Unitek Peco PHASEMASTER 6 Manuals

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Unitek Peco PHASEMASTER 6 User Manual

Unitek Peco PHASEMASTER 6 User Manual (69 pages)

DIRECT ENERGY WELDING CONTROL

Brand: Unitek Peco | Category: Controller | Size: 0 MB

Table of Contents

Revision Record
2
Foreword
3
Safety Notes
4
Table of Contents
5
Chapter 1: Description

12
- Section I. Features
  12
- Features
  12
- Process Definitions
  13
- Sequence Welding Function
  13
- Weld Schedule
  13
- Remote Weld Schedule Selection
  13
- Run State
  14
- Program State
  14
- Section II. Major Components
  15
- Front Panel Description
  15
- Front Panel Keys and Switch
  15
- Indicators and Displays
  16
- Rear Panel
  18
Chapter 2: Getting Started

19
- Section I. Planning for Installation
  19
- Location
  19
- Power Line
  19
- Welding Cables
  19
- Output Cable
  21
- Initiation Switch Connection
  21
- Firing Switch
  21
- Optical Firing Switch
  21
- Installing Air Actuated Weld Heads
  22
- Air Valve Driver
  23
- Footswitch
  24
- 1-Level Footswitch
  24
- Footswitch Weld Abort
  24
- Replace Cover
  25
- External Inputs Connections
  26
Chapter 3: Operating Instructions

29
- Section I. Operation
  29
- Power up
  29
- Select Run or Program State
  29
- Select Schedule
  29
- Change Schedule Parameters
  29
- Change Parameters for Schedules 1 through 7
  31
- Copying Information in Schedule 0 to Another Schedule
  32
- Alarms
  32
- SCR Alarm A1
  32
- Machine Alarm A2
  32
- Machine Alarm A3
  33
- Machine Alarm A4
  33
- Machine Alarm A5
  33
- Section II. Programmable Options
  33
- Status Display
  33
- Schedule Protection Feature
  35
- Line Voltage Compensation Feature
  35
- Line Voltage Compensation Feature on
  36
- Line Voltage Compensation Feature off
  36
- Alarm Display
  36
- Change Schedule Protection
  38
- Schedule Protection Feature on
  38
- Schedule Protection Feature off
  38
- Section III. Adjusting Weld Heads
  39
- Adjusting Air Actuated Weld Heads
  39
- Measuring Preset Firing Force of the Weld Head with a Force Gauge
  40
- The Weld
  40
- Section IV. Developing Weld Schedules
  41
- Resistance Welding Parameters
  41
- Weld Schedule Development
  41
- Weld Head Parameters
  42
- Welding Transformer Parameters
  43
- PM6 Control Parameters
  44
- Making a Weld
  44
- Evaluating the Weld
  45
- Weak Weld
  45
- Electrode Sticking
  45
- Electrode Force and %CURRENT
  46
- Causes of Imperfect Welds
  46
- Polarity
  46
- Output Voltage Vs Weld Quality
  47
- Test Condition a
  48
- Test Condition B
  48
- Weld Strength Profiles
  49
- Destructive Testing
  49
- Typical Weld Strength Profile
  49
- Evaluate Results
  50
- Electrode Maintenance
  50
Chapter 4: Maintenance

51
- Modification and Calibration
  51
- Cover Removal
  51
- Line Voltage Modification
  51
- Calibration Check
  52
- Control Transformer Inside the PM6, Connected for 230V
  52
- Check Weld/No Weld Switch
  53
- Half Cycle Symmetry
  53
- Line Count
  53
- Memory Initialization
  54
- Repair Service
  54
- Telephone Service
  54
- Factory Service Repair
  54
Appendix A: Technical Specifications

55
- Section I. Specifications
  55
- Line Voltage
  55
- 50/60 Hz Operation
  55
- Output Current Vs Duty Cycle
  55
- Weld Schedules
  55
- Schedule Protection Feature
  56
- Sequence Welding Function
  56
- Squeeze Period
  56
- Weld Period
  56
- Weld Current
  56
- Hold Period
  56
- Automatic Line Voltage Compensation
  57
- Polarity Selection
  58
- Power Factor Correction
  58
- Head Type
  58
- Valve Driver
  58
- Footswitch
  59
- Initiation
  59
- Footswitch Weld Abort on
  59
- Footswitch Weld Abort off
  59
- Footswitch Weld Abort On/Off
  60
- Alarms
  60
- Alarm Buzzer
  60
- Front Panel Switches
  61
- Input/Output Cable Connectors and Fusing
  61
- Circuit Breakers and Fuses
  61
- Input and Output Cables
  62
- Firing Switch Cable
  62
- Optical Firing Switch Connector
  62
- Footswitch Connector
  63
- Valve Driver Connector
  63
- External Inputs Connector
  63
- Emergency Stop
  64
- Remote Weld Inhibit
  64
- Remote Weld Schedule Selection (PM6)
  64
- Physical Characteristics
  65
- PM6 Outline Drawing
  66
- Section II. UNIPULSE Transformer Specifications and Features
  67
- Transformer Specifications
  67
- Transformer Physical Characteristics
  68
- Input Connector
  68
- UNIPULSE Welding Transformers
  68
- Forced Air Option
  69
- Maximum Repetition Rate
  69
- Transformer Primary Tap Switch
  69
- Duty Cycle
  69

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