Amada IP-500A User manual

Z11OM1203975-03
OPERATION MANUAL
INVERTER WELDING POWER SUPPLY
IP-500A

IP-500A
Contents
1
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
1. Special Precautions ...................................................................................................... 1-1
(1) Safety Precautions..................................................................................................... 1-1
(2) Precautions for Handling............................................................................................ 1-4
(3) On Disposal ............................................................................................................... 1-5
(4) Warning Labels for Safety.......................................................................................... 1-5
2. Features ......................................................................................................................... 2-1
3. Name and Functions of Each Section.......................................................................... 3-1
(1) Front ..........................................................................................................................3-1
(2) Rear...........................................................................................................................3-3
4. How to Operate Screens ............................................................................................... 4-1
(1) STARTING Screen .................................................................................................... 4-1
(2) SCHEDULE Screen ................................................................................................... 4-3
(3) MONITOR Screen...................................................................................................... 4-7
(4) MONITOR SET Screen.............................................................................................. 4-9
(5) MONITOR MODE Screen ........................................................................................ 4-11
(6) MODE SELECT Screen ........................................................................................... 4-14
(7) SETUP Screen ........................................................................................................ 4-20
(8) I/O CHECK Screen .................................................................................................. 4-22
(9) INITIALIZE Screen................................................................................................... 4-23
(10) SCHEDULE COPY Screen .................................................................................... 4-24
(11) ERROR Screen...................................................................................................... 4-26
5. Installation and Connection.......................................................................................... 5-1
(1) Installation Place........................................................................................................ 5-1
(2) Grounding Work......................................................................................................... 5-2
(3) Basic Connection....................................................................................................... 5-2
(4) Connection Procedure ............................................................................................... 5-5
6. Interface ......................................................................................................................... 6-1
(1) Connection Diagram for External Input/Output Signals .............................................. 6-1
(2) Description of External I/O Signals............................................................................. 6-3
(3) Connection of Input Signals ....................................................................................... 6-7
7. Basic Operation............................................................................................................. 7-1
8. Timing Chart .................................................................................................................. 8-1
(1) Basic Sequence......................................................................................................... 8-1
(2) Sequence when the Monitor Judgment is NG ............................................................ 8-3
(3) Occurrence of an Error during Welding Sequence ..................................................... 8-5
(4) Sequence in TRANS SCAN ....................................................................................... 8-6
(5) Sequence when the Monitor Judgment of TRANS SCAN is NG................................. 8-7
9. External Communication Function .............................................................................. 9-1

IP-500A
Contents
2
(1) Introduction ................................................................................................................ 9-1
(2) Data Transmission ..................................................................................................... 9-1
(3) Configuration ............................................................................................................. 9-2
(4) Protocol (Single-Directional Communication) ............................................................. 9-3
(5) Protocol (Bi-Directional Communication).................................................................... 9-6
(6) Data Code Table...................................................................................................... 9-19
10. Specifications .............................................................................................................. 10-1
(1) Specifications........................................................................................................... 10-1
(2) Options (Sold Separately) ........................................................................................ 10-3
(3) Duty Cycle Graph..................................................................................................... 10-4
(4) Schematic................................................................................................................ 10-5
11. Outline Drawing........................................................................................................... 11-1
12. Maintenance................................................................................................................. 12-1
(1) Cleaning and Replacement of Filter ......................................................................... 12-1
13. Troubleshooting .......................................................................................................... 13-1
(1) Fault Code List......................................................................................................... 13-1
14. Schedule Data Table ................................................................................................... 14-1

