Amada S-2200CA User manual

990-412 REV G
INVERTER POWER SUPPLY
IS-2200CA/4500CA
OPERATION MANUAL

IS-2200CA/4500CA INVERTER POWER SUPPLY
ii 990-412
Copyright

2016 - 2020 AMADA WELD TECH INC.
The engineering designs, drawings and data contained herein are the proprietary work ofAMADAWELD
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 44470 11/16 Original publication
B 44551 02/17 Manual updates
C 44980 06/18 Update info on IS-2200CR & IS-4500CR
D 45546 07/19 Update EtherNet/IPTM terminology + content
E 45804 04/20 Update Company Name (Amada Weld Tech) + Model Names
F 45984 07/20 Update Fuse values in Maintenance section
G 46130 12/20 Update I/O Schematics in Appx B

IS-2200CA/4500CA INVERTER POWER SUPPLY
990-412 iii
FOREWORD
About This Equipment
Thank you for purchasing an AMADA WELD TECH IS-2200CA/4500CA Inverter Power Supply. For
the rest of this manual, the IS-2200CA/4500CA 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]
About This Manual
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-2200CA/4500CA 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-2200CR, 380V
IS-2200CR-xx-xx
→
IS-800CA/380
IS-800CA-xx-xx
IS-2200CR, 480V IS-2200CR-xx-xx
→
IS-800CA/480V IS-800CA-xx-xx
IS-4500CR, 480V IS-4500CR-xx-xx →IS-4500CA/480 IS-4500CA-xx-xx

IS-2200CA/4500CA INVERTER POWER SUPPLY
iv 990-412
CONTENTS Page
Chapter 1. System Description
Section I: Features .................................................................................................................................. 1-1
Basic and Advanced Units ...............................................................................................................1-1
Section II: System Components for IS-2200CA....................................................................................1-3
Front Panel .....................................................................................................................................1-3
WELD POWER Lamp .............................................................................................................1-3
READY Lamp ..........................................................................................................................1-3
START Lamp ........................................................................................................................... 1-3
WELD Lamp ............................................................................................................................1-3
TROUBLE Lamp .....................................................................................................................1-3
RESET Pushbutton Switch .......................................................................................................1-3
WELD ON/OFF Pushbutton Switch ........................................................................................1-3
Internal Components ........................................................................................................................1-4
Connecting Terminal Strip for External Input / Output Signals .............................................. 1-5
Charge Indicator Lamp .............................................................................................................1-6
External Connections ....................................................................................................................... 1-7
Cooling Water Pipe Connectors ...............................................................................................1-7
RS-485/RS-232C Connector ....................................................................................................1-8
Transformer Sensing Connector (Optional Toroidal Coil) ......................................................1-8
Section III: System Components for IS-4500CA...................................................................................1-9
Front Panel .....................................................................................................................................1-9
CONTROL and MONITOR Unit Connector .........................................................................1-10
WELD POWER Lamp ...........................................................................................................1-10
READY Lamp ........................................................................................................................1-10
START Lamp ......................................................................................................................... 1-10
WELD Lamp ..........................................................................................................................1-10
TROUBLE Lamp ...................................................................................................................1-10
RESET Pushbutton Switch .....................................................................................................1-10
WELD ON/OFF Pushbutton Switch ......................................................................................1-10
Internal Components ......................................................................................................................1-10
Power Module ........................................................................................................................1-12
Main PCB ............................................................................................................................... 1-12
ME-3050 Expansion Board .................................................................................................... 1-12
I/O Terminal Block .................................................................................................................1-12
Valve Transformer ..................................................................................................................1-12
Standby Transformer ..............................................................................................................1-12
Control Transformer ............................................................................................................... 1-12
Fuse Block .............................................................................................................................. 1-12
Driver Interface PCB ..............................................................................................................1-12
Capacitor Discharge Indicator ................................................................................................1-12

