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Miyachi STA-100A Operation, Maintenance And Service Manual

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USER'S MANUAL NO. 990-350
REVISION E: January 2002
OPERATION, MAINTENANCE
AND SERVICE MANUAL
FOR THE
STA-100A
AC CONTROL
Version 2.11 Software

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Summary of Contents for Miyachi STA-100A

  • Page 1 USER’S MANUAL NO. 990-350 REVISION E: January 2002 OPERATION, MAINTENANCE AND SERVICE MANUAL FOR THE STA-100A AC CONTROL Version 2.11 Software...
  • Page 2 Copyright © 2000, 2002, 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.
  • Page 3 FOREWORD Thank you for purchasing a Miyachi STA-100A AC Control. This unit is a component of a larger resistance welding system. 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 Miyachi 245 E.
  • Page 4 SAFETY NOTES This instruction manual describes how to operate, maintain and service the STA-100A AC Timer, and provides instructions relating to its SAFE use. For SAFETY, and to effectively take advantage of the full capabilities of the workstation, please read these instructions before attempting to use the workstation.

  • Page 5: Table Of Contents

    System Wide Values Screen ................3-7 Extended System Wide Values Screen ..............3-8 System Valve Status Screen................. 3-10 Valve Screen ......................3-10 Mode Screen ......................3-11 Linked Schedules Screen ..................3-14 Monitor Screen..................... 3-15 Stepper Screen ..................... 3-16 STA-100A AC CONTROL 990-350...
  • Page 6 Key Lock (Optional) .................... 5-9 SCR Assembly, 300 Amp, Air Cooled (Optional) ..........5-10 SCR Assembly, 600 and 1200 Amp, Water Cooled (Optional) ......5-10 Spare Parts Kit ......................... 5-13 Section III: Repair Service ......................5-13 STA-100A AC CONTROL 990-350...
  • Page 7 INDEX ..............................Index-1 ILLUSTRATIONS Figure Title Page STA-100A AC Control, Major Components ................1-2 Controls and Indicators ........................ 1-3 Installing Mounting Tabs onto Cabinet ..................2-2 Power Connection Points ......................2-3 Placement of Secondary Current Sensor Toroidal Coil ............... 2-4 Wiring Connections to Valve (Input Power) Transformer ............
  • Page 8 TABLES Table Title Page Valve Transformer Fuse Selection....................4-1 Spare Parts Kit, 4-35732-01 ......................5-13 STA-100A AC CONTROL viii 990-350...

  • Page 9: Chapter 1: Description

    CHAPTER 1 DESCRIPTION Section I: Features The STA-100A AC Control, herein called the “Control,” is a device for controlling single-phase AC welding. It has the following features: • Multiple pulse capability • Controlled current ramps • 300, 600, or 1200 amp SCRs with constant current control •...
  • Page 10 Components of Control with 300A (Air Components of Control with Cooled) SCR and Connector for 600A/1200A (Water Cooled) SCR and Secondary Current Sensor Input Primary Current Sensor Figure 1-1. STA-100A AC Control, Major Components Figure 1-1. STA-100A AC Control, Major Components STA-100A AC CONTROL 990-350...

  • Page 11: Controls And Indicators

    At the completion of making Schedule Program changes, pressing the PROGRAM/SAVE switch again, saves all program changes and places the Control into Run mode. During Run Mode, the DATA ON/OFF pushbutton switch will be disabled, preventing the operator from modifying programs. STA-100A AC CONTROL 990-350...
  • Page 12 Mode screen to appear on the display. See Chapter 3 for details of this screen. RESET pushbutton switch – Pressing this pushbutton switch will reset Control after a major error signal is received. (Major errors are Emergency Stop, Over-temperature, No Current, Mode Change Error, End STA-100A AC CONTROL 990-350...

  • Page 13: Internal Access

    (CT1) is already mounted in the bottom of the Control cabinet (figure 1-1). Water Connections The 600A and 1200A SCRs require cooling water, which enters the Control through fittings on the bottom of the Control. STA-100A AC CONTROL 990-350...

