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
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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

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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

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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

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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

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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
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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
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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.

IS-800CR/1400CR BASIC INVERTER POWER SUPPLY
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WARNING
Do NOT put your hands or fingers between the electrodes.
When welding, keep your hands and fingers away from the electrodes.
Do NOT touch any welded part or electrode during, or just after welding.
The welded parts and electrodes are very hot. If you touch them you will be burned.
Ground the equipment.
If the equipment is not grounded, you may get an electric shock.
Use a ground fault breaker.
Use a ground fault breaker to prevent an electric shock.
Only use specified cables.
A cable with insufficient capacity or loose connections can cause electric shock or fire.
Do NOT use a damaged power cable, connecting cables, or plugs.
Do not step on, twist, or tense any cable. The power cable and connecting cables may be
damaged which can cause electric shock, short circuit, or fire. If any part needs to be
repaired or replaced, consult Amada Miyachi America or your distributor.
Stop operation if any trouble occurs.
If you detect a burning smell, abnormal sounds, abnormal heat, smoke, etc., turn power
OFF immediately to prevent fire or electric shock. Contact Amada Miyachi America or your
distributor for help.
People with pacemakers MUST stay away from the Power Supply.
When the Power Supply is operating, it generates a magnetic field, which adversely affects
pacemakers. People who use a pacemaker must not approach the Power Supply, or walk
around the welding shop while the Power Supply is operating, unless their medical doctor
has deemed it safe to do so.
Wear protective gear.
Put on protective gear such as protective gloves, long sleeved jacket, and leather apron to
avoid being burned.

IS-800CR/1400CR BASIC INVERTER POWER SUPPLY
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CAUTION
Apply the specified source voltage.
Applying the wrong voltage can cause fire and electrical shock.
Keep water and water containers away from the Power Supply.
Water spilled on the Power Supply can cause a short circuit, electrical shock, or fire.
Use proper tools (wire strippers, pressure wire connectors, etc.) for terminations of the
connecting cables.
Do not nick the wire conductor. Doing so can cause a short circuit, electric shock, or fire.
Install the Power Supply on a firm, level surface.
Injury may result if the Power Supply falls over or drops from an uneven surface.
Keep combustible matter away from the Power Supply.
Spatter can ignite combustible materials. If you cannot remove all combustible materials,
cover them with a non-combustible material.
Do NOT cover the Power Supply with a blanket, cloth, etc.
Heat generated by the operating Power Supply may ignite a blanket or cover.
Wear ear protectors.
Loud noises can damage hearing.
Keep a fire extinguisher nearby.
Make sure there is a fire extinguisher in or near the welding shop in case of fire.
Regularly inspect and maintain the Power Supply.
Regular inspection and maintenance is essential to safe operation and long life of the
equipment. If you see any damage, make necessary repairs before operation.

IS-800CR/1400CR BASIC INVERTER POWER SUPPLY
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CHAPTER 1
SYSTEM DESCRIPTION
Section I: Features
Features
The Miyachi Unitek IS-800CR/1400CR, which is a highly configured version of Amada Miyachi’s ISB-
800A/1400A products, is an inverter-type power supply specially designed to be used for spot welding
and fusing. Most of the features and functions for these two power supplies are identical, however the
IS-800CR provides 800 amps primary current, while the IS-1400CR provides 1400 amps primary
current. For the rest of this manual, the Miyachi Unitek IS-800CR/1400CR will simply be referred to as
the Power Supply, unless a feature or procedure unique to a specific model is described.
The power supply accepts 3-phase voltage from 380VAC to 480VAC
Welding-current monitoring function for judgment of weld quality
Six control systems:
Primary constant-current effective value control
Secondary constant-current effective value control
Secondary constant-power effective value control
Primary constant-current peak value control
Secondary constant-voltage effective value control, and Constant-phase control) for stable
weld quality. The control method can be set for WELD1 to WELD3, respectively.
Pulse and upslope (downslope) can be set for WELD1 to WELD3, respectively.
Since the welding transformer turn ratio, the welding frequency (600 Hz to 3000 Hz in units of 100
Hz) and the current range can be set for each schedule, the Power Supply corresponds to finer
applications.
Comes equipped with a current-shutoff function, which shuts off current in response to external
input (e.g., displacement of the electrode) for WELD1 to WELD3 respectively, ensuring stable
fusing.
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
Applicable to inverter transformers manufactured by various companies by changing the frequency
(600 Hz to 3000 Hz in units of 100 Hz).
Seven protective functions for maximum ease of operation:
No-current / no-voltage
Overcurrent
Temperature
Self diagnostics
Grounding error
Load short error

