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Amada UB25 Operation Manual

Linear dc resistance welding control
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LINEAR DC RESISTANCE WELDING CONTROL
UB25
OPERATION MANUAL
990-665 REV J

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  • Page 1 LINEAR DC RESISTANCE WELDING CONTROL UB25 OPERATION MANUAL 990-665 REV J...
  • Page 2 Copyright © 2002 – 2021 AMADA WELD TECH The engineering designs, drawings and data contained herein are the proprietary work of AMADA WELD TECH and may not be reproduced, copied, exhibited or otherwise used without the written authorization of AMADA WELD TECH.
  • Page 3 FOREWORD Thank you for purchasing an AMADA WELD TECH - UB25 Linear DC Welding Power Supply / Control. Upon receipt of your equipment, please thoroughly inspect it for shipping damage prior to its installation. Should there be any damage, please immediately contact the shipping company to file a claim, and notify us at: AMADA WELD TECH INC.

  • Page 4: Table Of Contents

    Manual Weld Head Connections ....................2-4 Air-Actuated Weld Head Connections ..................2-6 Relay, Data, And Communication Connections ............... 2-6 Chapter 3. Using UB25 Welding and Monitoring Functions ............3-1 Section I: Introduction ........................3-1 Section II: Weld Schedules ......................3-2 Definition ..........................
  • Page 5 Section II: Initial Setup ........................4-2 Pre-Operational Checks ......................4-2 Connections ........................4-2 Power ..........................4-2 Compressed Air ......................... 4-2 Initial Setup Instructions ......................4-2 Section III. Programming Weld Schedules ..................4-3 Introduction ..........................4-3 MODEL UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 6 Stability Check Delay Setting ................... 5-7 Energy Capacity % Limit Setting ..................5-7 Weld Fire Lockout Charge % Setting ................5-8 Footswitch Weld Abort ......................5-8 Switch Debounce Time ......................5-9 Firing Switch ..........................5-9 MODEL UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 7 Section II. Operator Maintenance ....................6-1 Section III. Troubleshooting ......................6-1 General Kinds of Problems ...................... 6-1 Alarm Messages ........................6-2 Troubleshooting ........................6-2 Technical Assistance ........................ 6-5 Electrode Maintenance ......................6-6 Parts Replacement ........................6-6 MODEL UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 8 Appendix D. Quality Resistance Welding Solutions Defining the Optimum Process ....D-1 Appendix E. LCD Display Messages ....................E-1 Appendix F. Relay Timing Diagrams ....................F-1 Appendix G. Repetition Rates ......................G-1 MODEL UB25 LINEAR DC RESISTANCE WELDING CONTROL viii 990-665...
  • Page 9 Operator Guide – AMADA WELD TECH Power Supplies CAUTION! This symbol designates an operation which requires a qualified technician and User's Manual OPGELET! Dit symbool duidt een bediening aan waarvoor een gekwalificeerde technicus en de gebruikershandleiding vereist zijn VARNING! Denna symbol indikerar ett arbetsmoment som br utfras av en kvalificerad tekniker med hjlp av Anvndarhandledningen...
  • Page 10 Operator Guide – AMADA WELD TECH Power Supplies Examine weld terminals Kijk de lasterminals na Inspektera svetsterminalerna Tarkista hitsausterminaalit Examiner les bornes de soudure Schweiverbindungen prfen Esaminare i terminali di saldatura Examine os terminais de soldagem Examine las terminales soldadas...
  • Page 11 SAFETY NOTES This instruction manual describes how to operate and maintain the UB25 Linear DC Welding Power Supply and provides instructions relating to its SAFE use. Procedures described herein MUST be performed, as detailed, by QUALIFIED and TRAINED personnel. For SAFETY, and to effectively take advantage of the full capabilities of the workstation, please read this instruction manual before attempting to use the UB25 Linear DC Welding Power Supply.
  • Page 12 1. Applicability. (a) These terms and conditions of sale (these “Terms”) are the only terms which govern the sale of the goods (“Goods”) by Amada Weld Tech Inc. (“Seller”) to the buyer identified in the Sales Quotation and/or Acknowledgment (as each defined below) to which these Terms are attached or incorporated by reference (“Buyer”).
  • Page 13 Agreement. Buyer shall immediately discontinue use of the Software upon any termination of this license or Agreement. This license shall terminate upon any termination of the Agreement. MODEL UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 14 (b) IN NO EVENT SHALL SELLER’S AGGREGATE LIABILITY ARISING OUT OF OR RELATED TO THIS AGREEMENT, WHETHER ARISING OUT OF OR RELATED TO BREACH OF CONTRACT, TORT (INCLUDING NEGLIGENCE) OR OTHERWISE, EXCEED THE TOTAL OF THE AMOUNTS PAID TO SELLER FOR THE GOODS SOLD HEREUNDER. MODEL UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 15 Seller including, without limitation, acts of God, flood, fire, earthquake, explosion, governmental actions, war, invasion or hostilities (whether war is declared or not), terrorist threats or acts, riot, or other civil unrest, national emergency, revolution, insurrection, epidemic, lock-outs, strikes MODEL UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 16 27. Survival. Provisions of these Terms which by their nature should apply beyond their terms will remain in force after any termination or expiration of this Order including, but not limited to, the following provisions: Compliance with Laws, Confidentiality, Governing Law, Dispute Resolution, Survival, and the restrictions on Software in Sections 10(b), (c) and (d). MODEL UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 17: Chapter 1. Description

