SCI MM-380A User manual

WELD TESTER
MM-380A
OPERATION MANUAL
Thank you for your purchase of the Miyachi Weld Tester MM-380A.
Please read this manual carefully to ensure correct use. Keep the manual
handy after reading for future reference.
K05M0811E-02
www.spotweldingconsultants.com

MM-380A
1
Contents
1. Special Notes .............................................................................................................................1-1
(1) Safety Precautions................................................................................................................................................. 1-1
(2) Handling Precautions ............................................................................................................................................ 1-4
2. Features .....................................................................................................................................2-1
3. Packing List ...............................................................................................................................3-1
(1) Accessories ............................................................................................................................................................ 3-1
(2) Options .................................................................................................................................................................... 3-2
4. Name and Function of Each Part .............................................................................................4-1
(1) Front......................................................................................................................................................................... 4-1
(2) Top........................................................................................................................................................................... 4-2
(3) Right Side................................................................................................................................................................ 4-3
(4) Left Side .................................................................................................................................................................. 4-3
(5) Rear ......................................................................................................................................................................... 4-4
5. Operation Flow ..........................................................................................................................5-1
6. Preparations and Connections.................................................................................................6-1
(1) Connecting the MM-380A and Power Supply ................................................................................................ 6-1
(2) Preparations for Measurement – Connection between the MM-380A and Measurement Devices ...... 6-2
a. Connecting a toroidal coil.......................................................................................................................6-2
b. Connecting the Force Sensor.................................................................................................................6-4
c. When using an external ±10V voltage input ...........................................................................................6-5
7. Basic Operation .........................................................................................................................7-1
(1) Startup ..................................................................................................................................................................... 7-1
(2) Using the Encoder ................................................................................................................................................. 7-2
a. Selecting Menus.....................................................................................................................................7-2
b. Moving the Cursor and Changing Parameters .......................................................................................7-3
c. Scrolling a Screen ..................................................................................................................................7-4
(3) Shutdown................................................................................................................................................................ 7-5
8. Operation Screens.....................................................................................................................8-1
(1) Operation Screen Organization ........................................................................................................................... 8-1
(2) Description of the Operation Screens ................................................................................................................. 8-3
a. MEASUREMENT Screen.......................................................................................................................8-3
b. VIEW screen ..........................................................................................................................................8-4
c. WAVEFORM screen ..............................................................................................................................8-6
d. WAVEFORM Screen (Time Axis)...........................................................................................................8-7
e. WAVEFORM Screen (Vertical Axis).......................................................................................................8-8
f. WAVEFORM Screen (Measurement Mode) ..........................................................................................8-9
g. ALL CYCLE screen ..............................................................................................................................8-10
h. ALL CYCLE (Force) Screen.................................................................................................................8-11
i. WAVEFORM (FORCE) screen ............................................................................................................8-12
j. SETUP (1) Screen ...............................................................................................................................8-14
k. SETUP (2) Screen ...............................................................................................................................8-24
l. SETUP (3) Screen ...............................................................................................................................8-30
m. PRINT screen.......................................................................................................................................8-31
n. COMMUNICATION screen ..................................................................................................................8-34
o. HISTORY screen .................................................................................................................................8-36
p. DATA READ screen.............................................................................................................................8-38
q. STATUS (1) Screen .............................................................................................................................8-39
r. STATUS (2) Screen .............................................................................................................................8-41
s. STATUS (3) Screen .............................................................................................................................8-42
9. Measurement .............................................................................................................................9-1

MM-380A
2
(1) Measuring Current (Current Flow Time)/Voltage............................................................................................... 9-1
(2) Measuring Force (Option)..................................................................................................................................... 9-6
10. Interface .................................................................................................................................10-1
11. Maintenance...........................................................................................................................11-1
(1) Charging the Battery............................................................................................................................................11-1
(2) Battery Specification ............................................................................................................................................11-1
(3) Replacing the Lithium-Ion Battery......................................................................................................................11-2
(4) Replacing the Lithium Battery.............................................................................................................................11-2
12. Data Communication.............................................................................................................12-1
(1) Data Transfer........................................................................................................................................................12-1
(2) Configuration ........................................................................................................................................................12-1
(3) Protocol .................................................................................................................................................................12-2
a. Unidirectional communication mode (unidirectional in the COMMUNICATION screen).......................12-2
13. Error List ................................................................................................................................13-1
14. Specification ..........................................................................................................................14-1
(1) Measurement Specification ................................................................................................................................14-1
(2) Specification of the MM-380A .........................................................................................................................14-5
15. Calibration..............................................................................................................................15-1
16. Appearance............................................................................................................................16-1
EC Declaration of Conformity

