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

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

User's Manual993-603Revision A: October, 1996

IP-215A AND IP-217AFINE SPOT

WELDING POWER SUPPLIESModel

IP-215A

IP-215A/RS485

IP-217A

IP-217A/RS485

Definition

Standard 50 Amp PowerSupply

50 Amp Power SupplyWith RS-485 Data Port

Standard 200 Amp PowerSupply

200 Amp Power SupplyWith RS-485 Data Port

Copyright © 1996Unitek Miyachi Corporation

All Rights Reserved

Prepared byUnitek Miyachi Corporation1820 South Myrtle AvenueMonrovia, CA 91017-7133

Phone (818) 303-5676FAX (818) 358-8048

TWX (910) 585-1836

IP-215A and IP-217A Fine SpotWelding Power Supplies

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

Unitek Miyachi Corporation1820 South Myrtle AvenueMonrovia, CA 91017-7133

Phone (818) 303-5676FAX (818) 358-8048

TWX (910) 585-1836

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES993-603 REV A: October, 1996 i

©1996, Unitek Miyachi Corporation

The engineering designs, drawings and data contained herein are the proprietarywork of UNITEK MIYACHI CORPORATION and may not be reproduced,copied, exhibited or otherwise used without the written authorization of UNITEKMIYACHI 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 SUPPLIESiv 993-603 REV A: October, 1996

CAUTIONSAND

WARNINGS

HIGH VOLTAGEIS USED IN THE OPERATION OF THIS EQUIPMENT

DEATH ON CONTACTMAY 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 personnearby who is familiar with the operation and hazards on theequipment and who is competent in administering first aid. Thetechnician who is aided by operators must warn them about thehazards.

Whenever possible, shut off the power supply to the equipmentbefore beginning work on it. When you have shut off power, groundall parts. Be sure to discharge every capacitor that may hold adangerous potential to ground when working inside the equipment.

Do not touch high-voltage connections or 208/230 volt inputconnections when installing or operating the equipment. WARNING:Do not be misled by the term low voltage. Potentials as low as50 volts may cause death under adverse conditions.

PLEASE READ THE SAFETY STEPS ON THE NEXT PAGE

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES993-603 REV A: October, 1996 v

SAFETY STEPS TO FOLLOW IF SOMEONE IS THE VICTIM OF ELECTRICAL5

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 woodenpole, a dry rope, or some other non-conductivematerial.

4. Send for medical help as soon as possible.

5. When the victim is free of contact with the sourceof electrical shock, move the victim away and startartificial resuscitation.

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

CONTENTSCHAPTER 1 ABOUT THIS MANUAL

Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Referencing Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2How Are We Doing? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2If You Need Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

CHAPTER 2 ABOUT YOUR EQUIPMENT

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Performance Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Welding Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Welding Monitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Welding Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Weld Data Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Automation Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Equipment Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

CHAPTER 3 GETTING STARTED

Space Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Standard Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Making a Trial Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

CHAPTER 4 CONTROLS

Rear Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Front Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Control Mode Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4System Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Weld Program Key Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Weld Control Key Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Welcard Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10POWER Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES993-603 REV A: October, 1996 vii

CONTENTS (continued)CHAPTER 5 OPERATING YOUR POWER SUPPLY

Display Screen Data Editing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Setting the Weld Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3Monitoring Power Supply Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Monitoring Weld Heat Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4Weld Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4Current Setting Monitor (IP-217A Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6Monitoring Average Pulse Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6Automatic Performance Monitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Selecting the Welding Transformer (217 Power Supply Only) . . . . . . . . . . . . . . . . . . . 5-8Selecting the Weld Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9Setting Control Feedback Gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9Activating the Data Output Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

CHAPTER 6 USING THE WELCARDCare and Treatment of the Welcard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1Welcard Data Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Installing the Welcard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Operating With the Welcard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Initializing the Welcard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Referencing the Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3Copying a Schedule to a Welcard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4Copying a Schedule to the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Welcard System Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

CHAPTER 7 IN CASE OF DIFFICULTY General Kinds of Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1Electrode Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1Adjusting Display Viewing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2Memory Backup Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2Technical Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

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

CONTENTS (continued)

APPENDICES A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1B Cable Wiring and Signal Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1C Welding Transformer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1D Resistance Welding Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1E Alarm Message List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1F Weld Programming Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1

ALPHANUMERIC SUBJECT INDEX

READER COMMENT SHEET

WARRANTY

ILLUSTRATIONS 2-1 IP-215A Fine Spot Welding Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-2 Using the Power Supply With Multiple Welding Transformers . . . . . . . . . . . . 2-3

3-1 Standard Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23-2 System Interconnections for Multiple Welding Transformers . . . . . . . . . . . . . 3-3

4-1 Rear Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14-2 Front Panel Controls and Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

6-1 The Welcard Data Storage System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

7-1 Factory Adjusted Display Viewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27-2 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 SUPPLIES993-603 REV A: October, 1996 1-1

CHAPTER 1ABOUT 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 andinstructions in Chapters 1 through 3 will allow you to get the equipment up and runningsafely and efficiently, and make basic welds. Chapter 4 explains the operation of the controlsand the display. Chapter 5 and the appendices deal with more advanced welding consider-ations and procedures.

NOTE: Where the data in this manual is specific to either the IP-215A or theIP-217A, the data is noted as such. All other data is relevant to both the IP-215A and the IP-217A.

OrganizationThis chapter lets you know how to use this manual effectively. The manual contains manytools to help you find and understand information. The physical, electrical and performancespecifications are listed in Appendix A. Specific subject matter is listed in the AlphanumericSubject Index at the back of the manual; the subjects are sorted alphabetically and showtheir 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 makingyour first simple weld. It covers the physical and electrical installation of the IP-215A/IP217A High Frequency Inverter Power Supply. Details of mounting and applyingAC power to the system are discussed, and a description of the initial power-on actions ispresented. These procedures bring the system up to operational status and lead you throughyour first welds.

Chapters 4 and 5 respectively present detailed descriptions of key functions and operatinginstructions 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 7offers courses of action if you run into difficulty with system operation.

CHAPTER 1: ABOUT YOUR MANUAL

IP-215A/217A FINE SPOT WELDING POWER SUPPLIES1-2 993-603 REV A: October, 1996

Referencing ConventionsFor ease of referencing the related components of the IP-215A/IP-217A High FrequencyInverter Welding Power Supply, here is the way that they will be referred to in the rest of thenarrative in this manual:

IP-215A or IP-217A High Frequency Inverter Welding Power Supply: Power Supply

IP-215A High Frequency InverterWelding Power Supply: 215 Power Supply

IP-217A High Frequency InverterWelding Power Supply: 217 Power Supply

Welding Transformers:

Model IT-500A 500 Welding TransformerModel IT-501A 501 Welding TransformerModel IT-510A 510 Welding TransformerModel IT-511A 511 Welding TransformerModel IT-512A 512 Welding TransformerModel 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 asin parts lists, or where confusion may result from using the short form of the titles.

Related ManualsFor additional reference support for this manual, the following manual is available fromUnitek 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 Supplyinto the Welding System successfully. We have made every effort to present this informa-tion clearly and concisely. If you have any suggestions for improving the manual, please

CHAPTER 1: ABOUT YOUR MANUAL


note them on the Reader Comment Sheet at the back of this manual and drop it in the mail tous.

If You Need AssistanceThere are unique aspects to every installation and application, so your particular needs maynot be covered. If you need further assistance, please contact our sales representative inyour area, or contact the factory directly at:

Unitek Miyachi Corporation1820 South Myrtle AvenueMonrovia, California 91017-7133Telephone: (818) 303-5676Fax: (818) 358-8048


IP2PFRON.WPG

Figure 2-1. IP-215A Fine-SpotWelding Power Supply

CHAPTER 2ABOUT YOUR EQUIPMENT

OverviewThe IP-215A/IP-217A is a high frequency inverter resis-tance welding power supply designed for fine spotwelding of precision parts. Figure 2-1 shows the physi-cal characteristics of the 215 Power Supply. The 217Power Supply is identical except for minor differencesin the front panel key locations.

Simple programming through the front panel controlsand display provides you with a choice of up to threewelding control modes and a variety of welding parame-ter settings. This versatility brings to your weldingapplications reliable and consistent nugget formation,improved weld quality, and the welding speed requiredto work with semi-automated or fully automated equip-ment.

Performance FeaturesFor a complete listing of the Power Supply’s technicalspecifications, please refer to Appendix A. The follow-ing is a summary of the Power Supply’s performance capabilities.

Feedback Control Modes

Constant Current: Use where welding load resis-tance is subject to variation, suchas in varying weld forces, weldpiece plating inconsistencies, anduneven work surfaces. Since thismode is suitable for all types ofwork pieces, always use it whenstarting an application.

