IP-500A Thank you for purchasing our Inverter Welding Power Supply IP-500A. 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 Special Precautions ...................... 1-1 (1) Safety Precautions .....................
IP-500A 1. Special Precautions (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.
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IP-500A 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.
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IP-500A 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.
IP-500A (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 Power Supply on a firm and level surface. If it is inclined, malfunction may result.
IP-500A (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 Labels for Safety On the main body are warning labels for safety.
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IP-500A Location: Input breaker cover DANGER Meaning: Shock hazard, Cautions for high voltage HIGH VOLTAGE 1. Special Precautions...
IP-500A 2. Features The IP-500A is an inverter-type power supply, specially designed to be used for spot welding and fusing. In addition, it is small in size and convenient to move or shift. Monitor function is provided, which enables judging defective or non-defective welding.
IP-500A 3. Name and Functions of Each Section (1) Front Operation panel (See “Detailed view of operation panel.”) ⑫Cooling fan filter cover ⑦WELD lamp ⑥WELD key ①LCD display ⑩MENU key ⑨+/- key ⑧Cursor key ⑤RESET key ②READY lamp ③START lamp ⑪ENTER key...
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TROUBLE lamp (orange) Lights up when an error is detected. At this time, the IP-500A makes a peeping sound, and the work done is interrupted. RESET key Used to reset the error display.
IP-500A (2) Rear ②Welding power supply ①Terminal strip for breaker external input/output signal ③Breaker lever ⑤Welding transformer I/O connector ④Trip button ⑧COIL connector ⑥Terminal block for welding power output ⑦Screw for connecting shielded line Terminal strip for external input/output signal Used to input the schedule signals and output error signals.
IP-500A 4. How to Operate Screens (1) STARTING Screen (1) STARTING screen The STARTING screen is displayed when the welding power supply is started. After the welding power supply is started, this screen is displayed for 10 seconds until welding is ready, the buzzer sounds once, and then the last displayed screen is displayed.
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IP-500A Performing predetermined operation while a screen (2) to (7) is displayed displays a screen (8) to (10). (8) I/O CHECK screen When the ENTER, + and - keys are pressed simultaneously for a second, the I/O CHECK screen is displayed.
IP-500A (2) SCHEDULE Screen On the SCHEDULE screen, welding schedules are set. 63 schedules (SCH#01 to 63) can be set. The weld time, current and others of each SCH can be set. The initial position of the cursor is the first digit of the SCH number and the number blinks.
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IP-500A Setting Setting Initial Setting contents Unit CTRL setting item range value ① SCH# Schedule number 01 to 63 ② UP1 Upslope 1 time 00 to 99 ③ WEL1 Weld 1 time 000 to 999 ④ DN1 Downslope 1 time...
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IP-500A The setting range is 0 to 999 ms. Set the total time of UP2 and DN2 to be shorter than WEL2. If not, “E-07 SCHEDULE SET ERROR” (Schedule setting error) will be displayed. ⑧ DN2 Set the downslope time (to decrease the welding current gradually) for Weld 2.
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IP-500A Large control gain Small control gain Setting Setting Overshoot Slow increase in current 4. How to Operate Screens...
IP-500A (3) MONITOR Screen ① ② line line ③ ⑤ ⑥ ④ line ⑦ ⑧ ⑨ ⑩ line Example display of no measurement (initial display) Example display of GOOD (normal welding) Example display of NG (abnormal welding) On the MONITOR screen, the work state at welding is checked. The welding result of each SCH is displayed.
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IP-500A Initial Setting item Setting contents Unit Setting range value ② SCH# Schedule number 01 to 63 Initial Display item Display contents Unit Display range display ① <GOOD/NG> Judgment result GOOD/NG ---- Monitor value of WELD1 ③ 1-[ms] 000 to 999...
IP-500A (4) MONITOR SET Screen line ① line ③ ④ ② ⑤ line ⑥ ⑦ ⑧ line ⑨ ⑩ ⑪ ⑫ line ⑬ ⑭ ⑮ line On the MONITOR SET screen, upper/lower limits of the welding current and voltage are set.
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IP-500A Setting Initial Setting contents Unit Setting range item value ⑧ 1L-[V] Lower limit of WELD1 voltage 0.00 to 9.99 0.00 ⑨ 2H-[ms] Upper limit of WELD2 time 000 to 999 ⑩ 2H-[kA] Upper limit of WELD2 current 0.00 to 9.99 9.99...
