Ip-215A and Ip-217A Fine Spot Welding Power Supplies

User's Manual 993-603 Revision A: October, 1996

IP-215A AND IP-217A FINE SPOT WELDING POWER SUPPLIES

Model Definition

IP-215A Standard 50 Amp Power Supply

IP-215A/RS485 50 Amp Power Supply With RS-485 Data Port

IP-217A Standard 200 Amp Power Supply

IP-217A/RS485 200 Amp Power Supply With RS-485 Data Port

WARNING: Please be sure to read all personnel and equipment safety precautions noted in this manual.

Prepared by Unitek Miyachi Corporation 1820 South Myrtle Avenue Monrovia, CA 91017-7133 Phone (818) 303-5676 FAX (818) 358-8048 TWX (910) 585-1836 IP-215A and IP-217A Fine Spot Welding Power Supplies User's Manual 993-603, October 1996, Revision A

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

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 i CAUTIONS 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

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES iv 993-603 REV A: October, 1996 5 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.

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 v CONTENTS

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

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES vi 993-603 REV A: October, 1996 CONTENTS (continued) 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

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 vii CONTENTS (continued)

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

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES vi 993-603 REV A: October, 1996 CHAPTER 1 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 considerations 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.

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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 information clearly and concisely. If you have any suggestions for improving the manual, please

IP-215A/217A FINE SPOT WELDING POWER SUPPLIES 1-2 993-603 REV A: October, 1996 CHAPTER 1: ABOUT YOUR MANUAL 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

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CHAPTER 2 ABOUT YOUR EQUIPMENT

Overview The IP-215A/IP-217A is a high frequency inverter resistance welding power supply designed for fine spot welding of precision parts. Figure 2-1 shows the physical 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 parameter 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 equipment.

Performance Features IP2PFRON.WPG Figure 2-1. IP-215A Fine-Spot For a complete listing of the Power Supply’s technical Welding Power Supply specifications, please refer to Appendix A. The following is a summary of the Power Supply’s performance capabilities.

Feedback Control Modes Constant Current: Use where welding load resistance 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.

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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

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Sense Cable Data I/O Cable

IP2MA600.WPG Figure 2-2. Using the Power Supply With Multiple Welding Transformers

I/O Cable Connector User’s Manual, Part No. 993-603

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CHAPTER 3 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).

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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.

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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 adjusting the selected welding parameters each time until you reach production weld quality. The opera-ting controls and the display are described in Chapter 4. Detailed operating instructions for

IP-215A/217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 3-3 CHAPTER 3: GETTING STARTED 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)

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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.

The Second Trial Weld

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.

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CHAPTER 4 CONTROLS

Rear Panel Components The components on the rear panel are shown in Figure 4-1.

IP2BACK.WPG Figure 4-1. Rear Panel Components

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.

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Data I/O Connector: Optional 15 pin D-connector for remote programming 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 transformer. The output cable is supplied in the shipping kit. Please see Appendix B for signal 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

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IP2FRONT.WPG Figure 4-2. Front Panel Controls and Display

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 4-3 CHAPTER 4: CONTROLS 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

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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).

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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.

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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

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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

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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 screen allows you to monitor the number of welds (shown here as WELD COUNT = 04589)

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 4-9 CHAPTER 4: CONTROLS 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.

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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 example, 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.

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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) 0.20 - 2.00 KA Constant Voltage Control (215) 0.20 - 2.00 V Constant Power Control (215) 0.40 - 4.00 KW Constant Current Control (217) 0.40 - 4.00* KA Constant Voltage Control (217) 0.4 - 4.00 V Constant Power Control (217) 0.16 - 9.99 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) Model No. IT-501A (215, 217) Model No. IT- 510A (217) Model No. IT-511A (217) Model No. IT-512A (217) Model No. Feedback Gain (C—GAIN=) 0 - 9 (215) Units 0 - 5 (217) 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)

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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).

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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

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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:

IP2LIM.WPG

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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.

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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 during 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).

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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.

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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

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 5-9 CHAPTER 5: OPERATING YOUR POWER SUPPLY 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.

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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

ME35.WPG store it in a safe place. Figure 6-1. The Welcard Data Storage Battery: System 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.

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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 contents 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 optional 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:

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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:

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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 installed, 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.

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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.

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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 Format the card. installed. 2. Damaged card is installed. Install undamaged card and format the card. 3. Card battery is dead. Replace the battery and format the card. COPY FROM 1. Unformatted card is Format the card. UNFORMATTED CARD installed. IMPOSSIBLE !! 2. Card battery is dead. Replace the battery and format the card.

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Table 6-1. Welcard Error Messages (continued) Display Message Probable Cause Remedy ?? CARD IS NOT SET!! The card is not properly Install the card properly. installed in its slot. ? FILE F [XX] HAS An error has been found in Attempt the copy operation ERROR!! the card copying operation. again. If not successful, there is a Power Supply failure or the card is defective. Contact the factory. ? FILE F [XX] HAS NO In the card to Power Supply Specify a file containing data. DATA!! copy direction, the specified file contains no data. FXX [ ] NOT RECORDED When the directory is Use a card that has data referenced, the specified file recorded. contains no data. FXX [ ]* COPY During data copying from Cancel file write protection. IMPOSSIBLE !! the Power Supply to a card, (Refer to Referencing the the specified file is found to Directory in this chapter.) be write-protected. FXX [ ] ERASE? During data copying from To copy, select YES and YES NO the Power Supply to a card, press ENTER. the specified file is found to To cancel, select NO and already exist. press ENTER. COPY FROM MONITOR Card copying is selected but Replace the Monitor Card CARD IMPOSSIBLE!!` a Monitor Card is installed. with a Schedule Card or reinitialize the installed card as a Schedule Card.