    Features The UB25 Linear DC Welding Control is a Resistance Welding Power Supply. For the rest of this manual, the UB25 will be referred to simply as the Power Supply. The Power Supply has the following features: • Programming of time in 10 µsec increments (minimum) provides shorter weld times, less part deformation, longer electrode life, and greater weld strength with more part ductility.

  • Page 18: Applications

    The Power Supply has a closed-loop feedback circuit that allows the user to program constant current, constant voltage, or constant power welding pulses. Chapter 3, Using UB25 Welding and Monitor Functions, describes the Power Supplies functions and how to use them for different welding applications.

  • Page 19: Section Ii. Description

    Power Supply. Connection instructions are described in Chapter 2, Getting Started. Complete technical specifications for the Power Supply are listed in Appendix A, Technical Specifications. Connector pin identification and specifications are listed in Appendix B, Electrical and Data Connectors. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 20: Section Iii. Overview

    The LCD displays two types of screens: Data screens and Menu screens. NOTE: The purpose of this section is to describe the content of LCD screens. For clarity, LCD screens are shown here without the Weld Selector keys located directly under the display. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 21: Menu Screens

    (left side). Menu Screens do not display the operational state, but the menu itself indicates the Power Supply is in the MENU state. The following table describes each of the Power Supplies operational states. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 22 Pressing the MENU key puts the Power Supply in the MENU state, which displays the MAIN MENU MENU on the LCD. A series of menu and sub-menu screens enable you to change the Power Supplies operating parameters (see Chapter 4, Operating Instructions). UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 23: Graphed Data

    You can compensate for this by using the upslope feature when programming a weld schedule [see Chapter 3, Using UB25 Welding and Monitoring Functions and Chapter 4, Operating Instructions]. The data lines on the LCD may also display alarm messages showing that the weld was inhibited, stopped, or terminated and the reason why the action was taken.

  • Page 24: Section Iv. Controls And Indicators

    99 stored Weld Schedules, or use the numeric keypad to enter the two-digit number of the desired schedule. Weld Selector Keys. A group of nine keys used to program the time periods and energy levels for each complete weld schedule. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 25 Press to enter the amount of time for the hold period after the weld. To select the value, use either the ▲▼ (up/down) keys, or use the numeric keypad to enter the numbers. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 26: Numeric Keypad And Operational Controls

    Data is displayed in the top data line on the LCD. Press to: Increment (increase) or decrement (decrease) numeric values on the display Scroll the weld schedule numbers up and down. UB25 LINEAR DC RESISTANCE WELDING CONTROL 1-10 990-665...
  • Page 27 When MONITOR or RUN is displayed in the MONITOR state, press the kA key to view the current graph on the LCD display. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665 1-11...
  • Page 28 Press to return to the RUN state or to clear alarms. When using any MENU screen, press this key to exit the menu. Press to display the MENU screen. Chapter 4, Operating Instructions describes how to use the different MENU options. UB25 LINEAR DC RESISTANCE WELDING CONTROL 1-12 990-665...

  • Page 29: Section V. Emergency Stop Switch And 24V Jumpers

    For user convenience, pins 9 and 13 of I/O Connector B have an additional input to stop the functioning of the unit. This input will stop weld current and raise the weld head. This input requires the microprocessor to be operational and is not the emergency stop for the unit. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665 1-13...

  • Page 30: Section Vi. Related Publications

    CHAPTER 1: DESCRIPTION Section VI. Related Publications Related publication, which you may wish to obtain from AMADA WELD TECH is: • SL-300A Fast Response Weld Head System, Part Number 990-115. Please consult your representative to obtain this information. UB25 LINEAR DC RESISTANCE WELDING CONTROL...

  • Page 31: Chapter 2 Getting Started

    230 volts, AC,10 amps The power cable for the 230-volt version of the Power Supply the (Model UB25/230) is not supplied with a wall connector due to the variety of connectors used by different countries. You will need to install the appropriate connector to the Power Supply power cable before installation and setup.

