Miyachi Unitek ISA Series User manual

OPERATOR MANUAL 990-364
Revision B August 2009
OPERATORS MANUAL
FOR THE
ISA-4000 and ISA-4001CR
INVERTER POWER SUPPLIES

ISA-4001CR INVERTER POWER SUPPLY
ii 990-364
Copyright
¤
2007, 2009 Miyachi Unitek Corporation
The engineering designs, drawings and data contained herein are the proprietary work of MIYACHI
UNITEK CORPORATION and may not be reproduced, copied, exhibited or otherwise used without the
written authorization of MIYACHI UNITEK CORPORATION.
Printed in the United States of America
Revision Record
Revision EO Date Basis of Revision
A 21466 7/07 Original publication
B 31456 8/09 Updated dipswitch settings.

ISA-4001CR INVERTER POWER SUPPLY
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CONTENTS
Page
Revision Record ........................................................................................................................................ ii
Contact Us ..................................................................................................................................... viii
Safety Precautions ..................................................................................................................................... ix
Chapter 1 System Description
Section I: Features .................................................................................................................................. 1-1
Section II: System Components Power Supply ..................................................................................... 1-2
Front Panel Controls, Indicators, and Connector ............................................................................. 1-2
Control and Monitor Unit Connector ....................................................................................... 1-3
WELD POWER ........................................................................................................................... 1-2
READY ..................................................................................................................................... 1-2
START ..................................................................................................................................... 1-2
WELD ..................................................................................................................................... 1-2
TROUBLE .................................................................................................................................. 1-2
RESET ..................................................................................................................................... 1-2
WELD ON/OFF ......................................................................................................................... 1-2
Internal Components ........................................................................................................................ 1-3
Capacitor Discharge Indicator .................................................................................................. 1-5
I/O Terminal Block .................................................................................................................. 1-5
ME 1887 Expansion Board ......................................................................................................1-5
PCB Panel Sub-Assembly (Not-Shown) .................................................................................. 1-5
Power Module ......................................................................................................................... 1-5
Power Transformer .................................................................................................................. 1-5
Power and Ground Connections ...................................................................................................... 1-6
Input Power Connections ......................................................................................................... 1-6
Circuit Breaker ......................................................................................................................... 1-7
Grounding Lug ........................................................................................................................ 1-7
Input Power Connections ........................................................................................................ 1-7
Output Power Connections ....................................................................................................... 1-7
Rear Panel Connections ................................................................................................................... 1-7
Cooling Water Fittings ............................................................................................................ 1-7
Secondary Current Sensor Input Connector ............................................................................ 1-7
Program Unit (MA-627A) ............................................................................................................... 1-8
Connector ................................................................................................................................. 1-5
Display ..................................................................................................................................... 1-8
TROUBLE RESET key ................................................................................................................ 1-8
CURSOR keys ........................................................................................................................... 1-8
+ON/–OFF keys ......................................................................................................................... 1-8
ENTER key ................................................................................................................................ 1-8
MENU key .................................................................................................................................. 1-8
Monitor Unit (MA-628A) ................................................................................................................ 1-9
Optional Communications Capability ............................................................................................. 1-9

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CONTENTS (Continued)
Page
Chapter 2. Installation ad Setup
Section I: Planning ................................................................................................................................. 2-1
Environmental Factors ..................................................................................................................... 2-1
Space and Mounting Requirements ................................................................................................. 2-1
Power Requirements ........................................................................................................................ 2-1
Section II: Installation ............................................................................................................................ 2-2
Unpacking ..................................................................................................................................... 2-2
Installation ..................................................................................................................................... 2-2
Mounting the Power Supply ..................................................................................................... 2-2
Eectrical Connections ............................................................................................................... 2-3
Input Power Connections ......................................................................................................... 2-3
Output Power Connections ....................................................................................................... 2-4
Signal Sensing Connection ....................................................................................................... 2-6
Section III: Cooling Water ..................................................................................................................... 2-7
Cooling Water Requirements ......................................................................................................... 2-7
Cooling Water Hose Connections ................................................................................................... 2-7
Chapter 3. Using Programming Functions
Section I: Operation Precautions ........................................................................................................... 3-1
Section II: Programming the Power Supply .......................................................................................... 3-1
Menu Screen .................................................................................................................................... 3-1
Power Supply State Screen .............................................................................................................. 3-2
PROGRAMMED DATE ................................................................................................................ 3-2
MA-627A ROM VERSION # ......................................................................................................... 3-2
POWER SOURCE FREQUENCY ................................................................................................ 3-2
WELD POWER FREQUENCY ..................................................................................................... 3-2
Schedule Screens ............................................................................................................................. 3-2
SCHEDULE # ...................................................................................................................... 3-2
CTRL ................................................................................................................................. 3-3
TIME ................................................................................................................................... 3-3
UPSLOPE ........................................................................................................................... 3-3
DOWNSLOPE ..................................................................................................................... 3-3
HEAT .................................................................................................................................. 3-3
PULSATION ........................................................................................................................ 3-3
GAIN (1-9) .................................................................................................................................. 3-4
WELD ON/OFF ........................................................................................................................... 3-4
PAGE DOWN ............................................................................................................................. 3-4
SCHEDULE # ............................................................................................................................. 3-4
FORGE VALVE # ........................................................................................................................ 3-4
FORGE DELAY .......................................................................................................................... 3-4
TURNS RATIO ............................................................................................................................ 3-4
CHAINING .................................................................................................................................. 3-4
SUCCESSIVE ............................................................................................................................. 3-4

