Page 1: Table Of Contents
990-800 Revision A March 2003 Inverter Power Supply UP-120B Operation Manual CONTENTS W E L D I N G P O W E R S U P P L Y W E L D I N G P O W E R S U P P L Y 1.
Page 2 Copyright © 2003 Unitek Miyachi Corporation The engineering designs, drawings and data contained herein are the proprietary work of UNITEK MIYACHI CORPORATION and may not be reproduced, copied, exhibited or otherwise used without the written authorization of UNITEK MIYACHI CORPORATION. Printed in the United States of America.
Page 3 UP-120B 1. Special Precautions Safety Precautions C A U T I O N Before using, read "Safety precautions" carefully to understand the correct method Denotes operations and practices of use. that may result in personal injury or damage to the equipment if not •...
Page 4 UP-120B W A R N I N G Do not put your hands between the electrodes. When welding, keep your fingers and hands away from the electrodes. Do not touch any welded part or electrodes during welding and just after welding finished.
Page 5 UP-120B CAUTION Apply the specified source voltage. Application of a voltage out of the specified range can cause fire and electric shock. Do not splash water on the equipment. Water splashed over the electric parts, can cause electric shock and short circuits.
Page 6 UP-120B Precautions for Handling Install this Power Supply on a firm and level surface. If it is inclined, malfunction may result. For ventilation, provide 10 cm clearances to the intake and exhaust (page 8-3). Do not install this Power Supply in the following places:...
Page 7 WHEN INSPECTING INTERNAL, MAKE SURE TO TURN OFF MAIN CIRCUIT BREAKER AND WAIT FOR AT LEAST 5 MINUTES NOT TO GET AN ELECTRIC SHOCK. Location: UP-120B interior, side surface of acrylic cover. Location: UP-120B interior, side surface of acrylic cover. Output terminal cover. DANGER...
Page 8 UP-120B...
Page 9: Introduction
UP-120A 2. Introduction The Unitek Peco FINE SPOT-INVERTER UP-120B is an inverter-type power supply, large in capacity and specially designed to be used for spot welding and fusing. In addition, it is small in size and convenient to move or shift. Monitor function is provided, which enables judging defective or non-defective welding.
Page 10 UP-120A...
Page 11: N Am E And F Unctions Of E Ach S Ection 3 - 1 T
O N / O F F Fig. 3-1 [WELD POWER] lamp (Green LED) This lamp lights up when the power is supplied to UP-120B. [READY] lamp (Green LED) This lamp lights up when the system is ready to start welding.
Page 12 For external communication. Data Out "YES/NO" is selectable by setting DIP switch on the internal PC board (Factory default is "YES"). This PC board is mounted rear left of the UP-120B. (See Fig. 3-2) When the DIP switch is turned on, weld time, current, count, etc., are output after HOLD has ended through the RS-485 serial interface.
Page 13 UP-120B Setting DIP switch M any DI P swi t ches ar e on t he PC boar d; W h e n c h a n g i n g o v e r D I P sel ect t he cor r ect one.
Page 14 UP-120B Rear panel P o w e r s u p p l y b r e a k e r c o v e r I/O terminal cover POW ER OUT O u tp u t t e r m i n a l c o v er...
Page 15 R ESET Fig. 3-4 [TROUBLE RESET] key If this key is pressed while the [TROUBLE] lamp of UP-120B is lit, the lamp goes off. It has the same function as the [RESET] key of UP-120B. [CURSOR] keys These keys are used to move the cursor ( or ) to select an item.
Page 16 Note: To go to MODE SWITCH screen , press [MENU] key and [TROUBLE RESET] key on the program unit panel simultaneously for 4 seconds. POWER SUPPLY STATE screen This screen is used to display and set the information on UP-120B. -POWER SUPPLY STATE 0001 CONTROL # 2000.
Page 17 (a) CONTROL # Input the identification No. of your UP-120B. If you have two or more units of UP-120B, input 0001 for the first one, 0002 for the second one, 0003 for the third one, and so on. (b) PROGRAMED DATE Input the date when the data is set.
Page 18 UP-120B SCHEDULE screen Up to 15 welding schedules can be set on UP-120B. Those schedules are indicated as SCHEDULE #01 to #15. This screen is used to set the schedule No., length of weld time, welding current, and so on. This data can be indicated in the 12 modes as shown below, but the indicated items are the same in all the modes.
