Amada MEA-100B User manual

Z06OM1200070-10
OPERATION MANUAL
Original instructions
AC WELDING POWER SUPPLY
MEA-100B

MEA-100B
1
Thank you for purchasing our AC Welding Power Supply MEA-100B.
・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.................................. 1-1 to 1-5
2. Features..................................................... 2-1
3. Packaging.................................................. 3-1
4. Name and Functions of Each Section ..... 4-1 to 4-4
5. Connection ................................................ 5-1
6. Before the Operation ................................ 6-1 to 6-4
7. Basic Operation ........................................ 7-1 to 7-13
8. Stepper-Up Function................................. 8-1 to 8-4
9. Detail Settings (SET2 Screen) .................. 9-1 to 9-7
10. Interface................................................... 10-1 to 10-8
11. Timing Chart............................................ 11-1 to 11-6
12. Troubleshooting...................................... 12-1 to 12-4
13. Specifications.......................................... 13-1 to 13-8
14. External Communication Function ........ 14-1 to 14-13
15. Outline Drawing ...................................... 15-1
16. Schedule Table........................................ 16-1 to 16-4
EU Declaration of Conformity

MEA-100B
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, W
ARNING 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 Power Supply if not correctly
followed.
Do not touch the inside of the Power Supply unnecessarily
Since very high voltages are applied to the inside of this Power Supply, it is very
dangerous to touch it unnecessarily.
Any person other than service personnel, or authorized representatives’
personnel must not touch the inside.
Never disassemble, repair or modify the Power Supply
These actions can cause electric shock and fire. Consult us or your distribution
for inspection and repair.
Never burn, destroy, cut, crush or chemically decompose the Power Supply
This product incorporates parts containing gallium arsenide (GaAs).
DANGER
！
W
ARNING
！
CAUTION
！
DANGER
！

MEA-100B
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 fault
occurs, or electricity leaks.
Apply Single-Phase, 200/220/230/240/380/400/460/480 V AC 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 surface flash and expulsion directly during welding, your eyes
may be damaged. If any surface flash and expulsion gets in your eyes, you may
lose your eyesight.
WARNING
！

MEA-100B
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
！

MEA-100B
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.
■Install this Welding Power Supply on a firm, level, horizontal 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 45°C or below 0°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
Power Supply.
■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.
■Operate the switches and buttons one at a time. If two or more of them are
operated at a time, the Power Supply may have trouble or may be broken.
■The Power Supply is not equipped with auxiliary power such as an outlet for
lighting.
■The welding head, the welding transformer, the secondary cable for connecting
the welding head with the welding transformer, and the connecting cable for
connecting the welding transformer 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. Press the crimp-on
terminal (terminal block screw, M3) for wiring.
■The cable to supply power to the Power Supply is not attached. Press the
crimp-on terminal (terminal block screw, M6) for wiring. For the cable to use, see
3. (2) Option.
■The cable to connect between the welding transformer and the Power Supply is
not attached. Press the crimp-on terminal (terminal block screw, M6) for wiring.
For the cable to use, see 3. (2) Option.

MEA-100B
1. Special Precautions
1-5
(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.

