Amada IS-800CR User manual

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

IS-800CR/1400CR BASIC INVERTER POWER SUPPLY
ii 990-391
Copyright 2014, 2015 Amada Miyachi America
The engineering designs, drawings and data contained herein are the proprietary work of AMADA
MIYACHI AMERICA and may not be reproduced, copied, exhibited or otherwise used without the
written authorization of AMADA MIYACHI AMERICA.
Printed in the United States of America
Revision Record
Revision EO Date Basis of Revision
A 43185 9/14 Original publication.
B 43633 3/15 Updated to Amada Miyachi America name and logo.
Updated Appendix A notes.

IS-800CR/1400CR BASIC INVERTER POWER SUPPLY
990-391 iii
CONTENTS
Page
Revision Record ......................................................................................................................................... ii
Contents .............................................................................................................................................. iii
Contact Us ............................................................................................................................................ viii
Safety Precautions ..................................................................................................................................... ix
Chapter 1. System Description
Section I: Features .................................................................................................................................. 1-1
Features ..................................................................................................................................... 1-1
Section II: System Components ............................................................................................................. 1-2
Front Panel ..................................................................................................................................... 1-2
WELD POWER Lamp .................................................................................................................... 1-2
READY Lamp ................................................................................................................................. 1-2
START Lamp .................................................................................................................................. 1-2
WELD Lamp ................................................................................................................................... 1-2
TROUBLE Lamp ............................................................................................................................. 1-2
RESET Key ..................................................................................................................................... 1-2
WELD ON/OFF Key ....................................................................................................................... 1-2
PROGRAM UNIT Connector ......................................................................................................... 1-3
Internal and Rear Panel ........................................................................................................................... 1-4
Terminal Block for Welding Power Input ....................................................................................... 1-5
Terminal Block for Welding Power Output .................................................................................... 1-5
Connecting Terminal Strip for External Input/Output Signals ........................................................ 1-6
Cooling Water Pipe Connectors ...................................................................................................... 1-7
CHARGE INDICATOR Lamp ........................................................................................................ 1-8
RS485/232C Connector ................................................................................................................... 1-8
Transformer Sensing Connector (Optional Toroidal Coil) ............................................................ 1-10
MA-627A (Welding Schedule Preogram Unit) ............................................................................. 1-11
TROUBLE RESET Key ......................................................................................................... 1-11
CURSOR Keys ....................................................................................................................... 1-11
+ON/-OFF Keys ..................................................................................................................... 1-11
ENTER Key ............................................................................................................................ 1-12
MENU Key ............................................................................................................................. 1-12
Connector ............................................................................................................................... 1-12
Chapter 2. Installation And Setup
Section I: Planning ................................................................................................................................. 2-1
Environmental Factors ............................................................................................................................ 2-1
Space and Mounting Requirements ........................................................................................................ 2-1
Power Requirements ............................................................................................................................... 2-2

IS-800CR/1400CR BASIC INVERTER POWER SUPPLY
iv 990-391
CONTENTS (Continued)
Page
Section II: Installation ............................................................................................................................ 2-3
Unpacking ..................................................................................................................................... 2-3
Installation ..................................................................................................................................... 2-3
Mounting the Power Supply ................................................................................................................... 2-3
Electrical Connections ............................................................................................................................ 2-4
Input Power Connections ................................................................................................................. 2-4
Breaker ..................................................................................................................................... 2-5
Breaker Rated Current .............................................................................................................. 2-5
Input/Output Cable .................................................................................................................................. 2-6
Output Power Connections ..................................................................................................................... 2-7
Signal Sensing Connections .................................................................................................................... 2-8
Section III: Cooling Water ..................................................................................................................... 2-9
Cooling Water Requirements ................................................................................................................. 2-9
Cooling Water Hose Connections ........................................................................................................... 2-9
Chapter 3. Using Programming Functions
Introduction ..................................................................................................................................... 3-1
MENU Screen ..................................................................................................................................... 3-1
POWER SUPPLY STATE Screen ......................................................................................................... 3-2
LCD CONTRAST ........................................................................................................................... 3-2
CONTROL # ................................................................................................................................... 3-2
PROGRAMMED DATE ................................................................................................................. 3-2
POWER SOURCE FREQUENCY .................................................................................................. 3-2
MA-627A ROM VERSION # ......................................................................................................... 3-2
IS-800A (IS-1400A) ROM VERSION # ......................................................................................... 3-2
SCHEDULE Screen ................................................................................................................................ 3-3
CURRENT AND TIME SETTING SCREEN ....................................................................................... 3-3
SCHEDULE # ................................................................................................................................. 3-3
TIME ..................................................................................................................................... 3-3
WELD (1, 2, 3) ................................................................................................................................ 3-4
UP (1, 2, 3) ............................................................................................................................... 3-4
DOWN (1, 2, 3) ........................................................................................................................ 3-4
WELD ON/OFF ............................................................................................................................... 3-8
HEAT ..................................................................................................................................... 3-8
UF (UP SLOPE FIRST) ........................................................................................................... 3-8
DL (DOWN SLOPE LAST) .................................................................................................... 3-8
CTRL ..................................................................................................................................... 3-9
PAGE DOWN .............................................................................................................................. 3- 10
PULSATION and Transformer Screen ................................................................................................. 3-11
SCHEDULE # ............................................................................................................................... 3-11
PULSE LIM ................................................................................................................................... 3-11
PULSATION / INT1 to 3 .............................................................................................................. 3-11

