Amada MA-520B User manual

Y02OM1200944-02
OPERATION MANUAL
WELD FORCE SENSOR FOR RESISTANCE WELDING MACHINES
MA-520B/521B/522B

MA-520B/521B/522B
Contents
1
Thank you for purchasing our MA-520B/521B/522B, Weld Force Sensor for Resistance
Welding Machines.
For correct use, read this Operation Manual carefully. After reading, save it properly for
future reference.
Contents
1. Special Precautions...................................1-1 to 1-4
2. Features......................................................2･3-1
3. Specifications ............................................2･3-1
4. Name of Each Section ...............................4-1
5. Measurement Method ................................5-1
6. Option.........................................................6-1 to 6-2

MA-520B/521B/522B
1. Special Precautions
1-1
Denotes operations and practices that
may result in personal injury or damage to
the equipment if not correctly followed.
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.
Never disassemble, repair or modify the Sensor.
These actions can cause electric shock and fire. Do not do anything other
than the maintenance described in the operation manual.
DANGER
！
WARNING
！
C
A
UTION
！
D
A
NGER
！

MA-520B/521B/522B
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.
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.
Connect the specified cables securely.
Cables of insufficient current capacities and loose connections can cause fire
and electric shock.
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.
Wear protective glasses.
If you look at the surface flash and expulsion directly during welding, your
eyes may be damaged.
W
ARNING
！

MA-520B/521B/522B
1. Special Precautions
1-3
Use ear protectors.
Loud noises can damage hearing.
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.
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 Sensor 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 Sensor periodically.
Maintain and inspect the Sensor periodically, and repair any damage nearby
before starting operation.
C
A
UTION
！

MA-520B/521B/522B
1. Special Precautions
1-4
(2) Precautions for Handling
■Do not install this Sensor in the following.
Damp places where humidity is higher than 90%, places where the Sensor
may be subjected to vibration or impact, 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.
■Operate the Sensor according to the method described in this operation
manual.
■Never apply the welding current to the weld force sensor during welding. It can
cause a malfunction or breakage. However, a measurement can be done
while the welding current flows by connecting the optional part for measuring
the weld force of the welding head which has two electrodes such as parallel
gap welding and series welding.
■Do not apply a weld force larger than the rated load of the Sensor. Also, do not
apply a weld force or have an impact on the Sensor suddenly.
■Do not bend the flexible joint part of the Sensor unnecessarily. When bending,
do not bend it over 60° from right to left or up and down. Also, do not pull the
flexible joint part of the Sensor over 5 mm. The internal signal line may be
broken.
■Do not put anything other than a workpiece, e.g., a tool, a screw, etc., between
the electrodes. It can cause a malfunction.
■Clean the outside of the Sensor 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 Sensor.

MA-520B/521B/522B
2. Features / 3. Specifications
2･3-1
2. Features
MA-520B/521B/522B is an electrode force sensor for resistance welding machine.
By connecting this sensor to the special weld force gauge sold separately (MM-400A),
the weld force over a wide range can be measured easily.
This sensor can be carried easily, since it is both small and light.
Use the force sensor so that the welding current does not flow on it since it is not
insulated, otherwise the sensor will be broken.
3. Specifications
Model No. MA-520B MA-521B MA-522B
Rated load 9.8daN (10kgf) 98daN (100kgf) 980.6daN (1000kgf)
Effective measurement
range
0.2daN–9.8daN
(0.2kgf–10kgf)
2.0daN–98daN
(2.0kgf–100kgf)
20daN–980.6daN
(20kgf–1000kgf)
Acceptable load 1.5 times of rated load
Measurement accuracy ±3% of rated load
Using temperature range 0 – +40°C
Overall length
of body Approx. 170 mm Approx. 177 mm
Diameter of
sensor unit x
thickness
φ25 mm x 9 mm φ33 mm x 16 mm
External
dimensions
Cable length Approx. 1000 mm
Weight
(including cable and connector) 200 g 250 g
Option (See Chapter 6.)
Jig for simultaneous force
application and welding
(A-04860-001)
-
！
CAUTION

MA-520B/521B/522B
4. Name of Each Section
4-1
4. Name of Each Section
(Dimensions in mm)
Cable to connect
weld force gauge
Flexible joint Handle
Weld force
sensor unit
φ20
85
170(MA-520B,MA-521B) / 176.5(MA-522B)
φ25
7
9
φ5
φ3
φ33
13
16
MA-520B/521B MA-522B
φ12
φ10
Connector for weld force gauge
[Detail of weld force sensor unit]

MA-520B/521B/522B
5. Measurement Method
5-1
5. Measurement Method
(1) Connection to Weld Force Gauge
Confirm that the weld force to be measured is in the effective measurement range of
the sensor, then connect the sensor to the weld force gauge securely.
(2) Application of Weld Force
●Preparation of weld force sensor
Hold the weld force sensor so that it will be aligned with the electrodes of the
welding machine and the weld force will be applied to the sensor normally (see
figure below).
●Application of weld force
Slowly apply the weld force. Avoid applying any large shocks to the sensor.
Weld force sensor
Electrode
Line the axis of
the electrodes
Perpen-
dicular
force
In case of pointed
electrodes, turn the
sensor unit to the fixed
side to make a measurment
more accurate.
Before measuring the weld force, be sure to turn off the welding machine and confirm
that the power is not applied. If the welding power is applied while the weld force is
measured, the sensor may be broken.
Do not apply the weld force to any part other than the sensor unit. Do not apply a
weld force larger than the rated load of the sensor. If they are applied, the sensor
may be broken.
For the details of the measurement method, see the Operation Manual for the Weld
Force Gauge.
For weld force gauges other than MM-601, there are setting items of sensor
type and span value. The span value is indicated on the seal attached to each
weld force sensor. For details, refer to the Operation Manual for the Weld Force
Gauge to be connected.

MA-520B/521B/522B
6. Option
6-1
6. Option
In this chapter, we will explain about the optional jig for simultaneous force application
and welding (A-04860-001).
This jig can be used for MA-520B/521B only. (This cannot be mounted to MA-522B.)
(1) Introduction
This is a jig for measuring the weld force of the welding head which has two
electrodes such as parallel gap welding and series welding.
Also, when this jig is mounted, a measurement can be done even if the welding
current flows.
(2) Mounting Method
Fix the sensor with three setscrews (M3)
so that it will be set at the center of the jig.
M3 setscrew Copper
plate Insulation sheet
Parallel gap welding Series welding

MA-520B/521B/522B
6. Option
6-2
(3) Usage
•Set the electrodes at the center as much as possible.
•Put the electrodes on the weld force sensor as perpendicularly as possible.
Remove oxide and any extraneous substances from the surface of electrodes
to smoothen the surface, and then make a measurement.
If the welding current flows without the electrodes close to the copper plate,
surface flash and expulsion may be generated.
(4) Maintenance Parts
Item Model No.
Maintenance parts set
・Copper plate
・Insulation sheet
A-04888-001