Miyachi IPB-5000A User manual

INVERTER-TYPE WELDING POWER SUPPLY
IPB-5000A
OPERATION MANUAL
Thank you for purchasing the Miyachi Inverter-type Welding Power Supply IPB-5000A.
・For correct use, read this operation manual carefully.
・After reading, save it in a proper place where you can easily access to.
J03M0756E-05
POWERSTART
IPB-5000A
CURSOR
WELD MENU RESET
ENTER
＋－
WELDING POWER SUPPLY

IPB-5000A
1
Table of Contents
1. Special Precautions··································································································· 1-1
(1) Safety Precautions································································································· 1-1
(2) Precautions for Handling ······················································································· 1-4
(3) Warning Labels for Safety ····················································································· 1-5
(4) Function Difference Depending on Model ····························································· 1-5
2. Features ······················································································································ 2-1
3. Packaging ··················································································································· 3-1
4. Name and Functions of Each Section ····································································· 4-1
(1) Front Panel ············································································································ 4-1
(2) Rear Panel ············································································································· 4-3
5. Installation and Connection······················································································ 5-1
(1) Installation·············································································································· 5-1
(2) Connection············································································································· 5-2
6. Description of Display Screens················································································ 6-1
(1) Operation Flow······································································································· 6-1
(2) MENU Screen ········································································································ 6-2
(3) SCHEDULE Screen ······························································································· 6-2
(4) MONITOR Screen·································································································· 6-6
(5) COMPARATOR Screen························································································· 6-8
(6) ENVELOPE Screen ······························································································· 6-9
(7) PRECHECK Screen······························································································· 6-13
(8) CONTROL Screen ································································································· 6-14
(9) STATUS Screen ···································································································· 6-16
①STATUS (1/2) Screen ······················································································· 6-16
②STATUS (2/2) Screen ······················································································· 6-18
③ERROR SETTING Screen ················································································ 6-20
④MISC Screen ····································································································· 6-20
7. Basic Operation ········································································································· 7-1
8. External Interface······································································································· 8-1
(1) Connection Diagram for External Input/Output Signals········································· 8-1
①When contacts on PLC are used as input signal ·············································· 8-1
②When NPN transistor (sink type) on PLC is used as input signal····················· 8-2
③When PNP transistor (source type) on PLC is used as input signal················· 8-3
④When solenoid valves are activated by the use of an external power supply ·· 8-4
⑤When solenoid valves are activated by the use of an internal power supply ··· 8-4
(2) External Input/Output Signals ················································································ 8-4
(3) Schedule No. and Schedule Select Terminals ······················································ 8-8
9. Time Chart ················································································································ 9-1
(1) Fundamental Sequence························································································· 9-1
(2) Determination of Weld Schedule ··········································································· 9-3
(3) Behavior of START SIG. HOLD············································································· 9-4
(4) Behavior of END SIG. TIME ·················································································· 9-5

