Amada MD-A8000B-05 Series User manual

AA02OM1185331-08
OPERATION MANUAL
Original instructions
TRANSISTOR WELDING POWER SUPPLY
MD-A8000B-05- □□
MD-B4000B-05- □□

MD Series
Contents
1
Thank you for purchasing our MD Series, Transistor Welding Power Supply.
For correct use, read this Operation Manual carefully. After reading, save it properly for
future reference.
Contents
1. Special Precautions ........................................................................................................ 1-1
(1) Safety Precautions....................................................................................................... 1-1
(2) Precautions for Handling ............................................................................................. 1-4
(3) On Disposal ................................................................................................................. 1-4
(4) Function Difference Depending on Model ................................................................... 1-5
2. Features ........................................................................................................................... 2-1
3. Packaging ........................................................................................................................ 3-1
(1) Accessories ................................................................................................................. 3-1
(2) Options ........................................................................................................................ 3-1
4. Name and Functions of Each Section ............................................................................. 4-1
(1) Front Panel .................................................................................................................. 4-1
(2) Rear Panel................................................................................................................... 4-3
(3) Side Panel ................................................................................................................. 4-10
5. Connection....................................................................................................................... 5-1
(1) Basic Connection......................................................................................................... 5-1
(2) Connecting 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) 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) Changing the Initial Settings (STATUS Screen) ........................................................ 6-10
7. Basic Operation............................................................................................................... 7-1
8. Error Code........................................................................................................................ 8-1
9. External Communication Function................................................................................ 9-1
(1) Communication Specifications..................................................................................... 9-1
(2) Single-Directional Communication B Mode ................................................................. 9-2
(3) Single-Directional Communication C Mode ................................................................. 9-5
(4) Bi-Directional Communication Mode ........................................................................... 9-9
10. Specifications ................................................................................................................ 10-1
(1) Specifications............................................................................................................. 10-1
(2) Duty Cycle ................................................................................................................. 10-5
(3) Board List for Maintenance........................................................................................ 10-6

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

MD Series
1. Special Precautions
1-1
1. Special Precautions
(1) Safety Precautions
Before using, read "Safety Precautions" carefully to understand the correct method
of use.
■These precautions are shown for safe use of our products and for prevention of
damage or injury to operators or others.
Be sure to read each of them, since all of them are important for safety.
■The meaning of the words and symbols is as follows.
These symbols denote
"prohibition".
They are warnings about
actions out of the scope
of the warranty of the
product.
These symbols denote
actions which operators
must take.
Each symbol with a
triangle denotes that the
content gives notice of
DANGER, WARNING or
CAUTION 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 decompose the Power
Supply
This product incorporates parts containing gallium arsenide (GaAs).
Denotes operations and practices that
may imminently result in serious injury
or loss of life if not correctly followed.
DANGER
！
Denotes operations and practices that
may result in serious injury or loss of
life if not correctly followed.
WARNING
！
Denotes operations and practices that
may result in personal injury or damage
to the Power Supply, if not correctly
followed.
CAUTION
！
DANGER
！

MD Series
1. Special Precautions
1-2
Do not put your hands between the electrodes
When welding, keep your fingers and hands away from the electrodes.
Do not touch any welded part or electrodes during welding and just after
welding finished
The welded part of a workpiece, electrodes and arm are very hot.
Do not touch them; otherwise you may be burnt.
Ground this Power Supply
If the Power Supply is not grounded, you may get an electric shock when
there is trouble, or when electricity leaks.
Apply Single-phase, 100
― 120/200 ― 240VAC power supply
Application of a voltage out of the specified range can cause fire and electric
shock.
Connect the specified cables securely
Cables of insufficient current capacities and loose connections can cause fire
and electric shock.
Do not damage the power cable and connecting cables
Do not tread on, twist or tense any cable. The power cable and connecting
cables may be broken, and 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 stay clear of the welding machine
A person who uses a pacemaker must not approach the welding machine or
walk around the welding shop while the welding machine is in operation,
without being permitted by his/her doctor. The welding machine generates a
magnetic field and has effects on the operation of the pacemaker while it is
turned on.
Protective gear must be worn
Put on protective gear such as protective gloves, long-sleeve jacket, leather
apron, etc. Surface flash and expulsion can burn the skin if they touch the
skin.
Wear protective glasses
If you look at the flash directly during welding, your eyes may be damaged.
If any surface flash and expulsion gets in your eye, you may lose your
eyesight.
WARNING
！

