1. Manuals
  2. Brands
  3. Miyachi Unitek Manuals
  4. Inverter
  5. ISA Series
  6. Operator's manual

Miyachi Unitek ISA Series Operator's Manual

Inverter power supplies
Hide thumbs
Table of Contents

Advertisement

Quick Links

OPERATOR MANUAL 990-364
Revision B
August 2009
OPERATORS MANUAL
FOR THE
ISA-4000 and ISA-4001CR
INVERTER POWER SUPPLIES

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the ISA Series and is the answer not in the manual?

Questions and answers

Summary of Contents for Miyachi Unitek ISA Series

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

  • Page 2: Revision Record

    Copyright ¤ 2007, 2009 Miyachi Unitek Corporation The engineering designs, drawings and data contained herein are the proprietary work of MIYACHI UNITEK CORPORATION and may not be reproduced, copied, exhibited or otherwise used without the written authorization of MIYACHI UNITEK CORPORATION.

  • Page 3: Table Of Contents

    CONTENTS Page Revision Record ............................ii Contact Us ............................. viii Safety Precautions ............................. ix Chapter 1 System Description Section I: Features ..........................1-1 Section II: System Components Power Supply ..................1-2 Front Panel Controls, Indicators, and Connector ................1-2 Control and Monitor Unit Connector ..................1-3 ...........................
  • Page 4 CONTENTS (Continued) Page Chapter 2. Installation ad Setup Section I: Planning ..........................2-1 Environmental Factors ........................2-1 Space and Mounting Requirements ....................2-1 Power Requirements ........................2-1 Section II: Installation ..........................2-2 Unpacking ............................. 2-2 Installation ............................. 2-2 Mounting the Power Supply ..................... 2-2 Eectrical Connections .......................
  • Page 5 Page Sample Schedule Screens ........................ 3-5 Monitor Screen ..........................3-7 ............................. 3-7 TIME ............................. 3-7 CURR ............................. 3-7 VOLT ............................. 3-7 POWER ............................. 3-7 PULSE ........................3-7 STEPPER COUNT ............................. 3-7 STEP # ..........................3-7 WELD COUNT Monitor Set Screen .......................... 3-8 ........................
  • Page 6 CONTENTS (Continued) Page Chapter 4. Operating Instructions 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 Section III: Shutdown ..........................
  • Page 7 Page Appendix A. Technical Specifications ....................A-1 Appendix B. Electrical and Data Connections ..................B-1 Appendix C. System Timing .......................C-1 Appendix D. Wire Gauge Selection ....................D-1 Appendix E. Options ..........................E-1 Appendix F. Communications ......................F-1 Appendix G. Dipswitch Settings ......................G-1 Appendix H.

  • Page 8: Contact Us

    Thank you for purchasing a Miyachi Unitek ISA-4000CR Inverter Power Supply. The ISA Series has a wide variety of options, some are installed at the time of purchase, some may be added later. For the rest of this manual, the ISA-4000 and ISA-4001CR Inverter Power Supplies will be referred to simply as the Power Supply.

  • Page 9: Safety Precautions

    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 Miyachi Unitek. HIGH VOLTAGE is used in the operation of this equipment.
  • Page 10 Before using this equipment, read the SAFETY PRECAUTIONS carefully to understand the correct usage of the equipment. x These precautions are given for safe use of the Inverter Power Supply and for prevention of injury to operators or others. x Be sure to read each of the instructions, as they are all important for safe operation.
  • Page 11 Stop operation if any trouble occurs. If you detect a burning smell, abnormal sounds, abnormal heat, smoke, etc., turn power OFF immediately to prevent fire or electric shock. Contact Miyachi Unitek or your distributor for help. People with pacemakers MUST stay away from the Power Supply.
  • Page 12 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 13: Chapter 1 System Description

    SYSTEM DESCRIPTION Section I: Features The Miyachi Unitek ISA-4001CR Inverter Power Supply is a large-capacity, but compact, power supply designed for spot welding and fusing. The ISA-4001CR has a wide variety of options, some are installed at the time of purchase, some may be added later. For the rest of this manual, the ISA-4001CR Inverter Power Supply will be referred to simply as the Power Supply.

