Amada ITB-780C6 User manual

AB04OM1214141-01
OPERATION MANUAL
INVERTER WELDING TRANSFORMER
ITB-780C6

ITB-780C6
1
Thank you for purchasing our product.
・This operation manual explains its method of operation and precautions for use.
・Before using, read this operation manual carefully; after reading, save it in a proper place
where you can easily access.
Contents
1. Special Precautions................................ 1-1 to 1-5
2. Overview.................................................. 2-1 to 2-2
3. Installation and Connection ................... 3-1 to 3-3
4. Specifications ......................................... 4-1 to 4-4
5. Troubleshooting...................................... 5-1
6. Outline Drawing ...................................... 6-1 to 6-2
7. Duty Cycle Graph.................................... 7-1

ITB-780C6
1. Special Precautions
1-1
1. Special Precautions
(1) Safety Precautions
Before using, read “Safety
Precautions” carefully to
understand the correct method
of use.
・These precautions are shown for safe
use of our products and for prevention
of damage or injury to operators or
others. Be sure to read each of them,
since all of them are important for
safety.
・The meaning of the words and symbols
is as follows:
Do not touch the “Terminal block” on the rear panel of the
Transformer.
Since very high voltage is applied to the “Terminal block”, it is very dangerous
to touch it unnecessarily. When connecting or disconnecting a cable, be sure
to turn off the power.
After connecting the cable, install the terminal cover so that operator can not
touch the terminal block during work.
Never disassemble, repair or modify the Transformer.
These actions can cause electric shock and fire. Consult your distributor or us
for repair and maintenance.
Never burn, destroy, cut, crush or chemically decompose the
Transformer.
This product incorporates parts containing gallium arsenide (GaAs).
Denotes operations and practices that
may imminently result in serious injury
or loss of life if not correctly followed.
Denotes operations and practices that
may result in serious injury or loss of
life if not correctly followed.
DANGER
!
WARNING
!
DANGER
!
These symbols denote
"prohibition". They are
warnings about
actions out
of the scope of the
warranty of the product.
These symbols denote
actions which operators
must take.
Each symbol with a
triangle denotes that the
content gives notice of
DANGER, WARNING
or
CAUTION to the
operator.
Denotes operations and practices that may
result in personal injury or damage to the
equipment if not correctly followed.
CAUTION
!

ITB-780C6
1. Special Precautions
1-2
Do not put your hands between the electrodes.
When welding, keep your fingers and hands away from the electrodes.
Ground the Transformer.
If the Transformer is not grounded, you may get an electric shock when there
is trouble, or when electricity leaks.
Use the rated voltage.
Applying a voltage exceeding rated voltage can cause abnormal heat and fire.
Securely connect only specified cables.
Use of a cable of insufficient capacity or loose connection can cause fire and
an electric shock.
Do not touch +/- terminal, secondary cable, any welded part or
electrodes during welding and just after welding finished.
These parts are very hot while and right after processing.Do not touch them;
otherwise you may be burnt.
Do not damage the connecting cables.
Do not tread on, twist or tense any cable. The connecting cables may be
broken, and that can cause electric shock, short and fire. When repairing or
replacing, consult us or your distributor.
Stop the operation if any trouble occurs.
Continuous operation after occurrence of a trouble such as burning smell,
abnormal sound, abnormal heat, smoke, etc. can cause electric shock and
fire. If such a trouble occurs, immediately consult us or your distributor.
Wear protective glasses.
If you look at the flash directly during welding, your eyes may be damaged. If
any surface flash and expulsion gets in your eye, you may lose your eyesight.
Persons with pacemakers must stay clear of the Transformer.
A person who uses a pacemaker must not approach the welding transformer
or walk around the welding shop while the welding transformer is in operation,
without being permitted by his/her doctor. The welding transformer generates
a magnetic field and has effects on the operation of the pacemaker while it is
turned on.
Protective gear must be worn.
Put on protective gear such as protective gloves, long-sleeve jacket, leather
apron, etc. Surface flash and expulsion can burn the skin if they touch the
skin.
WARNING
!

