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Amada IS-300CA Operation Manual

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INVERTER POWER SUPPLY
IS-300CA
OPERATION MANUAL
990-418 REV D

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  • Page 1 INVERTER POWER SUPPLY IS-300CA OPERATION MANUAL 990-418 REV D...
  • Page 2 Copyright  2018-2020 Amada Weld Tech Inc. The engineering designs, drawings and data contained herein are the proprietary work of Amada Weld Tech and may not be reproduced, copied, exhibited or otherwise used without the written authorization of Amada Weld Tech.
  • Page 3 For the rest of this manual, the IS-300CA will be referred to simply as the Power Supply. Upon receipt of your equipment, please thoroughly inspect it for shipping damage prior to its installation.
  • Page 4 Section II. Programming Options For Basic and Advanced Models ............. 3-2 1. MENU Screen ..........................3-2 2. POWER SUPPLY STATE Screen ....................3-2 LCD CONTRAST ........................3-2 CONTROL # ..........................3-3 PROGRAMED DATE ......................3-3 POWER SOURCE FREQUENCY ..................3-3 IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 5 Chapter 3. Using Programming Functions (cont.) LANGUAGE ..........................3-3 MA-660A the Pendant ROM VERSION # ................3-3 MA-660A the Pendant (IS-300CA) PROGRAM VERSION ..........3-3 IS-300CA ROM VERSION # ....................3-3 3. SCHEDULE Screen ......................... 3-3 CURRENT and TIME Setting Screen ..................3-3 SCHEDULE # ........................
  • Page 6 MONITOR DISP MODE ....................... 3-33 RE-WELD ..........................3-33 COUNTER ..........................3-34 SCAN MODE ......................... 3-35 COMM CONTROL ........................ 3-35 COMM MODE ........................3-35 COMM SPEED ........................3-36 DISPLACEMENT SENSOR STEP ..................3-36 REV ............................3-36 IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 7 SCHEDULE ........................... 3-50 PROP VALVE # ........................3-50 STEP MODE (Continue) ......................3-50 SQD ............................3-51 SQZ ............................3-51 WE1 ............................3-51 CO1/WE2 ..........................3-51 CO2/WE3 ..........................3-51 SQD ............................3-52 SQZ ............................3-52 WE1 ............................3-52 IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 8 Section I: Introduction ........................... 4-1 Operator Safety ..........................4-1 Before You Start ..........................4-1 Preparing for Operation ........................4-1 Section II: Operation ..........................4-2 Starting Welding Operation ......................4-2 Check the Valve Sequence ........................ 4-2 IS-300CA INVERTER POWER SUPPLY viii 990-418...
  • Page 9 Section II: Repair Service, Storage, Shipment ..................5-8 Appendix A. Technical Specifications ....................A-1 Appendix B. Electrical and Data Connections ..................B-1 Appendix C. System Timing ........................C-1 Appendix D. Communications ......................D-1 Appendix E. EtherNet/IP Communications ................... E-1 IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 10 Before performing any maintenance on the Inverter Power Supply, read Chapter 5, Maintenance thoroughly. Use the appropriate tools for terminating the connecting cables, being careful not to nick the wire conductors. Do not modify the Power Supply without prior written approval from Amada Weld Tech. IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 11 When inspecting the inside of the Power Supply, be sure to turn the power source. NEVER DISASSEMBLE, REPAIR, OR MODIFY THE POWER SUPPLY. These actions can cause electric shock and fire. Do not do anything other than the maintenance described in the Operator Manual. IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 12 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 Amada Weld Tech or your distributor for help. People with pacemakers MUST stay away from the Power Supply.
  • Page 13 Make sure there is a fire extinguisher in or near the welding shop in case of fire. Regularly inspect and maintain the Power Supply. Regular inspection and maintenance is essential to safe operation and long life of the equipment. If you see any damage, make necessary repairs before operation. IS-300CA INVERTER POWER SUPPLY 990-418 xiii...
  • Page 14 1. Applicability. (a) These terms and conditions of sale (these “Terms”) are the only terms which govern the sale of the goods (“Goods”) by Amada Weld Tech Inc. (“Seller”) to the buyer identified in the Sales Quotation and/or Acknowledgment (as each defined below) to which these Terms are attached or incorporated by reference (“Buyer”).
  • Page 15 Seller may terminate this license upon written notice for any violation of any of the terms of this license or any material breach of any provision of this Agreement. Buyer shall immediately discontinue use of the Software upon any termination of this license or IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 16 TERMS, WHETHER OR NOT THE POSSIBILITY OF SUCH DAMAGES HAS BEEN DISCLOSED IN ADVANCE BY BUYER OR COULD HAVE BEEN REASONABLY FORESEEN BY BUYER, REGARDLESS OF THE LEGAL OR EQUITABLE THEORY (CONTRACT, TORT OR OTHERWISE) UPON WHICH THE CLAIM IS BASED, AND NOTWITHSTANDING THE FAILURE OF ANY AGREED OR OTHER REMEDY OF ITS ESSENTIAL PURPOSE. IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 17 Buyer; (b) known to Buyer at the time of disclosure without restriction as evidenced by its records; or (c) rightfully obtained by Buyer on a non- confidential basis from a third party. 19. Force Majeure. Seller shall not be liable or responsible to Buyer, nor be deemed to have defaulted or breached this Agreement, for any failure or IS-300CA INVERTER POWER SUPPLY 990-418 xvii...
  • Page 18 27. Survival. Provisions of these Terms which by their nature should apply beyond their terms will remain in force after any termination or expiration of this Order including, but not limited to, the following provisions: Compliance with Laws, Confidentiality, Governing Law, Dispute Resolution, Survival, and the restrictions on Software in Sections 10(b), (c) and (d). IS-300CA INVERTER POWER SUPPLY xviii 990-418...
  • Page 19 Basic, Advanced and EtherNet/IP Models The Amada Weld Tech IS-300CA is an inverter-type power supply specially designed to be used for spot welding and fusing. The IS-300CA provides 300 amps primary current. The IS-300CA can be ordered as a Basic (1-325-02 / 1-325-02-01) or Advanced (1-325-02-02 / 1-325- 02-03) or EtherNet/IP (1-325-02-04 / 1-325-02-05) units.
  • Page 20 (voltage input proportional to force) for force measurement have two channels, respectively.  Welding can be stopped at the set displacement by connecting the displacement gauge and measuring the displacement produced in fusing. IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 21 The RS-232 communications connector is also on the front panel. The IS-300CA power supply is typically sold with Amada Weld Tech’s IT Transformers with built-in current coil, thermal switch and voltage cable connection. The power supply is, therefore, calibrated for the IT Transformer coils, 220ma/kA.
  • Page 22 CHAPTER 1: SYSTEM DESCRIPTION Front Panel WELD POWER lamp READY lamp START lamp WELD lamp TROUBLE lamp TROUBLE reset key WELD ON/OFF key IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 23 CHAPTER 1: SYSTEM DESCRIPTION NOTE: The IS-300CA EtherNet/IP model connectors are shown here. IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 24 Used to write the set or changed value and [ON/OFF] data in the Power Supply connected to the MA- 660A. After any data is set or changed, be sure to press this key to write that data before moving ENTER the cursor. IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 25 Also, when changing a screen to call up another setting schedule during the welding sequence, the key does not work even if the TROUBLE RESET following screen appears. In this case, you need to turn on the power again. (When connecting to the Power Supply, IS-300CA Advanced IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 26  ...
  • Page 27 38 and 39 on the external I/O terminal strip. NOTE: If used with Amada Miyachi America IT Series transformers, you can purchase the 18- 046-01 transformer sense cable which will have these connections.
  • Page 28 Serious injury or death can result from contacting live power lines. • The installer must make electrical connections in accordance to all applicable codes. For appropriate cable rating, see Appendix B, Electrical and Data Connections. IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 29 3. If using an IT Series transformer and current and voltage sense is required, optional cable 18- 046-01 can be connected between the 25-pin D-sub on back of the unit and the transformer Note: the power supply is calibrated to the IT Series transformer IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 30  ...
  • Page 31 CHAPTER 3 USING PROGRAMMING FUNCTIONS Section I. Introduction This chapter shows Pendant screens used for both Basic, Advanced and EtherNet/IP models of the IS-300CA Power Supply. Functions related to the Advanced / EtherNet/IP models will only be noted in the text.
  • Page 32 Sets the LCD screen contrast. The contrast can be set in a range from 0 to 9. The larger the value, the darker the screen. Adjust the contrast if the screen is difficult to view. IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 33 Select the language from Japanese and English. f. MA-660A the Pendant ROM VERSION # Indicates the ROM version No. of the Pendant. g. MA-660A the Pendant (IS-300CA) PROGRAM VERSION Indicates the program version No. of the Power Supply’s screen display part. h. IS-300CA ROM VERSION # Indicates the ROM version No.