CHAPTER 2: ABOUT YOUR EQUIPMENT

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES2-2 993-603 REV A: October, 1996

Constant Voltage: Use where the electrodes haverelatively high resistance, such astungsten electrodes.

Constant Power: Use for cross wire welding and the welding of materialsthat 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 weldingschedules 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 whenpreset current, voltage, or power limits are exceed during a weld cycle.

Welding Parameters. Two separate weld current rise and weld periods offer flexibleweld control for multiple applications.

Weld Data Storage. Welcard, a compact data storage unit, collects weld scheduledetails. 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 integrationwith automated production equipment.

Multiple Welding Transformer Selection. The Power Supply has simultaneoussqueeze capability and four channels of transformer selection. With these features, the PowerSupply can be used with an optionally available MA-600A Welding Transformer Selector (seeFigure 2-2) to select up to four different welding transformers to implement sequential welding.

Equipment DescriptionThe Power Supply is delivered fully assembled, together with a shipping kit containing parts thatyou will need to install, operate and maintain it. The parts included in the shipping kit are asfollows:

Power Cable Output (Welding Transformer) Cable

CHAPTER 2: ABOUT YOUR EQUIPMENT


IP2MA600.WPG

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

Sense Cable Data I/O Cable

I/O Cable Connector

User’s Manual, Part No. 993-603

IP-215A/217A FINE SPOT WELDING POWER SUPPLIES993-603 REV A: October, 1996 3-1

CHAPTER 3GETTING STARTED

Space RequirementsWe 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 ofsupporting the combined weight of the total welding system. The weight of the PowerSupply 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 orstruck 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 466mm (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 weldsplash.

There are no sources of high-frequency energy close by.

NOTE: Be sure that all accessories that you ordered and all itemslisted in the shipping kit (see Equipment Description in Chapter 2)are available, and that the Power Supply shows no sign of damage.

Standard InstallationThe standard Power Supply/Welding Transformer installation is shown in Figure 3-1. Dependingon your welding application, you will require an appropriate welding transformer (see AppendixC).

CHAPTER 3: GETTING STARTED


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 useof a Model MA-600A Welding Transformer Selector.

CAUTION: Do not connect the AC input voltage cable to the AC powermains yet.

1. Connect the AC power input cable between the Power Supply AC220V 3 IN connectorand 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. Ifyour application requires the use of multiple welding transformers, interconnect thewelding transformers with the Power Supply through the Transformer Selector as shownin 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 firingmicroswitch to send a single START signal for each operation of the footswitch. Forother START switch selections, please refer to Appendix B.



IP2TRSEL.WPG

Figure 3-2. System Interconnections for Multiple Welding Transformers

4. Connect the Data I/O cable between the Power Supply RS 485 connector and a hostcomputer 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 thistime.

Making a Trial WeldMaking a production weld results from making several trial welds, testing the welds, then adjust-ing the selected welding parameters each time until you reach production weld quality. Theopera-ting controls and the display are described in Chapter 4. Detailed operating instructions for



selec-ting and editing functions are described in Chapter 5. The following “quick-start” exampleweld-ing procedures lead you through a typical weld cycle, from turning on welding systempower to completing a series of trial welds. It is assumed that the weld head that you are using isconnected 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 reflectthe mode and parameters previously set.

2. Adjust the display screen contrast foroptimum viewing, as described in Chapter 7.

3. Press the MODE key to access the ModeSelection data screen. With the CURSORand DATA keys, set the mode selectionfields 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 theMode Setting extended data screen.Withthe CURSOR and DATA keys, set theMode 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 theWeld Schedule display screen. With theCURSOR and DATA keys, set the weldschedule values as follows:

SCHEDULE: 1 Weld 1 Current Rise Time (R1): 5 ms Weld 1 Time (W1): 10 ms Cool Time (CO): 0 ms Weld 2 Current Rise Time (R2): 0 ms Weld 2 Time (W2): 0 ms Control Feedback Mode (I.F.W): Constant Current (I)



The Second Trial Weld

Weld 1 Current (HEAT 1): 1.5 KA

6. Press the WELD key to turn on the welding capability (WELD ON indicator turned on).

7. Position the work piece in the weld head. Press the footswitch to turn on the weld currentand weld your first trial piece.

You have tested the first trial weld piece and found that the weld strength is not adequate. Sinceyou 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 currentlevel. If you do not achieve a satisfactory weld when you reach maximum weld current,go to step 2.

2. Set the Weld 1 time to double the previous setting and reduce Weld 1 current by 50%.

3. Repeat steps 1 and 2 until you achieve a satisfactory weld.


IP2BACK.WPG

Figure 4-1. Rear Panel Components

CHAPTER 4CONTROLS

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

Ventilation Grill: Exhaust vent for heated air from the housinginterior. CAUTION: Do not block this ventilation.Overheating of the electronic circuitry can causepermanent damage.

CHAPTER 4: CONTROLS


Data I/O Connector: Optional 15 pin D-connector for remote pro-gramming control and remote datacollection using RS-485 protocol. Pleasecontact the factory for data organization andsignal de-tails.

Signal I/O Connector: Input/output terminals for external equip-men, such as automation equipment, inter-facing with the Power Supply. Please seeAppendix B for signal details.

Welding Transformer Connector: Supplies AC power to the welding trans-former. The output cable is supplied in theshipping kit. Please see Appendix B for sig-nal details.

Display Screen Contrast Adjustment Variable resistor for adjusting the contrast of(IP-215A Only): the display screen.

Welding Transformer Sense Connects the weld sense signals between In Connector: the weld transformer and the Power Supply.

The I/O cable is provided in the shipping kit.Please see Appendix B for signal details.

AC Voltage Input Connector: Connects AC main power to the Power Supply. The power cable is supplied in the shipping kit. Please see Appendix B for signal details.

Front Panel Components The front panel components consist of the display , operating control keys, the Welcard Drive,and the POWER ON/OFF circuit breaker (see Figure 4-2). Note that the indicators and keys areorganized into four functional fields: Control Mode Status Indicators, System Status Indicators,Weld Program Keys, and Weld Control Keys.

Display. The liquid crystal displayallows you to edit (enter or change) and readwelding values and program settings. The displayediting keys are the CURSOR and DATA keys.The display screen has two lines of 20 character

CHAPTER 4: CONTROLS


IP2FRONT.WPG

Figure 4-2. Front Panel Controls and Display

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, whenturned 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 arefive keys in this field that contribute to theselection of weld program values and settings.

Pressing this key accesses the Weld

CHAPTER 4: CONTROLS


Schedule display screen. Through the Weld Schedule display screen, you may view or set a weldschedule.

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) . Theother 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 andConstant Power control modes, HEAT 1 and HEAT 2 will be in terms of voltage (V) andpower (KW) respectively.

The MODE key accesses the Mode Selection display screen. The Mode Selectiondisplay screen has an extension (second) screen that appears when you pressMODE 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 monitoroff). 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 1voltage) and 2 (monitor Weld 2 voltage).

CHAPTER 4: CONTROLS


WM: Power monitor selection, shown here as 0 (power monitor off). Otherselections 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 outputsignal on a high or low limit error so that the next weld cycle can start). The otherselection is 1 (do not output an END signal and do not accept the next STARTsignal on a high or low error).

7S: 4 schedule or 7 schedule start, shown here as 1 (7 schedule start). Toimplement the 7 schedule start, the I/O connector must be wired to accept startsignals 1, 2 and 4 as binary equivalents of start signals 1 through 7. The otherselection is 0 (4 schedule start). To implement a 4 schedule start, the I/Oconnector 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 weldschedule defined on the display screens when the WELD key is pressed). Theother 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). Theother selection is 1 (you cannot change weld schedule settings unless you changethis mode setting to 0).

EXTENSION SCREEN

TRANSFORMER = IT-500A:Welding Transformer Model IT-500A is selected (transformerselection on 217 Power Supplyonly). Use the DATA key totoggle through the selections (seeAppendix C for the selections).

C—GAIN=0: Gain (responsespeed) 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 dataoutput through the port, toggle OFF to ON with the DATA key.

CHAPTER 4: CONTROLS


The SCAN key accesses theWelding Transformer ChannelProgramming display screen. You

use this function if you are using multiplewelding transformers.

SCAN COUNT =: The scan countis the welding transformer channel

number; that is, the channel on the weld transformer selector through which the transformer isconnected to the Power Supply (see Figure 3-2 in Chapter 3). If you set the scan count to 1, theChannel 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 theweld transformers, shown here as 50 ms.

