SOFT TOUCH for NON-UNITROL CONTROLS

SOFT TOUCH for NON-UNITROL CONTROLS
SOFT TOUCH for NON-UNITROL CONTROLS
9181-34YB/115, 9181-34WB/115
9181-34YB/24DC, 9181-34WB/24DC
9181-34YM/115, 9181-34YM/24DC
9181-34WM/115, 9181-34WM/24DC
9181-34YM/24AC, 9181-34WM/24AC
9181-34YB/24AC, 9181-34WB/24AC
UNITROL ELECTRONICS, INC.
702 LANDWEHR ROAD
NORTHBROOK, ILLINOIS 60062
[email protected]
1
847-480-0115
2
Thank you for purchasing this Unitrol SOFT
TOUCH system. It is designed to protect your
resistance welder operator from serious electrode pinch point injury. Please let us know if
there are any questions or problems with the
installation or use of this product. You can contact us:
By Phone:
Monday - Friday 9:00 - 5:00 CT: 847-480-0115.
By Email:
[email protected]
By Regular Mail:
Unitrol Electronics, Inc.
Technical Support
702 Landwehr Road
Northbrook, Illinois 60062
3
4
MODEL NUMBER AND OPTIONS AS CHECKED BELOW
SERIAL NUMBER:
CHECK
MODEL
9181-34WB/115
9181-34YB/115
9181-34WB/24DC
9181-34YB/24DC
9181-34WB/24AC
9181-34YB/24AC
9181-34WM/115
9181-34YM/115
9181-34WM/24DC
9181-34YM/24DC
9181-34WM/24AC
9181-34YM/24AC
WELDER TYPE
AND
HARDWARE
1Ø AC
INCLUDES A
SNUBBER
AND
2=MUFFLERS
MFDC
(INVERTER)
INCLUDES
2=MUFFLERS
RAM TYPE
HEAVY WEIGHT
LIGHT WEIGHT, ROCKER ARM
HEAVY WEIGHT
LIGHT WEIGHT, ROCKER ARM
HEAVY WEIGHT
LIGHT WEIGHT, ROCKER ARM
HEAVY WEIGHT
LIGHT WEIGHT, ROCKER ARM
HEAVY WEIGHT
LIGHT WEIGHT, ROCKER ARM
HEAVY WEIGHT
LIGHT WEIGHT, ROCKER ARM
VALVE
VOLTAGE
115AC
24VDC
24VAC
115VAC
24VDC
24VAC
OPTIONS
9181-34BPA
9181-34JA
9181-34JB
9181-34LSA
9181-34LSB
9181-34LSC
9181-34FRL-1/2
9181-34FRL-3/4
Timed bypass. Includes security lock selector switch, 2 = LED
indicator lights, faceplate. Closes electrodes under low force,
delays, and brings electrodes to welding force.
Retract Kit. Includes HEAD DOWN proximity switch and
mounting bracket kit. May require additional field bracketry
to match welder
Retract option without proximity switch. For use with welders that have separate RETRACT and WELD INITIATION
switches.
Limit Switch. Allows use of ram position or continuity. Includes RAM POSITION proximity switch and mounting bracket kit. May require additional field bracketry to match welder. Includes security lock selector switch, 2 = LED indicator
lights, faceplate
Limit Switch. Allows use of a ram position or continuity. Includes security lock selector switch, 2 = LED indicator lights,
faceplate. Does NOT include a proximity switch or mounting
bracket kit. Use with customer-supplied PNP proximity
switch.
Limit Switch used as a redundancy with continuity. Always in
operation and not keylock selected. Includes RAM POSITON
proximity switch and mounting bracket kit. May require additional field bracketry to match welder. Can be turned off by
moving a jumper on the control board inside the locked cabinet.
½” NPT Filter, regulator, lubricator with inter block for pilot
line. With air gauge. Not needed if existing regulator is good.
¾” NPT Filter, regulator, lubricator with inter block for pilot
line. With air gauge. Not needed if existing regulator is good.