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CHAPTER 7 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-

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 7-1 CHAPTER 7: IN CASE OF DIFFICULTY

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

Figure 7-1. Factory Adjusted 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

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 7-2 993-603 REV A: October, 1996 CHAPTER 7: IN CASE OF DIFFICULTY

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

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 7-3 CHAPTER 7: IN CASE OF DIFFICULTY

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

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 7-4 993-603 REV A: October, 1996 APPENDIX A Technical Specifications

IP-215A/217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 A-1 APPENDIX A: 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)

IP-215A/217A FINE SPOT WELDING POWER SUPPLIES A-2 993-603 REV A: October, 1996 APPENDIX A: TECHNICAL SPECIFICATIONS

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)

IP-215A/217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 A-3 APPENDIX A: TECHNICAL SPECIFICATIONS

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

IP-215A/217A FINE SPOT WELDING POWER SUPPLIES A-4 993-603 REV A: October, 1996

APPENDIX B Cable Wiring and Signal Specifications

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 B-1 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:

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES B-2 993-603 REV A: October, 1996 CABLE WIRING AND SIGNAL SPECIFICATIONS

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:

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 B-3 CABLE WIRING AND SIGNAL SPECIFICATIONS

Welding Transformer Cable Connections (continued)

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES B-4 993-603 REV A: October, 1996 CABLE WIRING AND SIGNAL SPECIFICATIONS

Welding Transformer Cable Connections (continued)

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 B-5 CABLE WIRING AND SIGNAL SPECIFICATIONS

Input/Output Cable and Signal Specifications The I/O connector on the rear panel is the means of exchanging input and output signals between

the Power Supply and external equipment such as relay contacts, switch contacts and line drivers. The I/O connector is provided in the shipping kit. You add cabling to suit your system requirements. The pin-in/pin-out diagram to the right of the I/O connector shows the input signal (pins 1 through 13) and output signal (pins 15 through 20) schematics.

START Inputs. The START signals initiate the weld cycle. Use normally open, dry

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES B-6 993-603 REV A: October, 1996 CABLE WIRING AND SIGNAL SPECIFICATIONS contact, no voltage relay contacts or open collector transistor opto-coupler devices. In the 4-schedule start mode, each one of the four input signals individually selects a single weld schedule. With the weld head firing switch connected across Pins 2 and 5 (START 2) for example, Weld Schedule 2 will start when the firing switch closes. In the 7-schedule start mode, the four input START signals are used to define the BCD number of the desired weld schedule, as follows: Pin 1: START 1 (Bit 20 ) Pin 2: START 2 (Bit 21 ) Pin 3: START 3 (Bit 22 ) Pin 4: START 4 (Bit 23 ) In this mode, the firing switch could be connected typically in series between Pin 5 (ground) and the START signal ground bus. Weld Schedule Selection and Start Timing. The weld schedule number is defined within 20 milliseconds from the ON state of the first START signal. If the first START signal is shorter than 20 milliseconds, the weld cycle will not start. As shown in the timing diagram on the following page, Weld Schedule 3 is being selected since START 1 and START 3 are turned ON within the 20-millisecond window.

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 B-7 CABLE WIRING AND SIGNAL SPECIFICATIONS

The schedule selection and start scheme is shown in the following table:

Weld Schedule Number Weld Schedule Start Type 1 2 3 4 5 6 7

4-Schedule (7S = 0):

START 1

START 2 START 3

START 4

Signal is ON (Closed)

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES B-8 993-603 REV A: October, 1996 CABLE WIRING AND SIGNAL SPECIFICATIONS

Weld Cycle Timing. The first of the following two timing diagrams illustrates the sequence of events during the weld cycle for driving a single welding transformer with one welding control. The second timing diagram illustrates the sequence of events during the weld cycle for sequentially switching between four welding transformers using one welding control. The single welding transformer timing diagram results from a SCAN = 0 setting on the Mode

Selection extension display screen (refer to Chapter 5 under Selecting the Welding Transformer). The timing diagram for four welding transformers results from a SCAN = 4 setting on the Mode Selection display screen. You select the scan interval time also with this display screen.

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 B-9 CABLE WIRING AND SIGNAL SPECIFICATIONS

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES B-10 993-603 REV A: October, 1996 CABLE WIRING AND SIGNAL SPECIFICATIONS

Reset Input Pins 6-7: RESET is a normally open switch. When actuated, it resets an error signal.

Weld Input (IP-215 Only) Pins 12-13: The WELD input signal controls the weld ON/OFF sequence through an external, normally closed switch. With the WELD switch open, no weld current flows but the weld sequence is executed.

Count Up Output

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 B-11 CABLE WIRING AND SIGNAL SPECIFICATIONS

Pins 15-16: The COUNT UP output turns on when the weld counter reaches the user pre-set limit. The output transistor can control 24 VDC at 0.1 A maximum. Reset the COUNT UP output by simultaneously pressing the front panel COUNT and RESET keys

Error Output Pins 17-18: Provides an error signal output when an error is detected. Can control a 24/115 VAC, 0.5 A maximum load. The mechanical relay is opened by shorting the RESET input, pins 6-7.

