Amada IS-300CA User manual

990-418 REV D
INVERTER POWER SUPPLY
IS-300CA
OPERATION MANUAL

IS-300CA INVERTER POWER SUPPLY
ii 990-418
Copyright 2018-2020 Amada Weld Tech Inc.
The engineering designs, drawings and data contained herein are the proprietary work of Amada Weld
Tech and may not be reproduced, copied, exhibited or otherwise used without the written authorization
of Amada Weld Tech.
Printed in the United States of America
Revision Record
Revision EO Date Basis of Revision
A 44980 06/18 Original publication
B 45217 10/18 Add Ethernet I/P Appendix + Miscellaneous corrections
C 45546 07/19 Update EtherNet/IPTM terminology + content
D 45804 04/20 Update Company Name (Amada Weld Tech) + Model Names

IS-300CA INVERTER POWER SUPPLY
990-418 iii
FOREWORD
Thank you for purchasing an Amada Weld Tech IS-300CA Inverter 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-300CA will be referred to simply as the Power Supply.
Upon receipt of your equipment, please thoroughly inspect it for shipping damage prior to its installation.
Should there be any damage, please immediately contact the shipping company to file a claim, and notify
us at: Amada Weld Tech Inc.
1820 South Myrtle Avenue
Monrovia, California 91016
Phone: [phone]
FAX: [phone]
E-Mail: [e-mail]
The purpose of this manual is to supply operating and maintenance personnel with the information needed
to properly and safely operate and maintain the IS-300CA Inverter Power Supply.
We have made every effort to ensure that the information in this manual is accurate and adequate. The
contents of this manual are subject to change without notice.
Should any questions arise, or if you have suggestions for improvement of this manual, please contact us
at the above location/numbers.
Amada Weld Tech is not responsible for any loss due to improper use of this product.
This manual covers the following models:
Original Model Name
Original P/N
Current Model Name
Current P/N
IS-300CR BASIC, 200-240V 1-325-01
→
IS-300CA-BASIC/200-240 1-325-02
IS-300CR BASIC, 380-480V 1-325-01-01
→
IS-300CA-BASIC/380-480 1-325-02-01
IS-300CR ADV, 200-240V 1-325-01-02 → IS-300CA-ADV/200-240 1-325-02-02
IS-300CR ADV, 380-480V 1-325-01-03
→
IS-300CA-ADV/380-480 1-325-02-03
IS-300CR ETHERNET IP, 200-240V 1-325-01-04
→
IS-300CA-EIP AB/200-240 1-325-02-04
IS-300CR ETHERNET IP, 380-480V
1-325-01-05
→
IS-300CA-EIP AB/380-480
1-325-02-05

IS-300CA INVERTER POWER SUPPLY
iv 990-418
CONTENTS Page
Chapter 1. System Description
Section I: Features ..................................................................................................................................1-1
Basic, Advanced and EtherNet/IPTM Models ....................................................................................1-1
Advanced Models Only ....................................................................................................................1-2
Section II: System Components .............................................................................................................1-3
External Input / Output Signals .......................................................................................................1-3
Front Panel ....................................................................................................................................1-4
WELD POWER Lamp .............................................................................................................1-4
READY Lamp ..........................................................................................................................1-4
START Lamp ...........................................................................................................................1-4
WELD Lamp ............................................................................................................................1-4
TROUBLE Lamp .....................................................................................................................1-4
TROUBLE RESET Key ...........................................................................................................1-4
WELD ON/OFF Key ................................................................................................................1-4
MA-660A Program Unit (“The Pendant”) .....................................................................................1-6
TROUBLE RESET key ............................................................................................................1-6
CURSOR Keys .........................................................................................................................1-6
+ON/-OFF Keys .......................................................................................................................1-6
ENTER Key .............................................................................................................................. 1-6
MENU Key................................................................................................................................1-7
Chapter 2. Installation And Setup
Section I: Planning .................................................................................................................................2-1
Environmental Factors ......................................................................................................................2-1
Power Requirements .........................................................................................................................2-1
Section II: Installation ............................................................................................................................2-2
Unpacking .....................................................................................................................................2-2
Electrical Connections ......................................................................................................................2-2
Power and Transformer Connections ................................................................................................2-3
Chapter 3. Using Programming Functions
Section I. Introduction ...........................................................................................................................3-1
Section II. Programming Options For Basic and Advanced Models .....................................................3-2
1. MENU Screen ..................................................................................................................................3-2
2. POWER SUPPLY STATE Screen ..................................................................................................3-2
LCD CONTRAST ...................................................................................................................3-2
CONTROL # ............................................................................................................................3-3
PROGRAMED DATE .............................................................................................................3-3
POWER SOURCE FREQUENCY ..........................................................................................3-3

