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Miyachi Unitek ISA Series, Operator'S Manual

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CHAPTER 5:  MAINTENANCE 

 

 

ISA-4001CR INVERTER POWER SUPPLY 

5-8 

990-364 

Valve Driver Board

 

The Valve Driver board contains six fuses for the four valves, retraction valve, and switching power 
supply (optional).  Before replacing any of these fuses, determine what caused it to fail and make 
appropriate repairs. 

 

FUSE DESCRIPTION 

TYPE 

PART 

NUMBER 

FS1–FS5

 

Valve output fuses

 

3AG, 1 A, 250 VAC 

330-017 

FS6

 

Valve output fuse

 

3AG, 6.3 A, 250 VAC 

330-096 

 

1. 

Disconnect power to the Power Supply, discharge the capacitors, and remove the plastic 
cover, as described in 

Section I, Before You Start

.

 

2.

 

Replace the blown fuse(s). 

 

Power Supply 

The Power Supply contains fuses, mounted on the load side of the Valve Transformer and the Power 
Transformer.  Before replacing either fuse, determine what caused it to fail and make appropriate 
repairs. 
 

Power Transformer 
 

FUSE 

DESCRIPTION 

UNIT VOLTAGE

FUSE TYPE 

PART NUMBER 

F2, F4

 

Power Transformer 
Fuses

 

480 or 575 VAC

 

KLDR Slow-blow, 3/4 A, 600 
VAC

 

330-175

 

 
 
Fuse Block 
 

FUSE DESCRIPTION 

TRANSFORMER 

VA RATING 

TYPE PART 

NUMBER 

F5, F6

 

Valve Transformer 
Fuses, primary

 

500 VA 

KLDR Slow-blow, 1.6A, 600VAC 

330-176 

 

Summary of Contents for ISA Series

Page 1: ...OPERATOR MANUAL 990 364 Revision B August 2009 OPERATORS MANUAL FOR THE ISA 4000 and ISA 4001CR INVERTER POWER SUPPLIES ...

Page 2: ...ein are the proprietary work of MIYACHI UNITEK CORPORATION and may not be reproduced copied exhibited or otherwise used without the written authorization of MIYACHI UNITEK CORPORATION Printed in the United States of America Revision Record Revision EO Date Basis of Revision A 21466 7 07 Original publication B 31456 8 09 Updated dipswitch settings ...

Page 3: ...Capacitor Discharge Indicator 1 5 I O Terminal Block 1 5 ME 1887 Expansion Board 1 5 PCB Panel Sub Assembly Not Shown 1 5 Power Module 1 5 Power Transformer 1 5 Power and Ground Connections 1 6 Input Power Connections 1 6 Circuit Breaker 1 7 Grounding Lug 1 7 Input Power Connections 1 7 Output Power Connections 1 7 Rear Panel Connections 1 7 Cooling Water Fittings 1 7 Secondary Current Sensor Inpu...

Page 4: ...nection 2 6 Section III Cooling Water 2 7 Cooling Water Requirements 2 7 Cooling Water Hose Connections 2 7 Chapter 3 Using Programming Functions Section I Operation Precautions 3 1 Section II Programming the Power Supply 3 1 Menu Screen 3 1 Power Supply State Screen 3 2 PROGRAMMED DATE 3 2 MA 627A ROM VERSION 3 2 POWER SOURCE FREQUENCY 3 2 WELD POWER FREQUENCY 3 2 Schedule Screens 3 2 SCHEDULE 3 ...

Page 5: ...y Setup Data Screen 3 9 Mode Select Screen 3 10 DELAY START SET 3 10 START SIG MODE 3 10 PARITY CHECK 3 10 CYC WELD 3 10 STEPPER 3 10 FORGE 3 10 WELD COUNT 3 10 RE WELD 3 10 END SIG MODE 3 11 INTERRUPT 3 11 RESET MODE 3 11 REMOTE PROG 3 11 ACTIVE SCHED 3 11 Stepper Count Screen 3 11 START ON STEP 3 11 STEP 1 STEP 9 3 11 Heat Increase Screen Non linear Stepper 3 11 Heat 3 11 Linear Stepper Function...

Page 6: ...1 Cleaning 5 2 Section II Troubleshooting 5 3 Section III Fuse Failure and Replacement 5 6 Fuse Locations 5 6 Main PCB 5 7 Valve Driver Board 5 8 Power Supply 5 8 Power Transformer 5 8 Fuse Block 5 8 Valve Transformer Fuse Secondary 5 9 24 Volt DC Power Supply Not Shown 5 9 Section IV Maintenance Procedures 5 10 Maintenance 5 10 Checking Water Hoses 5 10 Draining Water Hoses 5 10 Flushing Water Ho...

Page 7: ...ations A 1 Appendix B Electrical and Data Connections B 1 Appendix C System Timing C 1 Appendix D Wire Gauge Selection D 1 Appendix E Options E 1 Appendix F Communications F 1 Appendix G Dipswitch Settings G 1 Appendix H Schedule Data Tables H 1 Appendix I Force Control Option I 1 ...

Page 8: ... the unit please thoroughly inspect it for shipping damage prior to its installation Should there be any damage please immediately contact the shipping company to file a claim and notify us at 245 East El Norte Street P O Box 5039 Monrovia California 91016 Phone 626 256 4128 FAX 626 303 5396 E mail info miyachi1 com Miyachi Unitek is not responsible for any losses due to improper use of this produ...