ITB-780C6
1. Special Precautions
1-3
Do not use this Transformer for any purpose other than welding.
Use of this Transformer in a manner other than specified can cause electric
shock and fire.
Use proper tools (wire strippers, pressure wire connectors, etc.)
for termination of the connecting cables.
Do not cut the wire conductor. A flaw on it can cause fire and electric shock.
Install the Transformer on firm and level surface.
If the Transformer falls or drops, injury may result.
Do not splash water on the Transformer.
Water splashed over the electric parts, can cause electric shock and
short-circuits.
Do not place a water container on the Transformer.
If water spills, insulation will deteriorate, and this may cause electric leak and
fire.
Keep combustible matter away from the Transformer.
Surface flash and expulsion can ignite combustible matter. If it is impossible to
remove all combustible matter, cover them with non-combustible material.
Do not cover this Transformer with a blanket, cloth, etc.
Do not cover this Transformer with a blanket, cloth, etc. while you are using it.
The cover may be overheated and burn.
Keep a fire extinguisher nearby.
Keep a fire extinguisher in the welding shop in case of fire.
Use ear protectors.
Loud noises can damage hearing.
Maintain and inspect the Transformer periodically.
Maintain and inspect the Transformer periodically, and repair any damage
nearby before starting operation.
CAUTION
!

ITB-780C6
1. Special Precautions
1-4
(2) Precautions for Handling
When transporting or moving the Transformer, do not lay it down. Also, handle the
Transformer with care so as not to make an impact such as drop on it.
Install this Transformer securely on a firm and level surface. If it is inclined malfunction
may result.
Do not install this Transformer in the following places:
•Damp places where humidity is higher than 90%,
•Hot or cold places where temperatures are above 40°C or below 5°C,
•Places near a high noise source,
•Places where chemicals are handled,
•Places where water will be condensed,
•Dusty places,
•Places exposed to large amounts of vibration or shock,
•Places at an altitude above 1000 meters.
Do not block up the vent slits and provide the clearance of 10 cm minimum for better
radiation.
There's a risk of failure, prevent a foreign matter into the Transformer from slits.
Clean the outside of the Transformer with a soft, dry cloth or one wet with a little water. If it
is very dirty, use diluted neutral detergent or alcohol. Do not use paint thinner, benzine,
etc., since they can discolor or deform the Transformer.
Operate the Transformer according to the method described in this operation manual.
To use the transformer, it is necessary to prepare the welding power supply, the welding
head, and secondary cables for connecting to the welding head, and so on.
The Transformer is dedicated to our Inverter Welding Power Supply IPB-5000□and
cannot be used with other power supplies.
Verify that contents of the container agree with the kit list. If you see any the deficiency,
please contact us.
Packaged Kit Quantity
Main unit 1
Voltage-sensing cable 1

ITB-780C6
1. Special Precautions
1-5
(3) On Disposal
This product incorporates parts containing gallium arsenide (GaAs). At the time of
disposal, separate it from general industrial waste or domestic waste and carry out
the disposal in accordance with applicable laws and regulations.
(4) Warning Labels
Warning labels are pasted on the Transformer for safety. The pastingplace and
meaning of each label is as shown below.
Pasting place: Upper part of the terminal cover
Meaning: Danger of electric shock
注 意
CAUTION
CONNECT GROUNDING WIRE.
アース線を接続する事
注 意
DO NOT OPEN COVER.
TOUCHING THE INSIDE
MAY CAUSE AN ELECTRIC SHOCK.
CAUTION
感電の恐れあり
カバーを開けるな
注 意
CAUTION
ROTATING!
DO NOT INSERT A ROD
OR OTHER FOREIGN OBJECTS.
回転物注意
指、物等を入れるな
P-00202-003
Pasting place: Front side of the upper part of the main unit
Meaning:
Caution for grounding
wire connection
Danger of electric
shock
Pay attention to rotary
materials such as fan

ITB-780C6
2. Overview
2-1
2. Overview
(1) Inverter Welding Transformer
An inverter welding transformer is a type of transformer that supplies welding current
by converting the high-voltage, high-frequency AC current output of an inverter
welding power supply into DC current by using a built-in rectifier diode.

