Amada MD Series Operation Manual Download

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MD Series

4. Name and Functions of Each Section

4-2

START lamp

Comes on when the sequence starts after the start signal is input.

READY lamp

Comes on when the welding current is ready to be supplied to the equipment.
The following conditions must be met for this lamp to come on:

・

The WELD lamp on the front panel is on.

・

The WE ON/OFF signal of the I/O connector is closed.

・

No fault is occurring.

・

Not 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 when this key is pressed and the WELD lamp
goes out.

Cursor key

Moves the cursor on the display screen vertically and horizontally.

MENU key

Press this key to display the menu screen.

RESET key

When a fault is displayed, remove the cause and press this key. This will reset
the fault display.

ENTER key

Used to determine the set values and selected items. Press this key for each
item to determine the changed contents.

⑪

+ key

Press this key to increase the value of the item.

⑫

- key

Press this key to decrease the value of the item.

⑬

POWER switch

Turn this switch on to switch the power on.

⑭

INPUT POWER connector

Connects the power cable (optional).

⑮

RS-485 connector

Used to communicate with the sequencer and personal computer. For
connection and contents, refer to

9. External Communication Function

Summary of Contents for MD Series

Page 1: ...AA04OM1185327 07 OPERATION MANUAL Original instructions OPERATION MANUAL TRANSISTOR WELDING POWER SUPPLY MD A10000A MD B5000A ...

Page 2: ...r and Slave 5 2 3 Connecting Contacts or NPN Open Collector Transistors 5 7 4 Connecting PNP Source Transistors 5 8 5 Timing Chart 5 9 6 Explanation of the Screen 6 1 1 Menu Screen 6 1 2 Setting the Schedule SCHEDULE Screen 6 2 3 Displaying the Measured Value MONITOR Screen 6 4 4 Setting Upper Lower Limits for Judgment COMPARATOR Screen 6 6 5 Setting the Precheck Welding PRECHECK Screen 6 8 6 Chan...

Page 3: ...es Contents 2 3 Board List for Maintenance 10 7 4 Major Components List 10 7 5 Schematic 10 8 11 Outline Drawing 11 1 1 Master 11 1 2 Slave 11 1 12 Schedule Data Table 12 1 Index 1 EU Declaration of Conformity ...

Page 4: ...N 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 Never disassemble repair or modify the Power Supply These actions can cause electric shock and fire Consult us or your distributor for inspection and repair Never burn destroy cut crush or chemically dec...

Page 5: ...d 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 trouble such as burning smell abnormal sound abnormal heat smoke etc can cause electric shock and fire If such a trouble occurs immediately consult us or your distributor Persons with pacemakers must...

Page 6: ...ter If it is impossible to remove all combustible matter cover them with non combustible material Do not cover the Power Supply with a blanket cloth etc If such a cover is used it may be overheated and burn Do not use this Power Supply for purposes other than welding Use of this Power Supply in a manner other than specified can cause electric shock and fire Use ear protectors Loud noises can damag...

Page 7: ...elding Transformer Do not put a screw a coin etc in the Power Supply since they can cause a malfunction Operate the Power Supply according to the method described in this operation manual Operate the switches and buttons carefully by hand If they are operated roughly or with the tip of a screwdriver a pen etc this will cause malfunction or damage Operate the switches and buttons one at a time If t...

Page 8: ...00 09 200V 240V 00 10 100V 120V Master for 6 slave connection 00 11 200V 240V 00 12 100V 120V Master for 7 slave connection 00 13 200V 240V 00 14 100V 120V Master for 8 slave connection 00 15 200V 240V 00 16 100V 120V Master for 9 slave connection 00 17 200V 240V 00 18 100V 120V Master for 10 slave connection 00 19 200V 240V 00 20 100V 120V Master for 11 slave connection 00 21 200V 240V 00 22 100V...

Page 9: ...ce 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 having high contact resistance such as cross wire Combination control of constant current and constant voltage In the early stage of welding welding free of surface flash and expulsion can be performed...

Page 10: ...ries 2 Features 2 2 Large current can be supplied by connecting two or more MD A10000As MD B5000As MD A10000A 12 devices maximum 1 master and 0 to 11 slave s MD B5000A 2 devices maximum 1 master and 1 slave ...

Page 11: ... 11 00 12 00 13 00 14 00 15 00 16 00 17 00 18 00 19 00 20 00 21 00 22 00 23 MD B5000A 00 00 00 01 Item Model No Q ty Operation manual AS1185850 OM1185326 OM1185327 1 Connector D Sub 25 pins Male Case HDB CTH 10 1 Plug HDBB 25 05 1 V SENS cable 1 5 m 44904 1 MD A10000A 00 30 00 31 MD B5000A 00 30 00 31 Item Model No Q ty Operation manual AS1185850 OM1185326 OM1185327 1 Control cable 600 AS1155728 1...

Page 12: ...nnector kit Connector mounting screw Screw in mm L 04742 002 1 Exclusively for the MD series Do not use for other devices MD A10000A 00 01 00 03 00 05 00 07 00 09 00 11 00 13 00 15 00 17 00 19 00 21 00 23 00 31 00 33 MD B5000A 00 01 00 31 Item Model No Power cable 1 KP 244 KS 16D VCTF3 1 25mm 3m For Japan 200 V AC CEE3P W 1 8 Round shaped plug 200 to 240 V AC GBP F GBSS 3 For China 220 V AC RS 485...

Page 13: ...is supplied after the POWER switch is turned on Note This lamp does not indicate the power state of all connected devices For the power state of each device check the POWER lamp on each device 1Display screen 7Cursor key 4READY lamp 5TROUBLE lamp 6WELD key lamp 8MENU key 9RESET key ENTER key key key POWER switch INPUT POWER switch CURR SIG connector RS 485 connector CONTROL connector I O connector...

