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MIYACHI EUROPE CORPORATION Lindberghstr. 1 D-82178 Puchheim Tel. +49-89-839403-0 Fax: +49-89-839403-10 www.miyachieurope.com Operating Instructions MG3D Digital Measuring Unit Annex: Safety Regulations General References on Resistance Welding Contact Addresses Order number: Year: Serial number: Original Version: German Translation of Original Version Version: 1.6...
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. Declaration of Conformity 76609409EN-BA-MG3D-V1_6.docx 5/82 2010-08-02...
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. 76609409EN-BA-MG3D-V1_6.docx 6/82 2010-08-02...
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.
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). 76609409EN-BA-MG3D-V1_6.docx 8/82 2010-08-02...
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Graphic display 550 ms 610 ms 640 ms 790 ms 1100 ms (waveform I) Logging = on Graphic display 1580ms 1650ms 1690ms 1840ms 2140ms (waveforms I/U/P/W) Logging = on Tbl. 2: Maximum cycle for DC - active 76609409EN-BA-MG3D-V1_6.docx 9/82 2010-08-02...
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671 ms 704 ms 869 ms 1210 ms (waveform I) Logging = on Graphic display 1738 ms 1815 ms 1859 ms 2024 ms 2354 ms (waveforms I/U/P/W) Logging = on Tbl. 4: Maximum cycle of DC - without 76609409EN-BA-MG3D-V1_6.docx 10/82 2010-08-02...
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Quadrant 1-4 numerical duration approx. 600 ms. External selection: Quadrant 1-4 numerical Quadrant 1-4 graphical I(1),U(2),P(3),W(4) Main image renewal = on approx. 600 ms approx. 3000 ms Main image renewal = off approx. 50 ms approx. 50 ms 76609409EN-BA-MG3D-V1_6.docx 11/82 2010-08-02...
Fig. 1: MG3Digital with stirrup Remove measuring instrument MG3 Digital from the packing and set it up at the designated place. Pull apart both caps at the stirrup's pivot points (Fig. 1). Adjust desired position. 76609409EN-BA-MG3D-V1_6.docx 12/82 2010-08-02...
RS232 interface (e.g. to serial printer or PC) No usage Outputs for program number (set BCD or binary code accordingly, 1...99 with a standard device) See enclosures: Connection diagram 767.00590 ON-OFF switch for mains voltage Miniature fuses CANopen IN CANopen OUT 76609409EN-BA-MG3D-V1_6.docx 13/82 2010-08-02...
(valid part detection). c) if trigger source “0 penetration“ or “Force trigger“ is activated and no current is measured. Signal is deactivated: a) at beginning of measurement b) with signal at measuring value reset input 76609409EN-BA-MG3D-V1_6.docx 14/82 2010-08-02...
Parameter values received after signal are acquired but Trigger evaluated and transferred only after trigger signal has become LOW again with falling edge. Acquired parameter values during continuously waiting trigger signal are overwritten by newly arriving measurements without evaluation and transfer. 76609409EN-BA-MG3D-V1_6.docx 15/82 2010-08-02...
Depending on setup default; becomes active if the Path Parts currently measured parts detection path min./max. Detection min. is exceeded or remains under. Path Parts Detection max. Common plus terminal 10 – 30 V for PIN 17 and 34. Common (+) 76609409EN-BA-MG3D-V1_6.docx 16/82 2010-08-02...
Connect the black cable (–) terminal to the welding head (-) pole (Fig. 4) at the • position provided for this purpose. Insert the 5-pole male connector in socket X13 (Fig. 2/8) • or X14 (Fig. 2/10). 76609409EN-BA-MG3D-V1_6.docx 19/82 2010-08-02...
Ensure that the (+) side of the coil show points in the direction of the current source (+) terminal. Connect the cable for current measurement to the flap toroid coil or toroid coil. • Insert the 3-pole male connector in socket X21 (Fig. 2/9) • or X22 (Fig. 2/11). 76609409EN-BA-MG3D-V1_6.docx 20/82 2010-08-02...