Page 9: ... the Power Supply Operation Procedures other than those described in this manual or not performed as prescribed in this manual may expose personnel to electrical shock or DEATH When operating any welder always wear appropriate personal protective gear Maintenance Service Before performing any maintenance on the Inverter Power Supply read Chapter 5 Maintenance thoroughly Use the appropriate tools f...

Page 10: ...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 unnecessarily wit the power turned ON You may receive an electric shock When inspecting the inside of the Power Supply be sure to turn the power source OFF and push and hold the DISCHARGE switch until the C...

Page 11: ... 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 Miyachi Unitek or your distributor Stop operation if any trouble occurs If you detect a burning smell abnormal sounds abnormal heat smoke etc turn power OFF immediately to prevent fire or electric shock Contact Miyachi Unitek or y...

Page 12: ...ult 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 materials cover them with a non combustible material Do NOT cover the Power Supply with a blanket cloth etc Heat generated by the operating Power Supply may ignite a blanket or cover Wear ear protectors L...

Page 13: ...for every start without externally selecting any welding schedule number x Chain function enables welding by switching multiple welding schedules sequentially with only one input of the start signal x Retraction function offers temporarily retracting the electrodes during a welding process for easy reorientation of work piece x Has a forge function to provide a forge valve output signal x Inverter...

Page 14: ...CHAPTER 1 SYSTEM DESCRIPTION ISA 4001CR INVERTER POWER SUPPLY 1 2 990 364 Section II System Components Front Panel Controls Indicators and Connector ...

Page 15: ...he operation will again be interrupted and the TROUBLE indicator will again light After the RESET button is pressed the START signal must be re sent to the Power Supply for welding to begin WELD ON OFF This push push button enables the unit to weld When ON the green indicator lights When operating the button the switch needs to be held until the green LED lights or goes out This is one of three co...

Page 16: ...CHAPTER 1 SYSTEM DESCRIPTION ISA 4001CR INVERTER POWER SUPPLY 1 4 990 364 ...

Page 17: ... signals except for Secondary Current Sensor inputs and communications See Chapter 2 for details of these input and output signals ME 1887 Expansion Board This expansion board contains components for the Force Control Option described in Appendix I PCB Panel Sub Assembly Not Shown This assembly contains the Control Board Valve Driver Board and associated power supplies See Chapter 4 for a listing ...

Page 18: ...wer 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 are made directly power lugs or an optional Circuit Breaker Chassis ground connection is made to the Grounding Lug ...

Page 19: ...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 of the unit Rear Panel Connections Cooling Water Fittings These fittings provide source and drain connections for cooling water See Chapter 2 for required specifications of cooling water Secondary Cu...

Page 20: ...e function as the Reset button on the Power Supply That is pressing it will cause the Power Supply TROUBLE lamp to go off once the trouble has been cleared CURSOR keys These keys are used to move the cursor left right up and down to select an item ON OFF keys These keys are used to change the value of a selected item or turn it on and off When the ON key is pressed the selected value increases and...

Page 21: ...ost computer or with automation control systems The communications card uses RS 485 multi drop architecture to connect up to 30 controls to one host on a single channel Using optional Weldlab software your host computer will be able to connect a single Control or multiple Controls to a computer in order to compile store view and print weld history data for detailed analysis check the status of the...

Page 22: ......

Page 23: ...tion of the input power conduits output power to the weld transformer is made from the bottom of the Power Supply Signal connections may be made from either the top or bottom of the Power Supply The Power Supply is designed to work in the following ambient conditions x Temperature 41 104 F 5 40 C x Humidity Less than 90 non condensing Space and Mounting Requirements Power Supply dimensions are sho...

Page 24: ...all circuit breaker Allow 5 minutes for internal capacitor bank to discharge x The installer must make electrical connections in accordance to all applicable codes For appropriate cable rating see Appendix B Electrical and Data Connections x Before drilling holes be sure to wear safety glasses to protect your eyes from metallic shards x Protect electronic components from metal shards when drilling...

Page 25: ...TER POWER SUPPLY 990 364 2 3 Electrical Connections Input Power Connections Electrical input is made from holes drilled into the Power Supply to match the location of your power conduits 1 Verify that all power to the Power Supply has been turned OFF ...

Page 26: ...terminal at the bottom corner of the circuit breaker Output Power Connections Weld transformer connections are made from the bottom of the Power Supply through removable lower side panels We recommend that you remove these panels to an area away from the Power Supply before drilling holes This will reduce the need to protect the electronics from metallic shards that otherwise could damage the unit...

Page 27: ...sformer conduit s NOTE Remove all metal shards then re install the plate 6 Install the weld transformer conduit 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 panel and secure it in place with the screws removed in Step 1 ...

Page 28: ...ER POWER SUPPLY 2 6 990 364 Signal Sensing Connectior See Appendix B Electrical and Data Connections Section I Data Connectors for connector pin information and Section II Input Output Signal Configuration for connection and configuration instructions ...

Page 29: ...temperature is likely to drop below 32 F 0 C drain the water in accordance to the procedure in Chapter 4 Maintenance To prevent condensation which may cause unit failure do not run cooling water if the unit is not in use unless the water is not lower than 4qF 2 2 C below ambient temperature Cooling Water Hose Connections CAUTION Do not perform service on cooling system unless inverter power is OFF...

Page 30: ......

Page 31: ...operation during welding processes The Program Unit connects to the Power Supply through a connector on the front door of the Power Supply In the screens shown items shown in highlight are those items that can be changed using the ON OFF keys on the Program Unit Menu Screen Press the MENU key on the Program Unit display with the Menu screen By moving the cursor over any of those items on the scree...

