Amada S-2200CA Operation Manual
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Amada S-2200CA Operation Manual

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INVERTER POWER SUPPLY
IS-2200CA/4500CA
OPERATION MANUAL
990-412 REV G

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  • Page 1 INVERTER POWER SUPPLY IS-2200CA/4500CA OPERATION MANUAL 990-412 REV G...
  • Page 2 Copyright  2016 - 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 Should any questions arise, or if you have suggestions for improvement of this manual, please contact us at the above location/numbers. AMADA WELD TECH is not responsible for any loss due to improper use of this product. This manual covers the following models:...
  • Page 4 CONTENTS Page Chapter 1. System Description Section I: Features ..........................1-1 Basic and Advanced Units ....................... 1-1 Section II: System Components for IS-2200CA ..................1-3 Front Panel ............................. 1-3 WELD POWER Lamp ......................1-3 READY Lamp .......................... 1-3 START Lamp ........................... 1-3 WELD Lamp ..........................
  • Page 5 CONTENTS (Continued) Page Power and Ground Connections ....................1-13 Input Power Connections ....................... 1-13 Circuit Breaker ........................1-14 Grounding Lug ........................1-14 Output Power Connections ..................... 1-14 Rear Panel Base Connections ......................1-14 Cooling Water Fittings ......................1-14 Secondary Current Sensor Input Connector ................1-14 Section IV: MA-660A Program Unit (“The Pendant”) ................
  • Page 6 CONTENTS (Continued) Page IS-4500CA Cooling Water Requirements ..................2-16 IS-4500CA Cooling Water Hose Connections ................2-16 Chapter 3. IS-2200CA/4500CA: Using Programming Functions Introduction ............................3-1 1. MENU Screen ..........................3-1 2. POWER SUPPLY STATE Screen ....................3-2 SCHEDULE Screen ......................... 3-3 CURRENT and TIME Setting Screen ..................
  • Page 7 CONTENTS (Continued) Page STEP RATIO .......................... 3-15 CAP CHANGE ........................3-16 TOTAL COUNTER ....................... 3-16 MONITOR SET Screen ......................... 3-18 SCHEDULE .......................... 3-18 TIME ............................3-18 CURRENT ..........................3-18 VOLTAGE ..........................3-18 POWER ..........................3-18 PULSE ............................ 3-19 6. NG SIGNAL SELECT Screen ...................... 3-19 ERROR OUTPUT MODE .....................
  • Page 8 CONTENTS (Continued) Page 10. MONITOR MODE Screen ......................3-36 PRESET TOTAL COUNT ..................... 3-37 NO CURRENT TIME ......................3-40 NO CURRENT LEVEL ......................3-40 NO VOLTAGE LEVEL ......................3-40 MONITOR FIRST TIME ....................... 3-41 MONITOR SLOPE MODE ....................3-41 WELD STOP OFF TIME ....................... 3-41 11.
  • Page 9 CONTENTS (Continued) Page FORGE DELAY ........................3-54 FORGE MODE ........................3-54 17. DISPLACEMENT Screen ......................3-55 SCHEDULE # ........................3-55 WELD STOP INPUT ......................3-55 WELD STOP CONDITION ....................3-55 WORK DETECT LIMIT ....................... 3-55 WORK DETECT MONITOR ....................3-56 DISPLACEMENT LIMIT ......................
  • Page 10 CONTENTS (Continued) Page Section III: Fuse Failure and Replacement .................... 5-9 IS-2200CA Power Supply ........................ 5-9 Fuse /Component Locations ....................5-10 Main PCB ..........................5-11 Fuse Board ..........................5-11 IS-4500CA Power Supply ......................5-12 Fuse /Component Locations ....................5-12 Main PCB ..........................5-13 Fuse Board ..........................
  • Page 11 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-2200CA/4500CA INVERTER POWER SUPPLY...
  • Page 12 Before using this equipment, read the SAFETY PRECAUTIONS carefully to understand the correct usage of the equipment. • These precautions are given for safe use of the Inverter Power Supply and for prevention of injury to operators or others. • Be sure to read each of the instructions, as they are all important for safe operation.
  • Page 13 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 14 CAUTION Apply the specified source voltage. Applying the wrong voltage can cause fire and electrical shock. Keep water and water containers away from the Power Supply. Water spilled on the Power Supply can cause a short circuit, electrical shock, or fire. Use proper tools (wire strippers, pressure wire connectors, etc.) for terminations of the connecting cables.
  • Page 15 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 16 7. Inspection and Rejection of Nonconforming Goods. (a) Buyer shall inspect the Goods within two (2) days of receipt (“Inspection Period”). Buyer will be deemed to have accepted the Goods unless it notifies Seller in writing of any Nonconforming Goods during the Inspection Period and furnishes such written evidence or other documentation as required by Seller.
  • Page 17 (c) All patents, trademarks, copyrights or other intellectual property rights embodied in the Goods, including without limitation the Software, are owned by Seller and its licensors. Seller and its licensors retain all right, title and interest in such intellectual property rights. Except as expressly set forth herein, no license rights or ownership in or to any of the foregoing is granted or transferred hereunder, either directly or by implication.
  • Page 18 (b) IN NO EVENT SHALL SELLER’S AGGREGATE LIABILITY ARISING OUT OF OR RELATED TO THIS AGREEMENT, WHETHER ARISING OUT OF OR RELATED TO BREACH OF CONTRACT, TORT (INCLUDING NEGLIGENCE) OR OTHERWISE, EXCEED THE TOTAL OF THE AMOUNTS PAID TO SELLER FOR THE GOODS SOLD HEREUNDER.
  • Page 19 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 delay in fulfilling or performing any term of this Agreement when and to the extent such failure or delay is caused by or results from acts or circumstances beyond the reasonable control of Seller including, without limitation, acts of God, flood, fire, earthquake, explosion, governmental actions, war, invasion or hostilities (whether war is declared or not), terrorist threats or acts, riot, or other civil unrest, national emergency, revolution, insurrection, epidemic, lock-outs, strikes or other labor disputes (whether or not relating to either party’s workforce), or restraints or delays affecting carriers or inability or delay in obtaining supplies...
  • Page 20  ...
  • Page 21 The AMADA WELD TECH IS-2200CA/4500CA is an inverter-type power supply specially designed to be used for spot welding and fusing. The AMADA WELD TECH IS-2200CA/4500CA will simply be referred to as the Power Supply , unless a feature or procedure unique to a specific model is described.
  • Page 22 CHAPTER 1: SYSTEM DESCRIPTION • Seven protective functions for maximum ease of operation:  No-current / no-voltage  Over current  Temperature  Self diagnostics  Grounding error  Load short error  Phase error • Circuit breaker is included (IS-2200CA: 800 amps; IS-4500CA: 1200 amps). •...
  • Page 23 CHAPTER 1: SYSTEM DESCRIPTION Section II: System Components for IS-2200CA Front Panel WELD POWER Lamp Indicator that lights when the power is supplied to the Power Supply. READY Lamp Indicator that lights when the system is ready to start welding. For this status to exist, the following conditions must be met: •...
  • Page 24 CHAPTER 1: SYSTEM DESCRIPTION Internal Components DANGER touch the inside of the Power Supply for at least 20 minutes after power down, since you may get a severe electric shock. NOTE: There are minor differences between the size and connector locations between the IS-2200CA and the IS-4500CA, but in all other respects the internal components of the two models are identical.
  • Page 25 CHAPTER 1: SYSTEM DESCRIPTION Connecting Terminal Strip for External Input / Output Signals Used to input start signals and output trouble signals. IS-2200CA/4500CA INVERTER POWER SUPPLY 990-412...
  • Page 26 CHAPTER 1: SYSTEM DESCRIPTION CHARGE INDICATOR Lamp DANGER Lethal voltages are present when the capacitors are charged. Do touch the interior Leave it alone for at least 20 minutes of the Power Supply when the LED is ON. after turning the Power Supply OFF. DO NOT REMOVE SHIELD WITH POWER ON OR OPERATE THE MACHINE WITH SHIELD REMOVED! THIS WILL RESULT IN DEATH.
  • Page 27 CHAPTER 1: SYSTEM DESCRIPTION External Connections Cooling Water Pipe Connectors Located on the bottom of the unit. Used for the supply (input) and drain (output) of cooling water, which cools the inside of the enclosure and power supply unit. Fittings: 1/2" FNPT BOTTOM VIEW IS-2200CA/4500CA INVERTER POWER SUPPLY 990-412...
  • Page 28 CHAPTER 1: SYSTEM DESCRIPTION RS-485/RS-232C Connector For external communication see Appendix E, Communications. TRANSFORMER SENSING CONNECTOR (Optional Toroidal Coil) The Toroidal Coil is attached on the transformer away from the Power Supply. The signal comes through on bottom of Power Supply. The coil is used for the TRANSFORMER SENSING CONNECTOR secondary constant-current effective value control and secondary constant-power effective value control.