ITB-780C6
2. Overview
2-2
(2) Name and Functions of Each Section
[+] terminal *
Connect the positive (+) cable of
the welding head to this terminal.
[-] terminal *
Connect the negative (-) cable of
the welding head to this terminal.
[V-SENS] connector
Connect the plug of the attached
voltage-sensing cable. Connect
the other side of this cable to a
screw near the electrode, such
as by co-tightening it to the
electrode holder of the welding
head.
* [+] terminal and [-] terminal are
connected to chassis with a 30 Ω
of resistance.
[SENS] connector
This is a connecter for
connecting to our inverter
welding power supply with a
sense cable sold separately.
Terminal block
Connect the output cables(sold
separately) to these terminals
and to our inverter weldig power
supply. Terminal screw M5×12.
Terminal cover
This cover is installed so that a
worker will not touch the terminal
block directly.
Keep this cover installed
normally.
Front panel
①
②
③
:2.5%(at 6000A)
:13.0V(at 5kHz)
:6000A(at 5kHz)
・DUTY CYCLE
・SECONDARY VOLTAGE
・SECONDARY CURRENT
・PRIMARY VOLTAGE
SPECIFICATION
:300V/600V 5kHz
V-SENS
6
Rear panel
④
⑤
⑥
入 力
INPU T
入 力
INPU T
入 力
INPU T
入 力
INPU T
短 絡
SHOR T
短 絡
SHOR T
5
54321
短 絡
SHOR T
A1
IN
MADE
JAPAN
NO.
SERIAL
SENS

ITB-780C6
3. Installation and Connection
3-1
3. Installation and Connection
(1) Place for installation
For better radiation, ITB-780C6 has slits on side. Install ITB-780C6 in a well-ventilated
place and make a clearance of at least 10 cm from the surrounding walls. Don't block
each slit.
Condensation
Hot
Cold
Dust
Di r t
Chemical
Installonfirm,levelfloor
10cm min.
(2) Connection
After deciding where to install ITB-780C6, connect it to the other devices according to
the explanatory drawings on pages 3-2 to 3-3.
Explanatory drawing shows how to connect with MH-21AC welding head and
IPB-5000□ welding power supply.
The way of connection varies with the type and usage of the devices to be used.For
connection, refer instruction manual of each devices.
And make sure to turn off the supplying power before connecting work.
(3) Connecting jumper plate
When the welding power supply voltage is 200V to 240V AC, connect the attached
jumper plates to the terminals 1 and 2, and the terminals 3 and 4 as shown in the
illustration (A); when, 380 V to 480 V AC, two jumper plates to the terminals 2 and 3 as
shown in the illustration (B).
The terminals are factory-wired as shown in (B).
PE
UV
１２３４
PE
UV
１２３４
(A) (B)
Jumper plates
Two jumper plates stacked
Use2attached
jumper plates
together to short
2 and 3.
Notice
* Also make a clearance
of at least 10 cm from
the left and right sides

ITB-780C6
3. Installation and Connection
3-2
V- SEN S
SPECIFICATION
Securely connect secondary
cables to [+] terminal
and [- ] terminal with
special bolts.
(Select secondary cables
according to welding current
and duty cycle.)
NO .
SERIAL
JAPAN
MADE
IN
MH-21AC
ITB-780C6
Securely connect to
secondary cable
connecting screws
on rear panel.
Sec ondary c able
Referring to this page and the next, connect
ITB- 780C6
to the peripheral devic es. When c onnec ting to other than
MH- 21AC
, refer to the ins truction manual for it.
Vol tage s ensing cable
Securely connect
secondary cables to
screws on rear
panel.
(Select secondary cables,
Considering welding current
and duty cycle.)
Voltage-sensing cable
Refer this page and next page to connect ITB-780C6 with
peripheral devices. To connect with devices other than
MH-21AC, refer instruction manuals attached to each
devices.
Theillustrationbelowshows
ITB‐780C6connectedto
MH‐21AC,ourweldinghead
All of the following components except the ITB-780C6 are sold separately.