  • Page 15: Chapter 2: Getting Started

    See Appendix A, Technical Specifications, for SCR cooling water requirements. The connections to the SCR are made with ¼-18 NPT fittings through the bottom of the Control cabinet. It is recommended that filtered water be used to prevent sediment build-up in the hoses and SCR. STA-100A AC CONTROL 990-350...

  • Page 16: Section Ii: Control Set-Up

    300 amp SCRs. Loosely install the two Typical Mounting lower mounting screws. Bracket and Screw Slide the Control bottom (slotted) tabs into the two lower Figure 2-1. Installing Mounting Tabs onto Cabinet mounting screws. With STA-100A AC CONTROL 990-350...

  • Page 17: Electrical Connections

    Perform this step only if you do not have optional Terminal Block L2. Connect the second wire from the weld transformer (H2-1) to the line 2 (L2) wire in accordance with all applicable codes. (See Appendix C for appropriate wire gauge.) STA-100A AC CONTROL 990-350...

  • Page 18: Secondary Current Sensor

    Descriptions of these signals follow their respective figure. With the exception of the valve outputs, all output signals are isolated contact relays. Valve outputs may be either 115 VAC (standard) or 24 VAC. Input signals are referenced to either an internal or external 24 VDC power supply. STA-100A AC CONTROL 990-350...
  • Page 19 CHAPTER 2: GETTING STARTED Figure 2-5. Input/Output Control Signals STA-100A AC CONTROL 990-350...

  • Page 20: Input/Output Signal Descriptions

    FR1 – Fault Reset Input – Input signal that resets a fault condition and clears the fault output. After an EMO (Emergency Stop), a fault reset input will re-boot the system. IN1 – General Purpose Input 1 – Unused IN2 – General Purpose Input 2 – Unused STA-100A AC CONTROL 990-350...
  • Page 21 VAL5, N & L through VAL12, N & L – Valve Output 5 Neutral and Line through Valve Output 12 Neutral and Line – Output signals to drive up to eight additional valves. Each set of connections provides 115 VAC (standard) or 24 VAC (optional) power to the valve solenoid connected across those connections. STA-100A AC CONTROL 990-350...

  • Page 23: Chapter 3: Operating Instructions

    *** INSTALLED BOARDS *** will be displayed briefly, followed by one of the following messages. If there are no expansion cards present, the message will be: Figure 3-1. Control Panel with Introductory Screen and Indicators NO EXPANSION CARDS DETECTED STA-100A AC CONTROL 990-350...

  • Page 24: Pre-Operational Setup

    00 00 00 00 00 00 00 00 00 00 00 00.0KA 00.0KA ELECTRODE VALVE=01 AND SCR # 1 IMPULSE=01 TURNS RATIO 053:1 COPY TO # 00 PLUS 01 FULL CURR. 05KA SHOW SYSTEM VALUES WELD COUNT 0000 Figure 3-2. Typical Initial Schedule Screen STA-100A AC CONTROL 990-350...
  • Page 25 If any changes have been made in any data field, the system will prevent the operator from changing to a different schedule until the changes have been accepted or rejected. The operator will get the following message: STA-100A AC CONTROL 990-350...
  • Page 26 000% to 100% (figure 3-5). The minimum conduction angle is 20 degrees of power at a power factor of 1.0. As the power factor decreases, the minimum conduction angle may increase. When CONTROL MODE is set to PRI C.C. or SEC. C.C., the current setting is programmable from STA-100A AC CONTROL 990-350...
  • Page 27 00 00 00 00 00 00 00 00 00 00 00 00.0KA 00.0KA ELECTRODE VALVE=01 AND SCR=1 IMPULSE=01 COIL X01 COPY TO # 00 PLUS 00 FULL CURR. 05KA SHOW SYSTEM VALUES WELD COUNT 0000 Figure 3-7. Schedule Screen Secondary Constant Current Mode STA-100A AC CONTROL 990-350...
  • Page 28 It is programmable in the System Wide Values Screen (below) from 1 to the number of SCRs in the control, however , the STA-100A is limited to one SCR. COPY TO # – Copying a schedule ––this includes all functions such as valves, etc.––to another schedule is done by changing the schedule number to the (new) desired schedule number.

