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Amada IS-800CR Operator's Manual

Basic inverter power supply
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OPERATOR MANUAL 990-391
Revision B
March 2015
OPERATORS MANUAL
FOR THE
IS-800CR/1400CR BASIC
INVERTER POWER SUPPLY
Model IS-1400CR-Ax-xx
Model IS-800CR-Ax-xx

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Summary of Contents for Amada IS-800CR

  • Page 1 OPERATOR MANUAL 990-391 Revision B March 2015 OPERATORS MANUAL FOR THE IS-800CR/1400CR BASIC INVERTER POWER SUPPLY Model IS-1400CR-Ax-xx Model IS-800CR-Ax-xx...
  • Page 2 Copyright  2014, 2015 Amada Miyachi America The engineering designs, drawings and data contained herein are the proprietary work of AMADA MIYACHI AMERICA and may not be reproduced, copied, exhibited or otherwise used without the written authorization of AMADA MIYACHI AMERICA.
  • Page 3 ENTER Key ..........................1-12 MENU Key ..........................1-12 Connector ..........................1-12 Chapter 2. Installation And Setup Section I: Planning ..........................2-1 Environmental Factors ..........................2-1 Space and Mounting Requirements ......................2-1 Power Requirements ..........................2-2 IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 4 DL (DOWN SLOPE LAST) ....................3-8 CTRL ............................. 3-9 PAGE DOWN ..........................3- 10 PULSATION and Transformer Screen ....................3-11 SCHEDULE # ..........................3-11 PULSE LIM ........................... 3-11 PULSATION / INT1 to 3 ......................3-11 IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 5 DELAY START SET ........................3-22 START SIG.MODE ........................3-23 When latched .......................... 3-23 When pulsed ........................... 3-23 When maintained ........................3-24 END SIG.TIME ..........................3-24 END SIG.MODE ........................... 3-25 WELD1 STOP/PARITY CHECK ....................3-25 IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 6 RESET TO DEFAULT Screen ......................3-41 PROGRAM PROTECT MODE Screen ....................3-42 Chapter 4. Operating Instructions Section I: Introduction ........................... 4-1 Operator Safety ............................. 4-1 Before You Start ........................4-1 Preparing for Operation .......................... 4-1 IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 7 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 and Circuit Breaker Setting ..........D-1 Appendix E. Options ..........................E-1 Appendix F. Communications ......................F-1 IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 8 Power Supply. This Power Supply 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 IS-800CR/1400CR will be referred to simply as the Power Supply.
  • Page 9 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 Miyachi America. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY...
  • Page 10 DISCHARGE switch until the CHARGE light goes OFF. NEVER DISASSEMBLE, REPAIR, OR MODIFY THE POWER SUPPLY. These actions can cause electric shock and fire. Do not do anything other than the maintenance described in the Operator Manual. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • 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 Amada Miyachi America or your distributor for help. People with pacemakers MUST stay away from the Power Supply.
  • Page 12 Make sure there is a fire extinguisher in or near the welding shop in case of fire. Regularly inspect and maintain the Power Supply. Regular inspection and maintenance is essential to safe operation and long life of the equipment. If you see any damage, make necessary repairs before operation. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 13 Most of the features and functions for these two power supplies are identical, however the IS-800CR provides 800 amps primary current, while the IS-1400CR provides 1400 amps primary current. For the rest of this manual, the Miyachi Unitek IS-800CR/1400CR will simply be referred to the Power Supply , unless a feature or procedure unique to a specific model is described.
  • Page 14 CHAPTER 1: SYSTEM DESCRIPTION  Phase error  Circuit breaker with rotary handle is included (IS-800CR: 250 amps, IS-1400CR: 400 amps)  120VAC 150VA valve transformer standard, 250VA optional  24VDC valve voltage: 2 amps (optional), 5 amps (optional)  Output contactors optional ...
  • Page 15 Each time this key is pressed, it is turned ON and OFF alternately. If it is turned on, lamp READY lights up, and if the key is turned off, the lamp goes off. Hold down this key to toggle ON and OFF. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 16 Used to connect the MA-627A Program Unit (Pendant) to set the weld schedules and see the monitored result. NOTE: The IS-800CR/1400CR is a configured version of Amada Miyachi’s ISB-800A/1400A and the MA-627A pendant will display “ISB-800A” or “ISB-1400A”) IS-800CR/1400CR BASIC INVERTER POWER SUPPLY...
