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CHAPTER 1: SYSTEM DESCRIPTION

IS-2200CA/4500CA INVERTER POWER SUPPLY

990-412

1-15

Section IV: MA-660A Program Unit (“The Pendant”)

(Sold Separately)

The

Power Supply

uses the

Pendant

to set the weld schedules and see the monitored results. The Pendant

is connected to the Power Supply by a cable attached to the connector on the front door of the Power
Supply as shown below.

Summary of Contents for S-2200CA

Page 1: ...990 412 REV G INVERTER POWER SUPPLY IS 2200CA 4500CA OPERATION MANUAL...

Page 2: ...written authorization of AMADA WELD TECH Printed in the United States of America Revision Record Revision EO Date Basis of Revision A 44470 11 16 Original publication B 44551 02 17 Manual updates C 4...

Page 3: ...of this manual is to supply operating and maintenance personnel with the information needed to properly and safely operate and maintain the IS 2200CA 4500CA Inverter Power Supply We have made every ef...

Page 4: ...6 External Connections 1 7 Cooling Water Pipe Connectors 1 7 RS 485 RS 232C Connector 1 8 Transformer Sensing Connector Optional Toroidal Coil 1 8 Section III System Components for IS 4500CA 1 9 Fron...

Page 5: ...tup Section I Planning 2 1 Environmental Factors 2 1 Space and Mounting Requirements 2 1 Power Requirements 2 2 Section II Installation of IS 2200CA 2 3 Unpacking 2 3 Installation 2 3 Mounting the Pow...

Page 6: ...Screen 3 3 SCHEDULE 3 3 TIME 3 3 WELD 1 2 3 3 4 WELD ON OFF 3 8 CTRL 3 8 HEAT 3 9 UF UP SLOPE FIRST 3 9 DL DOWN SLOPE LAST 3 9 NEXT 3 10 PULSATION and transformer screen 3 10 SCHEDULE 3 10 PULSE LIM...

Page 7: ...VER NO CURR WRK ERR 3 20 7 OUTPUT SELECT Screen 3 21 8 COPY SETUP DATA Screen 3 22 9 MODE SELECT Screen 3 24 DELAY START SET 3 24 START SIGNAL MODE 3 25 END SIGNAL TIME 3 26 END SIGNAL MODE 3 27 WELD...

Page 8: ...VALVE 3 44 STEP 1 9 3 45 COUNT 1 9 3 45 RP2 3 45 TD1 9 3 45 CAP CHANGE 3 45 12 PRECHECK Screen 3 46 SCHEDULE 3 46 PRECHECK TIME 3 46 PRECHECK HEAT 3 46 PRECHECK RESISTANCE HIGH 3 46 PRECHECK RESISTAN...

Page 9: ...AX AIR PRESSURE 3 58 MAX FORCE 3 58 CALIBRATION CONSTANT FORCE 3 58 CALIBRATION LOW 3 59 CALIBRATION HIGH 3 59 Chapter 4 Operating Instructions Section I Introduction 4 1 Operator Safety 4 1 Before Yo...

Page 10: ...Transformer 5 14 Fuse Block 5 14 Section IV Maintenance Procedures 5 15 Cooling Maintenance 5 15 Checking Water Hoses 5 15 Draining Water Hoses 5 15 Flushing Water Hoses and Cooling Chambers 5 15 Sec...

Page 11: ...ll capabilities of the Power Supply please read this instruction thoroughly before attempting to use it After reading this manual retain it for future reference when any questions arise regarding the...

Page 12: ...and symbols are as follows DANGER DO NOT TOUCH THE INSIDE OF THE POWER SUPPLY UNNECESSARILY High Voltages are present inside the Power Supply Cabinet Do not touch the inside of the Power Supply unnece...

Page 13: ...se any cable The power cable and connecting cables may be damaged which can cause electric shock short circuit or fire If any part needs to be repaired or replaced consult AMADA WELD TECH or your dist...

Page 14: ...esult if the Power Supply falls over or drops from an uneven surface Keep combustible matter away from the Power Supply Spatter can ignite combustible materials If you cannot remove all combustible ma...

Page 15: ...Goods within three 3 days of Seller s written notice that the Goods have been delivered to the Shipping Point Buyer shall be responsible for all loading costs including freight and insurance costs and...

Page 16: ...date of Seller s invoice If Seller does not have Buyer s financial information and has not provided pre approved credit terms for Buyer the payment must be made in cash with order or C O D in US doll...

Page 17: ...ANTABILITY b WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE c WARRANTY OF TITLE OR d WARRANTY AGAINST INFRINGEMENT OF INTELLECTUAL PROPERTY RIGHTS OF A THIRD PARTY WHETHER EXPRESS OR IMPLIED BY LAW COUR...

Page 18: ...ld Seller harmless for any violation or alleged violation by Buyer of such laws rules policies or procedures Buyer shall not transmit export or re export directly or indirectly separately or as part o...

Page 19: ...nd shall be finally settled in accordance with said rules The arbitration shall be conducted before a panel of three arbitrators Each party shall select one arbitrator and the two arbitrators so selec...

Page 20: ......

Page 21: ...ol Secondary constant current effective value control Secondary constant power effective value control Primary constant current peak value control Secondary constant voltage effective value control an...

Page 22: ...1200 amps 120VAC valve voltage 500VA 24VDC valve voltage 5 amps optional CE compliance optional RS 232 communications standard RS 485 optional The analog output terminal voltage output proportional t...

Page 23: ...ghts when the weld current is flowing 5 TROUBLE Lamp Indicator that lights when trouble is detected The Pendant will also make a beeping sound When this condition occurs the unit operation is interrup...

Page 24: ...ck NOTE There are minor differences between the size and connector locations between the IS 2200CA and the IS 4500CA but in all other respects the internal components of the two models are identical 3...

Page 25: ...CHAPTER 1 SYSTEM DESCRIPTION IS 2200CA 4500CA INVERTER POWER SUPPLY 990 412 1 5 Connecting Terminal Strip for External Input Output Signals Used to input start signals and output trouble signals...