MD Series
1. Special Precautions
1-3
Do not splash water on the Power Supply
Water splashed over the electric parts can cause electric shock and short
circuits.
Use proper tools (wire strippers, pressure wire connectors, etc) for
termination of the connecting cables
Do not cut the conductor of wire. A flaw on it can cause fire and electric
shock.
Install the Power Supply on firm and level surface
If the Power Supply falls or drops, injury may result.
Do not place a water container on the Power Supply
If water spills, insulation will deteriorate, and this may cause electric leak and
fire.
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 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 damage hearing.
Keep a fire extinguisher nearby
Keep a fire extinguisher in the welding shop in case of fire.
Maintain and inspect the Power Supply periodically
Maintain and inspect the Power Supply periodically, and repair any damage
nearby before starting operation.
CAUTION
！

MD Series
1. Special Precautions
1-4
(2) Precautions for Handling
■When transporting or moving the Power Supply, do not lay it down. Also,
handle the Power Supply with care so as not to make an impact such as drop
on it. Moving the Power Supply by hand must be done by at least two people.
■Install this Welding Power Supply on a firm and level surface. If it is inclined,
malfunction may result.
■Do not install this Welding Power Supply in the following:
Damp places where humidity is higher than 90%,
Hot or cold places where temperatures are above 40C or below 5C,
Places near a high noise source,
Places where chemicals are handled,
Places where water will be condensed,
Dusty places, and
Places at an altitude above 1000 meters.
■Clean the outside of the Welding Power Supply with a soft, dry cloth or one
wet with a little water. If it is very dirty, use diluted neutral detergent 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 malfunction.
■Operate the Welding 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.
■The Power Supply is not equipped with auxiliary power such as an outlet for
lighting.
■The welding head and the secondary cable for connecting the welding head
with the Power Supply are separately needed to use the Power Supply.
■The I/O signal line to start the Power Supply is not attached. Prepare the
crimp-on terminal and line for wiring to the terminal block.
(3) On Disposal
This product incorporates parts containing gallium arsenide (GaAs). At the time
of disposal, separate it from general industrial waste or domestic waste and carry
out the disposal in accordance with applicable laws and regulations.

MD Series
1. Special Precautions
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 type
MD-B4000B-05-31 200 – 240V AC

MD Series
2. Features
2-1
2. Features
MD-A8000B and MD-B4000B are transistor welding power supplies for precision
welding. Small power supply units can be used since all welding is powered by energy
accumulated in a capacitor.
MD-A8000B: Standard type
MD-B4000B: Polarity switching type
■The switching method adopted for welding current control permits the small model to
achieve high output and high efficiency.
■Select any of the following three control methods:
Constant-current control ( )
Realizes a stable welding since a fixed current is supplied regardless of the
resistance of workpiece.
Constant-voltage control ( )
Controls the voltage between electrodes. Welding free of surface 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 by the constant-voltage setting. The weld time to start of constant
current can be adjusted.
■The quick welding current rise is optimal for fine welding.
Current of the later stage is
suppressed and excessive
burn is prevented.
Only the welding
start part can be
adjusted by the
constant-voltage
setting.
Voltage becomes
high and surface
flash and expulsion
can easily occur.
constant-
voltage constant-current
Current waveform
Voltage waveform
constant-
voltage constant-current

MD Series
3. Packaging
3-1
3. Packaging
(1) Accessories
Item Model No. Q’ty
Operation manual AS1185889(OM1185330,OM1185331) 1
(2) Options
Item Model No.
Power cable*1
100 to 120V AC KP-35 KS-16A SVT#18 x 3
B-TYPE (3-pin plug)
200V AC KP244 VCTF3*1.25 KS16D 3m
gray (for Japan)
200 to 240V AC CEE3P-W-1.8
(Round-shaped plug)
3 pin – 2 pin
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 on head side: M6 A-03082-002
1m-long, Crimp-on
terminal on head side: M3 A-03082-003
3m-long, Crimp-on
terminal on head side: M3 A-03082-004
Secondary cable Various types are available.
Contact us.
RS-485 connector kit
(Connector-mounting screw, Screw (in mm)) L-04742-002
*1: Exclusively for the MD series. Do not use for other devices.

MD Series
4. Name and Functions of Each Section
4-1
4. Name and Functions of Each Section
(1) Front Panel
①Display screen
⑦Cursor key
②POWER lamp
③START lamp
④READY lamp
⑤TROUBLE lamp
⑥WELD key/lamp
⑧MENU key
⑨RESET key
⑩ENTER key
⑪+ key
⑫- key
⑬POWER switch

MD Series
4. Name and Functions of Each Section
4-2
①Display screen
Displays the welding schedule, welding current monitor value, and other
information.
②POWER lamp
Comes on when the POWER switch is turned on, the power is supplied, and
the equipment functions normally.
③START lamp
Comes on when the start signal is input and the sequence starts.
④READY 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 WELD ON/OFF terminal of the control signal terminal strip on the rear
panel is closed.
・No fault is occurring.
・Not in the middle of welding or charging
⑤TROUBLE lamp
Comes on when a fault occurs.
⑥WELD 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.
To turn ON and OFF the WELD key, hold it down for approx. 1 second.
⑦Cursor key
Moves the cursor on the display screen vertically and horizontally.
⑧MENU key
Press this key to display the menu screen.
⑨RESET key
When a fault is displayed, remove the cause and press this key. This will reset
the fault display.
⑩ENTER 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.
⑬POWER switch
Turn this switch on to switch the power on.

