Amada MK-110B User manual

AA05OM1208909-02
OPERATION MANUAL
MOTOR-DRIVEN UNIT
MK-110B

MK-110B
1
Thank you for purchasing our Motor-Driven Unit MK-110B.
・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-110B ················································································· 3-1
(2) Controller Front········································································· 3-2
(3) Controller Rear ········································································· 3-4
4. Installation and Connection
(1) Basic Installation and Connection·················································· 4-1
(2) Example Installation··································································· 4-2
5. Interface
(1) Connection Diagram of External Input/Output Signal ························· 5-1
(2) Explanation of Input/Output Signal ················································ 5-3
6. Operation
(1) Getting Started ········································································· 6-1
(2) Mode Setting ············································································ 6-2
(3) Applying Power and Moving to Start Point······································· 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. Specifications
(1) Specifications ··········································································· 8-1
(2) Separately Sold Items ································································ 8-1
(3) Mountable Force Follow-Up Mechanism ········································· 8-2
(4) Timing Chart ············································································ 8-3
9. Data Communication
(1) Communication Specifications······················································ 9-1
(2) Connection of Communication Connector ······································· 9-1
(3) Bidirectional Communication························································ 9-3
10. Outline Drawings
(1) MK-110B ················································································· 10-1
(2) Controller················································································· 10-3
11. Example Combination·································································· 11-1

MK-110B
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-110B
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 operat
ion 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.
Wear protective glasses
If you look at the surface flash and expulsion directly during welding, your eyes
may be damaged.
W
A
RNING
！

MK-110B
1. Special Precautions
1-3
Do not splash water on the Unit
Water splashed over the electric parts can cause electric shock an
d 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-110B
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.
■For the standard motor, since power supply to the motor is cut off at power off or
emergency stop, the force follow-up mechanism may lower to the maximum
stroke position by its own weight. For the motor with brakes, since power supply
to the motor is cut off at power off or emergency stop, the built-in brake works to
hold the force follow-up mechanism.
(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-110B
2. Features
2-1
2. Features
Since MK-110B is motor-driven, a piping for an air actuation is not needed, enabling
an easy installation.
Owing to the motor-driven mechanism, stable electrode force is always obtained
although an electrode opening (length) changes. Also, you don’t need to adjust the
electrode opening finely when replacing the electrode.
The electrode force is 500
N (approx. 50 kgf).
Since the electrode-forward/backward speed is adjustable in eight steps (four steps
from Mid-Point to Weld Point), you can fit the electrode-force speed to suit your
welding work.
Totally, thirty-one operation schedules can be set. And the operation schedules can
be externally selected.
The electrode can be set to move fast from the start point (stand-by position) to the
mid-point (middle-stop position); then slowly to contact a workpiece.
Very little shock gives the workpiece less deformation, so it can also extend the life of
the electrode.
The positions of the start point and the mid-point are arbitrarily adjustable.
For continuous welding, the electrode moves only between the mid-point and
workpiece. It reduces the tact time because the electrode doesn’t need to return to the
start point every time it welds.
The dedicated controller can easily set the electrode position and speed.

MK-110B
3. Name and Functions of Each Section
3-1
3. Name and Functions of Each Section
(1) MK-110B
Column and Base
For the Unit.
Motor Cable
Feed Block
Mounts the secondary conductor.
1
2
33
Mountingsurface of
follw-up mechanism

MK-110B
3. Name and Functions of Each Section
3-2
(2) 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:
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.
READY
READY＋MID
SCH
FORCE CHK
WELD
AUTO
HOLD
MID＋WELD
MID＋WELD
+FORCE CHK
MID
WELD＋HOLD
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
⑭

