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PHASEMASTER 6
Unitek Peco PHASEMASTER 6 User Manual
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USER'S MANUAL
No. 990
-
083
Revision D: January 2002
PHASEMASTER™ 6
DIRECT ENERGY WELDING CONTROL
MODEL NUMBER
STOCK NUMBER
PM6
1
-
237
-
XX
PM6/115
1
-
237
-
XX
-
01
PM6/230
1
-
237
-
XX
-
02
PM6/100
1
-
237
-
XX
-
03
PM6/460
1
-
238
-
XX
AIR
MANUAL
NO WELD
WELD
2 LEVEL
1 LEVEL
MACHINE
SCR
OFF
ON
RUN
SAVE
PROGRAM
SCHEDULE
NUMBER
POLARITY
SQUEEZE
CYCLES
WELD
CYCLES
HOLD
CYCLES
% CURRENT
HEAD
TYPE
FOOTSWITCH
FOOTSWITCH
WELD ABORT
ALARM
PHASEMASTER
TM
6
AC WELDING CONTROL
2
Table of Contents
default chapter
2
Revision Record
2
Foreword
3
Safety Notes
4
Table of Contents
5
Chapter 1: Description
12
Section I. Features
12
Features
12
Process Definitions
13
Sequence Welding Function
13
Weld Schedule
13
Remote Weld Schedule Selection
13
Run State
14
Program State
14
Section II. Major Components
15
Front Panel Description
15
Front Panel Keys and Switch
15
Indicators and Displays
16
Rear Panel
18
Chapter 2: Getting Started
19
Section I. Planning for Installation
19
Location
19
Power Line
19
Welding Cables
19
Output Cable
21
Initiation Switch Connection
21
Firing Switch
21
Optical Firing Switch
21
Installing Air Actuated Weld Heads
22
Air Valve Driver
23
Footswitch
24
1-Level Footswitch
24
Footswitch Weld Abort
24
Replace Cover
25
External Inputs Connections
26
Chapter 3: Operating Instructions
29
Section I. Operation
29
Power up
29
Select Run or Program State
29
Select Schedule
29
Change Schedule Parameters
29
Change Parameters for Schedules 1 through 7
31
Copying Information in Schedule 0 to Another Schedule
32
Alarms
32
SCR Alarm A1
32
Machine Alarm A2
32
Machine Alarm A3
33
Machine Alarm A4
33
Machine Alarm A5
33
Section II. Programmable Options
33
Status Display
33
Schedule Protection Feature
35
Line Voltage Compensation Feature
35
Line Voltage Compensation Feature on
36
Line Voltage Compensation Feature off
36
Alarm Display
36
Change Schedule Protection
38
Schedule Protection Feature on
38
Schedule Protection Feature off
38
Section III. Adjusting Weld Heads
39
Adjusting Air Actuated Weld Heads
39
Measuring Preset Firing Force of the Weld Head with a Force Gauge
40
The Weld
40
Section IV. Developing Weld Schedules
41
Resistance Welding Parameters
41
Weld Schedule Development
41
Weld Head Parameters
42
Welding Transformer Parameters
43
PM6 Control Parameters
44
Making a Weld
44
Evaluating the Weld
45
Weak Weld
45
Electrode Sticking
45
Electrode Force and %CURRENT
46
Causes of Imperfect Welds
46
Polarity
46
Output Voltage Vs Weld Quality
47
Test Condition a
48
Test Condition B
48
Weld Strength Profiles
49
Destructive Testing
49
Typical Weld Strength Profile
49
Evaluate Results
50
Electrode Maintenance
50
Chapter 4: Maintenance
51
Modification and Calibration
51
Cover Removal
51
Line Voltage Modification
51
Calibration Check
52
Control Transformer Inside the PM6, Connected for 230V
52
Check Weld/No Weld Switch
53
Half Cycle Symmetry
53
Line Count
53
Memory Initialization
54
Repair Service
54
Telephone Service
54
Factory Service Repair
54
Appendix A: Technical Specifications
55
Section I. Specifications
55
Line Voltage
55
50/60 Hz Operation
55
Output Current Vs Duty Cycle
55
Weld Schedules
55
Schedule Protection Feature
56
Sequence Welding Function
56
Squeeze Period
56
Weld Period
56
Weld Current
56
Hold Period
56
Automatic Line Voltage Compensation
57
Polarity Selection
58
Power Factor Correction
58
Head Type
58
Valve Driver
58
Footswitch
59
Initiation
59
Footswitch Weld Abort on
59
Footswitch Weld Abort off
59
Footswitch Weld Abort On/Off
60
Alarms
60
Alarm Buzzer
60
Front Panel Switches
61
Input/Output Cable Connectors and Fusing
61
Circuit Breakers and Fuses
61
Input and Output Cables
62
Firing Switch Cable
62
Optical Firing Switch Connector
62
Footswitch Connector
63
Valve Driver Connector
63
External Inputs Connector
63
Emergency Stop
64
Remote Weld Inhibit
64
Remote Weld Schedule Selection (PM6)
64
Physical Characteristics
65
PM6 Outline Drawing
66
Section II. UNIPULSE Transformer Specifications and Features
67
Transformer Specifications
67
Transformer Physical Characteristics
68
Input Connector
68
UNIPULSE Welding Transformers
68
Forced Air Option
69
Maximum Repetition Rate
69
Transformer Primary Tap Switch
69
Duty Cycle
69
4
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Unitek Peco PHASEMASTER 6 Specifications
General
Brand
Unitek Peco
Model
PHASEMASTER 6
Category
Controller
Language
English
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