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Amada MEA-100B Operation Manual

Ac welding power supply
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AC WELDING POWER SUPPLY
MEA-100B
OPERATION MANUAL
Z06OM1200070-10

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Summary of Contents for Amada MEA-100B

  • Page 1 Original instructions AC WELDING POWER SUPPLY MEA-100B OPERATION MANUAL Z06OM1200070-10...
  • Page 2 MEA-100B Thank you for purchasing our AC Welding Power Supply MEA-100B. ・ This operation manual explains its method of operation and precautions for use. ・ Before using, read this operation manual carefully; after reading, save it in a proper place where you can easily access.
  • Page 3 MEA-100B 1. Special Precautions CAUTION (1) Safety Precautions ！ Before using, read "Safety Precautions" carefully to understand the correct method of Denotes operations and practices that use. may result in personal injury or damage to the Power Supply if not correctly ■...
  • Page 4 MEA-100B WARNING ！ Do not put your hands between the electrodes When welding, keep your fingers and hands away from the electrodes. Do not touch any welded part or electrodes during welding and just after welding finished The welded part of a workpiece, electrodes and arm are very hot.
  • Page 5 MEA-100B CAUTION ！ Do not splash water on the Power Supply Water splashed over the electric parts can cause electric shock and short circuits. Use proper tools (wire strippers, pressure wire connectors, etc) for termination of the connecting cables Do not cut the conductor of wire. A flaw on it can cause fire and electric shock.
  • Page 6 MEA-100B (2) Precautions for Handling ■ When transporting or moving the Power Supply, do not lay it down. Also, handle the Power Supply with care so as not to make an impact such as drop on it. ■ Install this Welding Power Supply on a firm, level, horizontal surface. If it is inclined, malfunction may result.
  • Page 7 MEA-100B (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. 1. Special Precautions...
  • Page 8 The MEA-100B realizes high quality welding, so it is suitable for small size precise welding. 1 Four welding current control systems are currently available for the MEA-100B. Select the control system best suited to the particular workpiece.
  • Page 9 1001283 monitoring. Used to supply power to the MEA- PK-03294-001 (2 m) 1001699 100B and connect the MEA-100B PK-03294-002 (5 m) 1001712 to the welding transformer. PK-03294-003 (10 m) 1001713 Note: If you provide a cable, select...
  • Page 10 This LCD panel is used to monitor various MEA-100B functions. Indicates various settings and weld measurement results.  [READY] Lamp Lights when the MEA-100B is ready to supply a welding current. This lamp is synchronized with Terminal 12 ([READY]) of the I/O Terminal Strip on the rear panel.
  • Page 11 MEA-100B Also, this lamp is turned off while settings are written in the flash memory after schedules are changed.  [KEY LOCK] Lamp If this lamp is lit, the schedules or other settings cannot be edited. However, you can still change screens and the schedule no. using the [MENU] key, and change functions using NP on the SET2 screen (See 9.
  • Page 12 MEA-100B [+] Key ○ Changes the number selected by the cursor. Press this key repeatedly to increase the value. [-] Key ○ Changes the number selected by the cursor. Press this key repeatedly to decrease the value. (2) Rear Panel ⑦...
  • Page 13  Power Cable Inlet Pass the power cable through this inlet to connect the cable to the power cable connecting terminal.  Grounding Terminal Be sure to ground the MEA-100B to prevent electric shock. 4. Name and Functions of Each Section...