Page 14: ...t flow when this key is pressed and the WELD lamp goes out 7 Cursor key Moves the cursor on the display screen vertically and horizontally 8 MENU key Press this key to display the menu screen 9 RESET key When a fault is displayed remove the cause and press this key This will reset the fault display ENTER key Used to determine the set values and selected items Press this key for each item to determ...

Page 15: ...s not have the emergency stop function When emergency stop is necessary install a circuit that breaks power supply to the equipment 3 2ND Close this pin and the weld sequence is started in the usual manner 4 17 5 18 6 Schedule select SCH 1 SCH 2 SCH 4 SCH 8 SCH 16 Terminal for selection of schedule No Functions when the external schedule select is selected Refer to 6 6 7SCHEDULE The schedule No is...

Page 16: ...nued without stopping the sequence To cancel the output input the reset signal or start signal The contact rating is 24V DC 20mA A semiconductor switch is used 13 OUT COM COM for output pins GOOD NG END CAUTION and READY 14 EXT COM Connect Pin 14 to Pin 1 to use an NPN transistor This pin is used as a COM pin when a PNP transistor is used refer to 5 Connection When inputting the external voltage u...

Page 17: ...udged to be within the range set on the COMPARATOR screen after the weld sequence is over The circuit closing time can be set within the range of 10 200ms in 10 ms steps The contact rating is 24V DC 20mA A semiconductor switch is used 24 END End signal output pins Close the circuit for a certain duration after sequence operation is over The circuit closing time can be set within the range of 10 20...

Page 18: ...5 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Note Schedule 1 is selected when all schedule select signals are open V SENS connector Connecting terminal for the V SENS cable Connect to it near the welding head There is no polarity When the V SENS cable is not connected the E19 VOLT SENS ERROR occurs CURR SIG2 12 connectors Used to connect to the slave For connection refer to 5 2 Connection bet...

Page 19: ...pment is overheated For details refer to E03 TRIP OF THERMO in 8 Fault Code 3 OVER CHAR lamp Comes on when the charge voltage is too high For details refer to E13 CHARGE TROUBLE OVER in 8 Fault Code SLAVE UNIT POWER READY OVER CHAR OVER HEAT OVER CURR WELD STAR 9CURR SENS connector 7POWER switch 8INPUT POWER switch CONTROL connector 1OVER CURR lamp 2OVER HEAT lamp 3OVER CHAR lamp 4WELD STAR lamp 5...

Page 20: ... on No fault is occurring Not in the middle of charging Note The READY lamp on the master indicates the state of all connected devices but that on the slave indicates the state of each device only 6 POWER lamp Comes on when the power is supplied after the POWER switch is turned on Note This lamp indicate the power state of each device For the power state of each device check the POWER lamp on each...

Page 21: ... 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 can cause the shorted state and the contact portion may be overheated and scattered Accordingly prepare the fire retarding protective cover 2 output terminal 2 output terminal 1Fan motor CAUTION ...

Page 22: ...see 2 Connection between Master and Slave 4 Install this device with a clearance of at least 20cm between the wall and the rear SLAVE UNIT POWER READY OVER CHAR OVER HEAT OVER CURR Master Slave Front Rear Option PLC WELD STAR Start signal 1 Option Input from PLC after force end Weld force signal 1 Option Input force timing from PLC Welding head Option V SENS cable 2 Connect near electrode Secondar...

Page 23: ... than the specified the welding is not performed correctly There is no rule about the order of connection in the specified connectors so connect them depending on arrangement of devices The position to connect the CURR SIG connector to the master is specified the connectors shown with diagonal line There is no rule about the order of connection in the specified connectors so connect them depending...

Page 24: ... master and 2 slaves When connecting 1 master and 3 slaves When connecting 1 master and 4 slaves When connecting 1 master and 5 slaves Master Slave Slave Slave Slave Slave Master Slave Slave Slave Slave Slave Slave Master Master Slave Slave Slave ...

Page 25: ...MD Series 5 Connection 5 4 When connecting 1 master and 6 slaves When connecting 1 master and 7 slaves Master Slave Slave Slave Slave Slave Slave Slave Master Slave Slave Slave Slave Slave Slave ...

Page 26: ...s 5 Connection 5 5 When connecting 1 master and 8 slaves When connecting 1 master and 9 slaves Master Slave Slave Slave Slave Slave Slave Slave Slave Slave Master Slave Slave Slave Slave Slave Slave Slave Slave ...

Page 27: ...n 5 6 When connecting 1 master and 10 slaves When connecting 1 master and 11 slaves Master Slave Slave Slave Slave Slave Slave Slave Slave Slave Slave Slave Master Slave Slave Slave Slave Slave Slave Slave Slave Slave Slave ...

Page 28: ...20 7 19 6 18 5 17 4 16 3 15 2 14 1 WE ON OFF PO SEL 2ND OUT COM READY CAUTION END NG GOOD CNTR RESET ERR RESET COM PARITY SCH16 SCH 8 SCH 4 SCH 2 SCH 1 COM STOP EXT COM INT 24V INT 24V EXT COM STOP 2ND COM SCH 1 SCH 2 SCH 4 SCH 8 SCH16 PARITY COM PO SEL WE ON OFF ERR RESET CNTR RESET GOOD NG END CAUTION READY OUT COM ...

Page 29: ... ON OFF PO SEL 2ND PNP current output type 24VDC PLC OUT COM READY CAUTION END NG GOOD CNTR RESET ERR RESET PARITY SCH16 SCH 8 SCH 4 SCH 2 SCH 1 STOP EXT COM INT 24V INT 24V EXT COM STOP 2ND SCH 1 SCH 2 SCH 4 SCH 8 SCH16 PARITY PO SEL WE ON OFF ERR RESET CNTR RESET GOOD NG END CAUTION READY OUT COM PLC PNP current output type 24 V DC ...

Page 30: ...onitor calculation time 10 ms 4 For the output time of end signal and normal signal refer to 4 External output signal For the processing time of screen display time communication output time etc refer to 5 Screen display and communication time 5 When the monitor value is within the setting range the normal signal is output When the monitor value is outside the range or a fault occurs a fault signa...

Page 31: ... are not output 3 Monitor calculation time 10 ms 4 For the output time of end signal and normal signal refer to 4 External output signal For the processing time of screen display time communication output time etc refer to 5 Screen display and communication time 5 When the monitor value is within the setting range the normal signal is output When the monitor value is outside the range or a fault o...

Page 32: ...schedule select signal and start signal refer to 3 External input signal 3 When a fault or caution occurs in precheck welding welding is not performed in WE and the fault signal or the caution signal is output GOOD END NG CAUTION HD WE SQ CP RC 3 4 6 6 3 3 UP DS 3 6 3 6 5 1 HD WE SQ CP RC 3 UP DS SCH1 2 4 8 16 2 1 Start input Welding current Welding current is open is closed End output Normal outp...

Page 33: ... fault signal or caution signal is output The selection of fault signal or caution signal can be changed on the ERROR SETTING screen 7 The weld force signal cannot be controlled with this device Control it by PLC or the like For the timing of weld force refer to 6 Weld force signal 2 step welding without polarity switching When SCHEDULE MODE is set to DOUBLE POLARITY CHANGE to OFF on the STATUS sc...

Page 34: ...aution signal can be changed on the ERROR SETTING screen At this time the end signal and the normal signal are not output 4 Monitor calculation time 10 ms 5 For the output time of end signal and normal signal refer to 4 External output signal For the processing time of screen display time communication output time etc refer to 5 Screen display and communication time 6 When the monitor value is wit...

Page 35: ...me 1 For the timing of polarity switching select signal refer to 3 External input signal 2 For the timing of schedule select signal and start signal refer to 3 External input signal NG CAUTION GOOD END CP RC SQ W1 HD W2 CL 4 3 6 6 3 3 U1 D1 U2 D2 3 6 3 6 5 CP RC SQ W1 HD W2 CL 3 U1 D1 U2 D2 1 2 SCH1 2 4 8 16 1 Schdule select input Start input Welding current Welding current is open is closed End o...

Page 36: ... normal signal refer to 4 External output signal For the processing time of screen display time communication output time etc refer to 5 Screen display and communication time 6 When the monitor value is within the setting range the normal signal is output When the monitor value is outside the range or a fault occurs a fault signal or caution signal is output The selection of fault signal or cautio...

Page 37: ...ration from start input to weld sequence start Common to MD series 1 Time duration from start input to weld sequence start changes depending on the setting of START SIG TIME on the STATUS screen The following time is required 1 ms for 1 ms setting 5 ms for 5 ms setting 10 ms for 10 ms setting and 20 ms for 20 ms setting PARITY SCH 16 SCH 8 SCH 4 SCH 2 SCH 1 1 Schedule select input Schedule select ...

Page 38: ...e squeeze start Polarity switching select signal MD B series only Screen other than SCHEDULE screen Input the polarity switching select signal 16 ms or more before the start signal SCHEDULE screen Input the polarity switching select signal 52 ms or more before the start signal The waveform display on the SCHEDULE screen is changed END SQ RC CP W1 CL HD W2 Start input Welding current 1 NO HOLD sett...

Page 39: ...normal signal is output for the same time as that of the end signal For the timing of output refer to 1 MD A series and 2 MD B series Output time of fault signal and caution signal 1 The fault signal is output when a fault occurs Outputs until the fault reset is input 2 The caution signal is output when a caution occurs Outputs until the fault reset is input and the next start is input END SQ HD R...

Page 40: ...ls are output when a fault or caution occurs Ready signal The ready signal is turned off when weld sequence is operated fault occurs or welding is turned off The signal is turned off when the weld sequence starts and turned on when the welding is being processed and the charging is complete When a fault occurs during welding operation it is turned off until a fault reset is input Welding processin...

Page 41: ...cation speed 47 ms max 38400 bps of communication speed 26 ms max When COMMUNICATION MODE on the STATUS screen is C MODE 9600 bps of communication speed 136 ms max 19200 bps of communication speed 72 ms max 38400 bps of communication speed 39 ms max Screen display time The display time varies by screen Displays the screen after the start of end output Menu screen 14 ms max SCHEDULE screen 80 ms ma...

Page 42: ... signal such as schedule select polarity switching select etc is changed When a fault and caution occur during welding 1 For the timing of the end signal refer to 1 MD A series and 2 MD B series Communication output time Communication output of monitor value Outputs after the start of end output When COMMUNICATION MODE on the STATUS screen is B MODE 9600 bps of communication speed 110 ms max 19200...

Page 43: ...reen display are all complete Fault reset waiting time 5 ms For the processing time at fault reset refer to Screen display at fault reset Screen display at fault reset Fault reset input time Input at least 30 ms For the timing of the acceptance of the fault reset refer to 5 Screen display and communication time Screen display time Fault reset processing and screen display time Screen display 212 m...

Page 44: ... the weld force by PLC or the like 1 Keep the weld force stable before the squeeze time is over When not setting SQ keep it stable before the squeeze time starts 2 Turn off the weld force after the hold time is over SOL HD W1 W2 CL SQ CP RC U1 D1 U2 D2 1 2 Weld force output Welding current Schedule select input Start input SCH1 to 16 2ND ...

Page 45: ...y 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 show the paragraph No in the chapter Setting of Values Move the cursor to the number or ON or OFF to be set or changed and press key to complete such setting as input of a number or change of ON OFF ...

Page 46: ...he cursor to SCHEDULE and press the ENTER key to display the SCHEDULE screen as follows 1 When 2 step weld sequence is selected When SCHEDULE MODE on the STATUS screen is set to DOUBLE 2 When 1 step weld sequence is selected When SCHEDULE MODE on the STATUS screen is set to SINGLE a SCH Denotes No of SCHEDULE welding condition Input the schedule number to set After welding the number is switched t...

Page 47: ...nslope is short there is not so much of a difference between the weld time WE1 and WE2 and the time of upslope downslope the set current value and the monitored average value may be different The difference between the set value and the monitored value varies depending on the rise rate of current The monitored interval can be set in MONITOR FIRST TIME Refer to 6 MONITOR FIRST TIME c CURR 2 Control...

Page 48: ...can be switched 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 displaying data of two or less When displaying data of three or more a SCH Denotes No of SCHEDULE welding condition Input the schedule number that you want to check the waveform and measured va...

Page 49: ...aveform 3 Grid spacing of waveform horizontal axis Displays the grid spacing for time axis of waveform 4 Measured value of WE1 Displays the measured value of WE1 welding for each measured value 5 Measured value of WE2 Displays the measured value of WE2 welding for each measured value Not displayed when SCHEDULE MODE on the STATUS screen is set to SINGLE 6 Count Displays the count of the welding ju...

Page 50: ...age 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 lower limits of current voltage and power called monitor values Measured values within the set monitor value range are judged good and those out of the range are judged no good If measured values and mo...

Page 51: ... for upper lower 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 of power for WE1 and WE2 respectively The setting range is 00 0 kW to 99 9 kW or 000 kW to 999 kW When SCHEDULE MODE on the STATUS screen is set to SINGLE upper limit H lower limit L and ...

Page 52: ...wer 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 and the current value to measure becomes higher than normal On the other hand when two or more parts are set or the contact is poor the resistance value becomes high and the current value to measure b...

Page 53: ...a 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 average value respectively LOW Lower limit of current for precheck welding Set the lower limit of current for PEAK peak value and AVE average value respectively f PRECHECK Sets whether to perform the pre...

Page 54: ...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 four STATUS screens are actually used Press the or key to change the settings Finally press the ENTER key to complete the setting operation Select NEXT to move to the second screen The first screen is common to all models Sele...

Page 55: ... 0kA 20 0kA 50 0kA Master 1 Slave 5 6 00kA 12 0kA 24 0kA 60 0kA Master 1 Slave 6 7 00kA 14 0kA 28 0kA 70 0kA Master 1 Slave 7 8 00kA 16 0kA 32 0kA 80 0kA Master 1 Slave 8 9 00kA 18 0kA 36 0kA 90 0kA Master 1 Slave 9 10 0kA 20 0kA 40 0kA 100kA Master 1 Slave 10 11 0kA 22 0kA 44 0kA 110kA MD A10000A Master 1 Slave 11 12 0kA 24 0kA 48 0kA 120kA MD B5000A Master 1 Slave 1 1 00kA 2 00kA 4 00kA 10 0kA 3...

Page 56: ... used 6 START SIG HOLD Selects the self holding timing for starting SQ HOLD Self holding is valid from the beginning of the squeeze sequence Even when the start signal is opened during the sequence operation the sequence does not stop WE HOLD Self holding is valid from the beginning of the weld sequence When the start signal is opened during the squeeze time SQ the sequence stops NO HOLD No self h...

Page 57: ... and the current rise portion tends to overshoot The set value can be changed within the range from 1 to 4 In most cases the initial setting should not be changed NEXT Moves to the STATUS 2 2 screen KEY LOCK Prevents the details of schedule from being changed via the panel Prevents changes in the various set values when the panel keys are pressed ON Change impossible OFF Change possible NG SIGNAL ...

Page 58: ...e setting ranges are W1 0 00 to 9 99 ms COOL 0 00 to 9 99 ms and W2 0 00 to 9 99 ms LONG The setting ranges are W1 00 0 to 99 9 ms COOL 00 0 to 49 9 ms and W2 00 0 to 99 9 ms Set the total time of W1 CO and W2 to 100 ms or less Time period for which a welding can be performed The time period for which a welding can be performed depends on the setting of current value and the status of load Check t...

Page 59: ...set to DATA OUTPUT B MODE Performs the same one way communication as MD A1000B MD A4000B MD A8000B MD B2000B MD B4000B and MD C2000B C MODE Adds the weld time monitor value of precheck welding etc to B MODE and performs the one way communication For contents output in communication refer to 9 External Communication Function 22 COMMUNICATION UNIT Inputs the device No ID The range is 01 to 31 When p...

Page 60: ...ach item Fault code Contents E04 NO CURRENT No current E05 NO VOLTAGE No voltage E06 OUT LIMIT OF CURR Fault of current E07 OUT LIMIT OF VOLT Fault of voltage E08 OUT LIMIT OF POWER Fault of power E15 PRECHECK ERROR Precheck error E18 COUNT MEMORY TROUBLE Count memory trouble E20 CYCLE TROUBLE The start signal is turned off during welding ...

Page 61: ...itor values average current and average voltage Change these settings to suit your purpose of use Refer to 5 Connection and connect peripheral equipment correctly to the MD A10000A Turn the POWER switches of all connected devices on and press the MENU key Turn on the POWER switch of the slave device before turning on that of the master device Otherwise a fault may occur Check that the display scre...

Page 62: ...TUS screen 7 Move the cursor to ERROR and press the cursor key Z to go to the following screen Set the signals trouble caution signals to be output when a fault occurs In this example all items are set OFF to output the trouble signal ON Caution signal output start signal acceptable OFF Trouble signal output start signal unacceptable Operation on the STATUS screen is now complete Press the MENU ke...

Page 63: ...n the WELD lamp on the front panel comes on and Pin 8 WE ON OFF of the I O connector on the front panel are closed It goes out when a fault occurs welding or charging Input the schedule select signal Turn on close SCH1 SCH2 SCH4 SCH8 SCH16 as well as PARITY of the I O connector on the front panel to select schedule No 15 Turn on close the 2ND start input to start welding The welding starts when th...

Page 64: ... in Lower the voltage when the peak current of precheck welding is flowing around the current value set for CURRENT RANGE on the STATUS screen Since the current is also put a limit with the maximum current at the precheck welding the precheck welding will not be performed correctly Next move to the COMPARATOR screen and set the upper and lower limit ranges of the CURR VOLT and POWER Set H at the m...

Page 65: ... again repair is required Contact us E02 SYSTEM ERROR A fault 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 Stop operation let the equipment to cool off and press the RESET button The device is overheated or the overcurrent is flowing The trouble state of the slave device can be check...

Page 66: ...uit This message appears when charging is not completed within 7 seconds after power is turned on Turn off the power immediately and contact us or your distributor E13 CHARGE TROUBLE OVER Failure of the charging circuit Displayed when the charging voltage is too high Turn off the power immediately and contact us or your distributor The trouble state of the slave device can be checked by the OVER C...

Page 67: ...power noise and electrostatic noise Faults in the supply voltage due to thunderbolts or lightning conduction Decrease in voltage of battery for memory backup E19 VOLT SENS ERROR The V SENS cable is broken or disconnected Confirm the connection of the V SENS cable 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 In...

Page 68: ...ations 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 code LF code LF 0AH CR code CR 0DH Space SP 32H Connector D Sub 9 pins connector 1 RS 2 RS 3 RS 4 RS 9 SG ...

Page 69: ...ng code 1 step welding W1 fixed C Schedule No 01 to 31 1 0 00 to 9 99 kA 4 2 00 0 to 99 9 kA 4 D 3 Peak value 000 to 999 kA 4 1 0 00 to 9 99 kA 4 2 00 0 to 99 9 kA 4 E 3 WELD Current Average value 000 to 999 kA 4 F Peak value 0 00 to 9 99 V 4 G WELD Voltage Average value 0 00 to 9 99 V 4 1 00 0 to 99 9 kW 4 H 2 3 WELD Power average value 000 to 999 kW 4 I WELD Resistance average value 0 00 to 9 99...

Page 70: ...to 999 kA 4 F Peak value 0 00 to 9 99 V 4 G W1 Voltage 1 Average value 0 00 to 9 99 V 4 1 00 0 to 99 9 kW 4 H 2 3 W1 Power 1 average value 000 to 999 kW 4 I W1 Resistance 1 average value 0 00 to 9 99 mΩ 4 J W2 Welding code 2 step welding W2 fixed 1 0 00 to 9 99 kA 4 2 00 0 to 99 9 kA 4 K 3 Peak value 000 to 999 kA 4 1 0 00 to 9 99 kA 4 2 00 0 to 99 9 kA 4 L 3 W2 Weld 2 Average value 000 to 999 kA ...

Page 71: ... five faults Data strings E 01 06 07 08 09 10 CR A B C C C C C D Ex E 01 06 07 08 09 10 CR Item Character string Content Range A E Fault send code E fixed B Schedule No 01 to 31 C 1 Fault code 01 to 20 D CR CR code 0DH fixed 1 Up to five fault codes are output If two or more fault codes exist the codes are separated with If no fault exists E00 is output ...

Page 72: ...A Current value in kA kA F W1 Welding code 1 step welding W1 fixed 1 0 00 to 9 99 kA 6 2 00 0 to 99 9 kA 6 G 3 Peak value 0000 to 0999 kA 6 1 0 00 to 9 99 kA 6 2 00 0 to 99 9 kA 6 H 3 WELD Current Average value 0000 to 0999 kA 6 I Peak value 0 00 to 9 99 V 6 J WELD Voltage Average value 0 00 to 9 99 V 6 1 00 0 to 99 9 kW 6 K 2 3 WELD Power average value 0000 to 0999 kW 6 L WELD Resistance average ...

Page 73: ...RANGE on the STATUS screen is kA 2 When CURRENT RANGE on the STATUS screen is kA 3 When CURRENT RANGE on the STATUS screen is kA 4 When WELD TIME on the STATUS screen is NORMAL 5 When WELD TIME on the STATUS screen is LONG 6 When the value exceeds the display range ...

Page 74: ...e 1 step welding W1 fixed 1 0 00 to 9 99 kA 6 2 00 0 to 99 9 kA 6 G 3 Peak value 0000 to 0999 kA 6 1 0 00 to 9 99 kA 6 2 00 0 to 99 9 kA 6 H 3 W1 Weld 1 Average value 0000 to 0999 kA 6 I Peak value 0 00 to 9 99 V 6 J W1 Voltage 1 Average value 0 00 to 9 99 V 6 1 00 0 to 99 9 kW 6 K 2 3 W1 Power 1 average value 0000 to 0999 kW 6 L W1 Resistance 1 average value 0 00 to 9 99 mΩ 6 4 0 00 to 9 99 ms M ...

Page 75: ...0 to 9 99 kA 6 2 00 0 to 99 9 kA 6 X 3 PRECHECK Current Average value 0000 to 0999 kA 6 4 0 00 to 1 00 ms Y 5 PRECHECK Weld time Set time 00 0 to 01 0 ms Z CR LF CR LF code 0DH 0AH fixed 1 When CURRENT RANGE on the STATUS screen is kA 2 When CURRENT RANGE on the STATUS screen is kA 3 When CURRENT RANGE on the STATUS screen is kA 4 When WELD TIME on the STATUS screen is NORMAL 5 When WELD TIME on t...

Page 76: ... faults Data strings E 01 06 07 08 09 10 CR LF A B C C C C C D Ex E 01 06 07 08 09 10 CR LF Item Character string Content Range A E Fault send code E fixed B Schedule No 01 to 31 C 1 Fault code 01 to 20 D CR LF CR LF code 0DH 0AH fixed 1 Up to five fault codes are output If two or more fault codes exist the codes are separated with If no fault exists E00 is output ...

Page 77: ...about Model and ROM version Device No I 1 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 A10000A V00 01A CR LF When the Device No ID1 ID2 is all connected devices respond The time lag of response is 100 ms multiplied by the Device No Reading of data Device No R Schedule No Specified code No 2 Ex Read...

Page 78: ...2 CD3 CR LF 01R000S13 CR LF MD series Host PC ID1 ID2 SH1 SH2 SH3 CD1 CD2 CD3 Data CR LF 01001S13 Data CR LF Write 000 for Schedule No SH1 SH2 SH3 Write S13 for Specified code No CD1 CD2 CD3 See 2 Data code table for the data order Schedule No for data output from the MD series becomes last welded Schedule No Resetting of fault Device No W Schedule No Specified code No Data 6 Ex Reset the fault of...

Page 79: ...ed 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 screen setting Changes the initial setting Specify the specified code No to perform reading and writing Set 000 for Schedule No S08 COMMUNICATION SETTING screen setting Changes the communication sett...

Page 80: ... ms 0 01 B 2 UP Upslope time 00 0 to 99 9 ms 0 1 1 0 00 to 9 99 ms 0 01 C 2 WE Weld time 00 0 to 99 9 ms 0 1 1 0 00 to 9 99 ms 0 01 D 2 DS Downslope time 00 0 to 99 9 ms 0 1 E HD Hold time 000 to 999 ms 1 F Unit of current value kA Current value in kA kA 3 0 00 to 9 99 kA 6 0 01 4 00 0 to 99 9 kA 6 0 1 G 5 WE Current value 0000 to 0999 kA 6 1 H WE Voltage value 0 00 to 9 99 V 0 01 1 When WELD TIME...

Page 81: ... 00 0 to 99 9 ms 0 1 1 0 00 to 9 99 ms 0 01 C 2 W1 Weld 1 time 00 0 to 99 9 ms 0 1 1 0 00 to 9 99 ms 0 01 D 2 D1 Downslope 1 time 00 0 to 99 9 ms 0 1 1 0 00 to 9 99 ms 0 01 E 2 CL Cool time 00 0 to 49 9 ms 0 1 1 0 00 to 9 99 ms 0 01 F 2 U2 Upslope 2 time 00 0 to 99 9 ms 0 1 1 0 00 to 9 99 ms 0 01 G 2 W2 Weld 2 time 00 0 to 99 9 ms 0 1 1 0 00 to 9 99 ms 0 01 H 2 D2 Downslope 2 time 00 0 to 99 9 ms ...

Page 82: ...n reading Device No 01 Set 000 for Schedule No Host PC MD series 01R000S03 CR LF MD series Host PC 01000S03 1 1 0 0 1 1 CR LF A B C D E F Item Character 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 value 0 Hide 1 Display 0 to 1 1 D Display of resistance m...

Page 83: ... 9 99 kA 0 01 2 00 0 to 99 9 kA 0 1 B 3 WE Current upper limit 0000 to 0999 kA 1 1 0 00 to 9 99 kA 0 01 2 00 0 to 99 9 kA 0 1 C 3 WE Current lower limit 0000 to 0999 kA 1 D Current judgment setting 0 With average value 1 With peak value 0 to 1 1 E WE Voltage upper limit 0 00 to 9 99 V 0 01 F WE Voltage lower limit 0 00 to 9 99 V 0 01 G Voltage judgment setting 0 With average value 1 With peak valu...

Page 84: ... 0999 kA 1 1 0 00 to 9 99 kA 0 01 2 00 0 to 99 9 kA 0 1 C 3 W1 Weld 1 current lower limit 0000 to 0999 kA 1 1 0 00 to 9 99 kA 0 01 2 00 0 to 99 9 kA 0 1 D 3 W2 Weld 2 current upper limit 0000 to 0999 kA 1 1 0 00 to 9 99 kA 0 01 2 00 0 to 99 9 kA 0 1 E 3 W2 Weld 2 current lower limit 0000 to 0999 kA 1 F Current judgment setting 0 With average value 1 With peak value 0 to 1 1 G W1 Weld 1 voltage upp...

Page 85: ...crement 1 00 0 to 99 9 kW 0 1 N 2 3 W2 Weld 2 power upper limit 0000 to 0999 kW 1 1 00 0 to 99 9 kW 0 1 O 2 3 W2 Weld 2 power lower limit 0000 to 0999 kW 1 1 When CURRENT RANGE on the STATUS screen is kA 2 When CURRENT RANGE on the STATUS screen is kA 3 When CURRENT RANGE on the STATUS screen is kA ...

Page 86: ...nt value kA Current value in kA kA 3 0 00 to 9 99 kA 0 01 4 00 0 to 99 9 kA 0 1 E 5 RC Current peak value upper limit 0000 to 0999 kA 1 3 0 00 to 9 99 kA 0 01 4 00 0 to 99 9 kA 0 1 F 5 RC Current peak value lower limit 0000 to 0999 kA 1 3 0 00 to 9 99 kA 0 01 4 00 0 to 99 9 kA 0 1 G 5 RC Current average value upper limit 0000 to 0999 kA 1 3 0 00 to 9 99 kA 0 01 4 00 0 to 99 9 kA 0 1 H 5 RC Current...

Page 87: ... 3 10 0kA MD A10000A slave 1 0 2 00kA 1 4 00kA 2 8 00kA 3 20 0kA MD A10000A slave 2 0 3 00kA 1 6 00kA 2 12 0kA 3 30 0kA MD A10000A slave 3 0 4 00kA 1 8 00kA 2 16 0kA 3 40 0kA MD A10000A slave 4 0 5 00kA 1 10 0kA 2 20 0kA 3 50 0kA MD A10000A slave 5 0 6 00kA 1 12 0kA 2 24 0kA 3 60 0kA MD A10000A slave 6 0 7 00kA 1 14 0kA 2 28 0kA 3 70 0kA MD A10000A slave 7 0 8 00kA 1 16 0kA 2 32 0kA 3 80 0kA MD A1...

Page 88: ...on method 0 EXT P 1 EXT NP 2 PANEL 0 to 2 1 H END SIG TIME End signal time 0 10ms ST 1 10ms 2 20ms 3 30ms 4 40ms 5 50ms 6 60ms 7 70ms 8 80ms 9 90ms 10 100ms 11 110ms 12 120ms 13 130ms 14 140ms 15 150ms 16 160ms 17 170ms 18 180ms 19 190ms 20 200ms 0 to 20 1 I VOLT RESPONSE Voltage detection response 0 1 1 2 2 3 3 4 0 to 3 1 J KEY LOCK Disabling the schedule via panel 0 Can be changed 1 Can not be c...

Page 89: ...ting 00 1 OFF 000 0 to 099 9 measurement start time ms 00 1 to 099 9 0 1 O WELD TIME Length of weld time 0 NORMAL 1 LONG 0 to 1 1 P 1 POLARITY CHANGE Welding polarity method 0 OFF 1 ON 0 to 1 1 Q 2 SEQUENCE WELD Sequence welding 0 0 1 R 2 MONITOR SELECT Monitor selection method 0 0 1 1 Function for MD B5000A only For other models set to 0 2 Set to 0 ...

Page 90: ... 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 B MODE 1 C MODE 0 to 1 1 C COMMUNICATION UNIT Device No 1 to 31 1 D COMMUNICATION SPEED Communication speed 0 9600bps 1 19200bps 2 38400bps 0 to 2 1 1 When changing the communication setting change t...

Page 91: ...F 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 NO VOLTAGE 0 to 1 1 C OUT LIMIT OF CURR 0 to 1 1 D OUT LIMIT OF VOLT 0 to 1 1 E OUT LIMIT OF POWER 0 to 1 1 F PRECHECK ERROR 0 to 1 1 G COUNT MEMORY TROUBLE 0 to 1 1 H CYCLE TROUBLE 0 to 1 1 ...

Page 92: ...3 WELD Current average value 0000 to 0999 kA 6 E WELD Voltage peak value 0 00 to 9 99 V 6 F WELD Voltage average value 0 00 to 9 99 V 6 1 00 0 to 99 9 kW 6 G 2 3 WELD Power average value 0000 to 0999 kW 6 H WELD Resistance average value 0 00 to 9 99 mΩ 6 4 0 00 to 9 99 ms I 5 WELD Weld time Set time 00 0 to 99 9 ms 1 0 00 to 9 99 kA 6 2 00 0 to 99 0 kA 6 J 3 PRECHECK Current peak value 0000 to 099...

Page 93: ...99 0 kA 6 C 3 W1 Current 1 peak value 0000 to 0999 kA 6 1 0 00 to 9 99 kA 6 2 00 0 to 99 0 kA 6 D 3 W1 Current 1 average value 0000 to 0999 kA 6 E W1 Voltage 1 peak value 0 00 to 9 99 V 6 F W1 Voltage 1 average value 0 00 to 9 99 V 6 1 00 0 to 99 9 kW 6 G 2 3 W1 Power 1 average value 0000 to 0999 kW 6 H W1 Resistance 1 average value 0 00 to 9 99 mΩ 6 4 0 00 to 9 99 ms I 5 W1 Weld 1 time Set time 0...

Page 94: ...1 0 00 to 9 99 kA 6 2 00 0 to 99 0 kA 6 R 3 PRECHECK Current average value 0000 to 0999 kA 6 4 0 00 to 1 00 ms S 5 PRECHECK Weld time Set time 00 0 to 01 0 ms 1 When CURRENT RANGE on the STATUS screen is kA 2 When CURRENT RANGE on the STATUS screen is kA 3 When CURRENT RANGE on the STATUS screen is kA 4 When WELD TIME on the STATUS screen is NORMAL 5 When WELD TIME on the STATUS screen is LONG 6 W...

Page 95: ... Host PC MD series 01R000S13 CR LF MD series Host PC in case of one fault 01000S13 E06 CR LF A MD series Host PC in case 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 codes are separated with If no fault exists E00 is output ...

Page 96: ... 0 to 99 9 kA 0000 to 0999 kW MD A10000A Slave 3 40 0kA 00 0 to 40 0 kA 00 0 to 99 9 kA 0000 to 0999 kW 5 00kA 0 00 to 5 00 kA 0 00 to 9 99 kA 00 0 to 99 9 kW 10 0kA 00 0 to 10 0 kA 00 0 to 99 9 kA 0000 to 0999 kW 20 0kA 00 0 to 20 0 kA 00 0 to 99 9 kA 0000 to 0999 kW MD A10000A Slave 4 50 0kA 00 0 to 50 0 kA 00 0 to 99 9 kA 0000 to 0999 kW 6 00kA 0 00 to 6 00 kA 0 00 to 9 99 kA 00 0 to 99 9 kW 12...

Page 97: ...99 kW 22 0kA 00 0 to 22 0 kA 00 0 to 99 9 kA 0000 to 0999 kW 44 0kA 00 0 to 44 0 kA 00 0 to 99 9 kA 0000 to 0999 kW MD A10000A Slave 10 110kA 0000 to 0110 kA 0000 to 0999 kA 0000 to 0999 kW 12 0kA 00 0 to 12 0 kA 00 0 to 99 9 kA 0000 to 0999 kW 24 0kA 00 0 to 24 0 kA 00 0 to 99 9 kA 0000 to 0999 kW 48 0kA 00 0 to 48 0 kA 00 0 to 99 9 kA 0000 to 0999 kW MD A10000A Slave 11 120kA 0000 to 0120 kA 000...

Page 98: ...simultaneously and priority is given to the control method whichever reaches the set value Timer setting 1 step weld sequence a Squeeze 0000 9999 ms b Precheck weld 0 00 1 00 ms 1 c Precheck judgment 2 ms fixed 1 d Upslope 0 00 9 99 ms 00 0 99 9 ms 2 e Weld 0 00 9 99 ms 00 0 99 9 ms f Downslope 0 00 9 99 ms 00 0 99 9 ms 2 g Hold 000 999 ms 2 step weld sequence a Squeeze 0000 9999 ms b Precheck wel...

Page 99: ...tting range 5 MD A10000A Master 1 Slave 0 0 00 1 00 kA 0 01kA increment 0 00 2 00 kA 0 01kA increment 0 00 4 00 kA 0 01kA increment 00 0 10 0 kA 0 1kA increment MD A10000A Master 1 Slave 1 0 00 2 00 kA 0 01kA increment 0 00 4 00 kA 0 01kA increment 0 00 8 00 kA 0 01kA increment 00 0 20 0 kA 0 1kA increment MD A10000A Master 1 Slave 2 0 00 3 00 kA 0 01kA increment 0 00 6 00 kA 0 01kA increment 00 0...

Page 100: ...nt 0 00 2 00 kA 0 01kA increment 0 00 4 00 kA 0 01kA increment 00 0 10 0 kA 0 1kA increment Voltage setting range 0 00 9 99 V 0 01 V increment Current setting accuracy 3 of maximum range When the specified load used Voltage setting accuracy 3 of maximum range When the specified load used Inductive component not included Repetition speed Refer to 2 Duty Cycle Graph Resistance precheck function Volt...

Page 101: ...y select 6 Common to all schedules Set by POLARITY CHANGE 2 step welding only ON The polarity of WE2 is opposite to that of WE1 OFF The polarity of WE2 is the same as that of WE1 Voltage detection response select Common to all schedules Set by VOLT RESPONSE Selected from among 1 2 3 4 steps No current no voltage neglecting time Set by NO CURR MONITOR START 00 5 99 9 ms Measured value start time Se...

Page 102: ... 0 15 0 20 0 ms 通電時間Ｔ 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 溶接電流 1 45 8000 1 00 9 990 T 1 S Weld cycle 1 time sec Load 1m Ω Welding current Weld time T ...

Page 103: ...Ｔ Weld cycle 1 time sec Load 1mΩ 1s 20 0 25 0 30 0 35 0 40 0 45 0 50 0 55 0 60 0 65 0 70 0 75 0 80 0 85 0 90 0 95 0 100 0ms 0 1000 2000 3000 5000 6000 7000 8000 9000 10000A 4000 20 0 2100 20 0 1630 50 0 1100 50 0 800 99 9 500 99 9 700 Weld time T Welding current ...

Page 104: ... ms Therefore in the case of above example the welding up to 8 15 ms per second can be performed These are duty cycle graphs in 1 mΩ load When the load capacity changes the time to perform welding per second may change too 3 Board List for Maintenance For repair or replacement contact us Board Master Slave Main control board ME 3086 13S1 Charge board ME 1876 00 ME 1876 00 Power block board ME 3102...

Page 105: ...UT FAN FET TH FET TH CONTROL CURR SIG Power block part Control part Display Current sensing part Charging part Slave AC INPUT OUTPUT I O FAN FET TH FET TH CONTROL CURR SIG Power block part LCD display Control part Operating part Current sensing part Charging part Master ...

Page 106: ... FET FET TH OUTPUT CONTROL CURR SIG LCD display Control part Operating part Current sensing part Charging part Power block part Master AC INPUT FAN TH FET FET TH OUTPUT CONTROL CURR SIG Control part Display Charging part Current sensing part Power block part Slave ...

Page 107: ...2 Slave Dimensions in mm 18 18 40 30 40 8 M8 146 174 10 240 240 49 5 49 5 33 10 23 5 636 102 40 35 40 350 9 6 φ9 Back side 102 18 18 40 30 40 40 35 40 8 M8 146 174 SLAVE UNIT POWER READY OVER CHAR OVER HEAT OVER CURR 350 240 240 49 5 49 5 10 10 23 5 614 WELD STAR 9 6 φ9 Back side ...

Page 108: ...dule Data Table SCH SQ WE1 COOL WE2 HOLD WE1 CURR WE2 WE1 VOLT WE2 H CURR WE1 L H CURR WE2 L CURR AVE PEAK H VOLT WE1 L H VOLT WE2 L VOLT AVE PEAK H POWER WE1 L H POWER WE2 L TIME VOLT HIGH PEAK LOW HIGH AVE LOW ON OFF COMPARATOR SCHEDULE PRECHECK ...

Page 109: ... NG SIGNAL TYPE NO CURR MONITOR START MONITOR FIRST TIME WELD TIME POLARITY CHANGE COMMUNICATION CONTROL COMMUNICATION MODE COMMUNICATION UNIT COMMUNICATION SPEED E04 NO CURRENT E05 NO VOLTAGE E06 OUT LIMIT OF CURR E07 OUT LIMIT OF VOLT E08 OUT LIMIT OF POWER E15 PRECHECK ERROR E18 COUNT MEMORY TROUBLE E20 CYCLE TROUBLE STATUS ERROR SETTING COMMUNICATION SETTING ...

Page 110: ...ction Difference Depending on Mode 1 5 I I O connector 4 3 INPUT POWER connector 4 2 4 8 M Major Components List 10 7 Master 1 5 5 2 11 1 MENU key 4 2 Menu Screen 6 1 MONITOR Screen 6 4 O Options 3 2 Outline Drawing 11 1 OVER CHAR lamp 4 7 OVER CURR lamp 4 7 OVER HEAT lamp 4 7 P Polarity switching type 2 1 POWER lamp 4 1 4 8 POWER switch 4 2 4 8 PRECHECK Screen 6 8 Product Specifications 10 1 R RE...

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