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Miyachi Unitek 250DPS User Manual
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USER'S MANUAL
990-280
Revision H
March 2004
250DP DUAL PULSE
STORED ENERGY RESISTANCE WELDING
POWER SUPPLIES
Model
Stock
No.
250DP 1-250-XX
250DP/208 1-250-XX-01
250DP/230 1-250-XX-02
250DP/100 1-250-XX-03
250DPS 1-254-XX
250DPS/208 1-254-XX-01
250DPS/230 1-254-XX-02
250DPS/100 1-254-XX-03
NOTE: Units with the built-in Weld Sentry
Option also require User's Manual No. 990-291.
2
Table of Contents
Default Chapter
2
Revision Record
2
Table of Contents
3
Contact Us
9
Safety Notes
10
Chapter 1: System Description
13
Applications
13
Features
14
Chapter 2: Installation
17
Location
17
Power Line
17
Welding Cables
17
Cable Routing Examples
18
Rear Panel Components
19
Firing Switch Connections
20
Mechanical Firing Switch
20
Optical Firing Switch
20
Wire Firing Switches
20
Air Actuated Weld Head Connections
21
Air Valve Driver
22
Air Actuated Weld Heads Without Force Firing Switches
23
Second Air Head
23
Footswitch
23
1-Level Footswitch
23
2-Level Footswitch
24
Remote Schedule Selection
24
Relay Outputs
24
Interconnection Diagram
25
Chapter 3: Operating Controls and Screens
27
Operating Controls
27
Screen Formats
29
Screen Flow Chart
31
Chapter 4: Getting Started
33
Powering up
33
Adjusting an Air Actuated Weld Head
33
Typical Solenoid Air Valve System with a Single Regulator
35
Measuring Preset Firing Force of the Weld Head with a Force Gauge
36
Results of Excessive Air Pressure
37
Chapter 5: Operating Instructions
39
Successful Welding
39
Resistance Welding Parameters
39
Weld Schedule Development
39
Weld Head Parameters
40
Recommended Electrode Materials
41
250DP Power Supply Parameters
42
Making a Weld
42
Evaluating the Weld
42
Weak Weld
43
Electrode Sticking
43
Causes of Imperfect Welds
43
Electrode Force and %Energy
43
Polarity
44
Weld Strength Profiles
45
Destructive Testing
45
Electrode Maintenance
46
Chapter 6: Process Definitions and Weld Functions
47
250DP States
47
RUN State
47
STANDBY State
48
PROGRAM State
48
MENU State
49
HELP State
50
NO WELD State
50
FIRE State
50
Weld Function Field
50
Basic Function
51
Repeat Function
52
Rollspot Function
53
Chapter 7: Maintenance
55
Modification and Calibration
55
Cover Removal
55
Capacitor Bank Modifications
55
Line Voltage Changes
56
VAC Line Voltage Configuration
58
VAC Line Voltage Configuration
59
VAC Line Voltage Configuration
60
VAC Line Voltage Configuration
61
Calibration
62
Power Supply Voltage Range Specifications
63
Troubleshooting
64
Repair Service
65
Factory Service Repair
65
Telephone Service
65
Appendix A: Technical Specifications
67
250DP Power Supply
67
Power Requirements
67
Capacitor Bank
67
Output Pulse Characteristics
67
Weld Fire Lockout
68
Line Voltage Regulation
68
Turndown Circuit
68
Line Failure Turndown
68
Over-Voltage Lockout
69
Charge Lockout Circuit
69
Polarity Selection
69
Welding Speed
69
Weld Schedules
72
Weld Schedule Definition
72
Options
72
Schedule Number at Power-Up
73
Utilities
73
Information
73
Weld Sentry
73
System Setup
74
Weld Functions
74
Head Type
74
Squeeze Line
74
Cool Time
75
Hold Time
75
Footswitch Type
75
FOOTSWITCH Connector
75
Footswitch Weld Abort Feature
76
Footswitch Weld Abort on
76
Footswitch Weld Abort off
76
Firing Switch Type
76
Firing Circuit
76
Switch Debounce Time
77
Mechanical Firing Switch Cable
77
Model 250Dp Dual Pulse Resistance Welding Power Supply
77
Optical Firing Switch Connector
77
Initiation Switch
78
Manual Head Operation
78
Air Head Operation
78
Chain Schedules Feature
78
Step Count
78
Next Schedule
79
Audible Buzzer
79
End of Cycle Buzzer ON/OFF
79
Key Click
79
Weld Counter
80
Alarms
80
Air Valve Driver 1
80
Air Valve Driver 2
81
Air Valve Driver Receptacles
81
Control Signals Connector
81
Emergency Stop
82
Charge (Process) Inhibit
83
Remote Weld Schedule Selection
83
Binary Schedule Selection Code
84
Relay Outputs
85
Accessory Port
86
Input/Output Cable Connectors and Fusing
86
Input Line Power
86
Circuit Breakers
86
Fuses
86
Power Input Connector
86
Front Panel Switches
87
Microprocessor CPU
87
Display
87
Cooling
87
Physical Characteristics
88
Index
89
5
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Miyachi Unitek 250DPS Specifications
General
Brand
Miyachi Unitek
Model
250DPS
Category
Power Supply
Language
English
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