If there was a low-cost An affordable, full-featured

resistance welding control

resistance welding control that: that will take you virtually
þ stored up to 75 schedules, anywhere you want to go...
þ had every RWMA function as a standard feature, Comes with everything
þ had an easy to use keypad with a full display... you need already built-in.

...would you buy it? You bet you would! Automatic

Voltage
Compensation

The UNITROL 75 Schedule

SOLUTION
Memory
®
Welding Control Electronic Weld
or Parts Counter
helps you solve all of Dual Schedule
your welding problems Keyboard Keylock

• 1Ø • 3Ø Frequency Converters • 3Ø DC Heat Stepper

• Temperature Feedback Resistance Brazing
Tip Force
Calculator

Water Saver

Pulsation

Repeat Mode

Retract

Squeeze

Weld

Hold

Preheat

Delay After
Available with remote Preheat
console or built in cabinet.
See back page for options.
Upslope

Downslope

Postheat

UNITROL Quench
and Temper
The UNITROL The UNITROL
SOLUTION ®
SOLUTION®
helps solve 4 big offers unique options:
welding problems: SOFT TOUCH SAFETY SYSTEM
Protects welder operators from electrode
REPEATABILITY 3 RELIABILITY
1 The UNITROL SOLUTION® uses The UNITROL SOLUTION® is
pinch-point injury. Cannot be defeated
or bypassed.
advanced digital electronics – your guarantee designed and built for continuous trouble-free
of absolute timing accuracy and consistent heat production. Every unit is tested on a production TIP FORCE MONITORING
control. It lets you set your machine and be welder before shipment to guarantee Welding force is monitored using a solid
confident of an accurate weld without the worry effectiveness of the high quality components state differential pressure transducer or
of constant adjusting, tweaking and fiddling utilized in each control. All functions have load cell. Every weld automatically starts
associated with older type controls. Uniform, built-in trouble shooting indicators that save you at the same precise point to eliminate the
predictable, consistent welds repeated over valuable time and hours of guesswork. need for SQUEEZE TIME. This option also
and over again – that’s what the UNITROL checks the TIP FORCE at the end of each
SOLUTION® is all about. weld to be sure it has remained within the
4 SERVICEABILITY customer set window.
Other controls, old and new, are
2 FLEXIBILITY made with far too many components which CONSTANT WELD CURRENT
The UNITROL SOLUTION lets you
®
increase the likelihood of breakdown. The Totally closed loop feedback system
say goodbye to inaccurate hard-to-understand, UNITROL SOLUTION® ’s concise and maintains welding current. This option
out-dated controls that put limitations on your uncomplicated design assures continuous allows setting of weld programs in actual
existing equipment. It’s accurate, simple, and production from your welder. Should a problem AMPS to eliminate trial-and-error setups.
gives you the ability to do more with your ever occur, the SOLUTION® ’s self-diagnosing Also includes a current monitor function to
equipment than any other control in the market! feature, together with only two circuit boards, reject out of range welds.
It also includes all RWMA functions in each lets your plant personnel bring the welder back
individual program (slope, pulsation, forge on line in minutes. No wiring to deal with – just ELECTRONIC PRESSURE
delay, etc.) – at no extra charge. plug in and start welding. REGULATOR
Automatically sets air pressure to match
required electrode force. Eliminates
manual settings and adjustments.

The UNITROL PRINTER/COMMUNICATION PORT

RS-232 or RS-485 serial port to capture
SOLUTION ® weld current, electrode force, line voltage,
and fault indicators. Can be supplied for
has something connection to an outside printer or PC.
for everyone
Welding Engineer Setup Operator Plant Management
The sky’s the limit. The Now you can have what At last, a welding control
RSW
UNITROL SOLUTION® you’ve been long waiting that will expedite
lifts all restrictions. for. An easy to use weld parts more smoothly
Now you can easily control that drastically through your welding
PROFIT
weld difficult jobs you reduces setup time, department enabling other
previously stayed away from calculates required pressure departments to coordinate
– galvanized, projections, aluminum, coated, regulator setting and electronically counts more efficiently. No more being held up by lack
stainless, cross wire, HSLA, exotics – as well welds or completed parts for consistant quality. of welded components or re-weld problems.
as common metals with complete reliability. Keeps up to 75 complete instantly available The UNITROL SOLUTION® helps your plant’s
Every UNITROL SOLUTION welding control
® welding schedules for easy job changes. welding department flow more smoothly,
is shipped with all the welding functions you’ll supports JIT (just in time) programs, gives you
ever need. Functions you’d pay extra for on more usable parts per shift, and helps increase
other controls are included in the UNITROL your operating profit.
SOLUTION® at no extra cost.
The UNITROL The UNITROL
SOLUTION ®
SOLUTION®
comes with is equipped with
everything you need SOFT TOUCH
Pinch Point Safety Function*

16 or 32 Digit Alpha-Numeric Read-Out

Shows instructions in simple full word form.
Just answer questions displayed. No special LED Indicators
codes or sequences to learn. Keeps operator aware of mode selected, single,
no-weld, or repeat, and indicates solenoid operation.