  • Page 14 MEA-100B 5. Connection The illustration below shows the MEA-100B connected to an MH-21AC, our welding head, and MT-510AC, our welding transformer. 5. Connection...
  • Page 15 MEA-100B 6. Before the Operation (1) Screen Configuration  MENU Screen Press the [MENU] key to select the desired screen. The screens are cycled like this: Welding schedule setting screen Current monitor display screen Ordinary (4 screens) Current monitor range setting screen...
  • Page 16 (2) Control Method and Welding Current Cycle Settings Follow the procedure described below and set the control method and welding current cycle according to the specific application after the MEA-100B is installed. (Secondary constant-current control is factory-set on shipment.)  To display the SET2 screen, press the [MENU] key and the [] key simultaneously for at least a second.
  • Page 17 Do not use this function other than the setting of the maximum current.  Connect the toroidal coil (sold separately) to the MEA-100B.  To display the #1 of the SET1 screens, press the [MENU] key and the [] key simultaneously for at least a second.
  • Page 18 MEA-100B (4) Contrast Setting Adjusts the LCD contrast.  To display the SET1 screen, press the [MENU] key and the [] key simultaneously for at least a second. ＃１ ＭＡＸ ＣＵＲＲＥＮＴ ２．０ｋＡ  Move the cursor to and change to the #2 screen.
  • Page 19 7. Basic Operation (1) Supplying Power Turn on the circuit breaker on the rear panel to supply power to the MEA-100B. During the startup self-diagnostics, the LCD screen displays the model number and software version. If the self-diagnostics completes without errors, the MENU screen is displayed.
  • Page 20 Be careful when changing settings frequently with the RS-485 bi-directional communication. The MEA-100B does not have the key to establish setting like “ENTER.” By either of the following procedures, settings can be written and stored in the flash memory.
  • Page 21 Welding Schedule Setting Press the [MENU] key to go to the Welding Schedule Setting screen. Set the schedule for the welding machine being used. The MEA-100B can save 31 schedules. This screen displays different data, according to the welding and control methods selected.
  • Page 22 MEA-100B Weld Force Welding Current Ｗ１ Ｗ２ Item Setting Range/Display a Squeeze (SQ) 00–99 cycles b Upslope 1 (UP1) 0–9 cycles (UP1 is included in W1.) c Weld 1 (W1) 00–99 cycles d Cool (CO) 00–99 cycles e Upslope 2 (UP2) 0–9 cycles (UP2 is included in W2.)
  • Page 23 MEA-100B  Power Supply Voltage Fluctuation Compensation Control at Multi-Cycle Welding Welding Schedule Setting Set the welding current (n, o) in a percentage to the maximum current expressed as 100% (For the maximum current, see 6. (3).) ａ ｂ ｃ...
  • Page 24 MEA-100B  Single-Cycle Welding Welding Schedule Setting Set the welding current (b, e) in a percentage to the maximum current expressed as 100% (For the maximum current, see 6. (3).) ａ ｂ ｃ １０ １ＳＴ ５０．０％ １０ ０１ ２ＮＤ ５０．０％...
  • Page 25 MEA-100B  Half-Cycle Welding Welding Schedule Setting Set the welding current (b) in a percentage to the maximum current expressed as 100% (For the maximum current, see 6. (3).) ａ ｂ ｃ １０ ＨＡＬＦ ５０．０％ １０ ０１ １ ｄ ｅ...
  • Page 26 MEA-100B (4) Ready for Welding (Turning on the [READY] Lamp) By following steps  to  below, the [READY] lamp lights and the MEA-100B is brought into the READY state (to flow the welding current).  If any fault occurs, rectify the fault and then clear fault output. (For clear of fault outputs, see 12.