INCLUDE ① NO CURR.TIME Set the time that the IP-500A will ignore the detection of no-current error/no-voltage error. The absence of welding current will not be detected as “E-08 NO CURRENT ERROR” (No-current error) or “E-09 NO VOLTAGE ERROR” (No-voltage error) as long as the absence lasts for a period within the time set here.
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IP-500A as long as it lasts no more than 3 ms. An absence of current will be detected as an error if it lasts for 4 ms or more, the TROUBLE lamp lights up, and an error code appears on the LCD display. COOL/HOLD times are not included in the time until the absence of current is detected.
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IP-500A Setting Explanation EXCLUDE Slope period will not be included. INCLUDE Slope period will be included. 4. How to Operate Screens 4-13...
IP-500A (6) MODE SELECT Screen line line ① ② line ③ line ④ line ⑤ line ⑥ line ⑦ line ⑧ line Setting item Setting contents Unit Setting range Initial value ① PARITY CHECK Parity check ON/OFF Start signal stabilization ②...
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IP-500A This check allows for detection of a failure resulting from a wire break in the schedule number selection input (Pins 7 to 12) signal lines. At ON, be sure that the total number of closed schedule number selection input and parity input (Pin 13) signal lines is always odd.
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IP-500A Setting Explanation Welding is performed in Primary constant-current peak value PRIMARY LIMIT control. Welding is performed in Secondary constant-current effective SECONDARY RMS value control. Welding is performed in Secondary constant-voltage effective VOLTAGE RMS value control. (See Note 2, Control method of the inverter welding power supply.) ⑤...
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Select a mode of the transformer selecting function. Up to 5 welding transformers can be switched by connecting the optional transformer selector MA-650A to the IP-500A and welding is performed using the selected schedule number and successive schedule numbers in order. Select a setting from 1-2 to 1-5 when connecting the transformer selector MA-650A.
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IP-500A Note 2, Control method of the inverter welding power supply The explanations for each control method of the inverter welding power supply is as follows. Control Feature Application Control mechanism method Requires no connection of toroidal coil on the...
01 to 16 ③ COMM CONTROL Communication function OFF/-->/<-> ④ BAUD RATE Baud rate 9600/19200/38400 9600 ⑤ ① ROM Ver# The program version of the IP-500A is displayed. (* Display only and no setting) 4. How to Operate Screens 4-20...
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IP-500A ② DEVICE No. Input the identification No. of your Power Supply. The setting range is 1 to 31. If you have two or more Power Supply units, input 01 for the first one, 02 for the second one, 03 for the third one, and so on.
IP-500A (8) I/O CHECK Screen On the I/O CHECK screen, input/output of the external I/O is checked. When the ENTER, + and - keys are pressed simultaneously for a second, the I/O CHECK screen is displayed. Can be moved from any of the following screens.
IP-500A (9) INITIALIZE Screen On the INITIALIZE screen, all data is initialized. When the RESET, + and - keys are pressed simultaneously foe a second, the INITIALIZE screen is displayed. Can be moved from any of the following screens. - SCHEDULE screen...
IP-500A (10) SCHEDULE COPY Screen On the SCHEDULE COPY screen, schedules are copied. When the MENU, + and - keys are pressed simultaneously for a second, the SCHEDULE COPY screen is displayed. Can be moved from any of the following screens.
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IP-500A Press the MENU key or cursor key to return to the SCHEDULE screen. Example 1) When copying the schedule of SCH#01 to that of SCH#02 Set to “#01 → #02-02.” Schedule of SCH#01 is copied to SCH#02. Example 2) When copying the schedule of SCH#01 to those of SCH#02 to SCH#05 Set to “#01 →...
IP-500A (11) ERROR Screen The ERROR screen is displayed when an error occurs. (See 13. (1) Fault Code list.) (Example: ERROR screen when E-11 has occurred) While the ERROR screen is displayed, the buzzer sounds continuously. How to cancel the error differs depending on the RESTART (restart method) setting in the MODE SELECT screen.
Allow at least 100 mm or more from the end of the wiring outlet projected at the output terminal cover in the rear potion of the IP-500A. As the IP-500A should be air-cooled, do not install it in a closed area. 100mm or more...
α Average input current = I x 0.817 x I : Primary output current (momentary maximum current) of IP-500A α : Duty cycle (%) Select the breaker rated current of at least the average input current above.
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(Note 2) Use the SENS cable SK-05741 specified by us. (Note 3) The screw of the power cable for the IP-500A is M8 (M6 for the PE terminal). The screw of the output cable is M6 for U, V and PE.
