Miyachi Amada ISQ20 Series User manual

Original Instructions: German
Translation of Original Instructions
76609605EN-ISQ20-V1.2
Inverter Power Source
ISQ20 Series
OPERATING INSTRUCTIONS

ISQ20
76609605EN-ISQ20-V1.2.docx 2/63 2016-04-21
Annex:
- Safety Regulations
- General References on Resistance welding
- Contact addresses
Valid for following models:
ISQ20-3-DC ISQ20-10-DC
ISQ20-6-DC ISQ20-20-DC
ISQ20-8-AC
Version Date Basis of Revision
1.0 2014-07 new
1.0a 2014-11 Adaption to new company name
1.1 2015-02 New installation notes (chap. 1.2)
1.1a 2015-09 New cover
1.2 2016-04 New declaration of conformity (CE)
Copyright 2016:
AMADA MIYACHI EUROPE GmbH
Lindberghstr. 1, 82178 Puchheim, Germany
Right to make amendments reserved. Deviations may occur. All rights reserved.
The products named in this manual are only used for identification purposes and may be trademarks
or registered trademarks of the respective companies.

ISQ20
Content
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Content
1General Information.............................................................................................5
1.1Safety Notes .......................................................................................................................5
1.2Installation Notes...............................................................................................................6
1.3Declaration of Conformity.................................................................................................7
2Technical Description..........................................................................................8
2.1Device Types ......................................................................................................................9
2.1.1Technical Data ISQ20-3-DC.............................................................................................................10
2.1.2Technical Data ISQ20-6-DC............................................................................................................. 11
2.1.3Technical Data ISQ20-10-DC...........................................................................................................12
2.1.4Technical Data ISQ20-20-DC...........................................................................................................13
2.1.5Technical Data ISQ20-8-AC .............................................................................................................14
2.2Operation..........................................................................................................................15
2.3Displacement Sensor (optional, only usable with OP-AWS3/TP-AWS3)....................15
2.4Pressure/Force Measuring (optional, only usable with OP-AWS3/TP-AWS3)...........15
2.5Sound Pressure Level.....................................................................................................15
2.6Maximum Duty Ratio .......................................................................................................16
3Design and Mode of Action...............................................................................17
3.1Front Panel ISQ20............................................................................................................17
3.2Rear Panel ISQ20-3 / ISQ20-6..........................................................................................18
3.3Rear Panel ISQ20-8 / ISQ20-10........................................................................................19
3.4Rear Panel ISQ20-20........................................................................................................20
4Connections.......................................................................................................21
4.1Overview...........................................................................................................................21
4.2RS232 Serial Interface .....................................................................................................21
4.2.1Data Transfer ...................................................................................................................................21
4.2.2Data Output Format, AWS3 Mode....................................................................................................22
4.2.3Data Output Format, Classic Mode..................................................................................................23
4.2.4Baud Rate ........................................................................................................................................23
4.2.5Software Update ..............................................................................................................................23
4.3Plug Assignments............................................................................................................24
4.3.1X1: Binary Inputs, potential free .......................................................................................................24
4.3.2X2: Binary Outputs, potential free ....................................................................................................27
4.3.3X3: Initiators .....................................................................................................................................30
4.3.4X4: Valves ........................................................................................................................................32
4.3.5X5: Start ...........................................................................................................................................32
4.3.6X6: Proportional Valve Head 1 .........................................................................................................33
4.3.7X7: Pressure Sensor Head 1 ...........................................................................................................33
4.3.8X8: Proportional Valve Head 2 .........................................................................................................33
4.3.9X9: Pressure Sensor Head 2 ...........................................................................................................34
4.3.10X10: Voltage Measurement 1...........................................................................................................34
4.3.11X11: Voltage Measurement 2 ...........................................................................................................34
4.3.12X12: Binary I/O.................................................................................................................................34
4.3.13X30: Welding Transformer ...............................................................................................................35
4.3.14X31: Temperature Sensor Transformer ............................................................................................35
4.3.15X32: Current Measuring Coil............................................................................................................35

ISQ20
Content
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5Commissioning..................................................................................................36
5.1Preconditions for Commissioning.................................................................................36
5.2Electrical Connections....................................................................................................36
5.2.1Mains Supply ...................................................................................................................................37
5.2.2Connecting Secondary Cables.........................................................................................................38
5.2.3Connecting Current Measurement ...................................................................................................39
5.3Mechanical Connections.................................................................................................40
5.3.1Connection Possibilities Heads / Valves etc.....................................................................................40
5.3.2Connection with One Head and Start 1............................................................................................41
5.3.3Connection with Two Heads and Start 1, 2 or 3 ...............................................................................42
5.4Insulation Test..................................................................................................................43
5.5Switching-on.....................................................................................................................43
6Sequence............................................................................................................44
6.1Standard Diagram with One Head..................................................................................44
6.2Diagram for One Head with Stroke Cylinder.................................................................45
6.3Diagram for Pincers resp. Locking Cylinder.................................................................46
7Error Messages..................................................................................................47
7.1Unit Errors (#10 – #59).....................................................................................................47
7.2Sequence Errors (#60 – #95)...........................................................................................49
8Connection Variants (Examples)......................................................................50
8.1ISQ20 - pneumatic 1-Head w/o Distance Measurement...............................................50
8.2ISQ20 - pneumatic 1-Head w/o Distance Measurement...............................................51
8.3AWS3 - pneumatic 1-Head...............................................................................................52
8.4AWS3 - pneumatic 2-Head...............................................................................................53
8.5AWS3 – pneumatic with Profibus...................................................................................54
8.6AWS3 – pneumatic with Ethernet IP ..............................................................................55
8.7AWS3 - motorized 1-Head ...............................................................................................56
8.8AWS3 - motorized 2-Head ...............................................................................................57
8.9AWS3 - motorized 1-Head with Profibus .......................................................................58
8.10AWS3 - motorized 1-Head with Ethernet IP...................................................................59
8.11AWS3 – motorized 1-Head with Router (Remote Service)...........................................60
9Connection Schemes ........................................................................................61
9.1Binary Connections 1......................................................................................................61
9.2Binary Connections 2......................................................................................................62
10Index ...................................................................................................................63
10.1Illustration Index ..............................................................................................................63
10.2Headword Index ...............................................................................................................63