  • Page 17 NOTE: There are minor differences between the size and connector locations between the IS-800CR and the IS-1400CR, but in all other respects the internal components of the two models are identical.
  • Page 18 Used to accept the three-phase power supply for welding. Do not connect the power supply with voltage other than the specified. Terminal Block for Welding Power Output Used to connect to the input of the welding transformer. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 19 CHAPTER 1: SYSTEM DESCRIPTION Connecting Terminal Strip for External Input/Output Signals Used to input start signals and output trouble signals. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 20 INPUT/OUTPUT Power Module. The charge level of this electrolytic capacitor is indicated by the brightness of the CHARGE lamp. The more the capacitor is INDICATOR charged, the brighter the CHARGE INDICATOR lamp is. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 21 CHAPTER 1: SYSTEM DESCRIPTION RS485/RS232C Connector For external communication see Appendix F, Communications. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 22 CHAPTER 1: SYSTEM DESCRIPTION TRANSFORMER SENSING CONNECTOR Amada Miyachi America’s IT series transformers are connected to this sensing connector. The Toroidal Coil is integrated in the IT transformer. The signal comes through the TRANSFORMER SENSING on bottom of Power Supply.
  • Page 23 Turn off the start signal and press key. TROUBLE RESET ISB-800A IS BUSY OR NOT CONNECTED Please RESET key in +ON/-OFF Keys Used to change the value of a selected item or turn it on and off. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391 1-11...
  • Page 24 Also, when changing a screen to call up another setting schedule during the welding sequence, the key does not work even if the following screen appears. In this case, you need to TROUBLE RESET turn on the power again. (When connecting to the Power Supply, IS-800CR) IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 1-12 990-391...
  • Page 25 Power Supply. The Power Supply is designed to work in the following ambient conditions:  Temperature: 41-104°F (5-40°C)  Humidity: Less than 90%, non-condensing Space and Mounting Requirements IS-800CR IS-1400CR IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 26 38 and 39 on the external I/O terminal strip. NOTE: If used with Amada Miyachi America IT- series transformers, you can purchase the 18-045-01 transformer sense cable which will have these connections. The voltage sense cable...
  • Page 27 Slide the Power Supply bottom (slotted) tabs into the two lower mounting screws. While the Power Supply is being held in place, install the two upper mounting screws then tighten the two lower mounting screws. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 28 5. Install service conduit to plate and feed input power cables into the Power Supply. 6. Connect three-phase power cables to the three socket head screws in the circuit breaker. Input is not phase dependent. IS-800CR/1400CR INVERTER POWER SUPPLY 990-391...
  • Page 29 α Effective continuous current = I x 0.817 x I : Output current (momentary maximum current) of IS-800CR/1400CR α : Duty cycle (%) Select the breaker rated current of at least the average input current above. Check the coordination of output current (momentary maximum current) and tripping time on the tripping characteristic curve of the breaker to select the appropriate breaker.
  • Page 30 Effective continuous current = I x 0.817 x α Effective continuous current = I x I : Output current (momentary maximum current) of IS-800CR/1400CR α : Duty cycle (%) Check the manufacturer’s characteristic table to select the cross section of the cable according to the allowable current.
  • Page 31 Cover Plate. We recommend that you remove the cover plate to an area away from the Power Supply before drilling holes. This will reduce the need to protect the electronics from metallic shards that otherwise could damage the unit or injure personnel. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 32 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. IS-800CR/1400CR INVERTER POWER SUPPLY 990-391...
  • Page 33 Connect a hose to the Cooling water pipe connector on the bottom of the Power Supply. NOTE: Adjust the cooling water flow rate to at least 2 L/min. If it is low, the IGBT thermostat error will be detected and operation will stop. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 35 ) indicate the paragraph No. within the chapter. [MENU] >POWER SUPPLY STATE COPY SETUP DATA SCHEDULE MODE SELECT (10) MONITOR MONITOR MODE (11) MONITOR SET STEPPER COUNT (12) NG SIGNAL SELECT PRECHECK (13) OUTPUT SELECT I/O CHECK (14) RESET TO DEFAULT IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 36 The frequency of the welding power is measured and indicated automatically. (e) MA-627A ROM VERSION # Indicates the ROM version No. of program unit MA-627A. (f) ISB-800A (ISB-1400A) ROM VERSION # Indicates the ROM version No. of the Power Supply. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 37 3 000 000ms 002.0 002.0 002.0kA SCD PAGE DOWN  NOTE: The screen shows the settings for IS-800CR. The settings surrounded with frames are 04.0kA for IS-1400CR. Also, unit, resolution, and setting range change depending on the settings of CTRL/CURR RANGE.