IS-300CA INVERTER POWER SUPPLY
990-418 v
CONTENTS (Continued) Page
Chapter 3. Using Programming Functions (cont.)
LANGUAGE ............................................................................................................................3-3
MA-660A the Pendant ROM VERSION # ..............................................................................3-3
MA-660A the Pendant (IS-300CA) PROGRAM VERSION ..................................................3-3
IS-300CA ROM VERSION # ..................................................................................................3-3
3. SCHEDULE Screen .........................................................................................................................3-3
CURRENT and TIME Setting Screen ...................................................................................... 3-3
SCHEDULE # ...................................................................................................................3-4
TIME .................................................................................................................................3-4
WELD (1, 2, 3) .................................................................................................................. 3-5
UP (1, 2, 3) ........................................................................................................................3-5
DOWN (1, 2, 3) .................................................................................................................3-5
WELD ON/OFF ................................................................................................................3-8
CTRL .................................................................................................................................3-8
HEAT ..............................................................................................................................3-10
UF (UP SLOPE FIRST) ..................................................................................................3-10
DL (DOWN SLOPE LAST) ...........................................................................................3-10
NEXT ..............................................................................................................................3-10
PULSATION and transformer screen ...........................................................................................3-10
SCHEDULE # ........................................................................................................................3-11
PULSE LIMIT ........................................................................................................................3-11
PULSATION / INTERVAL 1 to 3 .........................................................................................3-11
WELD TRANS FREQ ...........................................................................................................3-12
VALVE # ................................................................................................................................3-12
CURRENT RANGE ...............................................................................................................3-12
MAX CURRENT ...................................................................................................................3-12
WELD ON/OFF .....................................................................................................................3-12
VOLT COMPENSATION .....................................................................................................3-12
GAIN (01-09) .........................................................................................................................3-13
TURN RATIO ........................................................................................................................3-13
TRANS # ................................................................................................................................3-13
REV ........................................................................................................................................3-13
4. MONITOR Screen .........................................................................................................................3-14
SCHEDULE # ........................................................................................................................3-14
TIME ......................................................................................................................................3-14
CURRENT .............................................................................................................................3-14
VOLTAGE .............................................................................................................................3-14
POWER ..................................................................................................................................3-15
PULSE ....................................................................................................................................3-15
STEP # ....................................................................................................................................3-15
STEPPER COUNT .................................................................................................................3-15
STEP2 REPEAT .....................................................................................................................3-15