  • Page 34 CHAPTER 3: USING PROGRAMMING FUNCTIONS NOTE: The screen shows the settings for the IS-300CA. Unit, resolution, and setting range change depending on the settings of CTRL/CURR RANGE. a. SCHEDULE # Select from #1 to #255 to set the SCHEDULE. Normally select #1 first, then select additional schedules in sequential order.
  • Page 35 When the downslope time is set for the previous stage in the multi-stage welding, the downslope time is set for the previous stage, and the setting of and the setting of DL HEAT HEAT different. IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 36 UP and DOWN to be shorter than WELD. If not, E-10 (Schedule setting error) will be displayed.  Upslope / Downslope waveform when INT (downtime) is set to 0.  E-10 (Schedule setting error) will occur when the Power Supply starts with the setting below. IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 37 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 setting of and the setting of UF HEAT DL HEAT are different. IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 38 (SCD). Display Control method Primary constant-current effective value control Secondary constant-current effective value control Secondary constant-power effective value control Primary constant-current peak value control Secondary constant-voltage effective value control Constant-phase control IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 39 Used for special cases such as the Constant-phase control Welding with the fixed pulse test of welder, and Controls switching with the set pulse width. (Non-constant current) width. No feedback control. not used for normal welding. IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 40 Even though E-07 (No-current error) is displayed, current is flowing. Exercise caution in handling g. NEXT When the cursor is at, moving the cursor down will change the display to PULSATION transformer screen. PULSATION and transformer screen IS-300CA INVERTER POWER SUPPLY 3-10 990-418...
  • Page 41 If the MONITOR current gets out of the range of upper/lower limit judgment during repeated PULSATION operation, a caution signal is output after completion of welding (see the MONITOR SET screen.) IS-300CA INVERTER POWER SUPPLY 990-418 3-11...
  • Page 42 Compensates the pulse limit for the fluctuation in the three-phase power-supply voltage on the primary side. However, the compensation is for power-supply voltage prior to welding, and not applied during welding. The setting range is 000 to 100%. IS-300CA INVERTER POWER SUPPLY 3-12 990-418...
  • Page 43 Keep set to 1. Feature is not active and not shown on Basic models. m. REV When the cursor ( ) is displayed, pressing the key will change the display to Current and ENTER time setting screen. IS-300CA INVERTER POWER SUPPLY 990-418 3-13...
  • Page 44 The voltage during which current was supplied in the course of WELD1, WELD2 and WELD3 operations are displayed. To display the voltage, you need to measure the secondary voltage by connecting the voltage detecting cable. The latest measured value welded with the displayed SCHEDULE No. is displayed. IS-300CA INVERTER POWER SUPPLY 3-14 990-418...
  • Page 45 The number of times before prior notice for cap change setting for the stepper used for the displayed SCHEDULE is displayed when STEPPERMODE is not OFF on the MODE SELECT screen. The latest measured value welded with the displayed SCHEDULE No. is displayed. IS-300CA INVERTER POWER SUPPLY 990-418 3-15...
  • Page 46 2. When WELD2 STOP/WELD COUNT WELD2 STOP COUNTER GOOD is displayed. The count value is incremented by one when the monitored GOOD COUNTER value is within the range of the upper/lower limit. IS-300CA INVERTER POWER SUPPLY 3-16 990-418...
  • Page 47 OFF time setting, only PULSATION the last data is displayed as the monitored value. The passing data is not displayed.  The monitor display is not automatically updated depending on the MONITOR DISP setting. MODE IS-300CA INVERTER POWER SUPPLY 990-418 3-17...
  • Page 48 Set the upper limit ( ) and lower limit ( ) of the secondary voltage for each of e. POWER Set the upper limit ( ) and lower limit ( ) of the electric power for each of IS-300CA INVERTER POWER SUPPLY 3-18 990-418...
  • Page 49 Sets the output modes of of the external output signals. N.C. (NORMAL CLOSE) Closed at normal / Open at error N.O. (NORMAL OPEN) Open at normal / Closed at error NOTE: NG2 is N.O. only IS-300CA INVERTER POWER SUPPLY 990-418 3-19...
  • Page 50 OFF TIME (OFF) Upper/lower ERROR Receive Stop limit monitor CAUTION Receive Not stop error ERROR Not receive Stop No-current error, Work piece error CAUTION Receive Stop Counter error Receive Stop Other device error Not receive Stop IS-300CA INVERTER POWER SUPPLY 3-20 990-418...
  • Page 51 COUNT UP  (OUT I timing output)  (OUT II timing output) OUT I OUT II For output timings of , and , see the Timing Chart. WELD SIGNAL GOOD OUT I OUT II IS-300CA INVERTER POWER SUPPLY 990-418 3-21...
  • Page 52 Move the cursor to the required item then press the ENTER key; the data will be copied. a. IS-300CA MA-660A. The data in IS-300CA is copied to MEMORY of MA-660A. When  copy is complete, <END> is displayed. b. IS-300CA MA-660A.
  • Page 53 9. In Figure B above, only schedule signal 8 is ON. As a result, welding is performed using schedule number 8. Schedule signals 16 and 32 are invalid because they are OFF when the schedule is determined. IS-300CA INVERTER POWER SUPPLY 990-418 3-23...
  • Page 54 DELAY START SET A: DELAY START SET 2ND STAGE Schedule selection (1,2,4,8,16 32,64,128,P) Valve output (SOL1 or SOL2) Welding sequence B: Monitored value judgment SQD SQZ time C: END signal output END signal output time IS-300CA INVERTER POWER SUPPLY 3-24 990-418...
  • Page 55 > 200ms). End signal time is the 200ms. ( time = 200ms). is 10 to 200ms END SIGNAL TIME EXAMPLE: is 0ms ( time = 0ms). End signal time is the set time. ( time END SIG.TIME time). END SIG.TIME IS-300CA INVERTER POWER SUPPLY 990-418 3-25...
  • Page 56 > “Upper/lower limit error” > “Count-related error”. e. WELD TIME Use this setting to change the units for time settings available on the SCHEDULE screen. 50Hz: 1CYC = 20ms 60Hz: 1CYC = 16.6ms — IS-300CA INVERTER POWER SUPPLY 3-26 990-418...
  • Page 57 Be sure that the total number of closed schedule selection and parity signal lines is always odd. (Refer to Note 1, “Schedule Numbers and Schedule Selection Pins.”) NOTE: Schedule Numbers and Schedule Selection Pins IS-300CA INVERTER POWER SUPPLY 990-418 3-27...
  • Page 58 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● IS-300CA INVERTER POWER SUPPLY 3-28 990-418...
  • Page 59 COOL1 WE1STOP starts (the current is supplied for about 1 cycle) when input before the period, switching the sequence to . The signal will not shut off current if input during COOL1 WE1STOP period. IS-300CA INVERTER POWER SUPPLY 990-418 3-29...
  • Page 60 Flow switch input pin. Opening this pin will result in a flow rate error. When PRG PROTECT is selected Program inhibit input pin. Closing this pin will not allow you to change the settings. IS-300CA INVERTER POWER SUPPLY 3-30 990-418...
  • Page 61 Selects the schedule number by binary of the I/O terminal strip. Selects the schedule number by the SCHEDULE number of the Pendant. (Note) NOTE: When setting SCHEDULE to INT, be sure to connect the Pendant and select the SCHEDULE screen or the MONITOR screen. IS-300CA INVERTER POWER SUPPLY 990-418 3-31...
  • Page 62 After the welding sequence starts, the valve signal is output until the sequence ends even if the 1ST STAGE signal is turned OFF. When VALVE MODE is set to 2 VALVE, the following functions become disabled. ・OFF (repeated operation) IS-300CA INVERTER POWER SUPPLY 3-32 990-418...
  • Page 63 This cannot be used in combination with the off time (OFF). When the off time is set, works as even if . When is combined RE-WELD RE-WELD with , the welding current will be 5% greater than the value set for STEPPER STEPPER IS-300CA INVERTER POWER SUPPLY 990-418 3-33...
  • Page 64 ), work piece error ( )), count-up is ERROR/CAUTION ERROR/CAUTION not done. When the welding is interrupted, count-up is not done. Judgment in Monitor Counting Manner GOOD (normal) CAUTION Count-up. Upper/lower limit monitor ERROR Error/Interrupt No Count-up. IS-300CA INVERTER POWER SUPPLY 3-34 990-418...
  • Page 65 Cannot be used. Select OFF. r. COMM CONTROL Selects a communication function. No communication  One-way communication  Both-way communication s. COMM MODE Selects a communication mode. RS-485 Communication by RS-485 (optional) RS-232C Communication by RS-232C IS-300CA INVERTER POWER SUPPLY 990-418 3-35...
  • Page 66 When each count reaches the set value, E-28 (Count-up) is displayed and the COUNT UP signal is output. When WELD2 STOP/WELD COUNT is WELD2 STOP and COUNTER is TOTAL, the PRESET TOTAL COUNT is displayed. IS-300CA INVERTER POWER SUPPLY 3-36 990-418...
  • Page 67 G O O D E R R O R output C A U T I O N output E R R O R RE SE T C O U N T RE SE T IS-300CA INVERTER POWER SUPPLY 990-418 3-37...
  • Page 68 WEL D count va lue W O R K count va lue output C A U T I O N output E R R O R RE SE T C O U NT RE SE T IS-300CA INVERTER POWER SUPPLY 3-38 990-418...
  • Page 69 Also, 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. IS-300CA INVERTER POWER SUPPLY 990-418 3-39...
  • Page 70 The monitored value will not be displayed if the weld time is shorter than MONITOR FIRST . The monitored value will not be also checked against the upper and lower tolerance limits. TIME IS-300CA INVERTER POWER SUPPLY 3-40 990-418...
  • Page 71 The welding is stopped at the end of WELD STOP OFF TIME. We ld ing stop s igna l input W EL D S T O P OFF T I M E Set va lue IS-300CA INVERTER POWER SUPPLY 990-418 3-41...
  • Page 72 (or reduced) by the extent you have set this value for STEP3. Set the desired STEP No. 1–9 for VALVE1 and VALVE2, or SOL 1 – 4, respectively, depending on the valve mode selection. IS-300CA INVERTER POWER SUPPLY 3-42 990-418...