Page 26: ...st 20 minutes after turning the Power Supply OFF DO NOT REMOVE SHIELD WITH POWER ON OR OPERATE THE MACHINE WITH SHIELD REMOVED THIS WILL RESULT IN DEATH This lamp is located on the panel next to the t...

Page 27: ...ER SUPPLY 990 412 1 7 External Connections Cooling Water Pipe Connectors Located on the bottom of the unit Used for the supply input and drain output of cooling water which cools the inside of the enc...

Page 28: ...l Coil The Toroidal Coil is attached on the transformer away from the Power Supply The signal comes through the TRANSFORMER SENSING CONNECTOR on bottom of Power Supply The coil is used for the seconda...

Page 29: ...CHAPTER 1 SYSTEM DESCRIPTION IS 2200CA 4500CA INVERTER POWER SUPPLY 990 412 1 9 Section III System Components for IS 4500CA Front Panel...

Page 30: ...e of trouble is not removed the operation will again be interrupted and the TROUBLE indicator will light again After the RESET pushbutton switch is pressed the START signal must be re sent to the Powe...

Page 31: ...CHAPTER 1 SYSTEM DESCRIPTION IS 2200CA 4500CA INVERTER POWER SUPPLY 990 412 1 11...

Page 32: ...Transformer Supplies power to the 24V Power Supply for valve output Note The 24V power supply is located behind the I O Terminal Block not shown in the picture above Standby Transformer This transform...

Page 33: ...Power Connections Input power is brought into the Power Supply through an access plate in the top The plate can be removed for drilling appropriate size hole for input power cable conduit Connections...

Page 34: ...r Output Power Connections The connection points for the output power to the weld transformer are as shown The cables should exit through a conduit mounted in a convenient location on the bottom panel...

Page 35: ...ction IV MA 660A Program Unit The Pendant Sold Separately The Power Supply uses the Pendant to set the weld schedules and see the monitored results The Pendant is connected to the Power Supply by a ca...

Page 36: ...to move the cursor or to select an item ON OFF Keys Used to change the value of a selected item or turn it on and off ENTER Key Used to write the set or changed value and ON OFF data in the Power Sup...

Page 37: ...t 5 seconds maximum to initialize schedules in FLASH ROM During that time do not turn off the power MENU Key Used to display the MENU screen Press this key to return to MENU screen from any other scre...

Page 38: ......

Page 39: ...ignal cabling runs water cooling hose connections and to open the front door Electrical input is made from the top of the Power Supply output power to the weld transformer is made from the bottom of t...

Page 40: ...ems other than IS 2200CA 4500CA are sold separately In the secondary constant current effective value control and secondary constant power effective value control a toroidal coil and a volt sensing ca...

Page 41: ...hipping box Carefully save and store packing materials for future storage or shipment of the Power Supply Installation Installation consists of mounting the unit and making power signal and cooling wa...

Page 42: ...turned off and tagged Lock out Tag out Serious injury or death can result from contacting live power lines If the Power Supply was previously powered up allow 20 minutes for the internal capacitor ban...

Page 43: ...y turning the two quarter turn screws and turning the handle NOTE When the IS 2200CA handle is turned the circuit breaker turns OFF 3 Remove the terminal cover from the top of the circuit breaker by g...

Page 44: ...hat secure the Line Out Cover Plate on the bottom of the Power Supply 11 Drill appropriate hole s in the plate to receive the weld transformer power conduit s NOTE Remove all metal shards then re inst...

Page 45: ...connections are made from the bottom of the Power Supply through the Line Out Cover Plate We recommend that you remove the cover plate to an area away from the Power Supply before drilling holes This...

Page 46: ...990 412 Signal Sensing Connections See Appendix B Electrical and Data Connections Section I Data Connectors for connector pin information and Section II Input Output Signal Configuration for connecti...

Page 47: ...un cooling water through an unused Power Supply unit if the water is 4 F 2 2 C below the minimum operating ambient temperature Therefore take special care to keep the water temperature above the minim...

Page 48: ...e removed be sure all metallic shards from the Power Supply after completion of the work Unpacking Unpack the Power Supply from its shipping crate Carefully save and store packing materials for future...

Page 49: ...low 20 minutes for the internal capacitor bank to discharge The installer must make electrical connections in accordance to all applicable codes For appropriate cable ratings see Appendix D Wire Break...

Page 50: ...put is not phase dependent 7 Connect the ground cable to the chassis ground terminal at the bottom corner of the circuit breaker Output Power Connections Weld transformer connections are made from the...

Page 51: ...t to the plate and feed cables into the Power Supply 7 Connect the ground cable to the ground lug 8 Connect the two transformer cables to the power module 9 Replace the plastic high voltage protection...

Page 52: ...x Select the breaker rated current of at least the average input current above Check the coordination of output current momentary maximum current and tripping time on the tripping characteristic curve...

Page 53: ...able current Although a four core cable is used for the input cable and a three core cable is used for the output cable one of the cores is for grounding Therefore use the allowable current of three c...

Page 54: ...run cooling water through an unused Power Supply unit if the water is 4 F 2 2 C below the minimum operating ambient temperature Therefore take special care to keep the water temperature above the min...

Page 55: ...H ROM During that time do not turn the power OFF SHADED CHARACTERS Items for which a value must be input or which must be set ON or OFF will be shaded Move the cursor to the item and type in the appro...

Page 56: ...econd one 03 for the third one and so on Used for communication c PROGRAMMED DATE Input the date on which a schedule is set as data The date does not affect the set schedule When the Power Supply memo...

Page 57: ...ength of weld time welding current and so on The ms mode or CYC mode can be changed via WELD TIME Refer to Chapter 3 Section 10 on the MODE SELECT screen NOTE The unit resolution and setting range cha...

Page 58: ...T SIG MODE does not work It works as LATCHED c WELD 1 2 3 Set the length of time to allow welding current to flow As units of time ms and CYC may be selected Either unit can be selected via the MODE S...

Page 59: ...are set for the previous and subsequent stages in the multi stage welding The downslope time is set for the previous stage the upslope time is set for the subsequent stage and the DL HEAT setting of...