IP-500A
1. Special Precautions
1-1
These symbols denote
"prohibition". They are
warnings about actions
out of the scope of the
warranty of the product.
These symbols denote
actions which operators
must take.
Each symbol with a
triangle denotes that
the content gives
DANGER, WARNING
or CAUTION to the
operator.
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.
The meaning of the words and symbols is as follows.
Do not touch the inside of the Power Supply except as instructed.
The interior of this Power Supply carries high voltage. It is very dangerous to
touch any parts except as instructed. When inspecting the interior of the
Power Supply, be sure to turn off the power source of the Power Supply and
wait for at least 5 minutes.
Never disassemble, attempt to repair, or modify the Power Supply.
These actions can cause electric shock and fire.
Consult us or your distributor for inspection and repair.
Never burn, destroy, cut, crush or chemically decompose the Power
Supply.
This product incorporates parts containing gallium arsenide (GaAs).
Denotes operations and practices
that may imminently result in serious
injury or loss of life if not correctly
followed.
Denotes operations and practices
that may result in serious injury or
loss of life if not correctly followed.
WARNING
!
Denotes operations and practices that
may result in personal injury or
damage to the equipment if not
correctl
y
followed.
CAUTION
！
!
DANGER
!
DANGER
!

IP-500A
1. Special Precautions
1-2
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.
Do not touch them; burns may result.
Ground the equipment.
If the Power Supply is not grounded, you may receive an electric shock in
the event of malfunction or current leak. Be sure to perform grounding work.
400 V AC of input voltage: at least class C
!
Connect the specified cables securely.
Cables of insufficient current capacities and loose connections can cause
fire and electric shock.
Do not damage the power cable and connecting cables.
Do not tread on, twist, or apply force to any cable. Doing so may cause the
power cable and connecting cables to become broken, leading to electric
shock and fire.
If any part must be replaced or requires repair, consult us or your distributor.
!
Stop the operation if any trouble occurs.
Continuous operation after occurrence of a trouble such as burning smell,
abnormal sound, abnormal heat, smoke, etc. can cause electric shock and
fire.
If such a trouble occurs, immediately consult us or your distributor.
!
Persons with pacemakers must stay clear of the welding machine.
A person who uses a pacemaker must not approach the welding machine or
walk around the welding site while the welding machine is in operation,
without being permitted by his/her doctor. The welding machine generates a
magnetic field and has effects on the operation of the pacemaker while it is
turned on.
!
Protective gear must be worn.
Put on protective gear such as protective gloves, long-sleeve jacket, leather
apron, etc. Surface flash and expulsion can burn the skin if they touch the
skin.
!
Wear protective glasses.
If you look at the flash directly during welding, your eyes may be damaged.
If any surface flash and expulsion gets in your eye, you may lose your
eyesight.
WARNING
!

IP-500A
1. Special Precautions
1-3
!
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.
!
Use proper tools (wire strippers, pressure wire connectors, etc.) for
terminal treatment of the connecting cables.
Do not cut the wire conductor; fire or electric shock may result.
!
Install the equipment on a firm and level surface.
Injury may result if the equipment falls or is dropped.
Do not sit on or place objects on the Power Supply.
Failure to observe this precaution may lead to malfunction.
!
Keep combustible matter away from the Power Supply.
Surface flash and expulsion may ignite combustible matter. If it is
impossible to remove all combustible matter, cover it with non-combustible
material.
Do not cover the Power Supply with a blanket, cloth, etc.
Do not cover the Power Supply with a blanket, cloth, etc. while it is in use.
The cover may be overheated and burned.
Do not use this Power Supply for purposes other than welding.
Use of this Power Supply in a manner other than specified can cause
electric shock and fire.
!
Use ear protectors.
Loud noises can damage hearing.
!
Keep a fire extinguisher nearby.
Keep a fire extinguisher in the welding shop in case of fire.
!
Maintain and inspect the Power Supply periodically.
Maintain and inspect the Power Supply periodically, and repair any damage
nearby before starting operation.
CAUTION
!