  • Page 73: 1* 1 Step Mode

    2kA for current, the current is stepped up in a stepwise manner from Weld 3 to Weld 6 as shown below. Weld 1:2kA Weld 2:2kA Weld 3:2.5kA Weld 4:3.0kA Weld 5:3.5kA Weld 6:4.0kA <--------- ----------> <------------------------------ -----------------------------> STEP1 STEP2 IS-300CA INVERTER POWER SUPPLY 990-418 3-43...
  • Page 74 When the current is set to 2kA, HIGH; 2.2kA, LOW; 1.8kA. When the step becomes 150%, HIGH and LOW become as follows. HIGH: 2.2 x 1.5 = 3.3kA LOW: 1.8 x 1.5 = 2.7kA IS-300CA INVERTER POWER SUPPLY 3-44 990-418...
  • Page 75 (STEP9 COUNT) that the cap change error occurs. For example, when STEP9 COUNT is 1000 (the number of welds that the cap change error occurs) and CAP CHANGE is 10, prior notice is given when the stepper count is 990. IS-300CA INVERTER POWER SUPPLY 990-418 3-45...
  • Page 76 Set the upper limit of resistance value for pre-check. e. PRECHECK RESISTANCE LOW Set the lower limit of resistance value for pre-check. f. PRECHECK MONITOR Displays the monitor resistance value at the pre-check welding. IS-300CA INVERTER POWER SUPPLY 3-46 990-418...
  • Page 77 “0” to turn OFF the output signal, and “1” to turn it ON. Reception of an input signal while this screen is showing will not activate the corresponding function. You cannot move to another screen while the 1ST or 2NDSTAGE signal is input. NOTE: Not all fields are present on Basic Models. IS-300CA INVERTER POWER SUPPLY 990-418 3-47...
  • Page 78 Follow the procedure below to change the setting of PROGRAM PROTECT 1. Turn the power supply ON using the  key pressed or connect the jumper to the circuit cable with the power supply turned ON. The following screen will display: IS-300CA INVERTER POWER SUPPLY 3-48 990-418...
  • Page 79 On the other screens, the cursor can be moved and the settings can DEFAULT be checked, but the settings cannot be changed. <When the PROGRAM PROTECT is OFF> When the PROGRAM PROTECT is ON> IS-300CA INVERTER POWER SUPPLY 990-418 3-49...

  • Page 80: Propvalve

    Do not move the cursor from STEP MODE during this mode. Settings cannot be changed. Valid only when FORCE CONTROL MODE on the PRESSURE REGULATOR screen is not Turning on the step operation mode Set STEP MODE to ON. IS-300CA INVERTER POWER SUPPLY 3-50 990-418...
  • Page 81 STEP MODE signal. The force set in CO2/WE3 is output to the electro pneumatic proportional valve (ANALOG OUT), and CO2/WE3 and CONTINUE blink. The measured value input in the force input (ANALOG IN) is displayed at the monitor of CO2/WE3. IS-300CA INVERTER POWER SUPPLY 990-418 3-51...
  • Page 82 Set the valve # in the range of 1 to 4. EX SOL1 to EX SOL4 on the I/O terminal block. VALVE #1: EX SOL1 VALVE #3: EX SOL3 VALVE #2: EX SOL2 VALVE #4: EX SOL4 IS-300CA INVERTER POWER SUPPLY 3-52 990-418...

  • Page 83: Forge Valve

    (1ST and 2ND) input. m. SUCCESSIVE Used for the successive function. The welding is performed with SCHEDULEs with the successive setting in order each time the start signal (1ST and 2ND) is input. IS-300CA INVERTER POWER SUPPLY 990-418 3-53...

