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INSTRUCTION MANUAL
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AC TYPE SPOT WELDING MACHINE
Model : TSA-500
AC TYPE WELDER CONTROL SYSTEM TSA-500
AC TYPE WELDER TRANSFORMER TST-5T(10T)
Battery Specialist -------------------------------------------
JEONGWOOD TRADING CORP.
Room 1509, Seongsoo Academy Tower, 277-17 Seongsoo-Dong 2-Ka,
Seongdong-Ku, Seoul, Korea.
Tel : 82-2-3436-1212 Fax : 82-2-3436-1279
E-mail : [email protected] [email protected]
URL : http://www.jeongwood.co.kr
PLEASE READ THIS MANUAL BEFORE OPERATION OF WELDING MACHINE.
1. Feature
1) This is resistance welding power supply and weld controller.
2) Since welding time and current are adjustable depends on welding
materials, it makes easy to weld thin plates as well as thick one.
3) It provides high welding performance and reliability by use of 8 bit single
chip micro-computer.
4) It provides clean and strong welding points by 5 step welding control
with up and down slope.
5) It provides welding counter.
2. Specification
1) Name of equipment : Resistance welding controller and power supply
(transformer).
2) Model : Welding controller : TSA-500
Welding transformer : TST-5T
3) Input voltage : AC 220V/380V, +10%, -20%
4) Frequency : 50/60Hz
5) Control method : Thyristor controlled by 1 chip micro-computer
6) Number of timer setting : 10 kinds of setting
Squeeze(Pressure time), Up slope(Current increase), Heat 1(Weld 1),
Cool 1, Heat 2(Weld 2), Cool 2, Heat 3(Weld 3), Down slope(Current
decrease), Hold, Off time
7) Timer setting range : 00 ~ 99 cycle.
8) Method of timer : Cycle counter
9) Number of current setting : 3 kinds of setting
Current 1, Current 2, Current 3
10) Current setting range : 0' ~ 178'
11) Kinds of slope : 2 kinds
Up slope, Down slope
12) Slope step :
Up slope step : Heat 1 current ÷ Up slope time
Down slope step : Heat 3 current ÷ Down slope time
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13) Pressed signal output(solenoide output) : AC 400V/4Ah,
using non-contacts SSR
14) Pressed signal time : Squeeze time ~ hold time
15) Setting switches : 10 kinds
a. ⇦ Key : This key moves from right to left and fixed by key ⇧ and ⇩.
(Select the setting codes at the program mode.)
b. ⇨ Key : This key moves from left to right and fixed by key ⇧ and ⇩.
(Select the setting codes at the program mode.)
c. ⇧ Key : This key is to change the setting codes at the program mode.
(Increase the setting value.)
d. ⇩ Key : This key is to change the setting codes at the program mode.
(Decrease the setting value.)
e. RUN Key : Ready to operate and standby of operation.
* Four digits(count) are displayed in this mode.
f. PGM Key : Program mode.
* Two digits(setting value) are displayed in this mode.
g. W'ON Key : Weld On Key
h. W'OFF Key : Weld Off Key
i. SIN Key : This key is to take only one time operation from Squeeze
time to Hold time by one time continuous input and then stop the
operation.
j. REP Key : This key is to take repeat operation from Squeeze time
to Hold time with initial value of input.
16. Memory of setting codes : By use of EEPROMI, it maintains setting
codes more than 10 years under no electricity or no use
17. Detection of thyristor overheat(Transformer overheat) : Flicker to stop
operation.
18. Welding counter range : 0 ~ 9999
19. Dimension :
TSA-500 : 260mm(D) x 145mm(W) x 215mm(H)
TST-5T/10T : 260mm(D) x 160mm(W) x 215mm(H)
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3. Setting method of TSA-500 Spot Welding Machine
1. Turn “on” power and push “PGM” key.
2. When lamp is on at “SQEZ” and “≃”,
use “⇧” and “⇩” key to set figure into “0”
3. When “UPSL” lamp is on by push “⇨” key,
use “⇧” and “⇩” key to set figure into “0”
4. When HEAT1 lamp is on by push “⇨” key,
use “⇧” and “⇩” key to set figure into “1”
5. When COOL1 lamp is on by push “⇨” key,
use “⇧” and “⇩” key to set figure into “0”
6. When HEAT2 lamp is on by push “⇨” key,
use “⇧” and “⇩” key to set figure into “0”
7. When COOL2 lamp is on by push “⇨” key,
use “⇧” and “⇩” key to set figure into “0”
8. When HEAT3 lamp is on by push “⇨” key,
use “⇧” and “⇩” key to set figure into “0”
9. When DNSL lamp is on by push “⇨” key,
use “⇧” and “⇩” key to set figure into “0”
10.When HOLD lamp is on by push “⇨” key,
use “⇧” and “⇩” key to set figure into “0”
11.When OFF lamp is on by push “⇨” key,
use “⇧” and “⇩” key to set figure into “0”
12.When HEAT1 and % lamp are on by push “⇨” key,
use “⇧” and “⇩” key to set figure into “40”
13.When HEAT2 lamp is on by push “⇨” key,
use “⇧” and “⇩” key to set figure into “0”
14.When HEAT3 lamp is on by push “⇨” key,
use “⇧” and “⇩” key to set figure into “0”
15.When all above process are completed, push “RUN” key and
“RUN”/“SIN” /“WON” lamps are on. Then, feed battery and nickel tag
on right place and press foot pedal to proceed welding.