IS-800CR/1400CR BASIC INVERTER POWER SUPPLY
990-391 v
Page
WELD TRANS FREQ .................................................................................................................. 3-12
VALVE # ................................................................................................................................... 3-13
CURR RANGE .............................................................................................................................. 3-13
PAGE UP ................................................................................................................................... 3-13
VOLT COMP (effective when PULSE LIM is set) ...................................................................... 3-13
GAIN (01-09) ................................................................................................................................ 3-13
TURN RATIO ............................................................................................................................... 3-14
WELD ON/OFF ............................................................................................................................. 3-14
MONITOR Screen ................................................................................................................................ 3-15
SCHEDULE # ............................................................................................................................... 3-15
TIME ................................................................................................................................... 3-15
CURRENT ................................................................................................................................... 3-15
VOLT ................................................................................................................................... 3-15
POWER ................................................................................................................................... 3-15
PULSE ................................................................................................................................... 3-15
STEP # ................................................................................................................................... 3-16
STEPPER COUNT ........................................................................................................................ 3-16
COUNTER ................................................................................................................................... 3-16
MENU SET Screen ............................................................................................................................... 3-17
SCHEDULE # ............................................................................................................................... 3-17
TIME ................................................................................................................................... 3-17
CURRENT ................................................................................................................................... 3-17
VOLT ................................................................................................................................... 3-17
POWER ................................................................................................................................... 3-17
PULSE ................................................................................................................................... 3-17
NG SIGNAL SELECT Screen .............................................................................................................. 3-18
ERROR OUTPUT MODE ............................................................................................................ 3-18
TIME-OVER/CURR-OVER/VOLT-OVER/POWER-OVER/PULSE-OVER/
NO CURR/WRK ERR ........................................................................................................... 3-19
OUTPUT SELECT Screen ................................................................................................................... 3-20
COPY SETUP DATA Screen ............................................................................................................... 3-20
IS-800A (IS-1400A) MA-627A ............................................................................................... 3-21
IS-800A (IS-1400A) MA-627A ............................................................................................... 3-21
SCHEDULE [001] SCHEDULE [001]-[255] .......................................................................... 3-21
MODE SELECT Screen ....................................................................................................................... 3-22
DELAY START SET .................................................................................................................... 3-22
START SIG.MODE ...................................................................................................................... 3-23
When latched .......................................................................................................................... 3-23
When pulsed ........................................................................................................................... 3-23
When maintained..................................................................................................................... 3-24
END SIG.TIME ............................................................................................................................. 3-24
END SIG.MODE ........................................................................................................................... 3-25
WELD1 STOP/PARITY CHECK ................................................................................................. 3-25

IS-800CR/1400CR BASIC INVERTER POWER SUPPLY
vi 990-391
CONTENTS (Continued)
Page
WELD2 STOP/WELD COUNT .................................................................................................... 3-28
WELD3 STOP/COUNT RESET ................................................................................................... 3-28
WELD TIME ................................................................................................................................. 3-29
PAGE UP ................................................................................................................................... 3-29
STEPPER MODE .......................................................................................................................... 3-29
RE-WELD ................................................................................................................................... 3-30
COMM CONTROL ....................................................................................................................... 3-31
SCHEDULE ................................................................................................................................... 3-31
COMM MODE............................................................................................................................... 3-31
COMM SPEED .............................................................................................................................. 3-31
MONI DISP MODE ...................................................................................................................... 3-31
COUNTER ................................................................................................................................... 3-32
MONITOR MODE Screen ................................................................................................................... 3-33
PRESET COUNT TOTAL/GOOD/PRESET COUNT WELD/WORK/WELD COUNT ............ 3-33
NO CURRENT TIME ................................................................................................................... 3-36
NO CURRENT LEVEL/NO VOLTAGE LEVEL ........................................................................ 3-36
MONITOR FIRST TIME .............................................................................................................. 3-37
MONITOR SLOPE MODE ........................................................................................................... 3-37
WELD STOP OFF TIME .............................................................................................................. 3-37
STEPPER COUNT Screen ................................................................................................................... 3-38
STEP MODE ................................................................................................................................. 3-38
START ON STEP # ....................................................................................................................... 3-39
STEP 1–9 ................................................................................................................................... 3-39
VALVE # ................................................................................................................................... 3-39
PRECHECK Screen .............................................................................................................................. 3-40
SCHEDULE # ............................................................................................................................... 3-40
PRECHECK TIME ........................................................................................................................ 3-40
PRECHECK HEAT ....................................................................................................................... 3-40
PRECHECK RESISTANCE HIGH .............................................................................................. 3-40
PRECHECK RESISTANCE LOW ............................................................................................... 3-40
PRECHECK MONITOR ............................................................................................................... 3-41
I/O CHECK Screen ............................................................................................................................... 3-41
RESET TO DEFAULT Screen ............................................................................................................. 3-41
PROGRAM PROTECT MODE Screen ............................................................................................... 3-42
Chapter 4. Operating Instructions
Section I: Introduction ........................................................................................................................... 4-1
Operator Safety ..................................................................................................................................... 4-1
Before You Start .......................................................................................................................4-1
Preparing for Operation .......................................................................................................................... 4-1