Page 19 UP-120B -SCHEDULE #01 CTRL 2 POWER RMS -SCHEDULE #01 CTRL 2 POWER RMS SQD SQZ WE1 COOL WE2 HOLD OFF SQD SQZ WE1 COOL WE2 HOLD OFF TIME 0000 0000 000 000 000 000 0000 TIME 000 000 00 00 00 00 00 CYC...
Page 20 UP-120B -SCHEDULE #01 CTRL 5 FIXED PULSE -SCHEDULE #01 CTRL 5 FIXED PULSE SQD SQZ WE1 COOL WE2 HOLD OFF SQD SQZ WE1 COOL WE2 HOLD OFF TIME 0000 0000 000 000 000 000 0000 m TIME 000 000 00 00 00 00 00 CYC...
Page 21 UP-120B Length of time to cool workpiece after turning COOL / Cooling time off welding current WE2 / Weld 2 time Length of time to supply welding current HOLD / Hold time Length of time to hold workpiece after turning...
Page 22 Welding current Fig. 3-7 (h) VALVE # Up to two valves (welding heads) can be connected to UP-120B. Set the valve to use. GAIN (1- 9) Sets the amount of feedback correction in various controls. Though 1 is normally used, the larger value will give the shorter rise time.
Page 23 Set the No. of SCHEDULE to monitor. The measured values such as the welding current, voltage, etc. for the welding in that SCHEDULE are displayed. UP-120B stores the latest measured values of each Schedule No. For example, even if the all SCHEDULE #01 to #15 are executed at random, if #03 is input to the screen, the latest measured values in SCHEDULE #03 are displayed.
Page 24 UP-120B (f) PULSE The widest pulse among the supplied primary pulse current is displayed by the percentage to the pulse width in the full wave mode. The pulse width in the full wave mode varies with setting of the frequency (WELD POWER FREQUENCY).
Page 25 UP-120B (d) POWER HIGH/LOW Set the upper limit (HIGH) and lower limit (LOW) of the electric power for each of WELD1 and WELD2. (e) PULSE HIGH If the percentage of the welding current pulse to the pulse width in the full wave mode exceeds the percentage set in the PULSE HIGH, ERROR signal is output.
Page 26 UP-120B...
Page 27 I /O Fig. 8-3 When two or more units of UP-120B are used and the contents of the memory of the first unit need to be copied to the second unit, copy the data of the first unit to the memory of UP-627A temporarily, then copy those data to the second unit.
Page 28 UP-120B [01]-[01] Move the cursor (→) to a necessary item among (a) - (d), then press [ENTER] key; the data will be copied. 3-15...
Page 29 (e) SCHEDULE[ 01 ] --> SCHEDULE[ 01 ]-[ 01 ] This function is used to copy the SCHEDULE (welding condition). UP-120B can set up to 15 schedules. They are indicated as SCHEDULE #01 - #15. This function is also used to "change the setting of SCHEDULE #01 and perform welding according to another schedule".
Page 30 UP-120B DELAY-START SET sets the length of time after the schedule signals are input until SQD (Squeeze delay time) starts. The setting range is 5 – 20 ms. 3-17...
Page 31 UP-120B UP-120B selects one from SCHEDULES #01 through #15 according to the combination of the four schedule signals which are externally input. For binary format, see the following table. Schedule Schedule Schedule Schedule SCHEDULE signal 1 signal 2 signal 4 signal 8 ●...
Page 32 UP-120B may judge that no current flows. To prevent this trouble, this item is used to set the number of current pulses of less than specific level at which UP-120B judges that no current flows.
Page 33 UP-120B Set the turn ratio of the welding transformer (The ratio of primary voltage to secondary voltage). Its setting range is 001.0 - 199.9. ATTENTION When using <PRIMARY RMS> or <PRIMARY LIMIT>, be sure to set the turn ratio of the welding transformer properly. If incorrect value is set,...
Page 34 STEPPER OFF INTERRUPT CURR. RANGE HIGH (a) START SIG. MODE Set the input method for the schedule signals to operate UP-120B. If schedule signal which is longer than DELAY-START SET setting is input, operation (Operation by stop is continued from SQD to HOLD. If an emergency pulse input) signal is input externally, operation stops.
Page 35 UP-120B 3-22...
Page 36 UP-120B (e) STEPPER Turn on and off the step-up(down) operation (See the STEPPER COUNT screen on page 3-22). Step-up(down) operation is turned on. Step-up(down) operation is turned off. (f) CURR. RANGE Switches the range of HEAT that is set on SCHEDULE screen (See p. 3-8).
Page 37 UP-120B (h) END SIG. MODE Set the end signal to be output when any monitor trouble signal is output. End signal is not output when UP-120B finishes operation. End signal is output when UP-120B finishes operation. (i) 4-START Four single schedules are available.