Page 32: ...UENCY The frequency of the line power is automatically measured and indicated WELD POWER FREQUENCY The factory setting for output frequency is 1000Hz This can be switched by changing the settings on dipswitch SW3 on the motherboard There are 3 options x 600 Hz x 800Hz x 1000 Hz Instructions are in Appendix G Dipswitch Settings Schedule Screens Up to 64 welding schedules can be set on the Power Sup...

Page 33: ...e welded SQZ Squeeze Time Length of time between SQD and WE1 This allows for electrode pressure to build before weld current is applied WE1 Weld 1 Time Length of time welding current is applied COOL Cooling Time Length of time for work piece to cool between end of Weld 1 current and start of Weld 2 current WE2 Weld 2 Time Length of time welding current is applied HOLD Hold Time Length of time a wo...

Page 34: ...F WELD ON OFF OFF SCHEDULE This entry is used to designate the Schedule number 001 through 064 VALVE This entry is used to designate the Valve number for each Schedule 1 through 4 FORGE VALVE This entry is used to designate which valve will be used for forging 1 through 4 The forge valve should not be the same as the Valve above FORGE DELAY This entry is used to set the delay before activating the...

Page 35: ...GE DOWN WELD ON OFF OFF Secondary Constant Current Effective Value Control ms Mode SCHEDULE 001 CTRL 1 SECONDARY RMS SQD SQZ WE1 COOL WE2 HOLD OFF TIME 0000 0000 000 000 000 000 0000ms UP SLOPE 000 000 ms DOWN SLOPE 000 000 ms HEAT 32 0 32 0 kA PULSATION 1 GAIN 1 9 1 PAGE DOWN WELD ON OFF OFF Secondary Constant Current Effective Value Control CYC Mode SCHEDULE 001 CTRL 1 SECONDARY RMS SQD SQZ WE1 ...

Page 36: ...000 000 ms HEAT 32 0 32 0 kA PULSATION 1 GAIN 1 9 1 PAGE DOWN WELD ON OFF OFF Primary Constant Current Peak Value Control CYC Mode SCHEDULE 001 CTRL 3 PRIMARY LIMIT SQD SQZ WE1 COOL WE2 HOLD OFF TIME 000 000 00 00 00 00 00 CYC UP SLOPE 00 00 CYC DOWN SLOPE 00 00 CYC HEAT 32 0 32 0 kA PULSATION 1 GAIN 1 9 1 PAGE DOWN WELD ON OFF OFF Constant Phase Control ms Mode SCHEDULE 001 CTRL 4 FIXED PULSE SQD...

Page 37: ...00ms to update Therefore when the Power Supply is set for a repetition rate under 100ms the Monitor screen should be turned off Leaving it on will result in data errors and missed welds CURR This display presents the amount of current for Weld 1 and Weld 2 VOLT This display is presented when secondary voltage is applied to the Power Supply I O terminals They indicate amount of voltage for Weld 1 a...

Page 38: ...ENT TIME WELD COUNT This entry is used to set the number of counts that should occur during the welding process This count is compared with the count in the Monitor screen After a weld sequence if the count on the Monitor screen is less than the count that was set on the Monitor Set screen the Power Supply will produce a Count Error signal CURRENT MONITOR NUMBER This sets WE 1 or WE 2 for display ...

Page 39: ...ata from the Power Supply to Memory 2 of the Program Unit ISA 2000A Å MA 627A MEMORY 1 This selection is used to transfer data from Memory 1 of the Program Unit to the Power Supply ISA 2000A Å MA 627A MEMORY 2 This selection is used to transfer data from Memory 2 of the Program Unit to the Power Supply SCHEDULE 001 Æ SCHEDULE 002 002 This function is used to copy a schedule in the Power Supply to ...

Page 40: ...CHECK When this entry is set to ON an odd parity check is made for the binary Schedule signals 1 2 4 8 16 32 and 64 When the entry is set to OFF no parity check is made CYC WELD This entry is used to set the unit of time for TIME UPSLOPE and DOWNSLOPE on the Schedule screen When the entry is set to ON the time unit is expressed in cycles CYC When the entry is set to OFF the time unit is expressed ...

Page 41: ... remote ACTIVE SCHED This 2 digit number shows the Schedule that is currently selected NOTE If the schedule shows as 00 the schedule is set by hardware such as a PLC not by software Stepper Count Screen The following procedures are for the Non Linear Stepper function The Non Linear or stepped stepper function will adjust the energy delivered to each weld by the percentage specified in the stepper ...

Page 42: ...n to the next step Tip Dress Warning You can program a series of points along the stepper line where the electrodes will need to be dressed or cleaned To turn the tip dress function ON at the end of a step highlight on the X in the TD field on the stepper screen STEPPER ON VALVE 1 SCHEDULE 001 STEP HEAT TD STEP HEAT TD 1 0001 100 X 6 0000 125 2 0005 105 00 X 7 0000 130 3 0001 110 X 8 0000 140 4 00...

Page 43: ...sed to reset the contents of the Power Supply memory to the factory set defaults The memory contents are not erased with initialization Position the cursor on YES or NO and press the ENTER key RESET POWER SUPPLY BACK TO FACTORY DEFAULTS YES NO WARNING IF YES IS ENTERED THE POWER SUPPLY WILL ERASE ALL SCHEDULE DATA If you select YES after initialization FORMAT END will appear on the lower part of t...