  • Page 32: Section Ii: Unpacking

    Verify that the equipment shows no signs of damage. If you see any damage, please contact the carrier. Also, contact AMADA WELD TECH immediately by telephone, FAX, or the postal or e-mail address shown in the Foreword of this manual.

  • Page 33: Section Iii: Electrical And Data Connections

    NOTE: For clarity, illustrations in the rest of this manual do not show the power cable connected to the Power Supply, even though the power cable must be connected in order to operate the Power Supply. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 34: Section Iv. Setup

    Attach the voltage sensing cable connector to the VOLTAGE SENSE INPUT connector. Install electrodes in the weld head electrode holders. Attach voltage sensing cables to the screws on the electrode holders as shown. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 35 Connect the Firing Switch cable connector from the Power Supply to the firing switch cable connector from the weld head. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 36: Air-Actuated Weld Head Connections

    For the Power Supply programmable relay connections, PLC, data logging, or other I/O connections, you will have to fabricate the appropriate connecting cables. For the Power Supply connector pin identification and specifications, see Appendix B, Electrical and Data Connectors. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 37: Section I: Introduction

    Programmable Feedback Modes • Weld Monitor − Active Part Conditioner − Energy Limits − Pre-Weld Check Chapter 4, Operating Instructions, contains the step-by-step instructions on how to program each of the functions above. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 38: Section Ii: Weld Schedules

    CHAPTER 3: USING UB25 WELDING FUNCTIONS Section II. Weld Schedules Definition Weld Schedule is the name given to each of 99 separate weld profiles stored in the Power Supply, numbered from 01 → 99. A weld profile is the graphic representation [or waveform] of the numeric weld- time and weld-energy values.

  • Page 39: Welding Applications

    Welding. Weld Head Applicability The Power Supply is best used with an AMADA WELD TECH force-fired, manual weld heads or air actuated weld heads. For manually actuated weld heads, the weld sequence begins when the force-firing switch closes. For force fired, air actuated weld heads, the weld sequence begins when both levels of a two-level foot switch are closed and the force firing switch in the air actuated weld head closes.

  • Page 40: Single-Pulse Weld Profile

    CHAPTER 3: USING UB25 WELDING FUNCTIONS Single-Pulse Weld Profile Applications • Flat parts that do not have any plating or heavy oxides. Conductive parts made of copper or brass. Description Single-Pulse is a term used by the industry to describe the simplest heat profile used for many resistance spot-welding applications.

  • Page 41: Dual-Pulse Weld Profile

    CHAPTER 3: USING UB25 WELDING FUNCTIONS Upslope / Downslope Weld Profile Dual-Pulse Weld Profile Applications • Flat-to-flat parts. • Round-to-round parts. • Round-to-flat small parts that may or may not be plated. Description Adding upslope to the front of both weld periods allows a reduction in electrode force, this results in a cleaner appearance by reducing electrode indentation, material pickup and electrode deformation.
  • Page 42 CHAPTER 3: USING UB25 WELDING FUNCTIONS 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 43: Section Iii. Programmable Feedback Modes

    CHAPTER 3: USING UB25 WELDING FUNCTIONS Section III. Programmable Feedback Modes Introduction The feedback mode (current, voltage, power) is one of the selections entered when programming a weld schedule. Programming weld schedules is explained in Chapter 4, Operating Instructions. Current Mode Application •...

  • Page 44: Section Iv. Weld Monitor

    CHAPTER 3: USING UB25 WELDING FUNCTIONS Section IV. Weld Monitor Introduction The Power Supplies feedback sensors not only control weld energy output, but they can also be used to monitor each weld. The Power Supplies monitor features allow you to view graphic representations of...

  • Page 45: How It Works

    CHAPTER 3: USING UB25 WELDING FUNCTIONS How It Works Both constant current feedback and constant voltage feedback modes are limited in their ability to deal with varying levels of part contamination and oxide. If constant current feedback were used, the power supply would ramp the voltage to very high levels in order to achieve current flow through the oxide.

  • Page 46: Instructions

    CHAPTER 3: USING UB25 WELDING FUNCTIONS 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 47 CHAPTER 3: USING UB25 WELDING FUNCTIONS Note: When using the energy limits monitor, always select a monitor mode that is different from the feedback mode. For example: • If you are welding in constant current, monitor voltage. • If you are welding in constant voltage, monitor current.

  • Page 48: Pre-Weld Check

    CHAPTER 3: USING UB25 WELDING FUNCTIONS Pre-Weld Check Application • Detect Misaligned or Missing parts. Function This is used to see if parts are misaligned or missing before a welding pulse is delivered to the weld head. If a part is missing or misaligned, you do not want the machine to weld because the result would be an unacceptable weld and/or damaged electrodes.