End Output Pins 19-20: Provides an END output signal at the end of hold time. Can control a 24/115 VAC, 0.5 A maximum load. The END output remains on for 0.1 seconds when the END output feature is enabled.

Sense Cable Connections The Sense Cable returns voltage, current and over-temperature sense signals from the welding transformer to the Power Supply. The cable transfers welding transformer channel select signals from the Power Supply to the welding transformers. The cable also supplies 220 VAC power to the

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES B-12 993-603 REV A: October, 1996 CABLE WIRING AND SIGNAL SPECIFICATIONS welding transformer. The cable is connected between the Power Supply SENSE IN connector and the welding transformer SENSE connector (or the transformer selector SENSE OUT connector for multiple transformer systems).

NOTE: If the welding

transformer over-temperature sensor is not connected, you must jumper pins 5 and 13. Otherwise, you will not be able to start the weld cycle.

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 B-13

APPENDIX C Welding Transformer Specifications

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 C-1 APPENDIX C: WELDING TRANSFORMER SPECIFICATIONS

Model Specification IT-500A IT-501A IT-510A IT-511A IT-512A IT-540A Rated Capacity 2.0 2.3 4.1 4.7 10.7 17.2 (KVA) Maximum Input 300 300 300 300 300 300 Voltage (V) Input Frequency 221111 (kHz) Secondary Voltage 6.25 8.1 6.5 8.57 12/10 9.37 Without Load (V) Maximum Current 21.543451 (KA) Duty Cycle (%)876557 Cooling Air Air Air Air Air Water2 Weight (kg/lb) 6.5/14.3 7.0/15.4 13.0/28.6 14.0/30.9 19.0/41.9 15.0/33.1 Width (mm/in.) 138/5.4 138/5.4 183/7.2 183/7.2 183/7.2 155/6.1 Height (mm/in.) 176/6.9 176/6.9 184/7.2 184/7.2 184/7.2 105/4.1 Depth 280/11.0 295/11.6 340/13.4 360/14.2 410/16.1 300/11.8 NOTES: 1 With 15-cycle weld time 2 At 5.7 liters (1.5 U.S. gallons)/minute

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES C-2 993-603 REV A: October, 1996 APPENDIX D Resistance Welding Basics

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 D-1 APPENDIX D: RESISTANCE WELDING BASICS

Resistance Welding Parameters

Resistance welding heat is produced by passing electrical current through the parts for a fixed time period. The welding heat generated is a function of the magnitude of the weld current, the electrical resistance of the parts, the contact resistance between the parts, and the weld force applied to the parts. Sufficient weld force is required to contain the molten material produced during the weld. However, as the force is increased, the contact resistance decreases. Lower contact resistance requires additional weld current, voltage, or power to produce the heat required to form a weld.

The higher the weld force, the greater the weld current, voltage, power, or time required to produce a given weld. Low weld force usually results in lower bond strength. Increased weld force requires higher energy but usually results in a stronger bond. Weld heat is proportional to the square of the welding current (I), the total electrical resistance (Rt), and the weld time (t), and is inversely proportional to the contact area (A).

Welding Parameter Interaction

Figure D-1. Interaction between welding parameters.

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES D-2 993-603 REV A: October, 1996 APPENDIX D: RESISTANCE WELDING BASICS

Electrode Selection

Correct electrode selection strongly influences how weld heat is generated in the weld area. In general, use conductive electrodes such as a RWMA-2 (Copper alloy) when welding electrically resistive parts such as nickel or steel so that the weld heat is generated by the electrical resistance of the parts and the contact resistance between the parts. Use resistive electrodes such as RWMA-13 (Tungsten) and RWMA-14 (Molybdenum) to weld conductive parts such as copper and gold because conductive parts do not generate much internal heat so the electrodes must provide external heat. Use the following Electrode Specification Table for selecting the proper electrode materials.

MATERIAL ELECT MATERIAL ELECT Beryllium -2 Brass -2, -14 RWMA RWMA Copper TYPE TYPE Beryllium -2 Copper -14 Alumel -2 Alumel -2 Copper

Alumel -2 Chromel -2 Beryllium -2 Tinned Copper -14 Copper Alumel -2 Dumet -2 MATERIAL ELECT MATERIAL ELECT Alumimun -1 Alumimun -1 RWMA RWMA TYPE TYPE Alumimun -1 Aluminum -1 Alloys Beryllium -2 Nickel -2 Copper Alumimun -1 Cadmium Plating -1 Beryllium -2 Cold Rolled Steel -2 Alumimun -1 Tinned Brass -14 Copper

Alumimun -1 Tinned Copper -14 Beryllium -2 Stainless Steel -2 Copper Alumimun -1 Gold Plated -2 Dumet Brass -2, -14 Brass -2, -14

Alumimun -1 Gold Plated -2 Brass -2, -14 Tinned Brass -14 Kovar Brass -2, -14 Bronze -2 Alumimun -1 Kovar -2 Brass -2, -14 Consil -2 Alumimun -1 Magnesium -1 Brass -2, -14 Constantan -2 Alumimun -1 Cold Rolled Steel -2 Brass -2, -14 Copper -14 Alumimun -1 Stainless Steel -2 Brass -2, -14 Tinned Copper -14 Beryllium -2 Beryllium -2 Copper Copper Brass -2, -14 Dumet -2

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 D-3 APPENDIX D: RESISTANCE WELDING BASICS