IPB-5000A
2
Table of Contents (Continued)
(5) Behavior of SOL1 and SOL2 ················································································· 9-6
(6) “Error” or “Caution” in PRECHECK········································································ 9-7
(7) At Occurrence of “Error” or “Caution” ···································································· 9-8
(8) Behavior in TRANS SCAN MODE········································································· 9-9
①OFF Setting ······································································································· 9-9
②ON Setting········································································································· 9-9
③1-5 Setting ········································································································· 9-10
④1-2 Setting ········································································································· 9-11
⑤1-3 Setting ········································································································· 9-12
⑥1-4 Setting ········································································································· 9-12
(9) Movement of Displacement Sensor······································································· 9-13
10. External Communication Function ······································································ 10-1
(1) Introduction ············································································································ 10-1
(2) Data Transmission ································································································· 10-1
(3) Configuration·········································································································· 10-2
①RS-485 ·············································································································· 10-2
②RS-232C············································································································ 10-2
(4) Protocol ·················································································································· 10-3
①Single-directional Communication Mode ·························································· 10-3
②Bi-directional Communication Mode ································································· 10-4
(5) Data Code Table···································································································· 10-8
①Order Table of Schedule Data ·········································································· 10-8
②Order Table of Monitor Data (Most Recent Monitor Value) ······························ 10-9
③Specified Code ·································································································· 10-10
11. Specifications ········································································································ 11-1
(1) Specifications········································································································· 11-1
(2) Optional Items (Separately Sold)··········································································· 11-5
①Input Cables PK-01855-□□□········································································· 11-5
②Output Cables PK-01856-□□□ ······································································ 11-5
③[SENS] Cables SK-05741 ················································································· 11-6
④Start Cables A-03081························································································ 11-6
⑤Displacement Sensors ······················································································ 11-6
⑥Displacement Sensor Conversion Cables ························································ 11-6
12. Error Codes ············································································································ 12-1
13. Outline Drawing ····································································································· 13-1
(1) IPB-5000A-00-00/01/03/04···················································································· 13-1
(2) IPB-5000A-00-02/05······························································································ 13-2
14. Schedule Data Table······························································································ 14-1
(1) Weld SCHEDULE Setting······················································································ 14-1
(2) PRECHECK Setting······························································································· 14-8
(3) COMPARATOR Setting ························································································· 14-11
(4) CONTROL Setting ································································································· 14-18
(4) STATUS Setting····································································································· 14-25
EC Declaration of Conformity

IPB-5000A
1. Special Precautions
1-1
Denotes operations and practices that
may result in personal injury or damage
to the equipment if not correctly followed.
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 safe operation.
• The meaning of the words and
symbols is as follows.
Do not touch the inside of the Power Supply unnecessarily.
Since very high voltages are charged to the inside of this Power Supply, it is
very dangerous to touch it unnecessarily.
Any person other than service personnel, or authorized representatives’
personnel must not touch the inside.
Never disassemble, repair or modify the Power Supply.
These actions can cause electric shock and fire.
If any part needs to be checked or repaired, contact Miyachi Corp. or your
distributor for help.
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 o
r
loss of life if not correctly followed.
WARNING
!
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.
!
DANGER
!
C
A
UTION
！

IPB-5000A
1. Special Precautions
1-2
Do not put your hands between the electrodes.
When welding, keep your fingers and hands away from the electrodes.
Do not touch any welded part or electrodes during welding and just after
welding finished.
The welded part of a workpiece, electrodes and arm are very hot.
Do not touch them; otherwise you may be burnt.
Ground the equipment.
If the Power Supply is not grounded, you may get an electric shock when
there is trouble, or when electricity leaks.
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 tense any cable. The power cable and connecting
cables may be broken, and that can cause electric shock and fire.
If any part needs to be repaired or replaced, consult Miyachi Corp. or your
distributor.
Do not use any damaged power cable, connecting cable and plug.
That can cause electric shock, short circuits and fire.
If any part needs to be repaired or replaced, consult Miyachi Corp. 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 Miyachi Corp. or your
distributor.
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 shop 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
!
!
!
!
!
!

IPB-5000A
1. Special Precautions
1-3
Apply the specified source voltage.
Application of a voltage out of the specified range can cause fire and electric
shock.
Do not splash water on the equipment.
Water splashed over the electric parts, can cause electric shock and short
circuits.
Use proper tools (wire strippers, pressure wire connectors, etc.) for
termination of the connecting cables.
Do not cut the conductor of wire. A flaw on it can cause fire and electric
shock.
Install the equipment on firm and level surface.
If the equipment falls over or drops from an uneven surface, injury may
result.
Do not sit on or do not put things on it.
Sitting on it, or putting things on it may cause malfunction.
Keep combustible matter away from the welding machine.
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 equipment with a blanket, cloth, etc.
If such a cover is used, it may be heated and burn.
Do not use this Power Supply for purposes other than welding.
Use of this equipment 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.
Make sure there is a fire extinguisher in or near the welding shop in case of
fire.
Regularly inspect and maintain the equipment.
Regular inspect and maintenance is essential to safe operation of the
equipment. If you see any damage, make necessary before starting the
operation.
CAUTION
!
!
!
!
!
!
!
!