  • Page 49: Chapter 4, Operating Instructions

    • How to select and use the Control functions for your specific welding applications. For more information, see Chapter 3, Using UB25 Welding and Monitoring Functions. • The principles of resistance welding and the use of programmed weld schedules. For more information, see Appendix C, The Basics of Resistance Welding.

  • Page 50: Section Ii: Initial Setup

    Turn the ON/OFF switch on the rear panel of the Power Supply to the ON position. The default RUN screen will be displayed. You will use this screen to enter welding parameters. Default RUN Screen UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 51: Section Iii. Programming Weld Schedules

    01 through 99. Each schedule is set to the same preset value and looks like the display on the right. See Chapter 3, Using UB25 Welding And Monitoring Functions for descriptions of the features available in weld schedules.

  • Page 52: Single-Pulse Weld Schedule

    Press the HOLD key to enter the amount of time for the hold period after the weld. Use the numeric keypad or the ▲▼ arrows. Enter a time between 0 and 999 milliseconds. We recommend at least 50 milliseconds as weld strength is formed in the hold time. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 53: Upslope/Downslope Weld Schedule

    Press the HOLD key to enter the amount of time for the hold period after the weld. Use the numeric keypad or the ▲▼ arrows. Enter a time between 0 and 999 milliseconds. We recommend at least 50 milliseconds as weld strength is formed in the hold time. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 54: Dual-Pulse Weld Schedule

    Press the HOLD key to enter the amount of time for the hold period after the weld. Use the numeric keypad to enter the time or use the ▲▼ arrows. Enter a time between 0 and 999 milliseconds. We recommend at least 50 milliseconds. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 55: Section Iv. Programming The Weld Monitor

    Pulse 1 upper or lower NUMBER Select, MENU Previous menu limits are exceeded. You have four choices: • NONE takes no action if upper or lower energy limits are exceeded. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 56 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. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 57: Section V. Programming For Active Part Conditioning

    Section V. Programming For Active Part Conditioning Before you program for Active Part Conditioning, make sure you are familiar with these procedures described in this manual: • Chapter 3, Using UB25 Welding And Monitoring Functions • Chapter 4, Section III, Programming Weld Schedules •...
  • Page 58 Constant voltage is recommended for round parts and constant current for flat parts. An upslope may be required to restrict the current flow early in the second pulse and avoid weld splash. UB25 LINEAR DC RESISTANCE WELDING CONTROL 4-10 990-665...

  • Page 59: Section Vi. Operation

    Perform all software Test and Setup procedures to verify that the PLC is communicating properly with the Power Supply. Set the WELD/NO WELD switch on the front panel to the WELD position. Begin welding using normal automation operating procedures. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665 4-11...

  • Page 60: Normal Stop

    Inspect the production area to verify it is ready to continue welding. Press the RUN key on the front of the Power Supply and verify the desired weld schedule is displayed on the LCD. Continue to weld following normal automation procedures. UB25 LINEAR DC RESISTANCE WELDING CONTROL 4-12 990-665...

  • Page 61: Chapter 5, Setup Software

    Baud Rate Before programming the Power Supply, you must be familiar with the location and function of the LCD and front panel controls. If you need more information, see Chapter 1 of this manual. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 62: Section Ii. How To Use Menu Screens

    To go to the SETUP 2 menu, press the 3. FIRING SWITCH : AUTO ▼ (down) key. 4. INPUT SWITCH SELECT : MECH OPEN 5. CONTROL SIGNALS SELECT : MECH OPEN NUMBER Select, MENU Main menu, ▼ Page 2 UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 63 SETUP 1 menus, press the ▲ (up) key. NUMBER Select, MENU Main menu, ▲ Page 2 When you have finished programming the desired functions, press the MENU key on the front panel to return to the MAIN MENU. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 64: Section Iii. Operator Preferences

    Press the MENU key to return to the MAIN MENU. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 65: Update Graph After Weld

    : OFF front panel to return to the MAIN NUMBER Select, MENU Main menu, ▲▼ Page MENU. NOTE: After setting Operator Preferences, press the RUN button on the front panel to perform welding. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 66: Section Iv. System Settings

    MENU Press return WAVEFORM CHECK menu. STABILITY CHECK % LIMIT line will display your programmed setting along with deviation readings from the Pulse 1 and Pulse 2 of the most recent weld. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 67: Stability Check Delay Setting

    MENU Press return WAVEFORM CHECK menu. ENERGY CAPACITY % LIMIT line will display your programmed setting along with the Pulse 1 and Pulse 2 ENERGY CAPACITY readings from the most recent weld. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 68: Weld Fire Lockout Charge % Setting

    Keep pressing the MENU key on the front panel to return to the MAIN MENU. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 69: Switch Debounce Time

    AUTO accepts a single pole, double pole, or optical firing switch input, typically from an AMADA WELD TECH weld head. Firing switch activation indicates that the weld head has reached the set weld force and is ready for the weld energy sequence (including squeeze time) to start.