  • Page 29 CHAPTER 1: SYSTEM DESCRIPTION Section III: System Components for IS-4500CA Front Panel IS-2200CA/4500CA INVERTER POWER SUPPLY 990-412...
  • Page 30 CHAPTER 1: SYSTEM DESCRIPTION – Used to connect the MA-660A Program Unit. CONTROL AND MONITOR UNIT CONNECTOR WELD POWER Lamp – Indicator that lights when power is supplied to the Power Supply. READY Lamp – Indicator that lights when system is ready to start welding. For this status to exist, the following conditions must be met: •...
  • Page 31 CHAPTER 1: SYSTEM DESCRIPTION IS-2200CA/4500CA INVERTER POWER SUPPLY 990-412 1-11...
  • Page 32 CHAPTER 1: SYSTEM DESCRIPTION – The Power Module contains the IS-4500CA Power Modules. Power Module Main PCB – This is the Main Control PCB that operates the IS-4500CA. – This expansion board controls multiple valve outputs, the displacement ME-3050 Expansion Board input and the proportional valve outputs.
  • Page 33 CHAPTER 1: SYSTEM DESCRIPTION Power and Ground connections – Input power is brought into the Power Supply through an access plate in the Input Power Connections 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.
  • Page 34 CHAPTER 1: SYSTEM DESCRIPTION – Input power cables are Circuit Breaker connected to the Circuit Breaker. NOTE: The internal connections are shown on the previous page, the external panel is shown on the right. – Chassis ground Grounding connection point for input power. –...
  • Page 35 CHAPTER 1: SYSTEM DESCRIPTION Section IV: MA-660A Program Unit (“The Pendant”) (Sold Separately) The Power Supply uses the Pendant to set the weld schedules and see the monitored results. The Pendant is connected to the Power Supply by a cable attached to the connector on the front door of the Power Supply as shown below.
  • Page 36 CHAPTER 1: SYSTEM DESCRIPTION TROUBLE RESET key Press this key after the cause of trouble is eliminated. Once selected all error messages that appear on the screen will turn off. CURSOR Keys Used to move the cursor or to select an item. +ON/-OFF Keys Used to change the value of a selected item or turn it on and off.
  • Page 37 CHAPTER 1: SYSTEM DESCRIPTION The Power Supply writes data into FLASH ROM on the control board when a setting is changed or a schedule data is copied. The lamp on the front panel and the external signal are turned READY READY off during writing.
  • Page 39 CHAPTER 2 INSTALLATION AND SETUP Section I: Planning Environmental Factors We recommend that you install the Power Supply in a well-ventilated area that is free from excessive dust, weld expulsion, acids, corrosive gasses, salt, moisture, oil, coolant, and contaminants. Allow adequate space around the unit for power and signal cabling runs, water-cooling hose connections, and to open the front door.
  • Page 40 TB5-1 and TB5-2 on the external I/O terminal strip. NOTE: If used with AMADA WELD TECH IT Transformers, you can purchase the 18-045-01 transformer sense cable which will have these connections.
  • Page 41 CHAPTER 2: INSTALLATION AND SETUP Section II: Installation of IS-2200CA CAUTION • Make sure the mounting location can support the weight of the unit! • A mechanical lift or hoist should be used for unpacking and installation due to the weight of the unit! •...
  • Page 42 CHAPTER 2: INSTALLATION AND SETUP IS-2200CA Mounting Hole Locations 25.38” (644.5mm) 56.26” (1429.0mm) 0.44” (11.2mm) 4 plcs 3/8” bolt recommended Electrical Connections DANGER • Do not install power to the Power Supply without the input power service being turned off and tagged (Lock-out Tag-out).
  • Page 43 CHAPTER 2: INSTALLATION AND SETUP Input Power Connections HANDLE Electrical input is made from the top of the Power Supply through the Line-In cover plate. We recommend removal of the cover plate to an area away from the Power Supply before drilling holes.
  • Page 44 CHAPTER 2: INSTALLATION AND SETUP INPUT POWER CONNECTIONS (3Ø) Connect the ground cable to the chassis ground terminal to the right of the circuit breaker. 9. Slide the circuit breaker terminal cover back on to the circuit breaker. 10. Remove the four screws that secure the Line-Out Cover Plate on the bottom of the Power Supply.
  • Page 45 CHAPTER 2: INSTALLATION AND SETUP Output Power Connections Weld transformer connections are made from the bottom of the Power Supply through the Line-Out Cover Plate. We recommend that you remove the cover plate to an area away from the Power Supply before drilling holes.
  • Page 46 CHAPTER 2: INSTALLATION AND SETUP Signal Sensing Connections See Appendix B, Electrical and Data Connections, Section I, Data Connectors for connector pin information and Section II, Input / Output Signal Configuration for connection and configuration instructions. TRANSFORMER SENSING CONNECTOR BOTTOM VIEW IS-2200CA/4500CA INVERTER POWER SUPPLY 990-412...
  • Page 47 CHAPTER 2: INSTALLATION AND SETUP IS-2200CA Cooling Water Requirements The connections to the Power Supply are made with 1/2" FNPT fittings through the bottom of the Power Supply. We recommend the installation of quick-disconnect fittings to expedite water draining or Power Unit replacement.
  • Page 48 CHAPTER 2: INSTALLATION AND SETUP Section III: Installation of IS-4500CA WARNING • Make sure the mounting location can support the weight of the unit. • A mechanical lift or hoist should be used for unpacking and installation due to the weight of the unit! •...
  • Page 49 CHAPTER 2: INSTALLATION AND SETUP Electrical Connections DANGER • Do not install power to the Power Supply without the input power service being turned off and tagged (Lock-out Tag-out). Serious injury or death can result from contacting live power lines. If the Power Supply was previously powered up, allow 20 minutes for the internal capacitor bank to discharge.
  • Page 50 CHAPTER 2: INSTALLATION AND SETUP 1. Make sure the input 3-phase power coming from the wall is off. 2. Open the front doors by turning the respective handles. Verify that the capacitor bank is discharged. 3. Remove the four screws that secure the Line-In Cover Plate. 4.
  • Page 51 CHAPTER 2: INSTALLATION AND SETUP Drill appropriate hole(s) in the removable lower panels to receive the output power (weld transformer) 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.
  • Page 52 CHAPTER 2: INSTALLATION AND SETUP Breaker Breaker Rated Current Calculate the average Input current using output current (momentary maximum current) and duty cycle: α Effective continuous current = I x 0.817 x I : Output current (momentary maximum current) of IS-2200CA/4500CA α...
  • Page 53 CHAPTER 2: INSTALLATION AND SETUP Input / Output Cable An input/output cable is determined by the average input current and the average output current. Calculate the average input current and the average output current using output current (momentary maximum current) and duty cycle. α...
  • Page 54 CHAPTER 2: INSTALLATION AND SETUP IS-4500CA Cooling Water Requirements The connections to the Power Supply are made with 1/2” FNPT fittings through the rear of the Power Supply. See Appendix A, Technical Specifications for cooling water specifications. CAUTION: If the temperature drops below 32°F (0°C), the water inside the Power Supply can freeze. If the temperature is likely to drop below 32°F (0°C), drain the water in accordance to the procedure in Chapter 4, Maintenance.
  • Page 55 CHAPTER 3 IS-2200CA/4500CA: USING PROGRAMMING FUNCTIONS Introduction FLASH ROM The Power Supply writes data into FLASH ROM on the control board when a setting is changed or a schedule data is copied. The lamp on the front panel and the external signal READY READY...
  • Page 56 CHAPTER 3: USING PROGRAMMING FUNCTIONS 2. POWER SUPPLY STATE Screen This screen is used to display and set data for the Power Supply. Move the cursor to change the value. a. LCD CONTRAST Sets the screen contrast. The contrast can be set in a range from 0 to 9. The larger the value, the darker the screen.
  • Page 57 CHAPTER 3: USING PROGRAMMING FUNCTIONS 3. SCHEDULE Screen Up to 255 welding schedules can be set on the Power Supply. These schedules are indicated as SCHEDULE #1 to #255.In the SCHEDULE screen, there is a Current and time setting screen and a PULSATION and transformer screen.
  • Page 58 CHAPTER 3: USING PROGRAMMING FUNCTIONS Length of time added to SQZ; only for the first weld after start SQD / Squeeze delay time signal in repeat operation SQZ / Squeeze time Length of time until proper squeeze is applied to workpiece COOL1 / Cooling time 1 and Length of time to cool workpiece after turning off welding COOL2 / Cooling time 2...
  • Page 59 CHAPTER 3: USING PROGRAMMING FUNCTIONS A: WELD1 time or WELD2 time B: UP2 time or UP3 time C: WELD2 time or WELD3 time D: WELD1 HEAT or WELD2 HEAT E: UF2 HEAT or UF3 HEAT F: WELD2 HEAT or WELD3 HEAT 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 DL HEAT...
  • Page 60 CHAPTER 3: USING PROGRAMMING FUNCTIONS A: WELD1 time or WELD2 time B: DOWN1 time or DOWN2 time C: UP2 time or UP3 time D: WELD2 time or WELD3 time E: WELD1 HEAT or WELD2 HEAT F: DL1 HEAT or DL2 HEAT G: UF2 HEAT or UF3 HEAT H: WELD2 HEAT or WELD3 HEAT NOTES:...
  • Page 61 CHAPTER 3: USING PROGRAMMING FUNCTIONS When the downslope time is set in the pulsation welding. The downslope time is set, and the HEAT setting of and the DL HEAT setting of are different. A: WELD1 to 3 time B: DOWN1 to 3 time C: HEAT1 to 3 D: DL1 to 3 HEAT When the upslope time and the downslope times are set in the pulsation welding.
