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Amada IP-400B Operation Manual

Inverter welding power supply
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INVERTER WELDING POWER SUPPLY
IP-400B
OPERATION MANUAL
Y02M0667E-07

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Summary of Contents for Amada IP-400B

  • Page 1 INVERTER WELDING POWER SUPPLY IP-400B OPERATION MANUAL Y02M0667E-07...

  • Page 2: Table Of Contents

    IP-400B Thank you for purchasing our Inverter Welding Power Supply IP-400B. ・ 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-400B 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-400B 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-400B 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-400B (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-400B 2. Features The IP-400B is an inverter-type small-sized precision resistance welding power supply which has a constant-current control function applicable any workpiece and which realizes high weldability and operability.  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

    : 300V FREQUENCY : 4kHz ① LCD Panel This is the display panel to check the status of operation of IP-400B. This display appears when [POWER] main circuit breaker on the rear panel 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 IP-400B (a) SCHEDULE Sets and indicates the Welding Schedule Numbers. The number of settings of the welding schedule to be registered is sixty-three (63), ranging from Nos. 01 to 63. (b) R1 Sets and indicates the Upslope time (00 to 49 ms) given in the first stage of welding.
  • Page 10 IP-400B 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 [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-400B 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 4 mm min. ⑩ [POWER] Main Circuit Breaker Turns on and off IP-400B. 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. ⑪ [TEST] Button Checks for inspection whether the [POWER] main circuit breaker functions normally.
  • 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. ⑮ I/O Terminals Used to connect IP-400B and external equipment. Connect signal wires as necessary. ⑯ [SENS] Connector Connects to the [SENS] connector of the inverter-type welding transformer IT-513B through the attached SENS cable.

  • 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 both sides of IP-400B 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 IP-400B 4. Installation and Connection...
  • Page 16 IP-400B When finishing connection to the welding head, connect the power cable to IP-400B (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-400B 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-400B 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-400B monitors the difference between the current value set in 9 and , and the actual current. Error signal is output if the difference exceeds the monitoring range (tolerance).
  • Page 20 IP-400B ⑫ Setting Serial Communication Condition and Software Switch By changing the setting of Serial Communication Condition and Software Switch, function of IP-400B 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-400B 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-400B 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-400B ⑬ If another Welding Conditions become necessary Repeat the operations described in 1– ○ 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-400B 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-400B 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-400B 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-400B <GO> or [GO] is displayed on the monitor screen to indicate that IP-400B 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-400B ③ When monitoring range of welding current is set to 00% Setti ng Screen Monitor Screen Wh en mo ni to r cu rr ent i s se t to a ver ag e S CHE DU LE SC HED UL E...

  • Page 29: Replacing Battery

    IP-400B 6. Replacing Battery IP-400B 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-400B 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 (when using the internal power supply), connect this terminal to Terminal 2. • If IP-400B is connected to a NPN open collector output (when using an external power supply) or PNP current output-type device, connect this terminal to a 24V DC external power supply.
  • Page 32 IP-400B Terminal No. Description Output terminal for [READY] signal. This signal outputs when the following is satisfied, i.e., IP-400B 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-400B (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-400B 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-400B (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-400B Schedule SCH1 SCH2 SCH4 SCH8 SCH16 SCH32 Parity* No. # ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○...

  • Page 37: Timing Chart

    IP-400B 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-400B : 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-400B 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-400B or IT-513B 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 it is without starting.
  • Page 41 IP-400B 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-400B 10. Specifications (1) Specifications Welding power supply 3-phase, 180–240V AC, 50/60 Hz Maximum capacity 65 kVA (at 240V AC input voltage) Rated capacity 24 kVA (at 240V AC input voltage, duty cycle: 7%) Max. output current 200 A (at the primary side of transformer)
  • Page 43 IP-400B Temperature 0–45C and humidity 90% or less (Dew condensation not allowed), altitude 1000 meters or lower Caution: Use this product in the environment without Operation environment conductive dust. If conductive dust enters in the product, this may result in a failure, electric shock, or fire.

  • Page 44: External Communication Specifications

    IP-400B 11. External Communication Specifications (1) Introduction IP-400B can be connected to a PC to allow schedule setting or to read monitor or status data on the PC. (2) Data Transmission 1 Transmission Mode RS-485, Asynchronous, Half-Duplex 2 Transmission Rate...
  • Page 45 IP-400B (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,1.00kA,49ms,299ms,1.00kA,[CR] A: Device No. Fixed to 2 digits (01–31) B: Schedule No.
  • Page 46 IP-400B 2 When the bidirectional communication mode (SW2=2) is selected Inquiry of Model name and Code: # Device No. I ROM version Example: Model name of Device No.01 and the ROM version Host 0 1 : , V 0 0 - 0 0A...
  • Page 47 IP-400B 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 48 IP-400B 3 Data code list i) Schedule data (Common schedule data <Schedule No.: 000>) Character Item Contents strings Transmission rate (0: 9600 1: 19200 2: 38400) (*) nnn, END signal time (000–200) (unit: ms) SW0 (Start-input stabilize time 0: 20ms 1: 5ms 2: 1ms)
  • Page 49 IP-400B ii) Specified item 1. Operation sequence time Specified Item Note Code 01 Squeeze time 0000–9990 (unit: 10ms) (*) 02 Upslope 1 time 00–49 (unit: 1ms) 03 Weld 1 time 00–99 (unit: 1ms) 05 Cool time 00–99 (unit: 1ms) 06 Upslope 2 time 00–49...
  • Page 50 IP-400B 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 51: Outline Drawing

    IP-400B 12. Outline Drawing (Dimensions in mm) S C H E D U L E S Q ( × 1 0 ) H E A T 1 H E A T 2 R E A D Y W E L D...

  • Page 52: Schedule Data Table

    IP-400B 13. Schedule Data Table 13. Schedule Data Table 13-1...
  • Page 53 IP-400B 13. Schedule Data Table 13-2...

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