  • Page 84: Forge Delay

    This screen is used to make a measurement using a displacement gauge and set the weld stop function. a. SCHEDULE # Select from #001 to #255 to set the SCHEDULE. Normally select #001 first, then select additional schedules in sequential order. IS-300CA INVERTER POWER SUPPLY 3-54 990-418...
  • Page 85 (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 properly. f. DISPLACEMENT LIMIT g. DISPLACEMENT DELAY TIME IS-300CA INVERTER POWER SUPPLY 990-418 3-55...
  • Page 86 1: Mode using the electro pneumatic proportional valve. The electro pneumatic proportional valve (ANALOG OUT) is output.  At the operation of welding sequence, SQD, SQZ, WE1, CO1/WE2, CO2/WE3, and HOLD settings are output to the electro pneumatic proportional valve (ANALOG OUT). IS-300CA INVERTER POWER SUPPLY 3-56 990-418...
  • Page 87 AIR PRESSURE UNIT Select the unit of pneumatic pressure among Mpa, bar and psi. d. AIR CYLINDER DIAMATER Used when FORCE CONTROL MODE is 1 to 3. Set the diameter of pneumatic cylinder. IS-300CA INVERTER POWER SUPPLY 990-418 3-57...
  • Page 88 LOW. The force is applied by changing UP on the left side of CALIBRATION HIGH into DW and released by returning the setting to UP. About 80% of the maximum force is applied. Measure the force while the force is applied, and input the measured value in CALIBRATION HIGH. IS-300CA INVERTER POWER SUPPLY 3-58 990-418...
  • Page 89 Preparing for Operation Verify that the available electrical service meets the electrical requirements shown in Appendix A, Technical Specifications. The electrical and water supplies must also meet all applicable local, state, and federal safety standards. IS-300CA INVERTER POWER SUPPLY 990-380...
  • Page 90 READY 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. IS-300CA INVERTER POWER SUPPLY 990-414...
  • Page 91 SCHEDULE # and set new time and welding currents. Set the upper and lower limits on the Pendant screen for each MONITOR SET SCHEDULE 9. Begin welding following normal procedures. Adjust the settings as necessary. SCHEDULE IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 92  ...
  • Page 93 NO CURRENT E-07 NO CURRENT LEVEL is high. Set a lower NO CURRENT LEVEL. The fuse needs replacement. Contact Amada Fuse inside the equipment is blown. Weld Tech Connect toroidal coil, refer to Chapter 2, Toroidal coil is not connected.
  • Page 94 HEAT setting, including RATIO setting E-11 SET OVER is larger than maximum current value, Correct each setting. voltage, or power setting. HEAT setting, including RATIO setting is lower than minimum current value, voltage, or power setting. IS-300CA INVERTER POWER SUPPLY 990-...
  • Page 95 Built-in 24 VDC power supply on the Turn off the power and check the I/O CURRENT E-22 rear panel is shorted and overloaded. connection on the rear panel. (DC24V) SHORT E-23 The output cable is shorted. Check the output cable. CIRCUIT IS-300CA INVERTER POWER SUPPLY 990-...
  • Page 96 Counting has arrived at the tip change The time for a capacitor change is E-35 CAP CHANGE setting value. approaching. Check and reset it. CAP CHANGE STEPPER COUNT has completed final Dress or replace tip, then reset step. E-36 REQUIRED step. IS-300CA INVERTER POWER SUPPLY 990-...
  • Page 97 S QZ H OL D ( N ote 2 ) E N D ( N ote 3 ) Tb : Data co m mun icat ion t i me at end HE A T Ⅰ IS-300CA INVERTER POWER SUPPLY 990-...
  • Page 98 9600 bps. When the communication speed is 19200bps or 38400bps, the transmission time will be shorter. • Data transmission time when the communication speed is 9600 bps 132ms max. 42ms max. IS-300CA INVERTER POWER SUPPLY 990-...
  • Page 99 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. IS-300CA INVERTER POWER SUPPLY 990-...
  • Page 100 Section II: Repair Service, Storage, Shipment Repair Service If you have problems with your IS-300CA Power Supply that you cannot resolve, please contact our service department at the address, phone number, or e-mail address indicated in the Foreword of this manual.
  • Page 101 APPENDIX A TECHNICAL SPECIFICATIONS Specifications Parameter IS-300CA Basic / Advanced IS-300CA EtherNet/IP 269mm x 172mm x 660mm 269mm x 172mm x 573mm (H x W x D) Dimensions (Not including projection) (Not including projection) Weight Lbs (kg) 36.3lbs (16.5kg) 44lbs (20kg) 3-phase, 380–480 V AC or 200-240 V AC ±...
  • Page 102 APPENDIX A: TECHNICAL SPECIFICATIONS Parameter IS-300CA Basic / Advanced IS-300CA EtherNet/IP Transformer turns ratio * 1.0 – 199.9 (TURN RATIO) Transformer frequency * 600 – 3000 Hz (in units of 100 Hz) for Basic 600 – 1000 Hz (in units of 100 Hz) for Advanced / EtherNet/IP...
  • Page 103 APPENDIX A: TECHNICAL SPECIFICATIONS Parameter IS-300CA Basic / Advanced IS-300CA EtherNet/IP [WELD POWER] lamp [READY] lamp [START] lamp State indicator LED [WELD] lamp [TROUBLE] lamp [WELD ON/OFF] lamp Cooling method Forced air cooled Ambient temperature: +5 to +40°C Operating Humidity: 90% max.
  • Page 104 APPENDIX A: TECHNICAL SPECIFICATIONS Duty Cycles IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 105 I/O Configurations The I/O signals can be configured for SOURCING or SINKING. The IS-300CA Basic and Advanced come configured as SINKING. Customer can change the input terminals to SOURCING. The IS-300CA EtherNet/IP comes configured as SOURCING. Customer can change the input terminals to SINKING.
  • Page 106 NOTE: THIS COIL INPUT IS NOT CALIBRATED. The IS-300CA is calibrated with the Amada Weld Tech IT Transformers with built-in current coil. If a non-IT Transformer is used and an external coil is required, the COIL IN signal has to be re-...
  • Page 107 #5 -- Tx- RS-485 allows multiple Power Supplies to be daisy chained to a host. TRANSFORMER SENSING CONNECTOR OF SENSE CABLE TO IT TRANSFORMER DESCRIPTION Common (Thermostat) Thermostat Voltage Current Current Voltage Ground FRONT VIEW IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 108 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS DISPLACEMENT SENSOR CONNECTOR Advanced and EtherNet/IP Models ONLY Recommended Displacement Sensor: Heidenhain St3078 15-pin D-sub (female) DESCRIPTION GROUND 5 VOLT UNUSED A’ GROUND B’ 5 VOLT 13-15 UNUSED IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 109 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS Back connectors, Basic model Connector Pin out Comment FS-1 to TB1-17 (2 Connect any Amada Weld Tech Firing switch FS-2 to FTSW-3 EZ-AIR weld head firing switch FTSW-1 to GND FTSW-2 to TB1-16 (1...
  • Page 110 See DISPLACEMENT SENSOR Displacement CONNECTOR above See 26-pin D-Sub ANALOG Analog connector below J4-1,3 = E-Stop J4-1 to TB-1 J4-3,4 = Firing connector Firing switch / J4-2 to TB-3 E-Stop J4-3 to FTSW-3 J4-4 to TB-17 (2 IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 111 Pin 3: VALVE 3 Pin 4: VALVE 4 Valve OUT Pin 5: RETRACT 1 Pin 6: RETRACT 2 Pin 7: VALVE RELAY Pin 8: VALVE COM Pin 9: VALVE COM EtherNet/IP Connect to Allen Bradley PLC IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 112 NOTE: Signal sinking is shown for RETRACTION 1, RETRACTION 2, BACK STEP, STEP MODE. For sourcing connect pin 26 (24V) to the input switches instead of 24 GND. Configure EXT COM on TB1 connector to COM CAUTION: EtherNet/IP default is signal Sourcing. If switching to Sinking, disable EtherNet/IP IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 113 RETRACTION 2 can configure to signal Sinking, but EtherNet/IP will be disabled BACK STEP Advanced unit comes default with Signal Sinking. Customer can configure to signal Sourcing, STEP MODE +24VDC OUT MAX CURRENT DRAW: 100mA IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 114 T HE R M OST AT FL O WS W I T C H C O M E R R O R RESET STE P RE SET WE3 ST O P/ C O U NT RE SET IS-300CA INVERTER POWER SUPPLY B-10 990-418...
  • Page 115 NOTE: Signal sinking is shown for I/O’s. For Sourcing connect INT 24V to the input switches instead of COM (24V GND). Connect EXT COM to COM (24V GND) on TB1 connector (see also section Input Signal Connections below). CAUTION: EtherNet/IP default is signal Sourcing. If switching to Sinking, EtherNet/IP is disabled. IS-300CA INVERTER POWER SUPPLY 990-418 B-11...
  • Page 116 This pin allows for detection of failure resulting from a wire break in the schedule selection signal lines. Be sure that the total number of closed schedule selection and parity signal lines is always odd. IS-300CA INVERTER POWER SUPPLY B-12 990-418...
  • Page 117 Flow switch input pin. Opening this pin will result in a flow rate FLOWSWITCH error. 20ms or more is required for receiving the input signal. COM pin. This pin is internally connected to the GND chassis. IS-300CA INVERTER POWER SUPPLY 990-418 B-13...
  • Page 118 END, COUNT ERROR, READY, STEP END, WELD SIGNAL, OUT3 GOOD, COUNT UP, OUT I, OUT II (Refer to Chapter 3, Section 8. OUT4 Output Select Screen). IS-300CA INVERTER POWER SUPPLY B-14 990-418...