NOTE: Please refer to Appendix B for scan timing.

The MONITOR SET key accessesthe Monitor Limits display screen. The Monitor Limits display screen

allows you to set welding heat limits that, ifexceeded for the selected weld schedule, willgenerate 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

CHAPTER 4: CONTROLS


The ENTRY key initiates the selected Welcard operation. Use of this key is detailed in Chapter6, 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 theclock 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 forabout 1 second, you access the clock display inthe clock set mode. In this mode, the displayscreen adds a second line, requesting you to settime and date. Move the cursor to the time anddate fields and set the time and date with theDATA keys. At the exact time that you set intothe 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 weldcontrol parameters for the Power Supply and the Welcard system.

The WELD key/indicator initiates the weld cycle according to the selected weldschedule 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 pressthe WELD key for at least 0.5 seconds to turn off the weld cycle with the key.

The MONITOR 1 key accessesthe Weld Heat display screen.With this display, you may view

the actual (rather than programmed) weldenergy 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

CHAPTER 4: CONTROLS


BOTTOM LINE

WII: Weld 2

1.47KA: Actual weld currentdelivered for Weld 2

8.08V: Actual transformersecondary winding voltage

developed for Weld 2

9.02KW: Actual welding power delivered for Weld 2

The MONITOR 2 key accessesthe Average Pulse Width displayscreen. With this display screen,

you can view the average control pulse widthfor the selected weld schedule. Select the weldschedule number with the DATA key.

The average pulse width information allows youdetermine how close the welding transformer isto operating capacity.

4: The selected schedule number

V: The active feedback control mode, as selected with the Weld Schedule displayscreen. V = Constant Voltage, I = Constant Current, W = Constant Power

W1 = 082%: The average voltage control pulse width for Weld 1 has been measuredat 82%

W2 = 078%: The average voltage control pulse width for Weld 2 has been measuredat 78%

The CURSOR keys move the display screen cursor left and right tocharacter positions on the display screen for editing the characterpositions. 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 fornormal operation after an error occurs. NOTE: It does not remedythe error that caused the error output or alarm message.

The COUNT key, when pressed by itself, accesses the Weld Count display screen. This displayscreen allows you to monitor the number of welds (shown here as WELD COUNT = 04589)

CHAPTER 4: CONTROLS


performed since the counter was reset, and to set the number of counts at which you want thedisplay to indicate a SET COUNT and WELD COUNT match. When the SET COUNT equalsthe WELD COUNT, the END OF WELD COUNT!! alarm message is dsplayed and the COUNTEND 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 DATAkeys.

To reset the weld count to 00000, press theRESET and COUNT keys simultaneously. Thedisplay screen will indicate the reset condition.

The COPY key, when pressed by itself, copies a weld schedule tothe Welcard. The FILE key, when pressed by itself, sets the readmode for viewing Welcard data. When you press the COPY andFILE keys simultaneously, you clear (initialize) the Welcard

installed in the Welcard drive. As previously described, all Welcard operations are initiated withthe ENTRY key. Operation of the Welcard system is detailed in Chapter 6.

You increase and decrease data with this key. Pressing -DOWN decrementsnumerical values or toggles selections downward. Pressing UP+ incrementsnumerical values or toggles selections upward.

Welcard Drive. The Welcard drive operates similarly to a conventional PC floppy diskettedrive. It has only one control, the EJECT knob. You raise the knob to install and eject theWelcard.

POWER Circuit Breaker. The POWER circuit breaker is the main power switch for thePower Supply. It also provides power overload protection (50 A) to the AC power input circuit.


CHAPTER 5OPERATING YOUR POWER SUPPLY

This chapter gives you instructions about entering data to (editing) the display screens, settingweld schedules, selecting welding transformers, setting control modes, and monitoring PowerSupply performance with the display screens. Refer to Chapter 4 for functional descriptions forthe controls and the display.

Display Screen Data EditingTo enter or change data on the display screen:

1. Press the desired display entry key to activate the associated display function. For ex-ample, if you wish to activate the Weld Schedule display screen, press the WELDSCHED. key.

2. With the CURSOR keys, move the cursor to the position of the character that you wish toenter or change.

3. Press the -DOWN DATA key to lower the value or selection at the highlighted characterposition(s). Press the UP+ DATA key to raise the value or selection at the highlightedcharacter 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 toaccess the Weld Schedule displayscreen.

b. With the CURSOR keys, move thecursor to the mode selectioncharacter position (I.V.W).

c. With the -DOWN DATA and UP+DATA keys, scroll through thethree selections of I, V, and W. Thecharacter that you leave selected will be your choice of control modes.

CHAPTER 5: OPERATING YOUR POWER SUPPLY


Table 5-1. Display Data Entry Ranges

Display Screen Field Setting Range Unit

Weld Schedule (WELD SCHED. Key)

Weld 1 Current Rise (R1) 0 - 49 msec

Weld 1 (W1) 00 - 99 msec

Cool Time (CO) 00 - 99 msec

Weld 2 Current Rise (R2) 0 - 49 msec

Weld 2 (W2) 00 - 99 msec

CURR 1. or CURR. 2:Constant Current Control (215)Constant Voltage Control (215)Constant Power Control (215)Constant Current Control (217)Constant Voltage Control (217)Constant Power Control (217)

0.20 - 2.000.20 - 2.000.40 - 4.000.40 - 4.00*0.4 - 4.000.16 - 9.99

KAVKWKAVKW

*If the IT-500A Welding Transformer is selected and the current settingexceeds 2.01KA, a current setting error will occur.

Mode Selection (MODE Key)

Transformer Model IT-500A (215, 217)IT-501A (215, 217)IT- 510A (217)IT-511A (217)IT-512A (217)

Model No.Model No.Model No.Model No.Model No.

Feedback Gain (C—GAIN=) 0 - 9 (215)0 - 5 (217)

UnitsUnits

Welding Transformer Channel Programming (SCAN Key)

Scan Count 0 - 4 Units

Scan Interval Time 0 - 990 msec

Table 5-1. Display Data Entry Ranges (continued)



Monitor Limits (MONITOR SET Key)

Current ±0.00 - 9.99 KA

Voltage ±0.00 - 9.99 Volts

Power ±0.00 - 9.99 Watts

Weld Count (COUNT Key)

Weld Count 00000 - 99999 Units

Setting the Weld ScheduleThe weld schedule, together with the monitoring system, defines the welding program forcontrolling welding energy. You will find a convenient welding program sheet in Appendix Fwhich you can use as a worksheet.

You call up the Weld Schedule display screen with the WELD SCHED. key, as described inChapter 4. With this display screen, you may define up to seven weld schedules. The detailedtiming diagram of the weld cycle in Appendix B will be helpful in understanding therelationships of the weld cycle events. To set an example weld schedule 1 involving Weld 1only:

1. Press the WELD SCHED. key toaccess the Weld Schedule displayscreen.

2. With the CURSOR keys, move thecursor to the display SCHEDULEfield.

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 risevalue 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 forWeld 1).



7. With the DATA keys, enter the example weld time of 5 milliseconds (05). In makingyour trial welds, you will want to start out with a short time period and increase it insmall 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 valuefor cool time to accommodate Weld 2; that value would depend on the weld piecematerial and the amount of weld heat generated for Weld 1 (the duration andamplitude 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. Withthe CURSOR keys, move the cursor to the display I.V.W field (control modeselection).

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 currentvalue 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 selectthe Constant Voltage Control mode (V) or the Constant Power Control mode (W), theHEAT 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 OperationThe Power Supply monitoring function allows you to view, via the Weld Heat display screen, theactual 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 tooptimize the weld parameters.

The monitoring function also oversees operation of the Power Supply. Where errors occur, thedisplay screen presents an error message and the Power Supply outputs an error signal forexternal equipment to monitor.

Monitoring Weld Heat Limits. Assume that you wish to monitor the weld heatlimits for the example weld schedule that you previously programmed in this chapter under



IP2LIM.WPG

Setting the Weld Schedule. To activate the weldheat monitor (in this case, the current monitor)and set monitor current limits:

1. Press the MODE key to access theMode Selection display screen.

2. With the CURSOR keys, move thecursor to the display IM (current monitor) field.

3. With the DATA keys, set thecharacter to 1 (Weld 1 heat monitorON).

4. Press the MONITOR SET key toaccess the Monitor Limits displayscreen.

5. With the CURSOR keys, move thecursor 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 1.0KA, and you wish to limit the current positive swing to 1.10 KA and the negativeswing to 0.95 KA. With the CURSOR keys, move the cursor to the + current limitfield.

