failure Turndown When input power is interrupted, a turndown resistor is automatically connected, discharging the capacitor bank. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 66 The averaging period used to determine the repetition rate can be as long as 20 minutes. Hit rate, or maximum intermittent welding speed, defines how fast the power supply can make consecutive welds on a non-continuous basis. See table A-2 and figures A-1 and A-2. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 67 For example, if wired for the 10,500 μF Capacitor Bank, the energy level of Pulse 1 is 25% and Pulse 2 is 75%, the repetition rate for the dual pulse weld would be: (80) (40) = 26.7 welds/min. (1+2) 80 + 40 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 68 Minimum at low line voltage maximum intermittent repetition rate (Weld Sentry software not installed.) Figure A-1. 875DP Repetition Rate (10,500 μF) 25• • C Ambient and nominal line voltage 40• • C Ambient and nominal line voltage Model 875DP Power Supply...
- Page 69 40• • C Ambient and nominal line voltage Model 500DP Power Supply maximum continuous repetition rate 7 8 9 10 50 60 70 80 90 100 Percent Energy Figure A-4. 500DP Hit Rate (6000 μF) 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 70 Schedule Number at Power-Up g Footswitch Type End of Cycle Buzzer ON/OFF h Footswitch Weld Abort ON/OFF Chain Schedule ON/OFF i Firing Switch Type Squeeze Time j Switch Debounce Time k Hold Time 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 71 Force Firing Switch = 2 wire j Switch Debounce = 0.01 sec Display Units = % Energy k Squeeze Time = 0.00 sec System Security = Unprotected l Hold Time = 0.00 sec 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 72 Hold time is the delay from the end of the weld pulse until the head valve opens. Hold time applies only to an air head. The delay can be set from 0.00 to 9.99 seconds. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES...
- Page 73 FOOTSWITCH WELD ABORT ON is preferred since it allows the operator to abort the welding sequence by releasing the footswitch, or footpedal in the case of a manual head. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES A-10...
- Page 74 This cable is 5 feet long. It is a Type 2/C, 600 volt cable containing two shielded, twisted 22 AWG conductors of high-flex stranded wire. The firing switch connector is a 2-pin Amphenol 80-MC2FI 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES...
- Page 75 Air Head Operation If the power supply is connected to an air actuated head, the initiation switch is the footswitch. The first level of a 2-level footswitch instructs the power supply to: 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES A-12...
- Page 76 •• • • Next Schedule = [ . ] period: Causes the power supply to stop after the step count has reached 0 and issue a standby stop command alarm. •• • • Weld Function = Rollspot: Can only be used as the last schedule in a chain. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 77 0 at any time, unless system security is in the protected state. Note that all counters retain their counts when the input power is interrupted, because the contents of these counters are stored in battery-backed-up memory. Alarms 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES A-14 990-290...
- Page 78 The receptacle is wired so that either 115 or 24 volts are available. Air Valve Driver 1 is configured through the options menu, WELD HEAD TYPE, and selecting either AIR or AUTO. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES...
- Page 79 The relays and switch inputs are used to: Remotely select Weld Schedules 1 through 15 Remotely inhibit recharging the capacitor bank Invoke an emergency stop condition to abruptly terminate the welding sequence. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES A-16 990-290...
- Page 80 Pulse 1 or Pulse 2 has been initiated before the emergency stop signal occurs, that pulse will not be interrupted. After that, no further operation can be initiated until the short has been removed. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES...
- Page 81 Pins 1, 2, 3, and 4. Connecting any one of these inputs to Pin 11 will cause the power supply to load the weld schedule defined by the corresponding pin combination, immediately after the initiation switch closes. Weld schedules are selected according to the binary pattern shown in the table A-3. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES A-18...
- Page 82 For example, to select Schedule 15, connect the pins which correspond to the numbers totaling 15. Schedule 15 = 1 + 2 + 4 + 8 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290...
- Page 83 (closed) state during a Run state or if there is an alarm. Relay 1 can also be used to control a second 24 VAC air actuated weld head Relay 2 can provide a 5 to 50 VDC signal. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES A-20...
- Page 84 Relay 1 is defined as NOT USED. Accessory Port A 15-pin, sub-miniature D-type connector, located on the rear panel, is provided to control other devices contemplated for the future. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES 990-290 A-21...
- Page 85 A ¾ amp fuse, F1, is located near the top center of the control printed circuit board. The power supply is shipped wired for 115 VAC unless otherwise specified. Power Input Connector The standard power connector is an IEC-320 with a harmonized, molded power cord. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES A-22 990-290...
- Page 86 Circuit Breaker Circuit Line Voltage Range Frequency Current * (Amps) Size (Amps) Breaker (Volts RMS) (Volts RMS) (Hz) 500DP 500HV 875DP 500DP 500HV 875DP Quantity 87 - 113 50/60 100 - 130 50/60 180 - 235 50/60 200 - 260 50/60 * First half-cycle.
- Page 87 Do not allow the power supply to sit on surfaces which are covered with heavy dirt or dust. 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES...
- Page 88 APPENDIX A: TECHNICAL SPECIFICATIONS Physical Characteristics – 500DP, 500HV and 875DP Control Unit 16.5 POWER D A T A C O N T R O L W E LD MENU PROG CHNG HE LP SAVE N O W ELD 12.5...
- Page 89 APPENDIX A: TECHNICAL SPECIFICATIONS Physical Characteristics – 500DP, 500HV and 875DP Welding Transformers UNIPULSE Figure A-10. Physical Characteristics 500DP, 500HV, and 875DP Welding Transformers NOTE: Dimensions include any protrusions. 500DP / 500HV 875DP Height: 12 inches (30.5 cm) 14.25 inches (36.2 cm) Width: 9 inches (22.9 cm)
- Page 90 Connections ........2-5 CONTROL SIGNALS connector..A-16 Excessive air pressure results ..4-5 Cool time definition......A-9 Air valve driver connections....2-6, A-15 Cooling, 875DP ........A-24 Air valve driver specifications....A-15 Cover removal ........7-1 Alarms ........A-15 CPU, microprocessor......A-23 Application of system ......
- Page 91 Polarity (of current flow) considerations 5-7 Polarity selection ........A-3 Power requirements ......A-1 Jumper selection of weld heads .... 4-6, A-16 Power line, input........2-1 Power supply (875DP) parameters ..5-5 Powering up ........4-1 Key click ........A-14 Process definitions ........
- Page 92 Screen flowchart ........3-5 Screen formats ........3-3 Second air head connections....2-7 Selecting remote schedules ....2-8 Utilities, main menu......A-8 Size, 875DP ........A-25 Specifications: Air valve driver ....... A-15 Capacitor bank ........ A-1 Voltage changes, line......7-2 Firing switch ........
- Page 93 Weld Sentry options and utilities..A-7 Welding schedule specifications ..A-6 Weld strength profiles......5-8 Welding ........5-5 Welding speed specifications ....A-3 Welding cable installation ....2-1 Wiring diagram, interconnection ..2-9 875DP/500DP/500HV DUAL PULSE RESISTANCE WELDING POWER SUPPLIES INDEX-4 990-290...
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