5
WARRANTY
Unitrol Electronics provides a 5-year limited warranty to cover all of this SOFT TOUCH system. The warranty periods are determined using the date the new control was originally
shipped from Unitrol Electronics. All warranty coverage is FOB Northbrook. Illinois.
This warranty, except for exclusions shown herein covers the following items:
DURING YEAR #1: All parts (exclusive of fuses) that fail due to manufacturing defects.
Necessary labor to repair control that has failed due to manufacturing defects.
DURING YEAR #2: 80% cost of all parts (exclusive of fuses).
80% cost of necessary labor to repair control that has failed due to manufacturing defects.
DURING YEAR #3: 60% cost of all parts (exclusive of fuses).
60% cost of necessary labor to repair control that has failed due to manufacturing defects.
DURING YEAR #4: 40% cost of all parts (exclusive of fuses).
40% cost of necessary labor to repair control that has failed due to manufacturing defects.
DURING YEAR #5:
20% cost of all parts (exclusive of fuses).
20% cost of necessary labor to repair control that has failed due to manufacturing defects.
EXCLUSIONS TO WARRANTY
Any expense involved with repair of control by other than Unitrol Electronics personnel that
has not been authorized in advance and in writing by an officer of Unitrol Electronics.
All costs for freight, to and from Unitrol Electronics, are excluded from this warranty
All field service labor, travel expense, and field living expenses associated with field service
are excluded from this warranty.
No coverage, parts or labor, is offered for components that have failed on control not being
used as specified in Unitrol Electronics published literature, technical sheets, and this direction
book.
No warranty coverage will be made on controls that are being used contrary to specifications,
that were mechanically or electronically altered by customer or installer, or that were physically damaged after shipment from Unitrol Electronics.
Damages to a control by lightning, flood, or mechanical damage are excluded from this warranty.
Unitrol Electronics assumes no liability for damage to other equipment or injury to personnel
due to a failure in the Unitrol Electronics control.
Unitrol Electronics shall not be responsible for any consequential damages of whatever kind.
Expenses involving alteration or installation of a Unitrol Electronics control are not covered in
this warranty.
NO OTHER UNITROL ELECTRONICS INC. WARRANTY, WRITTEN OR
IMPLIED, COVERS THIS CONTROL UNLESS IN WRITING AND SIGNED
BY AN OFFICER OF UNITROL ELECTRONICS, INC. PRIOR TO SHIPMENT OF PRODUCT.
6
TABLE OF CONTENTS
1
HOW SYSTEM OPERATES
2
INSTALLATION, 9181-34W HEAVY WEIGHT SERIES
3
INSTALLATION, 9181-34Y LIGHT WEIGHT SERIES
4
WIRING CONTROL
5
ELECTRICAL HOOKUP, 9181-34WB/115, 9181/34YB/115
6
ELECTRICAL HOOKUP, 9181-34WB/24DC,9181/34YB/24DC
7
ELECTRICAL HOOKUP, 9181-34WB/24AC,9181/34YB/24AC
8
ELECTRICAL HOOKUP, 9181-34WM/115, 9181/34YM/115
9
ELECTRICAL HOOKUP,9181-34WM/24DC,9181/34YM/24DC
10
ELECTRICAL HOOKUP,9181-34WM/24AC,9181/34YM/24AC
11
RETRACT OPTION 9181-34JA
13
RETRACT OPTION 9181-34JB
15
TIMED BYPASS OPTION 9181-34BP
16
PNEUMATIC HOOKUP, 9181-34Y LIGHT WEIGHT
17
PNEUMATIC HOOKUP, 9181-34W HEAVY WEIGHT
18
ADJUSTING SOFT TOUCH VALVES
19
SETTING MAXIMUM DETECT TIME SWITCHES
19
TESTING ELECTRONIC SYSTEM
20
STARTUP PROCEDURE
21
TESTING ELECTRODE CLOSING FORCE
22
TROUBLE SHOOTING CHART
23
LED INDICATOR LIGHTS
7
VERIFY YOUR SOFT TOUCH SENSOR BOARD IS CORRECT
The SOFT TOUCH sensor board can be configured in several
ways. Before turning power on, check to be sure that the
mode and valve voltage matches your welder.