Page 60: ...T downtime is set to 0 E 10 Schedule setting error will occur when the Power Supply starts with the setting below When the upslope time is set in the pulsation welding The upslope time is set and the...

Page 61: ...D are different A A B B C D When the upslope time and the downslope times are set in the pulsation welding The upslope time and the downslope time are set and the UF HEAT setting of D and the DL HEAT...

Page 62: ...he inverter type welding power supply CONTROL METHOD FEATURE APPLICATION CONTROL MECHANISM Primary constant current control PWM effective value control Requires no connection of toroidal coil on the s...

Page 63: ...rent and the transformer turn ratio as current limiter and controls pulse width so that the switching is turned off when the primary current detected by the current sensor mounted into the power suppl...

Page 64: ...t error is displayed current is flowing Exercise caution in handling g NEXT When the cursor is at moving the cu3 10rsor down will change the display to PULSATION and transformer screen PULSATION and t...

Page 65: ...imary constant current effective value control or the primary constant current peak value control If a welding is performed with the other controls control and monitored value may not function correct...

Page 66: ...kA 8 0 120 0 kW 16 0 160 0 kA 16 0 240 0 kW 40 80 kA 4 0 40 0 kA 4 0 60 0 kW 8 0 80 0 kA 8 0 120 0 kW 20 40 kA 2 0 20 0 kA 2 0 30 0 kW 4 0 40 0 kA 4 0 60 0 kW 10 20 kA 2 0 9 99 kA 2 0 9 99 kW 4 0 20 0...

Page 67: ...wer Supply offers nine 9 choices of gain levels k TURN RATIO Set the welding transformer turns ratio The turns ratio can be set in a range from 001 0 to 199 9 NOTE When using the primary constant curr...

Page 68: ...re displayed The Power Supply stores the latest measured values of each SCHEDULE number The stored measurement values are not erased even when the power is turned off and thus can be checked for the n...

Page 69: ...s a percentage of pulse width in full wave mode The pulse width in full wave mode varies with the frequency setting WELD TRANS FREQ The latest measured value welded with the displayed SCHEDULE No is d...

Page 70: ...DULE No is displayed l TOTAL COUNTER The display changes depending on the setting of WELD2 STOP WELD COUNT and COUNTER on the MODE SELECT screen 1 When WELD2 STOP WELD COUNT is WELD2 STOP and COUNTER...

Page 71: ...4 When WELD2 STOP WELD COUNT is WELD COUNT WELD COUNTER is displayed This is different from WELD COUNTER described above Monitored Value Notes Only the last monitored value and the number of counts o...

Page 72: ...settings for 10 kA or 5 kA range In 20 kA 40 kA or 80 kA range CURRENT is 000 0 to 999 9 kA and POWER is 000 0 to 999 9 kW a SCHEDULE Input the number of the SCHEDULE to monitor b TIME Set the upper l...

Page 73: ...ng Therefore when STEPPER MODE is set to ON to perform step up step down for the initial setting the upper lower limit judgment value is stepped up or down automatically EXAMPLE When the current is se...

Page 74: ...isplacement measurement exceeds the upper lower limit DISPL OVER When the final displacement by displacement measurement exceeds the upper lower limit NO CURR When the no current error occurs For the...

Page 75: ...ngs Pressing the ON key switches the signal in the following order in the reverse direction when pressing OFF key END end signal COUNT ERROR count error signal READY ready signal STEP END step end sig...

Page 76: ...layed on the Monitor Panel When the data is changed and the ENTER key is pressed the contents of the memory of the Power Supply are overwritten by the new setting NOTE The MA 660A stores data for only...

Page 77: ...up to 255 schedules indicated as SCHEDULE 1 255 This function is also used to change from the SCHEDULE 1 setting to perform welding according to another schedule EXAMPLES Schedule 2 can be set by swit...

Page 78: ...FF OFF OFF OFF ON OFF OFF OFF ON ON OFF 2ND STAGE OFF OFF OFF OFF OFF ON OFF ON ON OFF ON OFF OFF OFF OFF 2ND STAGE OFF SCH1 OFF SCH2 OFF SCH4 OFF SCH8 OFF SCH16 OFF SCH32 OFF SCH64 DELAY START SET Se...

Page 79: ...tops during squeeze time SQZ The welding sequence proceeds to completion when the 2ND STAGE signal stops during Weld 1 time WE1 or later A 2ND STAGE A DELAY START SET Schedule selection 1 2 4 8 16 32...

Page 80: ...ains the end signal output during the start input When OFF is set actually output END time changes depending on the OFF setting even if a value is set for END SIG TIME see below Also this is not outpu...

Page 81: ...n the monitored value is outside the upper and lower tolerance limits in the event of an error or when the sequence is interrupted by START SIG MODE MAINTAINED 2 The end signal will be output even whe...

Page 82: ...function When PARITY CHECK is selected Parity check will be performed This check allows for detection of a failure resulting from a wire break in the schedule selection signal lines Be sure that the t...

Page 83: ...The WE1STOP signal shuts off current immediately after the WE1 starts the current is supplied for about 1 cycle when input before the WE1 period switching the sequence to COOL1 The WE1STOP signal will...

Page 84: ...upplied for at least 60ms and neglected for 15ms WELD 5ms INT 10ms This is also effective when the off time OFF is set A welding is stopped when the signal is input before each WE A welding is perform...

Page 85: ...TIO has an effect on HEAT only Fixed for UF DL When the HEAT value multiplied by RATIO falls below the UF DL value an error occurs The COUNT value works as each STEP value Example STEP1 0020 STEP2 001...

Page 86: ...128 P 1 2 4 8 16 T 1 S T S T A GE 2 N D S T A GE Va lve output S OL1 or S OL2 We ld ing sequence Schedu le se lect ion When the 2ND STAGE signal is input the valve signal SOL1 or SOL2 with the selecte...

Page 87: ...cycle time is relatively slow Communicated with the Program Unit each time welding is complete LAST The monitor display is not updated When the MONITOR screen is updated the last measured value is di...

Page 88: ...xed at 200 ms R E WEL D T i m ing Chart p COUNTER Sets the mode of counter There are three modes TOTAL GOOD WORK The counter value returns to 0 at the time the setting is changed Count up is done in a...