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Page
Sample Schedule Screens ................................................................................................................ 3-5
Monitor Screen ................................................................................................................................ 3-7
TIME ..................................................................................................................................... 3-7
CURR ..................................................................................................................................... 3-7
VOLT ..................................................................................................................................... 3-7
POWER ..................................................................................................................................... 3-7
PULSE ..................................................................................................................................... 3-7
STEPPER COUNT ...................................................................................................................... 3-7
STEP # ..................................................................................................................................... 3-7
WELD COUNT ............................................................................................................................ 3-7
Monitor Set Screen .......................................................................................................................... 3-8
NO CURRENT TIME ................................................................................................................... 3-8
WELD COUNT ............................................................................................................................ 3-8
CURRENT MONITOR NUMBER .................................................................................................. 3-8
CURRENT LOW/HIGH –VOLT LOW/HIGH ................................................................................... 3-8
POWER LOW/HIGH .................................................................................................................... 3-8
PULSE % HIGH .......................................................................................................................... 3-8
Copy Setup Data Screen .................................................................................................................. 3-9
Mode Select Screen ....................................................................................................................... 3-10
DELAY START SET .................................................................................................................. 3-10
START SIG. MODE ................................................................................................................... 3-10
PARITY CHECK ....................................................................................................................... 3-10
CYC WELD ............................................................................................................................... 3-10
STEPPER ................................................................................................................................. 3-10
FORGE ................................................................................................................................... 3-10
WELD COUNT .......................................................................................................................... 3-10
RE-WELD ................................................................................................................................. 3-10
END SIG. MODE ....................................................................................................................... 3-11
I
NTERRUPT ............................................................................................................................ 3-11
RESET MODE .......................................................................................................................... 3-11
REMOTE PROG ....................................................................................................................... 3-11
ACTIVE SCHED ....................................................................................................................... 3-11
Stepper Count Screen .................................................................................................................... 3-11
START ON STEP # ................................................................................................................... 3-11
STEP 1 – STEP 9 ..................................................................................................................... 3-11
Heat Increase Screen (Non-linear Stepper) ................................................................................... 3-11
% Heat ................................................................................................................................... 3-11
Linear Stepper Function ................................................................................................................ 3-12
Heat Increase Screen (Linear Stepper) ................................................................................... 3-12
Step 2 Repeat ................................................................................................................... 3-12
Tip Dress Warning .......................................................................................................... 3-12
Cap Change Warning ...................................................................................................... 3-12
Reset to Defaults Screen ................................................................................................................ 3-13

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CONTENTS (Continued)
Page
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 ............................................................................................................................ 4-3
Stopping Welding Operation ........................................................................................................... 4-3
Chapter 5. Maintenance
Section I: Before You Start .................................................................................................................... 5-1
Safety Precautions ........................................................................................................................... 5-1
Cleaning ........................................................................................................................................... 5-2
Section II: Troubleshooting ................................................................................................................... 5-3
Section III: Fuse Failure and Replacement ............................................................................................ 5-6
Fuse Locations ................................................................................................................................. 5-6
Main PCB ................................................................................................................................. 5-7
Valve Driver Board .................................................................................................................. 5-8
Power Supply ............................................................................................................................ 5-8
Power Transformer ................................................................................................................... 5-8
Fuse Block ................................................................................................................................ 5-8
Valve Transformer Fuse, Secondary ........................................................................................ 5-9
24 Volt DC Power Supply (Not Shown) ......................................................................................... 5-9
Section IV: Maintenance Procedures ................................................................................................... 5-10
Maintenance .................................................................................................................................. 5-10
Checking Water Hoses ........................................................................................................... 5-10
Draining Water Hoses ............................................................................................................ 5-10
Flushing Water Hoses and Cooling Chambers ....................................................................... 5-10
Memory Battery Replacement ....................................................................................................... 5-11
Section V: Spare Parts ......................................................................................................................... 5-12
Spare Parts .................................................................................................................................... 5-12
Section VI: Repair Service, Storage, Shipment ................................................................................... 5-13
Repair Service ................................................................................................................................ 5-13
Preparation for Storage or Shipment ............................................................................................. 5-13

