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Amada IP-100D Operation Manual

Inverter welding power supply
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INVERTER WELDING POWER SUPPLY
IP-100D/200D
OPERATION MANUAL
Y02M0821E-04

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Summary of Contents for Amada IP-100D

  • Page 1 INVERTER WELDING POWER SUPPLY IP-100D/200D OPERATION MANUAL Y02M0821E-04...

  • Page 2: Table Of Contents

    IP-100D/200D Thank you for purchasing our Inverter Welding Power Supply IP-100D/200D. ・ This operation manual explains its method of operation and precautions for use. ・ Before using, read this operation manual carefully; after reading, save it in a proper place where you can easily access.

  • Page 3: Special Precautions

    IP-100D/200D 1. Special Precautions CAUTION (1) Safety Precautions ！ Before using, read "Safety Precautions" carefully to understand the correct method Denotes operations and practices that of use. may result in personal injury or damage to the equipment if not correctly followed.
  • Page 4 IP-100D/200D WARNING ！ Do not put your hands between the electrodes When welding, keep your fingers and hands away from the electrodes. Do not touch any welded part or electrodes during welding and just after welding finished The welded part of a workpiece, electrodes and arm are very hot.
  • Page 5 IP-100D/200D CAUTION ！ Do not splash water on the Power Supply Water splashed over the electric parts can cause electric shock and short circuits. Use proper tools (wire strippers, pressure wire connectors, etc) for termination of the connecting cables Do not cut the conductor of wire. A flaw on it can cause fire and electric shock.
  • Page 6 IP-100D/200D (2) Precautions for Handling ■ When transporting or moving the Power Supply, do not lay it down. Also, handle the Power Supply with care so as not to make an impact such as drop on it. ■ Install this Welding Power Supply on a firm, level, horizontal surface. If it is inclined, malfunction may result.

  • Page 7: Features

    IP-100D/200D 2. Features The IP-100D/200D is an inverter type of compact Precise Resistance Welding Power Supply which realizes excellent weldability and operation, and is provided with Constant Current Control Function accommodating to various kinds of workpieces.  Sixty-three (63) types of welding schedules can be registered Once a welding schedule is registered, it can be invoked by one key operation only.

  • Page 8: Name And Functions Of Each Section

    ① LCD Panel This is the display panel to check the status of operation of IP-100D/200D. This display appears when [POWER] main circuit breaker is turned on. LCD Display Panel displays Setting Screen that is used to set each item of the welding conditions and Monitor Screen that is used to indicate measured values of the welding current actually flowed.
  • Page 9 This function is ready when the Software switch (SW5) is set to “1”. (h) HEAT1 Sets and displays the current in the first stage of welding. IP-100D: 0100 to 1300 A IP-200D: 0400 to 2500 A HEAT2 Sets and displays the current in the second stage of welding.
  • Page 10 IP-100D/200D On monitor screen, displays the first stage upslope time during which the welding current actually flowed within R1 time. (If WELD STOP has been input, the actual weld time is displayed.) On monitor screen, displays the weld time during which the welding current actually flowed within W1 time.
  • Page 11 ON/OFF) of [I/O] connector is in off position, current will not flow). When the key is pressed for 0.5 or more seconds while [WELD] lamp illuminates, the lamp will be turned off and IP-100D/200D cannot flow welding current. Furthermore, when this key is pressed during abnormal conditions, trouble signal output that indicates abnormal conditions is turned off.
  • Page 12 ⑯ I/O cable inlet [POWER] Main Circuit Breaker ⑪ Turns on and off IP-100D/200D. When the handle is pulled up to ON position, power supply is applied to its main body; pushed down to OFF position, power supply is disconnected.
  • Page 13 For grounding. This is mounted behind the cover. Connect the grounding wire when connecting the power cable to the [POWER] main circuit breaker. Vent ⑱ Cooling air for the interior of IP-100D/200D is sucked in through this vent. 3. Name and Functions of Each Section...