IS-2200CA/4500CA INVERTER POWER SUPPLY
990-412 v
CONTENTS (Continued) Page
Power and Ground Connections .................................................................................................... 1-13
Input Power Connections .......................................................................................................1-13
Circuit Breaker .......................................................................................................................1-14
Grounding Lug ....................................................................................................................... 1-14
Output Power Connections .....................................................................................................1-14
Rear Panel Base Connections ........................................................................................................ 1-14
Cooling Water Fittings ...........................................................................................................1-14
Secondary Current Sensor Input Connector ........................................................................... 1-14
Section IV: MA-660A Program Unit (“The Pendant”) ........................................................................1-15
TROUBLE RESET key .................................................................................................................1-16
CURSOR Keys ..............................................................................................................................1-16
+ON/-OFF Keys ............................................................................................................................1-16
ENTER Key ................................................................................................................................... 1-16
MENU Key ...................................................................................................................................1-17
Chapter 2. Installation And Setup
Section I: Planning .................................................................................................................................2-1
Environmental Factors ..................................................................................................................... 2-1
Space and Mounting Requirements ................................................................................................. 2-1
Power Requirements ........................................................................................................................2-2
Section II: Installation of IS-2200CA ....................................................................................................2-3
Unpacking .....................................................................................................................................2-3
Installation .....................................................................................................................................2-3
Mounting the Power Supply ..................................................................................................... 2-3
Electrical Connections .....................................................................................................................2-4
Input Power Connections ................................................................................................................. 2-5
Output Power Connections ..............................................................................................................2-7
Signal Sensing Connections ............................................................................................................ 2-8
IS-2200CA Cooling Water Requirements ......................................................................................2-9
IS-2200CA Cooling Water Hose Connections ................................................................................2-9
Section III: Installation of IS-4500CA ................................................................................................2-10
Unpacking ...................................................................................................................................2-10
Installation ...................................................................................................................................2-10
Mounting the Power Supply ................................................................................................... 2-10
Electrical Connections ...................................................................................................................2-11
Input Power Connections .......................................................................................................2-11
Output Power Connections .....................................................................................................2-12
Signal Sensing Connections ................................................................................................... 2-13
Breaker ...................................................................................................................................2-14
Input /Output Cable ....................................................................................................................... 2-15

IS-2200CA/4500CA INVERTER POWER SUPPLY
vi 990-412
CONTENTS (Continued) Page
IS-4500CA Cooling Water Requirements ....................................................................................2-16
IS-4500CA Cooling Water Hose Connections ..............................................................................2-16
Chapter 3. IS-2200CA/4500CA: Using Programming Functions
Introduction ............................................................................................................................................3-1
1. MENU Screen ..................................................................................................................................3-1
2. POWER SUPPLY STATE Screen ..................................................................................................3-2
3. SCHEDULE Screen .........................................................................................................................3-3
CURRENT and TIME Setting Screen ......................................................................................3-3
SCHEDULE # ................................................................................................................... 3-3
TIME .................................................................................................................................3-3
WELD (1, 2, 3) ..................................................................................................................3-4
WELD ON/OFF ................................................................................................................3-8
CTRL .................................................................................................................................3-8
HEAT ................................................................................................................................3-9
UF (UP SLOPE FIRST) ............................................................................................. 3-9
DL (DOWN SLOPE LAST) ......................................................................................3-9
NEXT ..............................................................................................................................3-10
PULSATION and transformer screen .................................................................................... 3-10
SCHEDULE # ................................................................................................................. 3-10
PULSE LIM ....................................................................................................................3-10
PULSATION / INTERVAL 1 to 3 .................................................................................3-11
WELD TRANS FREQ ....................................................................................................3-11
VALVE # ........................................................................................................................ 3-12
CURRENT RANGE .......................................................................................................3-12
MAX CURRENT ............................................................................................................ 3-12
WELD ON/OFF ..............................................................................................................3-12
CURRENT CAL .............................................................................................................3-12
GAIN (01-09) .................................................................................................................. 3-12
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 .............................................................................................................................3-15
POWER .................................................................................................................................. 3-15
PULSE ....................................................................................................................................3-15
STEP # .................................................................................................................................... 3-15
STEPPER COUNT .................................................................................................................3-15
STEP2 REPEAT ..................................................................................................................... 3-15

IS-2200CA/4500CA INVERTER POWER SUPPLY
990-412 vii
CONTENTS (Continued) Page
STEP RATIO .......................................................................................................................... 3-15
CAP CHANGE .......................................................................................................................3-16
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 / NO CURR / WRK ERR ...................................................................... 3-20
7. OUTPUT SELECT Screen ............................................................................................................3-21
8. COPY SETUP DATA Screen ....................................................................................................... 3-22
9. MODE SELECT Screen ................................................................................................................ 3-24
DELAY START SET ............................................................................................................. 3-24
START SIGNAL MODE .......................................................................................................3-25
END SIGNAL TIME ...........................................................................................................3-26
END SIGNAL MODE ...........................................................................................................3-27
WELD TIME .......................................................................................................................... 3-27
WELD1 STOP/PARITY CHECK .......................................................................................... 3-28
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 ......................................................................................................................3-32
MONITOR DISP MODE ....................................................................................................... 3-33
RE-WELD ..............................................................................................................................3-33
COUNTER .............................................................................................................................3-34
SCAN MODE .........................................................................................................................3-35
COMM CONTROL ................................................................................................................3-35
COMM MODE .......................................................................................................................3-36
COMM SPEED ......................................................................................................................3-36
DISPLC SENSOR STEP ........................................................................................................3-36
REV ........................................................................................................................................3-36