  • Page 14: Front Panel Controls, Indicators, And Connector

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

  • Page 15: Control And Monitor Unit Connector

    CHAPTER 1: SYSTEM DESCRIPTION – Used to connect the MA-627A Program Unit and the CONTROL AND MONITOR UNIT CONNECTOR Monitor Unit MA-628 to the Power Supply. – Red indicator that lights when power is supplied to the unit. WELD POWER –...
  • Page 16 CHAPTER 1: SYSTEM DESCRIPTION ISA-4001CR INVERTER POWER SUPPLY 990-364...

  • Page 17: Capacitor Discharge Indicator

    CHAPTER 1: SYSTEM DESCRIPTION – The electrolytic Capacitor Discharge Indicator capacitors are charged to a high voltage during operation of the Power Supply. The charge level is indicated by the brightness of the red indicator: the brighter the indicator, the higher the charge.

  • Page 18: Power And Ground Connections

    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 19: Circuit Breaker

    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 Lug connection point for input power. –...

  • Page 20: Program Unit (Ma-627A)

    CHAPTER 1: SYSTEM DESCRIPTION Program Unit (MA-627A) The illustration below shows the controls and indicators on the front of the Program Unit. The function of each control and indicator is described below. Because you will only need one Program Unit even if you have more than one Power Supply, the Program Unit is an optional piece that is sold separately.

  • Page 21: Monitor Unit (Ma-628A)

    CHAPTER 1: SYSTEM DESCRIPTION Monitor Unit (MA-628A) The illustration on the right shows the Monitor Unit. The Monitor Unit allows you to verify the operation of the Power Supply while it is operating. A cable is supplied to connect the Monitor Unit to the front panel of the Power Supply.

  • Page 23: Section I: Planning

    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 24: Section Ii: Installation

    CHAPTER 2: INSTALLATION AND SETUP Section II: Installation Unpacking Unpack the Power Supply from its shipping crate. NOTE: Carefully save and store packing materials for future storage or shipment of the Power Supply. Installation Installation consists of mounting the unit and making power, signal, and cooling water connections. Holes must be drilled into the Power Supply in order to install the Input and Output Power cables.

  • Page 25: Eectrical Connections

    CHAPTER 2: INSTALLATION AND SETUP Electrical Connections Input Power Connections Electrical input is made from holes drilled into the Power Supply to match the location of your power conduits. 1. Verify that all power to the Power Supply has been turned OFF. ISA-4001CR INVERTER POWER SUPPLY 990-364...

  • Page 26: Output Power Connections

    CHAPTER 2: INSTALLATION AND SETUP Open the front doors by turning the respective handles. Verify that the capacitor bank is discharged. Drill appropriate hole(s) in the enclosure to receive the input power conduit(s). NOTE: Remove all metal shards. Install service conduit to the enclosure and feed input power cables into the Power Supply. Need new photos below 5.
  • Page 27 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 28: Signal Sensing Connection

    CHAPTER 2: INSTALLATION AND SETUP Signal Sensing Connectior See Appendix B, Electrical and Data Connections, Section I, Data Connectors for connector pin information and Section II, Input/Output Signal Configuration for connection and configuration instructions. ISA-4001CR INVERTER POWER SUPPLY 990-364...

  • Page 29: Section Iii: Cooling Water

    CHAPTER 2: INSTALLATION AND SETUP Section III: Cooling Water Cooling Water Requirements The connections to the Power Supply are made with 1/2” brass compression 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, thus damage the unit.

  • Page 31: Chapter 3. Using Programming Functions

    CHAPTER 3 USING PROGRAMMING FUNCTIONS Section I: Operation Precautions WARNING: Operating, adjusting, maintaining or servicing the Power Supply, other than described in DEATH this manual may expose personnel to electrical hazards including WARNING: Always wear appropriate protection equipment when operating welding equipment. Section II: Programming the Power Supply The Program Unit is used to program the Power Supply and to monitor its operation during welding processes.

  • Page 32: Power Supply State Screen

    CHAPTER 3: USING ISA SERIES PROGRAMMING FUNCTIONS Power Supply State Screen This screen is used to set and display the POWER SUPPLY STATE information on the Power Supply. CONTROL # 1234 -- This is used to enter the CONTROL # PROGRAMMED DATE 1998.09.14...

  • Page 33: Ctrl

    CHAPTER 3: USING ISA SERIES PROGRAMMING FUNCTIONS This entry is used to designate one of the following five welding current control modes. CTRL – PRIMARY RMS Primary constant-current effective value control Secondary constant-current effective value control SECONDARY RMS Secondary constant-power effective value control...