  • Page 62 CHAPTER 3: USING PROGRAMMING FUNCTIONS d. WELD ON/OFF One of the settings required to turn the READY lamp of the Power Supply ON. NOTE: Even if this switch is ON, the Power Supply cannot supply welding current if the WELD ON/OFF key on the front panel or external WELD ON/OFF signal is OFF. In order for the Power Supply to supply welding current, this switch, the WELD ON/OFF key, and the external WELD ON/OFF signal must all be ON.
  • Page 63 CHAPTER 3: USING PROGRAMMING FUNCTIONS CONTROL METHOD FEATURE APPLICATION CONTROL MECHANISM Used when you Detects the welding current with toroidal Controls so that the power want to reduce coil and the voltage between electrodes with between electrodes becomes expulsion in early the voltage detecting cable to compare the Secondary constant-power constant.
  • Page 64 CHAPTER 3: USING PROGRAMMING FUNCTIONS NOTE: When UP/DOWN is set, UF/DL becomes effective. It becomes a target value in the effective value control, so a difference occurs between the set value and the value of actual welding. DANGER Even though E-07 (No-current error) is displayed, current is flowing.
  • Page 65 CHAPTER 3: USING PROGRAMMING FUNCTIONS c. PULSATION / INTERVAL 1 to 3 Set the number of repetitions PULSATION (01 to 19) and the downtime ( INT1 ) in (See the figure below). However, when the number of repetitions is set to 01, the downtime does not work.
  • Page 66 CHAPTER 3: USING PROGRAMMING FUNCTIONS CAUTION use the welding transformer whose frequency is higher than the output frequency of the inverter power supply, this will cause a malfunction. When setting the output frequency of the inverter power supply, check the frequency of the welding transformer. e.
  • Page 67 CHAPTER 3: USING PROGRAMMING FUNCTIONS control, and secondary constant-voltage effective value control. Though 1 is normally used, the larger value will give the shorter rise time. (Invalid in the primary constant-current peak value control and the constant-phase control.) NOTE: Control gain refers to a correction amount in feedback control. Although the current rises more rapidly with greater control gain, the current waveform may experience overshoot.
  • Page 68 CHAPTER 3: USING PROGRAMMING FUNCTIONS 4. MONITOR Screen In this screen, you can confirm the operational conditions during welding. Monitored data is displayed for each SCHEDULE NOTE: The screen shows the settings for 10 kA or 05 kA range. In 20 kA, 40 kA, or 80 kA range, CURRENT is 000.0 kA to 999.9 kA and POWER is 000.0 kW to 999.9 kW.
  • Page 69 CHAPTER 3: USING PROGRAMMING FUNCTIONS d. VOLTAGE 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.
  • Page 70 CHAPTER 3: USING PROGRAMMING FUNCTIONS k. CAP CHANGE 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. l.
  • Page 71 CHAPTER 3: USING PROGRAMMING FUNCTIONS 3. When WELD2 STOP/WELD COUNT WELD2 STOP and COUNTER is WORK: WELD COUNTER WORK COUNTER are displayed. When the count reaches the set WELD count value, WORK count value is incremented by one. This is different from WELD COUNTER described below.
  • Page 72 CHAPTER 3: USING PROGRAMMING FUNCTIONS 5. MONITOR SET Screen Set the conditions for determining a good or bad weld, including values for welding current, upper or lower limits for the secondary voltage, etc. If the monitored welding current, secondary voltage, etc., do not meet the set conditions, a caution signal is output, and can be used to activate an alarm buzzer, alarm lamp, or similar event.
  • Page 73 CHAPTER 3: USING PROGRAMMING FUNCTIONS f. PULSE If the ratio of welding current pulse / pulse width in full wave mode exceeds the percentage set in the PULSE HIGH , an ERROR signal is output. Pulse width is expressed assuming that the full wave is 100%.
  • Page 74 CHAPTER 3: USING PROGRAMMING FUNCTIONS b. TIME-OVER / CURR-OVER / VOLT-OVER / POWER-OVER / PULSE-OVER / NO CURR / WRK ERR. Sets the signal to output, ERROR CAUTION . The signal is output in the following states. TIME-OVER When the weld time exceeds the upper/lower limit CURRENT- When the current exceeds the upper/lower limit OVER...
  • Page 75 CHAPTER 3: USING PROGRAMMING FUNCTIONS OUTPUT SELECT Screen Sets the output signals OUT1 to OUT5 of the external output signals. NOTE: This screen shows initial settings. Pressing the key switches the signal in the following order (in the reverse direction when pressing - key): (end signal) →...
  • Page 76 CHAPTER 3: USING PROGRAMMING FUNCTIONS SETUP COPY DATA Screen The MA-660A can store data as shown in the figure below. When the MA-660A is connected to the Power Supply, the data stored in the Power Supply memory is displayed on the Monitor Panel. When the data is changed and the ENTER key is pressed, the contents of the memory of the Power...
  • Page 77 CHAPTER 3: USING PROGRAMMING FUNCTIONS Move the cursor to the required item then press the ENTER key; the data will be copied. a. Power Supply  MA-660A. The data in the Power Supply is copied to MEMORY of MA- 660A.When copy is complete, <END> is displayed. b.
  • Page 78 CHAPTER 3: USING PROGRAMMING FUNCTIONS 9. MODE SELECT Screen a. DELAY START SET One welding condition is determined via , a value corresponding to chatter DELAY START SET prevention time, after a start signal is input. The period can be set in a DELAY START SET range from 1 to 20ms, in unit of 1ms.
  • Page 79 CHAPTER 3: USING PROGRAMMING FUNCTIONS NOTE: When DELAY START SET is 1ms or 2ms, the schedule number when the 2ND STAGE signal is received is selected. Therefore, in Fig. A above, the schedule number is not selected and the schedule signal input error occurs. When DELAY START SET ms or ms, input the...
  • Page 80 CHAPTER 3: USING PROGRAMMING FUNCTIONS  WHEN MAINTAINED. If the 2ND STAGE signal stops halfway through the welding sequence (from the beginning of initial squeeze delay time through the end of hold time), the welding sequence will halt at that point. NOTE: The signal depends on the END SIG.MODE...
  • Page 81 CHAPTER 3: USING PROGRAMMING FUNCTIONS time is set (10ms ≤ OFF time) END SIG.TIME time is shorter than time ( END SIG.TIME time < time) End signal time is the set END SIG.TIME time. ( time = END SIG.TIME time). time ≥...
  • Page 82 CHAPTER 3: USING PROGRAMMING FUNCTIONS f. WELD1 STOP/PARITY CHECK. Set external input pin 13.  When is selected. Parity check will not be performed. The sequence will proceed WELD1 STOP to COOL1 if external input pin 13 is closed during the sequence operation.
  • Page 83 CHAPTER 3: USING PROGRAMMING FUNCTIONS NOTE: Current shutoff function. The current shutoff function shuts off current when the proper weld penetration is achieved—for example, during fusing—thus preventing excessive penetration. (Refer to the figure below.) W ith the Po wer Supp ly connected M iyach i we ld checker M M-370 A , set the d isp lace ment in advance .
  • Page 84 CHAPTER 3: USING PROGRAMMING FUNCTIONS WE2STOP signal shuts off current immediately when input during the period, switching the sequence to COOL2 . The WE2STOP signal shuts off current immediately after starts (the current is supplied for about 1 cycle) when input before the period, switching the sequence to .
  • Page 85 CHAPTER 3: USING PROGRAMMING FUNCTIONS j. NEXT When the cursor () is displayed, pressing the ENTER key will change the display to the MODE SELECT (2) screen. k. STEPPER MODE Select whether or not to perform step-up (step-down) operation, refer to the STEPPER COUNT Screen.
  • Page 86 CHAPTER 3: USING PROGRAMMING FUNCTIONS m. VALVE MODE Select the output method (1 VALVE or 2 VALVE) of the solenoid valve signal. When 1 VALVE is selected When the 1ST STAGE signal is input, the valve signal (SOL1 - 4) with the selected schedule number is output and the sequence waits for the 2ND STAGE signal input.
  • Page 87 CHAPTER 3: USING PROGRAMMING FUNCTIONS ・OFF (repeated operation) ・STEPPER (step-up (-down) operation) When the 1ST STAGE signal is input, VALVE 1 is output, and then SOL2 is output after SQD. After SQD and SQZ, the sequence waits for the 2ND STAGE signal input. Next, when the 2ND STAGE signal is input, the welding sequence after WELD1 starts.
  • Page 88 CHAPTER 3: USING PROGRAMMING FUNCTIONS When the off time is set, RE-WELD works as even if . When RE-WELD is combined with STEPPER , the welding current will be 5% greater than the value set for STEPPER R E- WEL D T i m ing Chart DEL A Y- S T A R T SET t i me 2 N D ST A GE S Q D...
  • Page 89 CHAPTER 3: USING PROGRAMMING FUNCTIONS GOOD: Count-up is done if the judgment is GOOD in current-supplied monitoring. In case of errors other than the counter error, count-up is not done. Also, when the welding is interrupted, count-up is not done. Counting Manner Judgment in Monitor Count-up.
  • Page 90 CHAPTER 3: USING PROGRAMMING FUNCTIONS s. COMM MODE Selects a communication mode. RS-485 Communication by RS-485 (optional) Communication by RS-232C RS-232C t. COMM SPEED Selects a communication speed. Communication at 9600 bps 9.6k Communication at 19200 bps 19.2k Communication at 38400 bps 38.4k For details of the external communication, see External Communication Function.
  • Page 91 CHAPTER 3: USING PROGRAMMING FUNCTIONS NOTE: This screen shows initial settings. The display surrounded with frame changes depending on the setting of WELD2 STOP/WELD COUNT COUNTER on the MODE screen. SELECT a. PRESET TOTAL COUNT The display changes depending on the setting of WELD2 STOP/WELD COUNT and COUNTER on the MODE SELECT screen.
  • Page 92 CHAPTER 3: USING PROGRAMMING FUNCTIONS Exa mp le ) P RE SE T C O U N T=3 C A UT I O N G O O D G O O D E R R O R G O O D C A UT I O N G O O D Judg ment...