Tactile Keypad
Keylock Switch Familiar telephone style layout provides fast
Restricts access to programs so no and uncomplicated setup.
unauthorized changes can be made.

Cast Steel Console Case

Provides the durability needed for shop floor
Hinged Polycarbonate Cover environment. Can be easily mounted anywhere
Keeps dirt and sparks away from keypad. on your welder.
(on controls with remote consoles) OR
Other Cabinet Styles
Various one piece control cabinet styles are
OPERATING FEATURES available. See back cover for descriptions.
Soft Touch Safety System protects operators
against pinch point injuries.* * Requires purchase of Soft Touch hardware

Microcomputer Control System offers ultimate

flexibility with minimum components.
Factory Programmed Software to handle all
welding functions – now and in the future.
STANDARD HARDWARE FEATURES
NEMA Output Safety Relays provide double
75 Weld Schedule Memory with all RWMA
complete functions in each program.
operator protection. SERVICE FEATURES
Automatic Power Factor requires no field Complete Diagnostic Test
Consistent Welder Output is assured with the
calibration. during each start-up.
Automatic Voltage Compensation (AVC). This
maintains welder output at ±1% with an input line Six Foot Interconnect Cable: remote console Fault Displays and Disabler:
voltage variation of ±10%. models can be mounted in any convenient location SCR overtemperature, transformer
(other cable lengths available). overtemperature, emergency stop, limit
Electronic Counter automatically displays welds
made or completed parts welded. Power Supply Cabinet NEMA 1 for series M, switch or pressure switch open, current
NEMA 4 for remote console series, series L, series D. error, electrode force error.
Water Saver Circuit to drive 115 volt solenoid valve,
conserve water and protect operator during tip Universal Mounting Bracket System supplied for Troubleshooting Diagnostic LED Indicators
replacement. easy mounting. for all input and output functions, as well and
all voltage supply levels.
Tip Pressure Calculation automatically calculates Voltage Selectable: remote console series = 208
required pressure regulator setting for desired tip force. through 600 volts. Series M/L/D = 115 through 600 Troubleshooting Test Points for all voltages and
volts. 60 Hz or 50 Hz. output functions.
Dual Level Initiation: Level A closes tips, Level B
starts weld. Solenoid Driver 115 VAC, 1 amp. continuous, fuse Circuit Boards utilize heavy duty quick disconnects
protected, photo-optically isolated. 24VDC available. for easy field replacement – no hard wiring of any
Anti-Tie Down for double hand button use. kind required.
Automatic detection for foot or hand switch operation. PLC compatible.
Console and Power Supply utilize a total of only
Dual Schedule: Assign any two of the 75 welding Utility Supply 115 VAC 0.5 amp., fuse protected. two plug-in printed circuit boards. No separate
programs to two different initiation inputs. Photo-Optically Isolated Inputs: Initiation A terminal strips or remotely mounted components.
Positive or Negative First Half Cycle Firing, (two stage) Initiation B (two stage), External no Simple Design utilizes only 2 circuit boards.
keypad selectable. weld, Transformer overtemperature N.O. or N.C.,
Limit Switch/Retract N.O., Pressure Switch N.O., Terminal Plugs for all external wiring allows quick
Half or Full Cycle Count, keypad selectable. service replacement without tedious wire removal.
Emergency Stop N.O.
Electronic Memory, no battery required. Retains
all data for an unlimited time. Returns to last used
program after power is turned on. AVAILABLE OPTIONS
Intensifier Valve Control for air-over-oil or • Soft Touch Hardware Kit • Seam Weld/Roll Spot • Constant Current • Solid State Pressure Transducer
intensifier cylinders. • Temperature Feedback Resistance Brazing • Printer/Communication Port • Electronic Pressure Regulator