ITB-780C6
3. Installation and Connection
3-3
I/O
(O PTIO N3)
( OPT ION 4)
SOL PO WER
(OP TIO N2)
(OP TIO N1)
13
2
CO UNT RE SET
W .IN TER RUPT
COM
(WE 1 S TOP )
PA RIT Y
P RG PRO TECT
SOLCOM
SO L 2
SO L 1
O UT COM
O UT COM
RE ADY
CO UNT UP
C AUT ION
END
NG
G OOD
COM
COM
ER ROR RE SET
WE LD ON/ OFF
E XT. COM
I NT. 24V
SC H64
SC H 2
SC H32
SC H16
SC H 8
SC H 4
SC H 1
COM
2ND
1ST
S TOP
4 6 8 1012141618202224262830323436
5 7 9 1315171921232527293133353711
38
39
CONTROL SIG
(OP TIO N5)
POWER OUT
P-14 63
VU
RS2 32C/ RS4 85
SENS
SER IAL
NO.
JAP AN
MAD E
IN
A1
SHORT
短絡
1234 5
5
SHORT
短絡
SHORT
短絡
INPUT
入力
INPUT
入力
INPUT
入力
INPUT
入力
[SENS] cable
Re move
terminal cover
MH-21AC
ITB-780C6
IPB-5000B
V
PE
VU
PE
U
Pass [S TART] cable through
terminal cover and connect.
(For SCHEDULE 1)
[START]
cable
Pass [OUTPUT] cabl e through
terminal cover and connect.
NOTE: Shown above is jumper plate
connection for 200 to 240 V AC of
IPB- 5000B
input voltage. For detail, see "Connecti ng
ju mper plate" on page 3- 1.
[OUTPUT] cable
#5
#6
NOTE：Above chart shows how to connect jumper plate
when using IPB-5000B which input voltage is 200V AC to
240V AC. For the details, see "Connecting jumper plate"
on page 3-1.
All of the following components except the ITB-780C6 are solseparately.
This is a diagram when connecting ITB-780C6 and welding head MH-21AC to our
inverter power supply IPB-5000B.
Terminalscrew
M6
Terminalscrew
M5

ITB-780C6
4. Specifications
4-1
4. Specifications
(1) Product Specifications
Rated capacity 17.4 kVA
Continuous capacity 12.3kVA
Number of phases 1
Rated frequency 5kHz
Rated input voltage 200–240 V AC of welding power supply: 300 V
380–480 V AC of welding power supply: 600 V
Rated No-load
voltage(1)
13V
Turn ratio 200–240 V AC of welding power supply: 23:1
380–480 V AC of welding power supply: 46:1
Max. output current(2) 6000 A *
Continuous output
current
948A
Max. duty cycle 2.5% (6000 A) NB: See 7. Duty Cycle Graph
Cooling method Forced air cooling
Protection 100°C thermostat switch (built-in)
Operating
environment
Temperature between 5℃- 40℃, Humidity 90% or less
(Dew condensation not allowed), Altitude 1000 meters or
lower
Caution: Use this product in the environment without
conductive dust. If conductive dust enters in the product,
this may result in a failure, electric shock, or fire. When
using this product in this environment, make contact with
us.
Storage environment Temperature between -10℃and +55℃,
dew condensation not allowed
Heat-resistant class H
Protection class IP20
Protection class for
electric shock Class I
Compliant standard GB15578-2008
Outline dimensions 183 mm (H) ×
190 mm (W) × 455 mm (D)

ITB-780C6
4. Specifications
4-2
(Not including projections)
Weight Approx. 13 kg
Accessories Voltage-sensing cable × 1
(1) Excluding losses in diode.
(2) The maximum current fluctuates, when load fluctuates.
When connecting a welding head, the approximate maximum current is 4000 A.
(3) When internal temperture of ITB-780C6 reaches 70℃or higher, the fan motor built
in ITB-780C6 start to work.

ITB-780C6
4. Specifications
4-3
(2) Operating Principle Diagram
1
3
2
1
3
5
2
4
1
2
1
3
2
4
1
3
5
2
4
6
1
3
2
17
6
20
14
19
5
18
2
1
7
5
V SENS
I SENS
TH
+24V
+24V
0V
0V
CN4
CN2
CN5
CN3
CN6
+
-
Coil Gain P.C.B
Thermal Switch
(UP61G 100℃）
Fan
(DC24V)
Thermal Switch
(UP61G 70℃）
1
2
3
4
1
2
3
430Ω
CN1
30Ω
(3) Main parts list
Product name Quantity
Fan motor 1
Transformer 1
Thermal protector 2
Diode module 5