  • Page 93: Output5

    CHAPTER 3: USING PROGRAMMING FUNCTIONS P RE SE T ( W EL D )=3 P RE SE T ( W O R K )=2 C A U T I O N C A U T I O N C A U T I O N C A U T I O N G O O D G O O D...
  • Page 94 CHAPTER 3: USING PROGRAMMING FUNCTIONS For example, if you set the number of welds to 5 from the programmable logic controller, select “ ” for PRESET COUNT as well. This function can be turned on or off through WELD2 STOP/WELD COUNT on the MODE SELECT...
  • Page 95 CHAPTER 3: USING PROGRAMMING FUNCTIONS e. MONITOR FIRST TIME Use this setting to specify the start time to measure the monitored value (current, voltage, power, pulse width). The start time can be set in a range from 0 to 15ms.Use this setting to exclude the initial rise of current from measurement.
  • Page 96 CHAPTER 3: USING PROGRAMMING FUNCTIONS When the welding stop signal is input after WELD STOP OFF TIME The welding is stopped when the welding stop signal is input. We ld ing stop s igna l input WEL D S T O P OFF T I M E Set va lue STEPPER COUNT Screen The Power Supply can change the level of the welding current depending on the welding conditions.
  • Page 97 CHAPTER 3: USING PROGRAMMING FUNCTIONS b. STEP MODE There are two types for step-up (step-down), stepwise ( FIXED ) and linear ( LINER ). When step- up (step-down) is not used, is displayed. The setting is made on the MODE SELECT screen.
  • Page 98 CHAPTER 3: USING PROGRAMMING FUNCTIONS Weld 1:2kA Weld 2:2kA Weld 3:2.5kA Weld 4:3.0kA Weld 5:3.5kA Weld 6:4.0kA <--------- ----------> <------------------------------ -----------------------------> STEP1 STEP2 START ON STEP # The counting of welds starts from the set here. For example, if you select STEP START ON STEP #3...
  • Page 99 CHAPTER 3: USING PROGRAMMING FUNCTIONS d. STEP 1–9 Set the welding current up (-down) ratio (RATIO) for each STEP. e. COUNT 1–9 Set the number of welds (COUNT) for each STEP. The sequence will proceed to the next STEP following completion of the specified number of welds.
  • Page 100 CHAPTER 3: USING PROGRAMMING FUNCTIONS 12. PRECHECK Screen Screen for setting the weld time and pulse width for resistance pre-check welding. The resistance pre-check welding is a function to apply a small current under constant voltage control before regular welding to confirm that the part to weld is set correctly by means of the measured current value.

  • Page 101: Error Reset

    CHAPTER 3: USING PROGRAMMING FUNCTIONS 13. I/O CHECK Screen This screen is used to check the status of the external I/O signals. The “*” symbol appears when the corresponding input signal is ON. The asterisk disappears if the signal is OFF. Set the cursor reading to “0”...
  • Page 102 CHAPTER 3: USING PROGRAMMING FUNCTIONS Displacement sensor DISP MON: The displacement gauge operation can be viewed. 14. RESET TO DEFAULT Screen This screen is used to initialize the Power Supply’s memory (i.e., to restore the initial settings).Initialization will not clear the memory of the MA-660A. To initialize, move the cursor over and press the ENTER...
  • Page 103 CHAPTER 3: USING PROGRAMMING FUNCTIONS 15. PROGRAM PROTECT MODE Screen When this function is used, set values cannot be changed by any person other than the supervisor. PROGRAM PROTECT is usually set to OFF. When it is set to ON, set values cannot be changed until is set to OFF again.

