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Amada IS-200A Operation Manual

Dc inverter welding power supply
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DC INVERTER WELDING POWER SUPPLY
IS-200A
OPERATION MANUAL
AA09OM1185335-03

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  • Page 1 DC INVERTER WELDING POWER SUPPLY IS-200A OPERATION MANUAL AA09OM1185335-03...
  • Page 2 IS-200A Thank you for purchasing our DC Inverter Welding Power Supply IS-200A. This operation manual describes its method of operation and precautions for use. Read this operation manual carefully prior to use. Store appropriately for ready reference. Contents 1. Special Notes (1) Safety Precautions ·································································...
  • Page 3 IS-200A 9. Specifications (1) Specifications ······································································· 9-1 (2) Options (Sold Separately) ······················································· 9-3 (3) Duty Cycle Graph ·································································· 9-4 (4) Board List for Maintenance ······················································ 9-4 (5) Major Components List ··························································· 9-5 (6) Schematic ············································································ 9-5 (7) Schedule Data Table ······························································ 9-6 10.
  • Page 4 IS-200A 1. Special Notes (1) Safety Precautions Before using, read "Safety Precautions" carefully to understand the correct method of use.  These precautions are shown for safe use of our products and for prevention of damage or injury to operators or others. Be sure to read each of them, since all of them are important for safety.
  • Page 5 IS-200A WARNING Do not insert your fingers or hands between the electrodes. When welding, keep your fingers and hands away from the electrodes. Do not touch any welded part or electrode during welding or just after completion of welding. The welded parts of a workpiece, electrodes, and the arm are very hot.
  • Page 6 IS-200A CAUTION Apply the specified supply voltage. Application of a voltage outside the specified range may result in fire or electric shock. Do not allow water to come in contact with the equipment. Water on the electric parts can cause electric shock and short circuit.
  • Page 7 IS-200A (2) Precautions for Handling  Any work on this Power Supply must be performed only by the personnel with sufficient knowledge and experience regarding an inverter welding power supply.  Install this Power Supply on a firm and level surface. Operation on an incline may result in malfunction.
  • Page 8 IS-200A (3) On Disposal This product incorporates parts containing gallium arsenide (GaAs). At the time of disposal, separate it from general industrial waste or domestic waste and carry out the disposal in accordance with applicable laws and regulations. (4) Warning Label for Safety On the main body is warning label for safety.
  • Page 9 IS-200A 2. Features The FINE SPOT-INVERTER IS-200A is a DC inverter-type, power supply specially designed for spot welding and fusing. The power supply is compact and convenient to transport or reposition. A monitor function is provided to enable judgment of defective or non-defective welding.
  • Page 10 IS-200A 3. Name and Functions of Each Section (1) Front Panel INDICATOR Ｗ Ｅ Ｌ Ｄ Ｐ ＯＷ Ｅ Ｒ WELD POWER READY Ｒ Ｅ Ａ Ｄ Ｙ START Ｓ ＴＡ Ｒ Ｔ WELD TROUBLE POWER Ｗ Ｅ Ｌ Ｄ...
  • Page 11 IS-200A [START] lamp (Green LED) This lamp remains lit while the start signal is input. [WELD] lamp (Green LED) This lamp remains lit while the welding current is flowing. [TROUBLE] lamp (Orange LED) This lamp lights when an error is detected. At this time, the program unit emits a beeping sound, and the Power Supply operation is interrupted.
  • Page 12 This terminal block is used to connect to the input of the welding transformer and the welding power supply (three-phase). The cable-mounting screw is for M5. Welding Transformer [I/O] connector For connecting the [SENS] cable for the welding transformer manufactured by Amada Miyachi Co., Ltd. 3. Name and Functions of Each Section...
  • Page 13 IS-200A (3) MA-627A (Sold Separately) CURSOR MENU TROUBLE ENTER RESET ⑥ ① ② ③ ④ ⑤ [TROUBLE RESET] key If this key is pressed while the [TROUBLE] lamp on the Power Supply is lit, the lamp goes off. This key has the same function as the [TROUBLE RESET] key on the Power Supply.
  • Page 14 IS-200A Connector This connector is used to connect the circuit cable. Connect the other end of the cable to the [PROGRAM MONITOR I/O] connector of the Power Supply. CAUTION No settings or changes may be made to any item from the receipt of the start signal through the end of the weld sequence and turning off the Start signal.
  • Page 15 IS-200A 4. How to Operate Screens Appearance of characters used in the following explanation Shaded characters (000) An item for which a value must be input, or which must be set ON or OFF. Move the cursor ( ) to the number (or to ON or OFF) to be selected or changed, and press the [+ON/-OFF] key.
  • Page 16 (f) MA-627A ROM VERSION # Indicates the ROM version No. of program unit MA-627A. (g) IS-200A ROM VERSION # Indicates the ROM version No. of the Power Supply. (Note) The Power Supply writes data into the flash memory on the control board when a setting is changed or a schedule data is copied.
  • Page 17 IS-200A (3) SCHEDULE Screen Up to 255 welding schedules can be set on the Power Supply. These schedules are indicated as SCHEDULE #1 to #255. This screen is used to set the SCHEDULE No., length of weld time, welding current, and so on.
  • Page 18 IS-200A <Secondary constant-power <Secondary constant-power effective value control ms mode> effective value control CYC mode> -SCHEDULE #001 WELD ON/OFF OFF -SCHEDULE #001 WELD ON/OFF OFF SQD SQZ COOL1 COOL2 HOLD OFF SQD SQZ COOL1 COOL2 HOLD OFF TIME 0000 0000 000...
  • Page 19 IS-200A (a) SCHEDULE # Select from #1 to #255 to set the SCHEDULE. Normally select #1 first, then select additional schedules in sequential order. (b) TIME Set the time for each operation during welding. Units of time are in ms or CYC.
  • Page 20 IS-200A When the Power Supply starts with the following setting, E-10 (schedule setting error) will occur. ・When the current value in the previous stage is equal to or larger than the current value in the subsequent stage even with the upslope setting in the subsequent stage.
  • Page 21 IS-200A (d) HEAT Set the welding current for WELD1, WELD2, and WELD3, respectively. When CTRL is changed, the items to be set also change. Effective value of <Primary constant-current effective value control> current Effective value of <Secondary constant-current effective value control>...
  • Page 22 IS-200A (g) PAGE DOWN When the cursor is at , moving the cursor down will change the display to the screen shown below. PAGE UP  -SCHEDULE #001 PULSATION 01 GAIN (1-9) 1 VALVE # 1 TURN RATIO 001.0 TRANS # 1...
  • Page 23 IS-200A (i) VALVE # Two valves (welding heads) can be connected to the Power Supply. Use this setting to select which of the two valves to use. (j) TRANS # Sets the transformer number used in each schedule (TRANS1 to 5).
  • Page 24 IS-200A (4) MONITOR Screen In this screen, you can confirm the operational conditions during welding. Monitored data is displayed for each SCHEDULE. (e) (a) -MONITOR SCHEDULE #001 TIME CURRENT VOLT POWER PULSE WELD1 000 ms 0.00kA 0.00V 0.00kW 00.0% WELD2 000 ms 0.00kA 0.00V 0.00kW 00.0% WELD3 000 ms 0.00kA 0.00V 0.00kW 00.0%...