  • Page 34: Gain (1-9)

    CHAPTER 3: USING ISA SERIES PROGRAMMING FUNCTIONS – This entry operates only in the secondary RMS and power RMS feedback modes and is GAIN (1-9) used to set the amount of gain for feedback. The larger the value, the greater the gain; thus shortening the current rise time.

  • Page 35: Sample Schedule Screens

    CHAPTER 3: USING ISA SERIES PROGRAMMING FUNCTIONS Sample SCHEDULE Screens Primary Constant-Current  SCHEDULE # CTRL 0 < PRIMARY RMS> Effective Value Control – SQD SQZ WE1 COOL WE2 HOLD TIME 0000 0000 000 0000ms ms Mode UP SLOPE DOWN SLOPE *HEAT 32.0...
  • Page 36 CHAPTER 3: USING ISA SERIES PROGRAMMING FUNCTIONS Secondary Constant-Power  SCHEDULE # CTRL 2 < POWER RMS > Effective Value Control – SQD SQZ WE1 COOL WE2 HOLD TIME 00 CYC CYC Mode UP SLOPE DOWN SLOPE HEAT 32.0 32.0...

  • Page 37: Monitor Screen

    CHAPTER 3: USING ISA SERIES PROGRAMMING FUNCTIONS Monitor Screen This screen is used to monitor any of the  MONITOR SCHEDULE # 001 64 schedules, as selected by SCHEDULE TIME CURR VOLT POWER PULSE Other than the selected Schedule, no...

  • Page 38: Monitor Set Screen

    CHAPTER 3: USING ISA SERIES PROGRAMMING FUNCTIONS Monitor Set Screen This screen is used to establish limits  MONITOR SET SCHEDULE # 001 beyond which alarm messages will be NO CURRENT TIME 99 ms WELD COUNT 0000 generated. CURRENT MONITOR NUMBER 1...

  • Page 39: Copy Setup Data Screen

    CHAPTER 3: USING ISA SERIES PROGRAMMING FUNCTIONS Copy Setup Data Screen This screen is used to transfer memory  COPY SETUP DATA contents between the Power Supply and the Program Unit. The Program Unit can > ISA-2000A -------> MA-627A (MEMORY 1) ISA-2000A ------->...

  • Page 40: Mode Select Screen

    CHAPTER 3: USING ISA SERIES PROGRAMMING FUNCTIONS Mode Select Screen This screen is used to set the various  MODE SELECT operational modes of the Power Supply. This entry is used to DELAY START SET – PARITY CHECK RE-WELD set the time from the input of the Stage 2 CYCLE WELD END SIG.

  • Page 41: End Sig. Mode

    CHAPTER 3: USING ISA SERIES PROGRAMMING FUNCTIONS – This entry is used to cause the End signal to occur when any monitor trouble signal END SIG. MODE (current, voltage, power, or pulse width) occurs. With the set ON, the End signal will END SIG.

  • Page 42: Linear Stepper Function

    CHAPTER 3: USING ISA SERIES PROGRAMMING FUNCTIONS Linear Stepper Function The linear stepper function will adjust the energy delivered to each weld by the percentage specified in the stepper setup for all welds within the first step. For all remaining steps, the current will be incremented or decremented in a linear fashion and will reach the desired %heat for that step at the end of each step.

  • Page 43: Reset To Defaults Screen

    CHAPTER 3: USING ISA SERIES PROGRAMMING FUNCTIONS ! ! ! TROUBLE ! ! ! At the end of all steps, the CAP CHANGE message will cause the Power REQUIRED CODE ERROR VALUE Supply to stop. An external reset must be E-09 END OF STEP.

  • Page 45: Chapter 4. Operating Instructions

    CHAPTER 4 OPERATING INSTRUCTIONS Section I: Introduction Operator Safety WARNINGS HIGH VOLTAGE is used in the operation of this equipment. DEATH ON CONTACT may result if personnel fail to observe the safety precautions labeled on the equipment and noted in this manual. To prevent blindness or eye injury, wear safety goggles at all times during welding.

  • Page 46: Section Ii: Operation

    CHAPTER 4: OPERATING INSTRUCTIONS Section II: Operation Starting Welding Operation Turn on cooling water supply at the temperature and flow rate shown in Chapter 2. Turn on the input power. Observe that the red lamp lights, and green WELD POWER READY lamp blinks for 35 seconds, then goes off.

