Amada ITH-1050C6W User manual

Y02OM1189298-03
OPERATION MANUAL
INVERTER WELDING TRANSFORMER
ITH-1050C6W

ITH-1050C6W
1
Thank you for purchasing our Inverter Welding Transformer ITH-1050C6W.
・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 1-4
2. Names and Functions of Each Section ..............2-1
3. Installation and Connection ................................3-1 to 3-3
4. Specifications .......................................................4-1
5. Troubleshooting ...................................................5-1
6. Outline Drawing....................................................6-1
7. Duty Cycle Graph .................................................7-1

ITH-1050C6W
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 Welding
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
!

ITH-1050C6W
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.
Do not touch +/- terminal, secondary cable, any welded part or
electrodes during welding and just after welding finished.
These parts are very hot. Do not touch them; otherwise you may be burnt.
Securely connect only specified cables.
Use of a cable of insufficient capacity or loose connection can cause fire
and an electric shock.
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 spatter gets in your eye, you may lose your eyesight.
Persons with pacemakers must stay clear of the welding 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. Spatter can burn the skin if they touch the skin.
WARNING
!

ITH-1050C6W
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.
Spatter 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
!

ITH-1050C6W
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%), dusty places, places where
chemicals are handled, places near a high noise source, hot or cold places
(where temperatures are above 40°C or below 5°C), places where water will be
condensed, and 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.
・Do not put a screw, a coin, etc., through the slits on the enclosure, since they can
cause a malfunction.
・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.
・The Transformer is not equipped with auxiliary power such as an outlet for lighting.
・The welding power supply, the welding head, and the secondary cables for
connecting the welding power supply, the welding head and the Transformer are
separately needed to use the Transformer.
(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.

ITH-1050C6W
2. Name and Functions of Each Section
2-1
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 the
screws near the electrode of the
welding head.
* [+] terminal and [-] terminal are
connected to chassis with a 30 Ω
of resistance.
[SENS] connector
Connect the dedicated [SENS]
Cable (separately sold) to our
inverter power supply.
Hose connector
Connect cooling water hoses to
[WATER OUT] and [WATER IN]
connectors. The connector outer
diameter is 10.5 mm. Upper one
is for drain; lower one, supply.
Use water of 35°C or below at 3
liters/min. minimum.
Terminal block
Connect the dedicated output
cables (separately sold) to these
terminals and to our inverter
power supply.
Terminal cover
This cover is installed so that a
worker will not touch the terminal
block directly. Keep this cover
installed normally.
V-SENS
＋
－
①
②
③
Front panel
Rear panel
１２３４５
WATER
OUT
WATER
IN
④
⑤
⑥
⑦
SENS

ITH-1050C6W
3. Installation and Connection
3-1
3. Installation and Connection
●Place for installation
Slits are provided on rear side and bottom of the ITH-1050C6W for higher heat radiation
efficiency. Install this transformer in a well-ventilated place and make a clearance of at
least 10 cm from the surrounding walls to extract the full performance.
Condensation
Hot
Cold
Dust
Dirt
Chemical
Install on firm, level floor
10cm min.
●Connection
After selecting a proper place for installation of ITH-1050C6W, connect it to the other
devices according to the explanatory drawings on pages 3-2 to 3-3.
Our welding head MH-31AC and welding power supply IS-300A are used in
the explanatory drawings.
The connection varies with the type and using method of the devices to be
used. When connecting them, refer to their instruction manuals.
Make sure to disconnect the power supply before connecting work.
●Connecting jumper plate
When the power supply voltage of the power supply part is 200 V to 240 V 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). When the power supply voltage of the power supply
part is 200 V to 240 V AC, the output voltage is 15 V with a connection shown in (A) and
7.5 V with a connection shown in (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

ITH-1050C6W
3. Installation and Connection
3-2
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-31AC
ITH- 1050C6W
V- S E N S
＋
－
Securely connect to
secondary cable connecting screws
on rear panel.
Secondary cable
Referring to this page and the next, connect ITH- 1050C6W
to the peripheral devices. When connecting to other than
MH-31AC, refer to the instruction manual for it.
Voltage sensing cable

ITH-1050C6W
3. Installation and Connection
3-3
WATER
OUT
I/O
MH-31AC
IS- 3 0 0 A
ITH-1050C6W
V
UPE
１２３４５
WATER
IN
Remove
terminal cover.
[SENS] cable
Cooling water OUT
Cooling water IN
Pass [OUTPUT] cable through terminal cover and connect.
[OUTPUT] cable
Pass [START] cable through terminal cover and connect.
#15 #17
[START]
cable
SENS
VPE
U

ITH-1050C6W
4. Specifications
4-1
4. Specifications
Rated capacity
40.7 kVA
Input voltage 200–240 V AC of welding power supply: 300 V, 1 kHz
380–480 V AC of welding power supply: 600 V, 1 kHz
No-load secondary
voltage
200–240 V AC of welding power supply: 15 V/7.5 V
380–480 V AC of welding power supply: 15 V
Turn ratio 200–240 V AC of welding power supply: 20:1/40:1
380–480 V AC of welding power supply: 40:1
Max. output current
7000 A
Max. duty cycle
8.5% (at 7000 A)
11% (at 6000 A) NB: See 7. Duty Cycle Graph.
Cooling method
Water cooling (Cooling water: ≦35°C, ≧3L/min.)
Fan motor voltage 24 V DC
Protection
100°C thermostat switch (built-in)
Operating
environment
Temperature 5°–40°C, 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 -10°–55°C and dew condensation not allowed
Heat-resistant class H
Case protection IP20
Outline dimensions 199 mm (H) ×
167 mm (W) × 403 mm (D)
(Not including projections)
Mass
Approx. 21 kg
Accessories Operation manual × 1
Voltage-sensing cable × 1

ITH-1050C6W
5. Troubleshooting
5-1
5. Troubleshooting
Contents Cause Measures
ITH-1050C6W
becomes hot
abnormally.
Fan motor does not work. Consult us or your distributor.
Cooling water does not flow. Clean up cooling water circuit,
especially cooling water hose.
Current does
not flow.
Secondary cables are not
connected correctly. Check that all cables are
connected correctly.
[Output] cable is not connected
correctly to power supply.
Current is
reduced.
Contacts of secondary cables are
oxidized.
Disconnect secondary cables and
polish their contacts.
Internal trouble of transformer. Consult us or your distributor.

ITH-1050C6W
6. Outline Drawing
6-1
6. Outline Drawing
(Dimensions in mm)
Inlet
Outlet
V-SENS
P-00351-001
2-φ9
Case
Panel
44 36
24
45
290
44
10
20
60
167
135
199
225
25
120 60
Hose connector outer dia.
10.5mm max ＜With terminal cover removed＞
3 4 521
A-00-00
WATER
IN
WATER
OUT
SENS
A-00-00
WATER
IN
WATER
OUT
SENS
55
105
16
86
16

ITH-1050C6W
7. Duty Cycle Graph
7-1
7. Duty Cycle Graph
Ambient temperature: 40°C
Cooling water temperature: 35°C
5000
12 3 45 6 789
Duty cycle (%)
Output current (A)
10 20 30 40 50
2000
1000
3000
4000
6000
7000
8000
(10000A at 3.9%)
(3700A at 20%)
70 100
(1800A at 50%)
(5900A at 10%)
9000
10000
(7000A at 7.5%)
(1000A at 100%)