MEA-100B
2. Features
2-1
2. Features
The MEA-100B is a single-phase AC resistance-welding power supply designed for fine
spot welding. The control method can be selected from secondary constant-current
control and power supply voltage fluctuation compensation control. The MEA-100B
realizes high quality welding, so it is suitable for small size precise welding.
1Four welding current control systems are currently available for the MEA-100B. Select
the control system best suited to the particular workpiece.
[Multi-Cycle Welding + Secondary Constant-Current Control]
Returns welding current feedback to the control at each half-cycle, using the toroidal
coil. The control makes adjustments based on this feedback to maintain a constant
current, compensating for voltage fluctuation and workpiece load variances.
[Multi-Cycle Welding + Power Supply Voltage Fluctuation Compensation
Control]
Monitors and compensates for power supply voltage fluctuation to maintain a constant
current. Compensation begins from the first half-cycle.
[Single-Cycle Welding + Power Supply Voltage Fluctuation Compensation
Control]
Permits the flow of one cycle current only. You can set the first half wave and the
second half wave separately. Compensation begins with the first half wave.
[Half-Cycle Welding + Power Supply Voltage Fluctuation Compensation Control]
Permits the flow of one half-cycle current only. The direction of the current is inverted
with each current flow.
2Current Monitor Function Provided
This function allows you to check the current at every welding. Also, a fault message is
displayed when the current range has been preset and the current is out of range.
3Automatic Maximum Current Setting
The highest optimum current is automatically set through test welding. (This setting is
then retained in memory even when the power supply is turned off. However, it is reset
when another test welding is performed.)

MEA-100B
3. Packaging
3-1
3. Packaging
(1) Accessory
Item Model No. Q’ty
Operation manual AS1200089(OM1200069,OM1200070) 1
(2) Options
Item
Model No.
Description
Item No.
Toroidal coil MB-35E-00
Required for secondary constant-
current control or current
monitoring.
1001283
Connecting
cable
(Power cable/
Output cable)
PK-03294-001
(2 m)
Used to supply power to the MEA-
100B and connect the MEA-100B
to the welding transformer.
Note: If you provide a cable, select
a cable with the following
specification.
Rated voltage............ 600 V min.
Number of cores........ 3
Cross section.............5.5 mm2 min.
Protection conductor..5.5 mm2 min.
Cable diameter.......... 18 mm max.
1001699
PK-03294-002
(5 m) 1001712
PK-03294-003
(10 m) 1001713
For China
PK-03887-001
(2 m)
1001745
PK-03887-002
(5 m)
1001746
PK-03887-003
(10 m) 1001747
Start cable
SK-03273-001
(2 m)
Connects the MEA-100B to the
welding head.
1001698
SK-03273-002 (5 m)
1001710
SK-03273-003
(10 m) 1001711

MEA-100B
4. Name and Functions of Each Section
4-1
4. Name and Functions of Each Section
(1) Front Panel
Display Panel
This LCD panel is used to monitor various MEA-100B functions.
Indicates various settings and weld measurement results.
[READY] Lamp
Lights when the MEA-100B is ready to supply a welding current.
This lamp is synchronized with Terminal 12 ([READY]) of the I/O Terminal
Strip on the rear panel.
This lamp lights when the following conditions are met:
The [WELD] lamp on the panel is on.
The [WELD ON/OFF] signal of the I/O Terminal Strip on the rear panel is
on.
No trouble has occurred.
WELD
MENU
RESET
READY START GOOD CAUTION N.G
SET 1 SET 2
SCHEDULE NO. CURR.1 CURR.2 PULSATION SOLENOID
UP2
10 0 10 00 0 00 0 10
KEY LOCK
DWNW2SQ UP1 W1 CO HLD
10 0.9 5 kA 1.00 kA 0 0
①
②
③
④
⑤
⑧
⑨
⑪
⑫
⑪
⑥
⑦
⑩
⑬
⑭