Brass -2, -14 Nichrome -2 Constantan -2 Nichrome -2

Brass -2, -14 Nickel -2 Constantan -2 Nickel -2

Brass -2, -14 NiSpan C -2 Copper -14 Copper -14

Brass -2, -14 Paliney 7 -2 Copper -14 Dumet -2

Brass -2, -14 Silver -11, -14 Copper -14 Invar -2

Brass -2, -14 Cold Rolled Steel -2 Copper -14 Karme -2

Brass -2, -14 Stainless Steel -2 Copper -14 Manganin -2

Bronze -2, -11 Bronze -2, -11

MATERIAL ELECT MATERIAL ELECT MATERIAL ELECT MATERIAL ELECT RWMA RWMA RWMA RWMA TYPE TYPE TYPE TYPE

Bronze -2, -11 Tinned Copper -14 Copper -14 Nichrome -2

Bronze -2, -11 Iron -2 Copper -14 Nickel -2

Bronze -2, -11 Nichrome -2 Copper -14 Paliney 7 -2

Bronze -2, -11 Nickel -2 Copper -14 Silver -11, -14

Chromel -2 Chromel -2 Copper -14 Cold Rolled Steel -2

Chromel -2 Constantan -2 Copper -14 Stainless Steel -2

Chromel -2 Copel -2 Dumet -2 Dumet -2

Chromel -2 Copper -14 Dumet -2 Nichrome -2

Chromel -2 Tinned Copper -14 Dumet -2 Nickel -2

Chromel -2 Dumet -2 Dumet -2 Platinum -2

Chromel -2 Nichrome -2 Dumet -2 Cold Rolled Steel -2

Chromel -2 Cold Rolled Steel -2 Evanohm -14 Copper -14

Consil -2 Consil -2 Gold -14 Gold -14

Consil -2 Tinned Copper -14 Gold -14 Kovar -2

Consil -2 Dumet -2 Hastalloy -2 Titanium -2

Constantan -2 Constantan Inconel -2 Inconel -2

Constantan -2 Copper -14 Inconel -2 Kulgrid -2

Constantan -2 Tinned Copper -14 Invar -2 Invar -2

Constantan -2 Iron -2 Iridium -2 Iridium -2

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES D-4 993-603 REV A: October, 1996 APPENDIX D: RESISTANCE WELDING BASICS

Iridium -2 Platinum -2 Nickel Alloy -2 Tinned Copper -14

Iron -2 Iron -2 Nickel Alloy -2 Nichrome -2

Karma -2 Karma -2 Nickel Alloy -2 Nickel -2

Karma -2 Nickel -2

Karma -2 Platinum -2

Kovar, Gold -2 Kovar, Gold -2 Plate Plate

Kovar, Gold -2 Kulgrid -2 Plate

Kovar, Gold -2 Stainless Steel -2 Plate

MATERIAL ELECT MATERIAL ELECT RWMA RWMA TYPE TYPE

Magnesium -1 Magnesium -1

Molybdenum -2 Molybdenum -2

Molybdenum -2 Nickel -2

Molybdenum -2 Tungsten -2

Nichrome -2 Nichrome -2

Nichrome -2 Nickel -2

Nichrome -2 Cold Rolled Steel -2

Nichrome -2 Stainless Steel -2

Nickel -2 Nickel -2

Nickel -2 Cold Rolled Steel -2

Nickel -2 Stainless Steel -2

Nickel -2 Tantalum -2

Nickel -2 Tungsten -2

Nickel Alloy -2 Nickel Alloy -2

Nickel Alloy -2 Tinned Brass -14

Nickel Alloy -2 Beryllium -2 Copper

Nickel Alloy -2 Consil -2

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 D-5 APPENDIX D: RESISTANCE WELDING BASICS

MATERIAL ELECT MATERIAL ELECT RWMA RWMA TYPE TYPE

Nickel Alloy -2 Cold Rolled Steel -2

NiSpan C -2 NiSpan C -2

NiSpan C -2 Cold Rolled Steel -2

NiSpan C -2 Stainless Steel -2

Niobium -2 Niobium -2

Platinum -2 Platinum -2

Paliney 7 -2 Paliney 7 -2

Silver -11, -14 Silver -11, -14

Silver -11, -14 Cadmium -13

Silver -11, -14 Cold Rolled Steel -2

Silver -11, -14 Stainless Steel -2

Silver -11, -14 Palladium -14

Cold Rolled Steel -2 Cold Rolled Steel -2

Cold Rolled Steel -2 Stainless Steel -2

Cold Rolled Steel -2 Tantalum -2

Stainless Steel -2 Stainless Steel -2

Stainless Steel -2 Tungsten -2

Tantalum -2 Tantalum -2

Titanium -2 Titanium -2

Tungsten -2 Tungsten -2

Zinc -14 Zinc -14

Electrode Maintenance

Depending on use, periodic tip resurfacing is required to remove oxides and welding debris from electrodes. Cleaning of electrodes on production line should be limited to use of #400-600 grit electrode polishing disks. For less critical applications, a file can be used to clean a badly damaged tip. However, after filing, polishing disks should then be used to ensure that the

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES D-6 993-603 REV A: October, 1996 APPENDIX D: RESISTANCE WELDING BASICS electrode faces are smooth. If this is not done, the rough surface of the electrode face will have a tendency to stick to the work piece.

Weld Schedule Development

Developing a weld schedule is a methodical procedure which consists of making sample welds and evaluating the results. The first weld should be made at low energy settings. Adjustments are then made to each of the welding parameters one at a time until a successful weld is made.