  • Page 38 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 IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 39 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 IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 40 HEAT setting of C and the DL HEAT setting of D are different. A: WELD1 to 3 time B: DOWN1 to 3 time C: HEAT1 to 3 D: DL1 to 3 HEAT IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 41 DL HEAT setting of F are different. A: UP1 to 3 time B: WELD1 to 3 time C: DOWN1 to 3 time D: UF1 to 3 HEAT E: HEAT1 to 3 F: DL1 to 3 HEAT IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 42 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-05 (No Current error) is displayed, current flowing. Use extreme caution to avoid electrocution. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 43 Primary Requires no connection Used for welding Sets the primary current constant-current of toroidal coil on the of coated metal obtained by the set current and IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 44 (Non-constant control. and not used for current) normal welding. (g) PAGE DOWN When the cursor is at , moving the cursor down will change the display to ○ 2 PULSATION and transformer screen. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 3-10 990-391...
  • Page 45 1 TURN RATIO 001.0 CURR RANGE 40kA WELD ON/OFF OFF NOTE: The screen shows the settings for IS-800CR. The settings surrounded with frames are 80.0kA for IS-1400CR. (a) SCHEDULE # Select from #1 to #255 to set the SCHEDULE. Normally select #1 first, then select additional schedules in sequential order.
  • Page 46 PULSATION operation, a caution signal is output after completion of welding. (d) WELD TRANS FREQ Sets the frequency of the welding transformer to be used. It can be set 600 Hz to 3000 Hz in units of 100 Hz. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 3-12 990-391...
  • Page 47 On the other hand, a smaller control gain suppresses current waveform overshoot but causes a slower increase in current. The Power Supply offers nine (9) choices of gain levels (1–9). IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391 3-13...
  • Page 48 An incorrect ratio will result in malfunction. (k) WELD ON/OFF One of the settings required to turn ON the [READY] lamp of the Power Supply. ON: WELD ON OFF: WELD OFF IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 3-14 990-391...
  • Page 49 The widest pulse among the supplied primary pulse current is displayed as a percentage of pulse width in full wave mode. The pulse width in full wave mode varies with the frequency setting (WELD TRANS FREQ). IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391 3-15...
  • Page 50 When the repetition welding is performed with PULSATION or OFF time setting, only the last data is displayed as the monitored value. The passing data is not displayed.  The monitor display is not automatically updated depending on the MONI DISP MODE setting. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 3-16 990-391...
  • Page 51 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%. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391 3-17...
  • Page 52 Sets the output modes of NG1 and NG2 of the external output signals. N.C. (NORMAL CLOSE) Closed at normal / Open at error N.O. (NORMAL OPEN) Open at normal / Closed at error IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 3-18 990-391...
  • Page 53 (OFF) ERROR Receive Stop Upper/lower limit monitor error CAUTION Receive Not stop ERROR Not receive Stop No-current error, Workpiece error CAUTION Receive Stop Counter error Receive Stop Other device error Not receive Stop IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391 3-19...
  • Page 54 MA-627A temporarily, then copy this data to the second unit. -COPY SETUP DATA ISB-800A -----> MA-627A ISB-800A <----- MA-627A SCHEDULE [001] ---> SCHEDULE [001]-[255] IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 3-20 990-391...
  • Page 55 Move the cursor  to the required item among (a) to (c), then press the [ENTER] key; the data will be copied. (a) ISB-800A (ISB-1400A)  MA-627A The data in IS-800CR/1400CR is copied to MEMORY of MA-627A. (b) ISB-800A (ISB-1400A)  MA-627A The data in MEMORY of MA-627A is copied to IS-800CR/1400CR.
  • Page 56 No. 9. In Fig. (B), only schedule signal 8 is ON. As a result, welding is performed using schedule No. 8. Schedule signals 16 and 32 are invalid because they are OFF when the schedule is determined. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 3-22 990-391...