MK-110B
3. Name and Functions of Each Section
3-3
⑫[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-110B
3. Name and Functions of Each Section
3-4
(3) 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 is for connecting a power supply cable (separately sold) of 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-110B
4. Installation and Connection
4-1
4. Installation and Connection
(1) Basic Installation and Connection
Before using your MK-110B, install it according to the following procedures.
Connect the grounding wire to the grounding terminal located near the
grounding mark.
Be sure to firmly install the MK-110B on the horizontal place before using.
When the distance from welding transformer is shorter, higher work
efficiency will be obtained.
Determination of Where to Install
Determine where to install MK-110B, the welding power supply and welding
transformer.
Connecting Cable of Weld Force Detecting Sensor
Connect the cable of Weld Force Detecting Sensor to controller of the motor.
Connection of I/O Connector
Connect I/O Connector to controller of the motor.
2-level type foot switch is connected to terminals of [1ST], [2ND] and [COM] of I/O
Connector (Accessories).
Connection of AC Cable
Finally, connect AC cable to the connector of the power supply cable and outlet for
100 to 240 V AC, 50/60 Hz.
CAUTION
！
W
ARNING
！

MK-110B
4. Installation and Connection
4-2
(2) Example Installation
Cable clamp (Note 3)
Controller (Rear)
Limit switch connector
Force follow-up mechanism portion
(Option, Note 4)
Upper electrode holder
(Option, Note 4)
Electrode
(Option, Note 4)
Lower electrode holder
(Option, Note 4)
Mounting plate of force
follow-up mechanismportion
Positioning pin (Note 1)
Weldforcedetectingsensorcable
Mounting screw of lower electrode holder, M6-15mm
(4 screws come with thelower electrode holder)
Mounting nut of lower electrode holder
(Comes with the lower electrode holder)
Secondary conductor
（Option, Note 4)
Mounting screw of force follow-up
mechanismportion (Note 2)
(Comes with the force follow-up
mechanism portion)
Note 1) Insert the pin into the specified pin hole of mounting plate of force follow-upmechanismportion,
then secure with the mounting screw.
Note 2) The size and number of screwsdepend onthe forcefollow-up mechanism portion youselected.
Note 3) Secure the weld force detecting sensor cable and the motor cable with clamps.
(Note that a load is not appliedon cables when the force follow-up mechanismportion isoperated.)
Note 4) For options, consult us.

MK-110B
5. Interface
5-1
5. Interface
(1) Connection Diagram of External Input/Output Signal
24VDC
READ Y
STAR T PO IN T
MID PO IN T
OUT CO M
ERRO R
OUT CO M
-COM
RY STOP
+COM
SCH1
SCH2
SCH4
SCH8
SCH16
+COM
-COM
-COM
WELD S TA RT
-COM
EXT.C O M
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
RESET
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-110B
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.CO M
+COM
8
9
10
11
12
13
14
15
-COM
24VDC
Å

MK-110B
5. Interface
5-3
(2) Explanation of Input/Output Signal
Each pin on I/O Connector 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-110B. Before
selecting the schedule
number by the operation button on MK-110B, 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.

MK-110B
5. Interface
5-4
Pin
No.
I/O Description
7 Output pins for 24 V DC through 100Ωinternal resistor.
8
9
Input
Input pin for start-up signal.
When [1ST] is closed, electrode moves from Start Point to Mid-Point.
When [2ND] is closed afte
r [1ST] was closed, electrode moves from
Mid-Point to Weld Point.
Although only [2ND] is closed, electrode does not move.
10
11 Spare pin: Do not connect.
12 Connected to [GND] (0V) internally at factory shipment.
13 Output pins for 24 V DC through 100Ωinternal resistor.
14
According to the usage, connect pins as follows.
・
When contact is used as input signal of I/O Connector, connect Pins 14
and 15.
(In the 2-level type foot switch which is Accessories, Pins 14 and 15
are connected at factory shipment.)
・
When NPN transistor (sink type) on PLC is used as input signal of I/O
Connector, connect Pins 13 and 14. COM terminal of PLC connects to
―COM terminal, that is, Pins 1, 12 and 15.
・
When PNP transistor (source type) on PLC is used as input signal of
I/O connector, connect Pin 14 to COM terminal of PLC.
15 Connected to [GND] (0V) internally at factory shipment.
16 Input Input pin for [End] signal from welding power supply.
If Pin 16 is closed, input signal of [2ND] cannot be accepted.
14
15
EXT.COM
-COM
13
14 EXT.COM
+COM
EXT.COM
14 PLC Output
Terminal COM

