AA02OM1185331-08
OPERATION MANUAL
Original instructions
TRANSISTOR WELDING POWER SUPPLY
MD-A8000B-05-
□□
MD-B4000B-05-
Page 1: ...AA02OM1185331 08 OPERATION MANUAL Original instructions TRANSISTOR WELDING POWER SUPPLY MD A8000B 05 MD B4000B 05...
Page 2: ...Contacts or NPN Open Collector Transistors 5 2 3 Connecting PNP Source Transistors 5 3 4 Timing Chart 5 4 6 Explanation of the Screen 6 1 1 Menu Screen 6 1 2 Setting the Schedule SCHEDULE Screen 6 2 3...
Page 3: ...MD Series Contents 2 4 Major Components List 10 6 5 Schematic 10 7 11 Outline Drawing 11 1 12 Schedule Data Table 12 1 Index 1 EU Declaration of Conformity...
Page 4: ...to the operator Do not touch the inside of the Power Supply unnecessarily Since very high voltages are applied to the interior of this Power Supply it is very dangerous to touch it unnecessarily Neve...
Page 5: ...that can cause electric shock and fire If any part needs to be repaired or replaced consult us or your distributor Stop the operation if any trouble occurs Continuous operation after occurrence of a...
Page 6: ...re Keep combustible matter away from the welding machine Surface flash and expulsion can ignite combustible matter If it is impossible to remove all combustible matter cover them with non combustible...
Page 7: ...gent or alcohol Do not use paint thinner benzine etc since they can discolor or deform the Welding Transformer Do not put a screw a coin etc in the Welding Power Supply since they can cause a malfunct...
Page 8: ...ns 1 5 4 Function Difference Depending on Model Model Power supply voltage Type MD A8000B 05 30 100 120V AC Standard type MD A8000B 05 31 200 240V AC MD B4000B 05 30 100 120V AC Polarity switching typ...
Page 9: ...flash and expulsion can be performed since the voltage is fixed from the start and the current is reduced even the welding of material having high specific resistance and the welding of workpiece hav...
Page 10: ...conversion adapter for power cable 1 100 to 120V AC KPR 24 SB B START cable 1m A 03081 001 3m A 03081 002 V SENS cable 1m long Crimp on terminal on head side M6 A 03082 001 3m long Crimp on terminal o...
Page 11: ...d Functions of Each Section 4 1 4 Name and Functions of Each Section 1 Front Panel Display screen Cursor key POWER lamp START lamp READY lamp TROUBLE lamp WELD key lamp MENU key RESET key ENTER key ke...
Page 12: ...ot in the middle of welding or charging TROUBLE lamp Comes on when a fault occurs WELD key WELD lamp Used to start the sequence without applying the welding current The welding current will not flow w...
Page 13: ...29 31 33 35 37 39 11 1 CONTROL SIG ERR RESET SCH16 SCH 8 SCH 4 SCH 2 SCH 1 2ND STAGE 1ST STAGE INT 24V PO CH SEL WELD ON OFF CNTR RESET SENS GND VOLT SENS1 VOLT SENS2 SOL CAUTION END NG GOOD COM OPTI...
Page 14: ...ction When emergency stop is necessary install a circuit that breaks power supply to the equipment 4 1st STAGE terminal 1st STAGE start input terminal Set START SIG INPUT on the STATUS screen before u...
Page 15: ...ons when the external schedule select is selected Refer to 6 6 SCHEDULE The schedule No is the sum of the SCH Nos of the closed terminals Refer to Table of schedule Nos and corresponding schedule sele...
Page 16: ...erational trouble occurs When a fault occurs operation is stopped until the reset signal is input You can change the function so that the circuit is opened normally and closed in the case above Refer...
Page 17: ...rying capacity is 0 2A Drives solenoid valves of up to 24V DC 5W 35 SENS GUARD terminal Shielded wire connection terminal for the V SENS cable Connected to the chassis inside 36 37 V SENS 1 terminals...
Page 18: ...and corresponding schedule select terminals Closed circuit Open circuit Schedule No SCH1 SCH2 SCH4 SCH8 SCH16 PARITY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 3...
Page 19: ...terminal Use this terminal for grounding when the ground wire of the power cable option is not used RS 485 serial interface connector D Sub connector 9 pin female 1 RS 1 2 RS 1 3 RS 2 4 RS 2 9 0V Not...
Page 20: ...current Note Since these output terminals are for the welding current do not input the external voltage Avoid contact of any metal object such as tool with the output terminals The contact situation...
