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Miyachi Unitek 100DP User Manual

Dual pulse stored energy resistance welding power supplies
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USER'S MANUAL
Revision B
100DP/300DP DUAL PULSE
RESISTANCE WELDING POWER SUPPLIES
990-295
June 2007
STORED ENERGY
Model
100DP/115
100DP/230
300DP/115
300DP/230
Stock No.
1-293-01
1-293-01-01
1-294-01
1-294-01-01

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  • Page 1 USER'S MANUAL 990-295 Revision B June 2007 100DP/300DP DUAL PULSE STORED ENERGY RESISTANCE WELDING POWER SUPPLIES Model Stock No. 100DP/115 1-293-01 100DP/230 1-293-01-01 300DP/115 1-294-01 300DP/230 1-294-01-01...

  • Page 2: Revision Record

    Copyright © 2005 Miyachi Unitek Corporation The engineering designs, drawings and data contained herein are the proprietary work of Miyachi Unitek Corporation and may not be reproduced, copied, exhibited or otherwise used without the written authorization of Miyachi Unitek Corporation.

  • Page 3: Table Of Contents

    Chapter 3. Operation Section I: Introduction ........................... 3-1 Before You Start ..........................3-1 Pre-Operational Checks ........................3-1 Connections ..........................3-1 Power ............................. 3-1 Compressed Air ........................3-1 Adjust Buzzer Loudness ........................3-1 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...
  • Page 4 Appendix B. Electrical and Data Connections ..................B-1 Appendix C. System Timing .......................C-1 Appendix D. The Basics of Resistance Welding ................D-1 Appendix E. Quality Resistance Welding Solutions: Defining the Optimum Process ....E-1 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...

  • Page 5: Contact Us

    The purpose of this manual is to supply operating and maintenance personnel with the information needed to properly and safely operate and maintain the Miyachi Unitek™ 100DP and 300DP Resistance Welding System Control. We have made every effort to ensure that the information in this manual is accurate and adequate.

  • Page 6: Safety Notes

    • Never perform any welding operation without wearing protective safety glasses. This instruction manual describes how to operate, maintain and service the 100DP and 300DP Resistance Welding Power Supplies, and provides instructions relating to its safe use. A separate manual provides similar information for the weld head used in conjunction with the power supply.

  • Page 7: Chapter 1. Description

    CHAPTER 1 Description Section I: Features Features The Miyachi Unitek 100DP/300DP Dual Pulse Resistance Welding Power Supply precisely controls welding energy and weld head timing. • Multi-function microprocessor control provides repeatable process control and is compatible with air or manually actuated weld heads.

  • Page 8: Description

    Detailed instructions on using these features are located in Chapter 3, Operating Instructions. NOTE: For the rest of this manual, the Miyachi Unitek 100DP/300DP Dual Pulse Resistance Welding Power Supply will simply be referred to as the Power Supply.

  • Page 9: Section Iii: Major Components

    Chapter 2, Installation and Setup. Front Panel Display and Display Controls The front panel of the Control below shows controls and indicators. The function of each item is described on the following pages. Front Panel Controls 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...

  • Page 10: Schedule Number And Chain Switch

    “editing” mode without accepting changes, press the clear button or any other button on the front panel. Press the button and follow the same procedures to modify Pulse 2. Pulse 2 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...
  • Page 11 VERY SHORT (VS) shortest duration for the energy setting. The setting gives the lowest LONG (L) peak current and longest duration for the energy setting. Weld Counter and Setup 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...
  • Page 12 Pressing this button for about 1 second causes the green LED on the button to go ON and the 6-digit display to blink. This allows the arrows to COUNTER increase or decrease the hold time. Pressing this button again saves the setting. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...

  • Page 13: Polarity Select

    Control), operate the switch to immediately stop the welding process. All power to the air valves and power circuits will be disconnected. The 6-digit display will show . To E-STOP resume operation, reset the to the normal position. EMERGENCY STOP SWITCH 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...

  • Page 15: Chapter 2. Installation And Setup Section I: Installation

    Verify that the Power Supply shows no signs of damage. If it does, please contact the carrier. Also, contact Miyachi Unitek Customer Service at the address, phone number, or e-mail address listed under in the front of this manual.

  • Page 16: Utilities

    PLC or other external device to supply +24VDC to activate, or to INPUTS turn an input ON. Instructions for changing this configuration, including electrical schematics, are in Appendix B. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...

  • Page 17: Section Ii: Setup

    Rear Panel Components and Connectors NOTE: The weld cable connections from the weld head are made at the weld cable terminals on the front panel. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...