  • Page 119 It’s because the contents when stopped is displayed on the program unit. *2 When using 24 V DC solenoid, install diodes on measures to prevent surge voltage. Example; when inputting + to Pin 34 and – to Pin 35. ＋ － ＋ － IS-300CA INVERTER POWER SUPPLY 990-418 B-15...
  • Page 120 OUT I WELD1 weld end output. Closed between the WELD1 weld end and the beginning of HOLD. OUT II WELD2 weld end output. Closed between the WELD2 weld end and the beginning of HOLD. IS-300CA INVERTER POWER SUPPLY B-16 990-418...
  • Page 121 Input Signal Connections Connection with equipment having a contact input. Connect pins 1 and 2. Connection with equipment featuring NPN (sink) open collector output using internal +24VDC power supply. Connect pins 1 and 2. IS-300CA INVERTER POWER SUPPLY 990-418 B-17...
  • Page 122 Connect the positive side of an external 24 VDC power supply to pin 2. (Note) The circuit between pins 1-2-3, 4-5, 18-19-20, and 21-22 are closed when shipped. Disconnect unnecessary jumper wires referring to each connection. IS-300CA INVERTER POWER SUPPLY B-18 990-418...
  • Page 123 C: END signal output (depends on the END SIG.MODE setting if END signal output (no output if the welding sequence is halted) time the welding sequence is halted) Start Signal Input in Maintained Mode IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 124 A: DELAY START SET 2ND STAGE Schedule selection (1,2,4,8,16 32,64,128,P) Valve output (SOL1 or SOL2) Welding sequence B: Monitored value judgment time C: END signal output END signal output time Start Signal Input in Latched Mode IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 125 RC: Resistance pre-check time CP: Resistance judgment time (2ms) WELD1: 1st weld time COOL1: Cooling time 1 WELD2: 2nd weld time COOL2: Cooling time 2 WELD3: 3rd weld time HOLD: Hold time OFF: Off time IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 126 STAGE input for a period longer than that set for DELAYSTART SET. (Note 2) When the current gets out of the range of upper/lower limit judgment (ERROR) in a sequence, repetition operation ends even if the OFF time is set. IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 127 1 S T S T A GE 2 N D S T A GE S OL1/ S OL2 We ld ing current S Q D S QZ WEL D : DELAY START SET setting + Welding preparation time. Two-Stage Start IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 128 APPENDIX C: SYSTEM TIMING Repeat Operation Repeat operation will occur whenever the Off time is set to any value other than zero (0). Repeat Operation IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 129 SQZ→ WELD1→ INT1→ WELD1→ INT1→ WELD1→ INT1→ WELD2... (Note 2) Repeat operation times set for PULSATION2 in WELD2 and INT2 set times. (Note 3) Repeat operation times set for PULSATION3 in WELD3 and INT3 set times. IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 130 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 IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 131 APPENDIX C: SYSTEM TIMING 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). IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 132 (Note 3) The output signal No. of FORGE VALVE is 4 (EX SOL3) when VALVE# is set to “1”, and 5(EX SOL4) on the 25-pin D-Sub connector when VALVE# is set to “2”. IS-300CA INVERTER POWER SUPPLY C-10 990-418...
  • Page 133 APPENDIX C: SYSTEM TIMING The timing charts below are for IS-300CA Advanced ONLY CHAINING Function This function can call up welding multiple SCHEDULEs in order to perform them while the 1ST STAGE signal and the 2ND STAGE signal are input.
  • Page 134 B A C K S TE P ( in ) T1 : T i me set by [ DEL A Y S T A RT SE T] T2 : Durat ion o f E N D output s igna l IS-300CA INVERTER POWER SUPPLY C-12 990-418...
  • Page 135 Weld1 stop (WE1) When the displacement weld stop (DISPLC) is set to the weld1 stop on the DISPLACEMENT screen and the displacement sensor arrives at the set displacement (f in the above figure), the weld1 IS-300CA INVERTER POWER SUPPLY 990-418 C-13...
  • Page 136  The displacement between “k” and “j” is the monitor displacement (WORK DETECT MONITOR) for work detection.  The displacement between “j” and “i” is the monitored value of the final displacement (DISPLACEMENT MONITOR). IS-300CA INVERTER POWER SUPPLY C-14 990-418...
  • Page 137 Section II. Communications Protocol and Commands. Using these codes, users can write customized software for controlling all functions of the welding control and interfacing the unit to automation control systems. IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 138 APPENDIX D: COMMUNICATIONS Section II. External Communication Function Introduction The IS-300CA can be used to set schedules from an externally-connected personal computer (abbreviated as PC) or to read monitored data and several kinds of status data. Data Transmission ITEM CONTENT...
  • Page 139 (Note 3) The RS-232C/RS-485 conversion adapter is not included in the accessories. It is required to prepare the adapter at customer’s side. RS-232C ○ Host Computer Device No.1 Only a single device can be connected. RS-232C IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 140 APPENDIX D: COMMUNICATIONS Protocol 1. Single-directional Communication Mode (When --> is selected at COMM CONTROL in MODE SELECT Screen) a) Monitor Data IS-300CA Basic Data strings: !01001:m,120,1.20,0.50,00.60,20.0,200,2.00,1.50,03.00,40.0, A B C D 300,2.50,2.00,05.00,50.0,2,0010,5,0100,2222,555555[CR][LF] IS-300CA Advanced / EtherNet/IP Data strings: !01001:m,120,01.20,0.50,00.60,20.0,200,02.00,1.50,03.00,40.0, A B C D 300,02.50,2.00,05.00,50.0,2,0010,5,0100,1,0000,1,0000,01,100,...
  • Page 141 COUNT of WORK) COUNTER (WORK of Fixed to 6 digits (000000 to 999999) TOTAL/GOOD/WORK) The following additional commands are for IS-300CA Advanced / EtherNet/IP only: STEP No. of VALVE4 Fixed to 1 digit (1 to 9) STEP COUNT of VALVE4...
  • Page 142 Fixed to 2 digits (01 to 39) Error code 8 Fixed to 2 digits (01 to 39) *1 The maximum number of Error Codes is five for IS-300CA Basic and eight for Advanced / EtherNet/IP Models. In the case of only one error code, the error codes D to G (Basic) and D to J (Advanced / EtherNet/IP ) are omitted.
  • Page 143 IS-300CA 1) Schedule numbers, SH1, SH2 and SH3 are fixed to 000. However, schedule numbers are sent from IS-300CA when “E06: Current error”, “E18: Voltage error”, “E19: Electric power error” and “E07: Pulse width error” occurs. 2) Screen numbers, SC1 and SC2 are fixed to 07.
  • Page 144 4) The set data is returned as a confirmation data. When data which is outside the range is set, previous data is returned. 5) It takes about 1 second at most to save data into the internal memory (READY is turned off during saving). Be careful when writing continuously. IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 145 000 to 050 (CYC mode) 000 to 999(ms mode) DOWN3 / Downslope 3 time nnn, 000 to 050 (CYC mode) 00000 to 20000 (ms mode) HOLD / Hold time nnnnn, 00000 to 00999 (CYC mode) IS-300CA INVERTER POWER SUPPLY 990-418...
  • Page 146 INT1 / Interval 1 nnn, 000 to 050 (CYC mode) PULSATION of WE2 / WE2 01 to 19 repetition 000 to 999 (ms mode) INT2 / Interval 2 nnn, 000 to 050 (CYC mode) IS-300CA INVERTER POWER SUPPLY D-10 990-418...
  • Page 147 Fixed to 4 digits (10.0 to 99.9) (%) PULSE LIM of WE3 nn.n Fixed to 4 digits (10.0 to 99.9) (%) The following is additional data for IS-300CA Advanced / EtherNet/IP MAX CURRENT nnn, 01 to 280 (kA) TRANS# 1 to 5 *1 The setting of ms/CYC cannot be changed.
  • Page 148 POWER H of WE3 (upper limit) nnn.n, 000.0 to 999.9 (kW) nn.nn, 00.00 to 99.99 (kW) POWER L of WE3 (lower limit) nnn.n, 000.0 to 999.9 (kW) PULSE H of WE3 (upper limit) nnn.n 010.0 to 100.0 (%) IS-300CA INVERTER POWER SUPPLY D-12 990-418...
  • Page 149 050 to 200 (%) STEP8 COUNT of VALVE2 nnnn, 0000 to 9999 STEP8 RATIO of VALVE2 nnn, 050 to 200 (%) STEP9 COUNT of VALVE2 nnnn, 0000 to 9999 STEP9 RATIO of VALVE2 050 to 200 (%) IS-300CA INVERTER POWER SUPPLY 990-418 D-13...
  • Page 150 APPENDIX D: COMMUNICATIONS Screen 03 (STEPPER data) Common data (Valve No.: 001 IS-300CA Advanced / EtherNet/IP to 004) Example of data writing: #01W001S03:1,0000,0,0000,100,0,0000,100,0,0000,100,0,0000,100,0,0000,100,0,0000,100,0,000 0,100,0,0000,100,0,01,0000 [CR][LF] Character Item Contents Range String START ON STEP # 1 to 9 COUNT of STEP1...
  • Page 151 0000 to 9999 STEP # of VALVE2 1 to 9 STEPPER COUNT of VALVE2 nnnn, 0000 to 9999 COUNTER (WELD/WELD nnnn, 0000 to 9999 COUNT of WORK) COUNTER (WORK of nnnnnn 000000 to 999999 TOTAL/GOOD/WORK) IS-300CA INVERTER POWER SUPPLY 990-418 D-15...
  • Page 152 APPENDIX D: COMMUNICATIONS Screen 04 (MONITOR data) (Data reading only) Specific IS-300CA Advanced / EtherNet/IP data in accordance with Schedule No. (Schedule No.: 001 to 255) Character Item Contents Range String Unit of time m: ms C: CYC 000 to 999 (ms mode)