  • Page 14: Installation And Connection

     Places where it is not extremely hot or cold.  Places where there is no splashed water. Slits are provided on right, rear sides and bottom of IP-100D/200D for higher heat radiation efficiency. Install this Power Supply with a clearance of at least 10 cm from the side wall to extract the full performance.
  • Page 15 10cm minimum F ront Rear Air flow Ai rflow Airflo w Int ake Ai rflow IP-200D installation clearance (2) Connection Connect IP-100D/200D to the welding head as shown below: Power cable Ｒ Ｓ Ｔ Ｅ Secondary IP-100D Welding cable Connect to Ter- head ＋...
  • Page 16 IP-100D/200D When finishing connection to the welding head, connect the power cable to IP-100D/200D (see drawing below). ① Remove the cover for the [POWER] main circuit breaker on the rear panel. ② Connect the power cable to the [POWER] main circuit breaker.

  • Page 17: Basic Operation

    IP-100D/200D 5. Basic Operation CAUTION Before operation, check that the display screen and lamps are turned on normally and the fan motor is operated. (1) Welding Schedule Setting ATTENTION Programming is inhibited if Terminals 15 and 18 of I/O terminals are shorted, and welding schedule cannot be set.
  • Page 18 IP-100D/200D ③ Setting RISE 1 Time Press [Cursor] to move the cursor to R1 . Press [+] and [-] to set RISE 1 Time. ④ Setting WELD 1 Time Press [Cursor] to move the cursor to W1 . Press [+] and [-] to set the first stage Weld Time.
  • Page 19 ⑪ Setting the Monitoring Range and the End Signal Output Time of Monitor Function IP-100D/200D monitors the difference between the current values set in ○ , and the actual current. Error signal is output if the difference exceeds the ○...
  • Page 20 IP-100D/200D ⑫ Setting Serial Communication Condition and Software Switch By changing the setting of Serial Communication Condition and Software Switch, function of IP-100D/200D can be altered. Change the function according to the following procedures. i) While pressing [Cursor] key , turn on [POWER] main circuit breaker.
  • Page 21 IP-100D/200D Setting Function Selects external communication function. (See 11. External Communication Specifications.) No external communication. Single-directional mode RS-485 outputs data after [END] signal has been output. (Monitor data or trouble data) The next Start signal accepted during external communication. Schedule data cannot be set in this mode.
  • Page 22 IP-100D/200D iv) Press [Cursor] key with the cursor positioned on SW7 or [Cursor] key with the cursor positioned on the left portion of ID# to display the screen on the LCD panel as shown. Set Software Switches SW8 to SWF.
  • Page 23 IP-100D/200D ⑬ If another Welding Conditions become necessary Repeat the operations described in ○ – ○ again to set necessary welding schedules. Up to sixty-three (63) welding schedules can be registered. For your convenience, Schedule Table is provided in 13. Schedule Data Table.
  • Page 24 IP-100D/200D iii) Initializing data Press the [Cursor] key on the Data Initialize screen ① to go to the Data Initialize screen ②. ＡＬＬ ＤＡＴＡ ＣＬＥＡＲ ？ Data Initialize screen ② －： ［Ｎ］ ＋： ［Ｙ］ Press [-] key to return to the Data Initialize screen ①.
  • Page 25 IP-100D/200D ⑮ LCD contrast setting screen i) While pressing [Cursor] key , turn on the [POWER] main circuit breaker. Ｒ Ｅ Ａ Ｄ Ｙ － ＋ Ｗ Ｅ Ｌ Ｄ Ｓ Ｔ Ａ Ｒ Ｔ ＯＮ Turn on [POWER] While pressing …...
  • Page 26 Welding Schedule NO. indicated on the LCD panel. (3) Monitored Current Display After delivering the welding current, IP-100D/200D automatically displays the magnitude of flowed current (monitored value) on LCD Panel. The display on the screen changes according to the monitored value.
  • Page 27 IP-100D/200D <GO> or [GO] is displayed on the monitor screen to indicate that IP-100D/200D is working normally. When any of the [Cursor], [+], [-], and [WELD] is pressed at this time, the Setting screen appears. Also, the display of monitor current can be switched to the average value or peak value by SW4 setting.
  • Page 28 IP-100D/200D ③ When monitoring range of welding current is set to 00% Setting Sc reen Monitor Screen Wh en mo ni to r cu rr ent i s se t to a ver ag e SCH ED ULE SC HED ULE...