  • Page 25: Weld Count

    IS-200A STEP # The present number of steps is displayed when STEPPER MODE is activated on the MODE SELECT screen. (In the example above, the VALVE 1 is set to STEP 1, the VALVE 2; STEP 3.) (h) STEPPER COUNT The number of welds in the present step is displayed when STEPPER MODE (see (7)(f)) is activated on the MODE SELECT screen.
  • Page 26 IS-200A (5) MONITOR SET Screen Set the conditions for determining a good or bad weld, including values for welding current, upper or lower limits for the secondary voltage, etc. If the monitored welding current, secondary voltage, etc., do not meet the set conditions, a caution signal is output, and can be used to activate an alarm buzzer, alarm lamp, or similar event.
  • Page 27 Power Supply memory is displayed on the Monitor Panel. When the data is changed and the [ENTER] key is pressed, the contents of the memory of the Power Supply are overwritten by the new setting. IS-200A stores data, MA-627A stores data for one independently from IS-200A unit.
  • Page 28 Move the cursor (>) to the required item among (a) to (c), then press the [ENTER] key; the data will be copied. (a) IS-200A -----> MA-627A The data in IS-200A is copied to the memory of MA-627A. (b) IS-200A <----- MA-627A The data in the memory of MA-627A is copied to IS-200A.