MEA-100B
4. Name and Functions of Each Section
4-2
Also, this lamp is turned off while settings are written in the flash memory
after schedules are changed.
[KEY LOCK] Lamp
If this lamp is lit, the schedules or other settings cannot be edited.
However, you can still change screens and the schedule no. using the
[MENU] key, and change functions using NP on the SET2 screen (See 9.
(2) ).
[START] Lamp
Indicates the status of Terminal 28 ([START(1ST)]) of the I/O Terminal Strip
on the rear panel.
Lights when the start signal is input.
[GOOD] Lamp
Lights when the current is within the monitor range after welding (See 7. (2)).
This lamp is synchronized with Terminals 17 and 18 ([GOOD]) of the I/O
Terminal Strip on the rear panel.
[CAUTION] Lamp
Lights if the items set to 0 on #4–#7 of the SET2 screen are troubled (See 9.
(2) ). Detailed information on the problem is provided on the display panel.
The lamp is synchronized with Terminal 10 ([CAUTION]) of the I/O Terminal
Strip on the rear panel.
[N.G] Lamp
Lights if the items set to 1 on #4–#7 of the SET2 screen are troubled (See 9.
(2) ). Detailed information on the problem is provided on the display panel.
The lamp is synchronized with Terminals 15 and 16 ([NG]) of the I/O
Terminal Strip on the rear panel.
[WELD] Lamp
This lamp is one of the three conditions to light the [READY] lamp. Lights
when the [WELD] key is pressed.
If the lamp is turned off, a sequence test can be performed without a
welding current.
[WELD] Key
Turns on the [WELD] lamp. To turn off the lamp, the key must be pressed
for at least a second.
[RESET] Key
Turns off an [NG] or [CAUTION] output.
The key does not work until the cause of the problem has been rectified.
○
11 Cursor Key
Used to move the cursor.
○
12 [MENU] Key
Used to move from the MENU screen to another screen or to return to the
MENU screen from the SET screen. For the SET screen, see 6. and 9.
To move to the SET1 screen, simultaneously press the [] key and the
[MENU] key. Press both for at least a second.
To move to the SET2 screen, simultaneously press the [] key and the
[MENU] key. Press both for at least a second.

MEA-100B
4. Name and Functions of Each Section
4-3
○
13 [+] Key
Changes the number selected by the cursor. Press this key repeatedly to
increase the value.
○
14 [-] Key
Changes the number selected by the cursor. Press this key repeatedly to
decrease the value.
(2) Rear Panel
I/O Terminal Strip
Terminal strip for signals, including the [START] and [NG] signals.
For details, see 10. Interface.
Toroidal Coil Connector
This serves as the input connector for the secondary current detection
signal.
Connect the toroidal coil (sold separately) to this connector when the
secondary constant-current control is selected, or if the power supply
voltage fluctuation compensation control is selected and the welding current
monitor is in use.
ON
PE
COIL
①
②
⑦
④
⑤
⑥
Remove the circuit
breaker cover
③

MEA-100B
4. Name and Functions of Each Section
4-4
Power Cable Connecting Terminal
Connect the power cable (sold separately) to this terminal for welding.
The other end of the power cable is connected to a single-phase power
supply for welding. For the power cable, see 3. (2) Options.
Circuit Breaker
Supplies or shuts off power to the MEA-100B.
Raise the handle to turn the circuit breaker on and to supply welding power
to the MEA-100B.
Lower the handle to turn off the circuit breaker and to shut off welding power
to the MEA-100B.
Output Terminal Block
The output cable (sold separately) is connected to this block.
The other end of the cable is connected to the input terminal of the welding
transformer. For the output cable, see 3. (2) Options.
Power Cable Inlet
Pass the power cable through this inlet to connect the cable to the power
cable connecting terminal.
Grounding Terminal
Be sure to ground the MEA-100B to prevent electric shock.

MEA-100B
5. Connection
5-1
5. Connection
The illustration below shows the MEA-100B connected to an MH-21AC, our welding
head, and MT-510AC, our welding transformer.
Connect the wire to the terminal having a frequency that matches the welding power supply
１
ON
PE
COIL
MEA-100B
MH-21AC
Connecting Cable
Connecting Cable
Connect to
No.27 and 28
on the I/O signal
terminal strip.
MT-510AC
ＵＶ
ＰＯＷＥＲ ＯＵＴ
２
19
21
25 26
Toroidal Coil
COM 50Hz 60Hz
AC200V IN
Connect the greenwireto
Remove the terminal cover
Connect the green wire to
Secondary Cable
Connect the green cable to the PE.
Grounding
Green
Single-phase welding power supply
27 28
Check that the wires and
cables are connected to the correct locations.
Wrong wiring can lead to malfunctions.
(All of the following
components except the
MEA-100B are sold
separately.)
Start Cable