1. TYPE OF WELDING CONTROL. This board can be set to
operate either a 1ØAC welder or an MFDC (inverter) welder.
This is done by pushing the three switches on the lower left
corner to a position to match your welding control.
FOR 1ØAC WELDERS
FOR MFDC (inverter) WELDERS
2. SOLENOID VALVE VOLTAGE. Be sure that the two tall
relays, K2 and K3, show the same voltage on the top printing
as the solenoid voltage of your welding control.
FOR 115VAC
SOLENOID VALVES
8
FOR 24VDC
SOLENOID VALVES
SOFT TOUCH PINCH POINT
PROTECTION SYSTEM
FOR INSTALLATION ON NON-UNITROL
1Ø AC and MFDC WELDING CONTROLS
HOW THE SYSTEM OPERATES
When the solenoid valve output from the welding control goes HIGH,
this voltage goes to the 9280-TS6 SOFT TOUCH detection board, terminal
#9.
The output terminal #11 (SVL) goes HIGH to turn on solenoid valve SVL.
For 9181-34WB systems, this closes the welding electrodes under gravity force with low force bucking pressure (ADVANCE) acting on the underside of the cylinder piston to counterbalance part of the ram dead
weight.
For 9181-34YB systems, this closes the welding electrodes under low
force using low air pressure on the forward port of the welder cylinder.
The 9280-TS6 board checks input at terminals #4 and #5 to see if the
voltage signal drops a minimum value indicating that the electrodes have
made contact on a conducting material (continuity detected).
If this contact is NOT sensed within the maximum time setting on
the board’s DIPswitches, the output terminal #11 (SVL) will go
LOW and drop out solenoid valve SVL to open the electrodes.
If this contact IS sensed within the maximum time setting:
Terminal #11 (SVL) will continue to be HIGH
Terminal #13 (SVH) will go HIGH
Solenoid valve SVH will be turned ON to start high electrode
pressure, and relay K4 on this board will close to start the welding sequence
The contact across terminals #6 and #7 on the TS2 board close
to tell the welding control to start the welding sequence.
1
INSTALLATION
Note that this system REPLACES the
existing weld solenoid valve.
1. Mount the control in a convenient location using the four
mounting tabs on the back of the box.
2. Remove hoses from the existing welding solenoid valve.
This solenoid valve will not be used with this this control.
3. Connect hoses from the control to the air cylinder as
shown in the photos below and the next page. Choose the
photo that matches your control model.
HOSE CONNECTION FOR 9181-34W SERIES CONTROLS
Connect to point between air
filter/water trap and input to
welding pressure regulator
Connect to air cylinder port
that opens the electrodes.
BOTTOM OF CABINET
BOTTOM
OF CABINET
Connect to point after airline
oiler (weld pressure)
Install two airline mufflers
supplied with this unit.
Connect to air cylinder port
that closes the electrodes.
2
HOSE CONNECTION FOR 9181-34Y SERIES CONTROLS
Note that this system REPLACES the existing weld solenoid valve.
Install two airline mufflers
supplied with this unit.
Connect to air cylinder port
that opens the electrodes.
BOTTOM OF CABINET
Connect to air cylinder port
that closes the electrodes.
Connect to point between air
filter/water trap and input to
welding pressure regulator
Connect to point after airline
lubricator (weld pressure)
3
WIRING CONTROL
1. Wire the control board to the welder per the HOOK-UP
drawing on the next two pages. Choose the drawing that
matches the solenoid valve voltage (24VDC or 115VAC).
WARNING: For 115V and 24VAC valve systems, be careful
that the wire going into terminal #14 (SVC) is the neutral of
the 115V or 24VAC supply, and that 115V or 24VAC high is
the same potential that is sent to the welding solenoid from
the welding control.