  • Page 70: Input Switch Select

    NUMBER Select, MENU Previous menu Mechanical Selection This selection accepts dry contact, single, or double pole switch or reed relay devices. This is the factory default setting and will run AMADA WELD TECH weld heads. From the INPUT SWITCH SELECT INPUT SELECT SWITCH menu, press 1 for the mechanical switch 1.

  • Page 71: Opto Selection

    Switch and Foot Switch inputs before selecting the +24 VDC Turn On option. Press the 1 or 2 key to select how the PLC input switches will initiate the Power Supply. The display automatically returns to the SETUP 1 menu. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665 5-11...

  • Page 72: Control Signals Select

    (period/decimal point) key. The original count will reappear. Press the MENU key to return to the WELD COUNTERS screen. When all counters have been reset, press the MENU key to return to the MAIN MENU. UB25 LINEAR DC RESISTANCE WELDING CONTROL 5-12 990-665...

  • Page 73: System Security

    If you forget the security code and wish to unlock the Power Supply from security protection: Return to the CHANGE STATUS screen. Enter a security code of 414, followed by a period. Keep pressing the MENU key to return to the MAIN MENU. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665 5-13...

  • Page 74: Calibration

    The chain code becomes part of each weld schedule. You can turn the Chain Schedules feature ON or OFF, or re-program chains, any time you want. UB25 LINEAR DC RESISTANCE WELDING CONTROL 5-14...
  • Page 75 4 through 8 to program the rest of the chain. When you finish programming the chain, press the MENU key to return to the CHAIN SCHEDULES menu. 10 Press the 1 key to toggle between ON or OFF. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665 5-15...
  • Page 76 Below the current schedule number, you can see the number of times the current schedule will be repeated, and the number of the next schedule in the chain. UB25 LINEAR DC RESISTANCE WELDING CONTROL 5-16 990-665...

  • Page 77: Section V. Pid Test Weld Setup

    TEST WELD, whether the feedback mode was actually changed or not. Changes to monitor settings, such as energy limits and actions, do not cause the Power Supply to perform a TEST WELD. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665 5-17...

  • Page 78: Ignore First/Last

    The delay time prevents the Power Supply from measuring noise early in the test weld and allows for more accurate load resistance to be measured. Press MENU to return to the SETUP 3 menu screen. UB25 LINEAR DC RESISTANCE WELDING CONTROL 5-18 990-665...

  • Page 79: Section Vi. Relay Settings

    4. OUT OF LIMITS 5. P1 HIGH LIMIT Use the numeric keypad to select when NUMBER Select, MENU Previous menu the relay will energize. The display screen automatically returns to the WHEN menu. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665 5-19...
  • Page 80 Press the MENU key two times to return to the RELAY screen. Repeat Steps 2 through 6 to program the other relays as needed. Press MENU to return to the MAIN MENU. UB25 LINEAR DC RESISTANCE WELDING CONTROL 5-20 990-665...

  • Page 81: Section Vii. Special Functions

    Defaults for Setup Menu 1 SYSTEM PARAMETER DEFAULT SETTING Foot Switch Weld Abort Switch Debounce Time 10 ms Firing Switch AUTO Input Switch Select MECH OPEN Control Signals Select MECH OPEN UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665 5-21...
  • Page 82 Weld Fire Lockout Charge 90 % Defaults for Communication Menu SYSTEM PARAMETER DEFAULT SETTING Communication Role CLIENT RS-485 ID Number Baud Rate 9600 Defaults for Chain Schedules Menu SYSTEM PARAMETER DEFAULT SETTING Chain Schedules UB25 LINEAR DC RESISTANCE WELDING CONTROL 5-22 990-665...

  • Page 83: Reset System Parameters

    NUMBER Select, MENU Previous menu parameters to the factory defaults and return the display to the RESET DEFAULTS? screen. Press MENU to return to the MAIN MENU. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665 5-23...

  • Page 84: Section Viii. Communication And Data

    NOTE: For weld data collection and host computer control information, refer to the 990-661 - Communications Manual, which describes how to use the HOST and CLIENT options. Press MENU to return to the MAIN MENU. UB25 LINEAR DC RESISTANCE WELDING CONTROL 5-24 990-665...

  • Page 85: I.d. Number

    The 4. 14.4K display automatically returns to the NUMBER Change, MENU Previous menu COMMUNICATION menu which shows the new baud rate. Press MENU to return to the MAIN MENU. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665 5-25...