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 deviationsthat you set and 1.0 KA of programmed weld current, limit errors are illustrated asfollows:



You turn on the voltage (VM) and power (WM) monitor similarly. In steps 2 and 3, you wouldset VM = 1 for the voltage monitor or WM = 1 for the power monitor instead of IM = 1. Thehigh and low limit alarm events shown in the preceding illustration result in a TROUBLE signaloutput at the I/O connector (see Appendix B) and an alarm message on the display screen (seeAppendix D) at the end of the weld cycle.

The operational events will depend on the setting that you specify for MR in the Mode Selectiondisplay screen. On exceeding an upper or lower current, voltage or power limit, the followingwill 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 statecan be reset by the next START signal or a TROUBLE RESET signal input at the I/Oconnector.

MR = 1: No END signal will be output, so the next START signal will not beaccepted. The error state can be reset only by a TROUBLE RESET signal at the I/Oconnector.

Current Setting Monitor (IP-217A Only). The IT-500A Welding Transformer has amaximum current output capability of 2.0 KA. When it is selected, if you program 2.01 KA orgreater welding current, a current setting monitor will not allow the system to start. The displayscreen will display the message CURR SET ERROR !! and the TROUBLE signal will be outputat the I/O connector. To remedy the error condition, you must either program a current settingbelow 2.0 KA or connect a welding transformer with higher current output capability, and applya TROUBLE RESET signal at the I/O connector.

Monitoring Average Pulse Width. The control pulse activates the weldingtransformer after the start of the weld cycle. Its width is a measure of how much time is left inthe duty cycle of the welding transformer before it will be damaged by exceeding its rated dutycycle.

You view the average pulse width for Weld 1and Weld 2 on the Average Pulse Width displayscreen. For example, an average pulse width of75% indicates that the transformer is operatingwith a 25% margin of safety. To access thisdisplay, press the MON. 2 key.

If the control pulse average width is 100% formore than 5 milliseconds during the weld cycle,a TROUBLE signal will be output through the I/O connector. The display screen will display thealarm message FULL WAVE !!. Operation will be restored by the next START signal orTROUBLE RESET signal input through the I/O connector.



Automatic Performance Monitors. In addition to the previously described performancemonitors whose limits you can program, there are several performance monitors which respondautomatically to alarm or error conditions without your intervention. These monitors each placean appropriate alarm message on the display screen and output the TROUBLE signal at the I/Oconnector. Please refer to Appendix E for the alarm messages and operator remedies, and toAppendix B for signal details. The monitors set up special operational states when the followingerror conditions occur:

Control Limit Monitor: The welding transformer control pulse width goes full wave(100% of the transformer capacity at its duty cycle) for more than 5 milliseconds dur-ing the weld cycle. The weld cycle will be completed. The next START signal willreset the error and start the next weld cycle. A TROUBLE RESET signal input at theI/O connector will also reset the error.

No Current Monitor: With the Constant Current Control mode active, the weldcurrent is less than 25 (50 for the IP-217A) amperes after 5 milliseconds from thestart of the weld cycle. Welding stops. A TROUBLE RESET signal at the I/Oconnector will be needed to reset the error condition and restore welding capability.

No Voltage Monitor: With the Constant Voltage Control or Constant Power Controlmode active, voltage is lower than 0.05 volts after 5 milliseconds from the start ofthe weld cycle. Welding stops. A TROUBLE RESET signal at the I/O connector willbe needed to reset the error condition and restore welding capability.

Transformer Thermostat Monitor: The welding transformer has overheated. Thetransformer thermostat has been tripped and welding is off. A TROUBLE RESETsignal at the I/O connector will be needed to reset the error condition and restorewelding capability.

Excessive Current Monitor: The peak value of the Power Supply output current hasexceeded 50 (200 for the IP-217A) amperes during a weld cycle. A TROUBLERESET signal at the I/O connector will be needed to reset the error condition andrestore welding capability.

Memory Monitor: When power is turned on, the system will not start. The memorybackup battery is discharged and program data has been lost. Press the RESET key toreset the error condition. Replace the backup battery (please refer to Chapter 7) andreprogram the lost weld program data.

The Power Supply will accept the next start signal in an error condition if MR = 0 on the ModeSelection display screen. If MR = 1, the Power Supply will need an error reset to continue. Youmay perform an error reset from the front panel with the RESET key; or, an error reset signalmay be supplied externally through the I/O interface at pins 6 and 7 (refer to Appendix B).



Selecting the Welding Transformer (217 Power Supply Only)If just one welding transformer is connected to the Power Supply, you need only to select itsmodel number with the Mode Selection display screen. If several welding transformers areconnected to the Power Supply through a welding transformer selector, you will also need toassign a transformer channel scan count and scan interval time with the Welding TransformerChannel Programming display screen.

To select the welding transformer that is connected to the Power Supply:

1. Press the MODE key twice to accessthe Mode Selection extension displayscreen.

2. With the CURSOR keys, move thecursor to the transformer modelnumber field (IT-510A is shownhere).

3. With the DATA key, scroll through the transformer model numbers until the modelnumber of the connected welding transformer is displayed. Select IT-500A for theModel 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 theWelding Transformer ChannelProgramming display screen.

2. With the CURSOR keys, move thecursor to SCAN COUNT field.

3. With the DATA keys, select thechannels to which the connected welding transformers are assigned at the weldingtransformer selector. For example, if Welding Transformers 1 and 2 are assigned toChannels 1 and 2, enter 2 at the SCAN COUNT field. Note: If you are using a singleweld head and transformer, you can select SCAN COUNT = 1 and use the interval assqueeze 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 intervaldefines the period between the firing of each weld transformer. Refer to the weldingtransformer timing diagram in Appendix B.



Selecting the Weld CountYou may set a counter in the Power Supply that will enable you to monitor the number of weldsmade since the counter was last reset. This feature is useful for electrode maintenance. Forexample, additional weld heat will be required to maintain weld quality as the electrodes wearthrough use. You can preset a weld count at which you would want to dress or replace theelectrodes rather than keep increasing weld heat (too much heat can have a damaging effect onthe weld pieces).

To set the weld count:

1. Press the COUNT key to access theWeld Count display screen. It isshowing the preset weld count of3000 (shown here as SET COUNT=03000) and the number of weldsmade 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 inproperly completed weld cycles (Engrg: Is that how it differentiates between goodand 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/Oconnector (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 bedisplayed on the display screen.

Setting Control Feedback GainYou may adjust the response speed (gain) of the control feedback in any of the three controlfeed-back modes: Constant Current, Constant Voltage, or Constant Power. The value that you



select will depend on the welding load; that is,the total resistance of the welding transformersecondary circuit, including the weld pieces. Toset the gain:

1. Press the MODE key twice to accessthe Mode Selection extension displayscreen (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). Use0 gain for normal operation. Increase gain as the resistance of the transformersecondary load rises. As resistance rises, weld current rise time increases, resulting inpoor welding performance unless you compensate the rise time increase by increasinggain.

Activating the Data Output PortThe optional RS-485 connector on the Power Supply rear panel can supply weld schedule andweld 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, asshown 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 astream of data to the host computer when data transfer is initiated by the hostcomputer.

NOTE: Keep the D—OUT = OFF setting if the data output option is not installedor when it is not communicating with a host computer.


ME35.WPG

Figure 6-1. The Welcard Data StorageSystem

CHAPTER 6USING THE WELCARD

The Welcard (Figure 6-1) allows you torecord, store and re-use welding schedulesand monitored weld data. It’s as easy to use asa PC diskette drive, which it resembles.

Care and Treatment of theWelcard Do not insert anything other than the

Welcard in the slot of the Welcarddrive.

Keep the Welcard edge connectorsfree of dirt, oil and moisture.

When you are not using the Welcard,place it in its antistatic vinyl case andstore it in a safe place.

Battery:

1. If you remove the battery fromthe Welcard, stored data willbe lost.

2. When you wish to replace the battery, insert the Welcard into the Welcard drive and besure that the Welcard status indicator turns ON. You may now replace the battery withoutlosing the data that was on the Welcard.

3. The battery is a Panasonic 3V BR2016, or equivalent. Its life is five years. Werecommend that you replace the battery more frequently.

4. When you replace the battery, observe the correct polarity.

CHAPTER 6: USING THE WELCARD


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 theweld schedule display. One Welcard can record up to sevenschedules containing thirteen files (one file for each of thirteenwelders), for a total of ninety-one schedules.

Monitor 1 Card: Records weld monitoring data during welding. To retrieve the con-tents of the Monitor 1 Card, you will need the optional Welcardreader/writer.