Fig. 8: Built-on, disconnected displacement measuring system Attach the displacement measuring system to the welding head using non-conductive • material (Fig. 8). Connect the displacement measuring system to the supplied adapter. • Connect the adapter to socket X31 (Fig. 2/7). • 76609409EN-BA-MG3D-V1_6.docx 21/82 2010-08-02...
If the equipment is switched off while booting, it will start up in a safe mode skipping initializations on being switched on. This may cause characters to be represented wrongly or not at all. Start up the equipment a second time in this case. 76609409EN-BA-MG3D-V1_6.docx 22/82 2010-08-02...
Operating Instructions MG3 Digital Operation Operation Measuring Instrument MG3D – What is What? MG3 Digital - Process Sentry READY TRIG 1 TRIG 2 CF I / II FAULT ACCEPT WARN REJECT Fig. 10: Control panel MG3 Digital LED status displays...
Depending on the control elements selected, the status bar shows you: Information on the last measurement (channel 1/2) • Details on the meaning of the control elements selected • Information on the condition of the function selected • Fault messages • 76609409EN-BA-MG3D-V1_6.docx 25/82 2010-08-02...
4.1.5 UNDO Function The menu bar offers the button UNDO for all windows where parameters can be set. As long as you are in this window, you may cancel the last 50 entries by that. 76609409EN-BA-MG3D-V1_6.docx 26/82 2010-08-02...
You can select the common languages on the display. UNIT Following units are ready for selection: for force measurement F: N or lbs for pressure measurement p: bar or psi for path measurement s: µm or th“ (thousandth inch) 76609409EN-BA-MG3D-V1_6.docx 28/82 2010-08-02...
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There you can select between “;” or ”,”. Select between “,” or “.” as decimal sign under Digit grouping symbol on the same tab. * CSV = Comma Separated Value DATE The date format is made up of the following: MM-DD-YY (month-day-year) 76609409EN-BA-MG3D-V1_6.docx 29/82 2010-08-02...
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This screen displays general system information. Among others, about: the main board (RAM assignment, built-in plug-in cards, hardware version, software version PPC and DSP) the display (RAM assignment, compact flash card or MicroDrive memory capacity, display software version) 76609409EN-BA-MG3D-V1_6.docx 30/82 2010-08-02...
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Use RAM RESET only, if you have no other • choice left. Before resetting, save your set parameters to the compact flash card. Loss of data! If you perform RAM RESET, all set parameters will be lost! Caution 76609409EN-BA-MG3D-V1_6.docx 31/82 2010-08-02...
20 kHz inverter 4 kHz MEASURE MODE You can select between: Coil (standard) or Shunt (See section 5.3.) In addition, you need to state the coil amplification factor (x1, x10). Please read the amplification factor from the coil label. 76609409EN-BA-MG3D-V1_6.docx 32/82 2010-08-02...
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Setting range AC: 0 to 5000 ms DC: 0 to 2000 ms DELAY Option CURRENT TYPE Set type of current of welding current source here. DC for direct current sources AC for alternating current sources 76609409EN-BA-MG3D-V1_6.docx 33/82 2010-08-02...
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(which suits the measured current and measured voltage). SECTOR SIGNAL Activation and the input of a MIN and MAX values allows you to determine a time slot in which measuring value monitoring should occur. 76609409EN-BA-MG3D-V1_6.docx 34/82 2010-08-02...
Principle connection to a welding unit weld control U channel 2 = Shunt voltage U channel1 = weld spot voltage Weld Sentry MG3 Digital R Shunt weld spot Fig. 12: Schematic connection scheme for special “shunt” operating mode 76609409EN-BA-MG3D-V1_6.docx 35/82 2010-08-02...
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5000(AC)ms Measuring pause 0-2000 ms Current type AC/DC Current X shunt current 2kA-500 kA Voltage X welding position X shunt voltage 0.5V-50 V voltage Sector signal X welding position X shunt voltage 0 measuring time ms voltage 76609409EN-BA-MG3D-V1_6.docx 36/82 2010-08-02...
