Download
Share
Print this page
Amada IS-800A-10 Series Operation Manual
  1. Manuals
  2. Brands
  3. Amada Manuals
  4. Welding Accessories
  5. IS-800A-10 Series
  6. Operation manual

Amada IS-800A-10 Series Operation Manual

Dc inverter welding power supply
Hide thumbs

Advertisement

Quick Links

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

Advertisement

loading
Need help?

Need help?

Do you have a question about the IS-800A-10 Series and is the answer not in the manual?

Questions and answers

Related Manuals for Amada IS-800A-10 Series

Summary of Contents for Amada IS-800A-10 Series

  • Page 1 Original instructions DC INVERTER WELDING POWER SUPPLY -10-□□ 800A 1400A OPERATION MANUAL Z06OM1182586-12...
  • Page 2 IS-800A/1400A 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. ATTENTION This operation manual is common to both IS-800A-10-□□...
  • Page 3 IS-800A/1400A 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 Basic Operation ....................... 7-1 Timing Chart ........................
  • Page 4 IS-800A/1400A 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.
  • Page 5 IS-800A/1400A WARNING 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;...
  • Page 6 IS-800A/1400A CAUTION 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.
  • Page 7 IS-800A/1400A (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. ...
  • Page 8 IS-800A/1400A (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.
  • Page 9 IS-800A/1400A 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 ...
  • Page 10 IS-800A/1400A 3. Name and Functions of Each Section (1) Front Front Panel ① ② ③ ④ ⑤ ⑥ ⑦ WELD WELD POWER READY START WELD TROUBLE RESET ON/OFF ⑨ WEL D RES ET W ELD PO WER REA DY ST ART WE LD TROU BLE ON /OFF...
  • Page 11 IS-800A/1400A  START lamp Stays lit while the start signal is input.  WELD lamp Stays lit while the welding current is flowing.  TROUBLE lamp Lights up when trouble is detected. At this time, the program unit makes a peeping sound, and the work done by IS-800A/1400A is interrupted.
  • Page 12 IS-800A/1400A (2) Internal and Rear Panel IS-800A (When the front door is opened, the internal panel appears.) Internal Rear CONTROL S IG   SCH 2 SCH 4 SCH 8 SCH16 SCH32 I/O CONNECTOR SCH64 SCH128 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  W E1 S TO P /P AR IT Y SOL COM W E2 S TO P...
  • Page 13 IS-800A/1400A  Connecting Terminal Strip for External Input/Output Signals Used to input start signals and output trouble signals. Specifications of Terminal Strip for External Input/Output Signals Crimp-on terminals allowed to 2 pieces max. be installed per a terminal Size of crimp-on terminal M3 or M3.5 (7.1 mm wide) Recommended cable 0.75 mm...
  • Page 14 IS-800A/1400A (3) MA-660A (Sold Separately) CURSOR  MENU  TROUBLE ENTER RESET      TROUBLE RESET key If this key is pressed while the TROUBLE lamp of IS-800A/1400A is lit, the lamp goes off. It has the same function as the RESET key of IS-800A/1400A. ...
  • Page 15 IS-800A/1400A  MENU key Used to display the MENU screen. Press this key to return to the MENU screen from any other screens.  Connector Used to connect the circuit cable. Connect the other end of the cable to the PROGRAM MONITOR I/O connector of the Power Supply.
  • Page 16 IS-800A/1400A 4. How to Operate Screens ATTENTION 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.
  • Page 17 IS-800A/1400A (2) POWER SUPPLY STATE Screen This screen is used to display and set data for the Power Supply. indicates settable items. Move the cursor ( ) to them to change the value. (Same for all screens.) (a) CONTRAST Sets the screen contrast. The contrast can be set in a range from 0 to 9. The larger the value, the brighter the screen.
  • Page 18 IS-800A/1400A (3) SCHEDULE Screen Up to 255 welding schedules can be set on the Power Supply. In the SCHEDULE screen, there are  Current and time setting screen and  Pulsation and transformer screen.  Current and time setting screen This screen is used to set the SCHEDULE No., length of weld time, welding current, and so on.
  • Page 19 IS-800A/1400A * OFF/Off time ･ Count and step value are increased each time OFF/Off time is over. ･ RE-WELD does not work simultaneously with OFF/Off time. When OFF/Off time is set, RE-WELD becomes invalid. ･ START SIGNAL MODE has limitations. When OFF/Off time is set, MAINTAINED of START SIGNAL MODE does not work.
  • Page 20 IS-800A/1400A A: WELD1 time or WELD2 time B: DOWN1 time or DOWN2 time C: WELD2 time or WELD3 time D: WELD1 HEAT or WELD2 HEAT E: DL1 HEAT or DL2 HEAT F: WELD2 HEAT or WELD3 HEAT  When the slope times are set for the previous and subsequent stages in the multi-stage welding.
  • Page 21 IS-800A/1400A  When the upslope time is set in the pulsation welding. The upslope time is set, and the UF HEAT setting of C and the HEAT setting of D are different. A: UP1 to 3 time B: WELD1 to 3 time C: UF1 to 3 HEAT D: HEAT1 to 3 ...
