Amada IS-800A-10 Series User manual

Z06OM1182586-12
OPERATION MANUAL
Original instructions
DC INVERTER WELDING POWER SUPPLY
IS--10- □□
800A
1400A

IS-800A/1400A
Contents
1
Thank you for purchasing our DC Inverter Welding Power Supply IS-800A-10-□□
/1400A-10-□□.
This operation manual describes its method of operation and precautions for use.
Read this operation manual carefully prior to use. Store appropriately for ready reference.
Contents
1. Special Precautions ........................................................................................................ 1-1
(1) Safety Precautions....................................................................................................... 1-1
(2) Precautions for Handling ............................................................................................. 1-4
(3) On Disposal ................................................................................................................. 1-5
(4) Warning Labels for Safety ........................................................................................... 1-5
2. Features ........................................................................................................................... 2-1
3. Name and Functions of Each Section ........................................................................... 3-1
(1) Front ............................................................................................................................ 3-1
(2) Internal and Rear Panel............................................................................................... 3-3
(3) MA-660A (Sold Separately) ......................................................................................... 3-5
4. How to Operate Screens................................................................................................. 4-1
(1) MENU Screen.............................................................................................................. 4-1
(2) POWER SUPPLY STATE Screen ............................................................................... 4-2
(3) SCHEDULE Screen..................................................................................................... 4-3
(4) MONITOR Screen ..................................................................................................... 4-14
(5) MONITOR SET Screen ............................................................................................. 4-18
(6) NG SIGNAL SELECT Screen.................................................................................... 4-20
(7) OUTPUT SELECT Screen......................................................................................... 4-22
(8) COPY SETUP DATA Screen..................................................................................... 4-23
(9) MODE SELECT Screen............................................................................................. 4-25
(10) MONITOR MODE Screen........................................................................................ 4-38
(11) STEPPER COUNT Screen...................................................................................... 4-44
(12) PRECHECK Screen ................................................................................................ 4-46
(13) I/O CHECK Screen .................................................................................................. 4-47
(14) RESET TO DEFAULT Screen ................................................................................. 4-48
(15) PROGRAM PROTECT MODE Screen.................................................................... 4-49
5. Connection Procedures.................................................................................................. 5-1
(1) Basic Configuration...................................................................................................... 5-1
(2) Earth Leakage Breaker................................................................................................ 5-4
(3) Connection Method...................................................................................................... 5-5
(4) Input/Output Cable....................................................................................................... 5-7
(5) Noise Filter................................................................................................................... 5-8
This operation manual is common to both IS-800A-10-
□□
and
IS-1400A-10-
□□
.
IS-800A-10-
□□
is used in the explanatory drawings unless there is a
significant difference.
ATTENTION

IS-800A/1400A
Contents
2
6. Interface ........................................................................................................................... 6-1
(1) Connection Diagram for External Input/Output Signals ............................................... 6-1
(2) Description of External I/O Signals.............................................................................. 6-3
(3) List of External Output Signals .................................................................................... 6-9
(4) Connection of Input Signals....................................................................................... 6-10
7. Basic Operation............................................................................................................... 7-1
8. Timing Chart .................................................................................................................... 8-1
(1) Basic Sequence........................................................................................................... 8-1
(2) Detailed Description of Welding Current and Sequence in the Event of an Error ....... 8-3
(3) Sequence at PULSATION Setting............................................................................... 8-5
(4) Sequence at 2-Stage Start Operation.......................................................................... 8-6
9. External Communication Function................................................................................ 9-1
(1) Introduction.................................................................................................................. 9-1
(2) Data Transmission....................................................................................................... 9-1
(3) Configuration ............................................................................................................... 9-2
(4) Protocol........................................................................................................................ 9-3
(5) Data Code Table.......................................................................................................... 9-7
10. Specifications ................................................................................................................ 10-1
(1) Specifications............................................................................................................. 10-1
(2) Options (Sold Separately).......................................................................................... 10-3
(3) Duty Cycle Graph ...................................................................................................... 10-4
(4) Weld Time Limit......................................................................................................... 10-5
(5) Board and Component List for Maintenance ............................................................. 10-6
(6) Major Components List.............................................................................................. 10-6
(7) Schematic.................................................................................................................. 10-7
11.Outline Drawing............................................................................................................. 11-1
(1) IS-800A...................................................................................................................... 11-1
(2) IS-1400A.................................................................................................................... 11-2
12. Troubleshooting ............................................................................................................ 12-1
(1) Fault Code List........................................................................................................... 12-1
(2) When the Welding Does not Start Even if the Start Signal is Input ........................... 12-5
13. Schedule Data Table ..................................................................................................... 13-1
Index ..........................................................................................................................................1
EU Declaration of Conformity