  • Page 29: System Wide Values Screen

    CNTRL MODE – Control Mode (CNTRL MODE) allows the operator to set the control mode of operation. The four modes are: • %HEAT – Percent Heat • %HEAT SEC. – Percent Heat Secondary • PRI. C.C. – Primary Constant Current • SEC. C.C. – Secondary Constant Current STA-100A AC CONTROL 990-350...

  • Page 30: Extended System Wide Values Screen

    87° DELAY - This control turns the 87° Delay Mode ON or OFF. This mode is used with Hypersil transformers to limit the firing of the SCR to 87° on the first half cycle thereby preventing saturation of the transformer. STA-100A AC CONTROL 990-350...

  • Page 31: System Valve Status Screen

    Stepper function. The number displayed is the total count of welds performed on each valve by all schedules. The operator can set this count to zero by placing the cursor at the ↵ symbol and pressing the DATA + key. STA-100A AC CONTROL 990-350...
  • Page 32 CHAPTER 3: OPERATING INSTRUCTIONS STA-100A AC CONTROL 3-10 990-350...
  • Page 33 CHAPTER 3: OPERATING INSTRUCTIONS The number of valves displayed on the screen will be either 4 or 12, depending on the option selected at the System Wide Values Screen. STA-100A AC CONTROL 990-350 3-11...

  • Page 34: Valve Screen

    The screen will show entries for the correct number of valves in that particular unit. The Valves screen consists of the following settings (figure 3-11): SCHEDULE #01 VALVE ELECTRODE VALVE 01 STATUS COUNT 1=ON 00200 2=OFF 00000 3=OFF 00000 4=OFF 00000 Figure 3-11. Valve Screen STA-100A AC CONTROL 3-12 990-350...

  • Page 35: Mode Screen

    SCHEDULE # - The schedule number is used to select the program for making parameter settings. Entering a particular schedule number will cause the previously selected parameters for that schedule to be displayed. The schedule is programmable from 00 to 63. STA-100A AC CONTROL 990-350 3-13...
  • Page 36 Start signal. There is a pause between each schedule until a new Start signal is received. To set up a succession, select the first desired schedule, then turn Successive Mode ON at the Mode screen. Repeat the procedure for subsequent schedules in the succession. Then link the STA-100A AC CONTROL 3-14 990-350...
  • Page 37 It tells the operator whether the binary selective input is active. That is, whether or not the Control is slaved to external logic, such as a separate Programmable Logic Controller (PLC). If OFF, the binary inputs are ignored and control will default to the schedule presented on the control panel. STA-100A AC CONTROL 990-350 3-15...

  • Page 38: Linked Schedules Screen

    Reference Number – This left-hand column of figures, labeled 01., 02., 03., and so on up to 64., provides a reference for the operator’s convenience. Pressing the up or down key shall scroll through all reference numbers, rolling over from largest to smallest and vice versa. STA-100A AC CONTROL 3-16 990-350...

  • Page 39: Monitor Screen

    The operator will get the following message: MODIFIED SCHEDULE NOT SAVED. PRESSING THE PROGRAM/SAVE KEY SAVES MODIFICATIONS, THEN PRESS DESIRED SCREEN BUTTON AFTER SAVING. OR PRESS PLUS OR MINUS KEY TO LOSE MODIFICATIONS STA-100A AC CONTROL 990-350 3-17...

  • Page 40: Stepper Screen

    This is done by adjusting power to compensate for the electrode deformation. An example of how the stepper functions is shown in figure 3-16. The screen consists of the following: STA-100A AC CONTROL 3-18 990-350...
  • Page 41 Set value of Step 3 Set value of Step 2 Set value of Step 1 (Fixed to 100%) Number of welds Step 2 Step 3 Step 4 Step 5 Figure 3-16. Example of Stepper Function STA-100A AC CONTROL 990-350 3-19...