  • Page 153: Items Inhibited From Setting (When Setting Data, Omit These Items.)

    Character Item Contents Range String POWER SOURCE FREQUENCY 50 or 60 (Hz) Model name nnnnnnnn, IS-300A is same as IS-300CA ROM VERSION Vnn-nnn, V00-00A ~ DELAY START SET 01 to 20 (ms) 0: LATCHED 1: PULSED 2: MAINTAINED START SIGNAL MODE...
  • Page 154 0: OFF 1: ON *1 Items inhibited from setting (When setting data, omit these items.) “,” is not transmitted, too. In other words, the 4th item (DELAY START SET) will be the first data. IS-300CA INVERTER POWER SUPPLY D-18 990-418...
  • Page 155 Character Item Contents Range String POWER SOURCE FREQUENCY 50 or 60 (Hz) Model name nnnnnnnn, IS-300A is same as IS-300CA ROM VERSION Vnn-nnn, V00-00A DELAY START SET 01 to 20 (ms) 0: LATCHED 1: PULSED START SIGNAL MODE 2: MAINTAINED...

  • Page 156: Is Not Transmitted, Too

    1:COUNTERROR OUTPUT2 2:READY OUTPUT3 3:STEPEND OUTPUT4 4:WELDSIGNAL 5:GOOD 6:COUNTUP OUTPUT5 7:OUTI 8:OUTII DISPL SENSOR STEP 0.5 to 5.0(um) *1 Items inhibited from setting (When setting data, omit these items.) “,” is not transmitted, too. IS-300CA INVERTER POWER SUPPLY D-20 990-418...
  • Page 157 The number of Error Codes is of five max. In the case of only one error code, the items 2 to 5 are omitted. For Error Codes, see Chapter 5, Maintenance. Screen 07 (Error data) Common data (Schedule No.: 000) IS-300CA Advanced / EtherNet/IP  Error data confirmation (Data reading only) Character...

  • Page 158: Table Of Contents

    APPENDIX D: COMMUNICATIONS : Screen 08 FORCE SETUP screen Specific data in accordance IS-300CA Advanced / EtherNet/IP with Schedule No. (Schedule No.: 001 to 255) Example of data writing: #01W001S08:1,02000,02100,02200,02300,02400,02500,1,0,0,00000,0 [CR][LF] Character Item Contents Range String STEP MODE 0:OFF 1:ON...