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Pins 38 and 39 on the external input/output signal terminal strip. (Note 3) The screw of the power cable for the IP-500A is M8 (M6 for the PE terminal). The screw of the output cable is M6 for U, V and PE.
IP-500A (4) Connection Procedure When using our transformer (IT-H190A6) Connection to the transformer’s input terminal block and the 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.
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IP-500A When using another manufacturer's transformer Connection to the welding transformer’s input terminal block 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.
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IP-500A Specifications of Terminal Strip for External Input/Output Signals Crimp-on terminals allowed to be 2 pieces max. installed per a terminal Size of crimp-on terminal M3 or M3.5 (7.1 mm wide) Recommended cable cross-section 0.2 mm min. (Note 1) Use the shielded cable for the interface input/output cable and connect the shielded part to the screw for connecting shielded line on the rear panel.
IP-500A (2) Description of External I/O Signals Pin No. Name Description Pin 1 is 24 V DC present. (Maximum rating: 24 V DC, 0.4 A) Pin 2 is a COM pin for input circuits of the external interface. When using a contact or open collector (sink type) PLC INT.24V...
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IP-500A Pin No. Name Description Parity input pin. This pin allows for detection of a wire break in the schedule number selection signal lines. Be sure that the total number of PARITY closed schedule number selection input pins of pins 7 to 12 and parity signal lines is always odd.
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IP-500A Pin No. Name Description Welding normal signal output pin. This pin is closed when the measured value is within the range set in the MONITOR SET screen after a welding sequence ends. GOOD Setting range of output time: 0 to 200 ms (Output is kept in 0 ms.)
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IP-500A Pin No. Name Description Welding timing signal output pin. This pin is closed during welding (WELD1, WELD2). This is not WELD output during COOL. When the weld time is set for WELD1 or SIGNAL WELD2, this pin is closed even if WELD ON/OFF is started with OFF.
IP-500A (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.
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IP-500A 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. (Internal) (External) Internal power supply Connection with equipment featuring NPN open collector output (when using ...
IP-500A 7. Basic Operation (1) Turn on the welding power Pull up the breaker lever at the rear of the IP-500A to turn on the welding power. Breaker lever IP-500A rear After power-on, the STARTING screen appears at the LCD display.
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MONITOR SET screen for each schedule number if necessary. (See 4. (4) MONITOR SET Screen.) (4) Turn off the welding power Push down the breaker lever at the rear of the IP-500A to turn off the welding power. Breaker lever IP-500A rear Panel LEDs and the LCD display go off....
IP-500A 8. Timing Chart (1) Basic Sequence Shown below is a basic sequence when TRANS SCAN is set to OFF. (Note 1) (Note 1) (Note 1) (Note 1) External input SCH 1 SCH 2 READY (Note 2) (Note 2) External output...
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IP-500A A: ST.DELAY TIME (Start signal stabilizing time. See 4. (6) ②ST.DELAY TIME.) B: GOOD/END TIME (GOOD/END signal output time. See 4. (6) ⑤GOOD/END TIME.) C: Single-directional communication output time COMM CONTROL (*1) BAUD RATE (*2) Communication output time 0 ms 9600 80 ms max.
IP-500A (2) Sequence when the Monitor Judgment is NG Operation when the monitor judgment is NG depending on the RESTART setting (See 4. (6) ⑦RESTART.) changes as follows. (The TRANS SCAN setting (See 4. (6) ⑧TRANS SCAN.) is OFF.) ① When RESTART is set to RESET...
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IP-500A ② When RESTART is set to NEXT START A sample weld sequence is shown, which represents the occasion where the CAUTION signal is output when a monitored value goes out of the range between the upper and lower limit set in the MONITOR SET screen.
IP-500A (3) Occurrence of an Error during Welding Sequence A sample weld sequence is shown, which represents the occasion where an error (*1) occurs. When an error occurs, a weld sequence is not performed after that. SQZ~HOLD NG1(ERROR) A: ST.DELAY TIME (Start signal stabilizing time) (*1) The relevant error codes are as follows.
IP-500A (4) Sequence in TRANS SCAN Shown below is the sequence when using the IP-500A in combination with the transformer selector MA-650A. (For details of function, see 4. (6) ⑧TRANS SCAN.) Sequence when TRANS SCAN is set to 1-5 (SCH2 is selected)
IP-500A (5) Sequence when the Monitor Judgment of TRANS SCAN is NG Operation when the monitor judgment is NG depending on the RESTART setting (See 4. (6) ⑦RESTART.) changes as follows. (The TRANS SCAN setting (See 4. (6) ⑧TRANS SCAN) is not OFF.) ①...