2. Connect the two blue wires from the bottom of the box to the
upper and lower secondary pad on the welding transformer
or any point close to the pad per the HOOK-UP drawing in
this book.
3. Connect blue snubber cylinder in this kit across the SCR
contactor per the HOOK-UP drawing.
NOTE: If the welding control already has a snubber or
a resistor in series with a capacitor wired across the SCR
contactor, remove this device.
4
INSTALLATION
HOOK-UP DRAWING
9181-34WB/115, 9181-34YB/115
5
INSTALLATION
HOOK-UP DRAWING
9181-34WB/24VDC, 9181-34YB/24DC
6
INSTALLATION
HOOK-UP DRAWING
9181-34WB/24VAC, 9181-34YB/24AC
7
INSTALLATION
HOOK-UP DRAWING
9181-34WM/115, 9181-34YM/115
8
INSTALLATION
HOOK-UP DRAWING
TO
24VAC
9181-34WM/24VDC, 9181-34YM/24DC
9
INSTALLATION
HOOK-UP DRAWING
9181-34WM/24VAC, 9181-34YM/24AC
10
OPTIONAL RETRACT WITH SOFT TOUCH
9181-34JA
FOR WELDERS WITH A RETRACT TYPE CYLINDER.
OPERATED BY A 3-SECTION FOOT SWITCH
This type of foot switch has the RETRACT switch controlled as the first
level and mechanically latched. The other two levels of this foot switch
operate the welding sequence.
This option protects against pinch point injury when bringing the electrodes from
fully open RETRACT position to the WORK position (small space between electrodes). The option includes a PNP proximity switch that is adjusted to go high
when the retract cylinder is fully bottomed putting the electrodes in the (small
opening) WORK position.
1. Install the PNP proximity switch using the starter bracket kit in this option.
Modify as necessary to work with your welder. The proximity switch has to
be blocked when the ram is down in the WORK (small opening) position.
This will put 24VDC into terminal 26.
2. Wire the PNP proximity switch as shown below.
RETRACT HEAD
DOWN LIMIT
SWITCH
PNP
RETR.
FOOT
SWITCH
29
HEAD
DOWN
LIM. SW
31
-24IS
28
27
26
25
24
BROWN
31
+24IS
P-N-P
BLUE
ELECTR.
CLOSED
LIM. SW
-24IS
LEDS
P-N-P
BLACK
SELECT
SWITCH
INPUT
P-N-P
BROWN
BLACK
BLUE
3. Move the double RETRACT jumper plug to
the RETRACT (upper) position as shown.
This is located on the upper left corner of
the board.
11
OPTIONAL RETRACT WITH SOFT TOUCH
9181-34JA
(continued)
SVC
SVH
SVC
SVL
SVC
SVRH
SVRL
FOR /24DC CONTROLS: TO WELDER 24VDC -.
FOR /115 CONTROLS: TO WELDER 115V NEUTRAL
LATCHING RETRACT
FOOT SWITCH
#14 ON THIS BOARD
SVC SVR
VALVE
SUPPLY
SVC
SUPPLY
RETRACT
HIGH
PRES.
RETRACT
LOW PRES.
RETRACT
VALVE
ON
17 18 19 20 21 22 23
Connect the foot switch as shown below to a mechanicallylatching 3-stage foot switch.
12
OPTIONAL RETRACT WITH SOFT TOUCH
9181-34JB
This option 9181-34JB is for RETRACT that operates from either a separate RETRACT foot switch, or from a RETRACT
VOLTAGE from the welding control.
DO NOT USE THIS OPTION FOR WELDERS THAT USE A
COMMON WELD AND RETRACT FOOT SWITCH.
1. HOOKUP FOR SYSTEMS USING RETRACT VOLTAGE SIGNAL FROM THE WELDING CONTROL:
2. Remove the existing wire from the welding control RETRACT
valve driver terminal and wire as shown below to terminal #16.