MM-380A
1. Special Notes
1-1
1. Special Notes
(1) Safety Precautions
Before using the weld checker, please read through the Safety Precautions carefully to
ensure proper use.
The precautions listed here are designed to ensure safe use and proactively prevent risks
and damage to the user and other people.
All precautions are critical for safety. Please read them all.
The hazard signs have the following meanings:
Mishandling may cause imminent risk of death or serious
injury.
Mishandling may cause risk of death or serious injury.
Mishandling may cause risk of injury and physical damage.
These signs represent “DON’Ts.” They warn of actions not
covered by the product warranty” in the previous document.
These signs represent “DOs" which must be observed by
the product user.
A sign within a triangular border indicates that a hazard
(danger, warning or caution) is present.
DANGER
ATTENTION
CAUTION

MM-380A
1. Special Notes
1-2
NEVER ATTEMPT to disassemble, repair or modify the instrument.
Do not touch any parts inside the instrument. Failure to observe this may result
in an electric shock or fire.
For battery replacement, inspection or repair, please contact your dealer or
Miyachi Corporation.
DO NOT place your hands between the electrodes.
When welding, be extremely careful not to get your fingers or hand caught in
the electrodes.
During or immediately after welding, DO NOT touch the welded areas or
electrode.
The welded areas of the workpiece, the electrodes and the welding machine’s
arm are extremely hot. To prevent burns, do not touch these areas.
ALWAYS use the specified power supply.
Failure to use the power supply specified in the Instruction Manual may result
in a fire or electric shock.
Use the specified cables and connect them securely.
Failure to do so or improper connection may result in a fire or electric shock.
Keep the power and connection cables free of damage.
Do not walk on, twist or tug the cables.
Damaged cable may result in an electric shock, short circuit, or fire.
For repair or replacement, contact your dealer or Miyachi Corporation.
In the event of an anomaly, STOP the operation.
Continuing the operation with anomalies such as a the generation of fumes, a
burning odor, strange noise, or overheating unattended may result in an
electric shock or fire. In the event of the above or other anomaly, immediately
contact your dealer or Miyachi Corporation.
STAY AWAY from the instrument if you have a pace maker.
If you have a pacemaker, do not approach a welding machine in operation or
the immediate area unless your doctor has given consent.
Welding machines generate a magnetic field which interferes with the
operation of a pacemaker.
ALWAYS wear appropriate work clothing.
Wear protective gear such as gloves, a long-sleeved top and leather apron.
Surface flash and expulsion can cause burns if it contacts the skin.
ALWAYS wear protective goggles.
Directly looking at surface flash and expulsion during welding can temporary
impair vision. Welding spatter can cause permanent eye damage, including
blindness.
DANGER
A
TTENTION

MM-380A
1. Special Notes
1-3
DO NOT splash water.
Electrical parts may cause an electric shock or short circuit if they become wet.
Keep the area clear of flammable objects.
Surface flash and expulsion generated during welding may ignite flammable
objects, resulting in a fire. If work involves use of flammable items, place a
non-flammable cover over such items.
DO NOT cover the instrument with a blanket or cloth.
During operation, do not cover the instrument with a blanket or cloth. This may
lead to the instrument overheating and catching fire.
Wipe off dust from the power plug and securely insert it all the way.
Dust or improper insertion may lead to the plug heat up and catch fire.
Hold the power plug when removing or inserting it.
Removing the power plug by pulling on the cable may damage the power
cable, resulting in an electric shock or causing the cable to catch fire.
If you do not use the instrument for extended periods, remove the power
plug from the outlet.
Failure to do so may deteriorate the insulation, resulting in an electric shock,
current leakage or fire.
Provide fire extinguishers.
Provide fire extinguishers at the welding site as a precautionary measure.
Perform maintenance and inspection on a regular basis.
Perform maintenance and inspection regularly and repair damaged areas and
parts before using the instrument.
Wear soundproof earmuffs.
Loud noise may impair hearing.
CAUTION