  • Page 29: Replacing Battery

    IP-100D/200D 6. Replacing Battery IP-100D/200D comes with a built-in lithium battery for data storage. The service life of this lithium battery is approximately 5 years. Replace the battery, when it dies, observing the instructions below: (Battery used: CR2450 or the equivalent) If the battery is replaced, all the registered welding schedules are lost.

  • Page 30: Interface

    IP-100D/200D 7. Interface (1) External I/O Signals １ EXT.COM ２ INT.24V ３ ４ START ５ ６ SCH1 ７ SCH2 ８ SCH4 ９ SCH8 １ ０ SCH16 １ １ SCH32 １ ２ PARITY １ ３ １ ４ WELD ON/OFF １ ５...
  • Page 31 (2) Explanation on the External I/O Signals Terminal No. Description  When IP-100D/200D is connected to a contact or NPN open collector output-type device (when using the internal power supply), connect this terminal to Terminal 2.  If IP-100D/200D is connected to a NPN open collector output...
  • Page 32 IP-100D/200D Terminal No. Description Output terminal for [READY] signal. This signal outputs when the following is satisfied, i.e., IP-100D/200D is ready for welding.  [WELD] lamp on the front panel lights up. , 22*  [WELD ON/OFF] is closed.  Trouble signal [NG] is not output (excluding current monitor trouble).
  • Page 33 IP-100D/200D (3) Input Signal Connection ① When Connecting to Contact Input Device Connect Terminals 1 and 2 with a jumper wire. (Powe r supply inter ior) (User connection) EXT.COM +24V Short ! ＋ +24VOUT Internal power supply 〃 〃 START ②...
  • Page 34 IP-100D/200D ③ When Connecting to NPN Open Collector Output Device (using an external power supply) Connect Terminal 1 to the "+" terminal of the external 24V DC power supply. (P o we r su p pl y i nt er io r )
  • Page 35 IP-100D/200D (4) Determining Welding Schedule Number 63-Schedule Input Select #1 to #63 schedules by opening and closing schedule input signals [SCH1], [SCH2], [SCH4], [SCH8], [SCH16] and [SCH32] on the rear-panel terminal block. * For parity check, set SW1 of the Software Switch to “1”. (See 5. Basic Operation (1) .) In addition to the Schedule signals, parity signal is provided so that error signal...
  • Page 36 IP-100D/200D Schedule SCH1 SCH2 SCH4 SCH8 SCH16 SCH32 Parity* No. # ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...

  • Page 37: Timing Chart

    IP-100D/200D 8. Timing Chart WELD ON/OFF SCHEDULE 1,2,4,8, 16,32,P When START signal is turned off after W1 starts, self-holding circuit of Sequence works. START t (NOTE 1) WELD STOP (NOTE 3) RESET Sequence* (NOTE 4) HOLD Sequence COOL HOLD (NOTE 4)
  • Page 38 IP-100D/200D : The timing when WELD STOP is input. : The timing when SW8 is set to 1. (NOTE 1): Input Schedule No. (SCH.) before Start signal is input. “t” is to stabilize time of Start signal. (1 ms, 5 ms or 20 ms can be selected by Software Switch (SW0).) (See 5.

  • Page 39: Troubleshooting

    IP-100D/200D 9. Troubleshooting When abnormal condition occurs, message will be displayed on LCD Panel and NG signal indicating abnormal condition is output. Memory Data Trouble Message MEMORY TROUBLE 1!! Time when Detected When power is turned on. Cause of Occurrence Welding Schedule data differ from those programmed.
  • Page 40 Overheating Trouble Message OVER HEAT !!! Time when detected When not starting. Cause of Occurrence IP-100D/200D itself is overheating extraordinary. Either input [RESET] signal or push any key on the front panel of Resetting Method the main body. Turn on [POWER] circuit breaker and leave the equipment as ○...
  • Page 41 IP-100D/200D WELD STOP Input Trouble Message STOP INPUT NG Time when Detected When started. Cause of Occurrence [WELD STOP] has been on when [START] is input. Either input [RESET] signal or press any key on the front panel of Resetting Method the main body.