  • Page 42: Section Iii: Setup Messages

    You may receive one of the following messages during set-up of the Control. The message tells you what corrective action should be taken. If you cannot correct the action by performing these instructions, contact your Miyachi representative. SCHEDULE 01 WELD 1 CURRENT LESS THAN 20% OF SYSTEM FULL CURRENT.
  • Page 43 OR PRESS SCHEDULE KEY TO VIEW OR CHANGE THESE TIMES MODIFIED SCHEDULE NOT SAVED. PRESSING THE PROGRAM/SAVE KEY SAVES MODIFICATIONS, THEN PRESS DESIRED SCREEN BUTTON AFTER SAVING. OR PRESS PLUS OR MINUS KEY TO LOSE MODIFICATIONS STA-100A AC CONTROL 990-350 3-21...
  • Page 44 GREATER THAN SYSTEM FULL CURRENT ENTER THE SYSTEM VALUES SCREEN AND CHECK FULL CURR. WELD 2 STEP CURRENT MUST BE LESS THAN THIS. STEP CURRENT IS THE PRESENT STEP NUM’S HEAT % TIMES WELD 2 CURRENT. STA-100A AC CONTROL 3-22 990-350...

  • Page 45: Section Iv: Operation

    87 In % Heat Mode, the conduction angle depends on both the user-programmed % Heat and the power factor of the secondary circuit. Changes in that power factor can result in changes of the measured conduction angle even though there are no programmed changes to the % Heat. STA-100A AC CONTROL 990-350 3-23...

  • Page 46: Programming Examples

    ***SAVING*** will flash briefly on the top of the screen. 11.11 If operating in Local Mode, press the WELD ON/OFF button to put the control into the ready to weld mode. 12.12 Actuate the Start signal to begin welding. STA-100A AC CONTROL 3-24 990-350...

  • Page 47: Continuous Seam Weld

    ***SAVING*** will flash briefly on the top of the screen. 13.13 If operating in Local Mode, press the WELD ON/OFF button to put the control into the ready mode. 14.14 Actuate the Start signal to begin welding. STA-100A AC CONTROL 990-350 3-25...

  • Page 48: Section Vi: Operational Messages

    You may receive one of the following error messages during set-up or operation of the Control. The message tells you what corrective action should be taken. If you cannot correct the action by performing these instructions, contact your Miyachi representative. Major Run-Time Error Messages...
  • Page 49 3. INCREASE W1 HIGH LIMIT AT THE MONITOR SCREEN. PRESS RESET BUTTON TO RESUME WELDING. SCHEDULE 01 WELD 1 CONDUCTION ANGLE EXCEEDED LIMIT. PRESS RESET BUTTON TO RESUME WELDING. IF PROBLEM CONTINUES, INCREASE THE W1 COND. LIMIT AT THE MONITOR SCREEN. STA-100A AC CONTROL 990-350 3-27...
  • Page 50 3. PUSH RESET TO CONTINUE WITH THIS SCHEDULE (AND REDISPLAY THIS MSG). ** IMPROPER SCHEDULE NUMBER DETECTED ** FOUND AN OUT OF RANGE SCHEDULE NUMBER. VALID NUMBERS ARE 00 – 63. PRESS THE RESET KEY AND CONTINUE. STA-100A AC CONTROL 3-28 990-350...

  • Page 51: Minor Run-Time Error Messages

    PRESS RESET BUTTON TO RESUME WELDING. SCHEDULE 01 REACHED THE LAST STEP COUNT FOR CURRENT STEP. THE NEXT WELD WILL MODIFY WELDING CURRENT USING THE PERCENTAGE FACTOR SPECIFIED IN THE NEXT STEP OF THE CURRENT STEPPER SCHEDULE. STA-100A AC CONTROL 990-350 3-29...
  • Page 52 *** ADVISORY MESSAGE ONLY *** HIGH LINE VOLTAGE WAS DETECTED. CHECK LINE VOLTAGE AND PRESS RESET KEY TO CONTINUE. *** SCALE CURRENT ERROR *** SCALED CURRENT WAS GREATER THAN MAX. PRESS RESET KEY TO CONTINUE STA-100A AC CONTROL 3-30 990-350...

  • Page 53: Section Vii: Shutdown

     Reset the Control either by pressing the front panel RESET switch or providing an external reset signal. The Control will re-boot following the Reset signal. Set the Control to the desired schedule. Normal Shutdown Turn off power from the external, customer-supplied circuit breaker or power contactor. STA-100A AC CONTROL 990-350 3-31...