  • Page 27: Sch.1

    Without parity Select #1–#31 schedules by combining schedule signals [SCH.1], [SCH.2], [SCH.4], [SCH.8], and [SCH.16]. When no schedule is input (all signal circuits are opened), the MEA-100B operates with schedule #1. With parity To use the parity function, set SS on the SET2 #1 screen to 1. (See 9. (2) .) Parity check is odd parity.

  • Page 28: Table Of Contents

     5-Schedule Input from External To select 5-schedule input, set SS on the SET2 #1 screen to 2. (See 9. (2) .) If no schedule is input (all the signal circuits are opened), the MEA-100B operates with schedule #1. If the schedules are input under 2 or more numbers at a time, the schedule under the lower SCHEDULE number is used.

  • Page 29: Curr.1

    MEA-100B (7) Welding (Current) End  If the welding is initiated while the welding schedule setting screen is displayed, the screen indicates the measured currents (b and c) and the determination of the welding result (d). (See figure below.)  The End signal and the determination of the welding result (Normal (GOOD) signal, Caution (CAUTION) signal and Trouble (NG) signal) are output from the I/O terminal strip.
  • Page 30 MEA-100B (8) Current Monitor Display Screen The current monitor display screen indicates the welding currents, the weld time and the conduction angle. Press the [MENU] key to go to the current monitor display screen. (Switching off power clears the monitored currents.) ...
  • Page 31 MEA-100B  Half-Cycle Welding ａ ｂ ｃ １ ＨＡＬＦ ０．５５ｋＡ １０１° ０１ ｄ Item Setting Range/Display a Weld force number Indicates the weld force number used for welding. b HALF current Indicates the effective current in the half-cycle. HALF conduction...
  • Page 32 MEA-100B 8. Stepper-Up Function The stepper-up (-down) function lets you increase or decrease the welding current when the weld count reaches the set value. Increasing the welding current automatically according to wear of the electrode can extend the life of the electrode. (Stepper-up) Use this function for fusing in which the welding current must be reduced to accommodate increased temperatures within an electrode or workpieces.
  • Page 33 MEA-100B (2) Stepper Count and Current Settings The stepper-up (-down) function is performed when the weld count reaches the set value. Stepper-Up Operation Chart Current [kA] Stepper-up completed Set current Stepper count Stepper No. W e l d c o u n t [ t i m e s ] N1–5: Stepper count...
  • Page 34 MEA-100B (3) Stepper-Up (-Down) Rate Setting ATTENTION Set the value of “the welding current x the stepper-up rate” so that it does not exceed the following value:  The set maximum current (6. (3)) in the secondary constant-current control  99.9% in the power supply voltage fluctuation compensation control When the value over the maximum current is set, the fault code [E09: STEPUP RATE TROUBLE] is given at the input of the start signal.
  • Page 35 MEA-100B (4) Checking the Stepper-Up Status Use this screen to check the currently operating stepper number and the weld count for each weld force number (solenoid). (This is not a total count from stepper  Press the [MENU] key to go to the Stepper-Up Status Display Screen.
  • Page 36 9. Detail Settings (SET2 Screen) Various functions of the MEA-100B can be set on the SET2 screen. The MEA-100B is factory-set to a set of standard settings. For most applications, no editing of these settings is required. If the settings need to be edited, read this chapter carefully before attempting to do so.
  • Page 37 1: Performs re-welding. or the no-current Determines how the 0: Skips to the next sequence. (Skips MEA-100B functions to COOL (CO) if WELD1 (W1) is when the WELD underway.) SKIP signal is input 1: Skips to HOLD (HLD).
  • Page 38 MEA-100B Initial Display Function Setting Setting DEF: Ignores errors in the first 1.0 cycle and upslopes. 00.0: Detects errors from the start in all cycles. Sets the Current 00.5: Ignores errors in the first half- monitor cycle cycle. (Ignores downslopes 01.0: Ignores errors in the first full...
  • Page 39 If the toroidal coil is broken or missing, the current is not detected even if it flows actually, therefore the MEA-100B tries to flow large current forcedly. As the result, the welding machine is overloaded and may be damaged.
  • Page 40 MEA-100B  #4–#7 Screens Select a signal output when the fault occurs from three signals, Trouble signal, Caution signal and No Trouble-Caution signal. Welding does not start at Trouble signal output even if the start signal is input. The next welding starts at Caution signal output when the start signal is input.
  • Page 41 MEA-100B Fault Initial Display and Description Setting Definition Code Setting STEPUP RATE TROUBLE Trouble (not Stepper-up rate error changeable) COUNT MEMORY ERROR Caution Count data stored in memory Trouble damaged CYCLE TROUBLE Start signal is turned off in welding Caution and then sequence is interrupted.
  • Page 42 - Storing data in the SRAM (The CONTROL setting is 2.) - Storing data in the flash memory (The CONTROL setting is 3.) The rewriting limit in the flash memory of the MEA-100B is 30,000 times. To rewrite schedules frequently in the bi-directional communication, set CONTROL to 2. If the rewriting limit is exceeded, data may not be stored normally.