IS-800A/1400A
1. Special Precautions
1-1
Denotes operations and practices that
may result in personal injury or
damage to the equipment if not
correctl
y
followed.
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
DANGER, WARNING
or CAUTION to the
operator.
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 inside of the Power Supply except as instructed.
The interior of this Power Supply carries high voltage. It is very dangerous to
touch any parts except as instructed. When inspecting the interior of the
Power Supply, be sure to wait at least 20 minutes after turning off the power
source of the Power Supply and confirm that the CHARGE LAMP lamp is
turned off.
Never disassemble, attempt to repair, or modify the Power Supply.
These actions can cause electric shock and fire.
Consult us or your distributor for inspection and repair.
Never burn, destroy, cut, crush or chemically decompose the Power
Supply.
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.
DANGER
!
Denotes operations and practices
that may result in serious injury or
l
oss
o
f lif
e
if n
o
t
co
rr
ec
tl
y
f
o
ll
o
w
ed
.
WARNING
!
!
DANGER
!
CAUTION
!

IS-800A/1400A
1. Special Precautions
1-2
Do not insert your fingers or hands between the electrodes.
When welding, keep your fingers and hands away from the electrodes.
Do not touch any welded part or electrode during welding or just after
completion of welding.
The welded parts of a workpiece, electrodes, and the arm are very hot.
Do not touch them; burns may result.
Ground the equipment.
If the Power Supply is not grounded, you may receive an electric shock in
the event of malfunction or current leak. Be sure to perform grounding work.
400V AC of input voltage: at least class C, 200V AC of input voltage: at least
class D
!
Connect the specified cables securely.
Cables of insufficient current capacities and loose connections can cause
fire and electric shock.
Do not damage the power cable and connecting cables.
Do not tread on, twist, or apply force to any cable. Doing so may cause the
power cable and connecting cables to become broken, leading to electric
shock and fire.
Do not use any damaged power cable, connecting cable, or plug.
Failure to observe this precaution can lead to electric shock, short circuit, or
fire.
If any part must be replaced or requires repair, consult us.
!
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.
!
Persons with pacemakers must stay clear of the welding machine.
A person who uses a pacemaker must not approach the welding machine or
walk around the welding site while the welding machine is in operation,
without being permitted by his/her doctor. The welding machine 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.
!
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.
WARNING
!

IS-800A/1400A
1. Special Precautions
1-3
!
Apply the specified supply voltage.
Application of a voltage outside the specified range may result in fire or
electric shock.
Do not allow water to come in contact with the equipment.
Water on the electric parts can cause electric shock and short circuit.
!
Use proper tools (wire strippers, pressure wire connectors, etc.) for
terminal treatment of the connecting cables.
Do not cut the wire conductor; fire or electric shock may result.
!
Install the equipment on a firm and level surface.
Injury may result if the equipment falls or is dropped.
Do not sit on or place objects on the Power Supply.
Failure to observe this precaution may lead to malfunction.
!
Keep combustible matter away from the Power Supply.
Surface flash and expulsion may ignite combustible matter. If it is
impossible to remove all combustible matter, cover it with non-combustible
material.
Do not cover the Power Supply with a blanket, cloth, etc.
Do not cover the Power Supply with a blanket, cloth, etc. while it is in use.
The cover may be overheated and burned.
Do not use this Power Supply for purposes other than welding.
Use of this Power Supply in a manner other than specified can cause
electric shock and fire.
!
Use ear protectors.
Loud noises can damage hearing.
!
Keep a fire extinguisher nearby.
Keep a fire extinguisher in the welding shop in case of fire.
!
Maintain and inspect the Power Supply periodically.
Maintain and inspect the Power Supply periodically, and repair any damage
nearby before starting operation.
CAUTION
!

IS-800A/1400A
1. Special Precautions
1-4
(2) Precautions for Handling
When transporting or moving the Power Supply, do not lay it down. Also,
handle the Power Supply with care so as not to make an impact such as drop
on it. Moving the Power Supply by hand must be done by at least two people.
When lifting the Power Supply using a crane, set the belt to the eyebolt on the
upper surface of the Power Supply.
Install this Power Supply on a firm and level surface. If it is inclined,
malfunction may result.
Do not install the Power Supply in the following locations:
Damp areas (where the humidity is higher than 90%),
areas where temperatures are above 40°C or below 5°C
areas near a high noise source,
areas where chemicals are handled,
areas where water may condense,
dusty areas,
areas exposed to large amounts of vibration or shock, and
areas at an altitude above 1000 meters.
Clean the exterior of the Power Supply using a soft, dry cloth or one slightly
dampened with water. If the Power Supply is very dirty, use diluted neutral
detergent or alcohol. Do not use paint thinner, benzine, etc., as they may
discolor or deform the Power Supply.
Do not insert a screw, coin, etc. into the Power Supply, as they may cause
malfunction.
Operate the Power Supply in accordance with the method described in this
operation manual.
Press switches/buttons carefully by hand. Handling them roughly (using a
screwdriver or the tip of pen) may result in a malfunction or failure.
Press switches/buttons one at a time. Pressing more than one switch/button
at a time may result in a malfunction or failure.
The Power Supply is not equipped with auxiliary power such as an outlet for
lighting.
Following cables are separately needed to use the Power Supply:
Program box, and circuit cable connecting to the Power Supply,
power cable, and cables connecting between the Power Supply and
welding transformer,
welding transformer,
welding head, and
secondary conductor connecting between welding head and welding
transformer.
The RS-485/232C communication signal line is not attached. Solder the line to
the RS-485/232C connector.
The I/O signal line to start the Power Supply is not attached. Prepare the
crimp-on terminal and line for wiring to the terminal block.
The Power Supply should be used with the industry power transmission and
distribution network (industrial distribution equipment). Do not connect it to the
public low-voltage distribution network (distribution equipment for
non-industrial office or home use).