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Page
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 ................................................................................................... D-1
Appendix E. Options ............................................................................................................................E-1
Appendix F. Communications ............................................................................................................F-1
Appendix G. Dipswitch Settings ........................................................................................................ G-1
Appendix H. Schedule Data Tables ................................................................................................... H-1
Appendix I. Force Control Option ......................................................................................................I-1

ISA-4001CR INVERTER POWER SUPPLY
viii 990-364
CONTACT US
About This Equipment
Thank you for purchasing a Miyachi Unitek ISA-4000CR Inverter Power Supply.
The ISA Series 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 ISA-4000 and
ISA-4001CR Inverter Power Supplies 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:
245 East El Norte Street
P. O. Box 5039
Monrovia, California 91016
Phone: [phone]
FAX: [phone]
E-mail: [email protected]
Miyachi Unitek 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.

ISA-4001CR INVERTER POWER SUPPLY
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SAFETY PRECAUTIONS
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 Miyachi Unitek.
HIGH VOLTAGE is used in the operation of this equipment.
DEATH ON CONTACT may result if personnel fail to observe the
safety precautions labeled on the equipment and noted in this manual.
WHEN WELDING always wear safety glasses.

ISA-4001CR INVERTER POWER SUPPLY
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Before using this equipment, read the
SAFETY PRECAUTIONS carefully to
understand the correct usage of the
equipment.
xThese precautions are given for safe use
of the Inverter Power Supply and for
prevention of injury to operators or
others.
xBe sure to read each of the instructions,
as they are all important for safe
operation.
xThe 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.

ISA-4001CR 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 Miyachi Unitek 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 Miyachi Unitek 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.

ISA-4001CR 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.

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CHAPTER 1
SYSTEM DESCRIPTION
Section I: Features
The Miyachi Unitek ISA-4001CR Inverter Power Supply is a large-capacity, but compact, power supply
designed for spot welding and fusing. The ISA-4001CR 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 ISA-4001CR
Inverter Power Supply will be referred to simply as the Power Supply. It has the following features:
xWelding current monitoring function for judging the weld quality.
xFor stable weld quality, five control systems
Primary RMS,
Secondary RMS,
Power RMS,
Primary limit, and
Fixed Pulse.
xHas an interrupt function to interrupt fusing current.
xAccommodates 2-level foot switch (2-stage function).
xSuccessive function offers automatic switching for every start without externally selecting any
welding schedule number.
xChain function enables welding by switching multiple welding schedules sequentially with
only one input of the start signal.
xRetraction function offers temporarily retracting the electrodes during a welding process for
easy reorientation of work piece
xHas a forge function to provide a forge valve output signal.
xInverter provides a high power factor with stabilized power conditions.
xVarious items can be set easily by the menu selection system.
xAdaptable to inverter transformers manufactured by various companies by changing the
frequency (600Hz/800Hz/1000Hz).
xThe Power Supply provides five protective functions
No-current,
Overcurrent,
Temperature,
Self-diagnostics, and
Cable fault.
xMaintainability is assured by easy access of wiring and piping and quick replacement of
components.
The Power Supply is also available with optional Isolation Contactors, Control Transformer, and a 24
Volt DC Power Supply. For details, see Appendix E, Options.

CHAPTER 1: SYSTEM DESCRIPTION
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Section II: System Components
Front Panel Controls, Indicators, and Connector