  • Page 47: Section Iii: Shutdown

    CHAPTER 4: OPERATING INSTRUCTIONS Section III: Shutdown Stopping Welding Operation Turn the input power OFF. Observe that all of the Power Supply LED lamps go OFF. Turn the cooling water OFF. ISA-4001CR INVERTER POWER SUPPLY 990-364...

  • Page 49: Chapter 5. Maintenance Section I: Before You Start

    CHAPTER 5 MAINTENANCE Section I: Before You Start 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. Turn the power to the Power Supply OFF.

  • Page 50: Cleaning

    CHAPTER 5: MAINTENANCE 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 51: Section Ii: Troubleshooting

    CHAPTER 5: MAINTENANCE Section II: Troubleshooting The table below lists the messages that may be displayed on the Program Unit or Monitor Unit, Error what those messages mean, and corrective actions you can take. Error Contents Cause Corrective Actions Code E-01 Self-diagnostic Memory backup battery is...
  • Page 52 CHAPTER 5: MAINTENANCE Error Contents Cause Corrective Actions Code ISA-4001CR: (HEAT setting) E-10 Condition setting Correct each setting. > 4000 A (TURNS RATIO) error or <400A or >4000A in primary modes. E-11 Increase ratio HEAT setting, including Lower each setting to below the maximum error HEAT INCREASE % setting value.
  • Page 53 CHAPTER 5: MAINTENANCE Error Contents Cause Corrective Actions Code E-27 Tip Dress Welding stopped due to Manually dress the tip to clear the error, then Required programmed Tip Dress code. resume welding. E-28 Approaching Cap Programmed warning No action required. Change message.

  • Page 54: Section Iii: Fuse Failure And Replacement

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

  • Page 55: Main Pcb

    CHAPTER 5: MAINTENANCE CAUTION Do not attempt to replace any fuses other than those described below. All other fuses in the Power Supply should only be serviced by factory-authorized technicians or serious damage to the Power Supply could result. Main PCB Disconnect power to the Power Supply, discharge the capacitors, and remove the Safety Shield as described in Section I, Before You Start.

  • Page 56: Valve Driver Board

    CHAPTER 5: MAINTENANCE Valve Driver Board The Valve Driver board contains six fuses for the four valves, retraction valve, and switching power supply (optional). Before replacing any of these fuses, determine what caused it to fail and make appropriate repairs. FUSE DESCRIPTION TYPE...

  • Page 57: Valve Transformer Fuse, Secondary

    CHAPTER 5: MAINTENANCE Valve Transformer Fuse, Secondary TRANSFORMER FUSE DESCRIPTION TYPE PART NUMBER VA RATING Valve Transformer FNQ15, Slow-blow, 15A, 600 500 VA 330-117 Fuses, secondary 24 Volt DC Power Supply ( Not Shown The 24 Volt DC Power Supply is only available as an option. When installed it provides 24 VDC to power the valves.

  • Page 58: Section Iv: Maintenance Procedures

    CHAPTER 5: MAINTENANCE Section IV: Maintenance Procedures 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. Any time you believe that there is a build-up of sediment that might decrease the water flow and cause the unit to overheat –...

  • Page 59: Memory Battery Replacement

    CHAPTER 5: MAINTENANCE Turn the water back on slightly, but enough to flush the system. When the water is running clean, turn the water OFF. Reconnect the hose back onto the Power Supply and restore power and water. Re-install the plastic high voltage protective cover with the four screws that secure it.

  • Page 60: Section V: Spare Parts

    Section V: Spare Parts Spare Parts Frequently required spare parts can be obtained by contacting your Miyachi Unitek representative. Additional parts are available by contacting us at the address/numbers indicated in the foreword of this manual, or your local Miyachi Unitek distributor.

  • Page 61: Section Vi: Repair Service, Storage, Shipment

    CHAPTER 5: MAINTENANCE Section VI: 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 Disconnect power to the Power Supply, discharge the capacitors, and remove the plastic cover, as described in Section I, Safety Precautions, above.