1. Install the correct electrodes in the electrode holders on the Weld Head. See the preceding table for electrode material recommendations.

2. Use a flat electrode face for most applications. Use a "domed" face if surface oxides are a problem. If either of the parts is a wire, the diameter of the electrode face should be equal to or greater than the diameter of the wire. If both parts are flat, the face should be at least one-half the diameter of the electrodes. Pencil point electrodes cause severe electrode sticking to the parts, unexplained explosions, and increase the weld heat substantially because of the reduced electrode-to-part contact area.

3. Use the Force Adjustment Knob on the Weld Head to set the Firing Force and adjust an Air Actuated Weld Head per the manufacturer’s instructions. Figure D-1 illustrates the effect of weld force on the parts.

4. Follow the “Getting Started” instructions in Chapter 3 to make your first weld. Always observe safety precautions when welding and wear safety glasses.

5. Use pliers to peel the welded materials apart. A satisfactory weld will show residual material pulled from one material to the other. Tearing of base material around the weld nugget indicates a material failure NOT a weld failure. Excessive electrode sticking and/or "spitting" should define a weld as unsatisfactory and indicates that too much weld current, voltage, power, or time has been used.

6. If the parts pull apart easily or there is little or no residual material pulled, the weld is weak. Increase the weld time in 1 cycle increments. Increase weld current if a satisfactory weld is achieved using 10 cycles of weld time. Note: Actual weld strength is a user defined specification.

7. Polarity, as determined by the direction of weld current flow, can have a marked effect on the weld characteristics of some material combinations. This effect occurs when welding materials with large differences in resistivity, such as copper and nickel or when welding

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 D-7 APPENDIX D: RESISTANCE WELDING BASICS

identical materials with thickness ratios greater than 4 to 1. The general rule is that the more resistive material or the thinner material should be placed against the negative (-) electrode.

Weld Strength Testing

Destructive tests should be performed on a random basis using actual manufacturing parts. Destructive tests made on spot welds include tension, tension-shear, peel, impact, twist, hardness, and macro-etch tests. Fatigue tests and radiography may also be used. Of these methods, torsional shear is preferred for round wire and a 45 degree peel test for sheet stock.

Weld Strength Profiles

Creating a Weld Strength Profile offers you a scientific approach to determining the optimum set of welding parameters and then displaying these parameters in a graphical form.

1. Start at a low weld current, make five or more welds, then perform pull tests for each weld. Calculate the average pull strength. Increase weld current and repeat this procedure. Do not change the weld time, weld force, or electrode area.

2. Continue increasing weld current until any unfavorable characteristic occurs, such as sticking or spitting.

3. Repeat steps 1 and 2 for different weld forces and then create a plot of part pull strength versus weld current for different weld forces as shown in Figure D-2.

4. Repeat steps 1 through 3 using a different, but fixed weld time.

Weld Strength Profile

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES D-8 993-603 REV A: October, 1996 APPENDIX D: RESISTANCE WELDING BASICS

Figure D-2 illustrates a typical Weld Strength Profile. Curve C shows the highest pull strengths but the lowest tolerance to changes in weld current. Curve B shows a small reduction in strength but considerably more tolerance to changes in weld current. Weld heat will vary as a result of material variations and electrode wear. Curve B is preferred since it shows more tolerance to changes in weld current and has nearly the same bond strength as Curve C. A comparison of weld schedules for several different applications might show that they could be Figure D-2. Weld Strength Profile. consolidated into one or two weld schedules. This would have obvious manufacturing advantages.

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 D-9

APPENDIX E Alarm Message List

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 E-1 APPENDIX E: ALARM MESSAGE LIST

ALARM MESSAGE DESCRIPTION CORRECTIVE ACTIONS

MEMORY ERROR!! Memory Trouble. Memory backup Error Reset: Press the front panel battery is discharged. Program data RESET key. may have been lost. TROUBLE output Remedies: Check program data after signal is generated at the I/O connector reset. Restore data if wrong or missing. when power is turned on (refer to Replace the lithium backup battery on Appendix B). the Power Supply printed circuit board (refer to Chapter 7).

OVER TEMPERATURE Welding Transformer Thermostat is Error Reset: Close the RESET input OF TRANSFORMER !! Open. The welding transformer has signal at the I/O connector (refer to Ap- overheated and its protective pendix B). thermostat has tripped. The system Remedies: Cool the welding cannot start. transform-er to reset the thermostat. Check the transformer cooling system. Reduce the duty cycle or use a larger capacity weld-ing transformer.

OVER TEMPERATURE Transistor Thermostat is Open. Pow- Error Reset: Close the RESET input OF TRANSISTOR !! er transistors have overheated and the signal at the I/O connector (refer to Ap- protective thermostat has tripped. The pendix B). system cannot start. Remedies: Cool the power supply to reset the thermostat. Reduce the duty cycle.

OVER CURRENT!! Excessive Current. Power Supply Error Reset: Close the RESET input peak output current exceeded 50 A for signal at the I/O connector (refer to Ap- the IP-215A or 200 A for the IP-217A pendix B). during the weld cycle. Remedies: Check for a short circuit between the welding transformer output terminals or in the welding transformer output cable.