Monitor 2 Card: Records weld monitoring data during welding, but records feweritems and more data about the items, than the Monitor 1 Card. Toretrieve the contents of the Monitor 2 Card, you will need the op-tional Welcard reader/writer.

Installing the WelcardAs indicated in Figure 6-1, you install the Welcard by lifting the Welcard drive knob andinserting the Welcard with the arrow on the Welcard pointing toward the drive. With gentlepressure, 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 WelcardThe read, write and storage operations of theWelcard are controlled with these eight keys whosefunctions are described in Chapter 4. You enternumerical and alphabetical characters to the displaywith the three CURSOR keys and the two DATAkeys.

Initializing the Welcard. An unused orpreviously used Welcard must be initialized(formatted) before recording new data on it. There isa similar initializing procedure for each of the threeWelcard types. The only difference in the procedures is the key selection of the Welcard type(Schedule, Monitor 1, or Monitor 2). To initialize the Welcard:



1. Press the COPY and FILE keys simultaneously. The display screen will indicate aCARD 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 displayscreen will ask you to confirm thatyou wish to initialize the selectedWelcard type.

4. With the CURSOR keys, move thecursor to YES and press the ENTRYkey to confirm that you wish toinitialize the selected Welcard type. If you enter NO, the program will return to step1.

5. Shortly following your YESconfirmation, the display screenwill automatically request that youconfirm that you wish to enter theWelcard name. With the CURSORkeys, move the cursor to YES andpress the ENTRY key to access theWelcard Name display screen. (If you enter NO, the program will bypass theWelcard name designation and complete initialization of the Welcard without namingit.)

6. With the CURSOR and DATA keys, key in up to eight characters as an identifyingname 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 setduring the initialization operation. For a schedule Welcard, the recording status will bedisplayed, and you can set write protection ON and OFF. To reference the directory:


IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLY6-4

1. Install the Welcard to be checkedand press the FILE key. TheWelcard type will be displayed,along with its name and the date itwas recorded. Assuming that it wasa Schedule Welcard that you instal-led, the message will look like this.

2. After a short delay, the display willautomatically present a file numberdialog, on which you can enter thefile number of the card that you wishto check. Assuming that theLABTEST1 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 andremove 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 ScheduleWelcard:

1. Press the COPY key to access theCopy Direction dialog screen. It isshowing the default direction of theWelcard (CARD) to the PowerSupply (IP-215A).

2. With the CURSOR keys, move thecursor to the bottom display screen line (IP215A CARD) and press the ENTRYkey to change copy direction. This action will access Copy Direction confirmationdisplay screen.



3. Select YES with the CURSOR keysand press the ENTRY key to confirmthe copy direction and access the FileNumber Selection display screen. Ifyou select NO, the procedure willreturn to Step 1.

4. With the CURSOR keys, move thecursor to the file number (F) field and key in a destination file number from 01 to 13with the DATA keys.

5. Press the ENTRY key to enter the file number and access the file name entry displayscreen. With the CURSOR and DATA keys, key in a destination file name up toeight characters long.

6. Press the ENTER key to store the file name and access the file name confirmationdisplay screen. With the CURSOR keys, move the cursor to YES and press theENTER key to confirm the file name that you stored. If you select NO, the procedurewill return to Step 1.

Copying a Schedule to the Power Supply. To copy a welding schedule from theSchedule Welcard to the Power Supply:

1. Press the COPY key to access theCopy Direction dialog screen. It isshowing the default direction of theWelcard (CARD) to the PowerSupply (IP-215A).

2. With the cursor on the top displayscreen line, press the ENTRY keyto accept the copy direction. This action will access the Copy DirectionConfirmation display screen.

3. Select YES with the CURSOR keysand press the ENTRY key to confirmthe copy direction and access theFile Number Selection displayscreen. If you select NO, theprocedure will return to Step 1.

4. With the CURSOR keys, move the cursor to the file number (F) field and key in asource file number from 1 to 13.


IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLY6-6

5. Press the ENTRY key to enter the file number and access the File Name Entrydisplay screen. With the CURSOR and DATA keys, key in a source file name up toeight characters long.

6. Press the ENTRY key to access theFile Confirmation display screen. Ifthe file number and name are as youspecified, select YES with theCURSOR keys and press the ENTRYkey to execute the data copy from theWelcard to the Power Supply. If youselect NO, the procedure will return to Step 1.

Welcard System Error MessagesRefer to Table 6-1 for a list of error messages that are displayed when a system or operatingerror occurs.

Table 6-1. Welcard Error Messages

Display Message Probable Cause Remedy

? UNFORMATTED CARD 1. Unformatted card isinstalled.2. Damaged card is installed.

3. Card battery is dead.

Format the card.

Install undamaged card andformat the card.Replace the battery andformat the card.

COPY FROMUNFORMATTED CARDIMPOSSIBLE !!

1. Unformatted card isinstalled.2. Card battery is dead.

Format the card.

Replace the battery andformat the card.



Table 6-1. Welcard Error Messages (continued)

Display Message Probable Cause Remedy

?? CARD IS NOT SET!! The card is not properlyinstalled in its slot.

Install the card properly.

? FILE F [XX] HASERROR!!

An error has been found inthe card copying operation.

Attempt the copy operationagain. If not successful, thereis a Power Supply failure orthe card is defective. Contactthe factory.

? FILE F [XX] HAS NODATA!!

In the card to Power Supplycopy direction, the specifiedfile contains no data.

Specify a file containing data.

FXX [ ] NOT RECORDED When the directory isreferenced, the specified filecontains no data.

Use a card that has datarecorded.

FXX [ ]* COPYIMPOSSIBLE !!

During data copying fromthe Power Supply to a card,the specified file is found tobe write-protected.

Cancel file write protection.(Refer to Referencing theDirectory in this chapter.)

FXX [ ] ERASE? YES NO

During data copying fromthe Power Supply to a card,the specified file is found toalready exist.

To copy, select YES andpress ENTER.To cancel, select NO andpress ENTER.

COPY FROM MONITORCARD IMPOSSIBLE!!`

Card copying is selected buta Monitor Card is installed.

Replace the Monitor Cardwith a Schedule Card orreinitialize the installed cardas a Schedule Card.


CHAPTER 7IN CASE OF DIFFICULTY

Your IP-215A and IP-217A Fine Spot Welding Power Supplies are designed with reliabilityas a top user priority. But, occasionally, you will run into a problem and need some help toget 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 resistancewelding power supply problems are caused by lack ofmaterial control, process control and electrode tip surfacemaintenance.

The problems that you might encounter fall into two groups:

Soft — The problem is transient, and you can correct it byresetting the system or resetting parameter limits, for example.

Hard — The problem is embedded in the system and someform of repair or modification will be needed.

In either case, built-in automatic self-test and self-calibration routines will bring up alarmmes-ages on the display screens. These messages will usually let you know what action isrequired of you to correct the reason for the alarm. For a complete listing of the alarmmessages, what they mean, and what to do about them, please refer to Appendix E for PowerSupply alarm messages or Chapter 6 for Welcard System alarm messages.

Electrode MaintenanceWhen a welding schedule has been suitable for a particular welding application over manywelds, but poor quality welds are now resulting, electrode deterioration could be theproblem. If you need to increase welding current to maintain the same weld heat, theelectrode tip has probably increased in surface area (mushroomed), effectively increasingweld current density, thus cooling the weld. If you have developed a history of weldcurrent/electrode wear relationship, use the step-up function to provide weld currentcompensation. Otherwise, try replacing the electrodes.

The rough surface of a worn electrode tip tends to stick to the work pieces. So, periodic tipresur-acing (dressing) is required to remove pitting, oxides and welding debris from theelectrode. You should limit cleaning of an electrode on the production line to using a #400-

CHAPTER 7: IN CASE OF DIFFICULTY


Figure 7-1. Factory Adjusted Display ViewingAngle

600 grit electrode po-ishing disk. If you must clean a badly damaged tip with a file, youmust 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 tipsurfaces and shapes in a certified machine shop.

WARNING: Only qualified technicians should performinternal adjustments or replace parts. Removal of the unit covercould ex-pose personnel to high voltage and may void thewarranty.

Adjusting the Display Viewing Angle

The viewing angle of the display screen is set at the factory at approximately 30° (see Figure7-1). You may adjust the angle with the CONTRAST screwdriver adjustment on the rearpanel. Turn-ing the adjustment clockwise and counterclockwise moves the viewing angledownward and upward respectively.

Memory Backup Battery Replacement



IP2PCB.WPG

Figure 7-2. Memory Backup Battery Location

The lithium memory backup battery is located at the bottom center of the Power Supply mainprinted circuit board (see Figure 7-2). Although the battery’s operational life is five years, werecommend that you replace this battery routinely every three years.