Page 21: ...larity Connect green to 35 The most basic connection 37 2 2 For safety be sure to connect one side of the output terminal of the power supply to ground WARNING 3 3 Connect the V SENS cable though the...
Page 22: ...LD ON OFF PO CH SEL SCH 8 SCH16 ERR RESET SCH 4 SCH 2 SCH 1 2ND STAGE 1ST STAGE COM SENS GUARD VOLT SENS1 INT 24V STOP EXT COM RY 24VDC READY Set START SIG INPUT on the STATUS screen before using thes...
Page 23: ...30 32 34 36 38 13 15 17 19 21 23 25 27 29 31 33 35 37 39 STOP INT 24V SENS GUARD VOLT SENS1 SOL RY 24VDC 24VDC PLC 2 PNP current output type Set START SIG INPUT on the STATUS screen before using these...
Page 24: ...e Refer to 3 On the end signal output time 4 Screen display time communication time Refer to 4 On the screen display time and communication time 5 Normal fault and caution signals When the monitor val...
Page 25: ...emarks SQ Squeeze time UP Upslope time WE Weld time DS Downslope time HD Hold time 1 The weld sequence does not start even if the 1st STAGE terminal is closed The timing of start input 2ND STAGE end s...
Page 26: ...ime HD Hold time 1 Close the 1st STAGE terminal and 24 V DC is output from the SOL terminal of Terminals 33 and 34 When the 1st STAGE terminal is opened in this state the weld force is released 2 When...
Page 27: ...ks SQ Squeeze time U1 Upslope 1 time W1 Weld 1 time D1 Downslope 1 time CL Cool time U2 Upslope 2 time W2 Weld 2 time D2 Downslope 2 time HD Hold time The timing of schedule select start input end sig...
Page 28: ...or caution occurs in precheck welding 2 Normal fault and caution signals When the monitor value is within the setting range a normal signal is output When the monitor value is outside the range or a f...
Page 29: ...tion from start signal input to weld force start 1 Time duration from schedule or start input to weld force start Changes depending on the setting of START SIG TIME on the STATUS screen The following...
Page 30: ...queeze start 3 On the end signal output time Common to MD series 1 Changes depending on the setting of END SIG TIME on the STATUS screen When the setting is 10 ms to 200 ms the end signal is output fo...
Page 31: ...STATUS screen 14 ms max When the start is input while the MONITOR screen is displayed the screen display is canceled to accept the next start The next start is accepted 5 ms after the communication ou...
Page 32: ...en Displays the screen after the end of communication output 1 Menu screen 50 ms max SCHEDULE screen 117 ms max MONITOR screen 181 ms max COMPARATOR screen 104 ms max PRECHECK screen 74ms max STATUS s...
Page 33: ...communication time 5 Normal fault and caution signals When the monitor value is within the setting range a normal signal is output When the monitor value is outside the range or a fault occurs a faul...
Page 34: ...welding 3 Normal fault and caution signals When the monitor value is within the setting range a normal signal is output When the monitor value is outside the range or a fault occurs a fault or caution...
Page 35: ...re before the start signal The display of the schedule waveform on the SCHEDULE screen is changed 7 On the fault reset Screen display time 212 ms max Start waiting time 5 ms Accepts a start after the...
Page 36: ...the menu screen At the upper left of the screen each function is displayed as a menu form Move the cursor to an item you desire press the ENTER key to go to the selected screen The numbers of 2 to 6...
Page 37: ...ve the cursor to SCHEDULE and press the ENTER key to display the SCHEDULE screen as follows When 2 step weld sequence is selected When SCHEDULE MODE on the STATUS screen is set to DOUBLE When 1 step w...
Page 38: ...rrent time Set it for WE1 and WE2 respectively 1 When the welding portion except upslope and downslope is short there is not so much of a difference between the weld time WE1 and WE2 and the time of u...
Page 39: ...itched by pressing the ENTER key after selecting the function key h i Note Waveform and measured value hold the latest data of each schedule When the power is turned off all values are cleared When di...
Page 40: ...waveform Grid spacing of waveform horizontal axis Displays the grid spacing for time axis of waveform Measured value of WE1 Displays the measured value of WE1 welding for each measured value Measured...
Page 41: ...e value or peak value of voltage Note Average value and peak value can not be displayed simultaneously 4 Setting Upper Lower Limits for Judgment COMPARATOR Screen Screen for setting the upper and lowe...
Page 42: ...ower limit judgment When SCHEDULE MODE on the STATUS screen is set to SINGLE upper limit H lower limit L and measured value of WE2 are not displayed d POWER Set the upper limit H and the lower limit L...