Page 44: ......

Page 45: ...arts They could get caught and cause injury Before You Start Before operating the Control you must be familiar with the following x The principles of resistance welding and the use of programmed weld schedules x The location and function of Controls and Indicators For more information see Chapter 1 of this manual x How to select and use the Control functions for your specific welding applications ...

Page 46: ... start signal while the READY lamp is not on and check each sequential operation WARNING When confirming the operation check that the Squeeze time SQZ is sufficient If the welding current begins before the welding electrodes have reached sufficient force expulsion is produced 3 If no error is detected in step b assure that the three READY requirements are met 4 The Power Supply WELD ON OFF LED mus...

Page 47: ...NG INSTRUCTIONS ISA 4001CR INVERTER POWER SUPPLY 990 364 4 3 Section III Shutdown Stopping Welding Operation 1 Turn the input power OFF Observe that all of the Power Supply LED lamps go OFF 2 Turn the cooling water OFF ...

Page 48: ......

Page 49: ... Power Supply Perform the following steps to eliminate electrical shock hazard 1 Turn the power to the Power Supply OFF 2 Open the front door by turning the two door handles 3 Turn power OFF 4 Press and hold both CAPACITOR DISCHARGE SWITCHES until the indicators are completely OFF NOTE If necessary for maintenance remove the Safety Shields by removing the four securing screws The Safety Shield bel...

Page 50: ...leaning CAUTION When cleaning the exterior of the Power Supply do not use paint thinner benzene or acetone These chemicals can damage the surface finish on the Power Supply Use a dry cloth or if it is heavily soiled use a cloth moistened with a mild detergent or alcohol ...

Page 51: ... Correct cause of high temperature and check temperature and flow rate of cooling water E 04 IGBT thermostat error Internal temperature of equipment is too high and thermostat for power transistors in power unit is open Check that the duty cycle is not too high Electrode force is not sufficient Increase electrode force SQZ time is set too short Check if setting of SQZ time is too short Set it long...

Page 52: ...o meet specifications E 15 Flow switch error Power supply for external signal is not connected Check that pins 1 through 4 of I O terminal block are correctly connected See Appendix B Electrical and Data Connections E 16 Schedule signal input error There was no Schedule signal present when external start signal was applied Provide Schedule signal before Start signal E 17 Input power supply error F...

Page 53: ...equired Welding stopped due to programmed Tip Dress code Manually dress the tip to clear the error then resume welding E 28 Approaching Cap Change Programmed warning message No action required E 29 Cap Change Required Welding stopped due to programmed Tip Dress code Manually change the cap to clear the error then resume welding ...

Page 54: ...CHAPTER 5 MAINTENANCE ISA 4001CR INVERTER POWER SUPPLY 5 6 990 364 Section III Fuse Failure and Replacement Fuse Locations ...

Page 55: ...uld only be serviced by factory authorized technicians or serious damage to the Power Supply could result Main PCB 1 Disconnect power to the Power Supply discharge the capacitors and remove the Safety Shield as described in Section I Before You Start 2 Remove and replace the damaged fuse FUSE DESCRIPTION FUSE TYPE PART NUMBER F1 24 VDC Control Power Supply Fuse 3AG A 250 VAC 330 024 ...

Page 56: ...o the Power Supply discharge the capacitors and remove the plastic cover as described in Section I Before You Start 2 Replace the blown fuse s Power Supply The Power Supply contains fuses mounted on the load side of the Valve Transformer and the Power Transformer Before replacing either fuse determine what caused it to fail and make appropriate repairs Power Transformer FUSE DESCRIPTION UNIT VOLTA...

Page 57: ...330 117 24 Volt DC Power Supply Not Shown The 24 Volt DC Power Supply is only available as an option When installed it provides 24 VDC to power the valves Two options are available 2 0amps 50 watts and 6 0amps 150 watts NOTE There must be a Valve Transformer of the correct VA installed to provide AC power to 24 Volt DC Power Supply FUSE DESCRIPTION FUSE TYPE PART NUMBER x 24 VDC Control Power Supp...

Page 58: ...es to check for brittleness Restore water flow 4 Re install the plastic high voltage protective cover with the four screws that secure it 5 Close the Power Supply doors 6 Reconnect power to the Power Supply Draining Water Hoses 1 Turn off power to the unit NOTE Opening the doors does NOT disconnect power to the unit 2 Turn off the water source wherever convenient NOTE Be sure to have a bucket or o...

Page 59: ... Spare Parts for battery part number CAUTION Stored data may be lost when the battery is replaced Before replacing the battery make a record of the data in the schedule data table Appendix H 1 Disconnect power to the Power Supply discharge the capacitors and remove the plastic cover as described in Section I Before You Start Battery Replacement 2 Insert your forefinger between the battery holder a...

Page 60: ...BER 575 VAC Valve Transformer 50VA T2 705 141 705 162 Valve Transformer 150VA T2 705 134 705 166 Valve Transformer 250VA T2 705 135 705 167 Battery Memory 145 014 Expansion Board 308 004 ME 1887 00 Expansion Board with Proportional Valve Option 4 36648 01 ME 1887 00 Front Panel Display PC Board 308 007 ME 1662 00 Main Control Board 4 37203 01 Power Supply 24 VDC 150 W 525 040 Power Supply 24 VDC 5...