  • Page 57 START SET and then 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) Valve output (SOL1 or SOL2) Welding sequence B: Monitored value judgment SQD SQZ time C: END signal output END signal output time IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391 3-23...
  • Page 58 End signal time is the 200 ms. (END time = 200 ms)  END SIG.TIME is 10 to 200 ms 1) OFF is 0 ms (OFF time = 0ms) End signal time is the set END SIG.TIME time. (END time = END SIG.TIME time) IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 3-24 990-391...
  • Page 59 Be sure that the total number of closed schedule selection and parity signal lines is always odd. (Refer to Note 1, “Schedule Nos. and Schedule Selection Pins.”) IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391 3-25...
  • Page 60                                  IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 3-26 990-391...
  • Page 61 WE1 starts (the current is supplied for about 1 cycle) when input before the WE1 period, switching the sequence to COOL1. The WE1STOP signal will not shut off current if input during the WE2 or WE3 period IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391 3-27...
  • Page 62 WELD3 sequence operation. When the WELD3 STOP signal is input before the start signal is input even if the WELD1 or the WELD2 is set, the welding stop error occurs. When COUNT RESET is selected The count will be reset. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 3-28 990-391...
  • Page 63 The COUNT value works as each STEP value. Example: “STEP1 0020 STEP2 0010” indicates that STEP1 is 20 times and STEP2 is 10 times. The conditions for stepper count-up is the same as the TOTAL counter. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391 3-29...
  • Page 64 Va lve outpu t We ld ing curren t HE A T1 H E A T2 HE A T3 h igher h ighe r h ighe r than than than HE AT1 HE AT2 HE AT1 IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 3-30 990-391...
  • Page 65 Used when the takt time is relatively fast. LAST Errors are also displayed only when updated (communicated with the program unit). * Not communicated with the program unit automatically. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391 3-31...
  • Page 66 WELD Counter is reset to 0 (zero) when NG is Error reset. WORK Counter does not count-up. WELD Counter does not count-up. Interrupt Since an error does not occur, the error reset is not received. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 3-32 990-391...
  • Page 67 WELD2 STOP/WELD COUNT is WELD2 STOP and COUNTER is TOTAL or GOOD -MONITOR MODE PRESET COUNT TOTAL/GOOD 000000 NO CURRENT TIME 99ms Sets the count value of TOTAL or GOOD set for COUNTER. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391 3-33...
  • Page 68 (NORMAL OPEN): Open at normal / Closed at error.  WELD2 STOP/WELD COUNT is WELD2 STOP and COUNTER is WORK. -MONITOR MODE PRESET COUNT WELD/WORK 0000 000000 NO CURRENT TIME 99ms Sets WELD and WORK counters. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 3-34 990-391...
  • Page 69 This function can be turned on or off through WELD2 STOP/WELD COUNT on the MODE SELECT screen. To clear the count error signal, you need to input the weld count signal again or add required number of welds to make up for insufficiency. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391 3-35...
  • Page 70 NOTE: No judgment as to no-current or no-voltage error will be made if you select 00.0 kA/0.00 V. If the toroidal coil and the voltage detecting cable are disconnected in the second control, excessive current may flow. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 3-36 990-391...
  • Page 71 Sets the neglecting time of the welding stop signal for each of WE1, WE2 and WE3. Even if the welding stop signal is input during welding, the current is supplied for the set time and the sequence will switch to the next. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391 3-37...
  • Page 72 STEP1. Similarly, the current is stepped up or down to the value for STEP3 following completion of the specified number of welds for STEP2. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 3-38 990-391...
  • Page 73 STEP. The sequence will proceed to the next STEP when the set number of welds is reached. (d) VALVE # Make settings for (a) and (b) above for each valve number. Change the number to set the schedule for each valve. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391 3-39...
  • Page 74 (c) PRECHECK HEAT Set the welding pulse width. (d) PRECHECK RESISTANCE HIGH Set the upper limit of resistance value for precheck. (e) PRECHECK RESISTANCE LOW Set the lower limit of resistance value for precheck. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 3-40 990-391...
  • Page 75 Initializes the Power Supply memory (restores the initial settings). After initialization, the screen will reflect the settings (a) YES shown in this chapter. Returns the display to the MENU screen without initializing the (b) NO Power Supply memory. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391 3-41...