  • Page 63: Appendix A. Technical Specifications

    APPENDIX A TECHNICAL SPECIFICATIONS Specifications ITEM DESCRIPTION Dimensions 500 lbs Weight Incoming Power Supply Three-phase 480VAC +10/-15 % common to 50Hz and 60Hz 480 VAC 575 VAC Three-phase 575VAC +10/-15 % common to 50Hz and 60Hz Stepped down from incoming power supply Control Power Supply 120VAC at 50 VA;...
  • Page 64 APPENDIX A: TECHNICAL SPECIFICATIONS ITEM DESCRIPTION Output Voltage 480 VAC Single-phase 679V (Peak value at input voltage of 480VAC) Single-phase 813V (Peak value at input voltage of 575VAC) 575 VAC (Peak value) (Duty Cycle: 12%) 4000 A Max. Output Current Max Capacity 480 VAC 2715 kVA...
  • Page 65 APPENDIX A: TECHNICAL SPECIFICATIONS ITEM DESCRIPTION 64 SCHEDULES Secondary current setting range ( HEAT Constant-current control: 32 - 200.0 kA Constant-power control: 15 - 300.0 kW Constant-phase control: 10.0 – 99.9% Primary current range Where CURRENT = 4000 for ISA-4001CR Transformer turns Setting range: 1.0 –...
  • Page 66 APPENDIX A: TECHNICAL SPECIFICATIONS ITEM DESCRIPTION Operating 5 - 40 qC @ 90% maximum humidity with no condensation Temperature Output Current: Internal overcurrent limiting circuit Protective Functions Control: 0.3 amp Time Delay Fuse Valves: Fuse (Size depends on options) No current: Power is turned off in the following cases: When a secondary current is not detected in secondary constant-current control, constant-power control or constant-phase control mode.

  • Page 67: Appendix B. Electrical And Data Connections

    Appendix B ELECTRICAL AND DATA CONNECTIONS Section I. Data Connectors The unit has two DB-9 (female) connectors wired as follows: #1 – Not Used #6 -- Not Used #2 -- Not Used #7 -- Not Used #3 -- Not Used #8 -- Rx+ #4 -- Tx+ #9 -- Rx-...
  • Page 68 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS Section II. Input/Output Signal Configuration Input/Output Signal Connections NOTE: Input/output signals can enter either the top or bottom of the Power Supply. If routed in from the top, they can be made through the RS-485 connector plate. If routed in from the bottom, they can be made through the current coil connector plate.
  • Page 69 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS Input/Output Signal Configuration ISA-4001CR INVERTER POWER SUPPLY 990-364...
  • Page 70 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS Input/Output Signals SIGNAL NAME SIGNAL DESCRIPTION NUMBER 0V Output Fuse-protected power output terminals for ISA-500AR use only. NOTE: Do not use for any other purpose. +24V Output External Signal Power IN Control power input terminals for external signals. NOTE: Connect pin 1 or 2 to these pins depending on input signal External Signal COM circuit.
  • Page 71 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS SIGNAL NAME SIGNAL DESCRIPTION NUMBER Step End Step End output terminal (open collector). When last step is finished in stepper mode, this output is present continuously until the Step Reset signal is applied. Then the output is open. Error Output These terminals close when an error occurs.
  • Page 72 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS SIGNAL NAME SIGNAL DESCRIPTION NUMBER Stage 2 Stage 2 input terminal. When this signal is present (connected to pin 50), welding commences according to the schedule selected at the binary inputs (pins 31 through 37). Retraction Retraction Valve input terminal.
  • Page 73 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS Configurations for Common Input Connections Sensing Connector DESCRIPTION Common (Thermostat) Thermostat Voltage Current Current Voltage Ground FRONT VIEW ISA-4001CR INVERTER POWER SUPPLY 990-364...
  • Page 74 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS I/O Binary Input I/O BINARY INPUT WELD Schedule Schedule Schedule Schedule Schedule Schedule Schedule SCHEDULE Schedule 01 Schedule 02 Schedule 03 Schedule 04 Schedule 05 Schedule 06 Schedule 07 Schedule 08 Schedule 09 Schedule 10 Schedule 11 Schedule 12 Schedule 13...
  • Page 75 APPENDIX B. ELECTRICAL AND DATA CONNECTIONS I/O BINARY INPUT WELD Schedule Schedule Schedule Schedule Schedule Schedule Schedule SCHEDULE Schedule 43 Schedule 44 Schedule 45 Schedule 46 Schedule 47 Schedule 48 Schedule 49 Schedule 50 Schedule 51 Schedule 52 Schedule 53 Schedule 54 Schedule 55 Schedule 56...