Page 61: ... I Safety Precautions above 2 Turn off water source and disconnect the water hoses to the Power Supply Using shop air dry out the hoses 3 Disconnect all line wires 4 Disconnect all load wires 5 Disconnect all signal wires 6 Remove any conduits from the top and bottom of the Power Supply as necessary 7 If a secondary current sensor is used disconnect the signal cable from the connector on the botto...

Page 62: ......

Page 63: ...ons Weight 500 lbs Incoming Power Supply 480 VAC 575 VAC Three phase 480VAC 10 15 common to 50Hz and 60Hz Three phase 575VAC 10 15 common to 50Hz and 60Hz Control Power Supply Stepped down from incoming power supply Valve Power Supply 120VAC at 50 VA Optional 150 VA or 250 VA Other Options 24VDC at 2 amps 24VDC at 5 amps ...

Page 64: ...y constant current effective value control Secondary constant current effective value control Primary constant current peak value control Constant phase control Non constant current Number of Schedules 64 Additional Connections 10 non weld control I O rated at 5amps Milliseconds Mode Cycle Mode Timer Settings Schedule Screen Settable for 64 schedules SQD Squeeze delay time SQZ Squeeze time WE1 Wel...

Page 65: ...nge 00 0 200 kA 64 SCHEDULES Monitor is turned off if set to 00 0kA Voltage Monitor VOLT LOW HIGH Upper limit HIGH setting range 00 0 9 99V Lower limit LOW setting range 00 0 9 99V 64 SCHEDULES Monitor is turned off if set to 00 0V Power Monitor POWER LOW HIGH Upper limit HIGH setting range 00 0 300 0 kW Lower limit LOW setting range 00 0 300 0 kW 64 SCHEDULES Monitor is turned off if set to 00 00...

Page 66: ...onstant power control or constant phase control mode B When a primary current is not detected in primary constant current control mode Temperature Overheating of power unit of inverters and welding transformer are detected Self Diagnostic error Program for setting schedule etc is diagnosed Cable Trouble If output cable has ground faults power is turned off Capacitor Discharge Discharge switch is f...

Page 67: ...minating resistor assembly is supplied with the unit If only one unit is connected to the host the terminating resistor assembly must be installed in that unit If multiple units are connected to the host only one unit the unit furthest from the host must have the terminating resistor assembly installed 1 Not Used 2 Not Used 3 Not Used 4 Tx 5 Tx 6 Not Used 7 Not Used 8 Rx 9 Rx ...

Page 68: ...for I O signal entry 3 Remove the four screws that secure that cover plate to the Power Supply Drill appropriate hole in the plate to receive the I O signal wires Be sure all metal shards are removed and re insall the plate and connector NOTE You can snap the I O signal terminal blocks from their mounting bracket to facilitate installation of I O signal wires 4 Connect the Inut Output I O signals ...

Page 69: ...APPENDIX B ELECTRICAL AND DATA CONNECTIONS ISA 4001CR INVERTER POWER SUPPLY 990 364 B 3 Input Output Signal Configuration ...

Page 70: ... An open switch will stop operation and create an error signal 13 Common COM Common COM terminal for pin 14 14 Weld ON OFF Weld ON OFF input terminal If this terminal is closed welding function is armed This is one of three signals required to start welding 15 Common COM Common COM terminal for pin 16 16 Thermostat Thermostat input terminal This terminal is connected to the weld transformer thermo...

Page 71: ...34 31 Schedule 1 32 Schedule 2 33 Schedule 4 34 Schedule 8 35 Schedule 16 36 Schedule 32 37 Schedule 64 Schedule input terminals Used for schedule selection signal inputs See Binary Code Chart table 2 2 38 Common Common terminal for valve outputs pins 39 42 39 Valve 1 40 Valve 2 41 Valve 3 42 Valve 4 Valve output terminals Output voltage is either 115VAC standard or 24VDC optional Refer to equipme...

Page 72: ... 10 VDC variable signal to an external proportional valve 53 54 Cable Error One side is connected to chassis ground The other side is connected to the shield on the weld transformer primary cable The shield is not connected at the transformer end If a device such as a robot begins to damage the cable it will touch the shield first thereby shorting the cable error connections The unit will stop wel...

Page 73: ...TA CONNECTIONS ISA 4001CR INVERTER POWER SUPPLY 990 364 B 7 Configurations for Common Input Connections Sensing Connector PIN DESCRIPTION A Common Thermostat B Thermostat C Voltage D Current E Current F Voltage G Ground FRONT VIEW ...

Page 74: ...e 04 Schedule 05 Schedule 06 Schedule 07 Schedule 08 Schedule 09 Schedule 10 Schedule 11 Schedule 12 Schedule 13 Schedule 14 Schedule 15 Schedule 16 Schedule 17 Schedule 18 Schedule 19 Schedule 20 Schedule 21 Schedule 22 Schedule 23 Schedule 24 Schedule 25 Schedule 26 Schedule 27 Schedule 28 Schedule 29 Schedule 30 Schedule 31 Schedule 32 Schedule 33 Schedule 34 Schedule 35 Schedule 36 Schedule 37...

Page 75: ...Schedule 2 Schedule 4 Schedule 8 Schedule 16 Schedule 32 Schedule 64 Schedule 43 Schedule 44 Schedule 45 Schedule 46 Schedule 47 Schedule 48 Schedule 49 Schedule 50 Schedule 51 Schedule 52 Schedule 53 Schedule 54 Schedule 55 Schedule 56 Schedule 57 Schedule 58 Schedule 59 Schedule 60 Schedule 61 Schedule 62 Schedule 63 Schedule 64 ...