MM-380A
1. Special Notes
1-4
(2) Handling Precautions
Avoid the following locations when installing the instrument:
Humid location (humidity of 90% or more)
Extremely hot (45°C or more) or cold (0°C or less) locations
Near a radio frequency noise source
Location where chemical substances, etc. are handled
Location where condensation occurs
Dusty location
Location exposed to direct sunlight
Location that is inclined, insecure, unstable, or weak
Check the voltage and power frequency before installation.
Keep the exterior clean with a soft cloth or cloth lightly dampened with water.
For stains, clean them off using a diluted neutral detergent or alcohol.
Do not use thinner or benzene as they may cause discoloration or deformation.
To prevent malfunction, do not allow any foreign objects such as screws or coins to
enter the instrument.
Operate the instrument according to the procedure described in the Operation
Manual.
Operate the switches and buttons with care. Rough operation or the use of a tool
or pen tip may result in damage or malfunction.

MM-380A
2. Features
2-1
2. Features
Miyachi Corporation Weld Tester MM-380A is a hand-held measuring instrument designed
for resistance welding machines.
The instrument can measure the current, voltage, current flow time, force*1, and external input
voltage (max. ±10 V)*1 and display their waveforms.
(*1: You can select to measure force or external input voltage in measurement section on the
STATUS screen.)
The LCD screen ensures clear viewing of the welding current and force waveforms for optimal
welding quality control. Further, it is equipped with a printer, allowing to print measurement
values and waveforms without having to attach an external printer.
The MM-380A offers the following features:
Easy to use with an encoder
You can scroll through the screens by simply turning the encoder and select items by moving
the cursor. Pressing the encoder confirms the item selected by moving the cursor.
Easy-to-view operation screens
The LCD offers approximately four-fold improvement in resolution over our conventional
products, and provides an accurate and clear display of the current and force waveforms.
Extensive display capability capabilities, obviating the need for an oscilloscope
Incorporates a zoom display function, which permits the user to change the spacings of the
X-axis (time) and Y-axis (force/current) freely, and a cursor measurement function, a
function for measuring the width and time difference between parts of the waveforms by
moving the vertical and horizontal cursors.
Optimal waveform redisplay (FIT) capability
If the waveform is moved or zoomed off the screen, the instrument can resize the waveform
to its optimal size and redisplay it on screen.
Simultaneous measurement of force and welding current during current flow
You can measure the force and welding current during current flow simultaneously using the
optional current/force sensor (MA-770A/MA-771A).
Storing measured values and waveforms
You can store measured values and waveforms in the built-in flash memory.
Managing measurement data with PC
You can transmit measurement data to your PC through the RS-232C interface.
Supports a wide range of welding machines
The instrument supports single-phase AC, DC inverter, AC inverter, and transistor welding
machines.
Supports multiple languages
Languages available are Japanese, English, Chinese, German, French, and Spanish.

MM-380A
3. Packing List
3-1
3. Packing List
Check the contents of the package. In the case of damaged or missing items, please
contact Miyachi Corporation.
(1) Accessories
Item Item code Qty
Strap PC021923 1
Operation manual EV000886 1
Stereo Plug PA022402 1

MM-380A
3. Packing List
3-2
(2) Options
Item Model Item code
MM-380A AC adapter BLM-110W PA021243
AC cable for the
MM-380A AC adapter
ACS-100J (Japan)
ACS-100U (US)
ACS-100G (Europe)
ACS-100E (UK)
PA021247
PA021244
PA021245
PA021246
Toroidal coil MB-800K (approx. 250mm in dia.) EI000006
Toroidal coil MB-400K (approx. 120mm in dia.) EI000001
Toroidal coil MB-45F (45mm in inner dia.) EI000010
Voltage detection cord A-06591-001 (for multi-connecter) EK000356
Current/force sensor MA-770A (4903N (500kgf) max.) EG000118
Current/force sensor MA-771A (9806N (1,000kgf) max.) EG000117
Voltage detection cord 42665 (for attaching current/force
sensor) EK000017
Force sensor MA-520 (98.06N (10kgf) max.) EG000112
Force sensor MA-521 (980.6N (100kgf) max.) EG000113
Force sensor MA-522 (9806N (1,000kgf) max.) EG000114
Force sensor
conversion connector A-03581-001 EK000275
Multiconnector
(For External ±10V
voltage)
SRCN6A21-16P PA001844
RS-232C
communication cable 1.5m, 9-pin female-female PA008130
Lithium-ion battery
(optional addition) UR-121 PA010658
Printer BL-58Rll PA008257
Printer cable 1.5m, 25-pin male-male PA009842
Printer AC adapter BL-100W PA008233
AC cable for printer AC
adapter
AC-100J (Japan)
AC-100U (US)
AC-100G (Europe)
PA008934
PA008935
PA008936
Printer thermal paper TPW058-25A 58 x 25 PA003088
Carry bag MM-380A soft case PC021959

