WARNING: Please be sure to read all personnel and equipment safety precautions noted in this manual.
993-603
Revision A: October, 1996
IP-215A AND IP-217A FINE SPOT
WELDING POWER SUPPLIES
Model IP-215A
IP-215A/RS485
IP-217A
IP-217A/RS485
Definition Standard 50 Amp Power Supply
50 Amp Power Supply With RS-485 Data Port Standard 200 Amp Power Supply
200 Amp Power Supply With RS-485 Data Port
Copyright © 1996 Unitek Miyachi Corporation
All Rights Reserved
Prepared by
Unitek Miyachi Corporation 1820 South Myrtle Avenue
Welding Power Supplies
User's Manual 993-603, October 1996, Revision A
Unitek Miyachi Corporation 1820 South Myrtle Avenue Monrovia, CA 91017-7133 Phone (818) 303-5676 FAX (818) 358-8048
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
REVISION RECORD
Revision EO Date Basis of Revision
A 16785 10/96 Not applicable
AND
WARNINGS
HIGH VOLTAGE
IS USED IN THE OPERATION OF THIS EQUIPMENT DEATH ON CONTACT
MAY RESULT IF PERSONNEL FAIL TO OBSERVE THE SAFETY PRE- CAUTIONS LABELED ON THE EQUIPMENT AND NOTED ON THIS PAGE
Only a qualified technician should be allowed to work inside the unit.
Never work on electronic equipment unless there is another person nearby who is familiar with the operation and hazards on the equipment and who is competent in administering first aid. The technician who is aided by operators must warn them about the hazards.
Whenever possible, shut off the power supply to the equipment before beginning work on it. When you have shut off power, ground all parts. Be sure to discharge every capacitor that may hold a dangerous potential to ground when working inside the equipment.
Do not touch high-voltage connections or 208/230 volt input connections when installing or operating the equipment. WARNING:
Do not be misled by the term low voltage. Potentials as low as 50 volts may cause death under adverse conditions.
PLEASE READ THE SAFETY STEPS ON THE NEXT PAGE
SAFETY STEPS TO FOLLOW IF SOMEONE IS THE VICTIM OF ELECTRICAL SHOCK:
1. Do not try to pull or grab the victim.
2. If possible, turn off the electrical power.
3. If you cannot turn off the electrical power, pull, push or lift the victim to safety using a dry wooden pole, a dry rope, or some other non-conductive material.
4. Send for medical help as soon as possible.
5. When the victim is free of contact with the source
of electrical shock, move the victim away and start
artificial resuscitation.
CHAPTER 1 ABOUT THIS MANUAL
Organization . . . 1-1 Referencing Conventions . . . 1-2 Related Manuals . . . 1-2 How Are We Doing? . . . 1-2 If You Need Assistance . . . 1-3
CHAPTER 2 ABOUT YOUR EQUIPMENT
Overview . . . 2-1 Performance Features . . . 2-1 Welding Schedules . . . 2-2 Welding Monitors . . . 2-2 Welding Parameters . . . 2-2 Weld Data Storage . . . 2-2 Automation Capability . . . 2-2 Equipment Description . . . 2-2
CHAPTER 3 GETTING STARTED
Space Requirements . . . 3-1 Standard Installation . . . 3-1 Making a Trial Weld . . . 3-3
CHAPTER 4 CONTROLS
Rear Panel Components . . . 4-1 Front Panel Components . . . 4-2 Display . . . 4-2 Control Mode Status Indicators . . . 4-4 System Status Indicators . . . 4-4 Weld Program Key Field . . . 4-4 Weld Control Key Field . . . 4-8 Welcard Drive . . . 4-10 POWER Circuit Breaker . . . 4-10
CHAPTER 5 OPERATING YOUR POWER SUPPLY
Display Screen Data Editing . . . 5-1 Setting the Weld Schedule . . . 5-3 Monitoring Power Supply Operation . . . 5-4 Monitoring Weld Heat Limits . . . 5-4 Weld Current . . . 5-4 Current Setting Monitor (IP-217A Only) . . . 5-6 Monitoring Average Pulse Width . . . 5-6 Automatic Performance Monitors . . . 5-7 Selecting the Welding Transformer (217 Power Supply Only) . . . 5-8 Selecting the Weld Count . . . 5-9 Setting Control Feedback Gain . . . 5-9 Activating the Data Output Port . . . 5-10
CHAPTER 6 USING THE WELCARD
Care and Treatment of the Welcard . . . 6-1 Welcard Data Records . . . 6-2 Installing the Welcard . . . 6-2 Operating With the Welcard . . . 6-2 Initializing the Welcard . . . 6-2 Referencing the Directory . . . 6-3 Copying a Schedule to a Welcard . . . 6-4 Copying a Schedule to the Power Supply . . . 6-5 Welcard System Error Messages . . . 6-6
CHAPTER 7 IN CASE OF DIFFICULTY
General Kinds of Problems . . . 7-1 Electrode Maintenance . . . 7-1 Adjusting Display Viewing Angle . . . 7-2 Memory Backup Battery Replacement . . . 7-2 Technical Assistance . . . 7-3
APPENDICES
A Technical Specifications . . . A-1 B Cable Wiring and Signal Specifications . . . B-1 C Welding Transformer Specifications . . . C-1 D Resistance Welding Basics . . . D-1 E Alarm Message List . . . E-1 F Weld Programming Sheets . . . F-1
ALPHANUMERIC SUBJECT INDEX
READER COMMENT SHEET WARRANTY
ILLUSTRATIONS
2-1 IP-215A Fine Spot Welding Power Supply . . . 2-1 2-2 Using the Power Supply With Multiple Welding Transformers . . . 2-3 3-1 Standard Connection Diagram . . . 3-2 3-2 System Interconnections for Multiple Welding Transformers . . . 3-3 4-1 Rear Panel Components . . . 4-1 4-2 Front Panel Controls and Display . . . 4-3 6-1 The Welcard Data Storage System . . . 6-1 7-1 Factory Adjusted Display Viewing . . . 7-2 7-2 Memory Backup Battery Location . . . 7-3
TABLES
5-1 Display Data Entry Ranges . . . 5-2 6-1 Welcard Error Messages . . . 6-6
ABOUT THIS MANUAL
This manual is organized to assist you in getting productive quickly with the IP-215A or IP- 217A High Frequency Inverter Welding Power Supply. The simplified information and instructions in Chapters 1 through 3 will allow you to get the equipment up and running safely and efficiently, and make basic welds. Chapter 4 explains the operation of the controls and the display. Chapter 5 and the appendices deal with more advanced welding consider- ations and procedures.
NOTE: Where the data in this manual is specific to either the IP-215A or the IP-217A, the data is noted as such. All other data is relevant to both the IP- 215A and the IP-217A.
Organization
This chapter lets you know how to use this manual effectively. The manual contains many tools to help you find and understand information. The physical, electrical and performance specifications are listed in Appendix A. Specific subject matter is listed in the Alphanumeric Subject Index at the back of the manual; the subjects are sorted alphabetically and show their page number locations in the manual.
Chapter 2 familiarizes you with physical aspects and performance capabilities of your IP- 215A/217A High Frequency Inverter Welding Power Supply.
Chapter 3 provides procedures for setting up the equipment in the workplace and making your first simple weld. It covers the physical and electrical installation of the IP-
215A/IP217A High Frequency Inverter Power Supply. Details of mounting and applying AC power to the system are discussed, and a description of the initial power-on actions is presented. These procedures bring the system up to operational status and lead you through your first welds.