  • Page 55: Section I: Maintenance Precautions

    Table 4-1. Valve Transformer Fuse Selection Transformer Rating Fuse Size Part Number 115VAC, 50 VA FNM-2 115VAC, 150 VA FNM-3 115VAC, 250 VA FNM-6 24VAC, 50 VA FNM-10 24VAC, 150 VA FNM-15 24VAC, 250 VA FNM-30 STA-100A AC CONTROL 990-350...

  • Page 57: Chapter 5: Service

    Transformer shown AC Timer Expansion wired for 460V; see Main Board Board, A4 Wiring Diagram for (Optional) Surge 230V configuration. Resistors Control Panel Assembly, A3 Lock Power Transformers Load 2 Figure 5-1. Control, Simplified Block Diagram STA-100A AC CONTROL 990-350...

  • Page 58: Fuse Replacement

    Control. Any exceptions will be clearly noted. AC Timer Main Board, A1 To replace the AC Timer Main Board, A1, located on the right side, perform the following steps: STA-100A AC CONTROL 990-350...

  • Page 59: Scr Driver Board, A2

    Two wire cable from the primary current sensor or the secondary current sensor connector connected to J11. b Two wire cable from the Valve Expansion Card, A4, connected to J16 and the 26 wire ribbon cable from the same circuit board connected to J5. STA-100A AC CONTROL 990-350...
  • Page 60 J1. Figure 5-3. SCR Drive Board, A2, Connector Locations 2 Remove the four 6-32x3/8 socket head screws, spring lock washers, and flat washers that secure the circuit board to the Control and remove the board. STA-100A AC CONTROL 990-350...
  • Page 61 4 Reconnect the following cable connectors to the indicated jacks on the assembly: Thirty-four wire ribbon cable connector from the AC Timer Main Board, A1, to J2. b (Optional) two wire cable connector from control panel key switch to J3. STA-100A AC CONTROL 990-350...

  • Page 62: Valve Expansion Board, A4 (Optional)

    Valve Transformer, T3 To replace the Valve Transformer T3, on the bottom of the Control, perform the following steps: 1 Remove the following four transformer terminals: H1 (yellow), H4 (orange and gray), XF (red), and X2 (black). STA-100A AC CONTROL 990-350...

  • Page 63: Power Transformer, T2

    4 Install a new transformer (or re-install the old one if it is being used) by supporting it with one hand while attaching it to the inside top of the Control with the two 4-40 nuts. 5 Reconnect the transformer cable connector to AC Timer Main Board, A1 connector J17. STA-100A AC CONTROL 990-350...

  • Page 64: Surge Resistors

    1 Loosen the slot head set screw and remove the ground wire. 2 Remove the 10-32 x 1/2 Phillips head screw, #10 internal tooth lock washer, and #10 flat washer attaching the terminal block to the Control. STA-100A AC CONTROL 990-350...

  • Page 65: Primary Current Sensor (Optional)

    3. Install a new key lock (or re-install the old one if it is being used) by sliding it into the double “D” hole in the Control and securing from inside with the nut that comes with the switch. 4. Reconnect the two-wire cable to connector J3 of the Control Panel Assembly. STA-100A AC CONTROL 990-350...

  • Page 66: Scr Assembly, 300 Amp, Air Cooled (Optional)

    SCR assembly containing the load cable. 5 Loosen the two slot head set screws and remove the line and load wires. 6 Disconnect the cable connector from the SCR Drive Board, A2, connector J2. STA-100A AC CONTROL 5-10 990-350...
  • Page 67 14 Turn on the water supply to the cooling hoses going to the SCR assembly. Check for leaks. 15 If the Control has been modified for an external transformer thermostat (see Appendix E), the modification described in Appendix E must also be performed on this new SCR assembly . STA-100A AC CONTROL 990-350 5-11...
  • Page 68 CHAPTER 5: SERVICE (ribbon) 28 Ga (all) 18 Ga STA-100A AC CONTROL 5-12 990-350...