  • Page 22 IS-800A/1400A  When the upslope time and the downslope times are set in the pulsation welding. The upslope time and the downslope time are set, and the UF HEAT setting of D and the DL HEAT setting of F are different. A: UP1 to 3 time B: WELD1 to 3 time C: DOWN1 to 3 time...
  • Page 23 IS-800A/1400A (Note) Control method of the inverter welding power supply Control Feature Application Control mechanism method Detects the primary current by Requires no connection Used for welding in the current sensor mounted of toroidal coil on the a robot or an into the power supply to Primary secondary side of the...
  • Page 24 IS-800A/1400A Control Feature Application Control mechanism method Used for special Constant-phase Welding with the fixed cases such as the control Controls switching with the set pulse width. No feedback test of welder, and (Non-constant pulse width. control. not used for normal current) welding.
  • Page 25 IS-800A/1400A (a) SCHEDULE # Select from #001 to #255 to set the SCHEDULE. Normally select #001 first, then select additional schedules in sequential order. (b) PULSE LIMIT When limiting the pulse width in Primary constant-current peak value control, set the limit for each of WELD1, WELD2 and WELD3. The setting range is 10.0 to 99.9%.
  • Page 26 IS-800A/1400A SET Screen.)  In the secondary constant-current control or the secondary constant-power control, the control may become unstable when the current flows for over 1 second continuously. In that case, use the primary constant-current control or the primary constant-current peak value control. (d) WELD TRANS FREQ Sets the frequency of the welding transformer to be used.
  • Page 27 IS-800A/1400A (g) MAX CURRENT Sets the maximum current of transformer. The setting range is 1 kA to the setting of CURRENT RANGE. Valid only in the primary constant-current effective value control, secondary constant-current effective value control and secondary constant-power effective value control.
  • Page 28 IS-800A/1400A Large control gain Setting Overshoot Small control gain Setting Slow increase in current (k) TURN RATIO Set the welding transformer turns ratio. The turns ratio can be set in a range from 001.0 to 199.9. ATTENTION When using the primary constant-current effective value control or primary constant-current peak value control, always set the correct turns ratio.
  • Page 29 IS-800A/1400A (4) MONITOR Screen In this screen, you can confirm the operational conditions during welding. Monitored data is displayed for each SCHEDULE. (Note) The screen shows the settings for 10 kA or 05 kA range. In 20 kA, 40 kA, or 80 kA range, CURRENT is 00.0 kA to 99.9 kA and POWER is 000.0 kW to 999.9 kW.
  • Page 30 IS-800A/1400A (e) POWER The power during which current was supplied in the course of WELD1, WELD2 and WELD3 operations are displayed. The value calculated from current and voltage (current x voltage) is displayed. To display the voltage, you need to measure the secondary voltage by connecting the voltage detecting cable.
  • Page 31 IS-800A/1400A  When WELD2 STOP/WELD COUNT is WELD2 STOP and COUNTER is GOOD GOOD COUNTER is displayed. The count value is incremented by one when the monitored value is within the range of the upper/lower limit.  When WELD2 STOP/WELD COUNT is WELD2 STOP and COUNTER is WORK WELD COUNTER and WORK COUNTER are displayed.
  • Page 32 IS-800A/1400A (Note) Monitored value  Only the last monitored value and the number of counts of each SCHEDULE are kept for a period of about 10 days after the power is turned off.  When the repetition welding is performed with PULSATION or OFF time setting, only the last data is displayed as the monitored value.
  • Page 33 IS-800A/1400A (5) MONITOR SET Screen Set the conditions for determining a good or bad weld, including values for welding current, upper or lower limits for the secondary voltage, etc. If the monitored welding current, secondary voltage, etc., do not meet the set conditions, a caution signal is output, and can be used to activate an alarm buzzer, alarm lamp, or similar event.
  • Page 34 IS-800A/1400A (Note) Upper/Lower limit judgment value when STEPPER MODE is not OFF The upper/lower limit judgment value set here is for the current when a welding is performed, not for the initial setting. Therefore, when STEPPER MODE is not OFF to perform step-up (-down) for the initial setting, the upper/lower limit judgment value is stepped up or down automatically.
  • Page 35 IS-800A/1400A (6) NG SIGNAL SELECT Screen Sets the output mode and the signal for each item to output, ERROR or CAUTION, in an error occurring. (This screen shows initial settings.) (a) ERROR OUTPUT MODE Sets the output mode of NG1 of the external output signals. (Refer to 6. Interface.) (NORMAL CLOSE) Closed at normal / Open at error (NORMAL OPEN) Open at normal / Closed at error...