  • Page 29: Weld Time

    IS-200A (7) MODE SELECT Screen -MODE SELECT DELAY START SET 20ms START SIG.MODE MAINTAINED SIG.TIME 200 ms END SIG. MODE 1 PARITY CHECK STEPPER MODE OFF WELD COUNT RE-WELD WELD TIME PAGE DOWN ▽ (a) DELAY START SET One welding condition is determined via DELAY START SET, a value corresponding to chatter prevention time, after a start signal is input.
  • Page 30 IS-200A (b) START SIG.MODE Set the input method of the start signal to activate the Power Supply. 1) LATCHED  The welding sequence halts if the 2ND STAGE signal stops during squeeze time (SQZ).  The welding sequence proceeds to completion when the 2ND STAGE signal stops during Weld 1 time (WE1) or later.
  • Page 31 IS-200A 3) MAINTAINED If the 2ND STAGE signal stops halfway through the welding sequence (from the beginning of initial squeeze delay time through the end of hold time), the welding sequence will halt at that point. Note that the end signal will not be output at this time.
  • Page 32 IS-200A (Note 1) Schedule Nos. and Schedule Selection Pins ●: Closed Blank: Open SCHEDULE# SCH 1 SCH 2 SCH 4 SCH 8 SCH16 SCH32 SCH64 SCH128 PARITY ● ● ● ● ● ● ● ● ● ● ● ● ●...
  • Page 33 IS-200A (Note 2) Current shutoff function The current shutoff function shuts off current when the proper weld penetration is achieved—for example, during fusing—thus preventing excessive penetration. (Refer to the figure below.) With the Power Supply connected our weld checker, set the displacement in advance.
  • Page 34 IS-200A (f) STEPPER MODE Select whether or not to perform step-up (step-down) operation. Step-up (step-down) will be performed. Step-up (step-down) will not be performed. (g) WELD COUNT Select whether or not to check the weld count. (Set external input pin 14.) When WELD COUNT = ON The weld count will be checked.
  • Page 35 IS-200A (j) PAGE DOWN When the cursor is at , moving the cursor down will change the display to the screen shown below. For details of the external communication, see 10. External Communication Function. -MODE SELECT PAGE UP △ COMM CONTROL COMM SPEED 38.4k...
  • Page 36 IS-200A Normal mode not using the transformer selecting function. First, welding is performed using the selected schedule No. (N), then using the next schedule No. (N+1). Next, welding is performed in sequence using successive schedule numbers (N+2, N+3, N+4...). At this time, welding is performed in sequence using transformer No.
  • Page 37 IS-200A  When the no-current error or the overcurrent error occurs, the function changes depending on the setting of END SIGNAL MODE.  When END SIGNAL MODE is 0 or 1, welding stops when an error occurs and does not move to the next schedule. The NG signal is output and the END signal is not output.