Chapters 4 and 5 respectively present detailed descriptions of key functions and operating instructions for the IP-215A/IP-217A High Frequency Inverter Welding Power Supply.
Chapter 6 instructs you in the use of the Welcard data storage system. Finally, Chapter 7 offers courses of action if you run into difficulty with system operation.
Referencing Conventions
For ease of referencing the related components of the IP-215A/IP-217A High Frequency Inverter Welding Power Supply, here is the way that they will be referred to in the rest of the narrative in this manual:
IP-215A or IP-217A High Frequency
Inverter Welding Power Supply: Power Supply IP-215A High Frequency Inverter
Welding Power Supply: 215 Power Supply
IP-217A High Frequency Inverter
Welding Power Supply: 217 Power Supply
Welding Transformers:
Model IT-500A 500 Welding Transformer
Model IT-501A 501 Welding Transformer
Model IT-510A 510 Welding Transformer
Model IT-511A 511 Welding Transformer
Model IT-512A 512 Welding Transformer
Model IT-540A 540 Welding Transformer
Welcard Unit Drive: Welcard Drive
Welcard Unit (the storage medium): Welcard (optional)
The full titles are still used where the components are referenced in a formal sense, such as in parts lists, or where confusion may result from using the short form of the titles.
Related Manuals
For additional reference support for this manual, the following manual is available from Unitek Miyachi: Fundamentals of Resistance Welding, Manual No. 990-1-210
How Are We Doing?
We hope you find in this manual all the information you need to integrate the Power Supply into the Welding System successfully. We have made every effort to present this informa- tion clearly and concisely. If you have any suggestions for improving the manual, please
note them on the Reader Comment Sheet at the back of this manual and drop it in the mail to us.
If You Need Assistance
There are unique aspects to every installation and application, so your particular needs may not be covered. If you need further assistance, please contact our sales representative in your area, or contact the factory directly at:
Unitek Miyachi Corporation 1820 South Myrtle Avenue Monrovia, California 91017-7133 Telephone: (818) 303-5676 Fax: (818) 358-8048
IP2PFRON.WPG
Figure 2-1. IP-215A Fine-Spot Welding Power Supply
ABOUT YOUR EQUIPMENT
Overview
The IP-215A/IP-217A is a high frequency inverter resis- tance welding power supply designed for fine spot welding of precision parts. Figure 2-1 shows the physi- cal characteristics of the 215 Power Supply. The 217 Power Supply is identical except for minor differences in the front panel key locations.
Simple programming through the front panel controls and display provides you with a choice of up to three welding control modes and a variety of welding parame- ter settings. This versatility brings to your welding applications reliable and consistent nugget formation, improved weld quality, and the welding speed required to work with semi-automated or fully automated equip- ment.
Performance Features
For a complete listing of the Power Supply’s technical specifications, please refer to Appendix A. The follow-
ing is a summary of the Power Supply’s performance capabilities.
Feedback Control Modes
Constant Current: Use where welding load resis- tance is subject to variation, such as in varying weld forces, weld piece plating inconsistencies, and uneven work surfaces. Since this mode is suitable for all types of work pieces, always use it when starting an application.
Constant Voltage: Use where the electrodes have relatively high resistance, such as tungsten electrodes.
Constant Power: Use for cross wire welding and the welding of materials that are sensitive to heat variation.
Welding Schedules. You can program a welding schedule for up to seven welds.
Alternatively, you can program a start on four only of the seven welding schedules. The welding schedules control:
Welding heat characteristics Weld piece cooling time Control mode selection Parameter monitoring limits
Welding transformer selection (217 Power Supply only)
Welding Monitors. Built-in performance monitors generate alarm conditions when preset current, voltage, or power limits are exceed during a weld cycle.
Welding Parameters. Two separate weld current rise and weld periods offer flexible weld control for multiple applications.
Weld Data Storage. Welcard, a compact data storage unit, collects weld schedule details. You can recall weld schedules from the Welcard to re-program the Power Supply.
Automation Capability. A signal I/O connector on the rear panel allows integration with automated production equipment.
Multiple Welding Transformer Selection. The Power Supply has simultaneous squeeze capability and four channels of transformer selection. With these features, the Power Supply can be used with an optionally available MA-600A Welding Transformer Selector (see Figure 2-2) to select up to four different welding transformers to implement sequential welding.
Equipment Description
The Power Supply is delivered fully assembled, together with a shipping kit containing parts that you will need to install, operate and maintain it. The parts included in the shipping kit are as follows:
Power Cable
Output (Welding Transformer) Cable
IP2MA600.WPG
Figure 2-2. Using the Power Supply With Multiple Welding Transformers Sense Cable
Data I/O Cable
I/O Cable Connector
User’s Manual, Part No. 993-603
GETTING STARTED
Space Requirements
We recommend that you install the Power Supply and its supporting equipment in a well venti- lated area that is free from excessive dirt and moisture. Other installation considerations are:
The work surfaces must be level, stable, free from vibration, and capable of
supporting the combined weight of the total welding system. The weight of the Power Supply is:
215 Power Supply 10 Kg (22 lb) 217 Power Supply 13 Kg (28.6 lb)
Allow ample work space around the Power Supply so that it will not be jostled or struck while welding. The dimensions of the Power Supply are:
215 Power Supply 269 mm (10.5 in.) high, 142 mm (5.5 in.) wide, and 436
mm (17.2 in.) deep
217 Power Supply 269 mm (10.5 in.) high, 172 mm (6.8 in.) wide, and 466
mm (18.3 in.) deep
The atmosphere is free of chemical vapors and particles, and a space of at least 10 cm (4 in.) is maintained behind the Power Supply for ventilation and air flow.
The Power Supply is far enough from the weld head to avoid contact with weld splash.
There are no sources of high-frequency energy close by.
NOTE: Be sure that all accessories that you ordered and all items listed in the shipping kit (see Equipment Description in Chapter 2) are available, and that the Power Supply shows no sign of damage.
Standard Installation
The standard Power Supply/Welding Transformer installation is shown in Figure 3-1. Depending on your welding application, you will require an appropriate welding transformer (see Appendix C).
IP2CONN.WPG
Figure 3-1. Standard Connection Diagram
An installation using multiple welding transformers is shown in Figure 3-2. It is based on the use of a Model MA-600A Welding Transformer Selector.
CAUTION: Do not connect the AC input voltage cable to the AC power mains yet.
1. Connect the AC power input cable between the Power Supply AC220V 3 IN connector and the 220 VAC, 3-phase power source as shown in Figure 3-1.
2. Interconnect the welding transformer and the Power Supply as shown in Figure 3-1. If your application requires the use of multiple welding transformers, interconnect the welding transformers with the Power Supply through the Transformer Selector as shown in Figure 3-2.
3. Connect the Signal I/O cable between the Weld Head and the Power Supply I/O Connect- or. The factory wiring of the Power Supply I/O connector allows the weld head firing microswitch to send a single START signal for each operation of the footswitch. For other START switch selections, please refer to Appendix B.
IP2TRSEL.WPG
Figure 3-2. System Interconnections for Multiple Welding Transformers
4. Connect the Data I/O cable between the Power Supply RS 485 connector and a host computer if you are using this option.
5. See Figure 3-1. Connect the Power Supply AC power input cable to the AC power mains.
CAUTION: Do not turn on the Power Supply POWER ON/OFF circuit breaker at this time.
Making a Trial Weld
Making a production weld results from making several trial welds, testing the welds, then adjust- ing the selected welding parameters each time until you reach production weld quality. The
selec-ting and editing functions are described in Chapter 5. The following “quick-start” example weld-ing procedures lead you through a typical weld cycle, from turning on welding system power to completing a series of trial welds. It is assumed that the weld head that you are using is connected to the welding transformer(s) according to the manufacturer’s instructions.