  • Page 18: Weld Head Connections

    ● Do not attach the firing switch, foot switch or cables at this time. EMERGENCY STOP ● If you need additional information about the weld heads, please refer to their user’s manuals. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...

  • Page 19: Foot Pedal-Actuated Weld Head Connection

    Power Supply cannot deliver weld energy, but the firing switch connection can be verified. Set the circuit breaker on the rear panel of the Power Supply to the ON position. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...

  • Page 20: Ez-Air Weld Head Connections

    CHAPTER 2: INSTALLATION AND SETUP EZ-AIR Weld Head Connections NOTE: These instructions describe connection to the Miyachi Unitek EZ-AIR weld head. Non-EZ- AIR heads may be connected to the Power Supply but are not covered in these instructions. For non-EZ- AIR head instructions, refer to the manual provided with the specific weld head.
  • Page 21 DOWN position, and send the firing switch signal back to the Power Supply when the preset electrode force is reached. The upper electrode should then ascend smoothly back to the UP position. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...

  • Page 23: Section I: Introduction

    0 to 4. 3. When you get the loudness you like, press on the front panel to accept the PULSE SELECT change and return to normal operation. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...

  • Page 24: Initial Setup

    A good starting point is the mid-point in the range of the weld head force. 3. When you are ready to perform a weld, be sure to set the switch back to the WELD/NO WELD position. WELD 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...

  • Page 25: Section Ii. Operation

    11. To modify the hold time, press and hold the button for about 1 second. The green LED HOLD on the button goes ON and the 6-digit display begins to flash. COUNTER 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...

  • Page 26: Using The Welds Counter

    3. To accept the changes, press the button again and the LED will stop flashing. To LIMIT SET exit the “editing” mode without accepting changes, press any other button on the front panel. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...

  • Page 27: Chain Schedules 1 & 2

    The programmed values of the 15 schedules and the schedule number itself can be locked so that no changes are possible. To set this lock, connect pin 27 of the 37 pin connector to the I/O common. See Appendix B for connection details. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...
  • Page 28 12 in the 6-digit display. The threshold for detecting an open load is typically about 15 milliohms. If your application requires operation with a secondary circuit that exceeds this resistance, please contact Miyachi Unitek for assistance. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY...

  • Page 29: Section I. Troubleshooting

    2. Contaminated electrode surface 2. Wrong electrode material 2. Contaminated electrode surface Electrode 1. Contaminated weld piece surface/ Weld Piece 1. Excessive weld time set at 100DP/300DP Sticking plating Warping 1. Excessive weld head force 1. Wrong electrode material/ tip shape 1.
  • Page 30 Contact Miyachi Unitek for did not complete within 1 second service. Memory error The values stored in memory have Contact Miyachi Unitek for been corrupted. Default values have service been reloaded into the unit. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...
  • Page 31 3) Verify that the electrode is properly installed in the weldhead 4) If the process requires operation with a high secondary circuit resistance, contact Miyachi Unitek for assistance 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...

  • Page 32: Calibration

    Calibration Calibration must be performed by factory-trained and qualified personnel. If your Power Supply needs calibration, contact your local Miyachi Unitek service representative, or contact our service department at the address, phone number, or e-mail address listed under in the front of this manual.

  • Page 33: Section Iv. Repair Service

    If you have problems with your Control that you cannot resolve, please contact our service department at the address, phone number, or e-mail address listed under in the front of this manual. Contact Us 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...

  • Page 35: Appendix A. Technical Specifications

    430 V max Voltage Weld Capacitance As required to achieve Output Energy 100DP -- 100Ws Output Energy Max per pulse 300DP 300Ws Voltage turndown 50W average power. Automatic turndown upon power interruption circuit 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...
  • Page 36 1.2 ms 1.6 ms Weld schedules Weld pulses per Schedule Watt Second 100DP -- 1 to 100 Watt Seconds (Ws) Adjustment Range 300DP -- 3 to 300 Watt Seconds (Ws) Polarity Selection Positive, Negative, or Alternating 0-2999 msec Squeeze Time...
  • Page 37 APPENDIX A: TECHNICAL SPECIFICATIONS Ship Kit Contents 1) 37-pin mating connector with hood. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-XXX...

