Miyachi MG3D User manual

Original Version: German Translation of Original Version Version: 1.6
76609409EN-BA-MG3D-V1_6.docx 1/82 2010-08-02
MIYACHI EUROPE CORPORATION
www.miyachieurope.com
Lindberghstr. 1 D-82178 Puchheim
Tel. [phone] Fax: [phone]
Operating Instructions
MG3D
Digital Measuring Unit
Annex: Safety Regulations
General References on Resistance Welding
Contact Addresses
Order number: Year:
Serial number:

Operating Instructions MG3 Digital
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Versions
Version Date Basis of revision
1.0 2002-11 new
1.01 2003-04 Corrections
1.02 2003-07 Software changes
1.03 2003-11 Plug assignment / Indices
1.03a 2004-02 Only English corrections
1.03b 2004-05 Checked CompactFlash
1.03c 2004-09 Only Czech corrections: Screenshots
1.1 2004-11 CanOpen; Pressure/Force; Measurement values; field bus
1.1a 2005-03 Miyachi-Peco
1.2a 2005-09 Safety regulations separate and div. small changes
1.3 2006-05 Diagrams 6.10 added, declaration by the manufacturer
1.3a 2007-04 Declaration of Conformity
1.3b 2008-07 Symbols changed
1.4 2009-09 New design (Spanish only)
1.5 2010-03 Flow diagrams new
1.6 2010-08 CE new Machinery Directives
Copyright ©2010: Miyachi Europe GmbH
All rights reserved. The products named in this manual are only used for identification purposes and may be
trademarks or registered trademarks of the respective companies.

Operating Instructions MG3 Digital
Table of Contents
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Table of Contents
1General Information ........................................................................... 5
1.1Declaration of Conformity............................................................................... 5
2Technical Description.......................................................................... 6
2.1Design and Mode of Action.............................................................................. 6
2.2Technical Data ................................................................................................ 7
2.3Maximum Cycle and Memory Times ................................................................ 8
3Commissioning ................................................................................. 12
3.1Connecting the Components ......................................................................... 13
3.1.1Description of the Connectors.......................................................................................13
3.1.2Connector Pin Assignment of Inputs & Outputs ............................................................14
3.1.2.1Connector X54 (Outputs) ..................................................................................................14
3.1.2.2Connector X55 (Inputs) .................................................................................................... 15
3.1.2.3Connector X38 (I/O Outputs) ............................................................................................ 16
3.1.2.4Connector X38 (I/O Inputs)............................................................................................... 17
3.1.2.5Connector X51 (RS232) / Baud rate ................................................................................... 17
3.1.2.6Connector X60 and X61 (CANopen).................................................................................... 18
3.1.3Establishing Connections for Voltage Measurement......................................................19
3.1.4Establishing Connections for Displacement Measuring .................................................20
3.1.5Establishing Connections for Displacement Measurement ............................................21
3.2Initial Commissioning................................................................................... 22
3.2.1Preconditions................................................................................................................22
3.2.2Starting-up ...................................................................................................................22
4Operation.......................................................................................... 23
4.1Measuring Instrument MG3D – What is What?.............................................. 23
4.1.1LED Status Displays ......................................................................................................23
4.1.2Screen (Display) ...........................................................................................................24
4.1.2.1Display Windows – Quadrant 1 to 4.................................................................................... 25
4.1.2.2Menu Bar........................................................................................................................25
4.1.2.3Program Display ..............................................................................................................25
4.1.2.4Measuring Mode............................................................................................................... 25
4.1.2.5Status Bar.......................................................................................................................25
4.1.3Board Slot for Compact Flash Card or MicroDrive..........................................................26
4.1.4Knob/pushbutton Combination.....................................................................................26
4.1.5UNDO Function .............................................................................................................26
4.2Menu Structure............................................................................................. 27
5How to …? ........................................................................................ 28
5.1Carry out a General Set-up ........................................................................... 28
5.2Measuring current and voltage ..................................................................... 32
5.3Conducting Measurements With “Shunt”...................................................... 35
5.4Changing Over Between Single and Continuous Measurement...................... 37
5.5Configuring Display Window for the Various Types of Measurement Categories38
5.6Displacement Measuring (digital or analog) ................................................. 39
5.7Measuring Pressure or Force ........................................................................ 41
5.8Determining Limit Values.............................................................................. 42
5.9Generating Reference Waveforms and Envelope Waveforms ........................ 43