Page 89: ...up is not done if the judgment is ERROR in current supplied monitoring Judgment in Monitor Counting Manner GOOD normal WELD Counter counts up WORK Counter counts up increment of 1 when WELD Count reac...

Page 90: ...communication speed 9 6k Communication at 9600 bps 19 2k Communication at 19200 bps 38 4k Communication at 38400 bps For details of the external communication see External Communication Function u DIS...

Page 91: ...ET TOTAL COUNT The display changes depending on the setting of WELD2 STOP WELD COUNT and COUNTER on the MODE SELECT screen The preset count is the count value set in advance When each count reaches th...

Page 92: ...R O R NOTES When ERROR RESET is input display of MA 660A TROUBLE lamp on panel and ERROR CAUTION output are turned OFF but COUNT UP output is not turned OFF When COUNT RESET is input display of MA 66...

Page 93: ...count is increased by 1 not 3 PRESET COUNT value When ERROR RESET is input display of MA 660A TROUBLE lamp on panel and NG CAUTION output are turned OFF but COUNT UP output is not turned OFF When COU...

Page 94: ...t 3ms the absence of current will not be detected as an error as long as it lasts no more than 3ms An absence of current will be detected as an error if it lasts for 4ms or more At this time the TROUB...

Page 95: ...monitored value will not be also checked against the upper and lower tolerance limits t Monitor measurement Weld Time WELD1 WELD2 WELD3 t MONITOR FIRST TIME f MONITOR SLOPE MODE Select whether or not...

Page 96: ...d that to decrease the welding current is called the step down function Set the step up or step down timing based on the number of welds When the set number of welds is complete the step end signal ST...

Page 97: ...pped up or down to the value for STEP3 following completion of the specified number of welds for STEP2 LINER S T E P2 S TE P1 S TE P4 S TE P3 S TE P5 100 F I XE D Current Nu mber of we lds Set va lue...

Page 98: ...he initial setting Therefore when STEPPER MODE is set to ON to perform step up step down for the initial setting the upper lower limit judgment value is stepped up or down automatically RATIO has an e...

Page 99: ...9 Set the chip dress for each STEP When TD is set X is displayed For STEP with the tip dress setting the tip dress error occurs following completion of the specified number of welds h CAP CHANGE Set...

Page 100: ...current value To use the pre check function the secondary current voltage needs to be monitored a SCHEDULE Select from 1 to 255 to set the SCHEDULE Normally select 1 first then select additional sched...

Page 101: ...corresponding function You cannot move to another screen while the 1ST or 2NDSTAGE signal is input I O Terminal Board see Appendix B for user accessible I O s Input signal SCHEDULE 1 SCHEDULE 128 ERR...

Page 102: ...the Power Supply s memory i e to restore the initial settings Initialization will not clear the memory of the MA 660A To initialize move the cursor over YES or NO and press the ENTER key a YES Initial...

Page 103: ...660A to the circuit cable with the power supply turned ON The following screen is displayed 2 When the ENTER key is pressed after the ON key is pressed ON is displayed You cannot go to other screens f...

Page 104: ...ge output proportional to force for electro pneumatic proportional valve and the ANALOG IN input terminal voltage input proportional to force for force measurement have two channels respectively Also...

Page 105: ...eumatic proportional valve ANALOG OUT and SQD and CONTINUE blink The measured value input in the force input ANALOG IN is displayed at the monitor of SQD SQZ The sequence proceeds from SQD to SQZ by p...

Page 106: ...ANALOG OUT and HOLD and CONTINUE blink The measured value input in the force input ANALOG IN is displayed at the monitor of HOLD Turning off the step operation mode The step operation mode ends by pr...

Page 107: ...d SOL2 and EX SOL1 to EX SOL2 on the I O terminal block are used for valve output VALVE 1 SOL1 SOL2 VALVE 2 EX SOL1 EX SOL2 k FORGE VALVE The forge force function can be used The forge valve can be us...

Page 108: ...and 6 are ON the welding is performed singly in order of SCHEDULE 1 SCHEDULE 2 SCHEDULE 5 SCHEDULE 6 each time the start signal 1ST and 2ND is input The CHAINING setting has a priority to the SUCCESS...

Page 109: ...lect items for weld stop OFF External Input WE1 to WE3Stop Input are effective DISPLC Weld Stop works at the set displacement value CURR Weld Stop works at the set current value VOLT Weld Stop works a...

Page 110: ...rom force releasing to force applying the measurement range of the displacement gauge is larger than distance between electrodes at force releasing Otherwise the work piece detection will not be done...

Page 111: ...onal valve ANALOG OUT After the completion of welding sequence the CALIBRATION CONSTANT FORCE setting is output to the electro pneumatic proportional valve ANALOG OUT Set AIR CYLINDER DIAMETER and MAX...

Page 112: ...g sequence the CALIBRATION CONSTANT FORCE setting is output to the electro pneumatic proportional valve ANALOG OUT Set CALIBRATION LOW and HIGH to set the maximum force AIR CYLINDER DIAMETER MAX AIR P...

Page 113: ...and the measured value adjust either AIR CYLINDER DIAMETER or MAX AIR PRESSURE so that the set value and the measured value become the same h CALIBRATION LOW i CALIBRATION HIGH Used when FORCE CONTROL...

Page 114: ......

Page 115: ...They could get caught and cause injury Before You Start Before operating the Power Supply you must be familiar with the following The principles of resistance welding and the use of programmed weld sc...

Page 116: ...and press the ENTER key 5 Set each item as described in Chapter 3 6 Again press the MENU key to bring back the Menu screen 7 Move the cursor to SCHEDULE and press the ENTER key 8 Set each item as des...

Page 117: ...Supply green READY lamp is lit 4 Start the weld sequence and confirm that the welding current is flowing normally by checking the red WELD lamp and the Monitor screen 5 Make any necessary adjustments...

Page 118: ...le to OFF to open the cabinet This will trip the breaker cut power to the inside of the cabinet and discharge the capacitors within 30 seconds Push the OFF button on the circuit breaker to power the s...