Page 38 UP-120B (k) INTERRUPT When the interrupt function is used, the current is turned off to avoid excessive displacement, for example, when displacement reaches a certain level in the fusing. Interrupt function is used. Interrupt function is not used This device is connected to...
Page 39 3-18). 9 STEPPER COUNT screen UP-120B can change the level of the welding current depending on the welding condition. The function to increase the welding current is called the step-up function, and that to decrease the welding current is called the step-down function. Set the timing for step-up (step-down) by the number of welds.
Page 40 UP-120B Fig. 3-14 As shown in Fig. 3-13, the current is stepped up(down) to the value for STEP2 when the number of welds for STEP1 finishes. Similarly, the current is stepped up(down) to the value for STEP3 when the number of welds for STEP2 finishes.
Page 41 UP-120B WELDING CONDITIONS INITIAL FORMAT Memory is initialized (returned to the initial settings). Screens after initializing show the same settings which appear on (a) YES the screens in "Explanation of Screen" on pages 3-6 to 3-23. (b) NO Memory is not initialized, and [MENU] screen appears.
Page 42 UP-120B 3-14...
Page 43: C Onnection M Ethod 4- 1 T O
UP-120B Rear Primary [SENS] I / O cable Match the designations of cable and POWER OUT termanals Input cable Output cable Fig. 4-1 NOTE: All items are separately sold except UP-120B (See p. 9-8) * On the Noise Filter...
Page 44 UP-120B For compliance to CE Marking, prepare Noise Filter: Manufacturer: TIMONTA Model name: FMAC-0954-H110 Specification: 440VAC, 50/60 Hz, 3 x 110A WARNING Be sure to ground the equipment. Be sure to install the terminal cover after wiring. Be sure to install an earth leakage breaker of 60A rated current or more to prevent electric shocks.
Page 45: Interface
UP-120B 5. Interface (1) Connection Diagram for External Input/Output Signals VALVE POWER IN VALVE 1(Current cap a c i t y , 0 . 5 A m a x ) VALVE 2(Current cap a c i t y , 0 . 5 A m a x )
Page 46 0.5A, operate an auxiliary relay with this VALVE output and supply a voltage with the relay contact to the valve. Pin 6 : 0V terminal for UP-120B only. Do NOT use for another purpose. Pin 7 : 24V terminal for UP-120B only. Do NOT use for another purpose.
Page 47 UP-120B Used as input terminal for start signal when interrupt mode switch is ON; then, schedule input, normally used as start signal, has only schedule selecting function. Pin 17 : Emergency stop input terminal. Operation is stopped when this terminal is open. This function is not for Interlock.
Page 48 UP-120B output. Pins 38, 39: Secondary voltage input terminal. Connect these terminals to secondary of welding transformer near to electrode for secondary constant-power effective value control, secondary constant- voltage effective value control or monitoring secondary voltage. (3) Connecting Input Signals When using a 100VAC power supply for valve, separate the wiring of the signal lines, Pins 6 to 31, from those of AC lines, Pins 1 to 5.
Page 49 UP-120B When external input signal is a common-minus input When external input signal is a common-plus input ― ―...
Page 50 UP-120B When external power supply input is used ― ―...
Page 51: Basic Operation
UP-120B 6. Basic Operation Turn on the welding power 1) Turn on the welding power. [WELD POWER] lamp lights up, and [READY] lamp blinks for 7 seconds, then goes off. Set the program unit 2) Call [MENU] screen. If another screen is displayed at present, press [MENU] key.
Page 52 UP-120B 13) Turn off the welding power all the LED lamps go off.
Page 53: Time Chart
UP-120B 7. Time Chart START input ( SCHEDULE ) COOL HOLD VALVE output DATA OUT (When DATAOUT function is turned on) ERROR STEP END ERROR RESET STEP RESET T1: Approx. 5 to 20 ms (Time set at DELAY-START SET ) T2: Approx.
Page 54 UP-120B...
Page 55 UP-120B 8. Maintenance Replacing Battery The life expectancy of the lithium battery installed to this equipment is five years. Following the procedures below, replace the battery before it runs out. DANGER When replacing the lithium battery, be sure to turn off the main power and wait for at least 5 minutes, then replace the battery so as not to get an electric shock.
Page 56 UP-120B Replacing Fuse UP-120B has a fuse in valve circuit (weld force power supply) (see Table below). If it is blown, replace it following the procedures below. Size (Dia x Length) in mm Circuit Fuse rating Valve T1A250VAC 6.35 x 31.75...