MM-380A
4. Name and Function of Each Part
4-1
4. Name and Function of Each Part
(1) Front
①HOLD lamp: Lit green when the HOLD button is ON.
Unlit when the HOLD button is OFF.
②HOLD button: You can perform the following operations
by turning this button ON/OFF. The
HOLD button is OFF when the
instrument is turned on.
Data
measurement
Screen
operation
HOLD button ON
(Hold mode) No Yes
HOLD button OFF
(Hold mode canceled) Yes No
③MENU button: Shows the menu list on the display.
④Display: Shows measured values, waveforms and
operation screens.
Refer to Chapter 8, “Operation Screens”
for details of the operation screens.
⑤Operation buttons A, B, C, D and E: For performing the operations shown on
the function keys at the bottom of the
operation screens.
The nature of the operation performed by
pressing each button varies from one
operation screen to another.
⑥POWER button: Turns ON the power for the MM-380A.
②
③
⑤
⑥
⑧
⑦
④
①

MM-380A
4. Name and Function of Each Part
4-2
⑦Encoder: Used to select menus and parameters
and confirm the selection. Refer to “(2)
Using the Encoder” in Chapter 7 for basic
use of the encoder.
⑧EXT POWER/CHARGE lamp: Lit when the MM-380A is connected to
an external power supply and blinked
when charged.
(2) Top
①Toroidal coil connector: Plug a toroidal coil into this connector.
②Multiconnector*1:Plug an optional displacement sensor
(MA-770A/MA-771A) into this connector. To
connect an optional force sensor
(MA520/MA-521/MA-522), use the force
sensor conversion cable.
①②

MM-380A
4. Name and Function of Each Part
4-3
(3) Right Side
①Printer connector: Connect the optional dedicated printer here with
the dedicated cable.
②AC adapter jack: Connect the dedicated AC adapter here when
charging the battery built into the MM-380A or
using an external power supply.
CAUTION
Connect only the dedicated AC adapter to the AC adapter jack. Failure to do
so may result in malfunction, fire, or electric shock.
(4) Left Side
①SOL signal (24V AC/DC) input connector: A connector for inputting a solenoid
signal.
①②
①
②

MM-380A
4. Name and Function of Each Part
4-4
②RS-232C connector: Connector to connect the instrument and PC with
an optional RS-232C communication cable. Used
to transfer measured values and waveform data
to the PC.
(5) Rear
①Battery cover: A cover to protect the battery. The rechargeable
lithium battery is housed under a cover, in a
holder.
①

MM-380A
5. Operation Flow
5-1
5. Operation Flow
The operation flow is shown below.
Printe
r
etc.
Device connection
Connect with othe
r
devices
(
Refer to
(
1
)
in Cha
p
ter 6
)
Install the MM-380
A
Startup the MM-380
A
(Refer to (1) in Chapter 7)
Print measurement results (Refer to (2) in Chapter 8)
Shut down the MM-380
A
Using recorded data
Perform measurement
Current
measurement
(Refer to (1) in
Chapter 9)
Voltage
measurement
(Refer to (1) in
Chapter 9)
Force
measurement
(Refer to (3) in
Chapter 9)
(Refer to (3) in Chapter 7)
(Refer to Chapter 12)
Connect measurement devices to the MM-380
A
Toroidal coil
Current
(Refer to (2) a,
Chapter 6)
Voltage
measurement
Voltage
detection
cord
(Refer to (2) a,
Chapter 6)
Force
sensor
o
r
Force
measurement
Current/force
sensor
(Refer to (2) c,
Chapter 6)
(Refer to (2) c,
Chapter 6)
Sequence
r
PC
Setup the system and conditions
(Refer to (2) j, k, l, m, r, s, t, Chapter 8)
= option