  • Page 77: Appendix Csystem Timing

    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 screen. START SIG. MODE Mode Select Maintained Mode When the Stage 2 signal is turned off during the weld sequence (between the...
  • Page 78 APPENDIX C: SYSTEM TIMING Pulsed Mode If the Stage 2 signal is held for more than the time set to , and subsequently turned off, the Delay Start Set weld sequence will continue to its conclusion. Start Signal Input in Pulsed Mode ISA-4001CR INVERTER POWER SUPPLY 990-364...
  • Page 79 APPENDIX C: SYSTEM TIMING Latched Mode If the Stage 2 signal is turned off during time, the weld sequence is interrupted. Squeeze If the Stage 2 signal is turned off after time, the weld sequence continue to its Weld 1 conclusion.
  • Page 80 APPENDIX C: SYSTEM TIMING One-Stage Start Stage 2 signal will begin the welding sequence with the selected Schedule #. One-Stage Start ISA-4001CR INVERTER POWER SUPPLY 990-364...
  • Page 81 APPENDIX C: SYSTEM TIMING Two-Stage Start When the signal is applied, the signal for the selected Schedule number is applied, but the Stage 1 Valve remaining weld sequence is delayed until input of the signal. The signal will start the Stage 2 Stage 2 weld sequence in the selected...
  • Page 82 APPENDIX C: SYSTEM TIMING Chaining Function function operates by allowing a sequence of Schedules to be performed as long as Chaining Stage 2 input signal is maintained. The schedules used for the chaining are set at in the Chaining Schedule screen.
  • Page 83 APPENDIX C: SYSTEM TIMING Successive Function function operates by allowing a sequential changing of multiple Schedules to be Successive performed as long as input signal is activated for each schedule. The schedules used for the Stage 2 succession are set to Successive in the Schedule screen. Example: A start (without a signal) causes the weld sequence to begin as a...
  • Page 84 APPENDIX C: SYSTEM TIMING Retraction Function function is used to temporarily widen the space between the electrodes to re-orient a Retraction work piece or to service the electrodes. The output signal occurs when the Retraction Valve Retraction input signal is applied. NOTE: This function can not be turned ON or OFF during a weld sequence.
  • Page 85 APPENDIX C: SYSTEM TIMING Forge Function function is performed when is set ON ( screen). The weld force of the Forge Forge Mode Select weld head can be changed during the weld schedule using . This operates a second valve at Forge Delay a programmed delay, allowing extra air pressure to be applied to the weld head.
  • Page 86 APPENDIX C: SYSTEM TIMING Repeat Operation Repeat operation will occur whenever the OFF time is set to any value other than zero (0) and Chaining is set OFF on the screen. Schedule Repeat Operation ISA-4001CR INVERTER POWER SUPPLY C-10 990-364...
  • Page 87 APPENDIX C: SYSTEM TIMING Pulsation Pulsation ISA-4001CR INVERTER POWER SUPPLY 990-364 C-11...
  • Page 88 APPENDIX C: SYSTEM TIMING Re-Weld will occur when is set ON ( screen), and a current monitor error occurs as a Re-weld Re-Weld Mode Select low weld current shown below. Under that circumstance, a re-weld will occur with a 5% increase in weld current.
  • Page 89 APPENDIX C: SYSTEM TIMING Interrupt will occur when is set On ( screen), and an Interrupt signal is applied Interrupt Interrupt Mode Select during a weld sequence. The weld cycle is immediately stopped and shifted to Hold Interrupt ISA-4001CR INVERTER POWER SUPPLY 990-364 C-13...
  • Page 90 APPENDIX C: SYSTEM TIMING Weld Monitor function is performed when is set ON ( screen). The Weld Monitor Weld Count Mode Select Monitor checks if the correct number of welds has been made during the period that the signal is on. Weld Count At the end of the period, if the weld count is less than that set at...

  • Page 91: Appendix D. Wire Gauge Selection

    ISA series is at its maximum peak current during the weld. Wire gauges for the AC Mains and Output lines to the transformer must meet the following criteria: a.
  • Page 92 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 ISA motherboard. The dipswitches are clearly labeled on the circuit breaker. There is a separate ABB Circuit Breaker Owner’s Manual in a pocket in the front door of the Power Supply, please refer to this manual if you need more information on the circuit breaker.