  • Page 104: B. Prop Valve

    CHAPTER 3: USING PROGRAMMING FUNCTIONS When the PROGRAM PROTECT is ON> 16. FORCE SETUP & MONITOR Screen This screen is used to set and monitor the force of the electro pneumatic proportional valve. Two electro pneumatic proportional valves can be used. The ANALOG OUT output terminal (voltage output proportional to force) for electro pneumatic proportional valve and the ANALOG IN input terminal (voltage input proportional to force) for force measurement have two channels, respectively.
  • Page 105 CHAPTER 3: USING PROGRAMMING FUNCTIONS c. STEP MODE This is the mode to check the force operation of the electro pneumatic proportional valve. In this mode, the force operation can be checked without flowing the welding current. The sequence proceeds to the next in order of SQD, SQZ, WE1, CO/WE2, CO2/WE3, and HOLD by pressing the ENTER key or input the STEP MODE signal.
  • Page 106 CHAPTER 3: USING PROGRAMMING FUNCTIONS (ANALOG OUT), and CO1/WE2 and CONTINUE blink. The measured value input in the force input (ANALOG IN) is displayed at the monitor of CO1/WE2. CO2/WE3 The sequence proceeds from CO1/WE2 to CO2/WE3 by pressing the ENTER key or input the STEP MODE signal.
  • Page 107 CHAPTER 3: USING PROGRAMMING FUNCTIONS i. HOLD Set the force of the electro pneumatic proportional valve (ANALOG OUT) output during HOLD. j. VALVE # Two or four valves (welding heads) can be connected to the Power Supply. Use this setting to select which of the two valves to use.
  • Page 108 CHAPTER 3: USING PROGRAMMING FUNCTIONS l. CHAINING Used for the chaining function. The welding is performed with SCHEDULEs with the chaining setting in order while the start signal (1ST and 2ND) is input. All values of the chained schedules must be entered, especially the turns ratio, to ensure proper weld output.
  • Page 109 CHAPTER 3: USING PROGRAMMING FUNCTIONS 17. DISPLACEMENT Screen 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. b.
  • Page 110 CHAPTER 3: USING PROGRAMMING FUNCTIONS e. WORK DETECT MONITOR The presence or absence of work piece can be detected by measuring the head travel distance from the beginning of SQD through the end of SQZ. The presence or absence and overlapping of work piece can be detected.
  • Page 111 CHAPTER 3: USING PROGRAMMING FUNCTIONS 18. PRESSURE REGULATOR Screen This screen is used to set the units of force and air pressure, set the maximum force, and calibrate force. a. FORCE CONTROL MODE Sets the control mode of the electro pneumatic proportional valve. 0: Mode not using the electro pneumatic proportional valve.
  • Page 112 CHAPTER 3: USING PROGRAMMING FUNCTIONS 3: Mode using the electro pneumatic proportional valve. The electro pneumatic proportional valve (ANALOG OUT) is output. • Regardless of welding sequence operation, the CALIBRATION CONSTANT FORCE setting is output to the electro pneumatic proportional valve (ANALOG OUT). •...
  • Page 113 CHAPTER 3: USING PROGRAMMING FUNCTIONS Set the force output to the electro pneumatic proportional valve (ANALOG OUT) Regardless of welding sequence operation. UP and DW at the left side of CALIBRATION CONSTANT FORCE can be used when FORCE CONTROL MODE is 3. The force can be checked with this setting when FORCE CONTROL MODE is 3.
  • Page 115 CHAPTER 4 OPERATING INSTRUCTIONS Section I: Introduction Operator Safety WARNING DEATH ON CONTACT may result if personnel fail to observe the safety • precautions labeled on the equipment and noted in this manual. HIGH VOLTAGE used in the operation of this equipment. •...
  • Page 116 CHAPTER 4: OPERATING INSTRUCTIONS Section II: Operation CAUTION If no secondary toroidal coil is connected, make sure that the Power Supply mode is set to or you may damage the Power Supply. PRIMARY RMS PRIMARY LIMIT Starting Welding Operation 1. Turn the cooling water supply ON at the temperature and flow rate shown in Chapter 2. Turn the input power ON.
  • Page 117 CHAPTER 4: OPERATING INSTRUCTIONS If no error is detected in Step 2, ensure that the three READY requirements are met: • The Power Supply must be ON. WELD ON/OFF LED • setting of the Pendant must be set to ON. ON/OFF •...
  • Page 118 CHAPTER 4: OPERATING INSTRUCTIONS Section III: Shutdown CAUTION DO NOT power ON the unit while the door is open. Touching anything inside the cabinet with power ON may cause death. Turn the Power Supply OFF The IS-2200CA requires to turn the power handle to OFF to open the cabinet. This will trip the breaker, cut power to the inside of the cabinet and discharge the capacitors within 30 seconds.
  • Page 119 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. Toroidal coil is not connected. Connect the toroidal coil.
  • Page 120 CHAPTER 5: MAINTENANCE FAULT CONTENTS CAUSE MEASURES CODE Check that the transformer capacity is OUT LIMIT OF Welding Current pulse width is out of sufficient. E-09 PULSE WIDTH PULSE HI setting range on MONITOR ERROR SET screen. Check workpiece and welding electrode. Primary current of turn ratio is out of range of the following formula: HEAT setting...
  • Page 121 CHAPTER 5: MAINTENANCE FAULT CONTENTS CAUSE MEASURES CODE Rectify cause of the STOP, and then close the External STOP input circuit is open. STOP circuit. STOP E-12 Power supply for external input is not Check the external input signal for proper connected.
  • Page 122 CHAPTER 5: MAINTENANCE FAULT CONTENTS CAUSE MEASURES CODE Memory was erased because the period for retaining memory of the count data elapsed RAM MEMORY Count data or schedule number data stored over the specified period. E-25 ERROR in memory is corrupt. Count data memory is retained up to 10 days after the power supply is turned off.
  • Page 123 E-39 EXTENSION repair is required. connected. BOARD Contact AMADA WELD TECH When Welding Does not Start Even if the Start Signal is Present When welding does not start even if the Start signal 2ND STAGE signal is present, the following causes may be occurring: •...
  • Page 124 CHAPTER 5: MAINTENANCE NOTES: • When the next start signal is received while the monitor error is displayed on the Pendant, the CAUTION signal is turned OFF and the previous screen is displayed. At this time, the data is transferred to the Pendant from the Power Supply. The start signal is not received while the data is transferred.
  • Page 125 CHAPTER 5: MAINTENANCE Section II. Before You Start IS-2200CA / IS-4500CA Cleaning 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 126 CHAPTER 5: MAINTENANCE IS-4500CA Service Safety Precautions DANGER DEATH ON CONTACT may result if you fail to observe all safety precautions. Lethal voltages are present in the Power Supply. Perform the following steps to eliminate electrical shock hazard. Make sure external power is turned OFF before performing any maintenance procedures.
  • Page 127 CHAPTER 5: MAINTENANCE Section III: Fuse Failure and Replacement Lethal Voltages exist in the IS-2200CA / IS-4500CA Power Supply. The information in this Section is provided to give the end user an overview of the protection devices that are installed in the Power Supply. If the Power Supply stops functioning and a fuse opens, it is important to identify and fix the problem before replacing the fuse and reapplying power to the Power Supply.
  • Page 128 CHAPTER 5: MAINTENANCE IS-2200CA Power Supply Fuse / Component Locations See next page for fuse descriptions, values and replacement part numbers. FB2 (see below) FB1 (see below) Control Transformer Fuse PCB (see below) Main PCB (see below) IS-2200CA/4500CA INVERTER POWER SUPPLY 5-10 990-412...
  • Page 129 The Main PCB contains a redundant Valve Fuse FS1 and is located under the System I/O PCB as shown above. Fuse Board (P/N 4-40132-01) The Fuse Board contains ten fuses, seven for the various valve functions and three for the Main PCB power. AMADA WELD TECH FUSE DESCRIPTION FUSE TYPE PART NUMBER Main Board, Valve Fuse...
  • Page 130 CHAPTER 5: MAINTENANCE IS-4500CA Power Supply Fuse / Component Locations IS-2200CA/4500CA INVERTER POWER SUPPLY 5-12 990-412...
  • Page 131 CHAPTER 5: MAINTENANCE Main PCB (P/N 4-40205-03) The Main PCB contains a redundant Valve Fuse FS1 and is shown below. AMADA WELD TECH FUSE DESCRIPTION FUSE TYPE PART NUMBER Main board fuse 5x20 mm, 1 A, slow blow 250 VAC...
  • Page 132 CHAPTER 5: MAINTENANCE Power Supply The Power Supply contains fuses, mounted on the load side of the Valve Transformer and the Power Transformer. Valve Transformer UNIT AMADA WELD TECH FUSE DESCRIPTION FUSE TYPE VOLTAGE PART NUMBER Valve FNQ-R 4 1/2, slow blow,...
  • Page 133 CHAPTER 5: MAINTENANCE Section IV: Maintenance Procedures Cooling Maintenance Perform the following maintenance on the cooling system: • Monthly – Check the water hoses to assure there is no leakage. • Any time there is a chance that the water might freeze – Drain the water. •...
  • Page 134 CHAPTER 5: MAINTENANCE Disconnect one of the hoses at the bottom of the Power Supply and allow the water to drain into the bucket. 4. Turn the water back on slightly, but enough to flush the system. When the water is running clean, turn the water OFF.
  • Page 135 CHAPTER 5: MAINTENANCE Section V: Repair Service, Storage, Shipment Repair Service If you have problems with your Control 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. Preparation for Storage or Shipment 1.
  • Page 136  ...
  • Page 137 APPENDIX A TECHNICAL SPECIFICATIONS Specifications Parameter IS-2200CA IS-4500CA Dimensions: inches 31.4” x 55.0” x 15.0” 47.2” x 79.0” x 19.7” (W x H x D) (mm) (797mm x 1,397mm x 381mm) (1,200mm x 2,005mm x 500mm) (see isometric images on page 2-1) Weight 340 lbs (160 kg) 500 lbs (227 kg)
  • Page 138 APPENDIX A. TECHNICAL SPECIFICATIONS Parameter IS-2200CA IS-4500CA Transformer frequency * 600 – 1000 Hz (in units of 100 Hz) (WELD TRANS FREQ) Pulsation setting * 01 – 19 (settable for WELD1 to WELD 3, respectively) (PULSATION) 2 valves (VALVEx (SOLx), 1 and 2; BASIC unit Valve setting * 8 valves (VALVEx (SOLx), 1 and 2;...
  • Page 139 APPENDIX A. TECHNICAL SPECIFICATIONS Parameter IS-2200CA IS-4500CA Power monitor * 000.0 – 999.9 kW 00.00 – 99.99 kW (POWER H/L) Voltage monitor * 9.99 V (VOLT H/L) Pulse width monitor * 010.0 – 100.0% (PULSE H) STEP Up (down) Step-up/-down 1 –...
  • Page 140 APPENDIX A. TECHNICAL SPECIFICATIONS Parameter IS-2200CA IS-4500CA Power is turned off in the following cases: a. When a secondary current is not detected in Secondary constant- No-current current effective value control, Secondary constant-power effective value control, or Constant-phase control. b. When a primary Under Secondary constant-voltage effective value control or Secondary Error No-voltage...
  • Page 141 APPENDIX A. TECHNICAL SPECIFICATIONS Duty Cycles IS-2200CA IS-2200CA Duty Cycle Graph 2500 2000 1500 1000 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 Duty Cycle (%) IS-4500CA IS-4500CA Duty Cycle Graph 5000 4000 3000 2000...
  • Page 142 APPENDIX A. TECHNICAL SPECIFICATIONS Weld Time Limit IS-2200CA IS-2200CA weld time limit 2500 2000 1500 1000 Weld Time (ms) IS-4500CA IS-4500CA Weld Time Limit 5000 4000 3000 2000 1000 Weld Time (ms) IS-2200CA/4500CA INVERTER POWER SUPPLY 990-412...
  • Page 143 APPENDIX B ELECTRICAL AND DATA CONNECTIONS CAUTION Use the shielded cable for the external input/output signals and connect the shielded part to the ground. Section I: Data and Signal Connectors RS-232 (standard) One DB-9 (female) connector wired as follows: #1 – Not Used #6 -- Not Used #2 -- Tx #7 -- Not Used...
  • Page 144 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS RS-485 (optional) Two DB-9 (female) connector wired as follows: #1 – Not Used #6 -- Not Used #2 -- Not Used #7 -- Not Used #3 -- Not Used #8 -- Rx+ #4 -- Tx+ #9 -- Rx- #5 -- Tx- RS-485 allows multiple Power Supplies to be daisy chained to a host.
  • Page 145 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS DISPLACEMENT SENSOR CONNECTOR ( ADVANCED 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-2200CA/4500CA INVERTER POWER SUPPLY 990-412...
  • Page 146 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS Section II: I/O Terminal Block for IS-2200CA (INTERNAL SINK MODE SHOWN) INTERNAL EXTERNAL +24VDC INT +24VDC OUT TB1 1 EXT. COM TB1 2 STOP TB1 3 INT +24VDC OUT GND (I/O COM) TB1 4 SCHEDULE 1 TB1 5 SCHEDULE 2...
  • Page 147 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS TB2 8 NG1 OUT (ERROR) TB2 9 NG2 OUT (CAUTION) TB2 10 OUT1 TB2 11 OUT2 TB2 12 OUT3 TB2 13 OUT4 TB2 14 OUT5 OUT COM TB2 15 TB3 1 ANALOG IN1+ ANALOG IN1- TB3 2 ANALOG OUT1+ TB3 3...
  • Page 148 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS RETRACTION 1 TB4 1 TB4 2 I/O COM INT +24VDC OUT GND (I/O COM) RETRACTION 2 TB4 3 BACK STEP TB4 4 STEP MODE TB4 5 EXT. COM TB4 6 INT +24VDC OUT CONTACTORS (OPTIONAL) TB4 7 AUX CONTACTS (N/O) CONTACTOR N.O.
  • Page 149 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS VALVE POWER (SOL) TB6 1 VALVE COM (SOL) TB6 2 TB6 3 VALVE1 (SOL1) These valves are only active in 2 valve mode (See page 3-33) Use EXT valves 1-4 (TB6 5-6) for VALVE2 (SOL2) TB6 4 normal valve operation EX VALVE1 (EX SOL1)
  • Page 150 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS External I/O Signals for IS-2200CA NAME DESCRIPTION NOTE: Do not use pin 1 unless connecting it to pin 2 or 3. Failure to observe this precaution will result in malfunction. TB1-1 INT +24VDC OUT MAX CURRENT DRAW: 100mA For internal Sink (pull down) Connect to pin 1.
  • Page 151 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS NAME DESCRIPTION WE2 stop input or Weld count input pin. When WE2 STOP is selected Closing this pin during the WELD2 sequence will switch the sequence to COOL2. Closing this pin in the sequence other than WELD2 is neglected. The sequence will switch to COOL2 if this signal is closed during the WELD2 sequence operation.
  • Page 152 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS NAME DESCRIPTION WE3 stop input or Count reset input pin. When WE3 STOP is selected Closing this pin during the WELD3 sequence will switch the sequence to HOLD. The interrupt error occurs when the WELD3 STOP signal is input before the start COUNT signal is input.