  • Page 76 <When the PROGRAM PROTECT is OFF> [MENU] >POWER SUPPLY STATE COPY SETUP DATA SCHEDULE MODE SELECT MONITOR MONITOR MODE MONITOR SET STEPPER COUNT NG SIGNAL SELECT PRECHECK OUTPUT SELECT I/O CHECK RESET TO DEFAULT IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 3-42 990-391...
  • Page 77 CHAPTER 3: USING PROGRAMMING FUNCTIONS <When the PROGRAM PROTECT is ON> [MENU] >POWER SUPPLY STATE SCHEDULE MODE SELECT MONITOR MONITOR MODE MONITOR SET STEPPER COUNT NG SIGNAL SELECT PRECHECK OUTPUT SELECT IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391 3-43...
  • Page 79 Verify that the electrical and water supplies meet the electrical and cooling (water) requirements, as shown in Appendix A, Technical Specifications. The electrical and water supplies must also meet all applicable local, state, and federal safety standards. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 80 3. If no error is detected in step b, assure that the three requirements are met: READY 4. The Power Supply must be on, WELD ON/OFF LED setting of the Program Unit must be set to ON, and ON/OFF IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 81 11. Set the upper and lower limits on Program Unit Monitor Set screen for each SCHEDULE 12. Begin welding following normal procedures. Adjust settings as necessary. SCHEDULE IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 82 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. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 83 SQZ time to a period longer than the stroke NO CURRENT E-07 time of the electrode.) NO CURRENT LEVEL is high. Set a lower NO CURRENT LEVEL. The fuse needs replacement. Contact Miyachi Fuse inside the equipment is blown. America Corp. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-...
  • Page 84 HEAT setting X   Y TURN RATIO IS-800CR: X = 15, Y = 800 IS-1400CR: X = 30, Y = 1400 The WELD1, WELD2, and WELD3 values are all “0.” The total time of UP SLOPE and DOWN SLOPE is longer than WELD.
  • Page 85 Current is out of range between upper electrodes, contact of electrodes and PRECHECK limit and lower limit set on the E-24 workpieces. ERROR PRECHECK screen when PRECHECK Current Supply is used. Check range set on PRECHECK Screen. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-...
  • Page 86 Check range set at DISPLACEMENT LIMIT. The workpiece detection is out of WORK Check work pieces setting and positioning. WORK DETECT E-38 DETECT LIMIT setting range on the ERROR Check range set at WORK DETECT LIMIT. DISPLACEMENT screen. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-...
  • Page 87 S Q D S QZ H OL D ( Note 2 ) E N D ( Note 3 ) Tb : Data co m mun icat ion t i me at end HE A T Ⅰ IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-...
  • Page 88 When the communication speed is 19200 bps or 38400 bps, the transmission time will be short.  Data transmission time when the communication speed is 9600 bps 132 ms max. 42 ms max. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-...
  • Page 89 When cleaning the exterior of the Power Supply, do not use paint thinner, benzene, or acetone. These chemicals can damage the surface finish on the Power Supply. Use a dry cloth or, if it is heavily soiled, use a cloth moistened with a mild detergent or alcohol. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-...
  • Page 90 FUSE DESCRIPTION 150VA valve transformer 250VA valve transformer Power Supply Transformer Fuse P/N 330-175 0.75 amps, slow-blow P/N 330-120 1.50 amps, slow-blow IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-...
  • Page 91 NOTE: Be sure to have a bucket or other receptacle handy to collect the drained water. 3. Disconnect one of the hoses at the bottom of the Power Supply and allow the water to drain into the bucket. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-...
  • Page 92 Close the Power Supply door and secure it with the two quarter-turn screws. NOTE: To reduce damage to the Power Supply, should there be an external problem, reconnect external power to the Power Supply before turning the circuit breaker ON. Turn the circuit breaker ON. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 5-10 990-...
  • Page 93 NOTE: Place a bucket or other receptacle under the quick-disconnect fittings to collect any residual drained water. 2. Push the quick-disconnect fittings at the bottom of the Power Module to disconnect both hoses and allow the water to drain into the bucket. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990- 5-11...
  • Page 94 CHAPTER 5: MAINTENANCE Disconnect the Wire Harness from the Main Board Connectors Disconnect wire harness connectors from the Power Supply as shown below. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 5-12 990-...
  • Page 95 NOTE: The weight of the Power Module is supported by the two support rails shown below. Remove the screws shown below in order to remove the Power Module from the cabinet. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990- 5-13...