Page 43: ...er limits of precheck current check and set the current value changing according to the normal or abnormal state of the part to weld When the part to weld is not set the resistance value becomes low a...
Page 44: ...of each schedule When the power is turned off all values are cleared e COMPARATOR CURR HIGH Upper limit of current for precheck welding Set the upper limit of current for PEAK peak value and AVE aver...
Page 45: ...customer s operating environment Thoroughly read this operation manual before changing the initial settings Setting method Move the cursor to the item to change There are many items so three STATUS s...
Page 46: ...1 step welding this will make the screen display easier to see SINGLE 1 step weld sequence DOUBLE 2 step weld sequence CONTROL Selects the welding control method COMB Combination control of constant c...
Page 47: ...uits of the schedule select terminal and PARITY terminal is an odd number Refer to 4 2 Control signal terminal strip END SIG TIME Selects the output time duration of the end signal 10 20 30 200ms The...
Page 48: ...to 99 9ms AVE average value measures the interval except the welding start to this setting and downslope regardless the upslope setting PEAK peak value measures the interval except the welding start t...
Page 49: ...When the 1st STAGE terminal is closed the SOL terminal operates Then when the 2nd STAGE terminal is closed the weld sequence starts When the 1st STAGE terminal is open the weld sequence does not star...
Page 50: ...No for one device 24 COMMUNICATION SPEED Selects a communication speed 9600 Communication at 9600 bps 19200 Communication at 19200 bps 38400 Communication at 38400 bps When the communication cannot be...
Page 51: ...o be made are as follows Schedule No 15 Welding sequence 2 step Precheck function ON Welding method COMB Monitor values average current and average voltage Change these settings to suit your purpose o...
Page 52: ...ess the ENTER key to go to the following screen To perform communication set items referring to 6 6 21 COMMUNICATION CONTROL to 24 COMMUNICATION SPEED In this example set as shown at left not to perfo...
Page 53: ...it down for approx 1 second Turn on close the WELD ON OFF of the control signal terminal strip on the rear panel Check that the READY lamp on the front panel is on The READY lamp comes on when the WEL...
Page 54: ...to to obtain an optimal result When welding is satisfactory set the monitor value Change to the PRECHECK screen and set the precheck judgment range Set the HIGH and LOW values so that the optimal val...
Page 55: ...e upper and lower limit ranges of CURR VOLT and POWER Set H at the maximum value and L at the minimum value when upper lower limit judgment is not desired Conduct operations to for all schedule Nos to...
Page 56: ...act us E02 SYSTEM ERROR An error has been detected in the MD series Once turn off power and turn on again If E02 SYSTEM ERROR is displayed again repair is required Contact us E03 TRIP OF THERMO The eq...
Page 57: ...TROUBLE Fault of the welding control circuit Welding current is output continuously Turn off the power immediately and contact us or your distributor E15 PRECHECK ERROR Displayed when the current exce...
Page 58: ...splayed on the screen Explanation of fault and corrective measures E20 CYCLE TROUBLE Occurs when START SIG HOLD on the STATUS screen is set to NO HOLD and the start signal is turned off during welding...
Page 59: ...tions Item Content Transmission mode RS 485 Asynchronous Half Duplex Transmission rate 9600 19200 38400 bps Data format Start bit 1 Data bit 8 Stop bit 1 Parity bit Even Character code Output in ASCII...
Page 60: ...onitor value sending code M fixed B W1 Welding code 1 step welding W1 fixed C Schedule No 01 to 31 D 1 WELD Current Peak value 000 to 999 A 3 2 0 00 to 9 99 kA 3 E 1 Average value 000 to 999 A 3 2 0 0...
Page 61: ...000 to 999 A 3 2 0 00 to 9 99 kA 3 F W1 Voltage 1 Peak value 0 00 to 9 99 V 3 G Average value 0 00 to 9 99 V 3 H 1 W1 Power 1 average value 0 00 to 9 99 kW 3 2 00 0 to 99 9 kW 3 I W1 Resistance 1 ave...
Page 62: ...In case of five faults Data strings E 06 07 08 09 10 CR A B B B B B C Ex E 06 07 08 09 10 CR Item Character string Content Range A E Fault send code E fixed B 1 Fault code 01 to 20 C CR CR code 0DH fi...
Page 63: ...lding W1 fixed G 1 WELD Current Peak value 0000 to 0999 A 5 2 0 00 to 9 99 kA 5 H 1 Average value 0000 to 0999 A 5 2 0 00 to 9 99 kA 5 I WELD Voltage Peak value 0 00 to 9 99 V 5 J Average value 0 00 t...