IS-2200CA/4500CA INVERTER POWER SUPPLY
viii 990-412
CONTENTS (Continued) Page
10. MONITOR MODE Screen ............................................................................................................3-36
PRESET TOTAL COUNT .....................................................................................................3-37
NO CURRENT TIME ............................................................................................................ 3-40
NO CURRENT LEVEL .........................................................................................................3-40
NO VOLTAGE LEVEL .........................................................................................................3-40
MONITOR FIRST TIME .......................................................................................................3-41
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
TD1–9 .....................................................................................................................................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 ........................................................................................ 3-49
16. FORCE SETUP & MONITOR Screen ................................................................................3-50
SCHEDULE # ........................................................................................................................ 3-50
PROP VALVE # .....................................................................................................................3-50
STEP MODE ..........................................................................................................................3-51
SQD ........................................................................................................................................3-52
SQZ .........................................................................................................................................3-52
WE1 ........................................................................................................................................3-52
CO1/WE2 ...............................................................................................................................3-52
CO2/WE3 ...............................................................................................................................3-52
HOLD .....................................................................................................................................3-53
VALVE # ................................................................................................................................3-53
FORGE VALVE # .................................................................................................................3-53
CHAINING ............................................................................................................................3-54
SUCCESSIVE ........................................................................................................................3-54

IS-2200CA/4500CA INVERTER POWER SUPPLY
990-412 ix
CONTENTS (Continued) Page
FORGE DELAY ....................................................................................................................3-54
FORGE MODE ...................................................................................................................... 3-54
17. DISPLACEMENT Screen .............................................................................................................3-55
SCHEDULE # ........................................................................................................................ 3-55
WELD STOP INPUT .............................................................................................................3-55
WELD STOP CONDITION ...................................................................................................3-55
WORK DETECT LIMIT .......................................................................................................3-55
WORK DETECT MONITOR ................................................................................................3-56
DISPLACEMENT LIMIT ......................................................................................................3-56
DISPLACEMENT DELAY TIME ........................................................................................3-56
DISPLACEMENT MONITOR ..............................................................................................3-56
18. PRESSURE REGULATOR Screen ..............................................................................................3-57
FORCE CONTROL MODE ................................................................................................... 3-57
FORCE UNIT .........................................................................................................................3-58
AIR PRESSURE UNIT ..........................................................................................................3-58
AIR CYLINDER DIAMETER ..............................................................................................3-58
MAX AIR PRESSURE .......................................................................................................... 3-58
MAX FORCE .........................................................................................................................3-58
CALIBRATION CONSTANT FORCE .................................................................................3-58
CALIBRATION LOW ........................................................................................................... 3-59
CALIBRATION HIGH ..........................................................................................................3-59
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
Section III: Shutdown ............................................................................................................................. 4-4
Turn the Power Supply OFF ............................................................................................................ 4-4
Chapter 5. Maintenance
Section I: Troubleshooting .....................................................................................................................5-1
When Welding Does not Start even if the Start Signal is Present ................................................... 5-5
Section II: Before You Start ..................................................................................................................5-7
IS-2200CA/ IS-4500CA Cleaning ................................................................................................... 5-7
IS-2200CA Service Safety Precautions ...........................................................................................5-7
IS-4500CA Service Safety Precautions ...........................................................................................5-8

IS-2200CA/4500CA INVERTER POWER SUPPLY
x 990-412
CONTENTS (Continued) Page
Section III: Fuse Failure and Replacement ............................................................................................ 5-9
IS-2200CA Power Supply ................................................................................................................5-9
Fuse /Component Locations ...................................................................................................5-10
Main PCB ............................................................................................................................... 5-11
Fuse Board .............................................................................................................................. 5-11
IS-4500CA Power Supply .............................................................................................................5-12
Fuse /Component Locations ................................................................................................... 5-12
Main PCB ............................................................................................................................... 5-13
Fuse Board .............................................................................................................................. 5-13
Power Supply ..........................................................................................................................5-14
Valve Transformer ..........................................................................................................5-14
Fuse Block ....................................................................................................................... 5-14
Section IV: Maintenance Procedures ...................................................................................................5-15
Cooling Maintenance .................................................................................................................... 5-15
Checking Water Hoses ...........................................................................................................5-15
Draining Water Hoses ............................................................................................................5-15
Flushing Water Hoses and Cooling Chambers .......................................................................5-15
Section V: Repair Service, Storage, Shipment ....................................................................................5-17
Repair Service ................................................................................................................................ 5-17
Preparation for Storage or Shipment .............................................................................................5-17
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 Selection ............................................... D-1
Appendix E. Communications ............................................................................................................E-1