Operating Instructions MG3 Digital
Table of Contents
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5.10Copying, saving and loading Programs and Parameters ............................... 50
5.11Counting Measurements ............................................................................... 52
5.12Viewing and Saving Measuring Waveforms................................................... 53
5.13Printing Measurement Values ....................................................................... 57
5.14Determining and Changing Password ........................................................... 58
5.15Configuring the Logger ................................................................................. 59
5.16Parameter Overview Display......................................................................... 61
5.17Analyzing Accept-Reject Ratio ...................................................................... 61
5.18Monitoring Statistical Values ........................................................................ 62
5.19Having Limit Values Determined Statistically................................................ 64
5.20Transferring Data to PC/Laptop.................................................................... 66
5.21Creating a Screenshot of the Current Display ............................................... 66
5.22Registering the Device.................................................................................. 66
6Integration in Automated Installations ............................................ 67
6.1Flow Chart Channel 1 or Channel 2 Alone ..................................................... 67
6.2Flow Chart Channel 1 and Channel 2 Parallel................................................ 68
6.3Flow Chart Channel 1 and Channel 2 Parallel, but Current 1 and Current 2 do
not Overlap................................................................................................... 69
6.4Flow Chart Channel 1 or Channel 2 alone, With Too Short Measuring Interval70
6.5Flow Chart Channel 1 and Channel 2 With Parallel Measuring Within the
Evaluation Time of the Respective Channel That Measures First................... 71
6.6Flow Chart Parts Detection and Current Measuring....................................... 72
6.7Flow Chart Part Detection and Current Measuring Parallel ........................... 73
6.8Flow Chart Measuring and External Selection ............................................... 74
6.9Connection to field bus system ..................................................................... 74
6.10Flow Chart 2 channel part detection with current......................................... 75
6.10.1Fault Example Flow Chart part detection with current ..................................................76
7Appendix .......................................................................................... 77
7.1Error messages............................................................................................. 77
7.2Accessories................................................................................................... 78
7.2.1MG3 Digital ...................................................................................................................78
7.2.2MG3 Digital – W1 ..........................................................................................................78
7.2.3MG3 Digital – W2 ..........................................................................................................78
7.3Enclosures .................................................................................................... 79
7.3.1Connection diagram, Interface MG3D, 767.00590 E......................................................79
7.3.2Connection diagram, X38 (Inputs / Outputs), 767.00 591 E........................................80
8Indexes ............................................................................................ 81
8.1Figures.......................................................................................................... 81
8.2Tables........................................................................................................... 81
8.2.1Headwords....................................................................................................................82

Operating Instructions MG3 Digital
General Information
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1General Information
Information about copyrights, protection rights, symbols, safety regulations,
usage location conditions and notes on resistance welding can be found in the
annex of the operating instructions.
Please read this information carefully before using the individual elements of
the AWS welding system.
Information
These device-specific operating instructions should help you familiarize yourself with
the unit and take advantage of its application possibilities when used as directed.
The Operating Instructions contain important notes to help operate the unit safely,
properly, and economically.
Observing the notes will help avoid risks, decrease repair costs and down times, and
enhance reliability and the service life of the unit.
1.1 Declaration of Conformity

Operating Instructions MG3 Digital
Technical Description
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2Technical Description
2.1 Design and Mode of Action
Measuring instrument MG3 comprises:
Operator and
display module (Display)
PCB holder and
housing with built-in power
supply
The housing dimension is 1/2 x 19 in. The MG3 can also be supplied in a 19 in. housing
then offering space for an additional control unit.
Data transfer between display unit and PCB holder is made through a CAN interface.
In its standard version, measuring instrument MG3 Digital is equipped
with a 2-channel current-measuring and voltage-measuring card with appropriate internal
periphery in a portable housing.
A combined path-, force-, and temperature-measuring card can supplement the standard
version. Please contact our sales department for further details.
After applying mains, the measuring instrument MG3 Digital detects existing plug-in cards
by plug & plays and configures itself automatically during the boot process.
Individual operator configurations remain stored even when the instrument has been
switched off.
MG3 Digital - Process Sentry