  • Page 69: Spare Parts Kit

    625-038 Washer, flat, #6 755-343 Additional parts are available by contacting Miyachi at the address/numbers indicated in the foreword of this manual, or your local Miyachi distributor. Section III: Repair Service If you have problems with your unit 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.
  • Page 71 Eight additional user-programmable valve outputs (optional). 115 VAC (24 VAC optional) at 50 VA (standard) or 150 VA or 250 VA (optional) Output Signals Four outputs, triac, 1 A, 125 VAC max. Functions are under program control. STA-100A AC CONTROL 990-350...
  • Page 72 *Resistive load regulation ±2% of set point for ±15% load induction fluctuation *Inductive load regulation ±1% of set point of full scale after initial response *Average Current Accuracy *For welds between 20% and 95% of full current STA-100A AC CONTROL 990-350...
  • Page 73 APPENDIX A: TECHNICAL SPECIFICATIONS Outline Drawings NOTE: Measurements are in inches STA-100A AC CONTROL 990-350...
  • Page 75 = Debounce Period (30-70 ms) = Hold Period (SQD + SQZ) = End of Weld Signal (40-70 ms, minimum). Signal will be held until Start signal(s) are removed. Figure B-1. Pulsed, Latched, and Maintained Start Signals STA-100A AC CONTROL 990-350...
  • Page 76 The microprocessor requires up to 70 ms of calculation time upon closure of FS1 and 50 ms of calculation of FS2. Valves and current may have a different calculation time. Calculation of weld results may require 15-35 ms at the end of each weld period. Figure B-2. Continuous Seam Weld STA-100A AC CONTROL 990-350...
  • Page 77 The microprocessor requires up to 70 ms of calculation time upon closure of FS1 and 50 ms of calculation of FS2. Valves and current may have a different calculation time. Figure B-3. Roll Spot Seam Weld STA-100A AC CONTROL 990-350...
  • Page 78 The microprocessor requires up to 70 ms of calculation time upon closure of FS1 and 50 ms of calculation of FS2. Valves and current may have a different calculation time. Calculation of weld results may require 15-35 ms at the end of each repeat period. Figure B-4. Spot Welding STA-100A AC CONTROL 990-350...
  • Page 79 The microprocessor requires up to 70 ms of calculation time upon closure of FS1 and 50 ms of calculation of FS2. Valves and current may have a different calculation time. Figure B-5. Spot Welding with 3 Impulses STA-100A AC CONTROL 990-350...
  • Page 80 Sched A Sched B Sched C Sched A Chained Initiation required only once at beginning. Control defaults to first schedule start signal for all linked schedules. Early release aborts in Maintained Mode. Figure B-6. Linked Schedules STA-100A AC CONTROL 990-350...
  • Page 81 Schedule 58      Schedule 59     Schedule 60      Schedule 61      Schedule 62       Schedule 63 STA-100A AC CONTROL 990-350...
  • Page 83 Table C-1. SCR Selection SCR Current 230V 460V Rating SCR 50% Equivalent Equivalent 100% Continuous Current Continuous Current 30-Cycle Current Demand Demand Current Demand Demand Current Weld Rating Current Rating (A) 1100 1200 1800 1250 1250 STA-100A AC CONTROL 990-350...
  • Page 84 Table C-3. Wire Gauge Based on Ampacity. 230V AC Mains 460V AC Mains Rated kVA Rated kVA 2x4/0 2x250 2x300 2x500 1031 1179 2x4/0 1473 2x250 2x300 2x400 2x500 1031 1179 1326 1000 1473 1200 1768 STA-100A AC CONTROL 990-350...