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vi 990-418
CONTENTS (Continued) Page
STEP RATIO .......................................................................................................................... 3-15
CAP CHANGE .......................................................................................................................3-15
TOTAL COUNTER ...............................................................................................................3-16
5. MONITOR SET Screen .................................................................................................................3-18
SCHEDULE ..........................................................................................................................3-18
TIME ......................................................................................................................................3-18
CURRENT .............................................................................................................................3-18
VOLTAGE .............................................................................................................................3-18
POWER ..................................................................................................................................3-18
PULSE ....................................................................................................................................3-19
6. NG SIGNAL SELECT Screen ......................................................................................................3-19
ERROR OUTPUT MODE .....................................................................................................3-19
TIME-OVER / CURR-OVER / VOLT-OVER / POWER-OVER /
PULSE-OVER / WORK-OVER / DISPL-OVER ..................................................................3-20
7. OUTPUT SELECT Screen ............................................................................................................3-21
8. COPY SETUP DATA Screen .......................................................................................................3-22
9. MODE SELECT Screen ................................................................................................................3-23
DELAY START SET .............................................................................................................3-23
START SIGNAL MODE .......................................................................................................3-24
END SIGNAL TIME ...........................................................................................................3-25
END SIGNAL MODE ...........................................................................................................3-26
WELD TIME ..........................................................................................................................3-26
WELD1 STOP/PARITY CHECK ..........................................................................................3-27
WELD2 STOP/WELD COUNT ............................................................................................3-30
WELD3 STOP/COUNT RESET ............................................................................................3-30
FLOW SWITCH/PRG PROTECT ......................................................................................... 3-30
NEXT .....................................................................................................................................3-31
STEPPER MODE ...................................................................................................................3-31
SCHEDULE ...........................................................................................................................3-31
VALVE MODE ......................................................................................................................3-31
MONITOR DISP MODE .......................................................................................................3-33
RE-WELD ..............................................................................................................................3-33
COUNTER .............................................................................................................................3-34
SCAN MODE .........................................................................................................................3-35
COMM CONTROL ................................................................................................................3-35
COMM MODE .......................................................................................................................3-35
COMM SPEED ......................................................................................................................3-36
DISPLACEMENT SENSOR STEP .......................................................................................3-36
REV ........................................................................................................................................3-36

IS-300CA INVERTER POWER SUPPLY
990-418 vii
CONTENTS (Continued) Page
10. MONITOR MODE Screen ............................................................................................................3-36
PRESET TOTAL COUNT .....................................................................................................3-36
NO CURRENT TIME ............................................................................................................3-40
NO CURRENT LEVEL .........................................................................................................3-40
NO VOLTAGE LEVEL .........................................................................................................3-40
MONITOR FIRST TIME .......................................................................................................3-40
MONITOR SLOPE MODE ................................................................................................... 3-41
WELD STOP OFF TIME .......................................................................................................3-41
11. STEPPER COUNT Screen ............................................................................................................3-42
START ON STEP # ...............................................................................................................3-42
STEP MODE ..........................................................................................................................3-43
VALVE # ................................................................................................................................3-44
STEP 1–9 ................................................................................................................................ 3-45
COUNT 1–9 ........................................................................................................................... 3-45
RP2 .........................................................................................................................................3-45
TD 1–9 .................................................................................................................................... 3-45
CAP CHANGE .......................................................................................................................3-45
12. PRECHECK Screen .......................................................................................................................3-46
SCHEDULE # ........................................................................................................................3-46
PRECHECK TIME ................................................................................................................3-46
PRECHECK HEAT ................................................................................................................3-46
PRECHECK RESISTANCE HIGH .......................................................................................3-46
PRECHECK RESISTANCE LOW ........................................................................................3-46
PRECHECK MONITOR ........................................................................................................ 3-46
13. I/O CHECK Screen ........................................................................................................................3-47
14. RESET TO DEFAULT Screen ......................................................................................................3-48
15. PROGRAM PROTECT MODE Screen ........................................................................................3-48
Section III. Options Available On Advanced Models ONLY .............................................................3-50
16. FORCE SETUP & MONITOR Screen ..........................................................................................3-50
SCHEDULE ...........................................................................................................................3-50
PROP VALVE # .....................................................................................................................3-50
STEP MODE (Continue) ........................................................................................................ 3-50
SQD ........................................................................................................................................3-51
SQZ .........................................................................................................................................3-51
WE1 ........................................................................................................................................3-51
CO1/WE2 ...............................................................................................................................3-51
CO2/WE3 ...............................................................................................................................3-51
SQD ........................................................................................................................................3-52
SQZ .........................................................................................................................................3-52
WE1 ........................................................................................................................................3-52