  • Page 96 CHAPTER 5: MAINTENANCE IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 5-14 990-...
  • Page 97 Restore water flow. Close the Power Supply door and secure it with the two latching screw-fasteners. Reconnect power to the Power Supply, then set the circuit breaker ON. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990- 5-15...
  • Page 98 8. Replace the plastic cover and secure it with the four mounting screws. Remove the Power Supply from its mounting location. 10. Repack the Power Supply into the original packing materials and packing box in which you originally received the unit. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 5-16 990-...
  • Page 99 Number of schedules Primary constant-current effective value control Secondary constant-current effective value control Control Secondary constant-power effective value control Primary constant-current peak value control method * Secondary constant-voltage effective value control Constant-phase control IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 100 02.0–40.0 kA 02.0–40.0 kA range Constant Setting range current 20 kA 01.0–20.0 kA 01.0–20.0 kA control range (HEAT) (Note 2) 10 kA 0.50–9.99 kA 0.50–9.99 kA range 5 kA 0.05–5.00 kA 0.05–5.00 kA range IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 101 50–200% (STEPPER Counter setting 0000–9999 COUNT) (COUNT) Weld count monitor 0000–9999 (PRESET COUNT) [WELD POWER] lamp [READY] lamp State [START] lamp indicator [WELD] lamp [TROUBLE] lamp [WELD ON/OFF] lamp Cooling Air-cooled (fan motor) method IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 102 1. No repetitive operation will be performed if “0” is selected for OFF (off time). 2. Primary current can be set up to 800 A for IS-800CR and 1400 A for IS-1400CR. 3. Using the fixed load and the specified transformer ...
  • Page 103 APPENDIX A: TECHNICAL SPECIFICATIONS Duty Cycles IS-800CR Ambient temperature: 40°C Ambient temperature: 25°C 10.5% 100% Duty cycle [%] * IS-1400CR Ambient temperature: 40°C Ambient temperature: 25°C 100% Duty cycle [%] * IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 104 For 600 A or more of the primary current, the maximum weld time [ms] = -4× (IGBT primary current value) + 3400. Example: Primary current is 700 A on IS-800CR -4×700 + 3400 = 600 [ms]. Therefore, the maximum weld time is 600 ms.
  • Page 105 Circuit 1200 SK-1174091-010 10 m cable 1000 SK-1174092-015 15 m SK-1174093-020 20 m MB-400L (Belt, 470 mm approx.) Toroidal coil Cable, 2.8 m MB-800L (Belt, 890 mm approx.) 1000 1200 通電時間[ms] Weld Time [ms] IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 107 #7 -- Not Used #3 -- Rx #8 -- Not Used #4 -- Not Used #9 -- Not Used #5 -- GND- RS-232 only allows one unit at a time to be connected to a host IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 108 #4 -- Tx+ #9 -- Rx- #5 -- Tx- RS-485 allows multiple units to be daisy chained to a host TRANSFORMER SENSING CONNECTOR DESCRIPTION Common (Thermostat) Thermostat Voltage Current Current Voltage Ground FRONT VIEW IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 109 SCHEDULE 16 SCHEDULE 32 SCHEDULE 64 SCHEDULE 128 WE1 STOP/PARITY WE2 STOP/WELD COUNT I/O COM STAGE 1 STAGE 2 I/O COM WELD ON/OFF THERMOSTAT FLOW SWITCH I/O COM ERROR RESET STEP RESET WE3 STOP/COUNT RESET IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 110 VALVE COM VALVE1 VALVE2 SECONDARY VOLTAGE +24VDC (OPTIONAL) CONTACTOR (OPTIONAL) AUX CONTACTS (N/O) ON CONTACTORS CONTACTOR OPEN (OPTIONAL) CONTACTOR COM (OPTIONAL) CONTACTOR CLOSED (OPTIONAL) AUX CONTACTS (N/C) ON CONTACTORS CURRENT COIL NOT USED NOT USED IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 111 This pin allows for detection of failure resulting from a wire break in the schedule selection signal lines. Be sure that the total number of closed schedule selection and parity signal lines is always odd. (See 4. (9) (e) Schedule Nos. and Schedule Selection Pins.) IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 112 20 ms or more is required for receiving the input signal. Step reset input pin. Closing this pin while the STEPPER is ON will reset the STEP number to 1. STEP RESET 20 ms or more is required for receiving the input signal. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 113 This pin is the common pin for the NG, CAUTION, END, COUNT ERROR, READY, STEP END, and WELD ON pins. Power input pins to drive the solenoid valve. SOL POWER Input 120 VAC or 24 VDC power. SOL COM COM pin for the solenoid valve. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 114 CURRENT COIL sense input connector. 47-48 UNUSED *1 When the sequence is stopped at (A), error (CAUTION) is not displayed. It’s because the contents when stopped is displayed on the program unit. CAUTIO CAUTION IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 115 WELD1 welding end output. Closed between the WELD1 welding end and the beginning of HOLD. OUT I (See 8.(1) and (3).) WELD2 welding end output. Closed between the WELD2 welding end and the beginning of HOLD. OUT II (See 8.(1) and (3).) IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 116 Input Signal Connections Connection with equipment having a contact input. Connect pins 1 and 2. Connection with equipment featuring NPN open collector output (when using internal power supply). Connect pins 1 and 2. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391 B-10...