1. Set the Power Supply POWER ON/OFF circuit breaker to ON. The display will reflect the mode and parameters previously set.
2. Adjust the display screen contrast for optimum viewing, as described in Chapter 7.
3. Press the MODE key to access the Mode Selection data screen. With the CURSOR and DATA keys, set the mode selection fields as follows:
Current monitor (IM) OFF (0) Voltage monitor (VM) OFF (0) Power monitor (WM) OFF (0) Start/End output (MR) OFF (0) 7 schedule start (7S) ON (1) Panel schedule start (PS) OFF (0) Program lock (NP) OFF (0)
4. Press the MODE key again to access the Mode Setting extended data screen.With the CURSOR and DATA keys, set the Mode Setting fields as follows:
Transformer: Model number of attached welding transformer Feedback response (C–GAIN): 0
Data output: OFF
5. Press the WELD SCHED. key to access the Weld Schedule display screen. With the CURSOR and DATA keys, set the weld schedule values as follows:
SCHEDULE: 1
Weld 1 Current Rise Time (R1): 5 ms
Weld 1 Time (W1): 10 ms
Cool Time (CO): 0 ms
Weld 2 Current Rise Time (R2): 0 ms
Weld 2 Time (W2): 0 ms
Control Feedback Mode (I.F.W): Constant Current (I)
The Second Trial Weld Weld 1 Current (HEAT 1): 1.5 KA
6. Press the WELD key to turn on the welding capability (WELD ON indicator turned on).
7. Position the work piece in the weld head. Press the footswitch to turn on the weld current and weld your first trial piece.
You have tested the first trial weld piece and found that the weld strength is not adequate. Since you now know how to program welding parameters, the following instructions will not reference actual program keys.
1. Increase weld 1 current (HEAT 1) in 0.5 KA steps and make a test weld at each current level. If you do not achieve a satisfactory weld when you reach maximum weld current, go to step 2.
2. Set the Weld 1 time to double the previous setting and reduce Weld 1 current by 50%.
3. Repeat steps 1 and 2 until you achieve a satisfactory weld.
IP2BACK.WPG
Figure 4-1. Rear Panel Components
CONTROLS
Rear Panel Components
The components on the rear panel are shown in Figure 4-1.
Ventilation Grill: Exhaust vent for heated air from the housing interior. CAUTION: Do not block this ventilation.
Overheating of the electronic circuitry can cause permanent damage.
Data I/O Connector: Optional 15 pin D-connector for remote pro- gramming control and remote data
collection using RS-485 protocol. Please contact the factory for data organization and signal de-tails.
Signal I/O Connector: Input/output terminals for external equip- men, such as automation equipment, inter- facing with the Power Supply. Please see Appendix B for signal details.
Welding Transformer Connector: Supplies AC power to the welding trans- former. The output cable is supplied in the shipping kit. Please see Appendix B for sig- nal details.
Display Screen Contrast Adjustment Variable resistor for adjusting the contrast of
(IP-215A Only): the display screen.
Welding Transformer Sense Connects the weld sense signals between In Connector: the weld transformer and the Power Supply.
The I/O cable is provided in the shipping kit.
Please see Appendix B for signal details.
AC Voltage Input Connector: Connects AC main power to the Power Supply. The power cable is supplied in the shipping kit. Please see Appendix B for signal details.
Front Panel Components
The front panel components consist of the display , operating control keys, the Welcard Drive, and the POWER ON/OFF circuit breaker (see Figure 4-2). Note that the indicators and keys are organized into four functional fields: Control Mode Status Indicators, System Status Indicators, Weld Program Keys, and Weld Control Keys.
Display. The liquid crystal display allows you to edit (enter or change) and read welding values and program settings. The display editing keys are the CURSOR and DATA keys.
The display screen has two lines of 20 character
IP2FRONT.WPG
Figure 4-2. Front Panel Controls and Display
positions. The program setting and value fields are defined around the display screen as follows:
SCHEDULE: 1 character weld schedule number field
R1: 2 character weld current rise time (msec) for Weld 1
W1: 2 character Weld 1 time (msec)
CO: 2 character cool time (msec)
R2: 2 character weld current rise time (msec) for Weld 2
W2: 2 character Weld 2 time (msec)
I.V.W 1 character control mode definition field, where I = current control, V = voltage control, and W = power control
HEAT 1: 5 character Weld 1 weld current (KA) HEAT 2: 5 character Weld 2 weld current (KA)
Control Mode Status Indicators. This field includes three indicators that, when turned on, indicate the feedback control mode that is currently active, as follows:
C.I Constant Current Mode C.V Constant Voltage Mode C.W Constant Power Mode
System Status Indicators. This field includes three indicators that, when turned on, indicate the status of the Power Supply, as follows:
WELCARD The Welcard is installed in the Welcard Drive properly.
READY The Power Supply is ready to weld (the TROUBLE status indicator is off, the weld on/off pins at the I/O connector are open, and the WELD key indicator is on).
TROUBLE There is a system problem.
Weld Program Key Field. There are five keys in this field that contribute to the selection of weld program values and settings.
Pressing this key accesses the Weld
Schedule display screen. Through the Weld Schedule display screen, you may view or set a weld schedule.
TOP LINE OF THE SCREEN
SCHEDULE: Weld schedule number, shown here as 1.
R1: Weld current rise time for Weld 1, shown here as 5 milliseconds.
W1: Weld time for Weld 1, shown here as 20 milliseconds.
CO: Cool time, shown here as 10 milliseconds.
R2: Weld current rise for Weld 2, shown here as 3 milliseconds.
W2: Weld time for Weld 2, shown here as 10 milliseconds.
BOTTOM LINE OF THE SCREEN
I.V.W: Active feedback control mode, shown here as I (Constant Current) . The other selections are V (Constant Voltage) and W (Constant Power).
HEAT 1: Weld current for Weld 1, shown here as 2 KW.
HEAT 2: Weld current for Weld 2, shown here as 1.5 KA
NOTE: HEAT 1 and HEAT 2 are control mode dependent. In the Constant Voltage and Constant Power control modes, HEAT 1 and HEAT 2 will be in terms of voltage (V) and power (KW) respectively.
The MODE key accesses the Mode Selection display screen. The Mode Selection display screen has an extension (second) screen that appears when you press MODE a second time. The settings that you may view or edit are as follows:
PRIMARY SCREEN
IM: Current monitor selection, shown here as 0 (current monitor off). Other selections are 1 (monitor Weld 1 current) and 2 (monitor Weld 2 current).
VM: Voltage monitor selection,
shown here as 0 (voltage monitor off). Other selections are 1 (monitor Weld 1 voltage) and 2 (monitor Weld 2 voltage).
WM: Power monitor selection, shown here as 0 (power monitor off). Other selections are 1 (monitor Weld 1 power) and 2 (monitor Weld 2 power).
MR: Start and end mode output selection, shown here as 0 (output an END output signal on a high or low limit error so that the next weld cycle can start). The other selection is 1 (do not output an END signal and do not accept the next START signal on a high or low error).
7S: 4 schedule or 7 schedule start, shown here as 1 (7 schedule start). To implement the 7 schedule start, the I/O connector must be wired to accept start signals 1, 2 and 4 as binary equivalents of start signals 1 through 7. The other selection is 0 (4 schedule start). To implement a 4 schedule start, the I/O
connector must be wired to accept start selections with start signals 1, 2, 3 and 4.