  • Page 93: Appendix E. Options

    APPENDIX E OPTIONS Overview Chapters 1 through 5 and Appendices A through D of this manual describe the standard configuration of the Power Supply. You may also order Power Supplies with these Options: Weldlab Software Communications Force Control Option Isolation Contactors Larger Control Transformer 24 Volt DC Power Supply Communications option that allows the Power Supply to be used with a host computer or with...
  • Page 94 APPENDIX E: OPTIONS Valve Transformer The Valve Transformer provides 120 VAC to power the valves and to the 24 VDC Power Supply if installed (option). The standard Control Transformer is rated at 50VA; two options are available the 150VA and the 250 VA. 24 Volt DC Power Supply ( Not Shown The 24 Volt DC Power Supply is only available as an option.

  • Page 95: Appendix F. Communications

    The communications option uses RS-485 multi-drop architecture to connect up to 30 controls to one host on a single channel. The Miyachi Unitek Weldlab software allows you to connect a single or multiple Power Supply to a computer in order to: Compile, store, view, and print weld history data for detailed analysis.
  • Page 96 APPENDIX F: COMMUNICATIONS Host settings Baud Rate 38.4k Data bits Stop bit Parity None Note that the host must be able to support 38.4 kbaud communications without interruptions or dropped bits. The computer hardware and operating system needed to achieve that level of performance depends upon the RS-485 adapter (or converter box) used.
  • Page 97 APPENDIX F: COMMUNICATIONS Section II. Communications Protocol and Commands RS-485 Communication External Protocol Each external command will be formatted as follows: <soh> <@> <cmd> <cnt> <data> <cksum> <eot>. Definition of Command Elements <soh> 1 BYTE The data packet will start with a SOH (start of header 0x01) character .
  • Page 98 APPENDIX F: COMMUNICATIONS Unit Responses To External Commands Errors or Unsupported Commands The ISA will respond with a Negative Acknowledge <NAK> (0x15) when an error is encountered. The ISA will return a Negative Acknowledge <NAK> in response to any command that is not supported.
  • Page 99 APPENDIX F: COMMUNICATIONS Host Originated Command Set These are commands sent by the host computer, via the RS-485 port to the ISA. NAME COMMAND DATA SIZE TYPE “TY” Read none 0 Bytes STATUS “TA” Read none 1 Bytes CONTROL# “CN” Read none 0 Bytes COUNT...
  • Page 100 APPENDIX F: COMMUNICATIONS NAME COMMAND DATA SIZE SCHEDULE “DR” Read Schedule # 1 Byte SCHEDULE “DS” Set SCHEDULE # 1 Byte SQD # (Squeeze Delay), 2 Bytes SQZ # (Squeeze Time), 2 Bytes UP1 # (Up Slope Time), 2 Bytes WELD1 # (Weld Time), 2 Bytes...
  • Page 101 APPENDIX F: COMMUNICATIONS NAME COMMAND DATA SIZE SCH 2 “HR” Read Schedule # 1 Byte SCH 2 “HS” Set SCHEDULE # 1 Byte VALVE # 1 Byte CONTROL MODE (see below) 1 Byte GAIN (1-9) 1 Byte TURNS RATIO 2 Bytes FORGE VALVE # 1 Byte CHAINING...
  • Page 102 APPENDIX F: COMMUNICATIONS NAME COMMAND DATA SIZE STEPPER “GR” Read Valve # 1 Byte STEPPER “GS” Set VALVE #, 1 Byte START ON STEP #, 1 Byte STEP 1 COUNT #, (0-9999) 2 Bytes STEP 2 COUNT #, 2 Bytes STEP 3 COUNT #, 2 Bytes STEP 4 COUNT #,...
  • Page 103 APPENDIX F: COMMUNICATIONS ISA Originated Command Set These are commands returned by the ISA-500CR to the host computer, via the RS-485 port. NAME COMMAND DATA SIZE TYPE “TY” Read “ISA”, Release # and Revision #. 16 Bytes Example: “ISA500A 01.02 CX”. CONTROL # ”CN”...
  • Page 104 APPENDIX F: COMMUNICATIONS NAME COMMAND DATA SIZE SCHEDULE “DS” Set <ACK OR NAK> 1 Byte SCHEDULE “DR” Read SCHEDULE # 1 Byte SQD # (Squeeze Delay), 2 Bytes SQZ # (Squeeze Time), 2 Bytes UP1 # (Up Slope Time), 2 Bytes WELD1 #(Weld Time), 2 Bytes DOWN1 # (Down Slope Time),...
  • Page 105 APPENDIX F: COMMUNICATIONS NAME COMMAND DATA SIZE SCH 2 “HS” Set <ACK OR NAK> 1 Byte SCH 2 “HR” Read SCHEDULE # 1 Byte VALVE # 1 Byte CONTROL MODE (see below) 1 Byte GAIN (1-9) 1 Byte TURNS RATIO 2 Bytes FORGE VALVE # 1 Byte...
  • Page 106 APPENDIX F: COMMUNICATIONS NAME COMMAND DATA SIZE STEPPER “GS” Set <ACK OR NAK> 1 Byte STEPPER “GR” Read VALVE #, 1 Byte START ON STEP #, 1 Byte STEP 1 COUNT #, (0-9999) 2 Bytes STEP 2 COUNT #, 2 Bytes STEP 3 COUNT #, 2 Bytes STEP 4 COUNT #,...
  • Page 107 APPENDIX F: COMMUNICATIONS NAME COMMAND DATA SIZE STATUS “TI” Sending <data> 0= Returns Last error 4 Bytes 1= Schedule and Heat: # if changed (1-127) else 0 1 Byte 2= Monitor: Schedule # if changed else 0 1 Byte 3= Step %: Schedule # if changed else 0 1 Byte 4= Stepper:...