MEA-100B
6. Before the Operation
6-1
6. Before the Operation
(1) Screen Configuration
MENU Screen
Press the [MENU] key to select the desired screen. The screens are cycled like this:
Welding schedule setting screen
Current monitor display screen
Current monitor range setting screen
Total count display screen
Step count setting screen
Stepper-up current up rate setting screen
Stepper-up display screen
These seven screens are called the MENU screens.
SET Screen
There is the SET screen for detail settings in addition to the MENU screen. The SET
screen is divided into two general screens, the SET1 screen and the SET2 screen.
To display the SET1 screen, press the [MENU]
key and the [] key simultaneously for at least
a second.
To display the SET2 screen, press the [MENU]
key and the [] key simultaneously for at least
a second.
Also, the SET1 screen has #1 and #2 screens,
and the SET2 screen has #1 to #8 screens.
The number is displayed at the upper left side
on the screen (See the circle in figure below.)
When screen is switched to the SET screen,
the #1 screen is always displayed first.
＃１ ＭＡＸ ＣＵＲＲＥＮＴ ２．０ｋＡ
For details of the SET1 screen, see 6. (3) and (4).
For details of the SET2 screen, see 9. Detail Settings.
MENU screen (7 screens)
SET2 screen (8 screens)
SET1 screen (2 screens)
Ordinary
(4 screens)
Stepper-Up
(7 screens)

MEA-100B
6. Before the Operation
6-2
(2) Control Method and Welding Current Cycle Settings
Follow the procedure described below and set the control method and welding current
cycle according to the specific application after the MEA-100B is installed.
(Secondary constant-current control is factory-set on shipment.)
To display the SET2 screen, press the [MENU] key and the [] key simultaneously for
at least a second. (For details of the SET2 screen, see 9. Detail Settings.)
＃１ ＮＰ ＣＣ ＳＳ ＳＭ ＳＤＴ
０００１０５
Change the value under CC (arrow above) to select a desired control method and
welding current cycle.
Setting
Control Method
Welding Current Cycle
0
Secondary constant-current control
Multi-cycle welding
1
Power supply voltage fluctuation
compensation control
Multi-cycle welding
2
Power supply voltage fluctuation
compensation control
Single-cycle welding
3
Power supply voltage fluctuation
compensation control
Half-cycle welding
After changing, press the [MENU] key to go to the welding schedule setting screen.
(3) Maximum Current Setting
The maximum current is set in one of two ways described below:
A: To set the maximum current of the welding machine directly
To display the SET1 screen, press the [MENU] key and the [] key simultaneously for
at least a second. When screen is switched to the SET screen, the #1 screen is
always displayed first.
＃１ ＭＡＸ ＣＵＲＲＥＮＴ ２．０ｋＡ
Move the cursor to and set the maximum current of the welding machine. Setting
range is 0.5 to 9.9 kA.
Caution: When the value is set to lower than 0.5, "∗∗∗" will be displayed and
the the maximum current will be set automatically.
For details, see next page.
Caution: Read 9. (2) carefully before modifying any of the above settings
other than CC.