In single measurement mode, the equipment switches to hold after triggering. The display SINGLE is grayed. Readiness for measurement is only re-enabled after renewed pressure onto button SINGLE. When in continuous measurement, readiness for measurement is always maintained. 76609409EN-BA-MG3D-V1_6.docx 37/82 2010-08-02...
You determine in this selection field how the measured categories shall be represented. Possible types of representation: numeric graphic (using graphic representations, you may select color of the graphs in addition) SPC*-Chart SPC*-Values SPC: Statistical Process Control 76609409EN-BA-MG3D-V1_6.docx 38/82 2010-08-02...
PART When button ON/OFF is enabled, parts detection is enabled (see also X38 outputs) (see also outputs X38). MIN/MAX Value for minimum/maximum displacement specifications for monitoring automatic part detection. Monitoring is active if both values are zero. 76609409EN-BA-MG3D-V1_6.docx 39/82 2010-08-02...
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The monitoring is deactivated with both values 0. SENSOR Here you determine the signal form (digital/analog) and resolution of the displacement measuring system connected. The maximum measurable stroke is specified additionally in the case of the digital displacement sensor. 76609409EN-BA-MG3D-V1_6.docx 40/82 2010-08-02...
Force sensors with a linear curve should be used. The no-load measured value for the sensor is entered in the OFFSET field. Input in the SENSOR RESOLUTION field is realized in N/V or lbs/V. The maximum possible resolution is 1000 N/V. 76609409EN-BA-MG3D-V1_6.docx 41/82 2010-08-02...
MIN LIM Here you determine the limits for the minimum or maximum warning and limit value. Limit value monitoring is deactivated if the min. and max. limit are set at zero. The same applies to warning limits. 76609409EN-BA-MG3D-V1_6.docx 42/82 2010-08-02...
WAVEFORMS opens, and now you can: generate a reference waveform and an • envelope waveform by yourself, or load an envelope waveform. • Generating a reference waveform Select button REFERENCE WAVEFORM with • the knob/pushbutton combination and depress button. 76609409EN-BA-MG3D-V1_6.docx 43/82 2010-08-02...
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Generating an envelope waveform Select button ENVELOPE WAVEFORM with • the knob/pushbutton combination and depress button. Screen ENVELOPE WAVEFORM opens. • A reference waveform previously generated is shown in the dialogue field. You can then continue directly with INTERVALL. 76609409EN-BA-MG3D-V1_6.docx 44/82 2010-08-02...
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You will now see a second white vertical • line that you can move by rotating the knob/pushbutton combination. Pressing the button again allows you to • determine the time slot at which the envelope waveform should end. 76609409EN-BA-MG3D-V1_6.docx 45/82 2010-08-02...
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If this is not the case, then enter a new number in the input field. Exit screen INPUT WAVEFORM NO. with • The ENV WF button is used to return to the • envelope waveform monitoring menu. 76609409EN-BA-MG3D-V1_6.docx 46/82 2010-08-02...
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You can return to the limit value setting with the LIMITS... or LIMITS button. Comparison of measuring waveforms and envelope waveforms. COMPARISON Press the COMPARE button to compare the loaded envelope waveform with the currently measured waveform. 76609409EN-BA-MG3D-V1_6.docx 47/82 2010-08-02...
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The line is activated. Note Press AUTOSCALE and the selected measurement variable is automatically and optimally adapted to suit the diagram. This function can also be utilized to achieve a clear representation again. 76609409EN-BA-MG3D-V1_6.docx 48/82 2010-08-02...
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Press the button and the diagram is illustrated in an enlarged version. Selecting the display window or ENV WF (ENVELOPE WAVEFORM) button enables you to return to the envelope waveform monitoring menu. 76609409EN-BA-MG3D-V1_6.docx 49/82 2010-08-02...
Copying a channel Select the channel to which others are to be copied with the knob/button. Press the selected button 1 2 or 2 1. This triggers the program parameter copying procedure within the current program. 76609409EN-BA-MG3D-V1_6.docx 50/82 2010-08-02...