  • Page 153: Table Of Contents

    APPENDIX B. ELECTRICAL AND DATA CONNECTIONS NAME DESCRIPTION ANALOG OUT1+ TB3-3 0-10VDC Analog output 1* TB3-4 ANALOG OUT1- ANALOG IN2+ TB3-5 0-10VDC Analog input 2 TB3-6 ANALOG IN2- TB3-7 ANALOG OUT2+ 0-10VDC Analog output 2* ANALOG OUT2- TB3-8 TB3-9 CURRENT OUT+ Current output (0-10 VDC)* / 5000 CURRENT OUT-...
  • Page 154 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS NAME DESCRIPTION INT +24VDC GND I/O COM pin. This pin is internally connected to the +24VDC GND TB4-13 TB5-1 Secondary voltage input pins. Internally connected to the IT XFMR sense connector. EXTERNAL VOLTAGE If IT XFMR sense cable not used may be connected directly to electrodes. TB5-2 For internal Sink (pull down) Connect to pin 1.
  • Page 155 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS NAME DESCRIPTION Solenoid valve output pins. TB6-5 EX VALVE1 TB6 5: EX VALVE1 (EX SOL1); (EX SOL1) TB6 6: EX VALVE2 (EX SOL2); TB6-6 EX VALVE2 TB6 7: EX VALVE (EX SOL3); (EX SOL2) TB6 8: EX VALVE4 (EX SOL4) TB6-7 EX VALVE3...
  • Page 156 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS External Output Signals The following signals can be assigned to output pins TB2-10 to TB2-14 (OUT 1 to 5) on the OUTPUT SELECT Screen. NAME DESCRIPTION Closed each time the sequence is complete and output the END signal. Output time selection (10 to 200ms, HOLD) When the off time (OFF) is set and the END signal time is set to time longer than OFF time, the END signal time will be equal to OFF time...
  • Page 157 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS Section III: I/O Terminal Block for IS-4500CA INTERNAL SINK MODE SHOWN INTERNAL EXTERNAL +24VDC INT +24VDC OUT EXT. COM STOP INT +24VDC OUT GND (I/O COM) SCHEDULE 1 SCHEDULE 2 SCHEDULE 4 SCHEDULE 8 SCHEDULE 16 SCHEDULE 32 SCHEDULE 64...
  • Page 158 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS NG1 OUT (ERROR) NG2 OUT (CAUTION) OUT1 OUT2 OUT3 OUT4 OUT5 OUT COM VALVE (SOL) POWER VALVE (SOL) COM These valves are active in valve 2 VALVE1 (SOL1) mode (See page 3-33) Use EXT valves 1-4 (pins 49-52) for normal valve operation VALVE2 (SOL2) SECONDARY VOLTAGE (use only for non-IT...