Page 76: ......

Page 77: ...ns of the Power Supply Start Signal Input Weld sequence operation varies by the setting of START SIG MODE on the Mode Select screen Maintained Mode When the Stage 2 signal is turned off during the weld sequence between the Squeeze Delay time and Hold time the weld sequence is immediately interrupted and there will be no END signal output Start Signal Input in Maintained Mode ...

Page 78: ...R INVERTER POWER SUPPLY C 2 990 364 Pulsed Mode If the Stage 2 signal is held for more than the time set to Delay Start Set and subsequently turned off the weld sequence will continue to its conclusion Start Signal Input in Pulsed Mode ...

Page 79: ...PLY 990 364 C 3 Latched Mode x If the Stage 2 signal is turned off during Squeeze time the weld sequence is interrupted x If the Stage 2 signal is turned off after Weld 1 time the weld sequence continue to its conclusion Start Signal Input in Latched Mode ...

Page 80: ...APPENDIX C SYSTEM TIMING ISA 4001CR INVERTER POWER SUPPLY C 4 990 364 One Stage Start Stage 2 signal will begin the welding sequence with the selected Schedule One Stage Start ...

Page 81: ...d the Valve signal for the selected Schedule number is applied but the remaining weld sequence is delayed until input of the Stage 2 signal The Stage 2 signal will start the weld sequence in the selected Schedule If the Stage 2 input is applied before the Stage 1 input a Stage 1 Start sequence will begin Two Stage Start ...

Page 82: ... Stage 1 signal causes the weld sequence to begin as a Stage 1 start A Stage 2 start would operate in the same manner except for the actual start sequence as described above As shown if the Chaining was set ON for Schedules 1 2 5 and 6 but OFF for other Schedules the sequence would go through that sequence but because of the loss of the Stage 2 Input would terminate after the completion of Schedul...

Page 83: ...ive in the Schedule screen Example A Stage 2 start without a Stage 1 signal causes the weld sequence to begin as a Stage 1 start A Stage 2 start would operate in the same manner except for the actual start sequence as described above As shown if the Successive was set ON for Schedules 1 2 5 but OFF for other Schedules the sequence would go through that sequence then return to the beginning of the ...

Page 84: ...odes to re orient a work piece or to service the electrodes The Retraction Valve output signal occurs when the Retraction input signal is applied NOTE This function can not be turned ON or OFF during a weld sequence The illustration below shows a One Stage Start Except for the actual start sequence the operation will be the same for a Two Stage Start Retraction Function ...

Page 85: ...een The weld force of the weld head can be changed during the weld schedule using Forge Delay This operates a second valve at a programmed delay allowing extra air pressure to be applied to the weld head The illustration below shows a One Stage Start Except for the actual start sequence the operation will be the same for a Two Stage Start Forge Function ...

Page 86: ...IMING ISA 4001CR INVERTER POWER SUPPLY C 10 990 364 Repeat Operation Repeat operation will occur whenever the OFF time is set to any value other than zero 0 and Chaining is set OFF on the Schedule screen Repeat Operation ...

Page 87: ...APPENDIX C SYSTEM TIMING ISA 4001CR INVERTER POWER SUPPLY 990 364 C 11 Pulsation Pulsation ...

Page 88: ...WER SUPPLY C 12 990 364 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 will occur with a 5 increase in weld current Re Weld ...

Page 89: ...INVERTER POWER SUPPLY 990 364 C 13 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 stopped and shifted to Hold HO Interrupt ...

Page 90: ...Weld Count period if the weld count is less than that set at Weld Count on the Monitor Set screen the Count Error signal is generated Example The illustration below shows that the Weld Count was set for 4 but only three welds occurred at the completion of the Weld Count signal Therefore a Count Error occurs To clear the COUNT ERROR output signal the WELD COUNT input must be triggered high The WELD...

Page 91: ...reduced to 4 maximum Ampacity must be in accordance with local codes b For the Output lines to the transformer it is recommended that voltage loss does not exceed 1 The unit is designed to have dual output cables on each primary output 4 cables total Ampacity must be in accordance with local codes In general The input current is the same for a 480 VAC ISA 4001CR or a 575 VAC ISA 4001CR Size all ca...

Page 92: ...up 0 4 1 0 0 4 0 5 0 6 0 7 0 8 0 9 0 95 1 0 X In t1 Long time delay 3 0 18 sec A 3 B 6 C 12 D 18 seconds I Instantaneous trip 1 5 12 0 1 5 2 0 4 0 6 0 8 0 10 0 12 0 15 0 X In In 1200 Amps for ISA 4001CR See circuit breaker front panel for dipswitch settings Setting L Calculate the breaker rated current using the Effective secondary current and duty cycle of the weld schedule DC is the duty cycle o...

Page 93: ...r with automation control systems Detailed descriptions for this option are in Appendix F Communications NOTE If you order these options the size of the Power Supply cabinet may change Outline Drawings showing the new dimensions follow the descriptions of these options Weldlab Software Communications The Weldlab communications option gives the Power Supply the ability to communicate with a host co...

Page 94: ...s are available the 150VA and the 250 VA 24 Volt DC Power Supply Not Shown The 24 Volt DC Power Supply is only available as an option When installed it provides 24 VDC to power the valves Two options are available 2 1amps 50 watts and 6amps 150 watts NOTE There must be a Valve Transformer of the correct VA installed to provide AC power to 24 Volt DC Power Supply RS 485 Connectors Not Shown These o...