  • Page 43: Sch.4

    MEA-100B 10. Interface Input and output signals are through the I/O terminal strip on the rear panel. (1) Connection of External I/O Signals Also see (B) and (C) in 13. (3) Model No.-Spec Reference Table. Shown below are the connections when [SOL1], [SOL2], [CAUTION], [STP/WELD END], and [READY] are photo-MOS relay outputs.
  • Page 44 MEA-100B  When external I/O are PNP transistors (It is the way in which the voltage is output.) I/O terminal strip 入出力端子台 24V-2 EXT +24V SOL COM SOL1 SOL2 EXT GND RS485+ RS485- CAUTION STP/WELD END READY GOOD WELD SKIP...
  • Page 45 MEA-100B (2) Explanation on the External I/O Terminals Description Terminal No.  If the MEA-100B is connected to a contact or NPN open collector output-type device (when using the built-in power supply), connect this terminal to terminal 2. [24V-2 EXT] ...
  • Page 46 For details, see 9. (2) .) The circuit is closed when [ERR RESET] is input. [NG] Note: When the power supply of the MEA-100B is off, the circuit is opened.  Relay contact output: 24 V DC, or 250 V AC or less, 0.5 A Output terminal for Normal End [GOOD] signal.
  • Page 47 MEA-100B Description Terminal No. Common terminal for input signals. [COM] Input terminal for [START] signal and 1ST STAGE signal. This circuit must be closed to supply a welding current in [READY] mode. The specific operation depends on [SM] setting of the #1 screen in the SET2 screen, as shown below (See 9.
  • Page 48 MEA-100B (3) Connection of Input Signals  Connection to Contact Input Device Use a jumper wire to connect terminals 1 and 2. (Outside) ( I n s i d e ) 24V-2 EXT +24V Short! ＋ Internal power supply START(1ST) ...
  • Page 49 MEA-100B  Connection to NPN Open Collector Output Device (when using the external power supply) Connect terminal 1 to the "+" terminal of the external 24 V DC power supply. (Outside) ( I n s i d e ) +24V ＋...
  • Page 50 MEA-100B (4) Connection of Output Signals Make connections as follows when (B) is Relay output and (C) is External power supply in 13. (3) Model No.-Spec Reference Table.  Connection of SOL1 and SOL2 [Relay Output] ( I n s i d e )
  • Page 51 MEA-100B 11. Timing Chart (1) Basic Weld Cycle Timing Chart Start signal(input) [START(1ST)] Weld force signal(output) [SOL1/SOL2] Welding currrent Repeat pulsation End signal(output) [END] Trouble signal(output) On detection of trouble On detection [NG] of trouble Caution signal(output) On detection of caution...
  • Page 52 MEA-100B T3: Depends on the communication setting (For the setting of COM, see 9. (2) ). Without communication With communication At normal: 68 ms max. (9600 bps) At trouble/caution: 80 ms max. With communication At normal: 34 ms max. (19200 bps) At trouble/caution: 40 ms max.
  • Page 53 MEA-100B  SM on the SET2 screen is set to 0 (For the setting of SM, see 9. (2) ) The welding sequence is halted if input of the start signal is stopped during SQ. The welding sequence is halted and [E11: CYCLE TROUBLE] is given if input of the start signal is stopped between W1 and W2 of the welding sequence.
  • Page 54 MEA-100B  SM on the SET2 screen is set to 2 (For the setting of SM, see 9. (2) ) Once the start signal is accepted, the welding sequence runs until completion, even if input of the start signal is stopped.
