Amada MG3 Hot Bar User manual

Original Instructions
76609576EN-MG3-HB-V1.0a
Digital Measuring Unit
MG3 Hot Bar
OPERATING INSTRUCTIONS

MG3 Hot Bar
76609576EN-MG3-HB-V1_0a.docx 2/49 2015-07-22
Annex:
-Safety Regulations
-General References on Resistance Welding
-Contact Addresses
Copyright 2015:
AMADA MIYACHI EUROPE GmbH
Lindberghstr. 1, 82178 Puchheim, Germany
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
Version Date Revision notification
1.0 2013-04 New
1.0a 2015-10 Changed company name

MG3 Hot Bar
Table of Contents
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Table of Contents
1General Information ........................................................................... 5
1.1Preface ........................................................................................................... 5
1.2Copyrights, Proprietary Rights........................................................................ 5
1.3Definition of Symbols Used ............................................................................. 6
1.3.1Prohibition and Warning Symbols...................................................................................6
1.3.2Further Symbols .............................................................................................................7
2Technical Description.......................................................................... 8
2.1Mode of Action................................................................................................ 8
2.2Technical Data ................................................................................................ 8
3Commissioning ................................................................................... 9
3.1Connecting the Components ......................................................................... 10
3.1.1Description of the Connectors.......................................................................................10
3.1.2Connector Pin Assignment of Inputs & Outputs ............................................................11
3.1.2.1Connector X54 (Outputs) ..................................................................................................11
3.1.2.2Connector X55 (Inputs) .................................................................................................... 12
3.1.2.3Connector X38 (I/O Outputs) ............................................................................................ 13
3.1.2.4Connector X38 (I/O Inputs)...............................................................................................14
3.1.2.5Connector X51 (RS232) / Baud rate ................................................................................... 14
3.1.2.6Connector X60 and X61 (CANopen).................................................................................... 15
3.1.3Connecting Temperature Sensor...................................................................................15
3.1.4Connecting Displacement Sensor (optional) .................................................................15
3.1.5Connecting Force or Pressure Sensor (optional)...........................................................15
3.1.6WK-Adapter (optional) .................................................................................................16
3.2Initial Commissioning................................................................................... 16
3.2.1Preconditions................................................................................................................16
3.2.2Starting-up ...................................................................................................................16
4Operation.......................................................................................... 17
4.1Toggle Wheel................................................................................................ 17
4.2LED Status Display........................................................................................ 18
4.3Screen (Display)........................................................................................... 18
4.3.1Display Windows – Quadrant 1 to 4 ..............................................................................19
4.3.2Menu Bar ......................................................................................................................19
4.3.3Program Display ...........................................................................................................19
4.3.4Measuring Mode............................................................................................................19
4.3.5Status Bar.....................................................................................................................19
4.4USB Port ....................................................................................................... 20
4.5UNDO Function ............................................................................................. 20
5How to …? ........................................................................................ 21
5.1Make General Settings .................................................................................. 21
5.2Measure Temperature................................................................................... 24
5.3Switch between Single and Multiple Measurement ....................................... 26
5.4Configure the Display Windows (Quadrants)................................................ 27
5.5Measure Displacement.................................................................................. 29
5.5.1Configure Displacement Measurement..........................................................................29
5.5.2Configure Part Detection...............................................................................................30

MG3 Hot Bar
Table of Contents
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5.6Measure Pressure or Force ........................................................................... 32
5.7Set Limit Values............................................................................................ 33
5.8Copy, Save and Load Programs and Parameters ........................................... 34
5.9Count Measurements .................................................................................... 35
5.10View and Save Measuring Waveforms........................................................... 36
5.11Print Measured Values .................................................................................. 38
5.12Set and Change Password............................................................................. 39
5.13Configure the Logger .................................................................................... 40
5.14Display the Parameter Overview................................................................... 42
5.15Analyze Accept-Reject Ratio ......................................................................... 43
5.16Monitor Statistical Values ............................................................................. 44
5.17Determine Limit Values Statistically ............................................................. 45
5.18Transfer Data to PC/Laptop.......................................................................... 46
5.19Make a Screenshot of the Current Display .................................................... 46
5.20Register the Device....................................................................................... 46
6Integration in Automated Installations ............................................ 47
6.1Connection to field bus system ..................................................................... 47
7Appendix .......................................................................................... 48
7.1Error messages............................................................................................. 48
8Indexes ............................................................................................ 49
8.1Figures.......................................................................................................... 49
8.2Headwords.................................................................................................... 49

MG3 Hot Bar
General Information
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1General Information
1.1 Preface
Information about safety regulations, usage location conditions,
copyrights, protection rights, symbols, and notes on resistance
welding can be found in the annex of the operating instructions.
Please read this information carefully before using this unit.
These operating instructions shall help you to familiarize yourself with the
unit and take advantage of its application possibilities when used as directed.
The operating instructions contain 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.
The operating instructions should always be accessible at the unit operating
site. It should be read, understood and utilized by any person assigned to
work on or with the unit. This applies in particular to the notes on safety,
notes concerning safety regulations as well as safety and warning notes.
The fundamental principle applies:
Safety first!
Always carry out a function test before the first weld!
Warning
Do not operate the unit before reading these operating instructions!
1.2 Copyrights, Proprietary Rights
The copyright of these operating instructions remains the property of our
company.
These operating instructions are only meant for the internal use of the
operator of resistance welding units (hereafter called “unit”) and his/her
personnel.
It contains descriptions, technical drawings, regulations and instructions
which should not be copied, distributed, passed on to others or use without
permission for competitive purposes, whether completely or in part. In the
event of competitors endeavoring to see these operating instructions, we
expect the same fairness from you that you, in turn, would expect from your
customers in such cases.
All rights are reserved, particularly in cases of patent granting or other
registrations. We reserve the right to make technical alterations.