FOR 24DC CONTROLS: TO WELDER -24VDC SUPPLY.
SVC
SVH
SVRH
FACTORY WIRED TO RETRACT HIGH PRES. VALVE
SVRL
SVL
SVC
SVC SVR
SVC
VALVE
SUPPLY
SVC
SUPPLY
RETRACT
HIGH
PRES.
RETRACT
LOW PRES.
RETRACT
VALVE
ON
17 18 19 20 21 22 23
FOR /115 CONTROLS: TO WELDER 115V NEUTRAL SUPPLY
WIRE TO EXISTING RETRACT SOLENOID VALVE
FOR 24DC CONTROLS: TO 24VDC+ RETRACT VALVE DRIVER
TERMINAL ON WELDING CONTROL.
FOR 115 CONTROLS: TO 115V HIGH RETRACT VALVE DRIVER.
This wire originally was connected to the RETRACT solenoid valve
output terminal.
SUPPLY
SVC
SUPPLY
SVC
SVH
SVC
SVL
SVC
MECHANICALLY-LATCHING
FOOT SWITCH.
#14 ON THIS BOARD
SVR
SVC
VALVE
RETRACT
HIGH PRES.
RETRACT
LOW PRES.
RETRACT
VALVE
ON
17 18 19 20 21 22 23
If RETRACT will be operating from a separate RETRACT foot
switch, connect the foot switch as shown below to terminal #18
and #14.
13
OPTIONAL RETRACT WITH SOFT TOUCH
9181-34JB
(continued)
Insert a jumper from terminal 26 to terminal 29. Note that the
HEAD DOWN LIM. SW light on the annunciator panel will be on
permanently when this jumper is in place.
29
RETR.
FOOT
SWITCH
31
HEAD
DOWN
LIM. SW
+24IS
P-N-P
BLUE
ELECTR.
CLOSED
LIM. SW
31
P-N-P
BLACK
SELECT
SWITCH
INPUT
-24IS
LEDS
P-N-P
BROWN
-24IS
28
27
26
25
24
PLUMBING: Connect hoses from the input port on the existing
RETRACT SOLENOID to the bulkhead on the SOFT TOUCH enclosure as shown below.
ADJUST the RETRACT BUCKING REGULATOR until the electrodes close with less than 50 pounds of force. If you change
the RETURN pressure you will have to adjust the bucking reguRETRACT BUCKING
lator.
NEW 3-WAY
SOLENOID VALVE
TO RETRACT
VALVE INPUT
EXISTING RETRACT
SOLENOID VALVE
3
2
3
2
1
1
RETR
RETURN
PRESSURE
REGULATOR
SVRH
EXT. PILOT
SET WHITE PLUG
TO READ 3-NO
FROM THIS SIDE
14
TO LINE AIR IN
OPTIONAL TIMED BYPASS
9181-34BPA
Some materials being welded have coatings or other
conditions that prevent good continuity between electrodes. For these conditions option #9181-34BPA will
allow the welder to be operated using TIMING rather
than CONTINUITY to switch from low force to high
welding force. In this case, the low force will be applied for the time set on the 4-position DETECT
TIME DIPswitch, and then the high welding force
will turn on. The time from initiation to high force is
the SUM of the switches pushed down on top.
CAUTION: When the key switch is in
the TIMED position, the HIGH WELDING
FORCE will turn after the selected delay
(detect) time unless initiation is opened.
This will happen even if a non-conductive material
or body part is between the electrodes.
This option will be factory wired and supplied with the faceplate
shown below. A key selector switch will allow selection of
CONTINUITY or TIMED DELAY. An LED will glow above the
selected mode of operation.
CONTINUITY
TIMED DELAY
15
PNEUMATIC HOOKUP
9181-34Y… LIGHT RAM OR ROCKER ARM WELDERS
16
PNEUMATIC HOOKUP
9181-34W… HEAVY WEIGHT RAM WELDERS
17
ADJUSTING THE SOFT TOUCH
VALVE SYSTEM
F0R 9181-34WB… SERIES CONTROLS - HEAVY WEIGHT RAMS
1.