Operating Instructions MG3 Digital
Technical Description
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The values of the last 2.500 welds are stored temporarily in a battery-buffered memory
module. If this memory is full the complete measurement data packet is written onto the
compact flash card as log file.
In the standard version, parameters prepared for one measurement from 99 welding-
control programs can be monitored via a program number interface. Miyachi Europe
GmbH multiple program controls, too, are equipped with the corresponding interface.
Output of the selected parameters of each welding to a commercially available is possible.
For that purpose, connect the printer to connector X51 (RS232 interface). In the printer
menu, set the printer format to numeric for all measurements.
Operation of the instrument through a knob/push button combination.
2.2 Technical Data
Instrument type MG3 Digital
Digital measuring and monitoring instrument
for resistance-welding installations
Program monitoring 99 programs, internal or external program
selection, extensible
Measuring functions AC and DC, effective (r.m.s.) current value,
peak value of current, charge (I x t) and
further effective voltage value,
peak value of voltage, voltage integral (u x t)
and further power in variances, energy
resistance in variances, weld time (ms)
Counter Up- and down-counter with prewarning and
final value signal output
Measuring range current Coil x 1:
2–5–20–100–500 kA peak value
Coil x 10:
0.2–0.5–2–10–50 kA peak value
Measuring range voltage 0.5–2.5–10–50 V peak value
Measurement accuracy ±1.5 % of upper limit of effective range for
current and voltage
Minimum measurable current Is±3 % for power. 10 % from measuring
range, (for lesser currents special toroid coil
10-fold)
Maximum measurable current time Approx. 2000 ms at DC, approx. 5000 ms at
AC
Minimum measurable current time Approx. 1 ms
Sampling rate (V, I) = 100 kHz per channel, simultaneous
sampling V, I of each channel
Graphic Resolution
Current/Voltage
Pressure/Force
Distance
measure time <= 50 msec: resolution 40
points per msec
measure time > 50 msec: resolution 5 points
per msec
Pressure/Force 10 points/ms
Digital distance 5 points/ms
Measuring interval Variable
Note
The more graphics are displayed, data
through RS232 and limit value and envelope
curves are monitored, the longer the
measuring interval.
Flattest permissible current rise di/dt ≥2 A/ms at measuring range 2 kA. In
the higher measuring ranges correspondingly
more
Limit value setting Independently from each other for the upper
and lower limit value across the entire
measuring range

Operating Instructions MG3 Digital
Technical Description
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Prewarning setting Independently from each other for the upper
and lower prewarning value across the entire
measuring range
Graphic display QVGA, 320 x 240 pixel
Optical display 8-fold via front LED
Outputs Analog output for current on current-
measuring card
Further control outputs see terminal diagram
Inputs 2-fold current and voltage channel,
program selection, CAN, RS232.
Further control inputs see terminal diagram
Mains voltage and frequency 90-260 Volt, ±10 %,
50-60 Hz, switching power supply
Power consumption 60 W
Ambient temperature 0 °C to 40 °C
Relative humidity max. 70%
Dimensions ½ 19“: (WxHxD) 280 x 140 x 340 mm
(Opt. 19”, 3HU)
Weight ca. 5.3 kg, (approx. 11.7 lbs)
2.3 Maximum Cycle and Memory Times
Conditions:
1000 measurements each time with consistent time, voltage, current. No limit value, pre-
warning or overrun outputs should be activated.
Validity:
Program versions
Display V1.2.7
PPC V1.119
DSP V1.4
Information:
These specifications only apply to signal-channel measurements. The recorded cycle time
is doubled for parallel measurement.
Printing via the RS232 is deactivated.
The counter is activated.
2 x pre-warning and limit values are monitored.
Trigger = 1.5%, Filter = off, Envelope waveform = off.
Maximum cycle:
The maximum cycle is the largest possible number of complete welding sequences in a
minute.
The table illustrates the cycle time (above) in ms and the maximum cycles per minute
(below).