  • Page 38: Weld Count

    IS-200A (8) MONITOR MODE Screen - MONITOR MODE WELD COUNT 0000 NO CURRENT TIME 99ms NO CURRENT LEVEL 0.00kA NO VOLTAGE LEVEL 0.00V MONITOR FIRST TIME 15ms MONITOR SLOPE MODE EXCLUDE CURRENT MONITOR NUMBER (a) WELD COUNT A count error signal is output if the number of welds deposited while the external...
  • Page 39 IS-200A (c) NO CURRENT LEVEL Set the current level for determining the absence of current as a no-current error. The [TROUBLE] lamp will light up, and operation will stop if the monitored current or voltage falls below the level set here. In the case of primary current control, supplying current with the welding transformer’s secondary side open will...
  • Page 40 IS-200A (9) STEPPER COUNT Screen The Power Supply can change the level of the welding current depending on the welding conditions. The function to increase the welding current is called the “step-up” function, and that to decrease the welding current is called the “step-down” function.
  • Page 41 IS-200A (10) I/O CHECK Screen This screen is used to check the status of the external I/O signals. You cannot move to another screen while the 1ST or 2ND STAGE signal is input. -I/O CHECK SCH01* SCH128* ERR RST* NG...
  • Page 42 IS-200A (11) RESET TO DEFAULT Screen This screen is used to initialize the Power Supply’s memory (i.e., to restore the initial settings). Initialization will not clear the memory of the MA-627A. To initialize, move the cursor (>) over YES or NO and press the [ENTER] key.
  • Page 43 IS-200A  Turn off the power supply and turn on it again, or disconnect the MA-627A with the power supply turned on and connect to the circuit cable again. When PROGRAM PROTECT is ON, the display of the MENU screen changes.
  • Page 44 IS-200A  OVER WRITE screen When the connected model is incompatible with the previously stored model name / program version, “CONNECT IMPOSSIBLE!!” is displayed at the bottom of the screen as shown below. Set OVER WRITE to YES with the [+ON] key and press the [ENTER] key to rewrite the memory.
  • Page 45 IS-200A 5. Connection Procedures (1) Basic Configuration 627A Power Supply front Welding head MENU Secondary INDICATOR cable WELD POWER READY START WELD TROUBLE POWER TROUBLE RESET Circuit Volt-sensing cable WELD ON/OFF cable PROGRAM RS-232C/485 MONITOR Earth Welding leakage transformer breaker...
  • Page 46 IS-200A (2) Connecting 1) Connecting to the transformer’s input terminal block and [SENS] cable Use the output cable to connect the welding power output terminal block on the Power Supply’s rear panel with the welding transformer’s input terminal block. For the output cable specification, see 9. (2) Options.
  • Page 47 IS-200A 6. Interface (1) Connection Diagram for External Input/Output Signals 24VDC INT.24V EXT.COM STOP SCH 1 SCH 2 SCH 4 SCH 8 SCH16 SCH32 SCH64 SCH128 WE1 STOP/PARITY WE2 STOP/WELD COUNT WELD ON THERMOSTAT FLOWSWITCH ERROR RESET STEP RESET WE3 STOP...
  • Page 48 IS-200A CAUTION COUNT ERROR READY STEP END WELD SIGNAL OUT COM SOL POWER SOL COM SOL 1 SOL 2 VOLT SENS Terminal strip specifications Terminals connectable Two pieces max. Pressure wire connectors M3 or M3.5 (7.1 mm wide) 0.75 mm min.
  • Page 49 IS-200A (2) Description of External I/O Signals Pin No. Name Description 24 V DC present. When using a contact, open collector (sink type), or PLC (programmable logic controller) as an input signal (e.g., for INT.24V startup or schedule selection), connect pins 1 and 2.
  • Page 50 IS-200A Pin No. Name Description COM pin. This pin is internally connected to the GND chassis. 1ST STAGE input pin. (This function is not available with this Power Supply.) 2ND STAGE input pin. Closing this pin will start the sequence.
  • Page 51 IS-200A Pin No. Name Description Count error output pin. This signal is output if the set number of COUNT welds is not reached during count input. The contact is rated at ERROR 24 V DC at 20 mA (semiconductor switch).
  • Page 52 IS-200A (3) Connection of Input Signals Connection with equipment having a contact input Connect pins 1 and 2. (Internal) (External) Internal power supply Connection with equipment featuring NPN open collector output (when using internal power supply) Connect pins 1 and 2.