Page 95: ...the status of the Power Supply x Remotely program weld schedules on the Power Supply x Remotely program menu items on the Power Supply Instructions for using Weldlab are in the separate Operator Manual that comes with the software Remote Programming Most users will find the Weldlab software functions sufficient for collecting and using weld history information and remote schedule programming Howev...

Page 96: ...based converter without an internal microprocessor such as the Telebyte model 285 the host computer should be at least a Pentium III 550 running Windows 98 Windows ME Windows 2000 Windows XP or Windows NT 4 0 Care must be taken not to exceed the capacity of each RS 485 communications channel The product of total number welds per second on all welders on that channel times total number of bytes exc...

Page 97: ...nit to which data is requested converted into ASCII decimal numbers 01 30 The first two characters of the unit ID serve as the RS 485 address cmd 2 BYTES This is a two character ASCII string denoting the command i e IA cnt 2 BYTES This is a count of data bytes to follow converted into an ASCII HEX number 00 FF data n BYTES aThis is optional BINARY data Multiple binary byte ordering LSB MSB cksum 2...

Page 98: ...ported soh NAK err cksum eot Where err 1 NO SOH 4 Timeout 2 BAD checksum 5 ISA is in Local 3 Unrecognized command 6 Data Bad Valid Commands A valid command will return EITHER data OR ACK 0x06 soh ACK cksum eot Data will be returned with the following structure soh cmd cnt data cksum eot NOTE When you issue a command to the ISA you need to wait for the response before you issue the next command wit...

Page 99: ...x0FF 1 Byte RESET RX Set Reset an Error and Returns STATUS 0 Bytes REMOTE RM Set 0 Local 1 Remote After Ver 1 01 B 1 Byte LOAD LR Read none 0 Bytes LS Set 0 Hardware Select 1 64 Selects 1 Byte active schedule NOTE Before Ver 1 02C this was set through hardware only COPY CP Set Source schedule 1 Byte Destination schedule 1 Byte Count past 1 Byte 3 Bytes Total TIME CLK RT Set data 0 Reset time clock...

Page 100: ... HEAT 2 10 100 2 Bytes CURRENT Energy 32 0 200 0k 2 Bytes CURRENT 2 Energy 32 0 200 0k 2 Bytes IMPULSE 0 9 1 Byte TIME ms 0 or CYC 1 1 Byte 33 Bytes Total MONITOR NR Read Schedule 1 Byte MONITOR NS Set SCHEDULE 1 Bytes HIGH1C High current 1 0 200kA 2 Bytes HIGH2C High current 2 2 Bytes LOW1C Low current 1 2 Bytes LOW2C Low current 2 2 Bytes HIGH1V High Voltage 1 0 9 9V 2 Bytes HIGH2V High Voltage ...

Page 101: ...SIGNAL see below 1 Byte DELAY START 1 Byte FORGE on off 0000 000x 1 Bit PARITY on off 0000 00x0 1 Bit INTERUPT on off 0000 0x00 1 Bit RE WELD on off 0000 x000 1 Bit RESET MODE on off 000x 0000 1 Bit WELD COUNT on off 00x0 0000 1 Bit END SIG MODE on off 0x00 0000 1 Bit CYCLE WELD on off x000 0000 1 Bit 1 Byte STEPPER on off 0000 000x 1 Bit WELD ON OFF on off 0000 00x0 1 Bit Added after V1 01 B REMO...

Page 102: ...Set Schedule 1 Byte Added after V1 01 B STEP 1 50 200 1 Byte STEP 2 1 Byte STEP 3 1 Byte STEP 4 1 Byte STEP 5 1 Byte STEP 6 1 Byte STEP 7 1 Byte STEP 8 1 Byte STEP 9 1 Byte Added after V1 01 B Tip Dress Step 1 0000 000x 1 Bit Tip Dress Step 2 0000 00x0 1 Bit Tip Dress Step 3 0000 0x00 1 Bit Tip Dress Step 4 0000 x000 1 Bit Tip Dress Step 5 000x 0000 1 Bit Tip Dress Step 6 00x0 0000 1 Bit 1 Byte Ti...

Page 103: ... CLK RT Set ACK OR NAK 1 Byte Read Read Time Offset 4 Bytes LINK KS Set ACK OR NAK 1 Byte KR Read 0 Chaining 1 Successive 1 Byte Number of Schedules in Link 1 Byte SCHEDULE SCHEDULE n Bytes RESET RX Returns STATUS 7 Bytes REMOTE RM Set ACK OR NAK Added after Ver 1 01 B 1 Byte REPORT RR Read Schedule 1 Byte Status 4 Bytes 1st pulse Current 2 Bytes 1st pulse Voltage 2 Bytes 1st pulse Power 2 Bytes 1...

Page 104: ...te HEAT 2 10 99 9 1 Byte CURRENT 1 Energy 2 40 0k 2 Bytes CURRENT 2 Energy 2 40 0k 2 Bytes IMPULSE 0 9 1 Byte TIME ms 0 or CYC 1 1 Byte 31 Bytes Total MONITOR NS Set ACK OR NAK 1 Bytes MONITOR NR Read SCHEDULE 1 Byte HIGH1C High current 1 0 99 9kA 2 Bytes HIGH2C High current 2 2 Bytes LOW1C Low current 1 2 Bytes LOW2C Low current 2 2 Bytes HIGH1V High Voltage 1 0 9 99V 2 Bytes HIGH2V High Voltage ...