  • Page 87: Chapter 6. User Maintenance

    The Power Supply does not require any Operator Maintenance other than calibration. To ensure consistently accurate welds, AMADA WELD TECH recommends that you calibrate the Power Supply at least once a year. For calibration instructions, please refer to Chapter 7, Calibration.

  • Page 88: Alarm Messages

    The problem is embedded in the system and some form of repair will be needed. For example, repair might include replacing a broken weld head flexure. In either case, you may telephone the AMADA WELD TECH Applications Laboratory for assistance by calling the telephone number listed in the Foreword and asking for the Applications Laboratory.
  • Page 89 Insufficient Weld Nugget Excessive weld head force Insufficient weld head force Contaminated electrode surface Incompatible weld piece projection design Slow weld head follow-up Incompatible weld piece materials No cover gas on weld piece UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 90 Troubleshooting Chart PROBLEM CAUSE (In Order of Probability) LCD Display is blank, fans are still Blown fuse located on internal Bias Power Supply. Contact AMADA WELD operational. TECH for support. Possible open circuit in the secondary circuit. Electrodes did not close LCD is operational, the Power Supply properly.

  • Page 91: Technical Assistance

    Excessive current/energy set at the Power Supply Technical Assistance If you need further technical assistance, please contact either your authorized service agent or AMADA WELD TECH by telephone or FAX, or at the postal or e-mail addresses shown in the Foreword of this manual.

  • Page 92: Electrode Maintenance

    • Only qualified technicians should perform internal adjustments or replace parts. • Removal of the unit cover could expose personnel to high voltage. • Removal of the unit cover may void the warranty. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 93: Chapter 7. Calibration

    The waveforms displayed on the oscilloscope screen will vary from pulse to pulse. To calibrate the Power Supply, adjust the energy output to the average value of each pulse displayed on the oscilloscope. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 94: Calibration Points

    Power Supply to operate and monitor accurately. There are 12 Calibration Points. The instructions in Section II, Calibration Procedure tell you how to perform the procedures, the illustration below gives a quick overview of the process. Calibration Points UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 95: Section Ii. Calibration Equipment Setup

    The ground of the oscilloscope should be isolated from the ground of the electrical "live" by an isolation transformer or other means. The filter in the Calibration Kit goes between the BNC cable and the oscilloscope input. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 96: Section Iii. Calibration Procedure

    10 Follow the instructions on the calibration screens. Each screen will show you the desired energy output value for that calibration step. Use the oscilloscope to measure the output, then use the ▲▼ keys to adjust the Power Supply output to the correct average value. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 97 MAIN MENU is displayed on the LCD. 13 Disconnect the Power Supply from the "Calibration Setup," then re-connect the Power Supply as required for your welding system. 14 Press the RUN button to return to normal operation. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 99: Appendix A. Technical Specifications

    TECHNICAL SPECIFICATIONS General The UB25 is a linear DC resistance welding power supply that sends energy directly into a weld without the use of a welding transformer. It is capable of executing any weld function at low current, voltage or power levels with high stability and good control.
  • Page 100 Voltage monitoring is not guaranteed below 0.1 V. Reference is actual voltage delivered. The sum of ± 5% of setting and ± 20 W Power Monitoring Accuracy Average value after settling time. Reference is actual power delivered UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 101 Additional connections for weld head, schedule selection, process inhibit, emergency stop. Four general purpose programmable relays. Firmware Firmware is subject to change without prior notice. Contact AMADA WELD TECH for latest version. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 103: Appendix B. Electrical And Data Connectors