  • Page 159: Analog Out1

    APPENDIX B. ELECTRICAL AND DATA CONNECTIONS VALVE COM EX VALVE1 (EX SOL1) EX VALVE2 (EX SOL2) EX VALVE3 (EX SOL3) EX VALVE4 (EX SOL4) RET VALVE1 (RET SOL1) RET VALVE2 (RET SOL2) VALVE RELAY (SOL RELAY) INT +24VDC OUT GND (I/O COM) RETRACTION 1 RETRACTION 2 BACK STEP...
  • Page 160 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS External I/O Signals for IS-4500CA NAME DESCRIPTION NOTE: Do not use pin 1 unless connecting it to pin 2 or 3. Failure to observe this precaution will result in malfunction. INT +24VDC OUT MAX CURRENT DRAW: 100mA For internal Sink (pull down) Connect to pin 1.
  • Page 161 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS NAME DESCRIPTION WE2 stop input or Weld count input pin. When WE2 STOP is selected Closing this pin during the WELD2 sequence will switch the sequence to COOL2. Closing this pin in the sequence other than WELD2 is neglected. The sequence will switch to COOL2 if this signal is closed during the WELD2 sequence operation.
  • Page 162 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS NAME DESCRIPTION WE3 stop input or Count reset input pin. When WE3 STOP is selected Closing this pin during the WELD3 sequence will switch the sequence to HOLD. The interrupt error occurs when the WELD3 STOP signal is input before the start WE3 STOP/ signal is input.
  • Page 163 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS NAME DESCRIPTION Solenoid valve output pins. 36: VALVE1 (SOL1); 37: VALVE2 (SOL2) These pins are closed for the duration of the STAGE 2 input. Output between SQD and HOLD. VALVE1 (SOL1) When the off time (OFF) is set, this pin is output between SQZ and HOLD after the VALVE2 (SOL2) second sequence.

  • Page 164: Out Out

    APPENDIX B. ELECTRICAL AND DATA CONNECTIONS NAME DESCRIPTION RETRACTION 1 RETRACTION 2 I/O Inputs BACK STEP STEP MODE ANALOG IN1+ 0-10VDC Analog input 1 ANALOG IN1- ANALOG OUT1+ 0-10VDC Analog output 1* ANALOG OUT1- ANALOG IN2- 0-10VDC Analog input 2 ANALOG IN2- ANALOG OUT2+ 0-10VDC Analog output 2*...
  • Page 165 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS External Output Signals The following signals can be assigned on the screen to output pins 28 to 32 OUTPUT SELECT (OUT 1 to 5) NAME DESCRIPTION Closed each time the sequence is complete and output the END signal. Output time selection (10 to 200ms, HOLD) When the off time (OFF) is set and the END signal time is set to time longer than OFF time, the END signal time will be equal to OFF time.
  • Page 166 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS Section IV: Input Connection Examples (All models) Input Signal Connections 1. Connection with equipment having a contact input. Connect pins 1 and 2. +24V (Internal Power Supply) INT. 24 V EXT. COM EMERGENCY STOP Schedule 1 SCH.
  • Page 167 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS 3. Connection with equipment featuring PNP (source) current output using external power supply. Connect the negative side of an external 24 VDC power supply to pin 2. +24V (Internal Power Supply) +24V (External) EMERGENCY STOP SCH.
  • Page 168  ...
  • Page 169 APPENDIX C SYSTEM TIMING Input and Output Timing Signals The following illustrations show the timing signals for different functions of the Power Supply. Start Signal Input Weld sequence operation varies by the setting of on the Mode Select screen. START SIG. MODE Maintained Mode If the 2ND STAGE signal stops halfway through the welding sequence (from the beginning of initial squeeze delay time through the end of hold time), the welding sequence will halt at that point.
  • Page 170 APPENDIX C: SYSTEM TIMING Pulsed Mode When the 2ND STAGE signal is input for more than the time set through and then DELAY START SET stops, the welding sequence will proceed to completion. A: DELAY START SET 2ND STAGE Schedule selection (1,2,4,8,16 32,64,128,P)
  • Page 171 APPENDIX C: SYSTEM TIMING One-Stage Start Stage 2 signal will begin the welding sequence with the selected Schedule #. A : DEL A Y S T A R T SE T ( N ote 1 ) 2 N D S T A GE S Q D S QZ WEL D1...
  • Page 172 APPENDIX C: SYSTEM TIMING A: DELAY START SET setting + Welding preparation time The welding preparation time changes depending on the WELD TRANS FREQ (frequency) setting. Frequency [Hz] Welding preparation time [ms] Frequency [Hz] Welding preparation time [ms] 1000 to 1200 1300 to 1600 1700 to 2400 2500 to 3000...
  • Page 173 APPENDIX C: SYSTEM TIMING Two-Stage Start When the 1ST STAGE is input, the solenoid valve output (SOL1 or SOL2) is turned ON and goes in to the standby state of the 2ND STAGE input. When the 2ND STAGE is input, welding sequence starts. 1 S T S T A GE 2 N D S T A GE S OL1/ S OL2...
  • Page 174 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-2200CA/4500CA INVERTER POWER SUPPLY 990-412...
  • Page 175 APPENDIX C: SYSTEM TIMING Pulsation Operation is repeated in WELD and INT set times. 2 N D S T A GE S Q D S QZ ( N ote 1 ) WEL D1 I N T1 C O OL1 ( N ote 2 ) WEL D2 I N T2 C O OL2...
  • Page 176 APPENDIX C: SYSTEM TIMING 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.
  • Page 177 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). Interrupt IS-2200CA/4500CA INVERTER POWER SUPPLY 990-412...
  • Page 178 APPENDIX C: SYSTEM TIMING VALVE MODE- specific difference in sequence When VALVE MODE is changed to “2 VALVE” from “1 VALVE”, two valve signals (SOL1 and SOL2) are output in a sequence. In this case, the settable VALVE No. is 1 or 2. 1 S T S T A GE 2 N D S T A GE REL A Y S W ( N ote 1 )
  • Page 179 APPENDIX C: SYSTEM TIMING 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. The SCHEDULE used in the chaining function is set in CHAINING on the FORCE SETUP & MONITOR screen.
  • Page 180 APPENDIX C: SYSTEM TIMING Successive and Back Step Function This function can switch welding multiple SCHEDULEs in order to perform them each time the 1ST STAGE signal and the 2ND STAGE signal are input. The SCHEDULE used in the successive function is set in SUCCESSIVE on the FORCE SETUP &...
  • Page 181 APPENDIX C: SYSTEM TIMING Retraction Function This function can output the retraction valve signal while the retraction signal is input. Since the electrode opening can be temporarily extended during welding, the direction of workpiece can be easily changed. However, the retraction valve signal cannot be turned ON/OFF during welding sequence.
  • Page 182 APPENDIX C: SYSTEM TIMING b: 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 at the above figure), the weld1 stop is stopped to make the sequence move to the next cool time(CO1).
  • Page 183 APPENDIX D WIRE GAUGE SELECTION AND CIRCUIT BREAKER SETTING Sizing Power Input Lines and Transformer Input Lines Due to the many possible combinations of transformer ratios, total secondary resistance and weld voltages, all which have a direct relationship for cable sizing, this section assumes that the secondary current is at its maximum peak current during the weld.
  • Page 184 APPENDIX D: WIRE GAUGE AND CIRCUIT BREAKER SELECTION Example: Using the table below: • If a 100amp output current at 100% duty cycle is required, the I is 100amps. • For the Transformer lines: use a 3/0 cable with a maximum length of 80 feet. •...
  • Page 185 APPENDIX D: WIRE GAUGE AND CIRCUIT BREAKER SELECTION Duty Cycles IS-2200CA IS-2200CA Duty Cycle Graph 2500 2000 1500 1000 Duty Cycle (%) IS-2200CA/4500CA INVERTER POWER SUPPLY 990-412...
  • Page 186 APPENDIX D: WIRE GAUGE AND CIRCUIT BREAKER SELECTION IS-4500CA IS-4500CA Duty Cycle Graph 5000 4500 4000 3500 3000 2500 2000 1500 1000 Duty Cycle (%) IS-2200CA/4500CA INVERTER POWER SUPPLY 990-412...
  • Page 187 APPENDIX D: WIRE GAUGE AND CIRCUIT BREAKER SELECTION CABLE TO OUTPUT TRANSFORMER CABLE TO UNIT (480 VAC INPUT) AWG @ I amps 1% Drop (feet) AWG @ I 5% drop (feet) 500 MCM 300 MCM 500 MCM 300 MCM ⁞ ⁞...
  • Page 188 APPENDIX D: WIRE GAUGE AND CIRCUIT BREAKER SELECTION Circuit Breaker Settings The dipswitches referred to in his section are located on the ABB circuit breaker, not on the IS motherboard. The dipswitches are clearly labeled on the circuit breaker. Please refer to this manual if you need more information on the circuit breaker.
  • Page 189 APPENDIX E Communications Section I. Description Overview The standard communication is RS-232C. RS-485 is a hardware option (pendant needs to be set to RS-232C) Remote Programming Advanced users may wish to perform programming for custom welding applications. The codes needed to perform remote programming are listed in Section II.
  • Page 190 APPENDIX E: COMMUNICATIONS Section II. External Communication Function Introduction The IS-2200CA/4500CA can be used to set schedules from an externally-connected personal computer (abbreviated as PC) or to read monitored data and several kind of status data. Data Transmission ITEM CONTENT Select only one mode on the MODE SELECT screen: RS-232C (RS-485 requires factory installed RS-485 option) Transmission Mode...
  • Page 191 APPENDIX E: COMMUNICATIONS Configuration ○ RS-232C H ost C om put er D evi ce N o. 1 Only a device can be connected. RS-232C ○ RS-485 H ost com put er D evi ce N o. 1 D evi ce N o. 2 D evi ce N o.
  • Page 192 APPENDIX E: COMMUNICATIONS Protocol Single-directional Communication Mode (When --> is selected at COMM CONTROL in MODE SELECT Screen) 1) Monitor Data IS-2200CA/4500CA BASIC Data strings: !01 001 :m, 120, 1.20, 0.50, 00.60, 20.0, 200, 2.00, 1.50, 03.00, 40.0, 300, 2.50, Continued on next line 2.00, 05.00, 50.0, 2, 0010, 5, 0100, 2222, 555555 [CR][LF]...
  • Page 193 APPENDIX E: COMMUNICATIONS Monitor voltage of WE3 Fixed to 4 digits (0.00 to 9.99) (V) Fixed to 5 digits (00.00 to 09.99) (kW) Monitor power of WE3 Fixed to 5 digits (000.0 to 999.9) (kW) Monitor pulse width of WE3 Fixed to 4 digits (10.0 to 99.9) (%) STEP No.
  • Page 194 APPENDIX E: COMMUNICATIONS 2) Error Data IS-2200CA/4500CA Data strings: !01 000 :E03, 04, 12, 15, 17, 19, 22, 26 [CR][LF] C D E F G H Device No. Fixed to 2 digits (01 to 31) Schedule No. Fixed to 3 digits (001 to 255) Error code 1 Fixed to 3 digits (E01 to E39) Error code 2...
  • Page 195 APPENDIX E: COMMUNICATIONS 3) Bi-directional Communication Mode (When <--> is selected at COMM CONTROL in MODE SELECT Screen) Reading of Trouble Code: # Device No. R Schedule No. Screen No. * Example: Read all troubled data in the specified device, No. 01. (Schedule No. is “008” and Voltage error and Electric power error are occurring.) Host 0 1 * * *...
  • Page 196 APPENDIX E: COMMUNICATIONS Reading of Data Code: # Device No. Screen No. R Schedule No. * Example: Read all data of Screen No. “01” of Schedule No. “008” of the specified device No. 01. Host 0 1 0 0 8 0 1 : 0 0 8 Data...
  • Page 197 APPENDIX E: COMMUNICATIONS Data Code Table Screen 01 (SCHEDULE data) Specific data in accordance with Schedule No. (001 to 255) Example of data writing: #01W001S01:0,0,0,m,0000,0000,000,000,000,0000,000,000,000,0000,000,000,000,00000,0000,1,00.50,0 0.50,00.50,00.50,00.50,00.50,00.50,00.50,00.50,01,000,01,000,01,000,1000,01,1,001.0,0,000,99.9,99.9,9 9.9,010,1[CR][LF] Item Contents Character String Range 0: Primary constant-current effective value control Control mode of WELD1 1: Secondary constant-current effective value control 2: Secondary constant-power...
  • Page 198 APPENDIX E: COMMUNICATIONS Character Item Contents Range String nnn.n, 004.0 to 120.0 (kW) 04.0 to 80.0 (kA) 02.0 to 40.0 (kA) nn.n, 04.0 to 60.0 (kW) UF1 / Initial heat 1 of upslope 01.0 to 20.0 (kA, kW) 10.0 to 99.9 (%) 0.50 to 9.99 / 0.05 to 5.00 (kA, kW) n.nn, 0.20 to 9.99 (V)
  • Page 199 APPENDIX E: COMMUNICATIONS Character Item Contents Range String nnn.n, 004.0 to 120.0 (kW) 04.0 to 80.0 (kA) 02.0 to 40.0 (kA) nn.n, 04.0 to 60.0 (kW) UF3 / Initial heat 3 of upslope 01.0 to 20.0 (kA, kW) 10.0 to 99.9 (%) 0.50 to 9.99 / 0.05 to 5.00 (kA, kW) n.nn, 0.20 to 9.99 (V)
  • Page 200 APPENDIX E: COMMUNICATIONS Screen 02 (MONITOR SET data) Specific data in accordance with Schedule No. (001 to 255) Example: #01W001S02:999,000,99.99,00.00,9.99,0.00,99.99,00.00,100.0,999,000,99.99,00.00,9.99, 0.00,99.99,00.00,100.0,999,000,99.99,00.00,9.99,0.00,99.99,00.00,100.0[CR][LF] Character Item Contents Range String 000 to 999 (ms mode) TIME H of WE1 (upper limit) nnn, 000 to 050 (CYC mode) 000 to 999 (ms mode) TIME L of WE1 (lower limit) nnn,...
  • Page 201 APPENDIX E: COMMUNICATIONS Screen 03 (STEPPER data) Common data (Valve No.: 001 to 004) Example of data writing: #01W001S03:1,0000,0,0000,100,0,0000,100,0,0000,100,0,0000,100,0,0000,100,0,0000,100,0,0 000,100,0,0000,100,0,01,0000[CR][LF] Character Item Contents Range String START ON STEP # 1 to 9 COUNT of STEP1 nnnn, 0000 to 9999 TIP DRESS of STEP1 0:OFF 1:ON(X) COUNT of STEP2 nnnn,...