Please refer to Appendix B for wiring.
PS: Panel schedule start, shown here as 0 (start the weld according to the weld schedule defined on the display screens when the WELD key is pressed). The other selection is 1, where weld start is initiated by an external START signal.
NP: Program lock, shown here as 0 (you can change weld schedule settings). The other selection is 1 (you cannot change weld schedule settings unless you change this mode setting to 0).
EXTENSION SCREEN
TRANSFORMER = IT-500A:
Welding Transformer Model IT- 500A is selected (transformer selection on 217 Power Supply only). Use the DATA key to toggle through the selections (see Appendix C for the selections).
C—GAIN=0: Gain (response
speed) of the control feedback (current, voltage or power), shown here as 0 (lowest response speed). Select the appropriate gain value (0 through 9 for the !P- 215A or 0 through 5 for the IP-217A) with the DATA key.
D—OUT=OFF: Status of the Data I/O port, shown here as OFF. To enable data output through the port, toggle OFF to ON with the DATA key.
The SCAN key accesses the Welding Transformer Channel Programming display screen. You use this function if you are using multiple welding transformers.
SCAN COUNT =: The scan count is the welding transformer channel
number; that is, the channel on the weld transformer selector through which the transformer is connected to the Power Supply (see Figure 3-2 in Chapter 3). If you set the scan count to 1, the Channel 1 scan period will act as squeeze time for a single unit setup. You set the scan count (channel number), shown here as 4, with the DATA key.
INTERVAL TIME = : The time interval between application of weld power to the weld transformers, shown here as 50 ms.
NOTE: Please refer to Appendix B for scan timing.
The MONITOR SET key accesses the Monitor Limits display screen.
The Monitor Limits display screen allows you to set welding heat limits that, if exceeded for the selected weld schedule, will generate a limit exceeded alarm.
TOP ROW
7: Weld schedule number +: Upper limit designator
2.50KA: Upper current limit set for Weld Schedule 7 9.99V: Upper voltage limit set for Weld Schedule 7 9.99KW: Upper power limit set for Weld Schedule 7
BOTTOM ROW
-: Lower limit designator
0.00KA: Lower current limit set for Weld Schedule 7 0.00V: Lower voltage limit set for Weld Schedule 7
0.00KW: Lower power limit set for Weld Schedule 7
The ENTRY key initiates the selected Welcard operation. Use of this key is detailed in Chapter 6, Using the Welcard.
The CLOCK key displays time and date, as used for tagging recorded weld data.
When you press and release this key quickly, you access the clock display in the clock mode. In the clock mode, the display screen shows only the date and time on the top line of the display sceen.
When you press and hold the CLOCK key for about 1 second, you access the clock display in the clock set mode. In this mode, the display screen adds a second line, requesting you to set time and date. Move the cursor to the time and date fields and set the time and date with the DATA keys. At the exact time that you set into
the display screen, press the CLOCK key again to return to the clock mode.
Weld Control Key Field. There are nine keys in this field that enable you to set weld control parameters for the Power Supply and the Welcard system.
The WELD key/indicator initiates the weld cycle according to the selected weld schedule if panel schedule start is selected with the Mode Selection display screen (PS=0), as previously described. The key indicator will be turned on when the WELD key is in the ON state. To avoid accidentally turning off the weld cycle, you must press the WELD key for at least 0.5 seconds to turn off the weld cycle with the key.
The MONITOR 1 key accesses the Weld Heat display screen.
With this display, you may view the actual (rather than programmed) weld energy applied during a weld cycle.
TOP LINE
3: Weld schedule 3 WI: Weld 1
12.36KA: Actual weld current delivered for Weld 1
5.33V: Actual transformer secondary winding voltage developed for Weld 1 9.42KW: Actual welding power delivered for Weld 1
BOTTOM LINE
WII: Weld 2
1.47KA: Actual weld current delivered for Weld 2
8.08V: Actual transformer secondary winding voltage developed for Weld 2
9.02KW: Actual welding power delivered for Weld 2 The MONITOR 2 key accesses
the Average Pulse Width display screen. With this display screen, you can view the average control pulse width for the selected weld schedule. Select the weld schedule number with the DATA key.
The average pulse width information allows you determine how close the welding transformer is to operating capacity.
4: The selected schedule number
V: The active feedback control mode, as selected with the Weld Schedule display screen. V = Constant Voltage, I = Constant Current, W = Constant Power
W1 = 082%: The average voltage control pulse width for Weld 1 has been measured at 82%
W2 = 078%: The average voltage control pulse width for Weld 2 has been measured at 78%
The CURSOR keys move the display screen cursor left and right to character positions on the display screen for editing the character positions. The character position is denoted on the display screen by a blinking, highlighted character.
The RESET key, when pressed by itself, resets the Power Supply for normal operation after an error occurs. NOTE: It does not remedy the error that caused the error output or alarm message.
The COUNT key, when pressed by itself, accesses the Weld Count display screen. This display
performed since the counter was reset, and to set the number of counts at which you want the display to indicate a SET COUNT and WELD COUNT match. When the SET COUNT equals the WELD COUNT, the END OF WELD COUNT!! alarm message is dsplayed and the COUNT END and END signals are output at the I/O connector (refer to Appendix B.
You set the count number (shown here as SET COUNT = 05000) with the CURSOR and DATA keys.
To reset the weld count to 00000, press the RESET and COUNT keys simultaneously. The display screen will indicate the reset condition.
The COPY key, when pressed by itself, copies a weld schedule to the Welcard. The FILE key, when pressed by itself, sets the read mode for viewing Welcard data. When you press the COPY and FILE keys simultaneously, you clear (initialize) the Welcard
installed in the Welcard drive. As previously described, all Welcard operations are initiated with the ENTRY key. Operation of the Welcard system is detailed in Chapter 6.
You increase and decrease data with this key. Pressing -DOWN decrements numerical values or toggles selections downward. Pressing UP+ increments numerical values or toggles selections upward.
Welcard Drive. The Welcard drive operates similarly to a conventional PC floppy diskette drive. It has only one control, the EJECT knob. You raise the knob to install and eject the Welcard.
POWER Circuit Breaker. The POWER circuit breaker is the main power switch for the Power Supply. It also provides power overload protection (50 A) to the AC power input circuit.
OPERATING YOUR POWER SUPPLY
This chapter gives you instructions about entering data to (editing) the display screens, setting weld schedules, selecting welding transformers, setting control modes, and monitoring Power Supply performance with the display screens. Refer to Chapter 4 for functional descriptions for the controls and the display.
Display Screen Data Editing
To enter or change data on the display screen:
1. Press the desired display entry key to activate the associated display function. For ex- ample, if you wish to activate the Weld Schedule display screen, press the WELD SCHED. key.
2. With the CURSOR keys, move the cursor to the position of the character that you wish to enter or change.
3. Press the -DOWN DATA key to lower the value or selection at the highlighted character position(s). Press the UP+ DATA key to raise the value or selection at the highlighted character position(s). For a list of numerical ranges for the data fields, refer to Table 5-1.
As an example exercise of display screen editing:
a. Press the WELD SCHED. key to access the Weld Schedule display screen.
b. With the CURSOR keys, move the cursor to the mode selection character position (I.V.W).
c. With the -DOWN DATA and UP+
DATA keys, scroll through the three selections of I, V, and W. The
character that you leave selected will be your choice of control modes.