MK-110B
5. Interface
5-5
Pin
No.
I/O Description
17
Input
Input pin for Start Point resuming signal.
When the circuit of Pin 17 becomes closed, the electrode resumes Start
Point. (In case that the motor finishes moving back to Original Point, the
electrode does not move.)
18
Input pin for [RESET] signal.
If a trouble occurs, rectify the trouble and close the circuit of the Pin to
turn off [NG] signal. (See Chapter 7 for fault codes.)
Close at least for 2 ms. Pin 18 does not work while the circuit of Pin 18 is
closed.
19
Input pin for prohibition of setting the operation schedule.
When Pin 19 is closed, the operation schedule of MK-110B cannot be
set. (The schedule number can be modified.)
20 Spare pin: Do not connect.
21
Output
Output pin for an emergency stop of the motor.
When the circuit between Pin 21 and 22 is opened, the motor carries out
emergency stop.
Usually, close it by an electric wire or switch whose capacity is more
than 24 V DC, 20 mA.
Since power supply to the motor is cut off, the force follow-up
mechanism may lower to the maximum stroke position
by its own
weight.
22
23 Output pin for current-supplying start signal to the welding power supply.
When the weld force is completed, the circuit between Pin 23 and 24
becomes closed.
Contact capacity is 24 V DC, 20 mA.
24
25
Output pin for completion signal of
being ready for work.
When the resumption of Start Point is
completed, the Pin becomes closed. In
an emergency of MK-110B, the Pin
becomes opened.
26
Output pin for completion signal of
arriving at Start Point.
When the electrode is at Start Point,
the Pin becomes closed.
27
Output pin for completion signal of
arriving at Mid-Point.
When the electrode is at Mid-Point, the
Pin becomes closed.
25 READY
OUT COM28
or 31
OUT COM28
or 31
26 START POINT
OUT COM28
or 31
27 MID POINT

MK-110B
5. Interface
5-6
Pin
No.
I/O Description
28 Common terminal to
[READY], [START POINT], [MID POINT] and
[ERROR]
29 Output
Output pin for a trouble signal.
When a trouble occurs in
MK-110B, the Pin becomes
opened until it is reset.
30 Spare pin: Do not connect.
31 Common terminal to [READY], [START POINT], [MID P
OINT] and
[ERROR]
32 Do not connect to the Pin for [EXT. 24 V].
33 Connected to [GND] (0V) internally at factory shipment.
34 Spare pin: Do not connect.
OUTCOM28
or 31
29 ERROR

MK-110B
6. Operation
6-1
6. Operation
(1) Getting Started
2-level Footswitch
It is of 2-level type. The switch of the first level is External Input [1ST]. The
switch of the second level is External Input [2ND].
These two switches allow a variety of operations.
Position of Electrode
MK-110B Electrode has five (5) positions to stop.
Position Description
Original Point The position where the electrode has completely returned.
Start Point
A little bit farther position from Original Point. It can be set
arbitrarily. [READY] Lamp lights up when the electrode is at
this position.
Mid-Point
Just before the position where the electrode contacts
workpiece. It can be set arbitrarily.
[MID] Lamp lights up when the electrode is at this position.
Weld Point
The position where the electrode contacts workpiece.
[WELD] Lamp lights up when the electrode is at this position.
Weld start signal is output and welding current flows.
Downstop
Point
A little bit beyond the position from Weld Point.
It can be set arbitrarily.
Working Mode of Electrode
MK-110B has two working modes.
Movement
Mode 0
Mode 1
For setting Position
or measuring Weld
Force
Performed by External
Input [1ST or 2ND]
Performed by External Input
[1ST or 2ND] or pressing the
operation button.
For resuming Start
Point of motor
Performed by External
Input [1ST or ORG]
Performed by External Input
[1ST or ORG] or pressing
[ORG/CANCEL] button.
Electrode is pressed
on the way other
than from Mid-Point
to Weld Point.
Error indicated
Error indicated and the
power supply to motor
turned off.
In Mode 1, when the electrode is at Start Point and no setting is performed, then,
“A” is shown on [SPEED HOLD TIME] Display.
Attention on movement
・Change of Schedule No.
Only the change of Schedule No. does not allow the electrode to move.
External Output [START POINT] continues to hold the signal of the previous
position.
In case that Start Point of changed Schedule No. differs from the one of the
last Schedule No., once make the electrode move to Mid-Point to attain the
new Start Point.