  • Page 202: Sqd Force

    APPENDIX E: COMMUNICATIONS Screen 04 (MONITOR data) (Data reading only) Specific data in accordance with Schedule No. (Schedule No.: 001 to 255) Item Contents Character String Range Unit of time m: ms C: CYC 000 to 999 (ms mode) TIME of WELD1 nnn, 000 to 050 (CYC mode) nn.nn,...

  • Page 203: Character

    APPENDIX E: COMMUNICATIONS Screen 05 (PRE-CHECK data) Specific data in accordance with Schedule No. (001 to 255) Character Item Contents Range String PRECHECK TIME nnn, 000 to 100 (ms) PRECHECK HEAT nn.n, 10.0 to 99.9 (%) 00.00 to 99.99 (mΩ) PRECHECK RESISTANCE HIGH nn.nn, 00.00 to 99.99 (mΩ)

  • Page 204: Character

    APPENDIX E: COMMUNICATIONS Character Item Contents Range String WORK of WELD/WORK, nnnnnn, 000000 to 999999 PRESET COUNT NO CURRENT TIME 01 to 99 (ms) NO CURRENT LEVEL n.nn, 0.00 to 9.99 (kA) NO VOLTAGE LEVEL n.nn, 0.00 to 9.99 (V) MONITOR FIRST TIME 00 to 15 (ms) MONITOR SLOPE MODE...
  • Page 205 APPENDIX E: COMMUNICATIONS Character Item Contents Range String 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. Screen 07 (Error data) Common data (Schedule No.: 000) •...

  • Page 206: 0:Off 1:On

    APPENDIX E: COMMUNICATIONS COOL2/WELD3 FORCE nnnnn, HOLD FORCE nnnnn, VALVE# 1 to 4 FORGE VALVE# 1 to 2 CHAINING 0:OFF 1:ON SUCCESSIVE 0:OFF 1:ON FORGE DELAY nnnnn, 00000 to 30000(ms) FORGE MODE 0:OFF 1:ON *1 Items inhibited from setting (When setting data, omit these items.) “,”...
  • Page 207 APPENDIX E: COMMUNICATIONS Screen 09 DISPLACEMENT screen Specific data in accordance with 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 2:CURR 3:VOLT WELD3STOP INPUT 4:POWER 5:PULSE WELD STOP INPUT: OFF 0000000 WELD STOP INPUT: DISPLC nnnnnnn,...
  • Page 208 APPENDIX E: COMMUNICATIONS Screen 10 PRESSURE REGULATOR screen Common data (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 nnn.n, 000.0 to 500.0(mm)
  • Page 209 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 210 AMADA WELD TECH INC. 1820 South Myrtle Ave., Monrovia, CA 91016, U.S.A. TEL. +1-626-303-5676 FAX. +1-626-358-8048...

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