  • Page 39: Appendix B. Electrical And Data Connections

    Connect the Power Supply power cable to a 1-phase, 50/60Hz power source. The voltage range for each model is set at the factory. If you wish to change the operating voltage of your unit, please contact Miyachi Unitek Corporation for the required components and installation instructions. See CONTACT in the front of this manual for contact information.
  • Page 40 . Move it to the position as shown below. Note that HIGH = TRUE this position is only used if Miyachi Unitek footswitch and weldhead firing switch connections are replaced by . If a Miyachi Unitek mechanical footswitch and standard weldhead...
  • Page 41 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Configuration for Low = True Inputs (Switch Closure to Activate Inputs) 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...
  • Page 42 APPENDIX B: ELECTRICAL AND DATA CONNECTIONS Configuration for High = True Inputs (PLC or +24V to Activate Inputs) 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...
  • Page 43 Weld out of limits relay (not available on all models) Not used Not used +24VDC. The total current draw from pins 1 and 19 must not exceed 500 mA. Ground Not used Not used FS2 (Foot switch level 2) 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...
  • Page 44 If you do not release the foot switch at the first level and proceed to the second level, the force-firing switch in the weld head will close. Weld current will flow, and the Power Supply will automatically return the upper electrode to its UP position. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...
  • Page 45 The Weld Head Connector combines all the inputs and outputs necessary to connect a plug-and-play EZ- AIR Miyachi Unitek weld head. If PLC or other means of trigger is used, refer to the I/O Signal Interface General Description on page B-3.
  • Page 46 Connect an approved, normally closed emergency stop switch across the 2-foot (61 cm) operator Emergency Stop Switch cable. When the switch is operated (opened), it de-energizes all power outputs from the Power Supply. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...

  • Page 47: Appendix C System Timing

    Hold time. Selectable range is 0 to 2999 ms. HOLD NOTE: The inputs signals (FS1, FS2 and firing switch) need to be at least 50 msec duration for the unit to recognize them. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...
  • Page 48 HOLD Hold time. Selectable range is 0 to 2999 ms. NOTE: The firing switch signal needs to be at least 50 msec duration for the unit to recognize it. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...

  • Page 49: Appendix D. The Basics Of Resistance Welding

    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 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...
  • Page 50 -2, -14 Brass -2, -14 Stainless Steel Copper Beryllium Copper Bronze -2, -11 Bronze -2, -11 Copper Beryllium Tinned Copper Bronze -2, -11 Tinned Copper Copper Beryllium Nickel Bronze -2, -11 Iron Copper 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...
  • Page 51 Copper Karme Kovar, Gold Kulgrid Plate Copper Manganin Kovar, Gold Nickel Plate Copper Nichrome Kovar, Gold Silver -11, -14 Plate Copper Nickel Kovar, Gold Stainless Steel Plate Copper Paliney 7 Magnesium Magnesium 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...
  • Page 52 If this is not done, the rough surface of the electrode face will have a tendency to stick to the work piece. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...
  • Page 53 Fatigue tests and radiography have also been used. Of these methods torsional shear is preferred for round wire and a 45-degree peel test for sheet stock. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...
  • Page 54 Typical Weld Strength Profile 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. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...

  • Page 55: Appendix E. Quality Resistance Welding Solutions: Defining The Optimum Process

    • Ceramic (alumina, sand) • Plastics/polymers (PVC, teflon) • Semiconductors (silicon, geranium) Of these, only metals can be resistance welded because they are electrically conductive, soften on heating, and can be forged together without breaking. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...
  • Page 56 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. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...
  • Page 57 Conductive metals dissipate heat and it can 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. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...
  • Page 58 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: 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...
  • Page 59 The contact resistances present at the weld when the power supply is fired have a great impact on the heat balance of a weld and, therefore, the heat affected zone. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...
  • Page 60 The stages of heat generation for conductive materials will be similar to that of resistive materials, but there will be less heat generated in the bulk resistance due to the conductivity of the materials. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...
  • Page 61 (for further details comparison see the Unitek Equipment “slide rule” tool). 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...
  • Page 62 Materials: Resistivity, melting point, thermal mass, shape, hardness, surface properties. • Heat balance: Electrode materials, shape, Polarity, heating rate (upslope). • Observation: visual criteria, cross section, and impact of variables on heat balance. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...
  • Page 63 This part of weld development is critical in order to proceed to a statistical method of evaluation (Design of Experiments or “DOEs”). Random explosions or unexpected variables will skew statistical data and waste valuable time. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295...
  • Page 64 DOE tool that is run in Excel® and is sufficient for the majority of possible applications (contact Unitek Equipment for details). Sophisticated software is also available from other vendors designed specifically for this purpose. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY E-10 990-295...
  • Page 65 Welded assemblies should be tested over time and under real use conditions to ensure that all functional criteria will be met. Validation testing is usually required to prove the robustness of the process under production conditions. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY 990-295 E-11...
  • Page 66 A troubleshooting guide can be requested in the form of a slide rule, to assist users in identification of welding problems and likely causes. 100DP/300DP DUAL PULSE RESISTANCE WELDING POWER SUPPLY E-12...

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