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IP-500A ② When RESTART is set to NEXT START Even when the monitor judgment is NG in SCH3, the welding sequence is performed to the last SCH6 and NG2 (CAUTION) is output. External input SCH2 READY External output SCH2's SCH3's...
IP-500A 9. External Communication Function (1) Introduction The IP-500A 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. Prepare the program and its development environment for controlling the Power Supply on the customer side.
IP-500A (3) Configuration Host computer Device No.01 Device No.02 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. for each device. Set Device No. at the SETUP screen in 7.
(4) Protocol (Single-Directional Communication) Single-directional communication mode (when the setting of 4. (7) ④COMM CONTROL is -->) Data is output one-sidedly from the IP-500A after each welding or a fault has occurred. ① Monitor data Commands transmitted from the IP-500A to the host computer are as follows:...
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IP-500A ② Error code Commands transmitted from the IP-500A to the host computer when an error has occurred in the IP-500A are as follows: Item Display Range Length Device number 01 to 31 Delimiter Schedule number 01 to 63 Delimiter...
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③ Monitor data when TRANS SCAN is set When TRANS SCAN is set to 1-2, 1-3, 1-4, or 1-5 to perform welding with two or more welding transformers connected, the IP-500A transmits the monitor data of all schedules in a batch after welding.
Do not send the next command until the data is sent back or the timeout time passes when sending command. When using a write command, a newly set data is returned from the IP-500A for check. When a wrong data is written, a currently set value is returned for check. (When a part of telegraphic message is wrong, normal data is converted and sent back, and the wrong data returns the original set value.)
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(*2) In “Vnn-nnn”, “V” is fixed, the trailing “n” is alphabet, and other “n”s are numbers. Communication example: Reading the model name of the IP-500A and the ROM version (Device number: 01) “Host computer → IP-500A” #01I[CR][LF] “IP-500A → Host computer”...
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All contents of the schedule data of the specified device number or a common schedule data are read. <Reading request data> (Host computer ⇒ IP-500A) Commands transmitted from the host computer to the IP-500A are as follows: Item Display Range...
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IP-500A Reading schedule data of the IP-500A (data for each schedule number) (Device number: 01, Schedule number: 02) “Host computer → IP-500A” #01R002*[CR][LF] “IP-500A → Host computer” !01002: 0000ms,00ms,000ms,00ms,00ms,00ms,000ms,00ms,000ms, 0.20kA,0.20kA,0.20V,0.20V,1,050.0,1,999ms,000ms,9.99kA,0.00kA, 9.99V,0.00V,100%,999ms,000ms,9.99kA,0.00kA,9.99V,0.00V,100%[CR][LF] 9. External Communication Function...
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All parameters of the schedule data or a common schedule data of the specified device number are written. <Writing request data> (Host computer ⇒ IP-500A) Commands transmitted from the host computer to the IP-500A are as follows: Item Display Range...
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Writing schedule data of the IP-500A (common schedule data) (Device number: 01) “Host computer → IP-500A” #01W000: 50,0.10,0.10,10,0,0,10,1,0,100,0,1,0,16[CR][LF] “IP-500A → Host computer” !01000: 50,0.10,0.10,10,0,0,10,1,0,100,0,1,0,16,0,2[CR][LF] Writing schedule data of the IP-500A (data for each schedule number) (Device number: 01, Schedule number: 02) “Host computer → IP-500A” #01W002: 1101ms,42ms,150ms,50ms,02ms,05ms,023ms,10ms,112ms, 1.50kA,0.80kA,1.20V,0.60V,1,064.5,1,989ms,001ms,6.98kA,0.20kA, 8.96V,3.21V,056%,111ms,021ms,1.01kA,1.22kA,9.99V,0.67V,090%[CR][LF] “IP-500A →...
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④ Reading the specified item An optional parameter of the schedule data of the specified device number is read. <Reading request data> (Host computer ⇒ IP-500A) Commands transmitted from the host computer to the IP-500A are as follows: Item Display Range...
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IP-500A Reading Weld 1 time (WEL1) of the IP-500A (Device number: 01, Schedule number: 10) “Host computer → IP-500A” #01R010T02[CR][LF] “IP-500A → Host computer” !01010T02: 100ms[CR][LF] 9. External Communication Function 9-13...
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⑤ Writing the specified item An optional parameter of the schedule data of the specified device number is written. <Writing request data> (Host computer ⇒ IP-500A) Commands transmitted from the host computer to the IP-500A are as follows: Item Display Range...