Page 119: ...cable E 05 TRIP OF EXTERNAL THERMO Welding transformer temperature rises and opens the external thermostat input circuit Lower transformer temperature When using a water cooled transformer properly a...

Page 120: ...ng is equal to or lower than UF or DL setting Although STEPPER MODE is set to LINER or FIXED STEPPER COUNT of STEP number set for START ON STEP are all 0 The series of welding currents in WELDs withou...

Page 121: ...NCY FAILURE Frequency of incoming power supply is not stable and equipment cannot determine whether it is at 50 Hz or 60 Hz Check power source E 18 OUT LIMIT OF VOLTAGE ERROR Secondary voltage is out...

Page 122: ...wer failure E 31 OUT LIMIT OF TIME ERROR Weld time is out of the TIME setting range on the MONITOR SET screen Check the welding stop input of the external interface E 32 COMM SETTING ERROR The bi dire...

Page 123: ...on board is not connected Recycle power If the E 39 error WITHOUT EXTENSION BOARD is displayed again repair is required Contact AMADA WELD TECH When Welding Does not Start Even if the Start Signal is...

Page 124: ...o the Pendant from the Power Supply to display the monitor error when the monitor data is beyond below the upper lower limit data communication time Tb2 The data communication time at end Tb is shown...

Page 125: ...following steps to eliminate electrical shock hazard Make sure external power is turned OFF before performing any maintenance procedures 1 Turn the power to the IS 2200CA Power Supply to the off posit...

Page 126: ...procedures 1 Turn the power to the IS 4500CA Power Supply OFF by pressing the OFF button on the circuit breaker located on the right side of the IS 4500CA 2 Open the front door 3 The capacitors will a...

Page 127: ...uld result Whenever a fuse needs to be replaced the following steps should always be followed 1 Turn OFF the Main A C Power to the IS Power Supply external breaker used to supply power to the Power Su...

Page 128: ...NVERTER POWER SUPPLY 5 10 990 412 IS 2200CA Power Supply Fuse Component Locations See next page for fuse descriptions values and replacement part numbers FB2 see below FB1 see below Control Transforme...

Page 129: ...fuses seven for the various valve functions and three for the Main PCB power FUSE DESCRIPTION FUSE TYPE AMADA WELD TECH PART NUMBER FS1 Main Board Valve Fuse 5 x 20 mm 1 A 250 VAC slow blow 330 182 F1...

Page 130: ...CHAPTER 5 MAINTENANCE IS 2200CA 4500CA INVERTER POWER SUPPLY 5 12 990 412 IS 4500CA Power Supply Fuse Component Locations...

Page 131: ...MADA WELD TECH PART NUMBER FS1 Main board fuse 5x20 mm 1 A slow blow 250 VAC 330 182 Fuse Board P N 4 40132 01 The Fuse Board contains ten fuses seven for the various valve functions and three for the...

Page 132: ...ransformer FUSE DESCRIPTION UNIT VOLTAGE FUSE TYPE AMADA WELD TECH PART NUMBER F11 Valve Transformer Fuse 480 VAC FNQ R 4 1 2 slow blow 4 5A 600VAC 330 204 Fuse Block FUSE DESCRIPTION UNIT VOLTAGE TYP...

Page 133: ...leness Restore water flow 4 Re install the plastic high voltage protective cover with the four screws that secure it 5 Close the Power Supply door and secure it with the two quarter turn screws 6 Reco...

Page 134: ...enough to flush the system When the water is running clean turn the water OFF 5 Reconnect the hose back onto the Power Supply and restore power and water 6 Close the Power Supply door and secure it wi...

Page 135: ...ce and disconnect the water hoses to the Power Supply Using shop air dry out the hoses 3 Remove the circuit breaker line terminal cover and disconnect all line wires Replace cover 4 Disconnect all loa...

Page 136: ......

Page 137: ...constant current effective value control Secondary constant current effective value control Secondary constant power effective value control Primary constant current peak value control Secondary const...

Page 138: ...LAY ADVANCED unit Control gain GAIN 1 9 Setting Range HEAT Constant Current Control 160 320 kA range 16 0 160 0 kA 32 0 320 0 kA 80 160 kA range 8 0 80 0 kA 32 0 160 0 kA 40 80 kA range 4 0 40 0 kA 32...

Page 139: ...lamp READY lamp START lamp WELD lamp TROUBLE lamp WELD ON OFF lamp Cooling method Water cooled for IGBT s and power components Flow Rate 6 liters minute minimum Water Temperature 35 C maximum Water P...

Page 140: ...are detected Self diagnostic error Setting dates e g schedule settings are diagnosed CURRENT Calibration Adjustment Percentage of setting 24 to 24 selectable for all 255 schedules NOTES 1 No repetiti...

Page 141: ...Cycles IS 2200CA IS 4500CA 0 500 1000 1500 2000 2500 0 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 Primary Current A Duty Cycle IS 2200CA Duty Cycle Graph 0 1000 2000 3000 4000 5000 0 6 12 18 24 3...

Page 142: ...0 1000 1500 2000 2500 0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 Primary Current A Weld Time ms IS 2200CA weld time limit 0 1000 2000 3000 4000 5000 0 50 100 150...

Page 143: ...the external input output signals and connect the shielded part to the ground Section I Data and Signal Connectors RS 232 standard One DB 9 female connector wired as follows RS 232 only allows one Po...

Page 144: ...9 female connector wired as follows RS 485 allows multiple Power Supplies to be daisy chained to a host TRANSFORMER SENSING CONNECTOR PIN DESCRIPTION A Common Thermostat B Thermostat C Voltage D Curre...

Page 145: ...VERTER POWER SUPPLY 990 412 B 3 DISPLACEMENT SENSOR CONNECTOR ADVANCED Models ONLY Recommended Displacement Sensor Heidenhain St3078 15 pin D sub female PIN DESCRIPTION 1 Asig 2 GROUND 3 Bsig 4 5 VOLT...