Table 5-1. Display Data Entry Ranges
Display Screen Field Setting Range Unit Weld Schedule (WELD SCHED. Key)
Weld 1 Current Rise (R1) 0 - 49 msec
Weld 1 (W1) 00 - 99 msec
Cool Time (CO) 00 - 99 msec
Weld 2 Current Rise (R2) 0 - 49 msec
Weld 2 (W2) 00 - 99 msec
CURR 1. or CURR. 2:
Constant Current Control (215) Constant Voltage Control (215) Constant Power Control (215) Constant Current Control (217) Constant Voltage Control (217) Constant Power Control (217)
0.20 - 2.00 0.20 - 2.00 0.40 - 4.00 0.40 - 4.00*
0.4 - 4.00 0.16 - 9.99
KA V KW KA V KW
*If the IT-500A Welding Transformer is selected and the current setting exceeds 2.01KA, a current setting error will occur.
Mode Selection (MODE Key)
Transformer Model IT-500A (215, 217)
IT-501A (215, 217) IT- 510A (217) IT-511A (217) IT-512A (217)
Model No.
Model No.
Model No.
Model No.
Model No.
Feedback Gain (C—GAIN=) 0 - 9 (215) 0 - 5 (217)
Units Units Welding Transformer Channel Programming (SCAN Key)
Scan Count 0 - 4 Units
Scan Interval Time 0 - 990 msec
Table 5-1. Display Data Entry Ranges (continued)
Monitor Limits (MONITOR SET Key)
Current ±0.00 - 9.99 KA
Voltage ±0.00 - 9.99 Volts
Power ±0.00 - 9.99 Watts
Weld Count (COUNT Key)
Weld Count 00000 - 99999 Units
Setting the Weld Schedule
The weld schedule, together with the monitoring system, defines the welding program for controlling welding energy. You will find a convenient welding program sheet in Appendix F which you can use as a worksheet.
You call up the Weld Schedule display screen with the WELD SCHED. key, as described in Chapter 4. With this display screen, you may define up to seven weld schedules. The detailed timing diagram of the weld cycle in Appendix B will be helpful in understanding the
relationships of the weld cycle events. To set an example weld schedule 1 involving Weld 1 only:
1. Press the WELD SCHED. key to access the Weld Schedule display screen.
2. With the CURSOR keys, move the cursor to the display SCHEDULE field.
3. With the DATA keys, enter 1 in the display SCHEDULE field.
4. With the CURSOR keys, move the cursor to the display R1 field (weld current rise value for Weld 1).
5. With the DATA keys, enter the example rise value of 2 milliseconds (02).
6. With the CURSOR keys, move the cursor to the display W1 field (weld time for Weld 1).
7. With the DATA keys, enter the example weld time of 5 milliseconds (05). In making your trial welds, you will want to start out with a short time period and increase it in small increments as necessary.
8. With the CURSOR keys, move the cursor to display CO field (cool time).
9. With the DATA keys, set the cool time to zero (00). You would need to set a value for cool time to accommodate Weld 2; that value would depend on the weld piece material and the amount of weld heat generated for Weld 1 (the duration and amplitude of Weld 1 energy).
10. You will now need to set the control feedback mode. Under normal circumstances, you would want to start your trial welds in the Constant Current Control mode. With the CURSOR keys, move the cursor to the display I.V.W field (control mode
selection).
11. With the DATA keys, scroll the selections to I (the Constant Current Control mode).
12. With the CURSOR keys, move the cursor to the display HEAT 1 field (weld current value for Weld 1).
13. With the DATA keys, enter a low current value to start trial welding, say 0.5 KA (0.50).
NOTE: The HEAT 1 and HEAT 2 fields are control mode dependent. If you select the Constant Voltage Control mode (V) or the Constant Power Control mode (W), the HEAT 1 and HEAT 2 fields become relative to voltage (V) or power (KW).
14. With the CURSOR and DATA keys, set the remaining (Weld 2) values to zero.
Monitoring Power Supply Operation
The Power Supply monitoring function allows you to view, via the Weld Heat display screen, the actual amount of heat delivered during both Weld 1 and Weld 2 for a selected weld schedule.
With this information, you can refine parameter settings as necessary following a weld to optimize the weld parameters.
The monitoring function also oversees operation of the Power Supply. Where errors occur, the display screen presents an error message and the Power Supply outputs an error signal for external equipment to monitor.
Monitoring Weld Heat Limits. Assume that you wish to monitor the weld heat limits for the example weld schedule that you previously programmed in this chapter under
Setting the Weld Schedule. To activate the weld heat monitor (in this case, the current monitor) and set monitor current limits:
1. Press the MODE key to access the Mode Selection display screen.
2. With the CURSOR keys, move the
cursor to the display IM (current monitor) field.
3. With the DATA keys, set the character to 1 (Weld 1 heat monitor ON).
4. Press the MONITOR SET key to access the Monitor Limits display screen.
5. With the CURSOR keys, move the cursor to the display SCHEDULE field.
6. With the DATA keys, enter 1 for Weld Schedule 1.
7. Assume that you have programmed weld current for Weld Schedule 1, Weld 1, at 1.0 KA, and you wish to limit the current positive swing to 1.10 KA and the negative swing to 0.95 KA. With the CURSOR keys, move the cursor to the + current limit field.
8. With the DATA keys, enter 1.10.
9. With the CURSOR keys, move the cursor to the - current limit field.
10. With the DATA keys, enter 0.95. With the example of monitoring with the deviations that you set and 1.0 KA of programmed weld current, limit errors are illustrated as follows:
You turn on the voltage (VM) and power (WM) monitor similarly. In steps 2 and 3, you would set VM = 1 for the voltage monitor or WM = 1 for the power monitor instead of IM = 1. The high and low limit alarm events shown in the preceding illustration result in a TROUBLE signal output at the I/O connector (see Appendix B) and an alarm message on the display screen (see Appendix D) at the end of the weld cycle.
The operational events will depend on the setting that you specify for MR in the Mode Selection display screen. On exceeding an upper or lower current, voltage or power limit, the following will occur depending on the setting for MR (see Appendix B for the I/O connector definition):
MR = 0: An END signal will be output through the I/O connector. The error state can be reset by the next START signal or a TROUBLE RESET signal input at the I/O connector.
MR = 1: No END signal will be output, so the next START signal will not be accepted. The error state can be reset only by a TROUBLE RESET signal at the I/O connector.
Current Setting Monitor (IP-217A Only). The IT-500A Welding Transformer has a maximum current output capability of 2.0 KA. When it is selected, if you program 2.01 KA or greater welding current, a current setting monitor will not allow the system to start. The display screen will display the message CURR SET ERROR !! and the TROUBLE signal will be output at the I/O connector. To remedy the error condition, you must either program a current setting below 2.0 KA or connect a welding transformer with higher current output capability, and apply a TROUBLE RESET signal at the I/O connector.
Monitoring Average Pulse Width. The control pulse activates the welding
transformer after the start of the weld cycle. Its width is a measure of how much time is left in the duty cycle of the welding transformer before it will be damaged by exceeding its rated duty cycle.
You view the average pulse width for Weld 1 and Weld 2 on the Average Pulse Width display screen. For example, an average pulse width of 75% indicates that the transformer is operating with a 25% margin of safety. To access this display, press the MON. 2 key.
If the control pulse average width is 100% for more than 5 milliseconds during the weld cycle,
a TROUBLE signal will be output through the I/O connector. The display screen will display the alarm message FULL WAVE !!. Operation will be restored by the next START signal or
TROUBLE RESET signal input through the I/O connector.