IS-800A/1400A
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 for Safety
On the main body are warning labels for safety. Their locations and meanings are
as noted below.
DANGER
NOT TO GET AN ELECTRIC SHOCK.
TO TURN OFF MAIN CIRCUIT BREAKER
WHEN INSPECTING INTERNAL, MAKE SURE
点検を行う際は必ず溶接電源の供給を止めた後、
本製品内部には非常に高い電圧が掛かっています｡
AND WAIT FOR AT LEAST 20 MINUTES
20分間待ってから行って下さい。
Location: Power Supply interior, front and acrylic cover
Meaning: Shock hazard
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
THE EQUIPMENT DOES NOT FALL BELOW 0ﾟC. WHEN AMBIENT TEMPERATURE
COOLING WATER WILL FREEZE AND EQUIPMENT MAY BE BROKEN BELOW 0ﾟC.
注意
気温が0ﾟC以下になりますと､冷却用の水が凍結し､装置が破損する
おそれがあります｡特に寒冷地におきましては、凍結しやすいため､
0℃以下の環境にならないようご注意ください｡
0℃以下になる場合は､装置内の水を完全に抜き取ってください。
PARTICULARLY IN COLD DISTRICTS,TAKE CARE THAT THE TEMPERATURE OF
WILL FALL BELOW 0ﾟC, MAKE SURE TO DRAIN WATER FROM EQUIPMENT.
CAUTION
！
ＢＥ ＳＵＲＥ ＴＯ ＩＮＳＴＡＬＬ ＡＮ ＥＡＲＴＨ ＬＥＡＫＡＧＥ
ＢＲＥＡＫＥＲ ＯＦ ＡＰＰＲＯＰＲＩＡＴＥ ＣＡＰＡＣＩＴＹ ＯＮ
ＯＶＥＲＣＵＲＲＥＮＴ ＡＮＤ ＥＬＥＣＴＲＩＣ ＬＥＡＫ．
ＰＯＷＥＲ ＩＮＰＵＴ ＴＯ ＰＲＯＴＥＣＴ ＦＲＯＭ ＡＮ
電源入力には過電流保護及び漏電保護のため、必ず適切な容量の漏電ブレーカー
を取り付けて下さい。
ＣＡＵＴＩＯＮ
Location: Power Supply interior, side
surface of acrylic cover
Meaning: Shock hazard
Location: Front door
Meaning: Shock
hazard
Location: Rear panel
Meaning: Cautions for cooling water
Location: Power Supply interior, front and
acrylic cover
Meaning: Caution for leakage breaker
connection
Location: Front door
Meaning: Caution for grounding
connection

IS-800A/1400A
2. Features
2-1
2. Features
The IS-800A/1400A is a DC inverter welding power supply, large in capacity
and specially but small in size, specially
designed to be used for spot
welding and fusing.
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.
Pulsation 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 error
• Grounding error
• Load short error
• Phase error
Languages available are Japanese, English, Chinese and Korean.

IS-800A/1400A
3. Name and Functions of Each Section
3-1
3. Name and Functions of Each Section
(1) Front
WELD POWER lamp
Lights up when the power is supplied to IS-800A/1400A.
READY lamp
Lights up when the system is ready to start welding.
To turn on this lamp:
• WELD ON/OFF key
• WELD ON/OFF setting of Program Unit MA-660A and
• External WELD ON/OFF signal
must all be turned on.
The Power Supply writes data into the flash memory on the control board when
a setting is changed or a schedule data is copied. The READY lamp on the
front panel and the external READY signal are turned off during writing. Check
that the READY lamp is turned on to start welding.
WELD
RESET
①②③④⑤ ⑥ ⑦
⑧
ON/OFF
WELDSTARTREADY TROUBLE
WELD POWE R
WELD
ON/OF F
RESET
TROUBLEWELDSTARTREADYPOWER
WELD
⑨
Front Panel