  • Page 36 IS-800A/1400A (Note) Receiving the start signal after error output and Continuous welding operation Start signal after error Continuous welding output with off time (OFF) ERROR Not receive Stop Upper/lower limit monitor error CAUTION Receive Not stop ERROR Not receive Stop No-current error, Workpiece error CAUTION...
  • Page 37 IS-800A/1400A (7) OUTPUT SELECT Screen Sets the output signals OUT1 (Pin 28) to OUT5 (Pin 32) of the external output signals. For the contents of each output signal, refer to 6.(3). (This screen shows initial settings.) Pressing +ON key switches the signal in the following order (in the reverse direction when pressing -OFF key): END (end signal) →...
  • Page 38 IS-800A/1400A (8) COPY SETUP DATA Screen The MA-660A can store data. (Refer to figure shown below.) When the MA-660A is connected to the Power Supply, the data stored in the Power Supply memory is displayed on the Monitor Panel. When the data is changed and the ENTER key is pressed, the contents of the memory of the Power Supply are overwritten by the new setting.
  • Page 39 IS-800A/1400A Move the cursor ( ) to the required item among (a) to (c), then press the ENTER key; the data will be copied. (a) IS-800A/1400A -----> MA-660A The data in IS-800A/1400A is copied to memory of MA-660A. When copy is complete, <END> is displayed. Perform this operation on the source IS-800A/1400A.
  • Page 40 IS-800A/1400A (9) MODE SELECT Screen (a) DELAY START SET One welding condition is determined via DELAY START SET, a value corresponding to chatter prevention time, after a start signal is input. The DELAY START SET period can be set in a range from 1 to 20 ms, in unit of 1 ms. When the schedule signal is not input and the start signal is input within the set time, E-16 (Schedule signal input error) is displayed.
  • Page 41 IS-800A/1400A (Note) When DELAY START SET is 1 ms or 2 ms The schedule number when the 2ND STAGE signal is received is selected. Therefore, in Fig. (A) above, the schedule number is not selected and the schedule signal input error occurs. When DELAY START SET is 1 ms or 2 ms, input the schedule signal in advance before the 2ND STAGE signal is received.
  • Page 42 IS-800A/1400A 3) MAINTAINED If the 2ND STAGE signal stops halfway through the welding sequence (from the beginning of initial squeeze delay time through the end of hold time), the welding sequence will halt at that point. Note that the END signal depends on the END SIGNAL MODE setting. A: DELAY START SET 2ND STAGE Schedule selection...
  • Page 43 IS-800A/1400A In 4) and 5), up to 255 schedules can be used by combining schedule signals SCH1/2/4/8/16/32/64/128 in binary. In Fig. B: Binary start, schedule No. 13 is selected since signals SCH1/4/8 are determined. In 6) and 7), a schedule of the smallest number among input schedule signals SCH1/2/4/8/16/32/64/128 can be used.
  • Page 44 IS-800A/1400A when the sequence is interrupted by START SIGNAL MODE (MAINTAINED). * There is no distinction between ERROR and CAUTION. END signal output Count-related Upper/lower Other errors Stopped halfway SIGNAL Normal error limit error at welding (MAINTAINED) MODE Output Output Output No output No output...
  • Page 45 IS-800A/1400A Note 1: Schedule Nos. and Schedule Selection Pins ●: Closed Blank: Open SCHEDULE# SCH 1 SCH 2 SCH 4 SCH 8 SCH16 SCH32 SCH64 SCH128 PARITY ● ● ● ● ● ● ● ● ● ● ● ● ● ●...
  • Page 46 IS-800A/1400A Note 2: Current shutoff function The current shutoff function shuts off current when the proper weld penetration is achieved—for example, during fusing—thus preventing excessive penetration. (Refer to figure below.) With the Power Supply connected our weld checker, set the displacement in advance.
  • Page 47 IS-800A/1400A The WE3 STOP signal shuts off current immediately when input during the WE3 period, switching the sequence to HOLD. The WE3 STOP signal shuts off current immediately after the WE3 starts (the current is supplied for about 1 cycle) when input before the WE3 period, switching the sequence to HOLD. When the welding stop signal is input before the start signal is received, the welding stop error occurs.
  • Page 48 IS-800A/1400A (i) FLOW SWITCH/PRG PROTECT Set external input pin 21. When FLOW SWITCH is selected Flow switch input pin. Opening this pin will result in a flow rate error. When PRG PROTECT is selected Program inhibit input pin. Closing this pin will not allow you to change the settings.
  • Page 49 IS-800A/1400A (m) VALVE MODE Select the output method (1 VALVE or 2 VALVE) of the solenoid valve signal. When 1 VALVE is selected When the 1ST STAGE signal is input, the valve signal (SOL1 or SOL2) with the selected schedule number is output and the sequence waits for the 2ND STAGE signal input.
  • Page 50 IS-800A/1400A after SQD. After SQD and SQZ, the sequence waits for the 2ND STAGE signal input. Next, when the 2ND STAGE signal is input, the welding sequence after WELD1 starts. The STEPPER (step-up (-down) operation) is operated with the specified valve 1ST STAGE 2ND STAGE Schedule selection...