  • Page 109: Appendix G. Dipswitch Settings

    APPENDIX G DIPSWITCH SETTINGS WARNING Do not attempt to adjust any dipswitches other than those described in this Appendix. Dipswitches are factory-set at time of manufacture to match specified input/output power requirements and other operating parameters. Changing these settings may present electric shock and fire hazards, damage the equipment, or render it inoperable.
  • Page 110 APPENDIX G: DIPSWITCH SETTINGS WARNING Never attempt to change dipswitch settings while power is ON or when the capacitors are charged. You may receive an electric shock. Before setting the dipswitch, perform the pre-maintenance shutdown procedures described in Chapter 4, Maintenance. Weld Power Frequency [SW3] CAUTION: Do not change the settings on switch positions 6-8.

  • Page 111: Appendix H. Schedule Data Tables

    APPENDIX H SCHEDULE DATA TABLES You may copy and use Setting List table on the following pages to record the values set in each weld schedule ISA-4001CR INVERTER POWER SUPPLY 990-364...
  • Page 113 Setting Items 64 Schedules 4 Schedules 1 Schedule (Display on Program Unit) (Corresponding to Start Number (Corresponding to Valve Number) (Common to Each Schedule) POWER SUPPLY STATE Control Number Programmed Date SCHEDULE CTRL UPSLOPE 1 WE 1 DOWNSLOPE 1 COOL UPSLOPE 2 WE 2 DOWNSLOPE 2...
  • Page 115 SETTING LIST Setting Items 64 Schedules 4 Schedules 1 Schedule (Display on Program Unit) (Corresponding to Start Number (Corresponding to Valve Number) (Common to Each Schedule) STEPPER COUNT Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9...
  • Page 117 Setting Items 64 Schedules 4 Schedules 1 Schedule (Display on Program Unit) (Corresponding to Start Number (Corresponding to Valve Number) (Common to Each Schedule) MONITOR SET No Current Time Current Monitor No. Weld Count High Weld 1 Current High Weld 2 High Weld 1 Volt...

  • Page 119: Appendix I. Force Control Option

    APPENDIX I FORCE CONTROL OPTION Description The Force Control (Force Output) Option controls an . Output Force is Electronic Pressure Regulator programmed in pounds ( ), kilograms of force ( ), or Newtons ( ) using controls on the Program Unit.
  • Page 120 Operation NOTE: Use the buttons on the Program Unit to move cursor in order to highlight a selection. Turn Force Control ON or OFF From the screen, select MENU [MENU] PRESSURE REGULATOR POWER SUPPLY STATE COPY SETUP DATA SCHEDULE MODE SELECT Press ENTER MONITOR...
  • Page 121 -force measurement are used for HIGH calibration. If you are unable to match these measurements, return the Control to Miyachi Unitek for factory calibration. Before you start Calibration, check the force gauge to be used between the electrodes to see what force units it measures.
  • Page 122 APPENDIX I: FORCE CONTROL OPTION First, calibrate the force setting. Highlight on the screen. LOW: 00000 UP 5. Place a force gauge between the electrodes. 6. Press the on the Program Unit to change from LOW UP LOW DOWN 7. To lower the weld head, press ENTER NOTE: In mode, the...

This manual is also suitable for:

Isa-4000Isa-4001cr

Table of Contents