IS-300CA INVERTER POWER SUPPLY
viii 990-418
CONTENTS (Continued) Page
CO1/WE2 ...............................................................................................................................3-52
CO2/WE3 ...............................................................................................................................3-52
HOLD .....................................................................................................................................3-52
VALVE # ................................................................................................................................3-52
FORGE VALVE # .................................................................................................................3-53
CHAINING ............................................................................................................................3-53
SUCCESSIVE ........................................................................................................................3-53
FORGE DELAY ....................................................................................................................3-54
FORGE MODE ......................................................................................................................3-54
17. DISPLACEMENT Screen .............................................................................................................3-54
SCHEDULE # ........................................................................................................................3-54
WELD STOP INPUT .............................................................................................................3-55
WELD STOP CONDITION ...................................................................................................3-55
WORK DETECT LIMIT .......................................................................................................3-55
WORK DETECT MONITOR ................................................................................................3-55
DISPLACEMENT LIMIT ......................................................................................................3-55
DISPLACEMENT DELAY TIME ........................................................................................3-55
DISPLACEMENT MONITOR ..............................................................................................3-56
18. PRESSURE REGULATOR Screen ..............................................................................................3-56
FORCE CONTROL MODE ...................................................................................................3-56
FORCE UNIT .........................................................................................................................3-57
AIR PRESSURE UNIT ..........................................................................................................3-57
AIR CYLINDER DIAMETER ..............................................................................................3-57
MAX AIR PRESSURE .......................................................................................................... 3-58
MAX FORCE .........................................................................................................................3-58
CALIBRATION CONSTANT FORCE .................................................................................3-58
CALIBRATION LOW ...........................................................................................................3-58
CALIBRATION HIGH ..........................................................................................................3-58
Chapter 4. Operating Instructions
Section I: Introduction ...........................................................................................................................4-1
Operator Safety .................................................................................................................................4-1
Before You Start................................................................................................................................4-1
Preparing for Operation ....................................................................................................................4-1
Section II: Operation ..............................................................................................................................4-2
Starting Welding Operation ..............................................................................................................4-2
Check the Valve Sequence ................................................................................................................4-2

IS-300CA INVERTER POWER SUPPLY
990-418 ix
CONTENTS (Continued) Page
Chapter 5. Maintenance
Section I: Troubleshooting .....................................................................................................................5-1
When the Welding Does not Start Even if the Start Signal is Input .................................................5-5
Cleaning ...............................................................................................................5-7
Section II: Repair Service, Storage, Shipment .......................................................................................5-8
Appendix A. Technical Specifications................................................................................................ A-1
Appendix B. Electrical and Data Connections ..................................................................................B-1
Appendix C. System Timing ................................................................................................................C-1
Appendix D. Communications ........................................................................................................... D-1
Appendix E. EtherNet/IPTM Communications...................................................................................E-1

IS-300CA INVERTER POWER SUPPLY
x 990-418
SAFETY PRECAUTIONS
DEATH ON CONTACTmay result if personnel fail to observe the safety
precautions labeled on the equipment and noted in this manual.
HIGH VOLTAGE is used in the operation of this equipment.
WHEN WELDING always wear safety glasses.
General
This instruction manual describes the operation and maintenance of the Power Supply and
provides instructions relating to its SAFE use. Procedures described in this manual must
be performed as detailed by QUALIFIED and TRAINED personnel.
For SAFETY, and to effectively take advantage of the full capabilities of the Power Supply,
please read this instruction thoroughly before attempting to use it.
After reading this manual, retain it for future reference when any questions arise regarding
the proper and SAFE operation of the Power Supply.
Operation
Procedures other than those described in this manual or not performed as prescribed in this
manual, may expose personnel to electrical shock or death.
When operating any welder, always wear appropriate personal protective gear.
Maintenance/Service
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 Weld Tech.