ISQ20
General Information
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1 General Information
1.1 Safety Notes
Information about safety regulations, symbols, copyrights, protection rights,
usage location conditions and notes on resistance welding can be found in the
back section of these operating instructions.
Please read this information carefully before using these operating instructions.
These operating instructions should help you familiarize yourself with the system and
take advantage of its application possibilities when used as directed.
It contains important notes to help operate the unit safely, properly, and economically.
Observing the notes will help avoid risks, decrease repair costs and down times, and
enhance reliability and the service life of the unit.
It is a rule: Safety first!
Warning
Incorrect or inappropriate configuration, installation, settings, handling or use can cause
mechanical, electrical or thermal hazards, which may result in serious damage or injury.
Ensure the correct execution of these points and follow the respective notes in the
operating instructions.
Danger
Do not put the system into operation before you have read the operating instructions!
Danger Persons with cardiac pacemakers and metallic implants are prohibited from
approaching to within a radius of at least 5 m of welding equipment!
Crushing Hazard
There is a risk of crushing during the adjustment movement due to closing electrodes,
stops for limiting adjustment or stroke movement and the stop on the basic pincers unit
for limiting floating movement.
Warning
This Class A welding equipment is not supposed to be used in living quarters, where
the power supply is carried out by a public low voltage supply.
There it can be difficult to ensure electromagnetic compatibility because of conducted or
radiated disturbances.
Warning

ISQ20
General Information
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1.2 Installation Notes
Please observe the following additionally to the points in chap. 5.1:
Ventilation:
To ensure adequate ventilation of the weld control and motor control units, the distance
on the side must be at least 40 mm and behind at least 100 mm.
19“ units (installation in a control cabinet):
ISQ20 - 1 U distance upwards
MNC (motor control) – at least 40 mm distance on the lateral ventilation slots
If the distances are too small, it can lead to increased temperatures in the inside of the
unit. This can affect the functionality.
Cable routing:
For the cable routing ensure an appropriate separation of control and field bus cables to
power cables, motor cables and cables with welding current.
EMC guidelines – and thus also the distances to arising magnetic fields – have to be
observed.
An appropriate shielding has to be scheduled if necessary.

ISQ20
General Information
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1.3 Declaration of Conformity

ISQ20
Technical Description
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2 Technical Description
The inverter power supply ISQ20 (hereinafter also referred to as inverter or weld
control) can be used as a stand-alone unit with the operating terminal MFT1 or as part of
the AWS3 (Active Welding System 3) with the operating terminals OP-AWS3 or
TP-AWS3.
Fig. 1: Standard device
A few important functions:
APC (Active Part Conditioner)
Setting of pre-warning and limit values
Error control and process monitoring
Displacement / Force measuring (optional, only possible with AWS3 operating
terminal and appropriate measurement technology))
The control mode for each welding pulse can be pre-selected in each of the 99 programs
of the ISQ20.

ISQ20
Technical Description
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2.1 Device Types
The ISQ20 is available in the following DC- and AC types:
DC device with internal transformer:
ISQ20-3-DC
ISQ20-6-DC 3 kA
6 kA
DC device with external transformer:
ISQ20-10-DC 10 kA consisting of basic device
ISQ20-EXT-AC/DC-250
and transformer IT-60X *
DC device with external transformer and external line filter:
ISQ20-20-DC 20 kA consisting of basic device
ISQ20-EXT-AC/DC-500,
transformer IT-113X * and external line filter
AC device with external transformer:
ISQ20-8-AC 8 kA consisting of basic device
ISQ20-EXT-AC/DC-250
and transformer TRM3/14 – 9V *
* Other transformers on request.
Special voltages for different mains supplies on request.

ISQ20
Technical Description
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2.1.1 Technical Data ISQ20-3-DC
Supply voltage 3x 400 VAC, ±10%, PE
Mains frequency 50...60 Hz
Connecting cable 4 x 2.5 mm²
Connected load 11 kVA
Fuse recommended 3 x 16 A, slow
Rated output current 2 kA at 11 % d.r. measured for Tu = 20 °C
Max. output current 3 kA at 5 % d.r.
Min. terminal voltage 4 V at 3 kA with 400 V rated mains voltage at
the unit input
Max. open circuit voltage 10 V
Max. output power 12 kVA
Switching frequency 20 kHz
Output frequency 40 kHz
Protection class IP 30
Permissible humidity 40 – 70 %, non-condensing
Ambient temperature 10..40 °C
Cooling forced ventilation, temperature controlled
Secondary connections Cu busbar, 2 x M8 thread
Minus connected with PE
Current measurement integrated measuring coil (toroidal coil)
Dimensions
(W x H x D) 216 x 420 x 480 mm
216 x 420 x 550 mm (incl. excess lengths)
Weight ca. 33 kg