MEA-100B
6. Before the Operation
6-3
B: To set the maximum current automatically, from the measurement of actual welding
If the maximum current of the welding machine is unknown, set the maximum current
automatically with the automatic setting function.
Connect the toroidal coil (sold separately) to the MEA-100B.
To display the #1 of the SET1 screens, press the [MENU] key and the [] key
simultaneously for at least a second.
＃１ ＭＡＸ ＣＵＲＲＥＮＴ ２．０ｋＡ
Decrease the value of below 0.5 kA to indicate “***kA”, the automatic maximum
current setting function is enabled.
＃１ ＭＡＸ ＣＵＲＲＥＮＴ ＊＊＊ｋＡ
ＳＱ：５０ Ｗ：０６Ｃ １．００ｋＡ １
a b c d
The initial settings are shown above. Edit the settings according to the specific welding
machine in use.
Description
Setting Range
a
Squeeze time.
The set squeeze time must be longer than the actual
squeeze time. (HLD (hold time) will equal SQ (squeeze
time).)
00–99 cycles
b
Weld time.
The set weld time must be the actual weld time.
01–99 cycles
c
The set current must be 60% to 90% of the actual welding
current in order to prevent the damage to the MEA-100B
caused by overcurrent.
0.20–9.99 kA
d Weld Force number. Select the welding machine for which
you want to set the maximum current automatically.
SOL1
SOL2
Close Terminal 28 ([START(1ST)]) of the I/O Terminal Strip on the rear panel.
After test welding is complete, the display will revert to the screen shown in .
The screen shows the maximum current set automatically.
If the display does not revert to the screen, repeat test welding until the screen returns.
(To measure the maximum current, welding must be performed for 6 cycles.)
Caution: Moving to another screen during the automatic maximum current
setting will interrupt the setting process.
Caution: The value set by the automatic setting function is an approximation.
Sometimes the value is differrent from an actual maximum current.
Do not use this function other than the setting of the maximum
current.

MEA-100B
6. Before the Operation
6-4
(4) Contrast Setting
Adjusts the LCD contrast.
To display the SET1 screen, press the [MENU] key and the [] key simultaneously for
at least a second.
＃１ ＭＡＸ ＣＵＲＲＥＮＴ ２．０ｋＡ
Move the cursor to and change to the #2 screen.
The #2 LCD CONTRAST screen is displayed.
＃２ ＬＣＤ ＣＯＮＴＲＡＳＴ：０６
＜＜＜＞＞＞
Change the value indicated by arrow to select one of 16 contrast levels.
The lower the value is, the darker the LCD is.
‘<<>>’ at the bottom line indicates the current contrast level.

MEA-100B
7. Basic Operation
7-1
7. Basic Operation
(1) Supplying Power
Turn on the circuit breaker on the rear panel to supply power to the MEA-100B.
During the startup self-diagnostics, the LCD screen displays the model number and
software version. If the self-diagnostics completes without errors, the MENU screen
is displayed.
An error prompt is displayed if a "trouble" arises.
The screen last displayed before power was turned off is displayed on the display
panel.
Attention: Do not turn on the circuit breaker while pressing a key on the panel.
Do not press a key within 2 seconds after power is turned on. For
example, pressing the [RESET] key during this period will return all
welding schedule data to their default settings.
Caution: Check that the display screen and lamps are turned on normally.

MEA-100B
7. Basic Operation
7-2
(2) Writing in the Flash Memory
ATTENTION
The Power Supply writes data into the flash memory on the control board when
a setting is changed. The [READY] lamp on the front panel and the external
READY signal are turned off during writing. Check that the [READY] lamp is
turned on to start welding.
It takes about 1 second at longest to change a setting in the flash memory.
During that time, do not turn off the power.
Also, the flash memory has the rewriting limit (30,000 times). If the limit is
exceeded, the set data may not be stored normally. Be careful when changing
settings frequently with the RS-485 bi-directional communication.
The MEA-100B does not have the key to establish setting like “ENTER.” By either
of the following procedures, settings can be written and stored in the flash memory.
After changing the set value with the [+] key or [-] key,
move to the next setting item with the cursor key (Settings cannot be stored just
by digit shift.)
move to the next screen with the [MENU] key, or
do nothing for 3 seconds or longer.
When the setting is stored in the flash memory, the [READY] lamp on the front
panel or the external READY signal is turned off for a moment. Wait until the
READY is turned on after off to start the sequence or turn off the power supply.