CHAPTER 1: SYSTEM DESCRIPTION
IS-800CR/1400CR BASIC INVERTER POWER SUPPLY
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Phase error
Circuit breaker with rotary handle is included (IS-800CR: 250 amps, IS-1400CR: 400 amps)
120VAC 150VA valve transformer standard, 250VA optional
24VDC valve voltage: 2 amps (optional), 5 amps (optional)
Output contactors optional
CE compliance optional
RS-232 communications standard, RS-485 optional

CHAPTER 1: SYSTEM DESCRIPTION
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Section II: System Components
Front Panel
1. WELD POWER Lamp.
Lights up when the power is supplied to the Power Supply.
2. READY Lamp
Lights up when the system is ready to start welding. To turn this lamp ON:
WELD ON/OFF key
WELD ON/OFF setting of program unit MA-627A and
External WELD ON/OFF signal must all be turned ON.
3. START Lamp
Stays lit while the start signal is input.
4. WELD Lamp
Stays lit while the welding current is flowing.
5. TROUBLE Lamp
Lights up when trouble is detected. At this time, the program unit makes a peeping sound, and the
work done by the Power Supply is interrupted.
6. RESET Key
If this key is pressed while the TROUBLE lamp is lit, that lamp is turned off.
The TROUBLE lamp lights up again, however, as long as there is trouble. Accordingly, remove the
cause of the trouble before pressing this RESET key.
If the TROUBLE lamp lights up while work is being done, press the RESET key, then input the start
signal again, and the work continues.
7. WELD ON/OFF Key
This key is one of those which are required for turning on the READY lamp.
Each time this key is pressed, it is turned ON and OFF alternately. If it is turned on, READY lamp
lights up, and if the key is turned off, the lamp goes off. Hold down this key to toggle ON and OFF.

CHAPTER 1: SYSTEM DESCRIPTION
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PROGRAM UNIT Connector
Used to connect the MA-627A Program Unit (Pendant) to set the weld schedules and see the monitored
result.
NOTE: The IS-800CR/1400CR is a configured version of Amada Miyachi’s ISB-800A/1400A and
the MA-627A pendant will display “ISB-800A” or “ISB-1400A”)

CHAPTER 1: SYSTEM DESCRIPTION
IS-800CR/1400CR BASIC INVERTER POWER SUPPLY
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Internal and Rear Panel
DANGER
Do not touch the inside of the body while the CHARGE INDICATOR lamp
is lit, since you may get a severe electric shock.
NOTE: There are minor differences between the size and connector locations between the IS-800CR
and the IS-1400CR, but in all other respects the internal components of the two models are identical.

CHAPTER 1: SYSTEM DESCRIPTION
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Terminal Block for Welding Power Input
Used to accept the three-phase power supply for welding. Do not connect the power supply with voltage
other than the specified.
Terminal Block for Welding Power Output
Used to connect to the input of the welding transformer.

CHAPTER 1: SYSTEM DESCRIPTION
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Connecting Terminal Strip for External Input/Output Signals
Used to input start signals and output trouble signals.

CHAPTER 1: SYSTEM DESCRIPTION
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Cooling Water Pipe Connectors
Used for supply and drain of cooling water, which cools the inside of the enclosure and power supply
unit.
CHARGE INDICATOR Lamp
This lamp is located on the panel next to the
transformer INPUT/OUTPUT terminals on the
Power Module.
The charge level of this electrolytic capacitor is
indicated by the brightness of the CHARGE
INDICATOR lamp. The more the capacitor is
charged, the brighter the CHARGE INDICATOR
lamp is.