Page 146: ...Y TB1 5 SCHEDULE 1 TB1 6 SCHEDULE 2 TB1 7 SCHEDULE 4 TB1 8 SCHEDULE 8 TB1 9 SCHEDULE 16 TB1 10 SCHEDULE 32 TB1 11 SCHEDULE 64 TB1 12 SCHEDULE 128 TB1 13 PARITY WE1 STOP TB1 14 WELD COUNT WE2 STOP TB1...

Page 147: ...TB2 9 OUT1 TB2 10 OUT2 TB2 11 OUT3 TB2 12 OUT4 TB2 13 OUT5 TB2 14 TB2 15 OUT COM TB3 1 TB3 2 TB3 3 TB3 4 TB3 5 TB3 6 TB3 12 TB3 7 TB3 8 TB3 9 TB3 10 TB3 11 ANALOG IN1 ANALOG IN2 ANALOG OUT 1 ANALOG OU...

Page 148: ...IONAL AUX CONTACTS N O ON CONTACTORS AUX CONTACTS N C ON CONTACTORS TB4 11 NO CONNECTION INT 24VDC OUT GND I O COM TB4 12 TB4 13 INT 24VDC OUT GND I O COM TB5 1 TB5 2 EXTERNAL VOLTAGE IN use only for...

Page 149: ...4 VALVE COM SOL VALVE1 SOL1 VALVE2 SOL2 TB6 5 EX VALVE1 EX SOL1 TB6 6 EX VALVE2 EX SOL2 TB6 7 EX VALVE3 EX SOL3 TB6 8 EX VALVE4 EX SOL4 These valves are only active in 2 valve mode See page 3 33 Use...

Page 150: ...al 24VDC GND NOTE DO NOT CONNECT TO PIN 1 INT 24VDC OUT TB1 5 TB1 6 TB1 7 TB1 8 TB1 9 TB1 10 TB1 11 TB1 12 SCHEDULE 1 SCHEDULE 2 SCHEDULE 4 SCHEDULE 8 SCHEDULE 16 SCHEDULE 32 SCHEDULE 64 SCHEDULE 128...

Page 151: ...connect inputs to INT 24VDC For External Sink attach PLC 24V For External Source attach PLC COM TB1 16 INT 24VDC GND I O COM COM pin This pin is internally connected to the 24VDC GND TB2 1 STAGE1 1ST...

Page 152: ...EN the pin is open with the power turned on but becomes closed with an error occurring The contact is rated at 24V DC at 20mA semiconductor switch TB2 9 NG2 OUT CAUTION Caution signal output pin This...

Page 153: ...nally connected to the 24VDC GND TB4 3 RETRACTION 2 Control pin for Retraction 2 Valve TB4 4 BACK STEP Input terminal for the back step When the signal is input with the successive function the SCHEDU...

Page 154: ...e connect to PLC 24V TB5 5 THERMOSTAT If the XFMR Sense connector is not used this pin should be connected to the appropriate voltage Sink or Source If the XFMR Sense connector is used this pin should...

Page 155: ...1 TB6 10 RETRACTION VALVE2 RET SOL2 TB6 11 VALVE RELAY SOL RELAY The contacts are rated at 120V AC or 24V AC DC at 0 5A semiconductor switches Use a solenoid valve with a current capacity of 0 5A or l...

Page 156: ...when required number of welds are added to make up for insufficiency the count error signal is output until the insufficient number of welds is complete READY Closed when no error occurs and the WELD...

Page 157: ...15 18 22 INTERNAL EXTERNAL INT 24VDC OUT GND I O COM THEMOSTAT COM INT 24VDC OUT GND I O COM INT 24VDC OUT GND I O COM 5 SCHEDULE 1 6 SCHEDULE 2 7 SCHEDULE 4 8 SCHEDULE 8 9 SCHEDULE 16 10 SCHEDULE 32...

Page 158: ...OM VALVE1 SOL1 VALVE2 SOL2 38 39 SECONDARY VOLTAGE use only for non IT transformers 40 41 42 43 45 44 47 INT 24VDC OUT CONTACTORS OPTIONAL CONTACTOR N O OPTIONAL CONTACTOR N C OPTIONAL CONTACTOR COM O...

Page 159: ...X VALVE3 EX SOL3 52 EX VALVE4 EX SOL4 56 INT 24VDC OUT GND I O COM 57 RETRACTION 1 58 RETRACTION 2 59 BACK STEP EXT COM 61 62 63 64 65 66 72 67 68 69 70 71 ANALOG IN1 ANALOG IN2 ANALOG OUT 1 ANALOG OU...

Page 160: ...the internal 24VDC GND NOTE DO NOT CONNECT TO PIN 1 INT 24VDC OUT 5 6 7 8 9 10 11 12 SCHEDULE 1 SCHEDULE 2 SCHEDULE 4 SCHEDULE 8 SCHEDULE 16 SCHEDULE 32 SCHEDULE 64 SCHEDULE 128 Schedule input pins 5...

Page 161: ...ne 17 STAGE2 2ND STAGE input pin Closing this pin will start the sequence 18 THERMOSTAT COM Common input for Transformer Thermostat through the XFMR Sense connector For Internal Sink operation connect...

Page 162: ...d on but becomes closed with an error occurring The contact is rated at 24V DC at 20mA semiconductor switch 27 NG2 OUT CAUTION Caution signal output pin This pin is closed upon completion of the weldi...

Page 163: ...TOR N O Detect position of contactors between pin 42 and 43 contactors normally open optional 43 CONTACTOR COM Contactor Aux contact common optional 44 CONTACTOR N C Detect position of contactors betw...

Page 164: ...2 65 66 ANALOG IN2 ANALOG IN2 0 10VDC Analog input 2 67 68 ANALOG OUT2 ANALOG OUT2 0 10VDC Analog output 2 2 69 70 CURRENT COM CURRENT OUT Current output 0 10 VDC 2 VOUT IOUT 5000 71 72 VOLTAGE COM VO...

Page 165: ...so when required number of welds are added to make up for insufficiency the count error signal is output until the insufficient number of welds is complete READY Closed when no error occurs and the WE...