Specifying and ordering the UNITROL SOLUTION® CABINET STYLES
Welding Control is as easy as using
2¾" it. 2¾"
Just follow these easy steps to select a SOLUTION® that matches your welder: 2¾"
1. Find the primary voltage of your welder in the red area of the chart below. 9½"
Remote Console Series 9½"
2. Move downward from this primary voltage to the blue box that includes the KVA as shown on the 9180, 9380, 9480 9½"
nameplate of your welder.
3. From this point, move to the right for the SOLUTION® Model Number in the 6¼" column that lists the desired
circuit protection and cabinet style (see photos at right). Note that circuit breakers are recommended 6¼"
for most production welding systems. 6¼"
EXAMPLE: The correct single phase SOLUTION® controls with circuit breaker protection for a
50 KVA spot welder working at 460 volts are: #9180-810, 9180L-810, or 9180D-810 (depending on
desired cabinet style). A
4. Order this model number from your authorized UNITROL representative or distributor who will A
A
recommend control options. 2¾"
SINGLE PHASE CONTROL SIZING CHART
B
WELDER PRIMARY VOLTAGE MODELCNUMBERS CABINET SIZE 9½"
With Circuit Without B C
208 Volts 230 Volts 380 Volts 460 Volts 575 Volts A B C B C
Breaker Protection
9180-990 9180-900 20 20 9 Series M Series L 6¼"
1-15 1-15 1-25 1-30 1-40 – 9180M-900 – – 8 9180M 9180L
KVA KVA KVA KVA KVA 9180L-990 9180L-900 20 20 9
9180D-990 9180D-900 20 20 9
9180-810 9180-800 20 20 9
16-30 16-35 26-50 31-65 41-80 A– 9180M-800
A – – 8 A 12"
KVA KVA KVA KVA KVA 9180L-810 9180L-800 20 20 9
9180D-810 9180D-800 20 20 9 A
A A
9180-620 9180-600 20 20 9 A
31-75 36-80 51-130 66-170 81-200 – 9180M-600 – – 14 9" C
KVA KVA KVA C
KVA KVA B 9180L-620 9180L-600 20 20 9
9180D-620 9180D-600 20 B 20 9
C B C
9180-630 24 C
76-120 81-130 131-200 171-250 201-325 same as C24 9
B
B B
9180L-630 24 24 9 B
KVA KVA KVA KVA KVA above C
9180D-630 24 24 9 C
9180-440 – 30 30 13
9180L-440 – 30 30 13
121-200 131-250 201-450 251-500 326-600 9180D-440 – 30 30 13
KVA KVA KVA KVA KVA – 9180-400 20 20 9
– 9180L-400 20 20 9
– 9180D-400 20 20 9
Series D A A
COMPLETE 1Ø RETROFIT SYSTEMS WITHOUT POWER CABINETS 9180D
For use with existing SCR Contactors................................................................ 9180-SCO, 9180M-S00, 9180-S00
THREE PHASE CONTROL SIZING CHART
C
WELDER PRIMARY VOLTAGE MODEL NUMBERS CABINET B
FREQUENCY CONVERTER D.C. SECONDARY SIZE C
208 & 230 380 Volts 460 Volts 575 Volts With Circuit Without With Circuit Without
Volts A B C
Breaker Protection Breaker Protection
5 Year Warranty
9380-610 – 9480-610 – 30 30 13 Your investment is protected by the exclusive
– to 50 KVA to 65 KVA to 80 KVA – 9380-600 – 9480-600 24 24 13
UNITROL 5 Year Limited Warranty. Factory labor
9380-620 – 9480-620 – 30 30 13
to 75 KVA 51-130 KVA 66-170 KVA 81-200 KVA – 9380-600 – 9480-600 24 24 13 and parts (excluding fuses) are fully covered for the
first year. This warranty is extended for an additional
9380-430 – 9480-430 – 36 30 13
76-150 KVA 131-200 KVA 171-250 KVA 201-325 KVA – 9380-400 – 9480-400 30 30 13 4 years on a Pro Rata basis (exclusive of fuses,
SCR, circuit breaker and transducers).
9380-440 – 9480-440 – 36 36 13
151-200 KVA 201-450 KVA 251-500 KVA 326-600 KVA – 9380-400 – 9480-400 30 30 13 Parts and labor are FOB our factory. Warranty
included with each system gives full details
COMPLETE 3Ø RETROFIT SYSTEMS WITHOUT POWER CABINETS
of this limited warranty along with all other
Frequency Converter Control for use with existing SCR Contactors..........................................................9380-S00
conditions of coverage.
3Ø D.C. Secondary Control for use with existing SCR Contactors............................................................9480-S00

Distributed By:

UNITROL
UNITROL Electronics, Inc.
Northbrook, IL • 847-480-0115
www.unitrol-electronics.com
info@unitrol-electronics.com