Page 105: ...ART SIGNAL see below 1 Byte DELAY START 1 Byte FORGE on off 0000 000x 1 Bit PARITY on off 0000 00x0 1 Bit INTERUPT on off 0000 0x00 1 Bit RE WELD on off 0000 x000 1 Bit RESET MODE on off 000x 0000 1 Bit WELD COUNT on off 00x0 0000 1 Bit END SIG MODE on off 0x00 0000 1 Bit CYCLE WELD on off x000 0000 1 Bit 1 Byte STEPPER on off 0000 000x 1 Bit WELD ON OFF on off 0000 00x0 1 Bit Added after V1 01 B ...

Page 106: ...CHEDULE 1 Byte Added after V1 01 B STEP 1 50 200 1 Byte STEP 2 1 Byte STEP 3 1 Byte STEP 4 1 Byte STEP 5 1 Byte STEP 6 1 Byte STEP 7 1 Byte STEP 8 1 Byte STEP 9 1 Byte Added after V1 01 B Tip Dress Step 1 0000 000x 1 Bit Tip Dress Step 2 0000 00x0 1 Bit Tip Dress Step 3 0000 0x00 1 Bit Tip Dress Step 4 0000 x000 1 Bit Tip Dress Step 5 000x 0000 1 Bit Tip Dress Step 6 00x0 0000 1 Bit 1 Byte Tip Dre...

Page 107: ... COMMAND DATA SIZE STATUS TI Sending data 0 Returns Last error 4 Bytes 1 Schedule and Heat if changed 1 127 else 0 1 Byte 2 Monitor Schedule if changed else 0 1 Byte 3 Step Schedule if changed else 0 1 Byte 4 Stepper Valve if changed else 0 1 Byte 5 0 zero 1 Byte 9 Bytes Total ...

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Page 109: ...ipswitches are factory set at time of manufacture to match specified input output power requirements and other operating parameters Changing these settings may present electric shock and fire hazards damage the equipment or render it inoperable This will require the unit to be returned to the factory for setup re calibration and any necessary repair Dipswitch Locations ...

Page 110: ...nance shutdown procedures described in Chapter 4 Maintenance Weld Power Frequency SW3 CAUTION Do not change the settings on switch positions 6 8 You have three weld output power frequency options as shown on the right x 600 Hz x 800Hz x 1000 Hz NOTE The factory setting is 1000Hz Stepper Settings SW4 CAUTION Do not change the settings on switch positions 1 2 or 4 8 Use switch position 3 to switch b...

Page 111: ...ISA 4001CR INVERTER POWER SUPPLY 990 364 H 1 APPENDIX H SCHEDULE DATA TABLES You may copy and use Setting List table on the following pages to record the values set in each weld schedule ...

Page 112: ......

Page 113: ...ng to Valve Number 1 Schedule Common to Each Schedule POWER SUPPLY STATE Control Number Programmed Date SCHEDULE CTRL SQD SQZ UPSLOPE 1 WE 1 DOWNSLOPE 1 COOL UPSLOPE 2 WE 2 DOWNSLOPE 2 HOLD OFF Heat 1 Heat 2 Pulsation Gain 1 9 Valve Number Forge Value Number Forge Delay ms Turns Ratio Chaining Successive ...

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Page 115: ...Schedules Corresponding to Start Number 4 Schedules Corresponding to Valve Number 1 Schedule Common to Each Schedule STEPPER COUNT Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 HEAT INCREASE Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 ...

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Page 117: ...hedule MONITOR SET No Current Time Current Monitor No Weld Count High Weld 1 Low High Current Weld 2 Low High Weld 1 Low High Volt Weld 2 Low High Weld 1 Low High Power Weld 2 Low Weld 1 High Pulse Weld 2 High MODE SELECT Delay Start Set ms Start Signal Mode Parity Check Cycle Weld Stepper Forge Weld Count Re Weld End Signal Mode Interrupt Reset Mode ...

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Page 119: ...o get the desired force The Amplifier for the Electronic Pressure Regulator is an integrated circuit chip located on the ME 1887 Expansion Board shown below This chip has regularly been manufactured in the color blue so it is commonly referred to as The Big Blue Chip NOTES x If you do not see The Big Blue Chip on the expansion board the Power Supply does not have the Force Control Option x The fol...

Page 120: ...CE UNITS lbs BACK PRESSURE 00 psi CALIBRATION VALVE 1 LOW 00000 UP HIGH 00001 UP Select Force Units Before using the Force Control Option select the FORCE UNITS you want to use 1 From the PRESSURE REGULATOR screen select FORCE UNITS PRESSURE REGULATOR FORCE ON FORCE UNITS lbs BACK PRESSURE 00 psi CALIBRATION VALVE 1 LOW 00000 UP HIGH 00001 UP 2 Use the or keys to select pounds lb kilograms of forc...

Page 121: ...actual force of the electrodes measured by the Force Gauge matches the force displayed on the LCD One LOW force and one HIGH force measurement are used for calibration If you are unable to match these measurements return the Control to Miyachi Unitek for factory calibration Before you start Calibration check the force gauge to be used between the electrodes to see what force units it measures The ...

Page 122: ... the force stabilize then check the force on the force gauge Write down the number of the force units 9 To raise the weld head press the on Program Unit to change from LOW DOWN to LOW UP then press ENTER 10 Move the cursor on the LCD to highlight LOW 00000 11 Use the or keys to increase or decrease the FORCE UNITS until the number on the LCD matches the number measured by the Force Gauge 12 Press ...

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