  • Page 85 3.153E-01 2.880E-02 8.640E-02 2.758E-01 1042 2.304E-02 6.912E-02 2.207E-01 1250 1.920E-02 5.760E-02 1.839E-01 1458 1.646E-02 4.937E-02 1.576E-01 1667 1.440E-02 4.320E-02 1.379E-01 1875 1.280E-02 3.840E-02 1.226E-01 1000 2083 1.152E-02 3.456E-02 1.103E-01 2x250 1200 2500 9.600E-03 2.880E-02 9.195E-02 2x300 STA-100A AC CONTROL 990-350...
  • Page 87 Existing SCR thermostat wires (2 red) Driver Board Thermostat Cut at tag "5" To Normally- DO NOT REMOVE Closed (NC) JUMPER Transformer Thermostat +24V PULLUP COM AC Timer Main Board, A1 Figure D-1. Adding Thermostat Relay for External Weld Transformer STA-100A AC CONTROL 990-350...
  • Page 89 The communications option uses either RS-232 to connect one control to one host or RS-485 multi-drop architecture to connect up to 30 controls to one host on a single channel. Miyachi’s Weldlab software allows you to connect a single or multiple Controls to a computer in order •...
  • Page 90 (such as the Telebyte model 285), the host computer should be at least a Pentium III-550 running Windows 98, Windows ME, Windows 2000, Windows XP or Windows NT 4.0. STA-100A AC CONTROLSSTA-200 A AC CONTROL 990-351350...
  • Page 91 This is optional BINARY data. Multiple binary byte ordering [MSB][…][LSB]. <cksum> 2 BYTES This is a two charter ASCII HEX string calculated from the sum of all fields except <soh>, <cksum>, and <eot>. Then masked CONTROLSSTA-200 A AC CONTROL STA-100A AC 990-351350...
  • Page 92 ‘8’ Output timeout Valid Commands A valid command will return EITHER data OR <ACK> (0x06). <soh> <@> <ACK> <cksum> <eot>. Data will be returned with the following structure: <soh> <@> <cmd> <cnt> <data> <cksum> <eot> STA-100A AC CONTROLSSTA-200 A AC CONTROL 990-351350...
  • Page 93 2 Bytes WELD1 # (Weld Time), 2 Bytes DOWN1 # (Down Slope Time), 2 Bytes COOL # (Cool Time), 2 Bytes UP2 # (Up Slope Time), 2 Bytes WELD2 # (Weld Time), 2 Bytes CONTROLSSTA-200 A AC CONTROL STA-100A AC 990-351350...
  • Page 94 15 Bytes Total ------------------------------------------------------------------------- start value: MAINTAINED = 0, PULSED = 1, LATCHED = 2, SEAM =3 ------------------------------------------------------------------------- weld mode: SPOT = 0, REPEAT = 1, SUCCESSIVE = 2. CHAINING = 3. ------------------------------------------------------------------------- STA-100A AC CONTROLSSTA-200 A AC CONTROL 990-351350...
  • Page 95 1 Byte VALVE 9 {ON=1 | OFF=0} 1 Byte VALVE 10 {ON=1 | OFF=0} 1 Byte VALVE 11 {ON=1 | OFF=0} 1 Byte VALVE 12 {ON=1 | OFF=0} 1 Byte 14 Bytes Total CONTROLSSTA-200 A AC CONTROL STA-100A AC 990-351350...
  • Page 96 {ON | OFF | LOCAL | REMOTE} 1 Byte LOW LINE ALARM {ON | OFF} 1 Byte BINARY SCHEDULE {0=Local, 1=Host} 1 Byte Freq REQ (Read only) {0=60hz, 1=50hz} 1 Byte 17 Bytes Total STA-100A AC CONTROLSSTA-200 A AC CONTROL 990-351350...
  • Page 97 "RT" Read Read Time Offset in cycles since power-up or reset 4 Byte <ACK> OR <NAK> 0 Byte LINK "KS" Set <ACK> OR <NAK> 0 Bytes "KR" Read SCHEDULE #, SCHEDULE #, 64 Bytes CONTROLSSTA-200 A AC CONTROL STA-100A AC 990-351350...
  • Page 98 2 Bytes CURRENT # (Energy 0-80.0kA), 2 Bytes CURRENT #2 See Note [1], 2 Bytes IMPULSE (0-25) 1 Byte SCR # (1-8) 1 Byte NOTE [1]: 8000 = 80.0kA 33 Bytes Total STA-100A AC CONTROLSSTA-200 A AC CONTROL E-10 990-351350...
  • Page 99 Bit 2 No current Bit 3 Mode change error Bit 4 Shorted SCR Bit 5 Weld 1 current high Bit 6 Weld 2 current high Bit 7 Weld 1 conduction angle high CONTROLSSTA-200 A AC CONTROL STA-100A AC 990-351350 E-11...