  • Page 117 Connect the negative side of an external 24 V DC power supply to pin 2. Connection with equipment featuring NPN open collector output (when using external power supply). Connect the positive side of an external 24 V DC power supply to pin 2. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY B-11 990-391...
  • Page 119 C: END signal output (depends on the END SIG.MODE setting if END signal output (no output if the welding sequence is halted) time the welding sequence is halted) Start Signal Input in Maintained Mode IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 120 A: DELAY START SET 2ND STAGE Schedule selection (1,2,4,8,16 32,64,128,P) Valve output (SOL1 or SOL2) Welding sequence B: Monitored value judgment time C: END signal output END signal output time Start Signal Input in Latched Mode IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 121 CP: Resistance judgment time (2 ms) WELD1: 1st weld time COOL1: Cooling time 1 WELD2: 2nd weld time COOL2: Cooling time 2 WELD3: 3rd weld time HOLD: Hold time OFF: Off time One-Stage Start IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 122 1 S T S T A GE 2 N D S T A GE S OL1/ S OL2 We ld ing current S Q D S QZ WEL D : DELAY START SET setting + Welding preparation time. Two-Stage Start IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 123 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-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 124 WELD1→ INT1→ WELD1→ INT1→ WELD1→ INT1→ WELD2... (Note 2) Repeat operation times set for PULSATION2 in WELD2 and INT2 set times. (Note 3) Repeat operation times set for PULSATION3 in WELD3 and INT3 set times. Pulsation IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 125 Re-weld will occur when Re-Weld is set On (Mode Select screen), and a current monitor error occurs as a low weld current shown below. Under that circumstance, a re-weld will occur with a 5% increase in weld current. Re-Weld IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 126 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-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 127 Insure that all connections are tight. Formulas used: = Output current times the square root of the duty cycle. = Resultant (I x 0.817 ) current in each phase of the 3-phase input source. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 128 For other output currents at different duty cycles, apply the above formula to find the new I the use the following table for cable sizes and maximum lengths.  If I is not in the table, use the next higher current. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 129 APPENDIX D: WIRE GAUGE AND CIRCUIT BREAKER SELECTION Duty Cycles IS-800CR Ambient temperature: 40°C Ambient temperature: 25°C 10.5% 100% Duty cycle [%] * IS-1400CR Ambient temperature: 40°C Ambient temperature: 25°C 100% Duty cycle [%] * IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 130 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 IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 131 Instantaneous trip 1.5 - 12.0 1.5, 2.0, 4.0, 6.0, 8.0, 10.0, 12.0 X I = 250 Amps for IS-800CR *See circuit breaker front panel for dipswitch settings. Setting L Calculate the breaker rated current using the Effective secondary current and duty cycle of the weld schedule.
  • Page 133 (nominal 24 VDC) referenced to pin 0 will the contacts close. This can be accomplished either with switch, jumper, PLC, Transistor or FET that can source a positive 24 volts DC of least 20mA. (Voltage source at TB1 pin 40 can be used) IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 134 APPENDIX E: OPTIONS External Communications Connectors IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 135 The Power Supply will give an error and stop all operations.  The Power Supply does not have any automatic means to know if the contactors are installed. All commands and contact sense lines states must be provided and detected OPEN/CLOSURE by the user. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 137 Section II. Communications Protocol and Commands. Using these codes, users can write customized software for controlling all functions of the welding control and interfacing the unit to automation control systems. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 138 APPENDIX F: COMMUNICATIONS Section II. External Communication Function Introduction The IS-800CR/1400CR 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...
