Amada MH-D500D User manual

AA05OM1208867-02
OPERATION MANUAL
MOTOR-DRIVEN RESISTANCE WELDING HEAD
MH-D500D

MH-D500D
1
Thank you for purchasing our Motor-Driven Resistance Welding Head MH-D500D.
・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) Head·························································································· 3-1
(2) Controller Front Panel ··································································· 3-3
(3) Controller Rear Panel ···································································· 3-5
4. Interface
(1) Connection Diagram of External Input/Output Signal···························· 4-1
(2) I/O Connector ·············································································· 4-3
5. Installation and Connection ······························································ 5-1
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. User’s Maintenance
(1) Installing and Replacing Electrode (Separately sold)···························· 8-1
(2) Adjustment of Weld Force ······························································ 8-1
9. Specifications
(1) Specifications ·············································································· 9-1
(2) Accessories················································································· 9-1
(3) Separately Sold Items ··································································· 9-2
(4) Timing Chart················································································ 9-3
10. Data Communication
(1) Communication Specifications························································· 10-1
(2) Connection of Communication Connector·········································· 10-1
(3) Bidirectional Communication··························································· 10-3
11. Welding Head with Load Cell
(1) Connection of Load Cell Sensor to Indicator······································· 11-1
(2) Comparison Functions of Indicator ··················································· 11-1
(3) How to Hold HI-LO Limit Judging and Indicated Value at Indicator ·········· 11-3
(4) Calibration of Load Cell·································································· 11-4
12. Outline Drawings
(1) MH-D500D-00-00/01/30/31 Head····················································· 12-1
(2) MH-D500D-00-40/41 Head ····························································· 12-2

MH-D500D
2
(3) MH-D500D-00-02/03/32/33 Head····················································· 12-3
(4) MH-D500D-00-42/43 Head ····························································· 12-4
(5) MH-D500D-00-50/51/80/81 Head····················································· 12-5
(6) MH-D500D-00-90/91 Head ····························································· 12-6
(7) MH-D500D-00-52/53/82/83 Head····················································· 12-7
(8) MH-D500D-00-92/93 Head ····························································· 12-8
(9) Head Controller············································································ 12-9

MH-D500D
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 Welding Head
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 Welding Head
This product incorporates parts containing gallium arsenide (GaAs).
DANGER
！
WARNING
！
CAUTION
！
DANGER
！

MH-D500D
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 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.
WARNING
！

MH-D500D
1. Special Precautions
1-3
Do not splash water on the Welding Head
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.
Connect the specified cables securely
Cables of insufficient current-carrying capacities and loose connections can
cause fire and electric shock.
Install the Welding Head on firm, level surface.
If the Welding Head 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 Welding Head 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 Welding Head periodically
Maintain and inspect the Welding Head 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 Welding Head for purposes other than welding
Use of this Welding Head in a manner other than specified can cause electric
shock and fire.
CAUTION
！

MH-D500D
1. Special Precautions
1-4
(2) Precautions for Handling
■Do not install this Welding Head 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 Welding Head 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 Head.
■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 Welding Head, since they can cause a
malfunction.
■Operate the Welding Head 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.

MH-D500D
2. Features
2-1
2. Features
Since MH-D500D 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 of MH-D500D is 50 to 500
N (approx. 5 to 50 kgf).
The Head with load cell displays the electrode force at welding on the color LCD by
the built-in load cell. The display of either of N and kgf can be selected.
Also, you can output a signal when the electrode force reaches the setting and do
welding by connecting an optional cable.
RS-232C, BCD data output, analog output, and RS-485 are available as options of the
indicator.
The Head with load cell can judge that the electrode force is OK or NG by using the
comparing display function of indicator.
The Head with load cell can output the welding start signal from the indicator when the
electrode force reaches the specified value for the workpiece to be weld.
CAUTION When starting welding by using the output from the indicator, the
judgment that the electrode force is OK or NG cannot be done by the
use of the comparison function.
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.
During welding, the workpiece expands and shrinks. MH-D500D employs a spring so
that the electrode can quickly follow-up the deformation of the workpiece, which
reduces the surface flash.
The dedicated controller can easily set the electrode position and speed.