  • Page 159: Nnnnn, Nnnnn, Nnnnn, Nnnnn

    APPENDIX D: COMMUNICATIONS : Screen 09 DISPLACEMENT screen Specific data in accordance IS-300CA Advanced / EtherNet/IP with Schedule No. (Schedule No.: 001 to 255) Example of data writing: #01W001S09:0,0,0,0000000,0000000,0000000,+00.000,+00.000,+00.000,+00.000,000 [CR][LF] Character Item Contents Range String 0:OFF WELD1STOP INPUT 1:DISPLC WELD2STOP INPUT...
  • Page 160 APPENDIX D: COMMUNICATIONS Screen 10 PRESSURE REGULATOR screen Common data IS-300CA Advanced / EtherNet/IP (Schedule No.: 000) Example of data writing: #01W000S10:1,0,0,200.0,0.40,00000,00000,00000,000.0,0.00,00000,00000,00000 [CR][LF] Character Item Contents Range String FORCE CONTROL MODE 1 to 4 FORCE UNIT 0:N 1:kgf 2:lbf AIR PRESSURE UNIT 0:Mpa 1:bar 2:psi AIR CYLINDER DIAMETER of VALVE1 nnn.n,...
  • Page 161 Introduction ® This appendix will provide the instructions on how to setup the connectivity from an Allen Bradley PLC to the Amada Miyachi IS-300CR Inverter Power Supply via an EtherNet/IP bus controller (X20BC0088). The machine builder / user who integrates the IS-300CR EtherNet/IP ®...
  • Page 162 APPENDIX E: EtherNet/IP COMMUNICATIONS System Hardware Overview IS-300CR INVERTER POWER SUPPLY 990-418...
  • Page 163 APPENDIX E: EtherNet/IP COMMUNICATIONS Section II. Setting up the Bus Controller IP Address By default, the bus controller is pre-configured with an IP address of 192.168.100.1 (subnet ® 255.255.255.0). If the Allen Bradley PLC also has a pre-configured IP address in this range (ex. 192.168.x.x), then the bus controller IP address does not need to be modified.
  • Page 164 APPENDIX E: EtherNet/IP COMMUNICATIONS Setting up the Local Area Connection Set the IP address on your PC: 192.168.100.x (example: 192.168.100.10) Note: Do not set “x” to 1, this IP address is reserved for the Bus Controller Connect the PC/Laptop directly to the first network connection port on the Bus Controller with a CAT 5E cable as shown on the right.
  • Page 165 APPENDIX E: EtherNet/IP COMMUNICATIONS Now the web server can be started from any browser by calling the IP address 192.168.100.1. Go to > Advanced Network and Select on [Login]. Parameters Enter the User name and Password as shown, then select [OK]. User name: admin Password: X20BC0088 Now the bus controller IP address can be...
  • Page 166 APPENDIX E: EtherNet/IP COMMUNICATIONS Section III. Configuring the Bus Controller with an Allen ® Bradley There are two options on how to add a Bus Controller Ethernet communication module to an Allen ® Bradley PLC .ACD project. • Option 1 - Add an Ethernet communication module to a new ACD project on an Allen Bradley ®...
  • Page 167 APPENDIX E: EtherNet/IP COMMUNICATIONS Option 1 – Add Ethernet Communication Module to New ACD Project ® Allen Bradley 1769 PLC If the machine builder PLC is either an AB1769, there is already a pre-configured, tested, sample of IS_1769_L32E.ACD (respectively) included in the installation package that contains the PLC programming routines and logic ready for controlling the IS-300CR digital I/O and reading/writing serial communication data.
  • Page 168 APPENDIX E: EtherNet/IP COMMUNICATIONS Example 2: IS_1769_L32E.ACD has the Bus Controller IP address pre-assigned with 10.0.0.1. Before downloading this opened ACD project, make sure the Project Path to the controller backplane is set correctly. If not, select the [Who Active] icon to select and set the correct PLC path. IS-300CR INVERTER POWER SUPPLY 990-418...
  • Page 169 APPENDIX E: EtherNet/IP COMMUNICATIONS ® Other Allen Bradley PLC’s If the machine builder PLC is NOT AB1769, the machine builder can open either the included IS_1769_L32E.ACD (respectively) and convert to their Allen Bradley controller type. The sample steps below demonstrate how to open an existing IS_1769_L32E.ACD and convert it to the machine ®...
  • Page 170 APPENDIX E: EtherNet/IP COMMUNICATIONS Then select [YES] to confirm If the ACD project is converted successfully, it should include the Ethernet communication module as shown below. All of the Controller Tags, Task program routines and Data Types should be converted and included as well.
  • Page 171 APPENDIX E: EtherNet/IP COMMUNICATIONS The machine builder/user would only need to verify that the bus controller IP address to connect to is correct by double-clicking on the ETHERNET-MODULE ST1 to open the Module Properties Report window and verify the IP address. If for some reason the ACD controller type conversion failed to add the Ethernet Communication Module, follow the steps under the next section (Option 2) on how to add the Ethernet communication module.
  • Page 172 APPENDIX E: EtherNet/IP COMMUNICATIONS Option 2 – Add Ethernet Communication Module to an Existing ACD ® If the machine builder already has an existing functional Allen Bradley PLC ACD project, this option will show how to add the Ethernet module through the RSLogix5000 backplane and import the data types, tags and program routines.
  • Page 173 APPENDIX E: EtherNet/IP COMMUNICATIONS ® When the New Module window is opened, enter the name LocalENB and IP Address of the Allen Bradley PLC. In this example, the IP address 10.0.0.2 is used. Under the Electronic Keying selection, choose the Disable Keying selection. Select [OK] when finished. IS-300CR INVERTER POWER SUPPLY 990-418 E-13...
  • Page 174 APPENDIX E: EtherNet/IP COMMUNICATIONS Then highlight the Ethernet item, perform a right-mouse select and select . When the New Module Select Module Type window appears, enter the word Generic in the search field to search for all of Generic Ethernet modules and select the Generic Ethernet Module .
  • Page 175 APPENDIX E: EtherNet/IP COMMUNICATIONS Select the “Connection” tab and change the highlight fields as shown below: • Requested Packet Interval (RP1) from 10.0ms to 1.0ms • Uncheck the Use Unicast Connection over EtherNet/IP Select [OK] when changes are complete. IS-300CR INVERTER POWER SUPPLY 990-418 E-15...
  • Page 176 APPENDIX E: EtherNet/IP COMMUNICATIONS Importing Data Types Under > , select User-Defined and perform a right-mouse select. Select the Data Types User-Defined Import option from the popup menu. When the Import Data Type window appears, navigate to the installation package \IS_Series_AB_EthernetIP\RSLogix_PLC\Importable\DataTypes folder. Select each of the *.L5X items from this folder to import the data types.
  • Page 177 APPENDIX E: EtherNet/IP COMMUNICATIONS Select the “ANALOG_INPUTS.L5X” item and select the [Import] button. When the Import Configuration window opens, select [OK] to continue. Repeat the import steps until all of *.L5X data type items get imported into the ACD project. IS-300CR INVERTER POWER SUPPLY 990-418 E-17...
  • Page 178 APPENDIX E: EtherNet/IP COMMUNICATIONS Task Programs / Routines Under > , select MainTask and perform a right-mouse select. Select the option Tasks MainTask Import from the popup menu. When the Import Program window is opened, navigate to the installation package \IS_Series_AB_EthernetIP\RSLogix_PLC\Importable\programs folder. Select each of the *.L5X item from this folder to import the programs.
  • Page 179 APPENDIX E: EtherNet/IP COMMUNICATIONS When the Import Configuration window is open, select [OK] to continue. Repeat the import steps until all of *.L5X program items get imported into the ACD project. IS-300CR INVERTER POWER SUPPLY 990-418 E-19...
  • Page 180 APPENDIX E: EtherNet/IP COMMUNICATIONS Controller Tags From the Tools menu, select > Import Tags and Logic Comments… When the Import window opens, navigate to the installation package \IS_Series_AB_EthernetIP\ RSLogix_PLC\Importable\Tags folder and select the IS800-Controller-Tags.CSV item. Select [Import] to continue. Before downloading this machine builder ACD project to the PLC and Go Online in the RUN mode, make sure the Project Path to the controller backplane is set correctly.
  • Page 181 APPENDIX E: EtherNet/IP COMMUNICATIONS Section IV. System Configurations Communication Settings Before running the RSLogix 5000 PLC and putting it online to communicate with the IS-300CR via the bus controller, make sure the serial communication mode is configured correctly in the MA-660 Pendant.