  • Page 53 IS-200A Connection with equipment featuring PNP current output (when using external power supply) Connect the negative side of an external 24 V DC power supply to pin 2. (External) (Internal) Internal power supply 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.
  • Page 54 IS-200A 7. Basic Operation (1) Turn on the welding power. Turn on the welding power. The [WELD POWER] lamp lights; the [READY] lamp blinks for 7 seconds, then goes off. CAUTION Check that the display screen and lamps are turned on normally and the fan motor is operated.
  • Page 55 IS-200A 8. Timing Chart (1) Basic Sequence A: DELAY START SET (Note 1) 2ND STAGE WELD1 COOL1 WELD2 COOL2 WELD3 HOLD C: Monitored value judgment time Valve output (0.1ms or less) (Note 2) B: END signal output time WELD SIGNAL...
  • Page 56 IS-200A (2) Detailed Description of Welding Current and Sequence in the Event of an Error 2ND STAGE DELAY-START SET time WELD1 WELD2 WELD3 DOWN1 COOL1 DOWN2 COOL2 DOWN3 HEAT3 HEAT1 HEAT2 Monitored value judgment time HOLD (0.1ms or less) (Note 1)
  • Page 57 IS-200A 9. Specifications (1) Specifications *: Selectable for every 255 schedule Welding power 3-phase, 200–240 V AC (50/60 Hz) ±10% 200 A (peak value) Max. output current Duty cycle: 4% (at 40°C of ambient temperature) Number of schedules Output frequency...
  • Page 58 IS-200A Pulse width monitor * HIGH (upper limit) 010–100% (PULSE % HIGH) STEP 1–9 (9 steps) Step-up/step-down Selectable for each valve Up (down) ratio (RATIO) 50–200% (STEPPER COUNT) Counter setting (COUNT) 0000–9999 Weld count monitor 0000–9999 (WELD COUNT) [WELD POWER] lamp...
  • Page 59 IS-200A (2) Options (Sold Separately) 1) Input Cables Customer-procured cables must meet the specifications at right. Model No. Length Specifications PK-1159747 2 m Rated Voltage 300 V AC min. PK-1159748 5 m Section Area 8 mm min. PK-1159749 10 m No.
  • Page 60 IS-200A (3) Duty Cycle Graph Ambient temperature: 40°C Ambient temperature: 30°C 5.4% (200A) 8.3% (150A) 5.6% 13.8% (100A) 20% (80A) 13.2% 54.4% (35A) 38.2% Duty cycle (%) (4) Board List for Maintenance For repair or replacement, contact us. Model IS-200A...
  • Page 61 IS-200A (5) Major Components List Item Q’ty Fan motor Power transformer Thermal protector Diode module IGBT module Fast-blow fuse Circuit breaker Electromagnetic contactor (6) Schematic IGBT IGBT DIODE MCCB Ｌ１ Ｌ２ Ｌ３ ＰＥ POWER P.C.B. TH(IGBT) CONTROL P.C.B. 9. Specifications...
  • Page 62 IS-200A (7) Schedule Data Table 9. Specifications...
  • Page 63 IS-200A TRANS # TURN RATIO VALVE # GAIN PULSATION CTRL HOLD DOWN3 COOL2 DOWN2 COOL1 DOWN1 9. Specifications...
  • Page 64 IS-200A 9. Specifications...
  • Page 65 IS-200A 10. External Communication Function (1) Introduction IS-200A can be used to set schedules from an externally-connected personal computer (abbreviated as PC) or to read monitored data and several kinds of status data. (2) Data Transmission Item Content Select either of the followings at MODE SELECT Screen:...
  • Page 66 IS-200A (3) Configuration  RS-485 Host computer Device No.1 Device No.2 Device No.31 RS-232C RS-485 … … RS-232C/RS-485 Conversion Adapter 31 Devices Max. (Note 1) When controlling two or more devices with one host computer, register the device No. (CONTROL#) for each device. Set the device No. at POWER SUPPLY STATE Screen (See 4.(2)(b)).
  • Page 67 IS-200A (4) Protocol  Single-directional Communication Mode (When --> is selected at COMM CONTROL in MODE SELECT Screen) 1) Monitor Data Data strings: !01001:m,120,1.20,0.50,00.60,20.0,200,2.00,1.50,3.00,40.0, A B C D 300,2.50,2.00,5.00,50.0,2,0010,5,0100,2222[CR][LF] Device No. Fixed to 2 digits (01 to 31) Schedule No.
  • Page 68 IS-200A 2) Error Data Data strings: !01001:E01,02,03,05,07[CR][LF] C D E F G Device No. Fixed to 2 digits (01 to 31) Schedule No. * Fixed to 3 digits (001 to 255) Error Code 1 Fixed to 2 digits (01 to 31)
  • Page 69 IS-200A Reading of Data Code: # Device No. R Schedule No. S Screen No. * Example: Read all data of Screen No. “01” of Schedule No. “008” of the specified device No. 01. Host 0 1 0 0 8 0 1 :...