IS-800CR/1400CR BASIC INVERTER POWER SUPPLY
990-391 vii
Page
Section II: Operation .............................................................................................................................. 4-2
Starting Welding Operation .................................................................................................................... 4-2
Check the Valve Sequence ...................................................................................................................... 4-2
Section III: Shutdown ............................................................................................................................. 4-3
Stopping Welding Operation ................................................................................................................. 4-3
Chapter 5. Maintenance
Section I: Before You Start .................................................................................................................... 5-1
Safety Precautions ................................................................................................................................... 5-1
Cleaning ............................................................................................................... 5-1
Section II: Troubleshooting ................................................................................................................... 5-2
When the Welding Does not Start Even if the Start Signal is Input ....................................................... 5-6
Section III: Fuse Failure and Replacement ............................................................................................ 5-8
Power Supply ................................................................................................................................... 5-8
Section IV: Maintenance Procedures ..................................................................................................... 5-9
Cooling Maintenance ............................................................................................................................. 5-9
Checking Water Hoses .................................................................................................................... 5-9
Draining Water Hoses ...................................................................................................................... 5-9
Flushing Water Hoses and Cooling Chambers ................................................................................ 5-9
Section V: Power Module Replacement .............................................................................................. 5-11
Remove Power Module ......................................................................................................................... 5-11
Cooling Water Hoses ..................................................................................................................... 5-11
Disconnect Wire Harness from Main Board Connectors .............................................................. 5-12
Remove the Power Module ........................................................................................................... 5-13
Replace the Power Module ............................................................................................................ 5-15
Section VI: Repair Service, Storage, Shipment ................................................................................... 5-16
Repair Service ................................................................................................................................... 5-16
Preparation for Storage or Shipment ..................................................................................................... 5-16
Appendix A. Technical Specifications ............................................................................................... A-1
Appendix B. Electrical and Data Connections .................................................................................B-1
Appendix C. System Timing ...............................................................................................................C-1
Appendix D. Wire Gauge Selection and Circuit Breaker Setting ................................................. D-1
Appendix E. Options ............................................................................................................................E-1
Appendix F. Communications ............................................................................................................ F-1

IS-800CR/1400CR BASIC INVERTER POWER SUPPLY
viii 990-391
CONTACT US
About This Equipment
Thank you for purchasing a Miyachi Unitek IS-800CR/1400CR 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-800CR/1400CR will be referred to simply as the
Power Supply.
Upon receipt of the unit, 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 Miyachi America
1820 South Myrtle Avenue
P. O. Box 5039
Monrovia, California 91016
Phone: [phone]
FAX: [phone]
E-mail: [email protected]
Amada Miyachi America is not responsible for any losses due to improper
use of this product.
About This Manual
The contents of this manual are subject to change without notice. If you
have any questions, find any errors/omissions, or if you have suggestions
for improving this manual, please contact us.

IS-800CR/1400CR BASIC INVERTER POWER SUPPLY
990-391 ix
SAFETY PRECAUTIONS
DEATH ON CONTACT may 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 Miyachi
America.

IS-800CR/1400CR BASIC INVERTER POWER SUPPLY
x 990-391
Before using this equipment, read the
SAFETY PRECAUTIONS carefully to
understand the correct usage of the
equipment.
These precautions are given for safe use
of the Inverter Power Supply and for
prevention of injury to operators or
others.
Be sure to read each of the instructions,
as they are all important for safe
operation.
The meanings of the words and symbols
are as follows:
DANGER
DO NOT TOUCH THE INSIDE OF THE POWER SUPPLY UNNECESSARILY.
High Voltages are present inside the Power Supply Cabinet. Do not touch the inside of the
Power Supply unnecessarily wit the power turned ON. You may receive an electric shock.
When inspecting the inside of the Power Supply, be sure to turn the power source OFF and
push and hold the DISCHARGE switch until the CHARGE light goes OFF.
NEVER DISASSEMBLE, REPAIR, OR MODIFY THE POWER SUPPLY.
These actions can cause electric shock and fire. Do not do anything other than the
maintenance described in the Operator Manual.