Technical Assistance



If you need further technical assistance, please contact either your authorized service agent or:

UNITEK MIYACHI CORPORATION1820 South Myrtle Avenue

Monrovia, CA 91017-7133Phone: (818) 303-5676FAX: (818) 358-8048TWX: (910) 585-1836

IP-215A/217A FINE SPOT WELDING POWER SUPPLIES993-603 REV A: October, 1996 A-1

APPENDIX ATechnical Specifications

APPENDIX A: TECHNICAL SPECIFICATIONS

IP-215A/217A FINE SPOT WELDING POWER SUPPLIESA-2 993-603 REV A: October, 1996

POWER

Input Power Line Voltage Range . . . . . . . . . . . . . . . . . . . 220 VAC, ±10%, 3 Phase, 50/60 Hz

Input Power Line Current (peak maximum) . . . . . . . . . . . . . . . . . . . . . . . . . IP-215A: 50AIP-217A: 200A

Control Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 KHz

IP-215A Heat 1 and Heat 2 Setting Ranges:

Heat 1 (Constant Current Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 2.00 KAHeat 1 (Constant Voltage Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 - 2.00 VHeat 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 KANOTE: 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 KAConstant Voltage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±0.00 - 9.99 VConstant 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

ENVIRONMENTAmbient Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . 0° to +45° C (32° to 113° F)


IP-215A/217A FINE SPOT WELDING POWER SUPPLIES993-603 REV A: October, 1996 A-3

PHYSICALDimensions:

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)

ELECTRICALControl 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 msecWeld 1 (W1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 99 msecCool (CO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 99 msecRise 2 (R2) (included in Weld 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 49 msecWeld 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 SUPPLIESA-4 993-603 REV A: October, 1996

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-501AIP-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/IP-217A FINE SPOT WELDING POWER SUPPLIES

993-603 REV A: October, 1996 B-1

APPENDIX B

Cable Wiring and

Signal Specifications

CABLE WIRING AND SIGNAL SPECIFICATIONS


B-2 993-603 REV A: October, 1996

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:



993-603 REV A: October, 1996 B-3

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:



B-4 993-603 REV A: October, 1996

Welding Transformer Cable Connections (continued)



993-603 REV A: October, 1996 B-5

Welding Transformer Cable Connections (continued)



B-6 993-603 REV A: October, 1996

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



993-603 REV A: October, 1996 B-7

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.



B-8 993-603 REV A: October, 1996

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)



993-603 REV A: October, 1996 B-9

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.



B-10 993-603 REV A: October, 1996



993-603 REV A: October, 1996 B-11

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



B-12 993-603 REV A: October, 1996

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



993-603 REV A: October, 1996 B-13

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 SUPPLIES993-603 REV A: October, 1996 C-1

APPENDIX CWelding Transformer

Specifications

APPENDIX C: WELDING TRANSFORMER SPECIFICATIONS

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIESC-2 993-603 REV A: October, 1996

SpecificationModel

IT-500A IT-501A IT-510A IT-511A IT-512A IT-540A

Rated Capacity(KVA)

2.0 2.3 4.1 4.7 10.7 17.2

Maximum InputVoltage (V)

300 300 300 300 300 300

Input Frequency(kHz)

2 2 1 1 1 1

Secondary VoltageWithout Load (V)

6.25 8.1 6.5 8.57 12/10 9.37

Maximum Current(KA)

2 1.5 4 3 4 51

Duty Cycle (%) 8 7 6 5 5 7

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 280/11.0 295/11.6 340/13.4 360/14.2 410/16.1 300/11.8NOTES:1 With 15-cycle weld time2 At 5.7 liters (1.5 U.S. gallons)/minute

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES993-603 REV A: October, 1996 D-1

APPENDIX DResistance Welding Basics

APPENDIX D: RESISTANCE WELDING BASICS

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIESD-2 993-603 REV A: October, 1996

Figure D-1. Interaction between welding parameters.

Resistance Welding Parameters

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

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

Welding Parameter Interaction



Electrode Selection

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

MATERIAL ELECTRWMATYPE


Alumel -2 Alumel -2

Alumel -2 Chromel -2

Alumel -2 Dumet -2

Alumimun -1 Alumimun -1

Alumimun -1 AluminumAlloys

-1

Alumimun -1 Cadmium Plating -1

Alumimun -1 Tinned Brass -14

Alumimun -1 Tinned Copper -14

Alumimun -1 Gold PlatedDumet

-2

Alumimun -1 Gold PlatedKovar

-2

Alumimun -1 Kovar -2

Alumimun -1 Magnesium -1

Alumimun -1 Cold Rolled Steel -2

Alumimun -1 Stainless Steel -2

BerylliumCopper

-2 BerylliumCopper

-2

BerylliumCopper

-2 Brass -2, -14

BerylliumCopper

-2 Copper -14

BerylliumCopper

-2 Tinned Copper -14



BerylliumCopper

-2 Nickel -2

BerylliumCopper

-2 Cold Rolled Steel -2

BerylliumCopper

-2 Stainless Steel -2

Brass -2, -14 Brass -2, -14

Brass -2, -14 Tinned Brass -14

Brass -2, -14 Bronze -2

Brass -2, -14 Consil -2

Brass -2, -14 Constantan -2

Brass -2, -14 Copper -14

Brass -2, -14 Tinned Copper -14

Brass -2, -14 Dumet -2



Brass -2, -14 Nichrome -2

Brass -2, -14 Nickel -2

Brass -2, -14 NiSpan C -2

Brass -2, -14 Paliney 7 -2

Brass -2, -14 Silver -11, -14

Brass -2, -14 Cold Rolled Steel -2

Brass -2, -14 Stainless Steel -2

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



Bronze -2, -11 Tinned Copper -14

Bronze -2, -11 Iron -2

Bronze -2, -11 Nichrome -2

Bronze -2, -11 Nickel -2

Chromel -2 Chromel -2

Chromel -2 Constantan -2

Chromel -2 Copel -2

Chromel -2 Copper -14

Chromel -2 Tinned Copper -14

Chromel -2 Dumet -2

Chromel -2 Nichrome -2

Chromel -2 Cold Rolled Steel -2

Consil -2 Consil -2

Consil -2 Tinned Copper -14

Consil -2 Dumet -2

Constantan -2 Constantan

Constantan -2 Copper -14

Constantan -2 Tinned Copper -14

Constantan -2 Iron -2

Constantan -2 Nichrome -2

Constantan -2 Nickel -2

Copper -14 Copper -14

Copper -14 Dumet -2

Copper -14 Invar -2

Copper -14 Karme -2

Copper -14 Manganin -2



Copper -14 Nichrome -2

Copper -14 Nickel -2

Copper -14 Paliney 7 -2

Copper -14 Silver -11, -14

Copper -14 Cold Rolled Steel -2

Copper -14 Stainless Steel -2

Dumet -2 Dumet -2

Dumet -2 Nichrome -2

Dumet -2 Nickel -2

Dumet -2 Platinum -2

Dumet -2 Cold Rolled Steel -2

Evanohm -14 Copper -14

Gold -14 Gold -14

Gold -14 Kovar -2

Hastalloy -2 Titanium -2

Inconel -2 Inconel -2

Inconel -2 Kulgrid -2

Invar -2 Invar -2

Iridium -2 Iridium -2



Iridium -2 Platinum -2

Iron -2 Iron -2

Karma -2 Karma -2

Karma -2 Nickel -2

Karma -2 Platinum -2

Kovar, GoldPlate

-2 Kovar, GoldPlate

-2

Kovar, GoldPlate

-2 Kulgrid -2

Kovar, GoldPlate

-2 Stainless Steel -2



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 BerylliumCopper

-2

Nickel Alloy -2 Consil -2

Nickel Alloy -2 Tinned Copper -14

Nickel Alloy -2 Nichrome -2

Nickel Alloy -2 Nickel -2





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 fromelectrodes. Cleaning of electrodes on production line should be limited to use of #400-600 gritelectrode polishing disks. For less critical applications, a file can be used to clean a badlydamaged tip. However, after filing, polishing disks should then be used to ensure that the



electrode faces are smooth. If this is not done, the rough surface of the electrode face will have atendency to stick to the work piece.

Weld Schedule Development

Developing a weld schedule is a methodical procedure which consists of making sample weldsand evaluating the results. The first weld should be made at low energy settings. Adjustmentsare 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 thepreceding table for electrode material recommendations.