IPB-5000A
1. Special Precautions
1-4
(2) Precautions for Handling
 Install the Power Supply on a firm and level surface. If it is used inclined or on its
side, it may have a malfunction.
Also, provide 10
cm clearance to the intake and exhaust for improving the effect of
heat release (Refer to 5. (1)Installation).
 Do not install this Power Supply in the following places:
▪ Where there is considerably damp (humidity is 90% or higher).
▪ Where the ambient temperature is above 40℃or below 5℃.
▪ Where there is nearby high-frequency noise source.
▪ Where the Power Supply may be exposed to chemicals.
▪ Where moisture may be condensed on the surface of the Power Supply.
▪ Where there is considerable dirt.
▪ Where the Power Supply may be subjected to vibration or impact.
 If the outside of the Power Supply is stained, wipe it with a dry cloth or a
moistened cloth. If it is badly stained, use diluted neutral detergent or alcohol to
clean it. Do not use paint thinner, benzene, etc., which can discolor or deform the
parts.
 Do not put screws, coins, etc., in the Power Supply, as they may cause a
malfunction.
 Operate the Power Supply according to the method described in this operation
manual.
 Operate the switches and buttons carefully by hand. If they are operated roughly
or with the tip of a screwdriver, a pen, etc. they may be broken.
 Operate the switches and buttons one at a time.
If two or more of them are operated at a time, the Power Supply may have trouble
or may be broken.

IPB-5000A
1. Special Precautions
1-5
(3) Warning Labels for Safety
The following warning labels are attached to the Power Supply for safe operation.
The location of labels and the meaning of the symbols are as follows:
Location: the side surface of a plastic cover inside IPB-5000A
Meaning: Danger
Location: Output terminal cover inside IPB-5000A
Meaning: Danger of Electrical Shock
(4) Function Difference Depending on Model
The function of “only for Model with Displacement Sensor” described in the
operation manual is effective for the models equipped with Displacement Sensor
as follows.
Other functions are effective for the Models with Sensor as same as the standard
models.
IPB-5000A-00-
Model 00/01/02 03/04/05
Standard Model
(without Sensor) Yes
Model
with Sensor Yes
DANGER
WHEN INSPECTING INTERNAL, MAKE SURE
TO TURN OFF MAIN CIRCUIT BREAKER
AND WAIT FOR AT LEAST 5 MINUTES
NOT TO GET AN ELECTRIC SHOCK.

IPB-5000A
2. Features
2-1
2. Features

Has a welding current monitoring function for the judgment of weld quality
 The selection from four control methods of Constant-current control, Constant-voltage
control, constant-current/constant-voltage combination control and constant-power
control is applicable for realizing the stable weld quality

Has an interrupting function (INTERRUPT)to interrupt fusing current by externally
inputting the displacement of an electrode, etc. for stable fusing
 Weld current can be stopped when the displacement reaches the set value, because
the displacement change between electrodes generated by fusion penetration etc. is
measured (only for the model with a displacement sensor).

As an inverter is used, the power factor is high and the power condition is stabilized

Because of the menu selection system, setting of various items can easily be done

With four protective functions, the operator can work at ease
・Overcurrent detecting function
・No-current / no-voltage detecting function
・Thermostat fault detecting function
・Self diagnostics
The Miyachi IPB-5000A is an inverter-type power supply designed for spot
welding and fusing.
It is easy to move and install, as it is small in size and compact. In addition, the monitor
function is provided which makes possible the judgment of defective or non-defective
welding.

IPB-5000A
3. Packaging
3-1
3. Packaging
Shipping Kit LIst
Verify that contents of the container agree with the kit list.
If you see any damage, please contact Miyachi Corp.
Packaged Kit Quantity
IPB-5000A 1
Operation Manual 1
Cable Clamp (Large)
for fixing I/O Cable 2
Cable Clamp (Small)
for fixing I/O Cable 3