Page 166: ...uipment featuring NPN sink open collector output using internal 24VDC power supply Connect pins 1 and 2 INT 24 V EXT COM EMERGENCY STOP SCH 1 SCH 2 1ST 1 2 3 5 6 4 16 15 24V Internal Power Supply Exte...

Page 167: ...ing NPN sink open collector output using external power supply Connect the positive side of an external 24 VDC power supply to pin 2 EMERGENCY STOP SCH 1 SCH 2 1ST 1 2 3 4 5 6 16 15 24V Internal Power...

Page 168: ......

Page 169: ...the welding sequence from the beginning of initial squeeze delay time through the end of hold time the welding sequence will halt at that point Note that the END signal depends on the END SIG MODE se...

Page 170: ...OL1 or SOL2 2ND STAGE A DELAY START SET SQD SQZ U U D D WE1 WE2 U D HO CO1 CO2 WE3 Start Signal Input in Pulsed Mode Latched Mode The welding sequence halts if the 2ND STAGE signal stops during squeez...

Page 171: ...OFF S OL1 S OL2 E N D B C C B P RE C HE C K HE AT1 HE AT2 HE AT3 P RE C HE C K HE AT1 HE AT2 HE AT3 G O O D A DEL A Y S T A R T SE T Note 1 We ld ing current Current f lo w t i m ing Note 2 Note 2 O U...

Page 172: ...time changes depending on the OFF time See Chapter 3 Using Programming Functions Section 10 Mode Select Screen Sub section c End Signal Mode C Monitored value judgment time 200 s max Note 1 To stop t...

Page 173: ...Q D S QZ A H O WEL D S OL1 S OL2 2 N D S T A GE 1 S T S T A GE We ld ing current TW 2ND STAGE input standby state A DELAY START SET setting Welding preparation time When the 2ND STAGE is input before...

Page 174: ...APPENDIX C SYSTEM TIMING IS 2200CA 4500CA INVERTER POWER SUPPLY C 6 990 412 Repeat Operation Repeat operation will occur whenever the Off time is set to any value other than zero 0 Repeat Operation...

Page 175: ...P ULS AT I O N1 P ULS AT I O N2 P ULS AT I O N3 HEAT3 HEAT3 Note 1 Note 2 Note 3 We ld ing current O U T I O U T I I Note 1 Repeat operation times set for PULSATION1 in WELD1 and INT1 set times When P...

Page 176: ...POWER SUPPLY C 8 990 412 Re Weld Re weld will occur when Re Weld is set On Mode Select screen and a current monitor error occurs as a low weld current shown below Under that circumstance a re weld wi...

Page 177: ...A INVERTER POWER SUPPLY 990 412 C 9 Interrupt Interrupt will occur when Interrupt is set On Mode Select screen and an Interrupt signal is applied during a weld sequence The weld cycle is immediately s...

Page 178: ...AL VE Note 3 We ld ing sequence 1 S T S T A GE 2 N D S T A GE E N D F O R GE DEL A Y Note 1 The RELAY SW signal is not output when VALVE is set to 1 It is output from SQD to HOLD only when VALVE is se...

Page 179: ...e operation after start is the same In this example the CHAINING settings for SCHEDULE1 2 5 and 6 are ON and those for other SCHEDULEs are OFF Since the 2ND STAGE signal is OFF when the sequence of SC...

Page 180: ...ne The END signal is output at the end of each SCHEDULE Example At 1 stage start operation For 2 stage start the start method is different but the operation after start is the same In this example the...

Page 181: ...O U U C O1 C O2 D WE2 U D WE1 WE2 D T1 RET R CT S OL1 2 out Va lve output E N D out We ld ing sequence T1 T i me set by DEL AY ST A RT SET RET R A CT I O N 1 2 in 1ST 2 N D ST A GE in T2 Durat ion of...

Page 182: ...lacement weld stop DISPLC is set to the weld3 stop on the DISPLACEMENT screen and the displacement sensor arrives at the set displacement h at the above figure the weld3 stop is stopped to make the se...

Page 183: ...hat gives the maximum length for the gauge selected calculation is linear Ampacity must be equal to or larger than the effective current based on NEC table 310 16 b For the Output lines to the transfo...

Page 184: ...INPUT Output Current Weld Duty Cycle IEFF IPH AWG IEFF Amps 1 Drop feet AWG IPH 5 Drop feet 500 15 194 158 3 0 80 1 0 282 400 24 196 160 3 0 80 1 0 282 280 50 198 162 3 0 80 1 0 282 200 100 200 163 3...

Page 185: ...SELECTION IS 2200CA 4500CA INVERTER POWER SUPPLY 990 412 D 3 Duty Cycles 0 500 1000 1500 2000 2500 0 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80 84 88 92 96 100 Primary Current A Duty C...

Page 186: ...ION IS 2200CA 4500CA INVERTER POWER SUPPLY D 4 990 412 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 0 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80 84 88 92 96 100 Primary Current A...

Page 187: ...IPH AWG IPH 5 drop feet 410 500 MCM 77 335 300 MCM 380 350 500 MCM 80 286 300 MCM 449 200 3 0 80 163 1 0 282 190 2 0 62 155 1 0 282 180 2 0 62 147 1 211 170 1 0 50 139 1 211 155 1 0 50 127 2 170 150...

Page 188: ...12 0 1 5 2 0 4 0 6 0 8 0 10 0 12 0 X In In 800 Amps for IS 2200CA In 1200 Amps for IS 4500CA See circuit breaker front panel for dipswitch settings Setting L Calculate the breaker rated current using...

Page 189: ...s to be set to RS 232C Remote Programming Advanced users may wish to perform programming for custom welding applications The codes needed to perform remote programming are listed in Section II Externa...

Page 190: ...res factory installed RS 485 option See Chapter 3 Using Programming Functions Section 10 Mode Select Screen Sub section S Comm Mode Communication Control Select either one way RS 232 or Both way RS 48...

Page 191: ...y State Screen Note 2 Do not assign one number to more than one device Do not send data simultaneously from two or more devices in the single directional communication mode otherwise data collision an...

Page 192: ...le No Fixed to 3 digits 001 to 255 C Unit of monitor time m ms C CYC D Monitor time of WE1 Fixed to 3 digits 000 to 999 ms Fixed to 3 digits 000 to 050 CYC E Monitor current of WE1 Fixed to 4 digits 0...