2. Use a flat electrode face for most applications. Use a "domed" face if surface oxides area problem. If either of the parts is a wire, the diameter of the electrode face should beequal to or greater than the diameter of the wire. If both parts are flat, the face should beat least one-half the diameter of the electrodes. Pencil point electrodes cause severeelectrode sticking to the parts, unexplained explosions, and increase the weld heatsubstantially 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 anAir Actuated Weld Head per the manufacturer’s instructions. Figure D-1 illustrates theeffect of weld force on the parts.

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

5. Use pliers to peel the welded materials apart. A satisfactory weld will show residualmaterial pulled from one material to the other. Tearing of base material around the weldnugget indicates a material failure NOT a weld failure. Excessive electrode stickingand/or "spitting" should define a weld as unsatisfactory and indicates that too much weldcurrent, 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 isweak. Increase the weld time in 1 cycle increments. Increase weld current if a satis-factory weld is achieved using 10 cycles of weld time. Note: Actual weld strength is auser defined specification.

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



identical materials with thickness ratios greater than 4 to 1. The general rule is that themore 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 thesemethods, 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 setof 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 eachweld. Calculate the average pull strength. Increase weld current and repeat thisprocedure. Do not change the weld time, weld force, or electrode area.

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

3. Repeat steps 1 and 2 for different weld forces and then create a plot of part pull strengthversus 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



Figure D-2. Weld Strength Profile.

Figure D-2 illustrates a typicalWeld Strength Profile. Curve Cshows the highest pull strengthsbut the lowest tolerance tochanges in weld current. CurveB shows a small reduction instrength but considerably moretolerance to changes in weldcurrent. Weld heat will vary as aresult of material variations andelectrode wear. Curve B is pre-ferred since it shows moretolerance to changes in weldcurrent and has nearly the samebond strength as Curve C. Acomparison of weld schedulesfor several different applicationsmight show that they could beconsolidated into one or twoweld schedules. This would have obvious manufacturing advantages.

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES993-603 REV A: October, 1996 E-1

APPENDIX EAlarm Message

List

APPENDIX E: ALARM MESSAGE LIST

ME-35A FINE SPOT WELDING POWER SUPPLIESE-2 993-603 REV A: October, 1993

ALARM MESSAGE DESCRIPTION CORRECTIVE ACTIONS

MEMORY ERROR!! Memory Trouble. Memory backupbattery is discharged. Program datamay have been lost. TROUBLE outputsignal is generated at the I/O connectorwhen power is turned on (refer toAppendix B).

Error Reset: Press the front panelRESET key.

Remedies: Check program data afterreset. Restore data if wrong or missing.Replace the lithium backup battery onthe Power Supply printed circuit board(refer to Chapter 7).

OVER TEMPERATUREOF TRANSFORMER !!

Welding Transformer Thermostat isOpen. The welding transformer hasoverheated and its protectivethermostat has tripped. The systemcannot start.

Error Reset: Close the RESET inputsignal at the I/O connector (refer to Ap-pendix B).

Remedies: Cool the weldingtransform-er to reset the thermostat.Check the transformer cooling system.Reduce the duty cycle or use a largercapacity weld-ing transformer.

OVER TEMPERATUREOF TRANSISTOR !!

Transistor Thermostat is Open. Pow-er transistors have overheated and theprotective thermostat has tripped. Thesystem cannot start.


Remedies: Cool the power supply toreset the thermostat. Reduce the dutycycle.

OVER CURRENT!! Excessive Current. Power Supplypeak output current exceeded 50 A forthe IP-215A or 200 A for the IP-217Aduring the weld cycle.


Remedies: Check for a short circuitbetween the welding transformer out-put terminals or in the weldingtransformer output cable.



NO CURRENT !! No Current. During welding, weldcur-rent is less than 25 A for the IP-215A or 50 A for the IP-217A after 5msec from the start of the weld cycle.Welding has stopped and the systemcannot be re-started.


Remedies: Check the welding trans-former secondary circuit and itsinternal toroidal coil for damaged wiresand loose connections.


NO VOLTAGE !! No Voltage. In the Constant Voltage orConstant Power control mode, sensedvoltage is less than 0.05 V after 5 msecfrom the start of the weld cycle.


Remedies: Check for disconnectedvolt-age sensing leads or an openvoltage sensing cable.

CURRENT ERROR !!LOWER THAN LIMIT

Current Lower Limit Exceeded. Themeasured current value has gone belowthe current monitor lower limit setting.

MR = 0: END signal is outputat I/O connector(refer to AppendixB). Next weld canbegin.

MR = 1: END signal is notoutput at I/Oconnector. Next weldcannot begin.

Error Reset:

MR = 0: Next START signalauto-matically clearserror con-dition.

MR = 1: Close RESET inputsignal at I/Oconnector.

Remedies: Check for problems in thewelding cables, work pieces, the weldhead, and the AC input voltage source.



CURRENT ERROR !!HIGHER THAN LIMIT

Current Upper Limit Exceeded.When the weld is completed, the meas-ured current value has gone above thecurrent monitor upper limit setting.



Error Reset:



Remedies: Check for problems in thewelding cables, work pieces, and theweld head.

VOLTAGE ERROR !!LOWER THAN LIMIT

Voltage Lower Limit Exceeded.When the weld is completed, themeasured voltage value between theelectrodes has gone below the voltagemonitor lower limit setting.



Error Reset:

MR = 0: Next START signalauto-matically clears error con-dition.


Remedies: Check for problems in thewelding cables, work pieces, and theweld head.




VOLTAGE ERROR !!HIGHER THAN LIMIT

Voltage Upper Limit Exceeded.When the weld is completed, themeasured vol-tage value between theelectrodes has gone above the voltagemonitor upper limit setting.



Error Reset:



Remedies: Check for problems in thework pieces and the weld head.

WATTAGE ERROR !!LOWER THAN LIMIT

Power Lower Limit Exceeeded.When the weld is completed, themeasured power value has gone belowthe power monitor lower limit setting.



Error Reset:



Remedies: Check for problems in thewelding cables, voltage sense cables, work pieces, the weld head, and the ACinput voltage source.

WATTAGE ERROR !!HIGHER THAN LIMIT

Power Upper Limit Exceeded. Whenthe weld is completed, the measuredpower value has gone above the powermonitor upper limit setting.



Error Reset:



Remedies: Check for problems in thework pieces and the weld head.



FULL WAVE !! Control Limit Exceeded. The controlpulse width was 100% for more than 5msec during the weld cycle.

Error Reset: Close the RESET inputsignal at the I/O connector or wait forthe next START signal toautomatically clear the error condition.

Remedies: Check for problems in thewelding cables, the work pieces, theweld head, and the AC input voltagesource.


(IP-217A Only)

CURR SET ERROR !!

Current Setting Error. The IT-500AWelding Transformer is selected. Atthe START signal, the weld currentsetting is greater than 2.01 KA. AnERROR output signal is present at theI/O connector (refer to Appendix B). The system cannot start.

Error Reset: Close the RESET signalinput at the I/O connector (refer toAppendix B).

Remedies: Reduce the current settingbelow 2.01 KA or change the weldingtransformer to an IT-510A.

END OF WELD COUNT !! Note: This alarm is not the result of anerror.

At the end of the last weld cycle, thenumber of good welds completed wasequal to the value preset into the weldcounter. The COUNT UP and ENDsignals are output at the I/O connector(see Appendix B). The next weld canbegin.

Alarm Reset: Press the front panelRESET and COUNT keyssimultaneously.

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES993-603 REV A: October, 1996 F-1

APPENDIX FWeld Programming Sheets

You will find the schedule sheets in this appendixuseful for planning or recording your Power Supplyweld mode and weld parameter selections. You maywish to reproduce a supply of blanks.

APPENDIX F: WELD PROGRAMMING SHEETS

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIESF-2 993-603 REV A: October, 1996

WELD SCHEDULE

Parameter UnitWeld Schedule Number

1 2 3 4 5 6 7

Rise 1 (R1) msec

Weld 1 (W1) msec

Cool (CO) msec

Rise 2 (R2) msec

Weld 2 (W2) msec

Control Mode I = CurrentV = VoltageW = Power

HEAT 1:Current ModeVoltage ModePower Mode

KAV

KW

HEAT 2:Current ModeVoltage ModePower Mode

KAV

KW

MODE SELECTION SCHEDULE


IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIES993-603 REV A: October, 1996 F-3

SettingModes for Weld Schedule No: ___

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 SUPPLIESF-4 993-603 REV A: October, 1996

Monitor LimitWeld Schedule Number

1 2 3 4 5 6 7

Current (KA)Upper (+)

Lower (-)

Voltage (V)Upper (+)

Lower (-)

Power (W)Upper (+)

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 SUPPLIES993-603 REV A: October, 1996 Index-1

ALPHABETICAL SUBJECT INDEXThis index is an alphabetically sorted listing of subjects coveredin this manual, showing the page number(s) where you can findthe subjects.