Operating Instructions MG3 Digital
Technical Description
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Maximum cycle for AC current
All specifications for active ready-output-inquiries.
Current display AC current in [periods] 50Hz
Measuring time 1 per. 2 per. 6 per. 13 per. 25 per.
Quadrant 1-4 numerical
Logging = on 125 ms 480 140 ms 428 230 ms 260 360 ms 166 600 ms 100
Quadrant 1-4 numerical
Logging = off 120 ms 500 140 ms 428 230 ms 260 360 ms 166 600 ms 100
Quadrant 1-4 graphical
I(1),U(2),P(3),W(4)
Logging = off
1630 ms
36 1670 ms 35 1750 ms 34 1910 ms 31 2190 ms 27
34Quadrant 1-4 SPC chart
Logging = off 210 ms 285 220 ms 272 230 ms 260 340 ms 176 590 ms 101
Analysis window
Logging = on 200 ms 300 220 ms 272 260 ms 230 420 ms 142 630 ms 95
Logging window
Logging = on
Last
300 ms
200 380 ms 157 440 ms 136 500 ms 120 680 ms 88
Logging window
Logging = on
All
390 ms
153 430 ms 139 470 ms 127 500 ms 120 650 ms 92
Graphic display
(waveform I)
Logging = on
550 ms
109 610 ms 98 640 ms 93 790 ms 75 1100 ms
54
Graphic display
(waveforms I/U/P/W)
Logging = on
1580 ms
37 1650 ms 36 1690 ms 35 1840 ms 32 2140 ms 28
Tbl. 1: Maximum cycle for AC – active
Maximum cycle for DC current
All specifications for active ready-output-inquiries.
Current display DC current in [ms]
Measuring time 23 ms 50 ms 100 ms 250 ms 500 ms
Quadrant 1-4 numerical
Logging = on 130 ms 461 170 ms 352 190 ms 315 340 ms 176 602 ms 99
Quadrant 1-4 numerical
Logging = off 126 ms 476 170 ms 352 190 ms 315 340 ms 176 602 ms 99
Quadrant 1-4 graphical
I(1),U(2),P(3),W(4)
Logging = off
1635 ms
36 1672 ms 35 1710 ms 34 1870 ms 32 2170 ms 27
Quadrant 1-4 SPC chart
Logging = off 130 ms 461 180 ms 333 210 ms 285 350 ms 171 620 ms 96
Analysis window
Logging = on 220 ms 272 240 ms 250 280 ms 214 400 ms 150 630 ms 95
Logging window
Logging = on
Last
250 ms
240 340 ms 176 380 ms 157 490 ms 122 680 ms 88
Logging window
Logging = on
All
390 ms
153 420 ms 142 470 ms 127 500 ms 120 660 ms 90
Graphic display
(waveform I)
Logging = on
550 ms
109 610 ms 98 640 ms 93 790 ms 75 1100 ms
54
Graphic display
(waveforms I/U/P/W)
Logging = on
1580ms
37 1650ms 36 1690ms 35 1840ms 32 2140ms 28
Tbl. 2: Maximum cycle for DC - active

Operating Instructions MG3 Digital
Technical Description
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Maximum cycle for AC current
All specifications without active ready-output-inquiries.
Current display AC current in [periods] 50Hz
Measuring time 1 per. 2 per. 6 per. 13 per. 25 per.
Quadrant 1-4 numerical
Logging = on 140 ms 428 154 ms 398 253 ms 237 396 ms 151 660 ms 91
Quadrant 1-4 numerical
Logging = off 132 ms 454 154 ms 398 253 ms 237 396 ms 151 660 ms 91
Quadrant 1-4 graphical
I(1),U(2),P(3),W(4)
Logging = off
1793 ms
33 1837 ms 32 1925 ms 31 2101 ms 28 2409 ms 24
Quadrant 1-4 SPC chart
Logging = off 221 ms 271 242 ms 247 253 ms 237 374 ms 160 649 ms 92
Analysis window
Logging = on 220 ms 272 242 ms 247 286 ms 209 462 ms 129 693 ms 86
Logging window
Logging = on
Last
330 ms
181 418 ms 143 484 ms 123 550 ms 109 748 ms 80
Logging window
Logging = on
All
429 ms
139 473 ms 126 517 ms 116 550 ms 109 715 ms 83
Graphic display
(waveform I)
Logging = on
605ms
99 671ms 89 704ms 85 869ms 69 1210ms 49
Graphic display
(waveforms I/U/P/W)
Logging = on
1738ms
34 1815ms 33 1859ms 32 2024ms 29 2354ms 25
Tbl. 3: Maximum cycle of AC - without
Maximum cycle for DC current
All specifications without active ready-output-inquiries.
Current display DC current in [ms]
Measuring time 23 ms 50 ms 100 ms 250 ms 500 ms
Quadrant 1-4 numerical
Logging = on 143 ms 419 187 ms 320 209 ms 287 374 ms 160 662 ms 90
Quadrant 1-4 numerical
Logging = off 138 ms 434 187 ms 320 209 ms 287 374 ms 160 662 ms 90
Quadrant 1-4 graphical
I(1),U(2),P(3),W(4)
Logging = off
1799 ms
33 1839 ms 32 1881 ms 31 2057 ms 29 2387 ms 25
Quadrant 1-4 SPC chart
Logging = off 143 ms 419 198 ms 303 231 ms 259 385 ms 155 682 ms 87
Analysis window
Logging = on 242 ms 247 264 ms 227 308 ms 194 440 ms 136 693 ms 86
Logging window
Logging = on
Last
275 ms
218 374 ms 160 418 ms 143 539 ms 111 748 ms 80
Logging window
Logging = on
All
429 ms
139 462 ms 129 517 ms 116 550 ms 109 726 ms 82
Graphic display
(waveform I)
Logging = on
605 ms
99 671 ms 89 704 ms 85 869 ms 69 1210 ms
49
Graphic display
(waveforms I/U/P/W)
Logging = on
1738 ms
34 1815 ms 33 1859 ms 32 2024 ms 29 2354 ms 25
Tbl. 4: Maximum cycle of DC - without