  • Page 51 IS-800A/1400A RE-WELD Timing Chart DELAY START SET time 2ND STAGE WELD1 COOL1 WELD2 COOL2 WELD3 HOLD 2nd supply of welding current 200ms (fixed at 200 ms) Valve output Welding current HEAT1 HEAT2 HEAT3 higher higher higher than than than HEAT1 HEAT2 HEAT3 (p) COUNTER...
  • Page 52 IS-800A/1400A WORK: If the judgment is GOOD in current-supplied monitoring or CAUTION is set to output when upper/lower limit monitor is outside the range, the count value is incremented. When the preset count is “0”, the count value is not incremented. Judgment Counting Manner WELD Counter is incremented.
  • Page 53 IS-800A/1400A (10) MONITOR MODE Screen (Note) This screen shows initial settings. The display changes depending on the setting of WELD2 STOP/WELD COUNT and COUNTER on the MODE SELECT screen. (a) PRESET TOTAL COUNT The display changes depending on the setting of WELD2 STOP/WELD COUNT and COUNTER on the MODE SELECT screen.
  • Page 54 IS-800A/1400A Example) PRESET COUNT=3 CAUTION GOOD GOOD ERROR GOOD CAUTION GOOD Judgment range Number of welds COUNT UP output COUNTER count value is TOTAL COUNT UP output COUNTER count value is GOOD ERROR output CAUTION output ERROR RESET COUNT RESET (Note) ...
  • Page 55 IS-800A/1400A PRESET WELD COUNT=3 PRESET WORK COUNT=2 CAUTION CAUTION CAUTION CAUTION ERROR GOOD GOOD GOOD GOOD GOOD GOOD CAUTION GOOD Judgment range Number of welds COUNT UP output WELD count value WORK count value ERROR output CAUTION output ERROR RESET COUNT RESET (Note)
  • Page 56 IS-800A/1400A external weld count signal is input is smaller than the value set for PRESET COUNT (weld count signal is turned off before the number of welds set for PRESET COUNT is not deposited). (Refer to figure below.) For example, if you set the number of welds to 5 from the programmable logic controller, select “5”...
  • Page 57 IS-800A/1400A (e) MONITOR FIRST TIME Use this setting to specify the start time to measure the monitored value (current, voltage, power, pulse width). The start time can be set in a range from 1 to 15 ms. Use this setting to exclude the initial rise of current from measurement. The monitored value will not be displayed if the weld time is shorter than MONITOR FIRST TIME.
  • Page 58 IS-800A/1400A  When the welding stop signal is input after WELD STOP OFF TIME The welding is stopped when the welding stop signal is input. Welding stop signal input WELD STOP OFF TIME Set value 4. How to Operate Screens 4-43...
  • Page 59 IS-800A/1400A (11) STEPPER COUNT Screen The Power Supply can change the level of the welding current depending on the welding conditions. The function to increase the welding current is called the “step-up” function, and that to decrease the welding current is called the “step-down”...
  • Page 60 IS-800A/1400A  LINEAR Current Set value of STEP5 Set value of STEP4 Set value of STEP3 Set value of STEP2 Set value of STEP1 (100%FIXED) Number of welds STEP1 STEP2 STEP3 STEP4 STEP5 As shown in the above figure, the current is stepped up or down to the value for STEP2 with the specified number of welds for STEP2 following completion of the specified number of welds for STEP1.
  • Page 61 IS-800A/1400A (12) PRECHECK Screen Screen for setting the weld time and pulse width for resistance precheck welding. The resistance precheck welding is a function to apply a small current under constant-voltage control before regular welding to confirm that the part to weld is set correctly by means of the measured current and voltage values.
  • Page 62 IS-800A/1400A (13) I/O CHECK Screen This screen is used to check the status of the external I/O signals. The “*” symbol appears when the corresponding input signal is ON. The asterisk disappears if the signal is OFF. Set the cursor reading to “0” to turn OFF the output signal, and “1” to turn it ON.
  • Page 63 IS-800A/1400A (14) RESET TO DEFAULT Screen This screen is used to initialize the Power Supply’s memory (i.e., to restore the initial settings). Initialization will not clear the memory of MA-660A. To initialize, move the cursor ( ) over YES or NO and press the ENTER key. Initializes the Power Supply memory (restores the initial settings).
  • Page 64 IS-800A/1400A (15) PROGRAM PROTECT MODE Screen When this function is used, set values cannot be changed by any person other than the supervisor. PROGRAM PROTECT is usually set to OFF. When it is set to ON, set values cannot be changed until PROGRAM PROTECT is set to OFF again. Follow the procedure below to change the setting of PROGRAM PROTECT.
  • Page 65 IS-800A/1400A <When PROGRAM PROTECT is ON> 4. How to Operate Screens 4-50...
  • Page 66 IS-800A/1400A 5. Connection Procedures (1) Basic Configuration IS-800A IS-800A CONTROL SIG S C H2 S C H4 S C H8 S C H1 6 S C H3 2 S C H6 4 SC H 12 8 WE 1 S T O P / P AR I T Y WE 2 S T O P /W E LDCO U N T...