Page 64: ...W1 Welding code 1 step welding W1 fixed G 1 W1 Weld 1 Peak value 0000 to 0999 A 5 2 0 00 to 9 99 kA 5 H 1 Average value 0000 to 0999 A 5 2 0 00 to 9 99 kA 5 I W1 Voltage 1 Peak value 0 00 to 9 99 V 5...
Page 65: ...e 0000 to 0999 A 5 2 0 00 to 9 99 kA 5 Y 3 PRECHECK Weld time Set time 0 00 to 1 00 ms 4 00 0 to 01 0 ms Z CR LF CR LF code 0DH 0AH fixed 1 When CURRENT RANGE on the STATUS screen is A 2 When CURRENT...
Page 66: ...strings E 01 01 06 07 08 09 10 CR LF A B C D D D D D E Ex E 01 01 06 07 08 09 10 CR LF Item Character string Content Range A E Fault send code E fixed B Device No 01 to 31 C Schedule No 01 to 31 D 1...
Page 67: ...about Model and ROM version Device No I Ex Read Model and ROM version of Device No 01 Host PC MD series ID1 ID2 I CR LF 01I CR LF MD series Host PC ID1 ID2 Model ROM version CR LF 01 MD A8000B V00 01...
Page 68: ...MD series Host PC ID1 ID2 SH1 SH2 SH3 CD1 CD2 CD3 Data CR LF 01008S01 Data CR LF See Data code table for the data order When the power is turned off the written data is cleared When Specified code No...
Page 69: ...Device No 01 Host PC MD series ID1 ID2 W SH1 SH2 SH3 CD1 CD2 CD3 Data CR LF 01W000S13 E00 CR LF MD series Host PC ID1 ID2 SH1 SH2 SH3 CD1 CD2 CD3 Data CR LF 01001S13 E00 CR LF Write 000 for Schedule...
Page 70: ...code No to perform reading and writing S06 PRECHECK screen setting Changes the conditions of precheck welding Specify the schedule No and specified code No to perform reading and writing S07 STATUS s...
Page 71: ...1 UP Upslope time 0 00 to 9 99 ms 0 01 2 00 0 to 99 9 ms 0 1 C 1 WE Weld time 0 00 to 9 99 ms 0 01 2 00 0 to 99 9 ms 0 1 D 1 DS Downslope time 0 00 to 9 99 ms 0 01 2 00 0 to 99 9 ms 0 1 E HD Hold tim...
Page 72: ...ms 0 01 2 00 0 to 99 9 ms 0 1 E 1 CL Cool time 0 00 to 9 99 ms 0 01 2 00 0 to 49 9 ms 0 1 F 1 U2 Upslope 2 time 0 00 to 9 99 ms 0 01 2 00 0 to 99 9 ms 0 1 G 1 W2 Weld 2 time 0 00 to 9 99 ms 0 01 2 00...
Page 73: ...acter string Content Range Increment Decrement A Display of current monitor value 0 Hide 1 Display 0 to 1 1 B Display of voltage monitor value 0 Hide 1 Display 0 to 1 1 C Display of power monitor valu...
Page 74: ...alue in A _ indicates space kA Current value in kA A or kA B 1 WE Current upper limit 0000 to 0999 A 1 2 0 00 to 9 99 kA 0 01 C 1 WE Current lower limit 0000 to 0999 A 1 2 0 00 to 9 99 kA 0 01 D Curre...
Page 75: ...99 A 1 2 0 00 to 9 99 kA 0 01 D 1 W2 Weld 2 current upper limit 0000 to 0999 A 1 2 0 00 to 9 99 kA 0 01 E 1 W2 Weld 2 current lower limit 0000 to 0999 A 1 2 0 00 to 9 99 kA 0 01 F Current judgment set...
Page 76: ...2 00 0 to 01 0 ms 0 1 C RC Voltage 0 00 to 9 99 V 0 01 D Unit of current value _A Current value in A _ indicates space kA Current value in kA A or kA E 3 RC Current peak value upper limit 0000 to 099...
Page 77: ...Charge voltage 00 AUTO 07 18V 01 6V 08 20V 02 8V 09 22V 03 10V 10 24V 04 12V 11 26V 05 14V 12 28V 06 16V 13 30V 00 to 13 B CURRENT RANGE MD A8000B 0 999A 1 2 00kA 2 4 00kA 3 9 99kA MD B4000B 0 500A 1...
Page 78: ...YPE NG output type 0 NC 1 NO 0 to 1 1 L LCD CONTRAST Brightness of screen 4 fixed M NO CURR MONITOR START Start time of no current no voltage detection 00 5 to 99 9 ms 0 1 N MONITOR START TIME Measure...