ITB-780C6
5. Troubleshooting
5-1
5. Troubleshooting
Contents Cause Measures
Body of ITB-780C6
becomes hot extremely.
Fan motor does not working
properly
Consult us or your distributor.
Current does not flow. Secondary cables are not
connected correctly.
Check that all cables are
connected correctly.
Output cable attached to power
supply is not connected
correctly.
Current is reduced. The connections of secondary
cables oxidized. For example,
secondary cables and electrode
holder, or secondary cables and
[+] / [-]terminal of, transfo
mer, or
electrode and electrode holder,
and so on.
Disconnect secondary cables
and polish their contacts.
Internal trouble of transformer Consult us or your distributor.

ITB-780C6
6. Outline Drawing
6-1
6. Outline Drawing
(Dimensions in mm)
:2.5(at 6000A)
:13.0V(at 5kHz) :6000A(at 5kHz)
A 1
SENS
FOR I NV ERTE R OU TPUT 6 00V
ｲﾝﾊ ﾞｰﾀ 出力 電圧 6００ Ｖ時
FOR INVER TER OUTP UT 300V
ｲﾝﾊﾞｰ ﾀ出 力電 圧 ３０ ０Ｖ 時
入力
I NPUT
入力
I NPUT
入力
I NPUT
入力
I NPUT
短絡
SHORT
短絡
S HORT
5 54321
短絡
S HORT
A 1
SENS
4-M4
・DUTY CYCLE ・SECONDARY VOLTAGE ・SECONDARY CURRENT ・PRIMARY VOLTAGE
SPEC IFI CA TION
:300V/600V 5kHz
V-SENS
S ERIA L
N O.
JAPA N
M ADE
IN
S ERIA L
N O.
JAPA N
M ADE
IN
17.52517.5
12
48(36)
(79)
328
229
66
17.5 25 40
17.517.5
17
17.5
25
15
143
190
62.547
183
4φ-9
POWER SUPPLY VOL TAGE POWER SUPP LY V OLTA GE
ＡＣ２００ Ｖ～ＡＣ ２４ ０ＶＡＣ３８０Ｖ ～Ａ Ｃ４ ８０Ｖ
Terminal screw M5 x 12mm
<With terminal cover removed>

ITB-780C6
6. Outline Drawing
6-2
Specitification sticker
变压器耐热等级: H 质量: 13 kg
外壳防护等级: IP20
50负载持续率下的功率%: S50 = 17.4kVA
2.5负载持续率下的功率%: S2.5 = 78kVA
额定输入电压: U1n = ～300V/600V
相数及额定频率: 1 ～5kHz
连续输出电流: I2p = 948A
次级最大短路电流: I2cc = 6000A(2.5负载持续率%)
额定空载电压: U2d = 13.0 V
执行标准: GB15578-2008
产品名称: 电阻焊机 产品型号: ITB-780C6
生产地址: 95-3 Futatsuka,Noda,Chiba,Japan
AMADA WELD TECH CO.,LTD. 日本制造
LB1214379
100负载持续率下的功率%: S100 = 12.3kVA
焊接电流:
Address 95-3Futatsuka,Noda,Chiba,Japan
Product name Resistance welding equipment Product model : ITB-780C6
Compliance standards GB15578-2008
Weld current
DC
Rated no-load output voltage U2d = 13.0V
Maximum short-circuit current in class I2cc = 6000A（2.5％Load duration）
Continuous output current I2p = 948A
Number of phases and rated frequency 1〜5kHz
Rated input voltage U1n = 〜300/600V
Power at 2.5% duty cycle S2.5 = 78kVA
Power at 50% duty cycle S50 = 17.4kVA
Power at 100% duty cycle S100 = 12.3kVA
Protection class IP20
Insulation class H
Weight 13kg

ITB-780C6
7. Duty Cycle Graph
7-1
7. Duty Cycle Graph
Ambient temperature: 40°C
Ambient temperature: 30°C
Duty cycle (%)
Output current (A)
5000
1 2 3 4 5 6 7 8 9 10 20 30 40 50
2000
1000
3000
4000
6000
7000
8000
2.5%
4%
7.5%
11%
70 100
▲
▲
▲
▲
3%
5%
15%
10%