ME-35A FINE SPOT WELDING POWER SUPPLIES E-2 993-603 REV A: October, 1993 APPENDIX E: ALARM MESSAGE LIST

NO CURRENT !! No Current. During welding, weld Error Reset: Close the RESET input cur-rent is less than 25 A for the IP- signal at the I/O connector (refer to Ap- 215A or 50 A for the IP-217A after 5 pendix B). msec from the start of the weld cycle. Remedies: Check the welding trans- Welding has stopped and the system former secondary circuit and its cannot be re-started. internal toroidal coil for damaged wires and loose connections.

ALARM MESSAGE DESCRIPTION CORRECTIVE ACTIONS

NO VOLTAGE !! No Voltage. In the Constant Voltage or Error Reset: Close the RESET input Constant Power control mode, sensed signal at the I/O connector (refer to Ap- voltage is less than 0.05 V after 5 msec pendix B). from the start of the weld cycle. Remedies: Check for disconnected volt-age sensing leads or an open voltage sensing cable.

CURRENT ERROR !! Current Lower Limit Exceeded. The Error Reset: LOWER THAN LIMIT measured current value has gone below MR = 0: Next START signal the current monitor lower limit setting. auto-matically clears MR = 0: END signal is output error con-dition. at I/O connector MR = 1: Close RESET input (refer to Appendix signal at I/O B). Next weld can connector. begin. Remedies: Check for problems in the MR = 1: END signal is not welding cables, work pieces, the weld output at I/O head, and the AC input voltage source. connector. Next weld cannot begin.

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 E-3 APPENDIX E: ALARM MESSAGE LIST

CURRENT ERROR !! Current Upper Limit Exceeded. Error Reset: HIGHER THAN LIMIT When the weld is completed, the meas- MR = 0: Next START signal ured current value has gone above the auto-matically clears current monitor upper limit setting. error con-dition. MR = 0: END signal is output MR = 1: Close RESET input at I/O connector signal at I/O (refer to Appendix connector. B). Next weld can begin. Remedies: Check for problems in the welding cables, work pieces, and the MR = 1: END signal is not weld head. output at I/O connector. Next weld cannot begin.

VOLTAGE ERROR !! Voltage Lower Limit Exceeded. Error Reset: LOWER THAN LIMIT When the weld is completed, the MR = 0: Next START signal measured voltage value between the auto-matically clears electrodes has gone below the voltage error con-dition. monitor lower limit setting. MR = 1: Close RESET input MR = 0: END signal is output signal at I/O at I/O connector connector. (refer to Appendix B). Next weld can Remedies: Check for problems in the begin. welding cables, work pieces, and the weld head. MR = 1: END signal is not output at I/O connector. Next weld cannot begin.

ALARM MESSAGE DESCRIPTION CORRECTIVE ACTIONS

ME-35A FINE SPOT WELDING POWER SUPPLIES E-4 993-603 REV A: October, 1993 APPENDIX E: ALARM MESSAGE LIST

VOLTAGE ERROR !! Voltage Upper Limit Exceeded. Error Reset: HIGHER THAN LIMIT When the weld is completed, the MR = 0: Next START signal measured vol-tage value between the auto-matically clears electrodes has gone above the voltage error con-dition. monitor upper limit setting. MR = 1: Close RESET input MR = 0: END signal is output signal at I/O at I/O connector connector. (refer to Appendix B). Next weld can Remedies: Check for problems in the begin. work pieces and the weld head. MR = 1: END signal is not output at I/O connector. Next weld cannot begin.

WATTAGE ERROR !! Power Lower Limit Exceeeded. Error Reset: LOWER THAN LIMIT When the weld is completed, the MR = 0: Next START signal measured power value has gone below auto-matically clears the power monitor lower limit setting. error con-dition. MR = 0: END signal is output MR = 1: Close RESET input at I/O connector signal at I/O (refer to Appendix connector. B). Next weld can begin. Remedies: Check for problems in the welding cables, voltage sense cables, MR = 1: END signal is not work pieces, the weld head, and the AC output at I/O input voltage source. connector. Next weld cannot begin.

WATTAGE ERROR !! Power Upper Limit Exceeded. When Error Reset: HIGHER THAN LIMIT the weld is completed, the measured MR = 0: Next START signal power value has gone above the power auto-matically clears monitor upper limit setting. error con-dition. MR = 0: END signal is output MR = 1: Close RESET input at I/O connector signal at I/O (refer to Appendix connector. B). Next weld can begin. Remedies: Check for problems in the work pieces and the weld head. MR = 1: END signal is not output at I/O connector. Next weld cannot begin.

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 E-5 APPENDIX E: ALARM MESSAGE LIST

FULL WAVE !! Control Limit Exceeded. The control Error Reset: Close the RESET input pulse width was 100% for more than 5 signal at the I/O connector or wait for msec during the weld cycle. the next START signal to automatically clear the error condition. Remedies: Check for problems in the welding cables, the work pieces, the weld head, and the AC input voltage source.

ALARM MESSAGE DESCRIPTION CORRECTIVE ACTIONS

(IP-217A Only) Current Setting Error. The IT-500A Error Reset: Close the RESET signal Welding Transformer is selected. At input at the I/O connector (refer to CURR SET ERROR !! the START signal, the weld current Appendix B). setting is greater than 2.01 KA. An Remedies: Reduce the current setting ERROR output signal is present at the below 2.01 KA or change the welding I/O connector (refer to Appendix B). transformer to an IT-510A. The system cannot start.

