Amada MK-108B User manual

AA05OM1208810-02
OPERATION MANUAL
MOTOR-DRIVEN UNIT
MK-108B/109B

MK-108B/109B
1
Thank you for purchasing our Motor-Driven Unit MK-108B/109B
・This operation manual explains its method of operation and precautions for use.
・Before using, read this operation manual carefully; after reading, save it in a proper place
where you can easily access.
Contents
1. Special Precautions
(1) Safety Precautions ···············································1-1
(2) Precautions for Handling········································1-4
(3) On Disposal························································1-4
2. Features·································································2-1
3. Name and Functions of Each Section
(1) MK-108B····························································3-1
(2) MK-109B····························································3-2
(3) Controller Front ···················································3-3
(4) Controller Rear ····················································3-6
4. Installation and Connection
(1) Basic Installation and Connection ····························4-1
(2) Example Installation ·············································4-3
5. Interface
(1) Connection Diagram of External Input/Output Signal····5-1
(2) Explanation of External Input/Output Signal ···············5-3
6. Operation
(1) Getting Started ····················································6-1
(2) Mode Setting·······················································6-2
(3) Applying Power and Moving to Start Position··············6-3
(4) Auto-Setting of Electrode Position····························6-4
(5) Manual Setting of Electrode Position ························6-5
(6) Welding Work······················································6-10
(7) Measuring Weld Force ··········································6-11
7. Fault Indications······················································7-1
8. User’s Maintenance ·················································8-1
9. Specifications
(1) Product Specifications···········································9-1
(2) Separately Sold Items ···········································9-1
(3) Mountable Force Follow-Up Mechanism····················9-2
(4) Timing Chart ·······················································9-3
10. Outline Drawings
(1) MK-108B····························································10-1
(2) MK-109B····························································10-2
(3) Controller ···························································10-3
11. Example Combination
(1) MK-108B····························································11-1
(2) MK-109B····························································11-4

MK-108B/109B
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.
Denotes operations and practices that
may imminently result in serious injury
or loss of life if not correctly followed.
Denotes operations and practices that
may result in serious injury or loss of
life if not correctly followed.
Denotes operations and practices that
may result in personal injury or damage
to the equipment if not correctly followed.
Never disassemble, repair or modify the Unit
These actions can cause electric shock and fire. Do not do anything other than
the maintenance described in the operation manual.
Never burn, destroy, cut, crush or chemically decompose the Unit
This product incorporates parts containing gallium arsenide (GaAs).
DANGER
！
W
ARNING
！
CAUTION
！
DANGER
！

MK-108B/109B
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 electrode holder are very hot.
Do not touch them; otherwise you may be burnt.
Apply the specified power supply
Application of a voltage out of the specified range can cause fire and electric
shock.
Stop the operation if any trouble occurs
Continuous operation after occurrence of a trouble suc
h 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.
Wear protective glasses
If you look at the surface flash and expulsion directly during welding, your eyes
may be damaged.
W
A
RNING
！

MK-108B/109B
1. Special Precautions
1-3
Do not splash water on the Unit
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.
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.
When you need any repair or replacement, consult us or your distributor.
Connect the specified cables securely
Cables of insufficient current-
carrying capacities and loose connections can
cause fire and electric shock.
Install the Unit on firm, level surface.
If the Unit falls or drops, injury may result.
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 Unit with a blanket, cloth, etc.
If such a cover is used, it may be overheated and burn.
Keep a fire extinguisher nearby.
Keep a fire extinguisher in the welding shop in case of fire.
Maintain and inspect the Unit periodically.
Maintain and inspect the Unit
periodically, and repair any damage nearby
before starting operation.
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.
Do not use this Unit for purposes other than welding
Use of this Unit in a manner other than specified can cause electric shock and
fire.
CA
UTION
！

MK-108B/109B
1. Special Precautions
1-4
(2) Precautions for Handling
■Do not install this Unit in the following:
・Damp places where humidity is higher than 90%,
・Dusty places,
・Places where chemicals are handled,
・Places near a high noise source,
・Hot or cold places where temperatures are above 40°C or below 0°C, and
・Places where water will be condensed.
■Clean the outside of the Unit 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 Unit.
■Do not put anything other than a workpiece, e.g., a tool, a screw, etc., between
the electrodes. It can cause serious trouble.
■Do not put a screw, a coin, etc., in the Unit, since they can cause a malfunction.
■Operate the Unit according to the method described in this operation manual.
■Operate the button carefully by hand. If it is operated roughly or with the tip of a
screwdriver, a pen, etc., this will cause malfunction or damage.
■Since power supply to the motor is cut at power off or emergency stop, the force
follow-up mechanism may lower to the maximum stroke position by its own
weight.
(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.