  • Page 42: Specifications

    IP-100D/200D 10. Specifications (1) Specifications IP-100D IP-200D Power supply 3-phase, 180–240V AC, 50/60 Hz Rated capacity 1.4 kVA 5.3 kVA Output voltage 5.5 V 8.1 V Maximum output 1300 A 2500 A current (Built-in welding transformer) (Built-in welding transformer) Control frequency 4 kHz 3.5% (1000 A)
  • Page 43 IP-100D/200D IP-100D IP-200D Ready signal Finish signal (Note: This is also output even when current monitor is faulty.) External output signals Trouble signal Normal signal Output capacity: 24V DC, 20 mA MAX (FET output) Memory backup battery Lithium battery, Life: 5 years (after shipment) Temperature 0–45C and humidity 90% or less (Dew...
  • Page 44 IP-100D/200D (2) Duty Cycle IP-100D : at 30 ℃ : at 45 ℃ 1 400 1200 1000 4 5 6 7 8 9 30 40 50 Duty cycle (%) IP-200D 300 0 2500 200 0 150 0 100 0 50 0...

  • Page 45: External Communication Specifications

    IP-100D/200D 11. External Communication Specifications (1) Introduction IP-100D/200D can be connected to a PC to allow schedule setting or to read monitor or status data on the PC. (2) Data Transmission  Transmission Mode RS-485, Asynchronous, Half-Duplex  Transmission Rate 9600, 19200, 38400 bps ...
  • Page 46 IP-100D/200D (4) Output Data ① When the single-directional communication mode (SW2=1) is selected (Device No. is sent in this mode, but in a one-to-one relationship to host computer.) Monitor data Data strings: 01,63,49ms,99ms,1000A,49ms,299ms,1000A,[CR] A: Device No. Fixed to 2 digits (01–31) B: Schedule No.
  • Page 47 Inquiry of Model name and Code: # Device No. I ROM version Example: Model name of Device No.01 and the ROM version → IP-100D and the ROM version is V00-00A. Host 0 1 : I P - 1 0 0 D , V 0 0 - 0 0...
  • Page 48 IP-100D/200D Code: # Device No. R Schedule No. Specified 4. Specified item reading code Example: Read Weld 2 time for Schedule No. “031” of Device No.01. Host 0 1 0 3 1 T 0 7 : 2 0 0 m s...
  • Page 49 (unit: %) Weld 2 current lower limit (00–49) (unit: %) (**) When SW5 is set to 0, Squeeze time is fixed to 0000ms and Hold time is fixed to 000ms. (***) IP-100D: 0100–1300A, IP-200D: 0400–2500A 11. External Communication Specifications 11-5...
  • Page 50 Specified Item Note Code 01 Weld 1 current (unit: A) (**) 02 Weld 2 current (unit: A) (**) (**) IP-100D: 0100–1300A, IP-200D: 0400–2500A 3. Monitor data Specified Item Note Code 00 Weld 1 monitor current 01 Weld 2 monitor current...
  • Page 51 IP-100D/200D 5. Error code Specified Data Item Note Code Trouble reset Trouble read No trouble Memory trouble (Checksum error) Parity error Overheating trouble Overcurrent trouble No-current trouble Welding stop input error Memory trouble (Out-of-range error) Battery voltage trouble Emergency stop Current monitor trouble 11.

  • Page 52: Outline Drawing

    IP-100D/200D 12. Outline Drawing IP-100D 2-φ8.5 12. Outline Drawing 12-1...
  • Page 53 IP-100D/200D IP-200D 73.5 2-φ8.5 12. Outline Drawing 12-2...

  • Page 54: Schedule Data Table

    IP-100D/200D 13. Schedule Data Table 13. Schedule Data Table 13-1...
  • Page 55 IP-100D/200D 13. Schedule Data Table 13-2...

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Ip-200d

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