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Loading all programs and parameters Select button SELECT ALL with the knob/pushbutton combination and depress button. Screen SELECT FILE opens. Select a file from the files list. Finally depress button OK. This will initiate the loading process. 76609409EN-BA-MG3D-V1_6.docx 51/82 2010-08-02...
Plus (+) counts forward Minus (-) counts backward END VALUE Last counter value of plus counter START VALUE First counter value of minus counter PREWARN Pre-warning value of active counter RESET Depressing button RESET resets the counter. 76609409EN-BA-MG3D-V1_6.docx 52/82 2010-08-02...
The double arrow pointing downwards enables you to move one level down to the enlarging menu. The CURSOR menu is accessed by pressing the double arrow again, and the SAVE menu is accessed by pressing it again. 76609409EN-BA-MG3D-V1_6.docx 53/82 2010-08-02...
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A range can be determined with Y<-> and X<-> which will subsequently be enlarged. A white line appears if Y<-> or X<-> is selected. Turn the knob/button to offset the line. Press the button to set the limit. 76609409EN-BA-MG3D-V1_6.docx 54/82 2010-08-02...
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The cursor can be moved on the graph by turning the knob/button. The value pair belonging to every measurement value is displayed numerically below. Press the button again to exit the cursor mode. 76609409EN-BA-MG3D-V1_6.docx 55/82 2010-08-02...
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The double arrow pointing upwards enables you to move one level higher again. You can return to the quadrant view again by selecting the display window or the MAIN button. 76609409EN-BA-MG3D-V1_6.docx 56/82 2010-08-02...
1..10000 • + poor measurement PRINT-TEST Press the button to test the connection via the RS232. FORMAT Set to numeric to transmit your data to a printer or the WinWeld program from Peco. 76609409EN-BA-MG3D-V1_6.docx 57/82 2010-08-02...
If you have correctly logged on, you can change the password. STATE Indicates whether you are authorized for access or not. Note Password on delivery: 0000 If you should have forgotten your password, please contact our service department. 76609409EN-BA-MG3D-V1_6.docx 58/82 2010-08-02...
Gray letters = invalid measurement (range overflow) Yellow background = beyond the warning limit (n) Red background = exceeded limit value The double arrows are used to scroll • forwards and backwards through the logging history. 76609409EN-BA-MG3D-V1_6.docx 59/82 2010-08-02...
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( ) indicates exceeded pre-warning limits, while {} indicates the exceeding of a limit determined by an envelope waveform. Select the SAVE button with the • knob/button and press the button if you wish to save values logged up until the present point in time. 76609409EN-BA-MG3D-V1_6.docx 60/82 2010-08-02...
Select which positive-negative condition parallel active monitorings in the detail should have here. LIMIT Limit value monitoring condition for freely-adjustable variables. Limit value monitoring condition for the penetration. Limit value monitoring condition for the force. Limit value monitoring condition for pressure. 76609409EN-BA-MG3D-V1_6.docx 61/82 2010-08-02...
Procedure Configure a display window for the SPC- • chart mode. See section 5.5. Select this display window with the • knob/pushbutton combination and depress button. Screen SPC-chart opens. • 76609409EN-BA-MG3D-V1_6.docx 62/82 2010-08-02...
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The value in input field SAMPLES must be Colors The colors in the histogram have the following meaning: GREEN LINE = average value (Xavg) YELLOW LINES = marginals RED LINE = limits BLUE LINE = standard deviation S (+/-3 sigma) 76609409EN-BA-MG3D-V1_6.docx 63/82 2010-08-02...
In the histogram you can see average and standard deviation values calculated of all measured values. DEFINE LIMITS Calculates new limit values and shows a window which acknowledges that these have been imported. The newly-calculated limit values are activated if importing is acknowledged. 76609409EN-BA-MG3D-V1_6.docx 64/82 2010-08-02...
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±6S / 5S 99% / 95% The first value is standard deviation S and the second value is the deviation of pre-warning. RESCALE Adapts graphic to window. RESET If you depress this button, the statistical calculation will be reset. 76609409EN-BA-MG3D-V1_6.docx 65/82 2010-08-02...