END OF WELD COUNT !! Note: This alarm is not the result of an Alarm Reset: Press the front panel error. RESET and COUNT keys simultaneously. At the end of the last weld cycle, the number of good welds completed was equal to the value preset into the weld counter. The COUNT UP and END signals are output at the I/O connector (see Appendix B). The next weld can begin.

ME-35A FINE SPOT WELDING POWER SUPPLIES E-6 993-603 REV A: October, 1993 APPENDIX F Weld Programming Sheets

You will find the schedule sheets in this appendix useful for planning or recording your Power Supply weld mode and weld parameter selections. You may wish to reproduce a supply of blanks.

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 F-1 APPENDIX F: WELD PROGRAMMING SHEETS

WELD SCHEDULE

Weld Schedule Number Parameter Unit 1234567 Rise 1 (R1) msec Weld 1 (W1) msec Cool (CO) msec Rise 2 (R2) msec Weld 2 (W2) msec Control Mode I = Current V = Voltage W = Power HEAT 1: Current Mode KA Voltage Mode V Power Mode KW

HEAT 2: Current Mode KA Voltage Mode V Power Mode KW

MODE SELECTION SCHEDULE

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES F-2 993-603 REV A: October, 1996 APPENDIX F: WELD PROGRAMMING SHEETS

Modes for Weld Schedule No: ___ Setting IM VM WM MR 7S PS NP 0 = Monitor OFF 1 = Weld 1 Monitor ON 2 = Weld 2 Monitor ON 0 = OFF 1 = ON 0 = 4 Schedule 1 = 7 Schedule 0 = External Start 1 = Panel Start 0 = Change Schedule 1 = No Change Schedule

MONITOR LIMITS SCHEDULE

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 F-3 APPENDIX F: WELD PROGRAMMING SHEETS

Weld Schedule Number Monitor Limit 1234567 Upper (+) Current (KA) Lower (-) Upper (+) Voltage (V) Lower (-) Upper (+) Power (W) Lower (-)

COMMON DATA SCHEDULE FOR 7 WELD SCHEDULES

Data Selection Transformer Scan Count (COUNT = ) Transformer Interval Time (INTERVAL TIME = ) Weld Counter (SET COUNT = ) Transformer Type (TRANSFORMER = ) Control Gain (C—GAIN = ) Data Output (D—OUT = ) (Option)

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES F-4 993-603 REV A: October, 1996 ALPHABETICAL SUBJECT INDEX

This index is an alphabetically sorted listing of subjects covered in this manual, showing the page number(s) where you can find the subjects. For your convenience, multiple context subjects and subjects having alternative key words are listed alphabetically more than once. For example, the subject SCAN key is listed under -S- as well as under -K- as Keys, front panel: SCAN. Similarly, the subject Mode Section Display Screen is listed under -M- , and under -D- as Display screens: Mode selection, and under -S- as Screens, display: Mode selection.

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 Index-1 ALPHABETICAL SUBJECT INDEX

-A- Constant voltage feedback mode, general 2-1) About this manual (1-1) Contents, table of (v) About your equipment (2-1) Contrast adjustment, display (4-2)(7-2) Activating the data output port (5-10) Control feedback gain setting (5-9) Adjustment of display viewing angle (7-2) Control limit monitor (5-7) Alarm messages (E-1) Control mode status indicators (4-4) Assistance (1-3)( 7-3) Controls: Automatic performance monitors (5-7) Front panel (4-3) Automation capability, general (2-2) Rear panel (4-1) Average pulse width display screen (4-9) Copy direction display screen, Welcard Average pulse width monitoring (5-6) (6-4) COUNT key (4-10) Count reset (4-10) -B- Current setting monitoring (5-6) Cursor keys (4-9) Battery replacement: Memory backup (7-2) Welcard (6-1) -D-

DATA -DOWN/UP+ key -C- Data I/O connector (4-2) Data output port activation (5-10) Cable wiring specifications (B-1) Data records, Welcard (6-2) Card identification display screen, Dimensions, installation (3-1) Welcard (6-4) Directory referencing, Welcard (6-3) Card name display screen, Welcard (6-3) Display contrast adjustment (4-2)(7-2) Card type display screen, Welcard (6-3) Display data entry ranges (5-2) Cautions and warnings page (iii) Display, liquid crystal (4-2) Clock display screen (4-8) Display screen editing (5-1) CLOCK key (4-8) Display screens: Connections: Average pulse width (4-9) I/O signals (B-1) Clock (4-8) Multiple welding transformers (3- Mode selection (4-5) 3) Mode selection extension (4-6)(5- Standard installation (3-2) 8) Connector functions (B-1) Monitor limits (4-7) Constant current feedback mode, general Welcard card name (6-3) (2-1) Welcard card type (6-3) Constant power feedback mode, general Weld heat (4-8) (2-2) Weld schedule (4-5)(5-3)

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES Index-2 993-603 REV A: October, 1996 ALPHABETICAL INDEX

-G- -D- (continued) Display Screens (continued): Gain setting, control feedback (5-9) Welding transformer channel Getting started (3-1) programming (4-7)(5-8) Display viewing angle adjustment (7-2) -H-

-E- Help with equipment (1-3)(7-3)

Electrical shock tips (iv) Electrical specifications: -I- Line power (B-2) System (A-2) Illustrations list (viii) Electrodes: In case of difficulty (7-1) Maintenenance of, general (7-1) Initializing the Welcard (6-2) Selection criteria (D-3) Input power line specifications (A-1) ENTRY key (4-8) Input/output signals (B-1) Equipment description, general (2-1) Installation: Equipment installation (3-1) Dimensions (3-1)(A-3) Equipment list (2-2) Equipment (3-1) Error messages, Welcard (6-6) Welcard (6-2) Excessive current monitor (5-7) Improvement of manual (1-3)