MM-380A
6. Preparations and Connections
6-1
6. Preparations and Connections
(1) Connecting the MM-380A and Power Supply
To charge the built-in battery (lithium battery) or use an external power supply, connect the
power supply to the AC adapter jack on the right side of the MM-380A with the dedicated
AC adapter.
1) Plug the dedicated AC adapter into the AC adapter jack on the right side of the
MM-380A.
A
C adapter jack
Dedicated AC adapte
r

MM-380A
6. Preparations and Connections
6-2
(2) Preparations for Measurement – Connection between the
MM-380A and Measurement Devices
a. Connecting a toroidal coil
To measure current, plug a toroidal coil into the toroidal coil connector on the top of the
of the MM-380A.
Toroidal coil
Connect a toroidal coil suited to your operating environment.
The toroidal coils of the following sizes can be used:
Toroidal coil model Type
MB-800K 1×sensitivity coil (with 800mm bracket)
MB-400K 1×sensitivity coil (with 400mm bracket)
MB-45F 10×sensitivity coil (mold type)
Follow the steps described below to connect the toroidal coil and the voltage detection
cord.
1) Plug the toroidal coil’s connector into the toroidal coil connector on the rear panel
of the MM-380A.
Zoom
Toroidal coil connecto
r
Toroidal coil
connector

MM-380A
6. Preparations and Connections
6-3
2) Fit the toroidal coil onto the welding machine’s arm or secondary conductor.
When fitting the coil, be careful with the following:
• Keep the toroidal coil’s hooking bracket as far away from the welding
machine’s arm (secondary conductor) as possible.
• Do not deform the circular form of the toroidal coil when fitting it.
CAUTION
• If the toroidal coil is fitted in reverse orientation, the waveforms in the
WAVEFORM screen and the analog output waveforms measured with the
oscilloscope are also shown in reverse.
• For a band-type toroidal coil, do not deform it when fitting it. Repeated
bending and extension may break internal wires.
Do not deform the circula
r
form of the toroidal coil.
Keep the hooking bracket at th
e
furthest point from the arm.
A
rm
Toroidal coil
Hooking
bracket

MM-380A
6. Preparations and Connections
6-4
b. Connecting the Force Sensor
The MM-380A can measure force when connected with force sensor
MA-520/MA-521/MA-522 or current/force sensor MA-770A/MA-771A.
Current/force sensor MA-770A/MA-771A incorporates a current sensor (toroidal
coil), making it possible to measure force and current at the same time simply by
applying a force and passing a current.
Current/force sensor
Follow the steps described below to connect the current/force sensor.
CAUTION
• When using a current/force sensor, do not connect any device to the
toroidal coil connector.
• The MM-380A is calibrated one to one with the current/force sensor. Do
not use any other sensors. If you purchase a current/force sensor later,
the sensor and MM-380A must be adjusted as a set. In this case, please
contact Miyachi Corporation. When you purchased the MM-380A and
current/force sensor as a set, they have already been adjusted and can
be used as is.
• Before measuring force, be sure to set the force sensor’s offset to “0.”
Note that you must at this time make sure that no force is applied to the
sensor. During HOLD OFF, the force sensor’s offset will be automatically
set to “0.”
1) Plug the current/force sensor’s connector into the toroidal coil connector on the top
of the MM-380A.

MM-380A
6. Preparations and Connections
6-5
2) Attach the current/force sensor to the welding machine’s electrodes.
When attaching the sensor, be
careful with the following:
• Be sure that the center of the
sensor’s detection area is
aligned with the centers of the
welding machine’s electrodes.
• Be sure that the force is
applied perpendicularly to the
sensor.
c. When using an external ±10V voltage input
The MM-380A’s force/displacement-equipped specification allows for force
measurement using a commercial force sensor and force sensor amplifier connected
to the external ±10 V voltage input.
(Have ready a force sensor and force sensor amplifier—purchased separately.)
Follow the steps described below to connect the external ±10V voltage equipment.
1) External ±10V Voltage Input Connection Diagram
The 16-pin female multiconnector is optional.
(Multiconnector SRCN6A21-16P: Japan Aviation Electronics Industry)
Zoom
Multiconnecto
r
Welding head
Electrode
Release
A
pply force
Clamp the
current/force sensor
between the
electrodes, and apply
force and current.
Current/force senso
r
Electrode
16-pin female
multiconnecto
r
External
±
10V
volta
g
e
Force sensor
amplifie
r
10 V voltage input
GND
GND