The ADVANCE PRESSURE puts air on the underside of the air cylinder piston to
LIFT the welder ram. This is used to partially lower the force between the electrodes due to the dead (gravity) weight of the welder’s ram. Increasing this ADVANCE PRESSURE value will decrease the force between the electrodes when
closed under low force.
2.
Be sure that all flow control valves have been removed from the welder cylinder before doing any adjustment of this system.
3.
Set the ADVANCE PRESSURE regulator inside the enclosure so that the ADVANCE
PRESSURE gauge on the door is at approximately 1-psi.
4.
Set the RETURN PRESSURE regulator inside the enclosure so that the RETURN
PRESSURE gauge on the door is at approximately 12 psi.
5.
Turn the TIP DRESS switch ON. The electrodes should close. Check the force between the electrodes and increase the pressure slightly if the force is great
enough to crush a wood pencil more than 1/16” in depth. If the electrodes do not
close, decrease the pressure to as low as 0 psi. Even though the pressure gauge
shows 0psi, this pressure is actually 1/2psi.
6.
Adjust the RETURN PRESSURE regulator so that when the TIP DRESS switch is
OFF, the electrodes open smoothly. Use the lowest setting on this RETURN PRESSURE regulator that will smoothly open the electrodes. This will produce the fastest electrode closing time.
F0R 9181-34YB… SERIES CONTROLS - LIGHT WEIGHT RAMS AND
ROCKER ARM WELDERS
1.
Set the ADVANCE PRESSURE regulator inside the enclosure so that the ADVANCE
PRESSURE gauge on the door is at approximately 3psi.
2.
Set the RETURN PRESSURE regulator inside the enclosure so that the RETURN
PRESSURE gauge on the door is at approximately 12 psi.
3.
Turn the TIP DRESS switch ON. The electrodes should close. If they don’t, increase
the ADVANCE pressure. Check the force between the electrodes and decrease
the pressure slightly if the force is great enough to crush a wood pencil more
than 1/16” in depth.
4.
Adjust the RETURN PRESSURE regulator so that when the TIP DRESS switch is
OFF, the electrodes open smoothly. Use the lowest setting on this RETURN PRESSURE regulator that will smoothly open the electrodes. This will produce the fastest electrode closing time.
18
SETTING SOFT TOUCH BOARD MAXIMUM DETECT
TIME SWITCHES
Locate the four-section DIPswitch on the left side of each SOFT TOUCH board. This
switch is marked: 1, .75, .5, and .25 seconds. Set the switches to a value that is about
2 to 3 times how long it will take for the electrodes to close. The on-board computer
adds the value of these switches. For example, pushing 1 and .5 down to the left side
will produce a detection time of 1.5 seconds. This setting is not critical. A typical
setting is 1 second. Longer times might be needed for very long stroke cylinders
For example, in the photo below the 0.25 and 1 switch is pushed down toward the
top of the board for a total maximum detect time of 1.25 seconds.
TESTING THE ELECTRONIC SYSTEM
1. Clean electrodes on welder
2. With nothing between electrodes, close electrodes by turning
ON the TIP DRESS switch at the bottom of the annunciator
panel.
3. The electrodes should close. The Continuity Detected with no
Start Signal LED should start flashing.
4.
Turn OFF the TIP DRESS switch and the electrodes will open.
19
STARTUP PROCEDURE
1. Turn on power to welding control.
2. The SOFT TOUCH annunciator panel should go through a
test procedure and then the READY LED should turn on solidly.
3. If the READY LED does flashes slowly or quickly see the
trouble shooting section in this direction book.
4. The system should be ready for operation. There is no customer calibration needed now or ever.
SUCCESSFUL SEQUENCE
WITHOUT LIMIT SWITCH
1. Weld control sends voltage to terminal 9 (SV).
2. START lights
3. Low Force solenoid valve (SVL) is
energized, Low Force ON LED lights.