Page 57 UP-120B Cleaning / Replacing Filter UP-120B has filters at its intake and outlet (Fig. 8-4). Clean the filters once a half year observing the following procedures. If it gets badly stained, replace it with a new one. If the filter is clogged, air does not flow enough, causing internal temperature to rise and malfunction.
Page 58 UP-120B Inlet Outlet W E L D I N G P O W E R S U P P L Y FINE SPOT - INVERTER I S -1 2 0 B PULL PROG RAM MO NITO R ‚h ^‚n C O I L I N RS-485 Fig.
Page 59 UP-120B 9. Specifications Controller specifications Model name UP-120B Overvoltage category Category III Three-phase 480 VAC/440 VAC/400 VAC/380 VAC/240 VAC/220 VAC Incoming power supply (Voltage fixed to a customer-specified one when shipped.) +10%/-15%, 50 Hz / 60 Hz Control power supply...
Page 60 UP-120B Primary constant-current 15 schedules effective value control Secondary constant-current 15 schedules effective value control Secondary constant-power 15 schedules effective value control Control method Primary constant-current 15 schedules peak value control Secondary constant-voltage 15 schedules effective value control Constant-phase control 15 schedules...
Page 61 UP-120B For primary constant-current peak value control, however,set the above ratio: 5A and 200A. 2 schedules Transformer turn ratio setting (P/S RATIO) Setting range: 1.0-199.9 Pulsation setting Setting range: 1-9 (PULSATION) HEAT INCREASE/ 50-200% 15 schedules Step-up(-down) Step-up ratio setting...
Page 62 UP-120B [WELD POWER] lamp [READY] lamp State indicator LED [START] lamp [WELD] lamp [TROUBLE] lamp [WELD ON/OFF] lamp Memory backup Lithium battery (Data backup period: 5 years after shipment) battery Cooling method Air-cooled (fan motor) +5 to +40 deg C...
Page 63 UP-120B Overcurrent 100A Fuse Power is turned off in the following cases: a. When a secondary current is not detected in secondary constant-current effective value control, secondary constant-power effective va lue control or constant-phase control. Non-current b. When a primary current is not detected...
Page 64 UP-120B nnn, WELD2 time C: 000 ~ 099 m: 000 ~ 600 nn. n, WELD2 current 00.0 ~ 20.0 n. nn, WELD2 voltage 0.00 ~ 9.99 nn. n, WELD2 power 00.0 ~ 20.0 nn. n, WELD2 pulse width 00.0 ~ 99.9 --.-...
Page 65 UP-120B (2)Monitor data in LOW range mode RS-485 specifications Character Item Description Range train Identifier M (fixed) nnnn, Control No. 0000 ~ 9999 Welding schedule No. 01 ~ 15 C or m, C:CYC m:ms C or m nnn, WELD1 time...
Page 66 UP-120B RS-485 (3) Error data Serial interface Character specifications Item Description Range train Identifier E (fixed) nnnn, Control No. 0000 ~ 9999 Schedule No. 01 ~ 15 4~19 Error code 00 ~ 20 Linefeed code Example: E, 0001, 01, 03, 00, 00, 00, 00, 00, 00, 00,...
Page 67 UP-120B Specifications of separately sold items Input cables PK-01855 Sub- Length Remarks -002 Specifications of CE marking-compliant cable -005 500 VAC min. Line voltage Standard -010 300 VAC min Line-to-ground Volt -015 Cross section -020 Number of cores -102 3000V...
Page 68 UP-120B 890mm Belt Duty cycle 8 , 200A 2 0 0 Pul se w i dth: 4 5 0 s m a x . 1 8 0 A m bi ent t em p: 4 0 1 6 0 12. 5 , 150A...
Page 69 9-10...
Page 70 9-11...
Page 73: Outline
UP-120B 10. Outline 10-1...
Page 74 UP-120B 10-1...
Page 75: Troubleshooting
UP-120B 11. Troubleshooting If this Power Supply has trouble, UP-627A displays the fault code and message; UP-628A, fault code. In this case, read this section carefully, then inspect the equipment and take necessary countermeasures. If you have any questions, consult Unitek Miyachi Corp. or your distributor.
Page 76 UP-120B Fault Contents Cause Countermeasures code Counted number of welds is Add number of welds to make Insufficient less than WELD COUNT up for insufficiency. (Page E-08 number of weld setting. counts 3-17) STEPPER COUNT finished Dress or replace tip, then reset...

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