  • Page 182 APPENDIX E: EtherNet/IP COMMUNICATIONS From the Menu screen, select the [NG Signal Select] and make sure the ERROR OUTPUT MODE is set as [N.O] normal open. IS-300CR Type Settings Each IS-Series type will have a different range of power level and limitations and must be specified so ®...
  • Page 183 APPENDIX E: EtherNet/IP COMMUNICATIONS Section V. Digital/Analog I/O’s and Weld Data Controls When online with the CPU in RSLogix 5000, the IS-300CR digital and analog inputs / outputs and screen data can be accessed and controlled through the Controller Tags. The controllable input and output tags of IS-300CR are defined under the “ioControl”...
  • Page 184 APPENDIX E: EtherNet/IP COMMUNICATIONS IO Read / Write Control Tags Write request flag. Set this flag to 1 when the screen data is ioControl.com.writeToIS800 populated and ready to be written to the IS-300CR. After the data is written, this flag will get reset back to 0. The PLC program should also monitor for the ioControl.com.writeNakError flag for write failure/error.
  • Page 185 APPENDIX E: EtherNet/IP COMMUNICATIONS These controller tags contain the mask bits to control the IS-300CR digital inputs. The PLC program is responsible for setting and clearing the bit tag since it doesn’t self-clear like the request flag tags. For example; to select schedule number 5 via digital inputs, ioControl.do.schdule1DO1_1 and ioControl.do.schdule4DO3_1 must be set to 1.
  • Page 186 APPENDIX E: EtherNet/IP COMMUNICATIONS These controller tags contain the IS-300CR digital outputs. These tags are read only tag from the IS-300CR digital outputs. The ioControl.di.out1 …. ioControl.di.out5 contain the assigned outputs from the Output Select Menu on the MA-660A pendant. No good weld output 1 error ioControl.di.ng1OutErrorDI1 No good weld output 2 caution...
  • Page 187 APPENDIX E: EtherNet/IP COMMUNICATIONS Analog Input / Output Tags IS-300CR analog output 1. ioControl.ai.analogIn1AI1 Output voltage can be +/- 10 volt. IS-300CR analog output 2. ioControl.ai.analogIn2AI2 Output voltage can be +/- 10 volt. IS-300CR analog output 3. ioControl.ai.analogIn3AI3 Output voltage can be +/- 10 volt. IS-300CR analog output 4.
  • Page 188 APPENDIX E: EtherNet/IP COMMUNICATIONS Screen Data Tags The PLC program can also request screen data for each of the 10 screens. Refer to the example in the Screen Data and Weld Control section below for steps to request screen data and write/update the screen data via the controller screen data tags.
  • Page 189 APPENDIX E: EtherNet/IP COMMUNICATIONS Screen Data and Weld Control To read and write the weld screen data and/or weld schedule data, refer to the next two sections for the steps and tags required to populate the read request and the write update. It is recommended the PLC program initialize/reset the data on PLC program startup before performing a read and write request of the serial data.
  • Page 190 APPENDIX E: EtherNet/IP COMMUNICATIONS Once the screen data is successfully read, the ‘ioControl.com.readFromIS800’ read request tag will be reset back to 0. The data for screen 1, schedule 1 will be populated into each field individually IS-300CR INVERTER POWER SUPPLY E-30 990-418...
  • Page 191 APPENDIX E: EtherNet/IP COMMUNICATIONS Writing Screen Data to the IS-300CR To update the screen data, user must first populate every individual screen data tag with the validated data value. User may also perform a screen data read request and then modify / update only the value of the tag that the user wants to change.
  • Page 192 APPENDIX E: EtherNet/IP COMMUNICATIONS Weld Control via Digital Input Tags To perform a weld via the IS-300CR digital inputs, the machine builder PLC can program the controller digital input tags to control the weld process. For example, to select the weld schedule number 2 and command the weld, the PLC program must set these tags as: Must turn on the Weld ON/OFF to ON ioControl.do.weldOnOffDO3_2 = 1...
  • Page 193 APPENDIX E: EtherNet/IP COMMUNICATIONS Section VI. Weld Schedule Controller Software Application Besides controlling the IS-300CR inverter power supply via a supplied MA-660A pendant, an IS-300CR that has built-in EtherNet/IP connectivity can also be controlled with the “IS-300CR Weld Controller Windows Software” Application. The “IS-300CR Weld Controller Windows Software” Application ®...
  • Page 194 APPENDIX E: EtherNet/IP COMMUNICATIONS • Now change the IP Address as shown above to “10.0.0.2”. • Save and close this notepad file when completed. • From the \IS_Series_AB_EthernetIP\Windows_EthernetIP_WeldControl\ folder, select the file “IS800-IS1400EIPControl.reg” • Double-click on this file to open it. •...
  • Page 195 APPENDIX E: EtherNet/IP COMMUNICATIONS • Make sure that the Allen Bradley ® PLC is online and running in remote RUN mode. From the \IS_Series_AB_EthernetIP\Windows_EthernetIP_WeldControl\ folder, double-click on the “IS800-IS1400EIPControl.exe” to start the Welder Controller Application. The Controller IP Address field should now show the “10.0.0.2” address. IS-300CR INVERTER POWER SUPPLY 990-418 E-35...
  • Page 196 APPENDIX E: EtherNet/IP COMMUNICATIONS IS-300CR Weld Schedule Controller Screens There are 10 different controlled screens with data similar to the screens on the MA-660A pendant. To access the weld schedule for each screen on the IS-300CR, the user must populate the Schedule # field with the schedule number and select the [Read] button.
  • Page 197 APPENDIX E: EtherNet/IP COMMUNICATIONS Monitor Set Screen Stepper Count Screen IS-300CR INVERTER POWER SUPPLY 990-418 E-37...
  • Page 198 APPENDIX E: EtherNet/IP COMMUNICATIONS Monitor Screen (READ ONLY) Pre-Check Screen IS-300CR INVERTER POWER SUPPLY E-38 990-418...
  • Page 199 APPENDIX E: EtherNet/IP COMMUNICATIONS System Mode Screen System Select Screen IS-300CR INVERTER POWER SUPPLY 990-418 E-39...
  • Page 200 APPENDIX E: EtherNet/IP COMMUNICATIONS Force Setup Screen Displacement Screen IS-300CR INVERTER POWER SUPPLY E-40 990-418...
  • Page 201 APPENDIX E: EtherNet/IP COMMUNICATIONS Pressure Regulator Screen Digital I/O Checker Screen IS-300CR INVERTER POWER SUPPLY 990-418 E-41...
  • Page 202 APPENDIX E: EtherNet/IP COMMUNICATIONS Section VII. Bus Controller Diagnostic Status and Wiring Diagrams ® The X20BC0088 bus controller makes it possible to connect the X20 I/O modules to the Allen Bradley PLC via EtherNet/IP . Once the bus controller is properly configured and powered up, it should ®...
  • Page 203 APPENDIX E: EtherNet/IP COMMUNICATIONS Bus Controller I/O Wiring Diagrams XC20BC0088 – Controller Module LED status indicators Network address switches Terminal block for bus controller and I/O supply Ethernet/IP connection with 2x RJ45 ports for easy wiring X20 PS9400 – I/O Supply Module IS-300CR INVERTER POWER SUPPLY 990-418 E-43...
  • Page 204 APPENDIX E: EtherNet/IP COMMUNICATIONS X20 CS1020 – RS-232 Communication Module X20DO9322 – Digital Output Module 1 The digital output signals from this module are wired to the digital input pins on the IS-300CR terminal block. Connection example: IS-300CR INVERTER POWER SUPPLY E-44 990-418...
  • Page 205 APPENDIX E: EtherNet/IP COMMUNICATIONS X20DO9322 – Digital Output Module 2 The digital output signals from this module are wired to the digital input pins on the IS-300CR terminal block. Connection example: X20AO2622 – Analog Output Module The analog output signals from this module are wired to the analog input pins on the IS-300CR terminal block.
  • Page 206 APPENDIX E: EtherNet/IP COMMUNICATIONS X20AI4622 – Analog Input Module The analog output signals from the IS-300CR terminal block are wired to this module. Connection example: X20DI9371 – Digital Input Module The digital output signals from the IS-300CR terminal block are wired to this module. Connection example: IS-300CR INVERTER POWER SUPPLY E-46...
  • Page 207 TEL. +1-626-303-5676 FAX, +1-626-358-8048 http://www.amadaweldtech.com AMADA WELD TECH CO., LTD. 200, Ishida, Isehara-shi, Kanagawa 259-1196, Japan AMADA WELD TECH KOREA CO., LTD. 28, Dongtanhana 1-gil, Hwaseong-si, Gyeonggi-do, 18423, Korea TEL. +82-31-8015-6810 FAX. +82-31-8003-5995 AMADA WELD TECH SHANGHAI CO., LTD. Unit 401, A206(C8), No. 77, Hongcao Road, Xuhui District, Shanghai, China TEL.
  • Page 208 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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