IP-500A
1. Special Precautions
1-4
(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. For ventilation, provide 100 mm clearances to the intake and exhaust
(See 5. (1)).
Do not install the Power Supply in the following locations:
Damp areas (where the humidity is higher than 90%),
areas where temperatures are above 40°C or below 5°C,
areas near a high noise source,
areas where chemicals are handled,
areas where water may condense,
dusty areas,
areas exposed to large amounts of vibration or shock, and
areas at an altitude above 1000 meters.
Clean the exterior of the Power Supply using a soft, dry cloth or one slightly
dampened with water. If the Power Supply is very dirty, use diluted neutral detergent
or alcohol. Do not use paint thinner, benzine, etc., as they may discolor or deform
the Power Supply.
Do not insert a screw, coin, etc. into the Power Supply, as they may cause
malfunction.
Operate the Power Supply in accordance with the method described in this
operation manual.
Press switches/buttons carefully by hand. Handling them roughly (using a
screwdriver or the tip of pen) may result in a malfunction or failure.
Press switches/buttons one at a time. Pressing more than one switch/button at a
time may result in a malfunction or failure. (However, the screen switching
operations in 4. (8) I/O CHECK Screen, (9) INITIALIZE Screen, and (10)
SCHEDULE COPY Screen are excluded.)
The Power Supply is not equipped with auxiliary power such as an outlet for
lighting.
Following cables are separately needed to use the Power Supply:
Power cable, and cables connecting between the Power Supply and welding
transformer,
welding transformer,
welding head, and
secondary conductor connecting between welding head and welding transformer.
The RS-485 communication signal line is not attached. Prepare the crimp-on
terminal and line for wiring to the terminal strip.
The I/O signal line to start the Power Supply is not attached. Prepare the crimp-on
terminal and line for wiring to the terminal strip.
The Power Supply should be used with the industry power transmission and
distribution network (industrial distribution equipment). Do not connect it to the
public low-voltage distribution network (distribution equipment for non-industrial
office or home use).

IP-500A
1. Special Precautions
1-5
(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. Their locations and meanings are
as noted below.
DANGER
NOT TO GET AN ELECTRIC SHOCK.
TO TURN OFF MAIN CIRCUIT BREAKER
WHEN INSPECTING INTERNAL, MAKE SURE
点検を行う際は必ず溶接電源の供給を止めた後、
本製品内部には非常に高い電圧が掛かっています｡
AND WAIT FOR AT LEAST 20 MINUTES
20分間待ってから行って下さい。
Location: Power Supply interior, side surface of acrylic cover and
output terminal cover
Meaning: Shock hazard
注意
CAUTION
CONNECT GROUNDING WIRE.
アース線を接続する事
注意
DO NOT OPEN COVER.
TOUCHING THE INSIDE
MAY CAUSE AN ELECTRIC SHOCK.
CAUTION
感電の恐れあり
カバーを開けるな
注意
CAUTION
ROTATING!
DONOTINSERTAROD
OR OTHER FOREIGN OBJECTS.
回転物注意
指、物等を入れるな
P-00202-003
Location: Power Supply interior, side
surface of acrylic cover
Meaning: Shock hazard
Location: Main unit cover
Meaning: Shock hazard
Location: Main unit cover
Meaning: Caution for rotating object
Location: Main unit cover
Meaning: Caution for grounding
connection

IP-500A
1. Special Precautions
1-6
Location: Input breaker cover
Meaning: Shock hazard,
Cautions for high voltage
HIGH
VOLTAGE
DANGER

IP-500A
2. Features
2-1
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.
Welding-current monitoring function for judgment of weld quality
Three control systems (Primary constant-current peak value control, Secondary
constant-current effective value control, and Secondary constant-power effective
value control) for stable weld quality.
Upslope (downslope) can be set for Weld 1 and Weld 2, respectively.
Use of an inverter allows for high power factor and stable power conditions
Easy setting of a variety of items through the menu selection system
Five protective functions for maximum ease of operation
• No-current
• No-voltage
• Overcurrent
• Temperature
• Self diagnostics error