  • Page 70: Character String

    IS-200A (5) Data Code Table  Screen 01 (SCHEDULE data) Specific data in accordance with Schedule No. (Schedule No.: 001 to 255) Character Item Contents Range String 0 to 5 0: Primary constant-current effective value control 1: Secondary constant-current effective value control...
  • Page 71 IS-200A Character Item Contents Range String n.nn, 0.10 to 9.99 (kA, kW, V) HEAT3 nn.n, 10.0 to 99.9 (%) PULSATION 01 to 19 GAIN 1 to 9 VALVE 1 to 2 TURN RATIO nnn.n, 001.0 to 199.9 0: OFF WELD ON/OF...
  • Page 72 IS-200A  Screen 03 (STEPPER data) Common data (Schedule No.: 000) Character Item Contents Range String START ON STEP # of VALVE1 1 to 9 STEP1 COUNT of VALVE1 nnnn, 0000 to 9999 STEP2 COUNT of VALVE1 nnnn, 0000 to 9999...

  • Page 73: 0000 To 9999

    IS-200A  Screen 04 (MONITOR data) (Data reading only) Specific data in accordance with Schedule No. (Schedule No.: 001 to 255) Character Item Contents Range String m: ms Unit of time C: CYC 000 to 999 (ms mode) Monitor time of WELD1...

  • Page 74: Table Of Contents

    IS-200A Character Item Contents Range String 0: OFF WELD COUNT 1: ON 0: OFF RE-WELD 1: ON 0: ms WELD TIME 1: CYC WELD COUNT nnnn, 0000 to 9999 NO CURRENT TIME 01 to 99 (ms) NO CURRENT LEVEL n.nn, 0.00 to 9.99 (kA)
  • Page 75 IS-200A 11. Outline Drawing (Dimensions in mm) INDICATOR WELD POWER READY START WELD TROUBLE POWER TROUBLE RESET WELD ON/OFF PROGRAM RS-232C/485 MONITOR OUTPUT POWER 200V-240V ～ 50/60Hz With terminal covers removed 11. Outline Drawing 11-1...
  • Page 76 IS-200A 12. Troubleshooting (1) Fault Code List In the event of a problem with the Power Supply, the MA-627A displays the fault code and message. In such cases, read this section carefully, then inspect the equipment and take the necessary countermeasures. If you have any questions, consult us or your distributor.
  • Page 77 IS-200A Fault Contents Cause Measures code Pulse width of welding current is Check workpiece and welding E-07 Pulse width error out of PULSE HIGH setting range electrode. on MONITOR SET screen. Add required number of welds to Insufficient number Counted number of welds is less E-08 make up for insufficiency.
  • Page 78 IS-200A Fault Contents Cause Measures code Cooling water flow in pipe to which Increase cooling water flow rate to flow switch is installed is low. meet specifications. E-15 Flow switch error Power supply for external input is Check external input signal for proper not connected.
  • Page 79 IS-200A (2) When a Welding Does not Start Even if the Start Signal is Input When a welding does not start even if the start signal (2ND STAGE signal) is input, the following causes can be thought.  READY does not light up.
  • Page 80 IS-200A (Note 3) When the MONITOR screen is displayed, the monitor data is transferred to the MA-627A simultaneously with the END signal output (transmission time Tb1). The monitor data is not transferred when the screen other than MONITOR screen is displayed.

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