    CURRENT NAME TYPE AGND Analog Ground Input #1 Pulse 15 V 0.1 A Signal is differential between Input #1 and Input #2 Input #2 Pulse 15 V 0.1 A (polarity is not important). UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 104 Isolated ground (1 kV DC Isolation) Not used Not used Transmit + RS-485 Driver + Transmit - RS-485 Driver - Not used Not used Receive + RS-485 Receiver + Receive - RS-485 Receiver - UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 105 RS-232 CONNECTOR SPECIFICATIONS PIN NO. DESCRIPTION PIN TYPE Not Used TX (Transmit Data) RS-232 Driver RX (Receive Data) RS-232 Receiver Not Used Signal Ground Analog Ground (ISOGND1) Not Used Not Used Not Used Not Used UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 106 PIN #4 -- RELAY2P PIN #16 -- 24VOUT PIN #3 -- RELAY2N PIN #15 -- SPOWER PIN #2 -- RELAY1P PIN #14 -- 24VGND PIN #1 -- RELAY1N Specification Table on next page. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 107 Not used Not used HEAD+ 24 VAC 24 VAC Valve Driver 24VAC RET 24 VAC Return 24 VAC Valve Driver Return ESON 24 VAC Emergency Stop 24 VAC 24 VAC Internal 24 VAC UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 108 PIN #10 -- IFIRE PIN #23 -- IFOOT1 PIN #11 -- 24VOUT PIN #24 -- IFOOT2 PIN #12 -- FPOWER PIN #25 -- CGND PIN #13 -- 24VGND Specification Table on next page. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 109 Not used Not used Not used Not used IFOOT1 +24 V 10 mA Foot switch normally open, Level 1 IFOOT2 +24 V 10 mA Foot switch normally open, Level 2 CGND CGND Chassis ground UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 110 11 and 12 (FPOWER). NOTE: In order to operate, both mating plugs must be attached to the I/O connectors, or I/O cables wired for the proper jumpers must be attached to the Power Supply. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 111 Firing Switch normally open. SHIELD CGND CGND Chassis ground. NOTE: In addition to the debounce time, there is a delay of no greater than 2.5 ms before the start signal is recognized by the Power Supply. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 112 Foot switch SW1 (Level 1) IFOOT1 Digital +24 V 10 mA normally open Foot switch SW2 (Level 2) IFOOT2 Digital +24 V 10 mA normally open 24V GROUND Digital SGND 20 mA Foot switch signal ground UB25 LINEAR DC RESISTANCE WELDING CONTROL B-10 990-665...
  • Page 113 APPENDIX B: ELECTRICAL AND DATA CONNECTORS AC Input Power Connection NEUTRAL GROUND AC INPUT POWER CONNECTION SPECIFICATIONS MODEL TERMINAL MAXIMUM VOLTAGE MAXIMUM CURRENT 132 volts 15 amps UB25 Neutral Ground 265 volts 10 amps UB25/230 Neutral Ground UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665 B-11...
  • Page 114 APPENDIX B: ELECTRICAL AND DATA CONNECTORS Weld Terminals POSITIVE WELD TERMINAL NEGATIVE WELD TERMINAL WELD TERMINAL SPECIFICATIONS TERMINAL MAXIMUM VOLTAGE MAXIMUM CURRENT COMMENTS 9.9 volts 1,300 amps Variable Return UB25 LINEAR DC RESISTANCE WELDING CONTROL B-12 990-665...

  • Page 115: Appendix C. The Basics Of Resistance Welding

    The formula for amount of heat generated is I RT -- the square of the weld current [ I ] times the workpiece resistance [ R ] times the weld time [ T ]. Welding Parameter Interaction Interaction of Welding Parameters UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 116 -2, -14 Bronze -2, -11 Iron Copper Bronze -2, -11 Nichrome Beryllium Copper Copper Bronze -2, -11 Nickel Beryllium Tinned Chromel Chromel Copper Copper Chromel Constantan Beryllium Nickel Copper Chromel Copel Chromel Copper UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 117 Nickel Alloy Tinned Copper Gold Gold Nickel Alloy Nichrome Gold Kovar Nickel Alloy Nickel Hastalloy Titanium Nickel Alloy Cold Rolled Steel Inconel Inconel NiSpan C NiSpan C Inconel Kulgrid NiSpan C Cold Rolled Steel UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 118 Use the Force Adjustment Knob on the Weld Head to set the Firing Force and adjust an Air Actuated Weld Head. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 119 Repeat steps 1 through 3 for different weld forces, then create a plot of part pull strength versus weld current, voltage, or power for different weld forces as shown in the illustration below, Typical Weld Strength Profile. Repeat steps 1 through 3 using a different but fixed weld time. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 120 14 lb electrode force curve. A comparison of weld schedules for several different applications might show that they could be consolidated into one or two weld schedules. This would have obvious manufacturing advantages. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 121: Appendix D. Quality Resistance Welding Solutions Defining The Optimum Process

    • Ceramic: alumina, sand • Plastics / polymers: PVC, teflon • Semiconductors: silicon, geranium Metals can be resistance-welded because they are electrically conductive, soften on heating, and can be forged together without breaking. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 122 As there is no real melting of the materials in a solid-state joint there is less chance of weld splash or material expulsion. A weld nugget can still be achieved with a solid-state joint. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 123 − Conductive metals dissipate heat and it can also be difficult to focus heat at the interface. A solid-state joint is therefore preferred. Typically resistive electrode materials are used to provide additional heating. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 124 Resistance Bulk Resistance Time The figure above shows the key resistances in a typical opposed resistance weld and the relationship between contact resistances and bulk resistances over time, during a typical resistance weld. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 125 The contact resistance present at the weld when the power supply is fired has a great impact on the heat balance of a weld and therefore also the heat affected zone. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 126 The basic welding profile or schedule consists of a controlled application of energy and force over time. Precision power supplies control the energy, time, and therefore heating rate of the parts. The weld head applies force from the start to finish of the welding process. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 127 Force, squeeze, hold Pull strength − − Actuation method Visual criteria − − Electrode material and shape Test method, other weld joint requirements • Power supply variables − Energy − Time (squeeze, weld, hold) UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 128 What other parameters will operators are able to adjust? • What are the quality and inspection requirements? • What are the relevant production testing methods and test equipment? • Do we have adequate control over the quality of the materials? UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 129 The figure above shows common welding problems that can often be identified in the basic set up of the force, energy and time welding profile. These problems can lead to weld splash and inconsistency and variation (contact AMADA WELD TECH for further information and support). UB25 LINEAR DC RESISTANCE WELDING CONTROL...
  • Page 130 If many variables are still not understood, multiple Screening DOE’S may be required. AMADA WELD TECH provides a simple Screening DOE tool that is run in excel and is sufficient for the majority of applications (contact us for details). Bespoke sophisticated software is also available from other vendors designed specifically for this purpose.
  • Page 131 AMADA WELD TECH will frequently use the Screening DOE tool to establish the impact of key variables and also to assist customers with troubleshooting. Often the testing as described above will provide the information and understanding to predict common failure modes and causes.