MK-108B/109B
2. Features
2-1
2. Features
Since this Unit is motor driven, the piping for air actuation is not needed, enabling an
easy installation.
Owing to motor-driven mechanism, stable electrode force is always obtained even if
the electrode opening changes. Also, you don’t need to adjust the electrode opening
finely when replacing electrode.
The electrode force is 70
N (approx. 7.0 kgf).
You can fit the electrode-force speed to suit your welding work as it is adjustable in
four steps; the electrode-up/down speed, in eight steps.
Thirty-one welding schedules are selectable; they are selectable externally.
The electrode moves down fast from the start point (stand-by position) to the mid-point
(middle-stop position); then slowly to contact the workpiece.
Very little shock deforms the workpieces less and extends the electrode life.
The start point and the mid-point are adjustable arbitrarily.
The electrode moves up and down between the mid-point and workpiece for
continuous welding. This reduces the weld cycle time as the electrode doesn’t need to
return to the start point every time it welds.
The dedicated controller easily sets the electrode position and speed.

MK-108B/109B
3. Name and Functions of Each Section
3-1
3. Name and Functions of Each Section
(1) MK-108B
 Base
For the Unit.
 Fixing Bracket
For fixing the Unit to the workbench. Two (2) brackets provided.
φ5.5
mm mounting hole diameter (M5 countersink).
Feed Block
Mounts the secondary conductor.
1
2
3
Mounting suefaceof
follow-up mechanism

MK-108B/109B
3. Name and Functions of Each Section
3-2
(2) MK-109B
 Column
For mounting the driving mechanism, etc.
Base
For the Unit.
Base-Mounting Holes
For mounting the Unit to the workbench. Six (6) holes are provided.
φ6.5
mm diameter, φ11 mm spot facing and 10 mm depth.
Feed Block
Mounts the secondary conductor.
2
3
1
4
Mounting surface of
follow-up mechanism

MK-108B/109B
3. Name and Functions of Each Section
3-3
(3) Controller Front
Operation Button
Operate the Unit by turning the button
clockwise/counterclockwise or pressing it.
By turning the button, the lamp
illumination changes as shown:
ORG/CANCEL
MID
HOLD
TROUBLE
READY
SCH
WELD
ORG
FORCE
CHECK
AUTO
SPEED
HOLD
TIME
W E L D H E A D
C O N T R OL U N I T
1
12
2
3
4
5
6
7
8
9
10
11
13
READY
READY＋MID
SCH
FORCE CHK
WELD
AUTO
HOLD
MID＋WELD
MID＋WELD
+FORCE CHK
MID
WELD＋HOLD
⑭

MK-108B/109B
3. Name and Functions of Each Section
3-4
See the list below for to ⑪
Lamp
When illuminated,
When blinking,
②
[SCH
(Schedule)]
Display
Schedule Nos. are displayed.
(31 combinations of Electrode
position, Speed and Hold Time
can be registered as Schedule.)
When power supply is applied,
zero “0” blinks.
When trouble occurs, fault code is
displayed.
Schedule No. is being changed.
Weld force is being measured
③
[SCH] Lamp
Operation button is selecting a
function.
Schedule No. is being changed
④
[READY]
Lamp
Electrode is at Start Point and
completed for work. Start Point is being changed.
Operation button is selecting a
function.
⑤
[MID] Lamp
Electrode is at Mid-Point.
Mid-Point is being changed.
Operation button is selecting a
function.
⑥
[Weld] Lamp
Electrode is at Weld Point. Lowest point (Downstop Point) is
being changed.
Operation button is selecting a
function.
⑦
[Hold] Lamp
Operation button is selecting a
function.
Hold Time is being changed.
⑧
[AUTO] Lamp
Operation button is selecting a
function.
Auto-function is setting electrode
position and movement.
⑨[FORCE CHK]
Lamp
Operation button is selecting a
function.
Weld force is being measured.
⑩[TROUBLE]
Lamp
Trouble is occurring.
⑪
[ORG] Lamp
The [ORG] Lamp is in no use.