MD Series
4. Name and Functions of Each Section
4-3
(2) Rear Panel
[6.3A T(H)]
AC100-120V
50/60Hz
2468101214161820222426283032343638
35791315171921232527293133353739 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
OPTION 1
OPTION 2
COM
COM
COM
PARITY
COM
STOP
EXT.COM
RS485
READY
①Control signal terminal strip
④Ground terminal
②Cable clamp
⑤RS-485
serial interface connector
③Power supply
connector

MD Series
4. Name and Functions of Each Section
4-4
①Control signal terminal strip
Terminal
No. Description
1
[INT.24V] terminal
24
V DC is output.
Connect Terminal 1 to Terminal 2 to use a contact or NPN transistor (open
collector) as input signals (for starting and schedule selection).
Use Terminal 1 only for connection to Terminal 2 or
Terminal 3. Connection to other terminals will result in
equipment failure.
2
[EXT.COM] terminal
Connect Terminal 2 to Terminal 1 to use an NPN transistor. This terminal is
used as a COM terminal when a PNP transistor is used. (Refer to 5.
Connection.)
3
[STOP] terminal
In most cases, connect Terminal 3 to Terminal 1.
When this terminal is opened, an operation stop error is displayed and
operation stops.
Open this terminal to stop the sequence in the middle of operation when
using the start function with self-holding.
This terminal does not have the emergency stop function.
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 using this terminal. (Refer
to 6.(6) ⑰START SIG. INPUT.)
To start the weld sequence with the combination of the [1st.STAGE] and
[2nd.STAGE] terminals, set START SIG. INPUT to 1ST+2ND.
[When START SIG. INPUT is 1ST+2ND]
Close this 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.
Since the weld sequence will not be started, the compression position can
be adjusted or checked.
When the [2nd.STAGE] is closed with the [1st.STAGE] terminal closed, the
weld sequence starts and welding at an optimal position is possible.
When the [1st.STAGE] terminal is open, the weld sequence does not start
even if the [2nd.STAGE] terminal is closed.
[When START SIG. INPUT is 2ND]
The weld sequence does not start even if the 1st.STAGE terminal is closed.
To use the [1st.STAGE] terminal, set START SIG.INPUT to 1ST+2ND.
CAUTION
CAUTION

MD Series
4. Name and Functions of Each Section
4-5
Terminal
No. Description
5
[2nd.STAGE] terminal
2nd.STAGE start input terminal.
Set START SIG. INPUT on the STATUS screen before using this terminal. (Refer
to 6.(6) ⑰START SIG. INPUT.)
To start the weld sequence with the [2nd.STAGE] terminal, set START SIG.
INPUT to 2ND.
To start the weld sequence with the combination of the [1st.STAGE] and the
[2nd.STAGE] terminals, set START SIG. INPUT to 1ST+2ND.
[When START SIG. INPUT is 1ST+2ND]
When the [2nd.STAGE] terminals is closed with [1st.STAGE] terminal closed,
the weld sequence is started in the usual manner.
When the [1st.STAGE] terminal is open, the weld sequence does not start
even if the [2nd.STAGE] terminal is closed.
[When START SIG. INPUT is 2ND]
When the [2nd.STAGE] terminal is closed, 24
V DC is output from the [SOL]
terminal of Terminals 33 and 34, the weld force is applied, and the weld
sequence starts.
6.13.
19.22
[COM] terminals
[COM] terminals to use a contact or NPN transistor.
7
8
9
10
11
Schedule-
select
terminals
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 the sum of the SCH Nos. of the
closed terminals. (Refer to Table of schedule Nos.
and corresponding schedule-select terminals.)
12
[PARITY] terminal
Functions when the external schedule select with parity is selected. (Refer
to 6.(6) ⑦SCHEDULE)
This terminal permits detection of nonconformance due to disconnection of
the schedule-select signal conductor.
Set so that the sum of the number of closed circuits for the schedule-select
signal conductors and the [PARITY] signal conductor is always an odd
number.
"When setting 2 for schedule No."
Close SCH2 and open the [PARITY] terminal. [The
number of closed circuits is 1.]
"When setting 6 for schedule No."
Close SCH2 and 4, and close the [PARITY] terminal. [The
number of closed circuits is 3.]
14
[PO/CH SEL] terminal
Input terminal for output changeover selection.
(This function is provided only for MD-B4000B.)
The direction of the welding current flow when the circuit is open is opposite
to that when the circuit is closed. (Refer to 5.(4) ⑤Operation of
MD-B4000B.)
15
[WELD ON/OFF] terminal
When this terminal is opened, the flow of welding current is not allowed
when the weld sequence is started. Use this terminal to tentatively activate
the equipment.
EXAMPLE