Page 193: ...ed to 4 digits 0000 to 9999 X COUNTER WORK of TOTAL GOOD WORK Fixed to 6 digits 000000 to 999999 Y STEP No of VALVE4 Fixed to 1 digit 1 to 9 Z STEP COUNT of VALVE4 Fixed to 4 digits 0000 to 9999 AA ST...

Page 194: ...ts 01 to 39 F 1 Error code 4 Fixed to 2 digits 01 to 39 G 1 Error code 5 Fixed to 2 digits 01 to 39 H 1 Error code 6 Fixed to 2 digits 01 to 39 I 1 Error code 7 Fixed to 2 digits 01 to 39 J 1 Error co...

Page 195: ...CA 1 Schedule numbers SH1 SH2 and SH3 are fixed to 000 However schedule numbers are sent from the Power Supply when E06 Current error E18 Voltage error E19 Electric power error and E07 Pulse width err...

Page 196: ...Schedule No Screen No Data Example Write data for a schedule of Screen No 01 of Schedule No 008 of the specified device No 01 Host I D 1 I D 2 W S H 1 S H 2 S H 3 S S C 1 S C 2 Data C R L F 0 1 0 0 8...

Page 197: ...elay time nnnn 0000 to 9999 ms mode 0000 to 0999 CYC mode 6 SQZ Squeeze time nnnn 0000 to 9999 ms mode 0000 to 0999 CYC mode 7 UP1 Upslope 1 time nnn 000 to 999 ms mode 000 to 050 CYC mode 8 WELD1 Wel...

Page 198: ...n 004 0 to 120 0 kW nn n 04 0 to 80 0 kA 02 0 to 40 0 kA 04 0 to 60 0 kW 01 0 to 20 0 kA kW 10 0 to 99 9 n nn 0 50 to 9 99 0 05 to 5 00 kA kW 0 20 to 9 99 V 24 UF2 Initial heat 2 of upslope nnn n 004...

Page 199: ...30 PULSATION of WE1 WE1 repetition nn 00 to 19 31 INT1 Interval 1 nnn 000 to 999 ms mode 000 to 050 CYC mode 32 PULSATION of WE2 WE2 repetition nn 00 to 19 33 INT2 Interval 2 nnn 000 to 999 ms mode 00...

Page 200: ...pper limit nnn 000 to 999 ms mode 000 to 050 CYC mode 11 TIME L of WE2 lower limit nnn 000 to 999 ms mode 000 to 050 CYC mode 12 CURRENT H of WE2 upper limit n nn 0 00 to 9 99 kA nn n 00 0 to 99 9 kA...

Page 201: ...of STEP3 nnn 050 to 200 9 TIP DRESS of STEP3 n 0 OFF 1 ON X 10 COUNT of STEP4 nnnn 0000 to 9999 11 RATIO of STEP4 nnn 050 to 200 12 TIP DRESS of STEP4 n 0 OFF 1 ON X 13 COUNT of STEP5 nnnn 0000 to 99...

Page 202: ...000 to 999 ms mode 000 to 050 CYC mode 13 CURRENT of WELD3 nn nn 00 00 to 9 999 kA nnn n 000 0 to 999 9 kA 14 VOLT of WELD3 n nn 0 00 to 9 99 V 15 POWER of WELD3 nn nn 00 00 to 99 99 kW nnn n 000 0 to...

Page 203: ...tents Character String Range 1 1 POWER SOURCE FREQUENCY nn 50 or 60 Hz 2 1 Model name nnnnnnnn IS 2200CA or IS 4500CA 3 1 ROM VERSION Vnn nnn V00 00A to 4 DELAY START SET nn 01 to 20 ms 5 START SIGNAL...

Page 204: ...GNAL SELECT n 0 ERROR 1 CAUTION 35 VOLT OVERof NG SIGNAL SELECT n 0 ERROR 1 CAUTION 36 POWER OVER of NG SIGNAL SELECT n 0 ERROR 1 CAUTION 37 PULSE OVER of NG SIGNAL SELECT n 0 ERROR 1 CAUTION 38 NO CU...

Page 205: ...to 39 6 Error code 6 nn 01 to 39 7 Error code 7 nn 01 to 39 8 Error code 8 nn 01 to 39 The number of error codes is of eight max In the case of only one error code the items 2 to 8 are omitted For err...

Page 206: ...WELD3 FORCE nnnnn 8 HOLD FORCE nnnnn 9 1 VALVE n 1 to 4 10 FORGE VALVE n 1 to 2 11 CHAINING n 0 OFF 1 ON 12 SUCCESSIVE n 0 OFF 1 ON 13 FORGE DELAY nnnnn 00000 to 30000 ms 14 FORGE MODE n 0 OFF 1 ON 1...

Page 207: ...0 50 to 0009 99 kA 10kA range 00001 0 to 00020 0 kA 20kA range 00002 0 to 00040 0 kA 40kA range 00004 0 to 00080 0 kA 80kA range 1 WELD STOP INPUT VOLT 0000 20 to 0009 99 V WELD STOP INPUT POWER 0000...

Page 208: ...ALVE1 n 0 UP 1 DOWN 10 CONSTANT LOW of VALVE1 nnnnn 00000 to 35000 N 00000 to 03569 kgf 00000 to 07868 lbf 11 1 CONSTANT HIGH UP DW of VALVE1 n 0 UP 1 DOWN 12 CONSTANT HIGH of VALVE1 nnnnn 00000 to 35...

Page 209: ...E 82178 Puchheim Germany TEL 49 89 839403 0 FAX 49 89 839403 68 AMADA WELD TECH TAIWAN CO LTD Rm 5 2F No 9 Dehui St Zhongshan Dist Taipei 10461 Taiwan R O C TEL 886 2 2585 0161 FAX 886 2 2585 0162 AMA...

Page 210: ...AMADA WELD TECH INC 1820 South Myrtle Ave Monrovia CA 91016 U S A TEL 1 626 303 5676 FAX 1 626 358 8048...

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