  • Page 100 System valve screen – 4 valve option System valve screen – 12 valve option Full current error screen Weld 1 current greater than full current error screen Weld 2 current greater than full current error screen STA-100A AC CONTROLSSTA-200 A AC CONTROL E-12 990-351350...
  • Page 101 Roll spot weld enabled mode screen Schedule number error screen System values continuation screen Schedule W1 and W2 times set to 0 error screen Pixel test info screen Not used Not used CONTROLSSTA-200 A AC CONTROL STA-100A AC 990-351350 E-13...
  • Page 102 VALVE 10 {ON=1 | OFF=0} 1 Byte VALVE 11 {ON=1 | OFF=0} 1 Byte VALVE 12 {ON=1 | OFF=0} 1 Byte 14 Bytes Total SCR's “UR” Read <ACK> OR <NAK> 0 Bytes STA-100A AC CONTROLSSTA-200 A AC CONTROL E-14 990-351350...
  • Page 103 Valve 9 scr # Count 5 Bytes Valve 10 scr # Count 5 Bytes Valve 11 scr # Count 5 Bytes Valve 12scr # Count 5 Bytes (1-8) (0-99999) 60 Bytes Total CONTROLSSTA-200 A AC CONTROL STA-100A AC 990-351350 E-15...
  • Page 104 Primary C. Current = 0, Secondary C. Current = 1, % Heat = 2, % Heat Secondary = 3. ------------------------------------------------------------------------- seam mode: Spot = 0, Continuous Seam = 1, Roll Spot = 2. ------------------------------------------------------------------------- STA-100A AC CONTROLSSTA-200 A AC CONTROL E-16 990-351350...
  • Page 105 Detailed Schedule Screen Detailed SYSTEM WIDE VALUES Initialization Full Current FULL CURR. Maximum Number of SCRs MAX # OF SCR Turns Ratio TURNS RATIO 053:1 Control Mode CNTRL MODE %HEAT Binary Schedule Selected BIN. SCHED. SELECT STA-100A AC CONTROLS 990-350...
  • Page 106 Step 5 Count COUNT 1000 Step 6 Count COUNT 1200 Step 7 Count COUNT 1400 Step 8 Count COUNT 1600 Step 9 Count COUNT 1800 Step 10 Count COUNT 2000 Step 1 Heat % HEAT% FIXED (100%) STA-100A AC CONTROLS 990-350...
  • Page 107 Step 5 Heat % HEAT% 110% Step 6 Heat % HEAT% 120% Step 7 Heat % HEAT% 125% Step 8 Heat % HEAT% 125% Step 9 Heat % HEAT% 125% Step 10 Heat % HEAT% 125% STA-100A AC CONTROLS 990-350...
  • Page 109 External transformer thermostat, Major ............1-1 modification ........D-1 Major, location ........1-2 Replacement ..........5-2 Connections Features of STA-100A ......... 1-1 Cooling water hoses ........ 2-4 Foreword ............iii Electrical ..........1-5, Fuse replacement.......... 4-1, Input/Output signals ........ 2-4 Water ............
  • Page 110 Ground terminal block ......5-8 Monitor screen ..........3-15 Key lock ........... 5-9 Mounting Holes ........... 1-5 L2 Terminal block ........5-8 Mounting requirements ........ 2-1 Lock, key ..........5-9 Mounting the STA-100A ......2-2 STA-100A AC CONTROL INDEX-2 990-350...
  • Page 111 ....D-1 Schedule ..........3-2 Valve, T3, replacement ......5-6 Stepper ............. 3-16 Power, T1, T2, replacement ....5-7 System valve status ........3-9 Turning equipment on ........3-1 System wide values ......... 3-7 STA-100A AC CONTROL 990-350 INDEX-3...
  • Page 112 Weld programming examples ..... 3-27 Replacement ..........5-6 Continuous seam weld ......3-23 Valve transformer, T3, replacement ... 5-6 Spot welds ..........3-22 Valve screen ..........3-10 Wiring Diagram ........... 5-12 Wire gauges..........2-3, C-1 – C-3 STA-100A AC CONTROL INDEX-4 990-350...

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