-F- -K-

Feedback control modes, general: Keys, front panel: Constant current (2-1) CLOCK (4-8) Constant power (2-2) COUNT (4-9) Constant voltage (2-1) CURSOR (4-9) File number confirmation display screen, DATA -DOWN/UP+ (4-10) Welcard (6-6) ENTRY (4-8) File number display screen, Welcard (6-4) MODE (4-5) File number selection display screen, MON. 1 (4-8) Welcard (6-5) MON. 2 (4-9) Firing switch input (3-2)(B-7) MONITOR SET (4-7) RESET (4-9) SCAN (4-7) WELD SCHED (4-5)

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 Index-3 ALPHABETICAL SUBJECT INDEX

-L- Operating with the Welcard (6-2) Operating your power supply (5-1) Liquid crystal display (4-2) Organization (of manual) (1-1) List of equipment (2-2) Output relays (B-11)(B-12) List of illustrations (viii) Overview of system (2-1) List of tables (viii)

-P- -M- Parts list, equipment (2-2) Maintenance (7-1) Performance features, general (2-1) Manual organization (1-2) POWER circuit breaker (4-10) Manual, suggestions for improvement of Power line voltage requirements (3-4) (1-2) Power supply: Manuals, related (1-2) Monitoring operation (5-4) Memory backup battery (7-2) Operating instructions (5-1) Memory monitor (5-7) Power up (3-4) Mode selection display screen (4-5) Problem solving, general (7-1) Mode selection extension display screen (4-6)(5-8) MON. 1 key (4-8) -Q- MON. 2 key (4-9) Monitor limits display screen (4-7) Quick start method (3-4) MONITOR SET key (4-7) Monitors, automatic performance (5-7) Monitoring average pulse width (5-6) -R- Monitoring the current setting (5-6) Monitoring power supply operation (5-4) Reader comment sheet (inside back cover) Monitoring weld heat limits (5-4) Rear panel components (4-1) Multiple Welding transformer selection, Referencing conventions (1-2) general (2-2) Referencing the Welcard directory (6-3) Related manuals (1-2) RESET key (4-9) -N- Resistance welding basics (D-1) Revision Record (i) No current monitor (5-7) RS-485 connector (5-10) No voltage monitor (5-7) Nomenclature usage (1-2)

-S- -O-

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES Index-4 993-603 REV A: October, 1996 ALPHABETICAL INDEX

SCAN key (4-7) Table of contents (v) Schedule recording (6- 4) Tables, list of (vii) Schedules, welding, general (2-2) Technical specifications (A-1) Screens, display: Test weld procedure (3-3) Average pulse width (4-9) Transformer connections (4-2)(B-1) Clock (4-8) Transformer model selection (C-1) Mode selection (4-5) Transformer selector (2-2) Mode selection extension (4-6)(5- Transformer thermostat monitor (5-7) 8) Trial weld procedure (3-3) Monitor limits (4-7) Troubleshooting (7-1) Welcard card name (6-3) Welcard card type (6-3) Weld count (4-10) -U- Weld heat (4-8) Weld schedule (4-5)(5-3) Using the Welcard (6-1) Welding transformer channel programming (4-7)(5-8) Selecting the weld count (5-9) -V- Selecting the welding transformer (5-8) Setting control feedback gain (5-9) Ventilation grill (4-1) Setting the weld schedule (5-3) Voltage requirements, input line (3-2)(A- Signal I/O connector (4-2)(B-1) 2) Space requirements, general (3-1) Specifications: Signal (B-1) -W- System (A-1) Welding transformer (C-1) Warranty (inside back cover) Status indicators: Welcard: Control mode (4-4) Battery (6-1) System (4-4) Card identification display screen System connections: (6-4) Firing switch (B-7) Card name display screen (6-3) Power (3-2)(B-2) Card type display screen (6-3) Weld head (3-2) Copy direction display screen (6-4) System controls (4-1) Data records (6-2) System electrical specifications (A-2) Directory referencing (6-3) System status indicators (4-4) Error messages (6-6) File number confirmation display screen (6-6) -T- -W- (continued)

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES 993-603 REV A: October, 1996 Index-5 ALPHABETICAL SUBJECT INDEX

Weld schedule display screen (4-5) Welcard (continued): Weld strength profiles (D-7) File number display screen (6-4) Weld strength testing (D-7) File number selection display Welding monitors, general (2-2) screen (6-5) Welding parameters, general (2-2) Initialization (6-2) Welding schedules: Installation (6-2) General (2-2) Weld count display screen (4-10) Setting (5-3) Weld counter selection (5-9) Welding transformer channel Weld cycle timing (B-9) programming display screen (4-7)(5-8) Weld data storage, general (2-2) Welding transformer connector (4-2)(B-1) Weld heat display screen (4-8) Welding transformer selection (5-8) Weld heat limit monitoring (5-4) Welding transformer selector (2-2) WELD key (4-8) Welding transformer specifications (C-1) Weld program key field (4-4) Welding transformer thermostat monitor Weld programming sheets (F-1) (5-7) WELD SCHED key (4-5) Welding transformer to weld head connections (3-2)

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES Index-6 993-603 REV A: October, 1996