  • Page 67 IS-800A/1400A IS-1400A Welding head Valve signal wire Welding transformer Secondary conductor Voltage detecting cable Toroidal coil Output cable IS-1400A (3-core: U,V,PE) Noise filter (See (5)) MA-660A To PE O UTP UT Earth leakage breaker Circuit cable INPUT AC380V ～ AC480V LB 1 1 6 0 7 8 6 Start signal wire Power cable...
  • Page 68 IS-800A/1400A WARNING Be sure to ground the equipment. Be sure to install the terminal cover after wiring. Be sure to install an earth leakage breaker on electricity input part to protect from an over current and electric leak. (See (2) Earth Leakage Breaker.) 5.
  • Page 69 IS-800A/1400A (2) Earth Leakage Breaker Breaker rated current Calculate the average Input current using output current (momentary maximum current) and duty cycle: α Average input current = I x 0.817 x I : Output current (momentary maximum current) of IS-800A/1400A α...
  • Page 70 IS-800A/1400A (3) Connection Method IS-800A Cooling water pipe connector WATER IN WATER IN WATER OUT WATER OUT To inlet To outlet  Connecting a hose (See figure above) Connect a hose to the Cooling water pipe connector on the rear. ・...
  • Page 71 IS-800A/1400A IS-1400A Cooling water pipe connector WATER IN WATER OUT To outlet To inlet  Removing the closure plate on the rear Connect a hose to the grommet on the closure plate.  Connecting a hose to the internal connector (See figure above) Connect a hose to the Cooling water pipe connector located on the inside of the closure plate.
  • Page 72 IS-800A/1400A (4) Input/Output Cable An input/output cable is determined by the average input current and the average output current. Calculate the average input current and the average output current using output current (momentary maximum current) and duty cycle. α Average input current = I x 0.817 x α...
  • Page 73 IS-800A/1400A (5) Noise Filter  Connection 1m max. Earth leakage Noise filter IS-800A/1400A breaker (IN) (OUT)  Caution  Singly connect the protective earth terminal ( ) of the noise filter to the ground.  Keep the input-side cable of the noise filter away from the output-side cable of that.
  • Page 74 IS-800A/1400A 6. Interface (1) Connection Diagram for External Input/Output Signals CAUTION Use the shielded cable for the external input/output signals and connect the shielded part to the ground. 24V DC INT.24V EXT.COM STOP SCH 1 SCH 2 SCH 4 SCH 8 SCH16 SCH32 SCH64...
  • Page 75 IS-800A/1400A NG1(ERROR) NG2(CAUTION) OUT1 OUT2 OUT3 OUT4 OUT5 OUT COM SOL POWER SOL COM SOL 1 SOL 2 VOLT SENS Specifications of Terminal Strip for External Input/Output Signals Crimp-on terminals allowed to be 2 pieces max. installed per a terminal Size of crimp-on terminal M3 or M3.5 (7.1 mm wide) 0.75 mm...
  • Page 76 IS-800A/1400A (2) Description of External I/O Signals Pin No. Name Description 24 V DC present. When using a contact, open collector (sink type), or PLC (programmable logic controller) as an input signal (e.g., for startup or schedule selection), connect pins 1 and 2. (Max. INT.24V load: 0.4 A) Note: Do not use pin 1 unless connecting it to pin 2 or 3, or...
  • Page 77 IS-800A/1400A Pin No. Name Description WE2 stop input or Weld count input pin. Switch between functions via the settings described in 4. (9) (g) WELD2 STOP/WELD COUNT. When WE2 STOP is selected Closing this pin during the WELD2 sequence will switch the sequence to COOL2.
  • Page 78 IS-800A/1400A Pin No. Name Description Flow switch input or Program inhibit input pin. Switch between functions via the settings described in 4. (9) (i) FLOW SWITCH/PRG PROTECT. When FLOW SWITCH is selected Flow switch input pin. Opening this pin will result in a flow rate error.
  • Page 79 IS-800A/1400A Pin No. Name Description Error signal output pin. This signal is output in the event of an operational error. For TIME-OVER, CURRENT-OVER, VOLTAGE-OVER, POWER-OVER, PULSE-OVER, WORK-OVER, DISPL-OVER, NO CURR/NO VOLT and WORK ERROR, you can select which signal to output, NG1 (ERROR) or (NG2 (CAUTION). (Refer to 4.
  • Page 80 IS-800A/1400A Pin No. Name Description Solenoid valve output pins. 36: SOL1; 37: SOL2 Switch between functions via the settings described in 4. (9) (m) VALVE MODE. When 1VALVE is selected When the 1ST STAGE is input, the selected valve No. (SOL1 or SOL2) is closed and output until HOLD, or when the 2ND STAGE is input, the selected valve No.
  • Page 81 IS-800A/1400A *2 When using 24 V DC solenoid, install diodes on measures to prevent surge voltage. Example) When inputting + to Pin 34 and – to Pin 35. ＋ － ＋ － *3 When solenoid valves are activated by the use of an internal power supply INT.24V SOL POWER SOL COM (connect together)
  • Page 82 IS-800A/1400A (3) List of External Output Signals The following signals can be assigned to output pins 28 to 32 (OUT1 to 5) on the OUTPUT SELECT screen. (See 4.(7).) Name Description Closed each time the sequence is complete and output the END signal.
  • Page 83 IS-800A/1400A (4) Connection of Input Signals The input signal current for all input terminals is 2.4 mA/24 V DC. Connection with equipment having a contact input  Connect pins 1 and 2. (Internal) (External) Internal power supply Connection with equipment featuring NPN open collector output (when using ...
  • Page 84 IS-800A/1400A Connection with equipment featuring PNP current output (when using external  power supply) Connect the negative side of an external 24 V DC power supply to pin 2. (Internal) (External) Internal power supply Connection with equipment featuring NPN open collector output (when using ...
  • Page 85 IS-800A/1400A 7. Basic Operation Supplying the Cooling Water  Supply cooling water at a temperature below 35°C at the rate of at least 2 liters/minute. Turning on the Welding Power  Turn on the welding power. The WELD POWER lamp lights up, and the READY lamp blinks (IS-800A: for 15 seconds, IS-1400A: for 20 seconds), then goes off.
  • Page 86 IS-800A/1400A 8. Timing Chart (1) Basic Sequence A: DELAY START SET (Note 1) 2ND STAGE WELD1 COOL1 WELD2 COOL2 WELD3 HOLD SOL1/SOL2 (Note 2) (Note 2) GOOD (Note 3) (Note 3) OUT I OUT II WELD SIGNAL Welding current PRECHECK HEAT1 HEAT2 HEAT3 PRECHECK HEAT1...
  • Page 87 IS-800A/1400A A: DELAY START SET setting + Welding preparation time The welding preparation time changes depending on the WELD TRANS FREQ (frequency) setting. Frequency Welding preparation time Frequency Welding preparation time [Hz] [ms] [Hz] [ms] 1000 to 1200 1300 to 1600 1700 to 2400 2500 to 3000 B: END SIGNAL TIME setting...
  • Page 88 IS-800A/1400A (2) Detailed Description of Welding Current and Sequence in the Event of an Error  When monitored value judgment caution/error occurs A sample weld sequence is shown, which represents the occasion where CAUTION or ERROR is produced when a monitored value goes out of the range between the upper and lower limit set in the MONITOR SET screen.
  • Page 89 IS-800A/1400A  When the step end occurs A sample weld sequence is shown, which represents the occasion where the step is complete in the step-up (-down) function set on the MODE SELECT screen and the STEPPER COUNT screen. 2ND STAGE WELD1 WELD2 WELD3...
  • Page 90 IS-800A/1400A (3) Sequence at PULSATION Setting Operation is repeated in WELD and INT set times. 2ND STAGE (Note 1) WELD1 INT1 COOL1 (Note 2) WELD2 INT2 COOL2 (Note 3) WELD3 INT3 HOLD SOL1/SOL2 OUT I OUT II WELD SIGNAL Welding current HEAT1 HEAT1 HEAT2...
  • Page 91 IS-800A/1400A (4) Sequence at 2-Stage Start Operation  When VALVE MODE is 1 VALVE (See 4. (9) (m).) When the 1ST STAGE is input, the solenoid valve output (SOL1 or SOL2) is turned ON and goes in to the standby state of the 2ND STAGE input. When the 2ND STAGE is input, welding sequence starts.
  • Page 92 IS-800A/1400A  When VALVE MODE is 2 VALVE (See 4. (9) (m).) The solenoid valve output (SOL1) is turned ON when the 1ST STAGE is input, the solenoid valve output (SOL2) is turned ON after SQD, and then the sequence goes in to the standby state of the 2ND STAGE input.
  • Page 93 IS-800A/1400A 9. External Communication Function (1) Introduction IS-800A/1400A can be used to set schedules from an externally-connected personal computer (abbreviated as PC) or to read monitored data and several kind of status data. Prepare the program and its development environment for controlling the Power Supply on the customer side.
  • Page 94 IS-800A/1400A (3) Configuration  RS-485 Host computer Device No.01 Device No.02 Device No.31 RS-232C RS-485 … … RS-232C/RS-485 Conversion Adapter 31 Devices Max. (Note 1) When controlling two or more devices with one host computer, register the device No. (CONTROL#) for each device. Set the device No. at POWER SUPPLY STATE screen (See 4.(2)(b)).
  • Page 95 IS-800A/1400A (4) Protocol  Single-directional Communication Mode (When --> is selected at COMM CONTROL in MODE SELECT screen) 1) Monitor Data Data strings: !01001:m,120,1.20,0.50,00.60,20.0,200,2.00,1.50,03.00,40.0, A B C D 300,2.50,2.00,05.00,50.0,2,0010,5,0100,2222,555555[CR][LF] Device No. Fixed to 2 digits (01 to 31) Schedule No. Fixed to 3 digits (001 to 255) m: ms Unit of monitor time...
  • Page 96 IS-800A/1400A 2) Error Data Data strings: !01001:E03,04,12,15,17,19,22,26[CR][LF] C D E F G H I Device No. Fixed to 2 digits (01 to 31) Schedule No. Fixed to 3 digits (000 to 255) Error code 1 Fixed to 3 digits (E01 to E32) Error code 2 Fixed to 2 digits (01 to 32) Error code 3...
  • Page 97 IS-800A/1400A  Bi-directional Communication Mode (When <--> is selected at COMM CONTROL in MODE SELECT screen) Reading of Trouble Code: # Device No. R Schedule No. S Screen No. * Example: Read all troubled data in the specified device, No. 01. (Schedule No. is “008”...
  • Page 98 IS-800A/1400A Reading of Data Code: # Device No. R Schedule No. S Screen No. * Example: Read data for a schedule of Screen No. “01” of Schedule No. “008” of the specified device No. 01. Host 0 1 0 0 8 0 1 : 0 0 8 Data...
  • Page 99 IS-800A/1400A (5) Data Code Table  Screen 01 (SCHEDULE data) Specific data in accordance with Schedule No. (Schedule No.: 001 to 255) Example of data writing: #01W001S01:1,1,1,m,0000,0000,000,000,000,0000,000,000,000,0000,000,000,000,000 00,0000,2,01.0,01.0,01.0,01.0,01.0,01.0,01.0,01.0,01.0,01,000,01,000,01,000,1000,01, 1,001.0,0,000,99.9,99.9,99.9,20,1[CR][LF] Character Item Contents Range String 0: Primary constant-current effective value control Control mode of WELD1 1: Secondary constant-current effective value control...
  • Page 100 IS-800A/1400A Character Item Contents Range String nnn.n, UF1 / Initial heat 1 of upslope nn.n, n.nn, nnn.n, HEAT1 / Heat 1 nn.n, n.nn, CTRL: PRI, SCD, PLM nnn.n, 0.05 to 05.00 (kA) 5 kA range 0.50 to 09.99 (kA) 10 kA range DL1 / End heat 1 of downslope nn.n, 01.0 to 020.0 (kA) 20 kA range...
  • Page 101 IS-800A/1400A *1 The setting of ms/CYC cannot be changed. You can change it via Screen 05 (SYSTEM data). *2 IS-1400A only *3 Only when the control mode is set to the primary constant-current peak value control. For other modes, set to 99.9. ...
  • Page 102 IS-800A/1400A Character Item Contents Range String n.nn, 0.00 to 9.99 (kA) CURRENT L of WE3 (lower limit) nn.n, 00.0 to 99.9 (kA) VOLT H of WE3 (upper limit) n.nn, 0.00 to 9.99 (V) VOLT L of WE3 (lower limit) n.nn, 0.00 to 9.99 (V) nn.nn, 00.00 to 99.99 (kW)
  • Page 103 IS-800A/1400A  Screen 03 (STEPPER data) Common data (Schedule No.: 000) Example of data writing: #01W000S03:1,0000,0000,100,0000,100,0000,100,0000,100,0000,100,0000,100,0000, 100,0000,100,1,0000,0000,100,0000,100,0000,100,0000,100,0000,100,0000,100,0000, 100,0000,100[CR][LF] Character Item Contents Range String START ON STEP # of VALVE1 1 to 9 STEP1 COUNT of VALVE1 nnnn, 0000 to 9999 STEP2 COUNT of VALVE1 nnnn, 0000 to 9999...
  • Page 104 IS-800A/1400A  Screen 04 (MONITOR data) (Data reading only) Specific data in accordance with Schedule No. (Schedule No.: 001 to 255) Character Item Contents Range String Unit of time m: ms C: CYC 000 to 999 (ms mode) TIME of WELD1 nnn, 000 to 050 (CYC mode) n.nn,...
  • Page 105 IS-800A/1400A  Screen 05 (PRECHECK data) Specific data in accordance with Schedule No. (Schedule No.: 001 to 255) Example of data writing: #01W001S05:000,10.0,00.00,00.00[CR][LF] Character Item Contents Range String PRECHECK TIME nnn, 000 to 100 (ms) PRECHECK HEAT nn.n, 10.0 to 99.9 (%) PRECHECK RESISTANCE HIGH nn.nn, 00.00 to 99.99 (mΩ)
  • Page 106 IS-800A/1400A  Screen 06 (SYSTEM data) Common data (Schedule No.: 000) Example of data writing: #01W000S06:20,0,200,0,0,0,0,0,0,0,0,0,0,000000,0000,000000,0000,50,0.00,0.00,15,0, 000,000,000,0,1,1,1,1,1,0,0,0,1,2014,02,27,0,0,0,0,1,2,3,4,1.0[CR][LF] Character Item Contents Range String POWER SOURCE FREQUENCY 50 or 60 (Hz) IS-800A␣ or IS1400A␣ Model name nnnnnnnn, ( ␣ indicates space) ROM VERSION Vnn-nnn, V00-00A to DELAY START SET...
  • Page 107 IS-800A/1400A Character Item Contents Range String TIME-OVER of NG SIGNAL 0: ERROR 1: CAUTION SELECT CURR-OVER of NG SIGNAL 0: ERROR 1: CAUTION SELECT VOLT-OVER of NG SIGNAL 0: ERROR 1: CAUTION SELECT POWER-OVER of NG SIGNAL 0: ERROR 1: CAUTION SELECT PULSE-OVER of NG SIGNAL 0: ERROR 1: CAUTION...
  • Page 108 IS-800A/1400A  Screen 07 (Error data) Common data (Schedule No.: 000)  Error data confirmation (Data reading only) Character Item Contents Range String Error code 1 nnn, E01 to E32 Error code 2 01 to 32 Error code 3 01 to 32 Error code 4 01 to 32 Error code 5...
  • Page 109 IS-800A/1400A 10. Specifications (1) Specifications *: selectable for every 255 schedules IS-800A IS-800A IS-1400A IS-1400A Model No. -10-10/-10-12 -10-11/-10-13 -10-10/-10-12 -10-11/-10-13 3-phase, 3-phase, 3-phase, 3-phase, 380–480 V 200–240 V 380–480 V AC 200–240 V AC ±10% AC ±10% ±10% (50/60 AC ±10% Welding power (50/60 Hz)
  • Page 110 IS-800A/1400A IS-800A IS-800A IS-1400A IS-1400A Model No. -10-10/-10-12 -10-11/-10-13 -10-10/-10-12 -10-11/-10-13 04.0–80.0 kA 80 kA range 02.0–40.0 kA 02.0–40.0 kA 40 kA range Constant current 01.0–20.0 kA 01.0–20.0 kA 20 kA range control (Note 2) 0.50–9.99 kA 0.50–9.99 kA 10 kA range 0.05–5.00 kA 0.05–5.00 kA 5 kA range...
  • Page 111 IS-800A/1400A IS-800A IS-800A IS-1400A IS-1400A Model No. -10-10/-10-12 -10-11/-10-13 -10-10/-10-12 -10-11/-10-13 Overcurrent 200 A Fuse 200 A Fuse (per unit) Power is turned off in the following cases: a. When a secondary current is not detected in Secondary constant-current effective value control, Secondary constant-power effective value control, or Constant-phase No-current control.
  • Page 112 IS-800A/1400A (3) Duty Cycle Graph IS-800A Ambient temperature: 40°C Ambient temperature: 25°C 10.5% 100% Duty cycle [%] * IS-1400A Ambient temperature: 40°C Ambient temperature: 25°C 100% Duty cycle [%] * * This duty cycle graph is applied when the frequency is set to 1 kHz. Decrease the duty cycle by 0.5% (from the above graph) for each additional 100 Hz of frequency.