4. Electrodes close
5. Continuity is detected and Continuity
Detected LED lights.
6. High Force solenoid valve (SVH) is
energized, High Force ON LED lights.
7. Output relay at terminals 6 & 7 closes to start weld control sequence,
and OK to Weld LED lights.
UNSUCCESSFUL SEQUENCE
If continuity is not detected within the maximum time set on the DIPswitch,
electrodes will not get to welding force, will open, and the Detect Time Exceeded, Dress Electrodes LED will light. Clean the electrodes and try
the sequence again. Or check to see if the DIPswitch on the board is set to
a long enough time to allow for the electrodes to close.
PAGE 10
20
TESTING ELECTRODE CLOSING FORCE
Adjust the pneumatic system to produce safe closing electrode
closing force using the directions on page 16 (to match the model number).
Use the TIP DRESS switch to close the electrodes each time
you make a change in the pressure regulator settings. A successful pneumatic setting will provide a force under 50 pounds
between the electrodes. There are two methods to check this
force:
1. The most precise method is to use a tip force measuring instrument between the electrodes. This produces data that
can be recorded on safety records and is less subjective to
visual observation. Unfortunately most of these devices do
not have any accuracy in the low force ranges. Do not use
an instrument that has poor or unknown accuracy in the
low force range. An excellent device that can read the
low forces is Tuffaloy model 601-3000DLC. This unit can also be used to read welding forces up to 3,000 pounds.
2. Place a wood pencil between the electrodes and close using
the TIP DRESS switch. The electrodes should not dent more
than 1/32” into either side. A typical #2 wood office pencil
works well. A carpenter’s pencil works better since the flat
area is much larger.
21
TROUBLE SHOOTING CHART
NOTE: This SOFT TOUCH system will not operate if any fault is
detected. SYSTEM READY will glow solidly if faults are clear.
INDICATION
CAUSE
WHAT TO CHECK OR DO
No power to control.
Start LED not on
solid
Start LED flashing
slowly
If any fault shown
below is detected.
The Start LED will
only
glow
solidly
when the system is
ready for operation.
Voltage on blue sensor wires too low or
not connected.
Or
Insulator missing or
some conducting
Continuity Detected component is conwith No Start Signal nected between insulated side of welder
LED on.
secondary and welder
frame.
Start LED
flashing quickly
Voltage on blue sensor wires is too high
Not enough time allowed to close electrodes
Detect Time Exceeded. Dress Elec- Electrodes not maktrodes LED flashing ing good contact.
Electrodes do not
touch when welder air
cylinder is fully exOutput relay K4 is
Output Closed Fault
mechanically closed
LED is on
(welded contacts)
22
Be sure that 115V is at terminals #1 and
#2.
Measure voltage between electrodes. It
should be a minimum of 25mv
(.025VAC). If it is above zero, a second
snubber might have to be added across
the SCR to bring this voltage up. Or the
snubber might need replacement.
Check mechanical system. Disconnect
flexible shunt that connects weld transformer secondary to moving arm, pull out
plug on SOFT TOUCH board at terminals
4 to 7. Measure resistance between electrodes. If it is not 0, check for bad insulator or some other patch between the insulated moving welder part and the welder
frame. Repair or replace as needed.
Contact Unitrol service for instructions.
Increase DIPswitch time. Remember that
this maximum time is the addition of all
switches pushed down towards the time
numbers (.25sec, .5 sec, .75sec, 1 sec)
Clean electrodes or check part being
welded.
Adjust electrode holders so that there is
at least a 1/4” left in the air cylinder travel
when the electrodes touch.
Replace K4 relay.
23
Having trouble or need answers to your
questions?
Call: Unitrol tech support
847-480-0115, M-F 9:00 - 5:00 CT.
Or Email at:
[email protected]
Unitrol supplies free phone support for
the life of this and all their products.
UNITROL ELECTRONICS, INC.
702 LANDWEHR ROAD
NORTHBROOK, IL 60062
847-480-0115
[email protected]
24
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