Automatic Performance Monitors. In addition to the previously described performance monitors whose limits you can program, there are several performance monitors which respond automatically to alarm or error conditions without your intervention. These monitors each place an appropriate alarm message on the display screen and output the TROUBLE signal at the I/O connector. Please refer to Appendix E for the alarm messages and operator remedies, and to Appendix B for signal details. The monitors set up special operational states when the following error conditions occur:
Control Limit Monitor: The welding transformer control pulse width goes full wave (100% of the transformer capacity at its duty cycle) for more than 5 milliseconds dur- ing the weld cycle. The weld cycle will be completed. The next START signal will reset the error and start the next weld cycle. A TROUBLE RESET signal input at the I/O connector will also reset the error.
No Current Monitor: With the Constant Current Control mode active, the weld current is less than 25 (50 for the IP-217A) amperes after 5 milliseconds from the start of the weld cycle. Welding stops. A TROUBLE RESET signal at the I/O connector will be needed to reset the error condition and restore welding capability.
No Voltage Monitor: With the Constant Voltage Control or Constant Power Control mode active, voltage is lower than 0.05 volts after 5 milliseconds from the start of the weld cycle. Welding stops. A TROUBLE RESET signal at the I/O connector will be needed to reset the error condition and restore welding capability.
Transformer Thermostat Monitor: The welding transformer has overheated. The transformer thermostat has been tripped and welding is off. A TROUBLE RESET signal at the I/O connector will be needed to reset the error condition and restore welding capability.
Excessive Current Monitor: The peak value of the Power Supply output current has exceeded 50 (200 for the IP-217A) amperes during a weld cycle. A TROUBLE RESET signal at the I/O connector will be needed to reset the error condition and restore welding capability.
Memory Monitor: When power is turned on, the system will not start. The memory backup battery is discharged and program data has been lost. Press the RESET key to reset the error condition. Replace the backup battery (please refer to Chapter 7) and reprogram the lost weld program data.
The Power Supply will accept the next start signal in an error condition if MR = 0 on the Mode Selection display screen. If MR = 1, the Power Supply will need an error reset to continue. You may perform an error reset from the front panel with the RESET key; or, an error reset signal may be supplied externally through the I/O interface at pins 6 and 7 (refer to Appendix B).
Selecting the Welding Transformer (217 Power Supply Only)
If just one welding transformer is connected to the Power Supply, you need only to select its model number with the Mode Selection display screen. If several welding transformers are connected to the Power Supply through a welding transformer selector, you will also need to assign a transformer channel scan count and scan interval time with the Welding Transformer Channel Programming display screen.
To select the welding transformer that is connected to the Power Supply:
1. Press the MODE key twice to access the Mode Selection extension display screen.
2. With the CURSOR keys, move the cursor to the transformer model number field (IT-510A is shown here).
3. With the DATA key, scroll through the transformer model numbers until the model number of the connected welding transformer is displayed. Select IT-500A for the Model IT-500A Transformer. Select IT-510A for all other transformers.
To assign multiple transformers to Power Supply channels and assign scanning intervals:
1. Press the SCAN key to access the Welding Transformer Channel Programming display screen.
2. With the CURSOR keys, move the cursor to SCAN COUNT field.
3. With the DATA keys, select the
channels to which the connected welding transformers are assigned at the welding transformer selector. For example, if Welding Transformers 1 and 2 are assigned to Channels 1 and 2, enter 2 at the SCAN COUNT field. Note: If you are using a single weld head and transformer, you can select SCAN COUNT = 1 and use the interval as squeeze time.
4. With the CURSOR keys, move the cursor to the INTERVAL TIME field.
5. With the DATA keys, enter a suitable time interval for channels 1 and 2. The interval defines the period between the firing of each weld transformer. Refer to the welding transformer timing diagram in Appendix B.
Selecting the Weld Count
You may set a counter in the Power Supply that will enable you to monitor the number of welds made since the counter was last reset. This feature is useful for electrode maintenance. For example, additional weld heat will be required to maintain weld quality as the electrodes wear through use. You can preset a weld count at which you would want to dress or replace the electrodes rather than keep increasing weld heat (too much heat can have a damaging effect on the weld pieces).
To set the weld count:
1. Press the COUNT key to access the Weld Count display screen. It is showing the preset weld count of 3000 (shown here as SET COUNT
=03000) and the number of welds made since the counter was last reset (shown here as WELD COUNT = 02754).
2. With the CURSOR keys, move the cursor to the WELD COUNT field.
3. With the DATA keys, enter the desired weld count. During Power Supply operation, the following events take place when the weld count equals the set count:
NOTE: The Power Supply counts only good welds; that is, welds that result in properly completed weld cycles (Engrg: Is that how it differentiates between good and bad welds?)
a. The message END OF WELD COUNT !! will be displayed on the display screen.
b. The COUNT END signal and weld cycle END signal will be output at the I/O connector (please see the weld cycle timing diagram in Appendix B).
4. To reset the weld count to zero, press the COUNT and RESET keys simultaneously.
When you do, the message WELD COUNT CLEAR COMPLETED !! will be displayed on the display screen.
Setting Control Feedback Gain
You may adjust the response speed (gain) of the control feedback in any of the three control feed-back modes: Constant Current, Constant Voltage, or Constant Power. The value that you
select will depend on the welding load; that is, the total resistance of the welding transformer secondary circuit, including the weld pieces. To set the gain:
1. Press the MODE key twice to access the Mode Selection extension display
screen (217 Power Supply display screen shown).
2. With the CURSOR keys, move the cursor to the C—GAIN field.
3. With the DATA keys, select a gain of 0 through 9 (0 through 5 for the IP-217A). Use 0 gain for normal operation. Increase gain as the resistance of the transformer
secondary load rises. As resistance rises, weld current rise time increases, resulting in poor welding performance unless you compensate the rise time increase by increasing gain.
Activating the Data Output Port
The optional RS-485 connector on the Power Supply rear panel can supply weld schedule and weld performance data to a host computer. To activate the port, if it is installed:
1. Press the MODE key twice to access the Mode Selection extension display screen, as shown in the previous section.
2. With the CURSOR keys, move the cursor to the D—OUT field.
3. With the DATA keys, scroll the state from OFF to ON. The data port will now feed a stream of data to the host computer when data transfer is initiated by the host
computer.
NOTE: Keep the D—OUT = OFF setting if the data output option is not installed or when it is not communicating with a host computer.
ME35.WPG
Figure 6-1. The Welcard Data Storage System
USING THE WELCARD
The Welcard (Figure 6-1) allows you to record, store and re-use welding schedules and monitored weld data. It’s as easy to use as a PC diskette drive, which it resembles.
Care and Treatment of the Welcard
Do not insert anything other than the Welcard in the slot of the Welcard drive.
Keep the Welcard edge connectors free of dirt, oil and moisture.
When you are not using the Welcard, place it in its antistatic vinyl case and store it in a safe place.
Battery:
1. If you remove the battery from the Welcard, stored data will be lost.
2. When you wish to replace the battery, insert the Welcard into the Welcard drive and be sure that the Welcard status indicator turns ON. You may now replace the battery without losing the data that was on the Welcard.
3. The battery is a Panasonic 3V BR2016, or equivalent. Its life is five years. We recommend that you replace the battery more frequently.
4. When you replace the battery, observe the correct polarity.
Welcard Data Records
You can capture three kinds of data records on independent Welcards. The three Welcards are:
Schedule Card: Records weld schedules that you can recall for programming the weld schedule display. One Welcard can record up to seven schedules containing thirteen files (one file for each of thirteen welders), for a total of ninety-one schedules.
Monitor 1 Card: Records weld monitoring data during welding. To retrieve the con- tents of the Monitor 1 Card, you will need the optional Welcard reader/writer.