(S/N) displayed for this purpose. You then receive a 4-digit code which you should enter in the password input field. You then click the "Register" button. The device is now enabled for unlimited use if the code has been edited correctly. 76609409EN-BA-MG3D-V1_6.docx 66/82 2010-08-02...
Channel 2 alone current1 Current signal or current 2 high Ready Output high limit values accept / reject outputs pre-warn value high Current Output adjusted measuring time ready for new measuring measuring delay new sequence no measuring possible! Dia1-MG3 76609409EN-BA-MG3D-V1_6.docx 67/82 2010-08-02...
Both measuring times need to be set generously enough so that they overlap in a 2- channel parallel measurement. As soon as the current outputs become “low” (within measuring interval), evaluation of the set outputs can commence. New measurement can be only started after the ready signal is “high”. 76609409EN-BA-MG3D-V1_6.docx 68/82 2010-08-02...
A parallel 2-channel measurement of the second current can be realized here because the Ready signal remains “high”. Evaluation subsequently follows for both channels within the measuring pause. 76609409EN-BA-MG3D-V1_6.docx 69/82 2010-08-02...
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Should a new flow cycle start within the measuring interval already, the outputs are undetermined and lead to wrong results. Remedy: Adjust measuring time to current time. • Shorten measuring interval by skipping evaluations. • Extend cycle time. • 76609409EN-BA-MG3D-V1_6.docx 70/82 2010-08-02...
Dia5-MG Misadjusted flow! Second channel starts measuring without ready signal being “high”. Remedy: Extend channel 1 measuring time such that it overlaps with the second measuring • time. 76609409EN-BA-MG3D-V1_6.docx 71/82 2010-08-02...
Evaluation Part detection high Start Part detection high Ready Output high Outputs Part detection high Current Output high different outputs high Welding cylinder Ready adjusted measuring time measuring delay for new no new measuring possible! measuring Dia6-MG3 76609409EN-BA-MG3D-V1_6.docx 72/82 2010-08-02...
Upper example: Channel 1 commences • Channel 1 is finished and waits on channel 2 because the part detection signal for • channel 2 is still active. The channel sequence is irrelevant during this. • 76609409EN-BA-MG3D-V1_6.docx 73/82 2010-08-02...
The MG3 acts as a CANopen slave. Detailed instructions can be found on our homepage www.miyachieurope.com under "Supplement to MG3 Digital operating instructions" The associated Electronic Data Sheet (EDS) can also be downloaded here. 76609409EN-BA-MG3D-V1_6.docx 74/82 2010-08-02...
Ch1 and Ch2 Zero X54.17 output current 1 Zero X54.21 output current 2 MG3D X54.1 output global ready from here new sequence part evaluation ch2 (X38.47) part evaluation ch1 (X38.48) start measuring part detection ch2 (X38.49) start measuring part detection ch1 (X38.50) Dia9-MG3 76609409EN-BA-MG3D-V1_6.docx...
Zero X54.17 output current 1 Zero X54.21 output current 2 MG3D X54.1 output global ready frome here new sequence part evaluation ch2 (X38.47) part evaluation ch1 (X38.48) start measuring part detection ch2 (X38.49) start measuring part detection ch1 (X38.50) Dia10-MG3 76609409EN-BA-MG3D-V1_6.docx...
Tbl. 2: Maximum cycle for DC - active ..................... 9 Tbl. 3: Maximum cycle of AC - without ....................10 Tbl. 4: Maximum cycle of DC - without ....................10 Tbl. 5: Menu structure ......................... 27 76609409EN-BA-MG3D-V1_6.docx 81/82 2010-08-02...
L Configuring the Logger ..........59 Connecting the Components ........13 LED Status Displays ..........23 Connection diagram, Interface MG3D, 767.00590 E ..79 Connection diagram, X38 (Inputs / Outputs), 767.00 591 M E ............... 80 Maximum Cycle and Memory Times ......8 Connection to field bus system ........
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