For your convenience, multiple context subjects and subjectshaving alternative key words are listed alphabetically more thanonce. For example, the subject SCAN key is listed under -S- aswell as under-K- as Keys, front panel: SCAN.

Similarly, the subject Mode Section Display Screen is listedunder -M- , and under -D- as Display screens: Mode selection, and under -S- as Screens, display: Mode selection.

ALPHABETICAL SUBJECT INDEX

IP-215A/IP-217A FINE SPOT WELDING POWER SUPPLIESIndex-2 993-603 REV A: October, 1996

-A-

About this manual (1-1)About your equipment (2-1)Activating the data output port (5-10)Adjustment of display viewing angle (7-2)Alarm messages (E-1)Assistance (1-3)( 7-3)Automatic performance monitors (5-7)Automation capability, general (2-2)Average pulse width display screen (4-9)Average pulse width monitoring (5-6)

-B-

Battery replacement:Memory backup (7-2)Welcard (6-1)

-C-

Cable wiring specifications (B-1)Card identification display screen,Welcard (6-4)Card name display screen, Welcard (6-3)Card type display screen, Welcard (6-3)Cautions and warnings page (iii)Clock display screen (4-8)CLOCK key (4-8)Connections:

I/O signals (B-1)Multiple welding transformers (3-

3)Standard installation (3-2)

Connector functions (B-1)Constant current feedback mode, general(2-1)Constant power feedback mode, general (2-2)

Constant voltage feedback mode, general2-1)Contents, table of (v)Contrast adjustment, display (4-2)(7-2)Control feedback gain setting (5-9)Control limit monitor (5-7)Control mode status indicators (4-4)Controls:

Front panel (4-3)Rear panel (4-1)

Copy direction display screen, Welcard(6-4)COUNT key (4-10)Count reset (4-10)Current setting monitoring (5-6)Cursor keys (4-9)

-D-

DATA -DOWN/UP+ keyData I/O connector (4-2)Data output port activation (5-10)Data records, Welcard (6-2)Dimensions, installation (3-1)Directory referencing, Welcard (6-3)Display contrast adjustment (4-2)(7-2)Display data entry ranges (5-2)Display, liquid crystal (4-2)Display screen editing (5-1)Display screens:

Average pulse width (4-9)Clock (4-8)Mode selection (4-5)Mode selection extension (4-6)(5-

8)Monitor limits (4-7)Welcard card name (6-3)Welcard card type (6-3)Weld heat (4-8)Weld schedule (4-5)(5-3)

ALPHABETICAL INDEX


-D- (continued)Display Screens (continued):

Welding transformer channel programming (4-7)(5-8)

Display viewing angle adjustment (7-2)

-E-

Electrical shock tips (iv)Electrical specifications:

Line power (B-2)System (A-2)

Electrodes:Maintenenance of, general (7-1) Selection criteria (D-3)

ENTRY key (4-8)Equipment description, general (2-1)Equipment installation (3-1)Equipment list (2-2)Error messages, Welcard (6-6)Excessive current monitor (5-7)

-F-

Feedback control modes, general:Constant current (2-1)Constant power (2-2)Constant voltage (2-1)

File number confirmation display screen,Welcard (6-6)File number display screen, Welcard (6-4)File number selection display screen,Welcard (6-5) Firing switch input (3-2)(B-7)

-G-

Gain setting, control feedback (5-9)Getting started (3-1)

-H-

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

-I-

Illustrations list (viii)In case of difficulty (7-1)Initializing the Welcard (6-2)Input power line specifications (A-1)Input/output signals (B-1)Installation:

Dimensions (3-1)(A-3)Equipment (3-1)Welcard (6-2)

Improvement of manual (1-3)

-K-

Keys, front panel:CLOCK (4-8)COUNT (4-9)CURSOR (4-9)DATA -DOWN/UP+ (4-10)ENTRY (4-8)MODE (4-5)MON. 1 (4-8)MON. 2 (4-9)MONITOR SET (4-7)RESET (4-9)SCAN (4-7)WELD SCHED (4-5)



-L-

Liquid crystal display (4-2)List of equipment (2-2)List of illustrations (viii)List of tables (viii)

-M-

Maintenance (7-1)Manual organization (1-2)Manual, suggestions for improvement of(1-2)Manuals, related (1-2)Memory backup battery (7-2)Memory monitor (5-7)Mode selection display screen (4-5)Mode selection extension display screen(4-6)(5-8)MON. 1 key (4-8)MON. 2 key (4-9)Monitor limits display screen (4-7)MONITOR SET key (4-7)Monitors, automatic performance (5-7)Monitoring average pulse width (5-6)Monitoring the current setting (5-6)Monitoring power supply operation (5-4)Monitoring weld heat limits (5-4)Multiple Welding transformer selection,general (2-2)

-N-

No current monitor (5-7)No voltage monitor (5-7)Nomenclature usage (1-2)

-O-

Operating with the Welcard (6-2)Operating your power supply (5-1)Organization (of manual) (1-1)Output relays (B-11)(B-12)Overview of system (2-1)

-P-

Parts list, equipment (2-2)Performance features, general (2-1)POWER circuit breaker (4-10)Power line voltage requirements (3-4)Power supply:

Monitoring operation (5-4)Operating instructions (5-1)

Power up (3-4)Problem solving, general (7-1)

-Q-

Quick start method (3-4)

-R-

Reader comment sheet (inside back cover)Rear panel components (4-1)Referencing conventions (1-2)Referencing the Welcard directory (6-3)Related manuals (1-2)RESET key (4-9)Resistance welding basics (D-1)Revision Record (i)RS-485 connector (5-10)

-S-

ALPHABETICAL INDEX


SCAN key (4-7)Schedule recording (6- 4)Schedules, welding, general (2-2)Screens, display:

Average pulse width (4-9)Clock (4-8)Mode selection (4-5)Mode selection extension (4-6)(5-

8)Monitor limits (4-7)Welcard card name (6-3)Welcard card type (6-3)Weld count (4-10)Weld heat (4-8)Weld schedule (4-5)(5-3)Welding transformer channel

programming (4-7)(5-8)Selecting the weld count (5-9)Selecting the welding transformer (5-8)Setting control feedback gain (5-9)Setting the weld schedule (5-3)Signal I/O connector (4-2)(B-1)Space requirements, general (3-1)Specifications:

Signal (B-1)System (A-1)Welding transformer (C-1)

Status indicators:Control mode (4-4)System (4-4)

System connections:Firing switch (B-7)Power (3-2)(B-2)Weld head (3-2)

System controls (4-1)System electrical specifications (A-2) System status indicators (4-4)

-T-

Table of contents (v)Tables, list of (vii)Technical specifications (A-1)Test weld procedure (3-3)Transformer connections (4-2)(B-1)Transformer model selection (C-1)Transformer selector (2-2)Transformer thermostat monitor (5-7)Trial weld procedure (3-3)Troubleshooting (7-1)

-U-

Using the Welcard (6-1)

-V-

Ventilation grill (4-1)Voltage requirements, input line (3-2)(A-2)

-W-

Warranty (inside back cover)Welcard:

Battery (6-1)Card identification display screen(6-4)Card name display screen (6-3)Card type display screen (6-3)Copy direction display screen (6-4)Data records (6-2)Directory referencing (6-3)Error messages (6-6)File number confirmation display screen (6-6)

-W- (continued)



Welcard (continued):File number display screen (6-4)File number selection display

screen (6-5)Initialization (6-2)Installation (6-2)

Weld count display screen (4-10)Weld counter selection (5-9)Weld cycle timing (B-9) Weld data storage, general (2-2)Weld heat display screen (4-8)Weld heat limit monitoring (5-4)WELD key (4-8)Weld program key field (4-4)Weld programming sheets (F-1)WELD SCHED key (4-5)

Weld schedule display screen (4-5)Weld strength profiles (D-7)Weld strength testing (D-7)Welding monitors, general (2-2)Welding parameters, general (2-2)Welding schedules:

General (2-2)Setting (5-3)

Welding transformer channelprogramming display screen (4-7)(5-8)Welding transformer connector (4-2)(B-1)Welding transformer selection (5-8)Welding transformer selector (2-2)Welding transformer specifications (C-1)Welding transformer thermostat monitor(5-7)Welding transformer to weld headconnections (3-2)

Documents

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