Monitor 2 Card: Records weld monitoring data during welding, but records fewer items and more data about the items, than the Monitor 1 Card. To retrieve the contents of the Monitor 2 Card, you will need the op- tional Welcard reader/writer.
Installing the Welcard
As indicated in Figure 6-1, you install the Welcard by lifting the Welcard drive knob and inserting the Welcard with the arrow on the Welcard pointing toward the drive. With gentle pressure, the Welcard connector will engage with the Power Supply internal drive connector.
Pressing the knob downward over the Welcard top edge completes the installation.
Operating With the Welcard
The read, write and storage operations of the Welcard are controlled with these eight keys whose functions are described in Chapter 4. You enter numerical and alphabetical characters to the display with the three CURSOR keys and the two DATA keys.Initializing the Welcard. An unused or previously used Welcard must be initialized
(formatted) before recording new data on it. There is a similar initializing procedure for each of the three
Welcard types. The only difference in the procedures is the key selection of the Welcard type (Schedule, Monitor 1, or Monitor 2). To initialize the Welcard:
1. Press the COPY and FILE keys simultaneously. The display screen will indicate a CARD CLEAR message and request CARD TYPE? (1-3).
2. Press the DATA keys to select the Welcard type, as follows:
Schedule Welcard: 1 Monitor 1 Welcard: 2 Monitor 2 Welcard: 3
Note: Functions 1 and 2 require special software and a card reader.
3. Press the ENTRY key. The display screen will ask you to confirm that you wish to initialize the selected Welcard type.
4. With the CURSOR keys, move the cursor to YES and press the ENTRY key to confirm that you wish to
initialize the selected Welcard type. If you enter NO, the program will return to step 1.
5. Shortly following your YES confirmation, the display screen will automatically request that you confirm that you wish to enter the Welcard name. With the CURSOR keys, move the cursor to YES and press the ENTRY key to access the
Welcard Name display screen. (If you enter NO, the program will bypass the
Welcard name designation and complete initialization of the Welcard without naming it.)
6. With the CURSOR and DATA keys, key in up to eight characters as an identifying name and press the ENTRY key to complete initialization of the Welcard.
7. Remove the Welcard from the Welcard drive.
Referencing the Directory. This function displays the name of the Welcard set during the initialization operation. For a schedule Welcard, the recording status will be
displayed, and you can set write protection ON and OFF. To reference the directory:
1. Install the Welcard to be checked and press the FILE key. The Welcard type will be displayed, along with its name and the date it was recorded. Assuming that it was a Schedule Welcard that you instal- led, the message will look like this.
2. After a short delay, the display will automatically present a file number dialog, on which you can enter the file number of the card that you wish to check. Assuming that the
LABTEST1 schedule card is File 1, move the cursor to the file number
(F) field with the CURSOR keys and enter 01 with the DATA key. The asterisk (*) denotes that the file is write-protected.
3. To change the status of the file to unprotected, move the cursor to the asterisk and remove it with the DATA key.
4. Press the FILE key to return to step 1 and continue checking other files.
Copying a Schedule to a Welcard. To record a welding schedule on a Schedule Welcard:
1. Press the COPY key to access the Copy Direction dialog screen. It is showing the default direction of the Welcard (CARD) to the Power Supply (IP-215A).
2. With the CURSOR keys, move the
cursor to the bottom display screen line (IP215A CARD) and press the ENTRY key to change copy direction. This action will access Copy Direction confirmation display screen.
3. Select YES with the CURSOR keys and press the ENTRY key to confirm the copy direction and access the File Number Selection display screen. If you select NO, the procedure will return to Step 1.
4. With the CURSOR keys, move the
cursor to the file number (F) field and key in a destination file number from 01 to 13 with the DATA keys.
5. Press the ENTRY key to enter the file number and access the file name entry display screen. With the CURSOR and DATA keys, key in a destination file name up to eight characters long.
6. Press the ENTER key to store the file name and access the file name confirmation display screen. With the CURSOR keys, move the cursor to YES and press the ENTER key to confirm the file name that you stored. If you select NO, the procedure will return to Step 1.
Copying a Schedule to the Power Supply. To copy a welding schedule from the Schedule Welcard to the Power Supply:
1. Press the COPY key to access the Copy Direction dialog screen. It is showing the default direction of the Welcard (CARD) to the Power Supply (IP-215A).
2. With the cursor on the top display screen line, press the ENTRY key
to accept the copy direction. This action will access the Copy Direction Confirmation display screen.
3. Select YES with the CURSOR keys and press the ENTRY key to confirm the copy direction and access the File Number Selection display screen. If you select NO, the procedure will return to Step 1.
4. With the CURSOR keys, move the cursor to the file number (F) field and key in a source file number from 1 to 13.
5. Press the ENTRY key to enter the file number and access the File Name Entry display screen. With the CURSOR and DATA keys, key in a source file name up to eight characters long.
6. Press the ENTRY key to access the File Confirmation display screen. If the file number and name are as you specified, select YES with the
CURSOR keys and press the ENTRY key to execute the data copy from the Welcard to the Power Supply. If you
select NO, the procedure will return to Step 1.
Welcard System Error Messages
Refer to Table 6-1 for a list of error messages that are displayed when a system or operating error occurs.
Table 6-1. Welcard Error Messages
Display Message Probable Cause Remedy
? UNFORMATTED CARD 1. Unformatted card is installed.
2. Damaged card is installed.
3. Card battery is dead.
Format the card.
Install undamaged card and format the card.
Replace the battery and format the card.
COPY FROM
UNFORMATTED CARD IMPOSSIBLE !!
1. Unformatted card is installed.
2. Card battery is dead.
Format the card.
Replace the battery and format the card.
Table 6-1. Welcard Error Messages (continued)
Display Message Probable Cause Remedy
?? CARD IS NOT SET!! The card is not properly installed in its slot.
Install the card properly.
? FILE F [XX] HAS ERROR!!
An error has been found in the card copying operation.
Attempt the copy operation again. If not successful, there is a Power Supply failure or the card is defective. Contact the factory.
? FILE F [XX] HAS NO DATA!!
In the card to Power Supply copy direction, the specified file contains no data.
Specify a file containing data.
FXX [ ] NOT RECORDED When the directory is referenced, the specified file contains no data.
Use a card that has data recorded.
FXX [ ]* COPY IMPOSSIBLE !!
During data copying from the Power Supply to a card, the specified file is found to be write-protected.
Cancel file write protection.
(Refer to Referencing the Directory in this chapter.)
FXX [ ] ERASE?
YES NO
During data copying from the Power Supply to a card, the specified file is found to already exist.
To copy, select YES and press ENTER.
To cancel, select NO and press ENTER.
COPY FROM MONITOR CARD IMPOSSIBLE!!`
Card copying is selected but a Monitor Card is installed.
Replace the Monitor Card with a Schedule Card or reinitialize the installed card as a Schedule Card.
IN CASE OF DIFFICULTY
Your IP-215A and IP-217A Fine Spot Welding Power Supplies are designed with reliability as a top user priority. But, occasionally, you will run into a problem and need some help to get back to normal operation. Reading this chapter will speed up the process.
General Kinds of Problems
NOTE: It has been our experience that 99% of all resistance welding power supply problems are caused by lack of material control, process control and electrode tip surface maintenance.
The problems that you might encounter fall into two groups:
Soft — The problem is transient, and you can correct it by resetting the system or resetting parameter limits, for example.
Hard — The problem is embedded in the system and some form of repair or modification will be needed.
