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Welding System
Miyachi Unitek STA-200A
Amada Miyachi Unitek STA-200A User Manual
154 pages
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990-351 Rev H
AC WELDER
STA SERIES
OPERATION MANUAL
2
Table of Contents
Default Chapter
2
Revision Record
2
Contact Us
3
Safety Notes
4
Table of Contents
5
Chapter 1 . Description
15
Section I: Features
15
Overview
15
Standard Features
16
Optional Features
16
Section II: Major Components
17
Major Components
17
Front Panel Controls and Indicators
19
Error
19
LCD Display
19
Program/Save
19
Ready
19
Start
19
Weld
19
Cursor
20
Data + on | off
20
Schedule
20
Valves
20
Weld ON/OFF
20
Modes
21
Monitor
21
Programming Lock
21
Reset
21
Stepper
21
External Connectors
21
Cylinder Air Hose Connections
22
Internal Access
22
Option Cards
23
Electrical Connections
23
Chapter 2. Installation and Setup Section I: Planning for Installation
25
Environmental Factors
25
Space and Mounting Requirements
25
Power Requirements
25
Cooling Water Requirements
25
Section II: Control Set-Up
26
Unpacking
26
Installation
26
Mounting the Control
26
Connecting Electrical Power
26
Secondary Current Sensing
27
Placement of Secondary Current Coils
27
Valve Transformer Wiring Connections
27
Cooling Water Hose Connections
27
Input/Output Signal Connections
27
Chapter 3. Using STA Series Control Functions Section I: Overview
29
Section II: Schedule Screen
30
Schedule
30
Program/Save
30
CO (Cool Time)
31
UP2 (Weld 2 Upslope Time)
31
W2 (Weld 2 Time)
31
DN2 (Weld 2 Downslope Time)
31
Off
31
Mode
31
Current Setting
31
CH (Force Output Channel)
31
Force
31
Elecvalve (Valve Associated with Electrode)
31
COPY to # - Copying a Schedule
32
Section III: Valves Screen
33
Schedule
33
Program/Save
33
Electrode Valve 01
33
Status
33
Count
33
Section IV: Monitor Screen
34
CURR (Weld Current)
34
COND (Conduction Angle)
34
Volts
34
Force(Lbs)
34
LO (Low Current Limit)
34
HI (High Current Limit)
34
Section V: Monitor Counts Screen
36
Weld Count
36
Weld Count Limit
36
Set Weld Count=0
36
Step Count
36
Elect. Valve
36
Section VI: Mode Screen
37
Program/Save
38
Start
38
Weld Mode
38
Chaining Mode
38
Repeat Mode
38
Spot Weld Mode
38
Successive Mode
38
Linked Sched
39
Section VII: Linked Schedules Screen
40
Reference
40
Schd
40
CURR WELD CNT (Weld Counts for Schedule)
40
Weld Mode
40
Error
40
Section VIII: System Values Screens
41
System Values Screen 1
41
BIN. SCHED. SELECT (Binary Schedule Select)
41
CNTRL MODE (Control Mode)
41
Coil
41
Contrast
41
Firing Switch
41
Turns Ratio
41
87° DELAY (on or OFF)
42
Auto Reset
42
End Output
42
Low Line Alarm
42
Mode
42
MORE (System Value Screen 2)
42
NUM VALVES (Number of Valves)
42
Step End Output
42
Valves Status
42
Weld On/Off
42
Error Output
43
Master Cntl
43
Set Defaults
43
Unit Address
43
System Values Screen 3
43
Retraction
43
Back Pressure
44
Monitored Time
44
Monitored Volts
44
Output Force
44
Pressure Switch
44
Screen 2
44
Section IX. System Valve Status Screen
45
VALVE (Valve Numbers)
45
CNT (Weld Count)
45
RESET (Reset Count to Zero)
45
SCR (SCR Used with each Valve)
45
Section X: Force Calibration Screen
46
Section XI. Stepper Screen
47
Valve Num
47
Stepper (On/Off)
47
Count
47
Heat
47
Chapter 4. Operating Instructions
49
Section I: Introduction
49
Overview
49
General Operator Safety
49
Section II: Preparing for Operation
50
Turning the Equipment on
50
Pre-Operational Setup
51
Section III: Setup Messages
52
Section IV. Operation
54
Spot Welds
55
Continuous Seam Weld
56
Cascading (Multiple Scrs)
57
Section V: Operational Messages
59
Major Run-Time Error Messages
59
Minor Run-Time Error Messages
61
Section VI: Shutdown
63
Emergency Shutdown
63
Normal Shutdown
63
Chapter 5. Maintenance Section I: Precautions
65
Section II: General Information
65
General Maintenance Procedures
65
Cooling Maintenance-Water Draining
65
Fuse Replacement
66
Principles of Operation
66
Wiring Diagram
67
Section III. Standard Components Replacement
69
AC Timer Main Board
69
Power Transformer T1
71
Power Transformer T2
71
Valve Transformer, T3
71
Surge Resistors
71
Snubber
71
SCR Drive Board
72
Control Panel Assembly
73
Section IV. Optional Components Replacement
74
Optional Primary Current Sensor
74
Optional Secondary Current Sensor Connector
74
Optional Key Lock
75
Optional SCR Assembly, 600,1200, 1800, and 2200 Amp
75
Section V. Spare Parts
76
Section VI. Repair
77
Section VII. Storage and Shipment
77
Preparation for Storage or Shipment
77
Packing for Storage or Shipment
77
Appendix A. Technical Specifications
79
Appendix B. Electrical and Data Connections
83
Appendix C. SCR, Wire Gauge, and Circuit Breaker Selection
91
Appendix Dsystem Timing
95
Appendix E. Cascade Option
105
Appendix F. Valve Expansion Board Option
105
Appendix G. Voltage Monitor Board Option
107
Appendix H. Force Control Option
109
Appendix I. Pressure Control Option
142
Appendix J. Communications
142
Appendix K. Circuit Modification for External Transformer Thermostat
142
Appendix L. Default Initializations
142
Index
145
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Amada Miyachi Unitek STA-200A Specifications
General
Output Power
200 W
Frequency
50/60 Hz
Cooling Method
Air-cooled
Power Supply
Single-phase
Duty Cycle
50%
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