MK-108B/109B
3. Name and Functions of Each Section
3-5
[SPEED HOLD TIME] Display
Indicate the “electrode speed” and “HOLD Time after the application of weld force
is completed”. The larger number indicates the faster electrode speed and the
longer HOLD Time.
And the lamp lights up simultaneously with other lamps as follows:
Lamp When illuminated, When blinking,
④
[READY] Lamp
and
⑤
[MID] Lamp
and
⑫
[SPEED
HOLD TIME]
Display
Operation button is selecting a
function. ([SPEED HOLD TIME]
Display does not light up.) Electrode speed between Start
Point and Mid-Point is being set.
Electrode is moving between
Start Point and Mid-Point.
⑤
[MID] Lamp
and
⑥
[WELD] Lamp
and
⑫
[SPEED
HOLD TIME]
Display
Operation button is selecting a
function. ([SPEED HOLD TIME]
Display does not light up.) Electrode speed from Weld Point
to Mid-Point is being set.
Electrode is moving from Weld
Point to Mid-Point.
⑤
[MID] Lamp
and
⑥
[WELD] Lamp
and
⑨
[FORCE CHK]
Lamp and
⑫
[SPEED
HOLD TIME]
Display
Operation button is selecting a
function. ([SPEED HOLD TIME]
Display does not light up.)
Electrode speed from Mid-Point
to Weld Point is being set.
Electrode is moving from
Mid-Point to Weld Point.
([FORCE CHK] Lamp does not
light up during movement.)
⑥
[WELD] Lamp
and
⑦
[HOLD] Lamp
and
⑫
[SPEED
HOLD TIME]
Display
Operation button is selecting a
function. ([SPEED HOLD TIME]
Display does not light up.)
The desired time for which the
additional weld force is exerted
on after applying the weld force at
Weld Point is being set.
⑦
[HOLD] Lamp
and
⑫
[SPEED
HOLD TIME]
Display
Operation button is selecting a
function. ([SPEED HOLD TIME]
Display does not light up.) Hold Time is being set.
⑫
[SPEED
HOLD TIME]
Display
In case of Movement Mode 1,
electrode position is at Start Point
and the Display shows “A” when
setting is not performed.
⑬[ORG/CANCEL] Button
The Button interrupts the operation of setting.
⑭Communication Connector (D-Sub, 25 pins)
For data communication with the external device.

MK-108B/109B
3. Name and Functions of Each Section
3-6
(4) Controller Rear
[MOTOR CONTROL] Connector
It is a connector for controlling a motor to drive the electrode.
I/O Connector
It is for input/output of signals.
Connector for Weld Force detecting Sensor
It is for inputting the weld force signal of the force follow-up mechanism portion.
Power Switch
It is a switch for turning on/off power supply of 100 to 240
V AC.
Fuse Holder
It contains a fuse.
Fuse Rating 250
V, 1A, 5 mm dia. 20
mm length (Delay melting and high
breaking capacity type)
Connector for Power Supply Cable
It connects a power supply cable (separately sold) to the power supply of 100 to
240
V AC.
Ground Terminal
Use the ground terminal when you can not take a ground by using a power supply
cable with a ground wire (separately sold).
Foot Switch
Operates the Unit manually. This is a 2-stage footswitch. Connected to the I/O
connector.
2
1
3
4
5
6
7
8

MK-108B/109B
4. Installation and Connection
4-1
4. Installation and Connection
(1) Basic Installation and Connection
Before using your Unit, install it according to the following procedures.
When using, install and fix the Unit firmly.
If you use it not fixed, it may cause injury due to its fall,
and degraded weld
quality.
①Determining Where to Install
Determine where to install the Unit, welding power supply and welding transformer.
②Drilling Mounting Holes
Drill mounting holes on the workbench to secure the Unit, following the drawings
below:
CAUTION
！
MK-109B Drillings
MK-108B Drillings
102 170 110 (18)
60
6-6.5mm Drills
[Front]
[Front]
2-5.5mm Drills
63
60

MK-108B/109B
4. Installation and Connection
4-2
③Installing the Unit
Install the Unit to the workbench with the hexagon socket head bolts/cross-recessed
countersunk head screws, plain washers, spring washers and hexagon nuts (See
drawings below). Use a proper tool suitable for the bolts/screw to secure the Head.
④Connecting the Controller
Connect the I/O connector (see 5. Interface).
Connect the connector for weld force detecting sensor and MOTOR CONTROL
connector.
Lastly, connect the AC Cable to the 100–240
V AC, 50/60 Hz outlet.
MK-109B
M6 Hexagon socket headbolt
Base
Workbench
M6 plain washer
M6 spring washer
M6 hexagonnut
MK-108B
M5 Countersunk head screw
Base
Head-fixing bracket
Workbench
M5 plain washer
M5 spring washer
M5 hexagon nut

MK-108B/109B
4. Installation and Connection
4-3
(2) Example Installation
MK-108B
Cable clamp (Note 3)
Controller (Rear)
Limit switch connector
Electrode
(Option, Note 4)
Upper electrode holder
(Option, Note 4)
Positioning pin (Note 1)
Mounting plate of force
follow-up mechanism portion
Lower electrode holder
(Option, Note 4)
Force follow-up mechanism portion
(Option, Note 4)
Secondary conductor
(Option, Note 4)
Weld force detecting sensor cable
Mounting screw of lower electrode holder, M5-15mm
(4 screws come with the lower electrode holder)
Note 1) Insert the pin into the specified pin hole of mounting plate of force follow-up mechanism portion,
then secure with the mounting screw.
Note 2) The size and number of screws depend on the force follow-up mechanism portion you selected.
Note 3) Secure the weld force detecting sensor cable and the motor cable with clamps.
(Note that a load is not applied on cables when the force follow-up mechanism portion is operated.)
Mounting screw of force follow-up mechanism portion (Note 2)
(Comes with the force follow-up mechanism portion)
Mounting nut of lower electrode holder
(Comes with the lower electrode holder)
Note 4) For options, consult us.