MG3 Hot Bar
General Information
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1.3 Definition of Symbols Used
1.3.1 Prohibition and Warning Symbols
This symbol indicates an imminent danger.
Failure to heed these instructions will lead to irreversible or even life-
threatening injuries, grave adverse effects on health or considerable material
damage.
Danger
This symbol indicates a potentially imminent danger.
Failure to heed these instructions can lead to irreversible or even life-
threatening injuries, grave adverse effects on health or considerable material
damage.
Warning
This symbol warns of hazards emanating from electrical voltage.
Failure to heed these instructions can lead to grave, irreversible or even life-
threatening injuries caused by electric shocks.
Warning
This symbol indicates a potentially harmful situation.
Failure to heed these instructions can lead to product damage or damage to
objects in its near vicinity.
Caution
This symbol indicates possibly harmful situations.
Failure to heed these instructions can lead to work delays or light damage to
the product.
Attention
Crush hazard
Magnetic field hazard
Tipping over hazard
Prohibition for wearers of cardiac pacemakers
Prohibition for wearers of metallic implants

MG3 Hot Bar
General Information
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1.3.2 Further Symbols
Wear eye protection
Disconnect power plug
Wear protection gloves
Pay attention to Operating Instructions
Information
This symbol indicates operator tips and other useful information for
optimum utilization of the machine.

MG3 Hot Bar
Technical Description
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2Technical Description
2.1 Mode of Action
The MG3 Hot Bar is a digital measuring and monitoring instrument for Hot
Bar installations.
You can adjust up to 99 programs with different parameters for monitoring.
Choose one of these programs for monitoring the welding process.
The values of the last welds (up to 2500) are stored in a buffer.
If this buffer is full (or the set number of welds to be stored is reached), the
complete measurement data packet is written as a log file onto the USB-
stick.
You can print selected parameters of each welding on a printer with serial
interface.
Individual operator configurations remain stored even when the device has
been switched off.
The MG3 is operated by a toggle wheel.
2.2 Technical Data
Program monitoring 99 programs, internal or external program
selection
Measuring functions 2 temperatures with temperature peak,
temperature integral, temperature average,
temperature gradient, temperature difference,
heat time (s)
Optional: displacement and force or pressure
Counter Up and down counter with prewarn and final value
signal-output
Measuring range
temperature Temperature 1 (T1): 25 to 600 °C Temperature 2 (T2): 25 to 600 °C
Measuring accuracy 1.5 % of upper range value for temperature
Graphic resolution Sample rate 100 ms
Measuring interval Variable
Note: The more graphics are displayed, data
through RS232 and limit values are monitored, the
longer the measuring interval.
Limit value setting Upper and lower limit value, independently from
each other
Prewarn setting Upper and lower prewarn value, independently
from each other
Graphic display VGA, 640 x 480 pixel
Optical indications 8 front LEDs
Inputs / outputs See chap. 3.1.1
Mains voltage and
frequency 110 - 240 Volt AC; 50-60 Hz, switching power supply
Power consumption 60 W
Ambient temperature 0 °C to 40 °C
Relative humidity max 70 %
Dimensions ½ 19“: (W x H x D) 280 x 140 x 340 mm
Weight approx. 5.4 kg, (approx. 11.9 lbs)

MG3 Hot Bar
Commissioning
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3Commissioning
The MG3 Hot Bar is supplied with an adjustable support stand.
To have a non-dazzling reading of the screen adjust the tilt angle with this
stand.
Fig. 1: MG3 with support stand
Remove the MG3 Hot Bar from the packing and set it up at the designated
place.
Pull apart both caps at the stand’s pivot points and adjust the desired
position.

MG3 Hot Bar
Commissioning
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3.1 Connecting the Components
3.1.1 Description of the Connectors
②
①
③④⑤ ⑥   ⑦  ⑧ ⑨
⑩
⑪
⑯⑮   ⑭  ⑬ ⑫
Fig. 2: Connectors on the housing rear side
No. Connector Function
①Mains Connector for mains cable.
Check mains voltage on type designation plate.
②On/off switch
③X56 Outputs for program number (set BCD or binary code
accordingly, 1...99)
④X55 Control inputs from peripheral equipment
⑤X54 Control outputs to peripheral equipment
⑥X38 Inputs and outputs extended I/O
⑦X31 Connector for displacement measuring or WK-Adapter
(for displacement and force or pressure measuring)
⑧X60 CANopen IN
⑨X61 CANopen Out
⑩TYPE J Connectors for thermocouples of thermode J
⑪TYPE K Connectors for thermocouples of thermode K
⑫X63 Ethernet
⑬X32 Not used
⑭X33 Not used
⑮X51 RS232 interface (e.g. to serial printer)
⑯X57 Inputs for program number (set BCD or binary code
accordingly, 1...99)