MH-D500D
3. Name and Functions of Each Section
3-1
3. Name and Functions of Each Section
(1) Head
Weld Force Adjustment Knob
Adjusts the electrode force.
Lock Screw
Locks the Weld Force Adjustment Knob.
Holder Upper
Fixes the electrode Holder.
ATTENTION
Should a metal object such as a
screwdriver and wire contact a
part such as a Holder through
which welding current flows
during operation, the object may
be welded to the Welding Head.
Before starting work, be sure to
remove all metal objects from
around the equipment.
0
1
2
0
1
2
3
4
①
②
③
④
⑭
⑮
⑤
⑤
⑥
⑦
⑧
⑨
⑩
⑪
⑫
⑬
⑬
④
①

MH-D500D
3. Name and Functions of Each Section
3-2
M6 Electrode Holder-Mounting Screw
Mounts the electrode Holder to the Holder Upper.
Electrode Holders
Fixes the electrodes.
Holder
Mounts the electrode holder.
Screws for connecting Voltage Sensing Cable
Connects the Voltage Sensing Cables.
Use the cables which your welding power supply designates.
Indicator for Electrode Force
Shows an approximate electrode force.
Holder Lower
Fixes the Holder and supplies power.
Column and Base
For the Welding Head.
⑪Flexible Feeder
Applies power to the upper electrode, transferring according to the movement of
the upper electrode.
⑫Block for supplying Power
Mounts a secondary cable.
⑬M8 Screws for fixing Secondary Cable
Fixes the secondary cable.
⑭Cable for Weld Force Detecting Sensor
⑮Motor Cable

MH-D500D
3. Name and Functions of Each Section
3-3
(2) Controller Front Panel
Operation Button
Operate the Welding Head 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 in the model of
MH-D500D.)
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 elec-
trode 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
WELD HEAD
CONTROL UNIT
1
12
2
3
4
5
6
7
8
9
10
11
13
⑭

MH-D500D
3. Name and Functions of Each Section
3-4
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.

MH-D500D
3. Name and Functions of Each Section
3-5
(3) Controller Rear Panel
[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
welding head.
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, 1 A, 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).
2
1
3
4
5
6
7

MH-D500D
4. Interface
4-1
4. Interface
(1) Connection Diagram of External Input/Output Signal
24VDC
READY
START POINT
MID POINT
OUT COM
ERROR
OUT COM
-COM
RY STOP
+COM
SCH1
SCH2
SCH4
SCH8
SCH16
+COM
-COM
-COM
WELD START
-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
RESET
P.LOCK
≈
External Input/Output Connector
Motor Head Controller
Spare: Do not connect
Spare: Do not connect
Spare: Do not connect
EXT.24V: Do not connect
Spare: Do not connect

MH-D500D
4. Interface
4-2
[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.COM
+COM
8
9
10
11
12
13
14
15
-COM
24VDC
≈
8
9
10
11
12
13
14
15
PLC
+24V
24VDC
≈
1ST
2ND
-COM
+COM
EXT.COM
+COM
8
9
10
11
12
13
14
15
-COM
24VDC
≈

MH-D500D
4. Interface
4-3
(2) I/O Connector
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 MH-D500D. Before selecting the schedule
number by the operation button on MH-D500D, 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.

MH-D500D
4. Interface
4-4
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 after [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

MH-D500D
4. Interface
4-5
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 MH-D500D 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 MH-D500D, 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

MH-D500D
4. Interface
4-6
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
MH-D500D, the Pin becomes
opened until it is reset.
30 Spare pin: Do not connect.
31 Common terminal to [READY], [START POINT], [MID POINT] 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.
OUT COM28
or 31
29 ERROR

MH-D500D
5. Installation and Connection
5-1
5. Installation and Connection
Before using your MH-D500D, 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 MH-D500D 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 MH-D500D, the welding power supply and welding
transformer.
Connection of Secondary Cable
Connect the secondary cable to MH-D500D.
When installing it, use appropriate tools for the screws, bolts and nuts to firmly fasten
them so as not to be loosened.
CAUTION
！
Fix by M8 bolt.
Fix by M8 bolt.
WARNING
！