MD Series
4. Name and Functions of Each Section
4-6
Terminal
No. Description
17
[ERR RESET] terminal
When a fault is displayed, remove the cause of the fault and close the
circuit. This resets the fault display.
Be sure to reset with the Start inputs ([1st.STAGE] and
[2nd.STAGE] terminals) opened.
18 [CNTR RESET] terminal
Closes the circuit to reset the counter.
20.21 [OPTION] terminals
Reserve input terminals. (Keep these terminals open without connecting,
otherwise the equipment may be damaged.)
23.24
[GOOD] terminals
Normal signal output terminal.
Closes the circuit for a certain duration when the measured value is judged
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 10–200
ms in 10 ms
steps.
The contact rating is 24
V DC, 20 mA. (A semiconductor switch is used.)
25.26
[NG] terminals
Fault signal output terminals. The circuit is closed when the power supply
is turned on. The circuit is opened in the following cases:
･When the measured value exceeds the range set on the COMPARATOR
screen and the PRECHECK screen after the weld sequence is over.
･When operational 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 to 6.(6) ⑫NG SIGNAL TYPE.)
The contact rating is 24
V DC, 20 mA. (A semiconductor switch is used.)
27.28
[END] terminals
End signal output terminals.
Close the circuit for a certain duration after sequence operation is over.
The circuit-closing time can be set within the range of 10–200
ms in 10 ms
steps.
The signal is output during sequence operation in the WELD OFF state as
well.
The contact rating is 24
V DC, 20 mA. (A semiconductor switch is used.)
29.30
[CAUTION] output terminals
Caution signal output terminals.
If a fault occurs in items that are set in the ON position for ERROR
SETTING (Refer to 6.(6) ⑳ERROR SETTING) on the STATUS screen,
this circuit is closed after the weld sequence is over.
If a fault occurs, operation can be continued without stopping the
sequence.
To cancel the output, input the reset signal or start signal.
The contact rating is 24
V DC, 20 mA. (A semiconductor switch is used.)
31.32
[READY] terminals
Ready signal output terminals.
Closed at the time when weld current is ready for being supplied. Open
during welding, charging or in the occurrence of NG.
The contact rating is 24
V DC, 20 mA. (A semiconductor switch is used.)
CAUTION

MD Series
4. Name and Functions of Each Section
4-7
Terminal
No. Description
33.34
[SOL] terminals
24
V DC output terminals for driving solenoid valve.
Terminal 33 is [+] and Terminal 34 is [-].
The current-carrying capacity is 0.2
A.
Drives solenoid valves of up to 24
V DC, 5 W.
35 [SENS GUARD] terminal
Shielded wire connection terminal for the V SENS cable. Connected to the
chassis inside.
36.37
[V-SENS 1] terminals
Connection terminals for the V SENS cable. There is no polarity.
When the V SENS cable is not connected in the constant-current control,
short on Terminals 36 and 37.
38.39 Unassigned. Do NOT connect.

MD Series
4. Name and Functions of Each Section
4-8
Table of schedule Nos. 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 ○●●●●●
31 ●●●●●○
NB: Schedule 1 is selected when all schedule-select terminals are open.

MD Series
4. Name and Functions of Each Section
4-9
②Cable clamp
Cable clamp for passing through the control signal cable.
③Power supply connector
Connects the power cable (option).
④Ground terminal
Use this terminal for grounding when the ground wire of the power cable
(option) is not used.
⑤RS-485 serial interface connector
D-Sub connector 9-pin (female)
1
RS+(1)
2
RS-(1)
3
RS+(2)
4
RS-(2)
9
0V
Note 1) Only a device can be connected.
Note 2) The RS-232C/RS-485 conversion adapter is not included in the
accessories.
Host computer MD series
RS-232C/RS-485
conversion adapter
RS-232C

MD Series
4. Name and Functions of Each Section
4-10
(3) Side Panel
The welding current output terminal is on the left side when viewed from the
front.
+/- output terminals
Output terminals for the welding 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 can cause the
shorted state and the contact portion may be overheated
and scattered. Accordingly, prepare the fire-retarding
protective cover.
CAUTION
①+ output terminal
①- output terminal
OUTPUT
DC30V MAX