In either case, built-in automatic self-test and self-calibration routines will bring up alarm mes-ages on the display screens. These messages will usually let you know what action is required of you to correct the reason for the alarm. For a complete listing of the alarm
messages, what they mean, and what to do about them, please refer to Appendix E for Power Supply alarm messages or Chapter 6 for Welcard System alarm messages.
Electrode Maintenance
When a welding schedule has been suitable for a particular welding application over many welds, but poor quality welds are now resulting, electrode deterioration could be the problem. If you need to increase welding current to maintain the same weld heat, the electrode tip has probably increased in surface area (mushroomed), effectively increasing weld current density, thus cooling the weld. If you have developed a history of weld current/electrode wear relationship, use the step-up function to provide weld current compensation. Otherwise, try replacing the electrodes.
The rough surface of a worn electrode tip tends to stick to the work pieces. So, periodic tip resur-acing (dressing) is required to remove pitting, oxides and welding debris from the electrode. You should limit cleaning of an electrode on the production line to using a #400-
Figure 7-1. Factory Adjusted Display Viewing Angle
600 grit electrode po-ishing disk. If you must clean a badly damaged tip with a file, you must use a polishing disk after filing to ensure that the electrode faces are smooth.
The best method of preventing electrode problems is to regularly re-grind electrode tip surfaces and shapes in a certified machine shop.
WARNING: Only qualified technicians should perform
internal adjustments or replace parts. Removal of the unit cover could ex-pose personnel to high voltage and may void the warranty.
Adjusting the Display Viewing Angle
The viewing angle of the display screen is set at the factory at approximately 30° (see Figure 7-1). You may adjust the angle with the CONTRAST screwdriver adjustment on the rear panel. Turn-ing the adjustment clockwise and counterclockwise moves the viewing angle downward and upward respectively.
Memory Backup Battery Replacement
IP2PCB.WPG
Figure 7-2. Memory Backup Battery Location
The lithium memory backup battery is located at the bottom center of the Power Supply main printed circuit board (see Figure 7-2). Although the battery’s operational life is five years, we recommend that you replace this battery routinely every three years.
Technical Assistance
If you need further technical assistance, please contact either your authorized service agent or:
UNITEK MIYACHI CORPORATION 1820 South Myrtle Avenue
Monrovia, CA 91017-7133 Phone: (818) 303-5676
FAX: (818) 358-8048
TWX: (910) 585-1836
Technical Specifications
POWER
Input Power Line Voltage Range . . . 220 VAC, ±10%, 3 Phase, 50/60 Hz
Input Power Line Current (peak maximum) . . . IP-215A: 50A IP-217A: 200A Control Frequency . . . 1 KHz IP-215A Heat 1 and Heat 2 Setting Ranges:
Heat 1 (Constant Current Control) . . . 0.20 - 2.00 KA Heat 1 (Constant Voltage Control) . . . 0.20 - 2.00 V Heat 2 (Constant Power Control) . . . 0.04 - 4.00 KW IP-217A Heat 1 and Heat 2 Setting Ranges:
Heat 1 (Constant Current Control) . . . 0.40 - 4.00 KA NOTE: If a Model IT-500A Welding Transformer is selected and the current setting is more than 2.01 KA, a current setting error will occur.
Heat 1 (Constant Voltage Control) . . . 0.40 - 4.00 V Heat 2 (Constant Power Control) . . . 0.16 - 9.99 KW Monitor Setting Ranges:
Constant Current Control . . . ±0.00 - 9.99 KA Constant Voltage Control . . . ±0.00 - 9.99 V Constant Power Control . . . ±0.00 - 9.99 KW NOTE: A 0.00 setting turns off monitoring.
Power Supply Memory Back-Up:
Type . . . Lithium battery, Fuji CR2/3 8.L or equivalent Service Life (minimum): . . . 5 years
ENVIRONMENT
Ambient Operating Temperature . . . 0° to +45° C (32° to 113° F)
PHYSICAL
Dimensions:Height . . . 269 mm (10.5 in.) Width . . . IP-215A: 142 mm (5.5 in) IP-217A: 172 mm (6.8 in.) Depth . . . IP-215A: 436 mm (17.2 in.) IP-217A: 466 mm (18.3 in.) Weight . . . IP-215A: 10 kg (22 lb) IP-217A: 13 kg (28.6 lb)
ELECTRICAL
Control Methods:
Constant Current, Constant Voltage, Constant Power
Number of Weld Schedules Stored in Memory . . . 7 Total Step Count Setting Range for Each Weld Schedule . . . 00000 - 99999 Timer Setting Ranges for Each Weld Schedule:
Rise 1 (R1) (included in Weld 1) . . . 0 - 49 msec Weld 1 (W1) . . . 0 - 99 msec Cool (CO) . . . 0 - 99 msec Rise 2 (R2) (included in Weld 2) . . . 0 - 49 msec Weld 2 (W2) . . . 0 - 99 msec Mode Selection Settings for Each Weld Schedule:
NOTE: The characters in parentheses indicate what is shown on the display screen.
Current Monitor (IM) . . . OFF (0)/Weld 1(1)/Weld 2 (2) Voltage Monitor (VM) . . . OFF (0)/Weld 1 (1)/Weld 2 (2) Power Monitor (WM) . . . OFF (0)/Weld 1 (1)/Weld 2 (2) Start and End Output Mode (MR) . . . OFF(0)/ON(1) 7-Schedule Start (7S) . . . OFF(0)/ON(1) Panel Schedule Start (PS) . . . OFF(0)/ON(1) Program Lock (NP) . . . OFF(0)/ON(1)
Mode Selection Settings for Each Weld Schedule (continued):
Feedback Gain Adjustment (C-GAIN=) . . . IP-215A: (0) - (9) IP-217A: (0) - (5) Data Output (D-OUT=) . . . (OFF)/(ON) I/O Signal Connector Functions:
NOTE: Please refer to Appendix B for signal specifications.
Input Signals: 5 normally open contacts – START 1 - START 4 and TROUBLE RESET Mechanical Relay Output Signals . . . 2 normally open contacts – END OUTPUT
and TROUBLE OUTPUT Transistor Output Signal . . . COUNT END OUTPUT DATA Connector Function (Optional Connector) . . . RS-485 Protocol Data Port Welding Transformer Compatibility:
NOTE: Please refer to Appendix C for welding transformer specifications.
IP-215A . . . IT-500A, IT-501A IP-217A . . . IT-500A, IT-501A, IT-510A, IT-511A, IT-512A, IT-540A Welding Transformer Selection Interval Time,
Multiple Weld Head Operation . . . 10 to 990 msec in 10 msec increments Welding Transformer Selection Channels, Multiple Weld Head Operation . . . 0 - 4 Welcard Schedule Card Capacity . . . 91 weld schedules (7 schedules, 13 files/schedule) Welcard Monitor 1 Card:
Parameters Stored . . . Start No., Step No., Current 1 and Current 2 values, Time Number of Parameters Stored (max) . . . 3,584 Welcard Monitor 2 Card:
Parameters Stored . . . Start No., Monitored Current ±%, Time Number of Parameters Stored . . . 7,168 Welcard Battery Back-Up:
Type . . . Lithium BR2016 Service Life (minimum) . . . 5 Years
APPENDIX B
Cable Wiring and
Signal Specifications
Power Cable Wiring and Interconnections
The Power Supply AC input cable is
supplied in the shipping kit. The
cable wiring and interconnections
for the IP-215A and IP-217A are as
follows:
Welding Transformer Cable Connections
The welding transformer AC
input and voltage sensing cables are
supplied in the shipping kit. The
cable wiring and interconnections
for the IP-215 and IP-217A are as
follows:
