Inverter Power Source ISQ20 Series · Inverter Power Source ISQ20 Series OPERATING INSTRUCTIONS ....

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


ISQ20-8-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


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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.


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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.


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2.1 Device Types

The ISQ20 is available in the following DC- and AC types:

DC device with internal transformer:


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.


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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


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Supply voltage 3x 400 VAC, ±10%, PE


Connecting cable 4 x 2.5 mm²



Rated output current 3 kA at 20 % d.r. measured for Tu = 20 °C





Switching frequency 14 kHz

Output frequency 28 kHz




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)


Weight ca. 43 kg


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with IT-60X transformer:

Supply voltage 3 x 400 VAC, ±10 %, PE


Connecting cable 4 x 6 mm²



Rated output current dep. on transformer measured for Tu = 20 °C





Switching frequency 1-5 kHz (dependent on primary current)

Output frequency 2-10 kHz




Cooling forced ventilation, temperature controlled; transformer water cooled

Secondary connections dep. on transformer

Current measurement external measuring coil

Dimensions inverter (W x H x D)


Dimensions transformer(W x H x D)

284 x 110 x 170

Weight inverter ca. 21 kg, transformer ca. 60 kg


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with IT-113X transformer:






Rated output current dep. on transformer measured for Tu = 20 °C





Switching frequency 1-5 kHz





Cooling inverter and transformer: water cooled






420 x 125 x 230 mm

Dimensions line filter (W x H x D)


Weight inverter ca. 32 kg, transformer ca. 25.5 kg line filter ca. 19 kg


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2.1.5 Technical Data ISQ20-8-AC

with TRM3/14 transformer:




Connected load dependent on main stage

Fuse recommended dependent on main stage

Rated output current dep. on transformer

Max. output current dep. on transformer

Min. terminal voltage dep. on transformer with 400 V rated mains voltage at the unit input

Max. open circuit voltage dep. on transformer


Switching frequency 1-10 kHz





Cooling forced ventilated, temperature controlled; transformer water cooled






360 x 150 x 185 mm

Weight inverter ca. 21 kg, transformer ca. 45 kg


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2.2 Operation

The operation of the ISQ20 is made with one of the following operating terminals:

OP-AWS3: TP-AWS3: MFT1:

AWS3 operating terminal with toggle wheel AWS3 operating terminal with touch panel Operating terminal with buttons

Find more information regarding the operating terminals in the respective operating instruction.

2.3 Displacement Sensor (optional, only usable with OP-AWS3/TP-AWS3)

Dependent on used weld head.

Article no. Name

770.66 186 Displacement sensor ST1278

770.66 318 Displacement sensor ST3078

770.66 263 Displacement sensor MT1271

770.66 317 Displacement sensor MT2571

Digital (5V/TTL)

Resolution: 0.1 μm / 1 μm / 2 μm

Digital double sampling

2.4 Pressure/Force Measuring (optional, only usable with OP-AWS3/TP-AWS3)

Dependent on used weld head.

0 – 10 V calibration

Voltage detection set values: potential free, connection external X7 / X9

Information regarding necessary measuring parts on request.

2.5 Sound Pressure Level

The equivalent continuous sound pressure level evaluated as A is below 70 dB.


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2.6 Maximum Duty Ratio

Duty ratio (d.r.) relative to the set welding current:

Fig. 2: Maximum duty ratio

For ISQ20 with external transformer (ISQ20-8, ISQ20-10 and ISQ20-20) the duty ratio is dependent on the used transformer.

See transformer data sheet for the respective characteristic line.

0

10

20

30

40

50

60

0 0,5 1 1,5 2 2,5 3 3,5

ED

in

%

I in kA

ISQ20-3

ED…

0

10

20

30

40

50

60

0 2 4 6 8

ED

in

%

I in kA

ISQ20-6

ED…

ISQ20 Design and Mode of Action

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3 Design and Mode of Action

3.1 Front Panel ISQ20

Main switch

Status display and error messages

RS232

Fig. 3 Front panel

On the front panel you find:

the main switch

the RS232 interface

the display for status and error messages

Status display:

1 2 3

STATUS

4 5 6

Abb. 4 Display

7

1 LED green

Ready 4 LED red Quick-Stop

2 LED green

Pressure contact (DK)

5 LED red Out of Limits

3 LED green

Stepping contact (FK)

6 LED red Sequence error

7 Status messages

00 Ready Operating voltage is present, system is OK, intermediate circuit is not charged

01 Converter ON Intermediate circuit successfully charged. Unit is ready for operation.

02 Controller free

03 Welding program running

04 Reference run active


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3.2 Rear Panel ISQ20-3 / ISQ20-6

X13 S3 X14

X1 X2

X3 X4 X12

S1 S2

X6 X7 X8 X9

X10 X11

X5

XN

Abb. 5: Rear panel ISQ20-3 / ISQ20-6

+

-


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3.3 Rear Panel ISQ20-8 / ISQ20-10

X13 S3 X14

X1 X2

X3 X4 X12

S1 S2

X6 X7 X8 X9

X10 X11

X5

X32

X31 3 4 5 6

1 2 PE

X30

XN

Abb. 6: Rear panel ISQ20-8 / ISQ20-10


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3.4 Rear Panel ISQ20-20

X13 S3 X14

X1 X2

X3 X4 X12

S1 S2

X6 X7 X8 X9

X31 X32 X10 X11

X5

U L1

V L2

X30 L3

PE

IN OUT

Abb. 7: Rear panel ISQ20-20

XN

ISQ20 Connections

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4 Connections

4.1 Overview

No. Name Description Mode

XN Power connection

X1 Binary inputs BIN IN DSUB 37 pin

X2 Binary outputs BIN OUT DSUB 37 socket

X3 Initiators DIST DSUB 25 socket

X4 Valves RESOLVER DSUB 15 socket

X5 Start START Binder 6+PE socket

X6 Proportional valve head 1 V1 Binder 7-pol. socket

X7 Pressure sensor head 1 PS1 Binder 4-pol. socket

X8 Proportional valve head 2 V2 Binder 7-pol. socket

X9 Pressure sensor head 2 PS2 Binder 4-pol. socket

X10 Voltage measurement 1 U1 Binder 5-pol. socket

X11 Voltage measurement 2 U2 Binder 5-pol. socket

X12 I/O Binary BIN I/O DSUB 15 socket

X13 Displacement sensor DIST DSUB 15 socket

X14 CAN CAN DSUB 9 pin

X20 MFT1-connection (on the front panel behind the cover plate)

MFT1 RJ45 socket

X21 RS232 (on the front panel) RS232 DSUB 9 socket

Additionally for ISQ20-8-AC, ISQ20-10-DC, ISQ20-20-DC:

X30 Welding transformer

X31 Thermo sensor

X32 Current measuring coil

Toggle switches S1, S2, S3:

S1 Changeover GND/proportional valve (connectors X6, X7) ext. (prop): switch to the left

int. (ISQ): switch to the right

S2 Changeover GND/proportional valve (connectors X8, X9)

S3 internal: supply voltage 24 V DC is supplied internally (max. 1.5 A)

external: supply voltage 24 V DC is supplied externally (input: X2 pin 33/34 to GND 35/36).

4.2 RS232 Serial Interface

The RS232 (X21) interface is situated on the front panel. It is used for transmitting data between the ISQ20 and a computer. The necessary cable you can order with order no. 77066028.

The format of the data output can be changed via the operating panel (default format for data output with OP-AWS3/TP-AWS3: AWS3 mode, with MFT1: classic mode).

4.2.1 Data Transfer

After each welding cycle the measuring results are transmitted via the RS232.

ISQ20 Connections

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4.2.2 Data Output Format, AWS3 Mode

Default with OP-AWS3/TP-AWS3

Character string Description Digits

Prg Program number 3

Space 1

AX Axis 1 or axis 2 2

Space 1

Is1_kA Peak current pulse 1 [kA] 6

Space 1

Ie1_kA RMS current pulse 1 [kA] 6

Space 1

Us1_V Peak voltage pulse 1 [V] 6

Space 1

Ue1_V RMS voltage pulse 1 [V] 6

Space 1

P1_kW Peak power pulse 1 [kW] 6

Space 1

W1_Ws Energy pulse 1 [Ws] 7

Space 1

R1_uOhm Resistance 1 [μOhm] 7

Space 1

tw1_ms Welding time pulse 1 [ms] 6

Space 1


Space 1

Ie2_kA RMS current pulse 2 [kA] 6

Space 1


Space 1

Ue2_V RMS voltage pulse 2 [V] 6

Space 1

P2_kW Peak power pulse 2 [kW] 6

Space 1

W2_Ws Energy pulse 2 [Ws] 7

Space 1

R2_uOhm Resistance 2 [μOhm] 7

Space 1

tw2_ms Welding time pulse 2 [ms] 6

Space 1

Count Global welding counter 5

Space 1

G+ Upper limit exceeding max. (ISQ-AWS3) 1 asterisk (*)

Space 1

G- Lower limit exceeding min. (ISQ-AWS3) 1 asterisk (*)

ISQ20 Connections

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4.2.3 Data Output Format, Classic Mode

Default with MFT1.

Classic mode in combination with AWS3 is only recommended, if compatibility with older previous units has to be enabled.

Character string Description Digits

Prg Program number 3

Space 1


Space 1


Space 1

Ps1_kW Peak power pulse 1 [kW] 6

Space 1

Sz1_ms Welding time pulse 1 [ms] 6

Space 1


Space 1


Space 1

Ps2_kW Peak power pulse 2 [kW] 6

Space 1

Sz2_ms Welding time pulse 2 [ms] 6

Space 1

Count Global welding counter 5

Space 2

G+ Upper limit exceeding max. (Out of Limits +) 1 asterisk (*)

G- Lower limit exceeding min. (Out of Limits -) 1 asterisk (*)

Space 2

+ No Out Of Limits (ISQ-AWS3) 1 asterisk (*)

- Out Of Limits (ISQ-AWS3) 1 asterisk (*)

4.2.4 Baud Rate

Pay attention to the baud rate during transmission!

Attention

Adjustable baud rates (bps) 2400, 9600, 38400, 115200

Data bits 8

Start bits 1

Stop bits 1

Parity none

4.2.5 Software Update

A software update can be uploaded via the RS232 interface on the ISQ20 or via the USB interface on the OP-AWS3/TP-AWS3.

ISQ20 Connections

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4.3 Plug Assignments

4.3.1 X1: Binary Inputs, potential free

DSUB 37 - pin

Pin I/O Function Note

X1.1 I01 without current 2.5 mA at 24 V Setup, run without current

X1.2 I02 Reset counter 2.5 mA at 24 V All counters (w/o action counter)

X1.3 I03 Reset Out Of Limits

2.5 mA at 24 V If set, error „Out of Limits“ is deleted.

X1.4 I04 External current break

2.5 mA at 24 V If set, current program is interrupted and jumps to hold time resp. to the end of the current program. (Suitable for realizing variable pulse duration – e.g. dependent on displacement)

X1.5 I05 Reset unit error 2.5 mA at 24 V Reset occurs at open start until unit is ready after about 30 sec.

X1.6 I06 Not defined 2.5 mA at 24 V ---

Enter the number of the desired welding program with pins 7 to 14. This includes BCD 1 (pin 7) of LSB and BCD 80 (pin 14) of MSB.

External program selection BCD coded Binary coded

X1.7 I07 Bit 0 2.5 mA at 24 V Single digit 1 1




X1.11 I11 Bit 4 2.5 mA at 24 V Tens digit 1 16




X1.15 I15 Start head 1+2 min. 35 mA at 24 V

Unit has to be “ready” before start is set (i.e. Quick Stop is set and unit is in a welding menu).

A program has to be selected in case of external program selection (not program “0”).

For a sequential program (e. g. lower stroke cylinder), the cylinder initiators have to be in basic position.

This input is used for automatic sequential run in twin-head mode (parallel with current changeover or consecutive sequence): head 1 –head 2 - FK – end.

Setting this input starts welding.

See also connector X5.

X1.16 I16 Start head 1 min. 35 mA at 24 V

Start signal for head 1 in twin head mode. See also connector X5.

X1.17 I17 Start head 2 min. 35 mA at 24 V

Start signal for head 2 in twin head mode. See also connector X5

X1.18 I18 Ini 1 head 1 back/top

2.5 mA at 24 V Necessary with one stroke cylinder or pincers.

Display shows error if welding head is not back. See also connector X3.1.

ISQ20 Connections

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X1.19 I19 Ini 2 head 2 back/top

2.5 mA at 24 V Necessary with two stroke cylinders or two pincers.

Display shows error, if welding head is not back. See also connector X3.4.

X1.20 I20 Ini 3 stroke 1 ahead/top

2.5 mA at 24 V Necessary with one stroke cylinder.

Display shows error, if welding head is not ahead. See also connector X3.7.

X1.21 I21 Ini 4 stroke 2 ahead/top

2.5 mA at 24 V Necessary with two stroke cylinders.

Display shows error, if welding head is not ahead. See also connector X3.10.

X1.22 I22 Ini 5 stroke 1 back/bottom

2.5 mA at 24 V Necessary with one stroke cylinder or pincers.


X1.23 I23 Ini 6 stroke 2 back/bottom or pincers locked

2.5 mA at 24 V Necessary with two stroke cylinders or two pincers.


X1.24 I24 Pressure switch head 1 or initiator

2.5 mA at 24 V A connected pressure switch signalizes that welding pressure in head 1 has been achieved. The input is queried before the on-time starts. If it is not set at this time, it waits until it is set.

This function can be deactivated in basic settings menu if no pressure switch is provided or if this function is not required.

The unit indicates “error” if the input changes during the welding time to “low” (error 61).

See also connector X3.19.

X1.25 I25 Pressure switch head 2 or initiator

2.5 mA at 24 V A second connected pressure switch signalizes that welding pressure in head 2 has been achieved.

The input is queried before the on-time starts. If it is not set at this time, it waits until it is set.


The unit indicates “error” if the input changes during the welding time to “low” (error 61).

See also connector X3.22.

X1.26 I26 External part detection ok head 1

2.5 mA at 24 V Limits for displacement ok, displacement measuring device has to be connected.

Special case for pneumatic head and activated (internal) displacement measuring: Activation option reference run head 1

ISQ20 Connections

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X1.27 I27 External part detection ok head 2

2.5 mA at 24 V Limits for displacement ok, displacement measuring device has to be connected.

Special case for pneumatic head and activated (internal) displacement measuring: Activation option reference run head 2

X1.28 I28 Thermo switch 2.5 mA at 24 V Error 73: Switches in case of over temperature

X1.29 I29 Mains compressed air

2.5 mA at 24 V Error 74: The mains pressure monitor must output 24 V if there is a pressure drop (“Low“ active)).

X1.30 ENB Enable Input Quick stop safety relay: Operation locked with open input.

A welding program can only run if this input is set.

The welding program is interrupted immediately at 0 V (“Low“ active Stop input, no STOP category 0, i.e. only the valves are currentless).

The input is active in all operating modes.

X1.31 I31 Reset action counter

2.5 mA at 24 V The action counter is reset to the initial program of this sequence.

X1.32 I32 Not defined 2.5 mA at 24 V ---

X1.33 EXT_+24V (output) External supply voltage

X1.34

X1.35 EXT_GND

0V ext. (ref. to 24V) X1.36

X1.37 PE Protective earth

ISQ20 Connections

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4.3.2 X2: Binary Outputs, potential free

DSUB 37 - socket


X2.1 O01 Ready 100 mA at 24 V The ready LED (green) shows whether a welding can be started.

Unit has to be “ready” before start is set (i.e. Quick Stop is not released and unit is in a welding menu).


The cylinder proximity switch has to be in initial position for sequential programs (e. g. lower stroke cylinder, etc.).

X2.2 O02 Locking active 100 mA at 24 V Active during on-time and hold time.

Set during a welding program. It is reset after current program and hold time ended.

X2.3 O03 Stepping contact (FK)

100 mA at 24 V Active after end of hold time.

In case of lower stroke cylinder or pincers not until head and lower stroke cylinder or pincers are in initial position.

The FK remains 10 ms active if the Start is broken (open) before the stepping contact (FK) actuates.

If input Start is still set, this output is only reset in case of falling edge at input Start.

If stepping contact (FK) is set to “forwards” during actual evaluation, the FK remains set until the deviation (out of limits) is evaluated.

X2.4 O04 Welding counter elapsed

100 mA at 24 V Set after a welding when the set number of weldings is reached with this welding.

Reset with the start of the next welding, the internal counter starts to count up again.

X2.5 O05 Out of limits head 1 100 mA at 24 V The actual welding value (depending on the control mode current /voltage / power) is checked for deviations from rated value. If deviation is greater than specified by maximum and minimum value (limits and curves), this output is set.

X2.6 O06 Error message active

100 mA at 24 V For all unit errors #10 - #59

Outputs for controlling the selected program or selection of another unit (e.g. motor head, weld sentry, changeover stage, etc.). BCD1 (pin 7) is LSB and BCD80 (pin 14) is MSB.

Program number BCD coded Binary coded

X2.7 O07 Bit 0 100 mA at 24 V Single digit 1 1




X2.11 O11 Bit 4 100 mA at 24 V Ten digits 1 16




ISQ20 Connections

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X2.15 O15 Valve 1 See also chap. 5.3

+24 V DC switched; 100 mA at 24 V

See also connector X4.1. function depends on control mode

X2.16 O16 Valve 2

X2.17 O17 Valve 3

X2.18 O18 Valve 4

X2.19 O19 Valve 5

X2.20 O20 Out of limits tw, I, U, P Kopf 1

100 mA at 24 V

X2.21 O21 Out of limits tw, I, U, P Kopf 2

100 mA at 24 V

X2.22 O22 Part detection evaluation head 1

100 mA at 24 V Output from start squeeze time to end of hold time. For control mode with adjustment cylinder 50 ms before current 1st head.

Special case for pneumatic head and activated (internal) displacement measuring:

Error part detection head 1

X2.23 O23 Part detection evaluation head 2

100 mA at 24 V Output from start squeeze time to end of hold time. For control mode with adjustment cylinder 50 ms before current 2nd head.

Special case for pneumatic head and activated (internal) displacement measuring:

Error part detection head 2

X2.24 O24 Start displacement head 1

100 mA at 24 V Signal during on-time head 1.

Special case for pneumatic head and activated (internal) displacement measuring: Error displacement head 1

X2.25 O25 Start displacement head 2

100 mA at 24 V Signal during on-time head 2.

Special case for pneumatic head and activated (internal) displacement measuring: Error displacement head 2

X2.26 O26 Counter pre-warning active

100 mA at 24 V A signal occurs if the set value is reached.

X2.27 O27 Action counter complete

100 mA at 24 V Reset to initial program (sequence abort).

ISQ20 Connections

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X2.28 O28 Out of limits head 2 100 mA at 24 V The actual welding value (depending on the control mode current /voltage / power) is checked for deviations from rated value. If deviation is greater than specified by maximum and minimum value (limits and curves), this output is set.

Opposite to X2.5 this output is only available if stepping contact (FK) is active.

It hast to be read out prior to breaking (opening) the Start.

X2.29 O29 Out of limits pulse 1

100 mA at 24 V The actual value of first welding pulse (depending on the control mode current /voltage / power) is checked for deviations from rated value. If deviation is greater than specified by maximum and minimum value, this output is set.

Special case for pneumatic head and activated (internal) pressure/force measuring: Error pressure/force head 1

X2.30 O30 Out of limits pulse 2

100 mA at 24 V The actual value of second welding pulse (depending on the control mode current /voltage / power) is checked for deviations from rated value. If deviation is greater than specified by maximum and minimum value, this output is set.

Special case for pneumatic head and activated (internal) pressure/force measuring: Error pressure/force head 2

X2.31 S3

Open: 24 V external Closed: 24 V internal (max. 1.5 A)

Output power supply; depending on switch position of S3 (see chap. 4.1). X2.32

X2.33 S3

Input power supply; depending on switch position of S3 (see chap. 4.1). X2.34

X2.35 GND

0 V external (refer to 24 V)

Reference ground X2.36


ISQ20 Connections

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4.3.3 X3: Initiators

DSUB 25 - socket


X3.1 I18 INI1: head 1 back/top

24 V at head back

Necessary with one stroke cylinder or pincers.

Display shows error if welding head is not back

X3.2 INI1_+24V Supply voltage +24 V

X3.3 INI1_GND 0 V ext. (ref. to 24 V)

X3.4 I19 INI2: head 2 back/top

24 V at head back

Necessary with two stroke cylinders or two pincers.

Display shows error if welding head is not back.



X3.7 I20 INI3: stroke 1 ahead/top

Necessary with one stroke cylinder.

Display shows error if welding head is not ahead.



X3.10 I21 INI4: stroke 2 ahead/top

Necessary with two stroke cylinders.

Display shows error if welding head is not ahead.



X3.13 I22 INI5: stroke 1 back/bottom

24 V at head back or pincers locked

Necessary with one stroke cylinder or pincers.

Display shows error if welding head is not back



X3.16 I23 INI6: stroke 2 back/bottom

24 V at head back or pincers locked

Necessary with two stroke cylinders or two pincers.

Display shows error if welding head is not back..



X3.19 I24 DS1 Pressure switch 1. Signal

A connected pressure switch signalizes that welding pressure in head 1 has been achieved.

The input is queried before the current time starts. If it is not set at this time, it waits until it is set.


The unit indicates “error” if the input changes to “low” during the welding time (error 61).

ISQ20 Connections

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X3.20 DS1_+24V Supply voltage +24 V

X3.21 DS1_GND 0 V ext. (ref. to 24 V)

X3.22 I25 DS2 Pressure switch 2. Signal

A second connected pressure switch signalizes that welding pressure in head 2 has been achieved.

The input is queried before the current time starts. If it is not set at this time, it waits until it is set.


The unit indicates “error” if the input changes to “low” during the welding time (error 61).

X3.23 DS2_+24V Supply voltage +24 V

X3.24 DS2_GND 0 V ext. (ref. to 24 V)


ISQ20 Connections

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4.3.4 X4: Valves

DSUB 15 - socket


X4.1 O15 VV1 Valve triggering 1 +24 V Function depends on control mode, see chap. 5.3.1

X4.2 VV1_GND 0 V ext. (ref. to 24 V)

X4.3 VV1_PE Protective earth

X4.4 O16 VV2 Valve triggering 2, +24 V Function depends on control mode, see chap. 5.3.1









X4.13 O19 VV5 Valve triggering 5, +24 V The valve output can be chronologically programmed.

On current changeover the valve comes after the first current program and remains until end of second hold time.



4.3.5 X5: Start

Binder 6 + PE - socket


X5.1 +24 V External supply voltage

X5.2 I15 Start head 1+2

min. 35 mA at 24 V Unit has to be “ready” before start is set (i.e. Quick Stop is set and unit is in a welding menu).


For a sequential program (e. g. lower stroke cylinder), the cylinder initiators have to be in basic position.

This input is used for automatic sequential run in twin-head mode (parallel with current changeover or consecutive sequence):

head 1 –head 2 - FK – end.

Setting this input starts welding.

X5.3 I16 Start head 1

min. 35 mA at 24 V Start signal for head 1 in twin head mode.

X5.4 I17 Start head 2

min. 35 mA at 24 V Start signal for head 2 in twin head mode.

X5.5 0 V ext. (ref. to 24 V)

X5.PE PE Protective earth

ISQ20 Connections

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4.3.6 X6: Proportional Valve Head 1

Binder 7 - socket

Pin Function Note

X6.1 PVV_OUT Input actual value 1 From pressure sensor on the welding head (“actual value”) (0..10 V) or from proportional valve “actual value” (no pressure sensor).

If this input is used, the toggle switch S1 must point in the direction of X6.

X6.2 PVV_+24V +24 V continuous voltage

X6.3 PVV_INGND 0 V set value 1

X6.4 PVV_IN 0..10 V (0-10 bar) output set value 1

Control voltage for proportional valve („set value “)

X6.5 PVV_GND 0 V ext. (ref. to 24 V)

X6.6 PVV_+24V +24 V supply voltage; max. 1 A

Voltage only when start on; supply proportional valve

X6.7 frei

4.3.7 X7: Pressure Sensor Head 1

Binder 4 - socket

Pin Function Note

X7.1 PS_+24V +24 V supply voltage Supply pressure sensor

X7.2 PS_GND 0 V ext. (ref. to 24 V)

X7.3 PS_OUT Input actual value 1 From pressure sensor on the welding head (“actual value”) (0..10 V) or from proportional valve “actual value” (no pressure sensor).


X7.4 PS_RESET OPERATE-signal inverted Reset signal force measuring (0 V – Operate, 24 V – Reset)

4.3.8 X8: Proportional Valve Head 2

Binder 7 - socket

Pin Function Note

X8.1 PVV_OUT Input actual value 2 From pressure sensor on the welding head (“actual value”) (0..10 V) or from proportional valve “actual value” (no pressure sensor).


X8.2 frei +24 V continuous voltage

X8.3 PVV_INGND 0 V set value 2

X8.4 PVV_IN 0..10V output set value 2 Control voltage for proportional valve („set value “)

X8.5 PVV_GND 0 V ext. (ref. to 24 V)

X8.6 PVV_+24V +24 V supply voltage max. 1 A

Voltage only when start on; supply proportional valve

X8.7 frei

ISQ20 Connections

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4.3.9 X9: Pressure Sensor Head 2

Binder 4 - socket

Pin Function Note

X9.1 PS_+24V +24 V supply voltage

X9.2 PS_GND 0 V ext. (ref. to 24 V)

X9.3 PS_OUT Input actual value 2 From pressure sensor on the welding head (“actual value”) (0..10 V) or from proportional valve “actual value” (no pressure sensor).


X9.4 PS_RESET OPERATE-signal inverted Reset signal force measuring (0 V – Operate, 24 V – Reset)

4.3.10 X10: Voltage Measurement 1

Binder 5 - socket

Pin Function Note

X10.2 U- Voltage measuring negative electrode

Connect voltage monitor for head 1 to X10. The voltage must be recorded at the electrodes near the deposit. X10.4 U+ Voltage measuring positive

electrode

4.3.11 X11: Voltage Measurement 2

Binder 5 - socket

Pin Function Note

X11.2 U - Voltage measuring negative electrode

Connect voltage monitor for head 2 to X11. The voltage must be recorded at the electrodes near the deposit. X11.4 U + Voltage measuring positive

electrode

4.3.12 X12: Binary I/O

DSUB 15 - pin

Pin I/O Function

X12.1 E16 Start head 1 min. 35 mA at 24 V

X12.2 E17 Start head 2 min. 35 mA at 24 V

X12.3 Enable input Quick stop safety relay (see. X1.30)

X12.4 INT1/1 Current breakdown pulse 1 head 1

X12.5 INT1/2 Current breakdown pulse 2head 1



X12.8 E64 Programmable input*

X12.9 +24V +24 V voltage output

X12.10 GND 0 V ext. (ref. to 24 V)

X12.11 A64 Programmable output* head 1 2.5 mA at 24 V

X12.12 A65 Programmable output * head 2 2.5 mA at 24 V

X12.13 A66 Programmable output * 2.5 mA at 24 V



* E64; A64 – A68 are only programmable with AWS3 system, otherwise A64 head 1 and A65 head 2. In this case A66 – A68 are not connected.

ISQ20 Connections

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4.3.13 X30: Welding Transformer

Terminals

Pin Function

X30.1 + Positive primary voltage

X30.2 - Negative primary voltage

X30.3 PE

4.3.14 X31: Temperature Sensor Transformer

Terminals

Pin Function

X31.3 TH1 Thermo safety plug 1

X31.4 TH2 Thermo safety plug 2

4.3.15 X32: Current Measuring Coil

Terminals

Pin Function

X32.1 Current measuring contact 1

X32.2 Current measuring contact 2

ISQ20 Commissioning

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5 Commissioning

5.1 Preconditions for Commissioning Stand-alone devices have to be placed firmly and stable on a table or a rack.

Built-in devices have to be mounted firmly and stable in a control cabinet or on a table rack.

Welding heads have to be mounted firmly and stable on a table or a rack.

Pay attention to the instructions on commissioning.

Make sure that all connections are made accordingly.

Caution

5.2 Electrical Connections

Electrical connections must be done only by qualified and trained personnel (electrician).

Warning

Applicable codes and regulations must be obeyed for dimensioning of the mains power cable, fuse protection and earthing. In case of long distance to the mains transformer, the cross section will eventually have to be increased to avoid a considerable drop of the mains voltage. It can be assumed as a guideline, that at max. short circuit current the voltage drop on the whole voltage line should not be higher than 5 %.

In order to compensate mains feedback, welding systems using their own power supplies must be operated at the main transformer. Sensitive units nearby should be protected using mains input filters.

Ensure that the units are adequately earthed. The unit housing should be included in safety measures. For this use the earth connection on the rear of the ISQ20.

When connecting auxiliary voltage the mains voltage should also be compared with the nominal voltage on the type label.

Read the connection diagram carefully before connecting a separate controller. Take care of phase balance for connection cables from the same mains.

Potentially lethal high voltage is present in the inverter during operation.

The housing may only be opened after disconnecting the unit from the mains power supply and awaiting the capacitors discharge period (approx. 3 min.).

Only trained and instructed personnel may be entrusted with service work.

Any unauthorized modifications are prohibited.

The welding current source may only be used for its intended purpose.

Warning

ISQ20 Commissioning

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5.2.1 Mains Supply

Note mains voltage!

Warning

First compare the existing connection voltage to the voltage stated on the type label of the equipment.

An intermediate power circuit of approx. 560V is created from the 3 phase 230/400 VAC / 50/60 Hz mains power supply in the inverter.

Due to the varying requirements in different countries the unit is delivered without a mains plug. A suitable plug should be fitted or the unit should be connected to a terminal box.

If the unit is part of a system, the mains connection must be made via the main switch of the system.

In this case the red/yellow main switch on the unit has to be replaced by a black switch. Please contact our service department for further information. Warning

ISQ20 Commissioning

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5.2.2 Connecting Secondary Cables

Use secondary cables with 95 mm² cross-section and a length of at least 500 mm. Use M8 x 16 mm fixing screws.

Connect one secondary cable with the

(+) pole of the ISQ20 (resp. the transformer) and the active electrode (at the corresponding connection behind the current band on the welding head).

Connect the other secondary cable to the (-) pole of the ISQ20 (resp. the transformer) and the corresponding connection on the holder of the passive electrode.

Fig. 8: Secondary cable connection ISQ20-3/ISQ20-6

Please ensure the following to maintain as low a current resistance in the secondary circuit as possible:

The cable lugs should make contact with the mounted component over as great a surface area as possible

Secondary cables should be laid as closely as possible and bound with cable ties to maintain a limited secondary window

Secondary cables should not be in contact with other conducting parts and should not form shunt circuits

Contact surfaces should be clean

Contact surfaces should not be corroded

Screw connections should not loosen during operation

Attention

The attachment of a second (third) secondary cable to each pole increases the cable cross section, thus reducing the current resistance. The shorter the secondary cable, the lower the conducting loss. A considerable loss should be expected with cables longer than 1.5 m.

Reversed pole connection can be advantageous, depending on the application involved. Voltage is created by the Peltier effect when welding materials which are widely disparate in the electrical voltage sequence. This voltage is added to the voltage of the welding power control (recommended) or acts against it, depending on the secondary cable pole configuration. A secondary cable pole configuration which suits your particular application should therefore always be selected.

ISQ20 Commissioning

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5.2.3 Connecting Current Measurement

A current measuring coil must be integrated in the secondary circuit for all inverters with external transformer (ISQ20-8, ISQ20-10, ISQ20-20). (Standard: Toroidal ring coil ø 70 mm, no. 770.60 152).

The current measuring coil is part of the power control or oft he measuring unit (if used).

Always make sure that only the supply cable of the secondary current is enclosed by the coil. The coil may never enclose both the supply and the return cable of the secondary current Attention

Abb. 9: Flap toroidal coil (example) with (+) side marking

Abb. 10: Ring toroidal coil (example) with (+) side marking

Install the coil on the (+) line of the power source. Ensure that the (+) side of the

coil points in the direction of the (+)connection of the power source. Ensure that all secondary cables of one pole are enclosed.

Connect the cable of current measurement with the coil and X32 on the ISQ20 (resp. when using an external measuring device with the corresponding input).

In order to ensure correct current indication the direction of current and, consequently,

the coil installation direction are important.

Ensure that the (+) side of the coil points to the direction of the (+) power source connection.

Ensure that all secondary cables of one pole are enclosed.

Attention

ISQ20 Commissioning

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5.3 Mechanical Connections

5.3.1 Connection Possibilities Heads / Valves etc.

The most common connection types for different welding tasks are listed in the following tables.

Legend (alphabetical) of abbreviations in the following tables: 0 Option, can be connected KV ZU Compacting unit closed PV Proportional valve

SLD Closing pressure SLH Closing stroke SWD Welding pressure SWZ Welding pincers SWZ ENT Welding pincers, unlocked SV Safety valve UHZ Lower stroke cylinder USV Change-over valve X Connect at all times ZSZ Adjustment cylinder

ISQ20 Commissioning

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5.3.2 Connection with One Head and Start 1

x x x x x x x x x x x x

x x x x x x x x x x x x

x x x x x x x x

x x x x x x x x

0 0 0 0 0 0 0 0

x x x x x x x x x x x x x x x xx x xx x x

SL

D

SL

D

SL

D

SL

D

SV

SV

SV

SV

ZS

Z

ZS

Z

ZS

Z

ZS

Z

ZS

Z

ZS

Z

ZS

Z

ZS

Z

SW

D

SW

D

SW

D

SW

D

0 0 0 0 0 00 00 00 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

SLD

/ S

WD

SLD

/ S

WD

SLD

/ S

WD

SLD

/ S

WD

SW

D

SW

D

SW

D

SW

D

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

UH

Z

UH

Z

UH

Z

UH

Z

SW

Z E

NT

SW

Z E

NT

SW

Z E

NT

SW

Z E

NT

KV

ZU

KV

ZU

KV

ZU

KV

ZU

x x x x x x x x x x x x x x x x

X5.2, X1.15

X5.3, X1.16

X2

.15

X4

.1X

2.16

X4.

4X

2.17

X4.

7X

2.18

X4.

10X

2.19

X4.

13X

6X

7X

8X

9

Clo

sin

g s

tro

ke

Pro

po

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na

l val

ve

Ad

just

men

t cy

lind

er

Ad

just

men

t cy

lind

er w

ith

Pro

po

rtio

nal

val

ve

Ad

just

men

t cy

lind

er w

ith

Pro

p.

valv

e w

eld

ing

pin

cers

and

Ad

just

men

t cy

lind

er w

ith

lo

wer

str

oke

cyl

. P

rop

. va

lve

and

Ad

just

men

t cy

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ith

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p.

valv

e co

mp

acti

ng

dev

ice

and

Clo

sin

g s

tro

ke w

ith

low

er s

tro

ke

cyl

ind

er

Pro

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l val

ve w

ith

wel

din

g p

ince

rs

Pro

po

rtio

na

l val

ve w

ith

co

mp

act

ing

dev

ice

Init

iato

rs

Pro

po

rtio

na

l val

ve w

ith

low

er s

tro

ke

cylin

der

Ad

just

men

t cy

lind

er w

ith

lo

wer

str

oke

cy

lind

er

Clo

sin

g s

tro

ke w

ith

co

mp

act

ing

dev

ice

Ad

just

men

t cy

lind

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ith

co

mp

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ing

dev

ice

Clo

sin

g s

tro

ke w

ith

we

ldin

g p

ince

rs

Ad

just

men

t cy

lind

er w

ith

wel

din

g p

ince

rs

Start 1

Start 2

Start 3

Head 1

Stroke 1 back

Stroke 1 ahead

Head 2

Stroke 2 back

Stroke 2 ahead

Pressure switch 1

Pressure switch 2

Stepping contact

Val

ve 1

Val

ve 2

valv

e 3

Val

ve 4

Va

lve

5P

rop

ort

ion

al-

valv

e 1

Pro

po

rtio

nal

-va

lve

2

Co

nn

ecti

on

po

ssib

iliti

es(S

elec

tio

n)

wit

h o

ne

hea

d

ISQ20 Commissioning

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5.3.3 Connection with Two Heads and Start 1, 2 or 3

X5.2, X1.15

X5.3, X1.16

X2.

15X

4.1

X2.

16X

4.4

X2

.17

X4

.7X

2.18

X4.

10X

2.1

9X

4.1

3X

6X

7X

8X

9

x x x x x xx x xx x x


x x xx x x



x x xx x x

x x x x

x x x x

x x x x x x x x x x x x x x x x x xx x xx x xx x xx x x

x

x x x x x x x x x x

x x x x x x x x x x

x x x x x x x x x

Co

nn

ecti

on

po

ssib

ilit

ies

(Sel

ecti

on

)w

ith

tw

o s

imil

ar

hea

ds

SLD

1S

WD

1S

LD

2S

WD

2

SL

D 1

/ S

WD

1S

LD 2

/ S

WD

2

SLD

2 /

SW

D 2

SLD

2 /

SW

D 2

SLD

2 /

SW

D 2

SLD

2 /

SW

D 2

SLD

2 /

SW

D 2

SW

D 2

SW

D 2

SW

D 2

SW

D 2

SW

D 2

SW

D 2

SL

D 1

/ S

WD

1

SL

D 1

/ S

WD

1

SL

D 1

/ S

WD

1

SL

D 1

/ S

WD

1

SL

D 1

/ S

WD

1

SW

D 1

SW

D 1

SW

D 1

SW

D 1

SW

D 1

SW

D 1

(US

V)

(US

V)

(US

V)

(US

V)

(US

V)

(US

V)

(US

V)

(US

V)

(US

V)

(US

V)

(US

V)

(US

V)

(US

V)

(US

V)

(US

V)

(US

V)

(US

V)

(US

V)

(US

V)

(US

V)

SL

D 2

SV

2

SV

2

SZ

S 2

SZ

S 2

SW

D 2

UH

Z 1

UH

Z 2

UH

Z 2

UH

Z 2

UH

Z 2

UH

Z 2

UH

Z 2

UH

Z 1

UH

Z 1

UH

Z 1

UH

Z 1

UH

Z 1

SW

Z

1 E

NT

SW

Z

1 E

NT

SW

Z

1 E

NT

SW

Z

1 E

NT

SW

Z

1 E

NT

SW

Z

1 E

NT

SW

Z

2 E

NT

SW

Z

2 E

NT

SW

Z

2 E

NT

SW

Z

2 E

NT

SW

Z

2 E

NT

SW

Z

2 E

NT

SLD

1S

WD

1

0 0 0 0 SV

2

SV

2

SV

2

SV

2

SV

1

SV

1

SV

1

SV

1

SV

1

SV

1

ZS

Z 1

ZS

Z 2

ZS

Z 2

ZS

Z 2

ZS

Z 2

ZS

Z 2

ZS

Z 2

ZS

Z 2

ZS

Z 2

ZS

Z 2

ZS

Z 1

ZS

Z 1

ZS

Z 1

ZS

Z 1

ZS

Z 1

ZS

Z 1

ZS

Z 2

ZS

Z 1

ZS

Z 1

ZS

Z 1

ZS

Z 1

ZS

Z 1

Clo

sin

g s

tro

ke

Clo

sin

g s

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Pro

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l val

ve

Pro

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Start 2

Start 3

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Stroke 1 ahead

Head 2

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Pressure switch 2

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ISQ20 Commissioning

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5.4 Insulation Test

We use power supply filters in our units to meet European EMC regulations. These filters have a discharge resistance to earth in each phase which is illustrated below. The resistance value is 1 M in each case. This results in an effective resistance of 333 k for a cumulative insulation resistance measurement (L1-L2-L3 to earth).

Abb. 11: Circuit structure for mains filter

We recommend disconnecting the unit for measuring insulation resistances of a system, as this will enable an insulation test under even this technical restriction.

5.5 Switching-on

Crushing Hazard!

During switching on the welding head can move.

Ensure that a safe distance is maintained to the welding head.

Plant set-up should only be carried out by qualified personnel and with extreme care.

Fundamental functions of the controller can be protected with a PIN, which should be fixed by the set-up personnel. Caution

For switching-on turn the main switch from „0“ to „1“.

Status display “01” indicates that the unit is “Ready”.

L1

L1

L1

L1’

L2

L1

R

R

R

RC3 R C3

C1

C1

C1R C3 C2 C2 C2

L2’

L3 L3’

PE PE

Mains

each with 1 MOhm

Device

ISQ20 Sequence

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6 Sequence

The chronological sequence of signals and functions is illustrated in the diagrams. The following diagrams are examples and cover a broad application range.

6.1 Standard Diagram with One Head

Dia-ISQ20-1K.cdr

P

P

P

I

START 1release

10 ms or as longas start 1

2 impulsesoff-time

1 2

closing time squeezetime

current program

hold timeset pointactual

start interlocking

steppingcontact

pressure contactcloses (option);head cushioned withadjustment cylinder

current program(option)

valve 2welding pressurewith closing stroke

valve 1 closing stroke;safety relief valve withproportional valve control;adjustment pressure withadjustment cylinder

proportionalvalve (PV)

proportional valve;welding pressure spring-biased with adjustment cylinder

ISQ20 Sequence

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6.2 Diagram for One Head with Stroke Cylinder

Dia-ISQ20-Hub-1K.cdr

P

P

P

I

START 1release


2 impulses

off-time

1 2

closing time squeezetime

current program


start interlocking

steppingcontact

proportioanal valve;welding pressure spring biased withadjustment cylinder

pressure contact closes (option);head cushioned withadjustment cylinder


valve 2 welding pressurewith closing stroke

valve 1 closing stroke;safety relief valve withproportional valve control;adjustment pressure with adjustment cylinder


proximity switchstroke cylinder back(bottom)

proximity switch head back

Valve 3stroke cylinder

stroke cylinder ahead(top)

ISQ20 Sequence

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6.3 Diagram for Pincers resp. Locking Cylinder

Dia-ISQ20-Zange-1K.cdr

P

P

P

I

START 1release


2 impulses

off-time

1 2

closing time squeeze t. current program


start interlocking

stepping contact

proportioanal valve;welding pressurespring-biased withadjustment cylinder

pressure contact closes(option); head cushioned with adjustment cylinder


valve 1 closing stroke;safety relief valve withproportioan valve control;adjustment pressure withadjustment cylinder


proximity switch head back

valve 3pliers unlocked

Valve 2 welding pressurewith closing stroke

proximity switchlocked

ISQ20 Error Messages

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7 Error Messages Each error is displayed twice: As digits in the 2-position Status display and additionally

on the display of the operating terminal with number and plain text.

7.1 Unit Errors (#10 – #59)

No. Message Cause 10 SQC3: EMERGENCY STOP active 11 SQC3: Undervoltage intermediate

circuit UZK < 450V ; Undervoltage, mains or fuses defective

12 SQC3: Overvoltage intermediate circuit

UZK > 650V ; Mains overvoltage

13 SQC3: Charging contactor defective Mains undervoltage or fuses defective 14 SQC3: Main contactor defective

15 SQC3: Over temperature cooling element

Over temperature at the cooler (power section) caused by defective fan or excessive ambient temperature

16 SQC3: Over temperature TGB Over temperature on the transformer block due to a lack of air cooling or overload

17 SQC3: Overcurrent - Reverse polarity of measuring connections or - low ohmic output load or - wrong direction of current measuring coil Sporadically occuring: Voltage fluctuations in mains line. Please contact our service department.

18 SQC3: Error, branch U Activation defective or critical closed-loop controller settings

19 SQC3: Error, branch V Activation defective or critical closed-loop controller settings

20 SQC3: I2t too large i2t limit reached: excessive current and current duration too long

21 SQC3: Wire breakage NTC-KK 22 SQC3: Pulse rest time too short Current rest time too short 23 SQC3: Pulse duration too long 24 Error Inverter Erroneous link to inverter (MFC only) 25

AW

S3-

Sys

tem

on

ly

internal CAN error 26 internal CAN error 27 welding active without

current

28 internal CAN error 29 internal CAN error


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No. Message 30 Wrong answer from SQC3 31 No communication with SQC3 32 Error when deleting flash 33 Error while writing on flash sector 1 34 Error while writing on flash sector 2 35 Error during transfer to terminal 36 Current too high! (> maximum current) 37 Current too low! (< minimum current) 38 Error during DSP booting 39 Error LCA (SPI)

40 Error LCA (SGC) 41 No communication with terminal 42

AW

S3-

Sys

tem

onl

y

internal CAN error 43 internal CAN error 44 internal CAN error 45 internal CAN error 46 AC-Stop is active (AC = action counter) 47 Program ready is missing 48 Display ready (AWS) is missing 49 Wrong start at 2 head-AC 50 Undervoltage 15V 51 Overvoltage 15V 52 Undervoltage –15V 53 Overvoltage -15V 54 Undervoltage 24 V 55 Overvoltage 24 V 56 Failure 24V external 57 Undervoltage 5V 58 Overvoltage 5V 59 Defective interlocking, or Start < 10 ms or no external supply voltage at X2.


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7.2 Sequence Errors (#60 – #95) No. Message Cause 60 Contact cylinder 1 not ahead (X3.7) 61 Error pressure switch 1 62 Head not back (X3.1) 63 Contact cylinder 1 not back (X3.13) 64 Current greater than maximum current 65 Start set when switching on 66 Pressure deviation 1 too big 67 Stroke cylinder 1 not in initial position 68 Head 1 not down (X3.1) 69 Progr. no. for changeover position incorrect

70 No external program selected 71 Part detection input 1 missing 72 Part detection input 2 missing 73 Error thermal switch 74 Mains compressed air error 75 Quick stop error 76 Error pressure switch 2 77 Contact cylinder 2 not ahead (X3.10) 78 Head 2 not up (X3.4) 79 Contact cylinder 2 not back (X3.16) 80 Pressure deviation 2 too big 81 Stroke cylinder 2 not in initial position 82 Head 2 not down (X3.4) 83 No program section AC chosen (AC = action counter) 84 Contact cylinder 1 back (X3.13) 85 Contact cylinder 2 back (X3.16) 86 Contact cylinder 1 ahead (X3.7) 87 Contact cylinder 2 ahead (X3.10) 88 Inputs DK1 and DK2 are missing 89 Inputs DK1 and TK1 are missing 90 Inputs DK2 and TK2 are missing 91 Inputs TK1 and TK2 are missing 92 Set point deviation – check

connections Transformer or coil polarity is reversed (with AC inverter)

93 External interlocking active

94 Voltage measuring cable not or wrong connected

Check voltage measuring cable; beware correct polarity I/U

ISQ20 Connection Variants (Examples)

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8 Connection Variants (Examples)

In the following drawings the article numbers for cables always refer to cable with standard length (3 m).

8.1 ISQ20 - pneumatic 1-Head w/o Distance Measurement


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8.2 ISQ20 - pneumatic 1-Head w/o Distance Measurement


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8.3 AWS3 - pneumatic 1-Head


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8.4 AWS3 - pneumatic 2-Head


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8.5 AWS3 – pneumatic with Profibus


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8.6 AWS3 – pneumatic with Ethernet IP


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8.7 AWS3 - motorized 1-Head


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8.8 AWS3 - motorized 2-Head


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8.9 AWS3 - motorized 1-Head with Profibus


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8.10 AWS3 - motorized 1-Head with Ethernet IP


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8.11 AWS3 – motorized 1-Head with Router (Remote Service)

ISQ20 Connection Schemes

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9 Connection Schemes

9.1 Binary Connections 1

ISQ20 Connection Schemes

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9.2 Binary Connections 2

ISQ20 Index

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10 Index

10.1 Illustration Index Fig. 1: Standard device ................................................................................................................... 8 Fig. 2: Maximum duty ratio ........................................................................................................... 16 Fig. 3 Front panel......................................................................................................................... 17 Abb. 4 Display ............................................................................................................................... 17 Abb. 5: Rear panel ISQ20-3 / ISQ20-6 .......................................................................................... 18 Abb. 6: Rear panel ISQ20-8 / ISQ20-10 ........................................................................................ 19 Abb. 7: Rear panel ISQ20-20 ......................................................................................................... 20 Fig. 8: Secondary cable connection ISQ20-3/ISQ20-6 ................................................................ 38 Abb. 9: Flap toroidal coil (example) with (+) side marking ............................................................. 39 Abb. 10: Ring toroidal coil (example) with (+) side marking ............................................................ 39 Abb. 11: Circuit structure for mains filter .......................................................................................... 43

10.2 Headword Index

B Baud rate ..................................................................................... 23 Binary Connections 1 ................................................................... 61 Binary Connections 2 ................................................................... 62

C Commissioning ............................................................................. 36 Connecting Current Measurement ............................................... 39 Connecting Secondary Cables ..................................................... 38 Connection ................................................................................... 42 Connection Possibilities Heads / Valves etc. ................................ 40 Connection Schemes ................................................................... 61 Connection Variants ..................................................................... 50 Connection with One Head and Start 1 ........................................ 41 Connections ................................................................................. 21

D Data Transfer ............................................................................... 21 Declaration of Conformity ............................................................... 7 Design and Mode of Action .......................................................... 17 Device Types ................................................................................. 9 Diagram for One Head with Stroke Cylinder ................................. 45 Diagram for Pincers resp. Locking Cylinder .................................. 46 Displacement Sensor ................................................................... 15

E Electrical Connections .................................................................. 36 Error Messages ............................................................................ 47

F Front Panel ISQ20 ....................................................................... 17

G General Information ....................................................................... 5

I Installation Notes ............................................................................ 6 Insulation Test .............................................................................. 43 ISQ20-10-DC Technical Data ....................................................... 12 ISQ20-20-DC Technical Data ....................................................... 13 ISQ20-3-DC Technical Data ......................................................... 10 ISQ20-6-DC Technical Data ......................................................... 11 ISQ20-8-AC Technical Data ......................................................... 14

M Mains Supply ............................................................................... 37 Maximum Duty Ratio .................................................................... 16 Mechanical Connections .............................................................. 40

O Operation ..................................................................................... 15

P Plug assignments ........................................................................ 24 Preconditions for Commissioning ................................................ 36 Pressure/Force Measuring .......................................................... 15

R Rear Panel ISQ20-20 .................................................................. 20 Rear Panel ISQ20-3 / ISQ20-6 .................................................... 18 Rear Panel ISQ20-8 / ISQ20-10 .................................................. 19 RS232 AWS3 mode .................................................................... 22 RS232 Classic mode ................................................................... 23 RS232 Data output format ..................................................... 22, 23 RS232 serial interface ................................................................. 21

S Safety Notes .................................................................................. 5 Sequence .................................................................................... 44 Software update .......................................................................... 23 Sound Pressure Level ................................................................. 15 Standard Diagram with One Head ............................................... 44 Status messages ......................................................................... 17 Switching-on ................................................................................ 43

T Technical Description .................................................................... 8 Toggle switches S1, S2, S3 ......................................................... 21

X X1: Binary inputs ......................................................................... 24 X10: Voltage Measurement 1 ...................................................... 34 X11: Voltage Measurement 2 ...................................................... 34 X12: Binary I/O ............................................................................ 34 X2: Binary Outputs ...................................................................... 27 X3: Initiators ................................................................................ 30 X30: Welding Transformer ........................................................... 35 X31: Temperature Sensor Transformer ....................................... 35 X32: Current Measuring Coil ....................................................... 35 X4: Valves ................................................................................... 32 X5: Start ...................................................................................... 32 X6: Proportional Valve Head 1..................................................... 33 X7: Pressure Sensor Head 1 ....................................................... 33 X8: Proportional Valve Head 2..................................................... 33 X9: Pressure Sensor Head 2 ....................................................... 34

Inverter Power Source ISQ20 Series · Inverter Power Source ISQ20 Series OPERATING INSTRUCTIONS ....

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