MK-108B/109B
4. Installation and Connection
4-4
MK-109B
Secondary conductor
(Option, Note 4)
Cable clamp (Note 3)
Controller (Rear)
Limit switch connector
Positioning pin (Note 1)
Lower electrode holder
(Option, Note 4)
Upper electrode holder
(Option, Note 4)
Mounting plate of force
follow-up mechanism portion
Force follow-up mechanism portion
(Option, Note 4)
Weld force detecting sensor cable
Mounting screw of force follow-up mechanism portion (Note 2)
(Comes with the force follow-up mechanism portion)
Mounting nut of lower electrode holder
(Comes with the lower electrode holder)
Mounting screw of lower electrode holder, M6-15mm
(4 screws come with the lower electrode holder)
Note 1) Insert the pin into the specified pin hole of mounting plate of force follow-up mechanism portion,
Note 2) The size and number of screws depend on the force follow-up mechanism portion you selected.
Note 3) Secure the weld force detecting sensor cable and the motor cable with clamps.
then secure with the mounting screw.
(Note that a load is not applied on cables when the force follow-up mechanism portion is operated.)
Electrode
(Option, Note 4)
Note 4) For options, consult us.

MK-108B/109B
5. Interface
5-1
5. Interface
(1) Connection Diagram of External Input/Output Signal
24VDC
READY
START POI NT
MID POI NT
OUT COM
ERROR
OUT COM
-COM
RY S TOP
+COM
SCH1
SCH2
SCH4
SCH8
SCH1 6
+COM
-COM
-COM
WELD ST ART
-COM
EXT. COM
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
32
33
34
2ND
1ST
+COM
END
ORG
RESE T
P.LOC K
Å
External Input/Output Connector
Motor Controller
Spare: Do not connect
Spare: Do not connect
Spare: Do not connect
EXT.24V: Do not connect
Spare: Do not connect

MK-108B/109B
5. Interface
5-2
[Example of Connection]
・When contacts are used as input terminal of I/O connector
・When NPN transistor (sink type) on PLC is used as input terminal of I/O connector
・When PNP transistor (source type) on PLC is used as input terminal of I/O
connector
1ST
2ND
-COM
+COM
EXT.C OM
+COM
8
9
10
11
12
13
14
15
-COM
24VDC
Å
8
9
10
11
12
13
14
15
PLC
+24V
24VDC
Å
1ST
2ND
-COM
+COM
EXT.C OM
+CO M
8
9
10
11
12
13
14
15
-COM
24VDC
Å

MK-108B/109B
5. Interface
5-3
(2) Explanation of Input/Output Signal
Each pin on I/O signal is described.
Input signal is explained as contact input.
Pin
No.
I/O Description
1 Internally connected to GND (0V).
2
Input
Select a schedule number, referred to as SCH No. below, indicating a
combination of the circuit-closed pins among Pins, No. 2, 3, 4, 5 and 6
(See table below.).
The schedule number selected by I/O Connector has priority over the
schedule number set on MK-108B/109B. Before selecting the schedule
number by the operation button on MK-108B/109B, open the circuits of
all the Pins of No. 2, 3, 4, 5 and 6 in I/O Connector.
Input [SCH] signal at least 2
ms before the welding current flows. During
in operation, the schedule number cannot be changed.
3
4
5
6
Pin No.
SCH No.
6 5 4 3 2
Pin No.
SCH No.
6 5 4 3 2
1
●
17
● ●
2
●
18
● ●
3
● ●
19
● ● ●
4
●
20
● ●
5
● ●
21
● ● ●
6
● ●
22
● ● ●
7
● ● ●
23
● ● ● ●
8
●
24
● ●
9
● ●
25
● ● ●
10
● ●
26
● ● ●
11
● ● ●
27
● ● ● ●
12
● ●
28
● ● ●
13
● ● ●
29
● ● ● ●
14
● ● ●
30
● ● ● ●
15
● ● ● ●
31
● ● ● ● ●
16
●
The mark ●denotes the circuit-closed pin.