CHAPTER 1: SYSTEM DESCRIPTION
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CONTROL AND MONITOR UNIT CONNECTOR – Used to connect the MA-627A Program Unit and the
MA-628 Monitor Unit to the Power Supply.
WELD POWER – Red indicator that lights when power is supplied to the unit.
READY – Green indicator that lights when system is ready to start welding. For this status to exist, the
following conditions must be met:
xThe WELD ON/OFF button must be pressed to ON (The WELD ON/OFF indicator is lit).
xThe WELD ON/OFF setting of the Program Unit must be On, and
xThe External WELD ON/OFF signal must be ON.
START – Green indicator that lights when Start signal is received.
WELD – Green indicator that lights when weld current is flowing.
TROUBLE – Red indicator that lights when trouble is detected. When this condition occurs, the unit
operation is interrupted.
RESET – This button resets a trouble condition only if the trouble has been corrected. If the trouble is
not removed, the operation will again be interrupted and the TROUBLE indicator will again light. After
the RESET button is pressed, the START signal must be re-sent to the Power Supply for welding to
begin.
WELD ON/OFF – This push-push button enables the unit to weld. When ON, the green indicator lights.
When operating the button, the switch needs to be held until the green LED lights (or goes out). This is
one of three conditions required to place the unit in the Ready condition; see "READY," above.
CIRCUIT BREAKER PANEL – Complete operation of the circuit breaker is described in the separate
circuit breaker manual included inside the ISA-4001CR cabinet.
Internal Components
WARNING
Before opening the doors, disconnect all power to the unit order to prevent electrical shock or
DEATH. Power is not turned OFF when the handle is turned and the door opened. Remove power
from the ISA and wait at least 5 minutes for the capacitors to discharge. Be sure capacitors
are discharged before removing internal protective plastic panel.
To open the cabinet doors, insert the silver key into the lock on the right door and turn to unlock. The
left door is unlocked with a handle inside the door.

CHAPTER 1: SYSTEM DESCRIPTION
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CHAPTER 1: SYSTEM DESCRIPTION
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Capacitor Discharge Indicator – The electrolytic
capacitors are charged to a high voltage during
operation of the Power Supply. The charge level
is indicated by the brightness of the red
indicator: the brighter the indicator, the higher
the charge.
I/O Terminal Block – This terminal block is used
to connect all input and output control signals
(except for Secondary Current Sensor inputs and
communications). See Chapter 2 for details of
these input and output signals.
ME 1887 Expansion Board – This expansion board contains components for the Force Control Option
described in Appendix I.
PCB Panel Sub-Assembly (Not Shown) – This assembly contains the Control Board, Valve Driver Board
and associated power supplies. See Chapter 4 for a listing of the fuses on this sub-assembly.
Power Module – The Power Module contains the Main Control Board and the Interface Board.
Power Transformer – This transformer provides power to the Power Supply circuit boards.

CHAPTER 1: SYSTEM DESCRIPTION
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Power and Ground connections
Input Power Connections – Input power is brought into the Power Supply through an access plate in the
top. The plate can be removed for drilling appropriate size hole for input power cable conduit.
Connections are made directly power lugs or an optional Circuit Breaker. Chassis ground connection is
made to the Grounding Lug.

CHAPTER 1: SYSTEM DESCRIPTION
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Circuit Breaker– Input power cables are
connected to the Circuit Breaker.
NOTE: The internal connections
are shown on the previous page, the
external panel is shown on the right.
Grounding Lug – Chassis ground
connection point for input power.
Output Power Connections – The
connection points for the output power to
the weld transformer are as shown. The
cables should exit through a conduit
mounted in a convenient location on the
bottom panel of the unit.
Rear Panel Connections
Cooling Water Fittings – These fittings provide source and drain connections for cooling water. See
Chapter 2 for required specifications of cooling water.
Secondary Current Sensor Input Connector – This connector is used to connect a secondary current
sensor to the Power Supply.

CHAPTER 1: SYSTEM DESCRIPTION
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Program Unit (MA-627A)
The illustration below shows the controls and indicators on the front of the Program Unit. The function
of each control and indicator is described below. Because you will only need one Program Unit even if
you have more than one Power Supply, the Program Unit is an optional piece that is sold separately.
Program Unit Controls and Indicators
Connector – The connector is used to connect the interface cable between the Program Unit and the
front panel of the Power Supply.
Display – The display is a 10-row, backlit, LCD.
TROUBLE RESET key – This button has the same function as the Reset button on the Power Supply.
That is, pressing it will cause the Power Supply TROUBLE lamp to go off, once the trouble has been
cleared.
CURSOR keys – These keys are used to move the cursor left, right, up, and down to select an item.
+ON/–OFF keys – These keys are used to change the value of a selected item or turn it on and off. When
the +ON key is pressed, the selected value increases, and when the –OFF key is pressed, the value
decreases. The selected item is turned on by pressing the +ON key and off by pressing the –OFF key.
ENTER key – This key is used to enter new values in the Program Unit. After any data is set or changed,
be sure to press this ENTER key to write that data before moving the cursor. If the ENTER key is not
pressed, the data will not be changed.
MENU key – This key is used to return to the Menu screen from any other screen.