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16. If welding result is not so strong, push “PGM” key and “SIN”
key. When “%” and “HEAT1” lamp are on, increase previously set
figure “40” into “45”.
17. Push “RUN” key and proceed welding by press of foot pedal.
18. If welding result is still not so strong, please proceed “item 16 and
item 17” repeatedly and increase figure setting.
19. When you push “PGM” key and lamps are on at “∽” & “HEAT1”, you
may use “⇧” and “⇩” key to set figure into “2” or “3” instead of
“1”.(Ref. To item 4) However, nickel tags may be oxidized into dark if
you set at “3” or higher figure. So, you are requested to set it “1” or
“2”.
Before shipment, we did weld test and weldin
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ou can use the
welder without any further adjustment.
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This is further technical information about TSA-500 AC type Spot Welding Machine and
there are two methods to control weld current by SCR and/or voltage selector.
A) Voltage Select Switch at Weld Transformer
To increase weld power, it is required to change voltage select switch from level 1 to
level 4 at weld transformer. Changing this switch, voltage will be changed as below.
Level 1 …… 2.5V
Level 2 …… 2.93V
Level 3 …… 3.5V
Level 4 …… 4.4V
B) Setting Method of Weld Controller
1) Though it is shown as “set figure into 0” on operation manual, it is required to
adjust this figure depends on weld material .
2) The meaning of “40” at “HEAT1” is 40% power of total 100%. If is set at “0”,
there will be no weld power. Higher figure means higher weld current flowing
to transformer. Changing 40% into 45%, weld output is increasing too. In case
“40%” is an ideal weld condition, 45% or 50% will result excess of weld output
and it may cause weld splash, excess melt and weld electrode may be easily
worn out. CYCLE(∽) means time to flow output current.(1 cycle = 16ms)
Higher cycle means more time to flow weld current.
3) Once started, it is available to get three output HEAT1, HEAT2 and HEAT3.
When it is set on “0”, there will be no output. In case thick material, it is
recommended to use HEAT1 and HEAT2 instead of HEAT1 only. When HEAT1
and HEAT2 are used, HEAT2 must be higher than HEAT1, and COOL time is also
required.
4) When CYCLE(∽) has increased, weld time will be prolonged and it may cause
material oxidization or excess melt. So, it is recommended to adjust as less
CYCLE(∽) and higher current(%). It is also recommended to start with low
figure and increase to high figure. When weld pressure has increased, weld
current must be also increased.
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5) In order to weld 0.2 – 0.3mm(T) material, please see as below.
SQEZ ≒ 3 : Start to weld after 48ms
UPSL ≒ 1 : Current increasing in 16ms
HEAT1 ≒ 30 : 30% output in 2 CYCLE(32ms)
COOL ≒ 1 : Cooling in 16ms
HEAT2 ≒ 40 : 40% output in 3 CYCLE(48ms)
Weld Transformer Selector Switch ≒ level 1
Weld Pressure ≒ 7 – 10Kg
SQEZ : Time until electrode touches on material and flow weld current.
(1 CYCLE = 16ms)
UPSL : Pre-heating time of material.
HEAT1 : Heating energy to melt material.(1st) Current(upper line) is showing by % and
CYCLE(lower line : Time to flow current) is showing by ∽.
COOL1 : Cooling time between HEAT1 and HEAT2.
HEAT2 : Heating energy to melt material.(2nd) Current(upper line) is showing by % and
CYCLE(lower line : Time to flow current) is showing by ∽.
COOL2 : Cooling time between HEAT2 and HEAT3.
HEAT3 : Heating energy to melt material.(3rd) Current(upper line) is showing by % and
CYCLE(lower line : Time to flow current) is showing by ∽.
DNSL : After-heating time of material.
HOLD : Standby time on weld output.
※ HEAT1 for ordinary use. Thick or plated material, use HEAT2 and HEAT3 along
with COOL1 and COOL2.
※ When use HEAT1 only, set figure of time into “0” for COOL1 – HOLD.
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