  • Page 133: Appendix E. Lcd Display Messages

    Momentarily close the Process Inhibit input on I/O Connector B on the rear panel. No action is required to resume operation if you see either Out of Limits or General Status messages. List of Messages The following pages list LCD display messages in alphabetical order. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 134 Switch input signals is preventing ALARM NOTE: The correct removal action SWITCH STATUS the Power Supply from continuing depends on how the INPUT SWITCH to operate. SELECT in the Setup 1 menu was programmed by the user. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 135 GREATER THAN the user set Upper Limit value for Troubleshooting Chart in Chapter 6. LIMITS UPPER LIMIT Pulse 2. Limits should be set by qualified by personnel and are designed to identify process variations. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 136 Activating the Inhibit NOTE: The correct removal action ACTIVATED input terminates only future depends on how the control signal I/O operations. It does NOT terminate logic was programmed by the user. present Power Supply operation. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 137 OUT OF THAN LOWER user set Lower Limit value for Refer to the Troubleshooting Chart in LIMITS LIMIT Pulse 1. Chapter 6. Limits should be set by qualified personnel designed to identify process variations. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 138 Supply to automatically reset all the MENU default features. There is GENERAL PARAMETERS I/O and other system parameters to no way to undo a reset to defaults STATUS ARE RESET their factory set default values. action. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 139 Refer to the Troubleshooting Chart in LOWER THAN the user set Lower Limit value for LIMITS Chapter 6. Limits should be set by LOWER LIMIT Pulse 2. qualified personnel designed to identify process variations. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 140 The user has attempted to program Re-program the welding parameters to WELD TIME TOO GENERAL zero for all upslope, weld, and be within the capability of the Power SMALL STATUS downslope time periods. Supply. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 141: Appendix F. Relay Timing Diagrams

    The following diagrams show the timing sequence for each relay WHEN state. WELD When welding, the relay output signal will start within 5 milliseconds after the start of SQUEEZE and will stay energized for 0-150 milliseconds after the end of the HOLD period. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 142 The relay output signal will start when the Control senses certain ALARM conditions (with the exception of OUT OF LIMITS alarms) and will stay energized until the ALARM state is cleared by pressing the RUN button (refer to Appendix E, LCD Display Messages). UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 143 It will start 0 - 150 milliseconds after the end of HOLD and will stay energized until the OUT OF LIMITS alarm state is cleared by pressing the RUN button, or at the start of the next weld. UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...

  • Page 145: Appendix Grepetition Rates

    The term repetition rate refers to how often weld pulses can be repeated based on the Power Supplies recharging time. The UB25 stores energy internally in a capacitor bank. This energy is used to provide the desired weld pulses. There are limits to the duration of weld pulses the unit can provide, and time must be provided between welds for the capacitor bank to recharge.
  • Page 146 APPENDIX G: REPETITION RATES Maximum Weld Pulse Duration as a Function of Weld Current UB25 LINEAR DC RESISTANCE WELDING CONTROL 990-665...
  • Page 147 TEL. +1-626-303-5676 FAX, +1-626-358-8048 http://www.amadaweldtech.com AMADA WELD TECH CO., LTD. 200, Ishida, Isehara-shi, Kanagawa 259-1196, Japan AMADA WELD TECH KOREA CO., LTD. 28, Dongtanhana 1-gil, Hwaseong-si, Gyeonggi-do, 18423, Korea TEL. +82-31-8015-6810 FAX. +82-31-8003-5995 AMADA WELD TECH SHANGHAI CO., LTD. Unit 401, A206(C8), No. 77, Hongcao Road, Xuhui District, Shanghai, China TEL.
  • Page 148 AMADA WELD TECH 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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