Page 79: ...Character string Content Range Increment Decrement A COMMUNICATION CONTROL Communication function setting 0 OFF 1 DATA OUTPUT 2 BI DIRECTION 0 to 2 1 B COMMUNICATION MODE Communication mode setting 0...
Page 80: ...MD series Host PC 01000S09 0 0 0 0 0 0 0 0 CR LF A B C D E F G H Item Character string Content Range Increment Decrement ERROR SETTING Fault caution setting 0 Caution 1 Fault A NO CURRENT 0 to 1 1 B...
Page 81: ...99 A 5 2 0 00 to 9 99 kA 5 D 1 WELD Current average value 0000 to 0999 A 5 2 0 00 to 9 99 kA 5 E WELD Voltage peak value 0 00 to 9 99 V 5 F WELD Voltage average value 0 00 to 9 99 V 5 G 1 WELD Power a...
Page 82: ...000 to 0999 A 5 2 0 00 to 9 99 kA 5 D 1 W1 Current 1 average value 0 00 to 9 99 kA 5 2 00 0 to 99 0 kA 5 E W1 Voltage 1 peak value 0 00 to 9 99 V 5 F W1 Voltage 1 average value 0 00 to 9 99 V 5 G 1 W1...
Page 83: ...of five faults 01000S13 E06 E07 E08 E09 E10 CR LF A A A A A Item Character string Content Range A E 1 Fault code 00 to 20 1 Up to five fault codes are output If two or more fault codes exist the code...
Page 84: ...iority is given to the control method with the lower set value Timer setting 1 step weld sequence a Squeeze 0000 9999ms b Precheck weld 0 00 1 00ms 1 c Precheck judgment 2ms fixed 1 d Upslope 0 00 9 9...
Page 85: ...Current lower limit setting range 000 999A 0 00 9 99kA The unit automatically changes according to the current range Weld time setting range 0 00 1 00ms Monitor value setting WE1 and WE2 setting range...
Page 86: ...ting time Common to all schedules Set by NO CURR MONITOR START 00 5 99 9ms Measured value start time Common to all schedules Set by MONITOR START TIME OFF 00 0 99 9ms Start operation mode Common to al...
Page 87: ...MD Series 10 Specifications 10 4 Power consumption 350W maximum Dimensions 399 H x 172 W x 390 D mm Projections not included Mass 30kg...
Page 88: ...0 20 0 ms 10000A 9000 8000 7000 6000 5000 4000 3000 2000 1000 0 35 40 8 15 3000 5 00 4000 7 00 4000 12 00 3000 3 20 6000 1 90 8000 1 30 9 990 2 50 6000 19 98 1630 19 98 2100 1 45 8000 1 00 9 990 T 1...
Page 89: ...lacement contact us Model Board MD A8000B 05 30 05 31 MD B4000B 05 30 05 31 Main control board ME 3086 12S1 Charge board ME 1876 00 Power block board ME 3102 00 4 Major Components List Item Q ty Power...
Page 90: ...T OUTPUT I O FAN FET TH FET TH Power block part LCD display Control part Operating part Charging part Current sensing part MD B4000B AC INPUT I O FAN TH FET FET TH OUTPUT LCD display Control part Oper...
Page 91: ...awing Dimensions in mm OUTPUT DC30V MAX P 00138 001 381 30 102 5 33 275 51 127 66 61 399 390 128 172 8 9 Thread portion 2 parts M8 Output terminal connecting screw Insulating Plate Feed Plate Internal...
Page 92: ...Data Table SCH SQ WE1 COOL WE2 HOLD CURR WE1 WE2 VOLT WE1 WE2 CURR WE1 H L CURR WE2 H L CURR AVE PEAK H L VOLT WE1 H L VOLT WE2 H L VOLT AVE PEAK H L POWER WE1 H L POWER WE2 H L TIME VOLT PEAK HIGH LO...
Page 93: ...L TYPE NO CURR MONITOR START MONITOR FIRST TIME WELD TIME POLARITY CHANGE START SIG INPUT COMMUNICATION CONTROL COMMUNICATION MODE COMMUNICATION UNIT COMMUNICATION SPEED E04 NO CURRENT E05 NO VOLTAGE...
Page 94: ...2 Error Code 8 1 External Communication Function 9 1 F Front Panel 4 1 Function Difference Depending on Model 1 5 G Ground terminal 4 9 M Major Components List 10 6 MENU key 4 2 Menu Screen 6 1 MONIT...
Page 95: ......