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IP-500A Communication example: Writing Weld 1 current (HEAT1) of the IP-500A (Device number: 01, Schedule number: 10) “Host computer → IP-500A” #01W010H01: 5.00kA[CR][LF] “IP-500A → Host computer” !01010H01: 5.00kA[CR][LF] Writing Weld 1 time (WEL1) of the IP-500A (Device number: 01, Schedule number: 10) “Host computer →...
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IP-500A ⑥ Reading the error status The abnormal state of the IP-500A is read. <Reading request data> (Host computer ⇒ IP-500A) Commands transmitted from the host computer to the IP-500A are as follows: Item Display Range Length Start code Device number...
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IP-500A Communication example: Reading the abnormal state of the IP-500A (an error code occurred) (Device number: 01) “Host computer → IP-500A” #01RE99[CR][LF] “IP-500A → Host computer” !01E99:16,[CR][LF] Reading the abnormal state of the IP-500A (three error codes occurred) (Device number: 01) “Host computer →...
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⑦ Error reset by the external communication The IP-500A can reset errors by the external communication. <Request data of error reset by the external communication> (Host computer ⇒ IP-500A) Commands transmitted from the host computer to the IP-500A are as follows: Item Display Range...
IP-500A (6) Data Code Table ① Schedule data ◇Common schedule data <Schedule number: 000> Item Contents Display Range Length No-current detection NO CURR.TIME 00 to 99 ignore time NO CURR.LEV. No-current detection level n.nn 0.00 to 9.99 NO VOLT.LEV. No-voltage detection level n.nn 0.00 to 9.99...
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IP-500A ◇Data for each schedule number <Schedule number: 001 to 063> Character Item Contents Range Length string SQZ[ms] Squeeze time nnnnms 0000 to 9999 UP1[ms] Upslope 1 time nnms 00 to 99 WEL1[ms] Weld 1 time nnnms 000 to 999...
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IP-500A ② Specified item ◇Schedule time setting Specified Character Item Contents Range Length code string UP1[ms] Upslope 1 time nnms 00 to 99 WEL1[ms] Weld 1 time nnnms 000 to 999 DN1[ms] Downslope 1 time nnms 00 to 99 UP2[ms]...
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IP-500A ◇Monitor data (Reading only) (*1) (*2) Specified Character Item Contents Range Length code string 1-[ms] Monitor value of Weld 1 time nnnms 000 to 999 1-[kA] Monitor value of Weld 1 current n.nnkA 0.00 to 9.99 Monitor value of Weld 1 1-[V] n.nnV...
IP-500A 10. Specifications (1) Specifications Model No. IP-500A-00-00 Input voltage 3-phase, 380 to 415 V AC ±10% (50/60 Hz) range Max. output 200 A (peak value) current Maximum capacity 112 kVA (input voltage at 415 V AC) Rating capacity 42 kVA (input voltage at 415 V AC)
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IP-500A Transportation and Ambient temperature -10 to +55°C storage conditions Humidity 90% max. (no condensation) Heat-resistant class Case protection IP20 Overcurrent 150 A Fuse The supply of current is stopped in the following cases: a. When a primary current is not...
IP-500A (2) Options (Sold Separately) Input Cables If a customer procures the cable by oneself, prepare it in accordance with the following right-hand specifications. Model No. Length Specifications PK-1176990 Rated voltage 600 V AC min. PK-1176991 Section area 14 mm min.
IP-500A 12. Maintenance (1) Cleaning and Replacement of Filter The IP-500A has filters at its intake. Outlet Intake Clean the filter once a month. When cleaning it, cleanse with neutral detergent water. If it gets badly stained, replace it with a new one.
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IP-500A Filter is inside the filter cover. Remove it and cleanse with neutral detergent water. Filter After drying the filter, return it (a new one when replacing) onto the filter cover. Secure the filter cover to the intake.
SYSTEM Error has been detected on control E-01 again. If this error is displayed again, ERROR system of IP-500A. repair is required. Contact us. Check all the settings. If the data in memory is damaged, the following are possible causes:...
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ERROR connected (in Secondary 4. Adjust the timing so that the start constant-current effective control). signal of IP-500A is input after 4. IP-500A starts welding before force is applied to workpiece. force is applied to the head. 5. Adjust force.
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IP-500A Fault Error message Cause Measures code When writing data in bi-directional communication mode at external COMM SET Check the write data or the data E-17 communication, data which is out of ERROR format. the range is written or data format is wrong.
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