  • Page 139 (Note 3) The RS-232C/RS-485 conversion adapter is not included in the accessories. It is required to prepare the adapter at customer’s side. RS-232C ○ Host Computer Device No.1 Only a device can be connected. RS-232C IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 140 STEP COUNT of VALVE2 Fixed to 4 digits (0000 to 9999) COUNTER (WELD/WELD Fixed to 4 digits (0000 to 9999) COUNT of WORK) COUNTER (WORK of Fixed to 6 digits (000000 to 999999) TOTAL/GOOD/WORK) IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 141 Data IS-800CR/1400CR 1) Schedule numbers, SH1, SH2 and SH3 are fixed to 000. However, schedule numbers are sent from IS-800CR/1400CR when “E06: Current error”, “E18: Voltage error”, “E19: Electric power error” and “E07: Pulse width error” occurs. 2) Screen numbers, SC1 and SC2 are fixed to 07.
  • Page 142 No. 01. Host Data 0 1 0 0 8 0 1 : 0 0 8 0 1 : Data IS-800CR/1400CR Insert [,] between data for a schedule. 1) SH1, SH2 and SH3 are schedule numbers. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 143 4) The set data is returned as a confirmation data. When data which is outside the range is set, previous data is returned. 5) It takes about 1 second at most to save data into the internal memory (READY is turned off during saving). Be careful when writing continuously. IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 144 00000 to 00999 (CYC mode) 0000 to 9990 (ms mode) OFF / Off time nnnn, 0000 to 0099 (CYC mode) 0: 05 1: 10 2: 20 3: 40 CURR RANGE / Current range 4: 80 (kA) IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 145 04.0 to 60.0 (kW) DL2 / End heat 2 of downslope 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) IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391...
  • Page 146 *1 The setting of ms/CYC cannot be changed. You can change it via Screen 05 (SYSTEM data). *2 IS-1400A only *3 Screen 02 (MONITOR SET data) Specific data in accordance with Schedule No. (Schedule No.: 001 to 255) IS-800CR/1400CR BASIC INVERTER POWER SUPPLY F-10 990-391...
  • Page 147 POWER H of WE3 (upper limit) nnn.n, 000.0 to 999.9 (kW) nn.nn, 00.00 to 99.99 (kW) POWER L of WE3 (lower limit) nnn.n, 000.0 to 999.9 (kW) PULSE H of WE3 (upper limit) 010 to 100 (%) IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391 F-11...
  • Page 148 STEP8 COUNT of VALVE2 nnnn, 0000 to 9999 STEP8 RATIO of VALVE2 nnn, 050 to 200 (%) STEP9 COUNT of VALVE2 nnnn, 0000 to 9999 STEP9 RATIO of VALVE2 050 to 200 (%) IS-800CR/1400CR BASIC INVERTER POWER SUPPLY F-12 990-391...
  • Page 149 PRECHECK RESISTANCE HIGH nn.nn, 00.00 to 99.99 (mΩ) PRECHECK RESISTANCE LOW nn.nn, 00.00 to 99.99 (mΩ) PRECHECK MONITOR nn.nn 00.00 to 99.99 (mΩ) *1 Items inhibited from setting (When setting data, omit these items.) IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391 F-13...
  • Page 150 OUTPUT MODE of NG SIGNAL 0: N.C. 1: N.O. SELECT TIME-OVER of NG SIGNAL 0: ERROR 1: CAUTION SELECT CURR-OVER of NG SIGNAL 0: ERROR 1: CAUTION SELECT VOLT-OVER of NG SIGNAL 0: ERROR 1: CAUTION SELECT IS-800CR/1400CR BASIC INVERTER POWER SUPPLY F-14 990-391...
  • Page 151 The number of Error Codes is of five max. In the case of only one error code, the items 2 to 5 are omitted. For Error Codes, see 12. (1) Fault Code List.  Error reset (Data setting only)  Character Item Contents Range String Error reset IS-800CR/1400CR BASIC INVERTER POWER SUPPLY 990-391 F-15...

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Is-1400cr