  • Page 113 IS-800A/1400A (4) Weld Time Limit Use the Power Supply with the weld time calculated with the following formula or less for the primary current.  IS-800A: For 600 A or more of the primary current Maximum weld time [ms] = -4× (IGBT primary current value) + 3400 ...
  • Page 114 IS-800A/1400A (5) Board and Component List for Maintenance For repair or replacement, contact us. Model IS-800A IS-1400A Item Main control board ME-3120-02S1 Drive board AS1162201 Snubber board AS1162200 Display board ME-1662-02 Fan motor assembly AS1157254 AS1157277 (6) Major Components List Q’ty Item IS-800A...
  • Page 115 IS-800A/1400A (7) Schematic IS-800A IGBT IGBT DIODE Ｌ１ Ｌ２ Ｌ３ ＰＥ TH(IGBT) POWER P.C.B. TH(SAFETY) CONTROL P.C.B. 10. Specifications 10-7...
  • Page 116 IS-800A/1400A IS-1400A IGBT IGBT DIODE Ｌ１ Ｌ２ Ｌ３ ＰＥ TH(IGBT) IGBT IGBT DIODE POWER P.C.B. TH(SAFETY) CONTROL P.C.B. 10. Specifications 10-8...
  • Page 117 IS-800A/1400A 11. Outline Drawing (1) IS-800A (Dimensions in mm) 331.5 WELD RESET WELD POWER READY START WELD TROUBLE ON/OFF 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...
  • Page 118 IS-800A/1400A (2) IS-1400A (Dimensions in mm) 331.5 WELD RESET WELD POWER READY START WELD TROUBLE ON/OFF 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...
  • Page 119 IS-800A/1400A 12. Troubleshooting (1) Fault Code List In the event of a problem with the Power Supply, the MA-660A displays the fault code and message. In such cases, read this section carefully, then inspect the equipment and take the necessary countermeasures. If you have any questions, consult us or your distributor.
  • Page 120 IS-800A/1400A Fault Contents Cause Measures code Set a lower NO CURRENT LEVEL. NO CURRENT LEVEL is high. (See 4. (10)(c).) The fuse needs replacement. E-07 NO CURRENT Fuse inside the equipment is blown. Contact us. Connect toroidal coil, referring to 5. Toroidal coil is not connected.
  • Page 121 IS-800A/1400A Fault Contents Cause Measures code Check for welding transformer and welding electrode problems. OVER Primary current above the limit is E-13 Check that the toroidal coil or the CURRENT detected. voltage detecting cable is connected in the secondary control. The output cable between the SHORT WITH E-14...
  • Page 122 IS-800A/1400A Fault Contents Cause Measures code OUT LIMIT OF Weld time is out of TIME setting Check the welding stop input of the E-31 TIME ERROR range on the MONITOR SET screen. external interface. When writing data in bi-directional communication mode at external COMM SETTING E-32 communication, data which is out of...
  • Page 123 IS-800A/1400A (2) When the Welding Does not Start Even if the Start Signal is Input When the welding does not start even if the Start signal (2ND STAGE signal) is input, the following causes can be thought. • READY does not light up. •...
  • Page 124 IS-800A/1400A (Note 3) When the MONITOR screen is displayed, the monitor data is transferred to MA-660A simultaneously with the END signal output (transmission time Tb1). The monitor data is not transferred when the screen other than MONITOR screen is displayed. The next Start signal is not received while the monitor data is transferred.
  • Page 125 IS-800A/1400A 13. Schedule Data Table Setting screen Setting item Initial value Setting POWER SUPPLY CONTRAST STATE screen CONTROL# PROGRAMED DATE LANGUAGE ENGLISH Setting screen Setting item Initial value SCHEDULE(1) 0000ms screen 0000ms COOL1 0000ms COOL2 0000ms HOLD 00000ms 0000ms 000ms WELD1 000ms DOWN1...
  • Page 126 IS-800A/1400A Setting screen Setting item Initial value SCHEDULE(2) PULSE LIMIT1 00.0% screen PULSE LIMIT2 00.0% PULSE LIMIT3 00.0% PULSATION1 PULSATION2 PULSATION3 INTERVAL1 000ms INTERVAL2 000ms INTERVAL3 000ms WELD TRANS 1000Hz FREQ VALVE # CURRENT RANGE 20kA MAX CURRENT 20kA VOLT 000% COMPENSATION GAIN...
  • Page 127 IS-800A/1400A Setting screen Setting item Initial value Setting NG SIGNAL ERROR OUTPUT SELECT screen MODE TIME-OVER CAUTION CURRENT-OVER CAUTION VOLTAGE-OVER CAUTION POWER-OVER CAUTION PULSE-OVER CAUTION NO CURR ERROR WORK ERROR ERROR Setting screen Setting item Initial value Setting OUTPUT SELECT OUTPUT 1 screen OUTPUT 2...
  • Page 128 IS-800A/1400A Setting screen Setting item Initial value Setting MONITOR MODE PRESET TOTAL COUNT 000000 screen PRESET GOOD COUNT PRESET WELD COUNT PRESET WORK COUNT WELD COUNT NO CURRENT TIME 50ms NO CURRENT LEVEL 0.20kA NO VOLTAGE LEVEL 0.10V MONITOR FIRST TIME 15ms MONITOR SLOPE MODE EXCLUDE...
  • Page 129 IS-800A/1400A Index Accessory ............10-3 Options ..............10-3 Outline Drawing ............ 11-1 OUTPUT SELECT Screen........4-22 COIL IN connector ..........3-4 Control method ............4-8 COPY SETUP DATA Screen ........ 4-23 POWER SUPPLY STATE Screen ......4-2 PRECHECK Screen ..........4-46 PROGRAM MONITOR I/O connector .....3-4 PROGRAM PROTECT MODE Screen ....

This manual is also suitable for:

Is-1400a-10 series