  • Page 55 MEA-100B (3) End, Normal End and Weld End Signals Timing Chart The output time for End, Normal and Weld End signals depends on the setting for the End signal output time (HET). Outputs upon completion of the welding sequence. The output time is the time set for HET (See 9. (2) ).
  • Page 56 MEA-100B  End Signal Output Time (HET) is set to 20 Output for 200 ms whether or not the start signal circuit is open. Start signal(input) [START(1ST)] Weld force signal(output) [SOL1/SOL2] Welding current 200ms 200ms End signal(output) [END] Normal signal(output)
  • Page 57 Any time during operation detection The letter in [ ] at the end of the message indicates the cause of fault.  "C" is displayed when the MEA-100B fails to monitor the frequency Cause of fault of the welding power supply.
  • Page 58 Any time except during the welding sequence. detection Cause of fault The MEA-100B is overheated.  Switch off the MEA-100B and leave it to stand to let it cool down.  If the MEA-100B has cooled down, turn on [ERR RESET]. Measures ...
  • Page 59 MEA-100B  E07 Message FULL WAVE Time of During welding detection The monitored conduction angle exceeds 175° during operation with the power supply voltage fluctuation compensation control. This fault may occur when it occurred for 3 times or more in the multi-cycle Cause of fault welding.
  • Page 60 The thyristor short-circuit current is detected during the squeeze. Cause of fault Note: The short-circuit current is not detected when the toroidal coil is not connected to the MEA-100B. Measures The thyristor may be broken. Contact us or your distributor for repairs.
  • Page 61 MEA-100B 13. Specifications (1) Specifications Item Specifications Single phase 200V/220V/230V/240V/380V/400V/460V/480V AC Power Supply (Voltage is selectable but factory-fixed on shipment.) +13%, -20%, 50/60 Hz 60 kVA (Duty cycle: 1.3% when 200 V AC is input) 66 kVA (Duty cycle: 1.3% when 220 V AC is input)
  • Page 62 MEA-100B Item Specifications  Multi-cycle welding a. Squeeze (SQ): 00–99 cycles b. Upslope1 (UP1): 0–9 cycles c. Weld1 (W1): 00–99 cycles d. Cool (CO): 00–99 cycles e. Upslope2 (UP2): 0–9 cycles f. Weld2 (W2): 00–99 cycles g. Downslope (DWN): 0–9 cycles h.
  • Page 63 MEA-100B Item Specifications  Secondary constant-current control 0.20–9.99 kA (in 10 A increment)  Power supply voltage fluctuation compensation control 10.0%–99.9% (in 0.1% increment) 0° 20° 150° 180° Current Setting Range Firing angle Set value 99.9% 10.0%  Secondary constant-current control Upper limit setting: +1%–...
  • Page 64 MEA-100B Item Specifications Detects when connecting the toroidal coil. No-Current The setting of the detecting level (Common to W1, W2, 1ST, 2ND Detection and HALF) (1 schedule) 01%–10% (If set to 00, the no-current detection is not performed.)  Multi-cycle welding — Select one of the following: ...
  • Page 65 MEA-100B Item Specifications  Selection of Way to input Start Signal  No self-sustaining function  Self-sustaining from W1  Self-sustaining  2-stage Start Mode  Selection of Way to change Schedule No.  31-Schedule No. Input without Parity  31-Schedule No. Input with Parity ...
  • Page 66 MEA-100B (2) Duty Cycle  Power supply 200 V, Ambient temperature 35°C ３ ２ ０ １ Ｃ Ｙ Ｃ ２ ８ ０ ５ＣＹＣ １０ＣＹＣ ２０ＣＹＣ ２ ４ ０ ２ ０ ０ １ ６ ０ ９ ９ Ｃ Ｙ Ｃ １ ２ ０...
  • Page 67 MEA-100B  Power supply 400 V, Ambient temperature 35°C ２０ ０ １８ ０ １ Ｃ Ｙ Ｃ １６ ０ ５ＣＹＣ １０ＣＹＣ ２０ＣＹＣ １４ ０ １２ ０ １０ ０ ９ ９ Ｃ Ｙ Ｃ ８ ０ ６ ０ ４ ０ ２ ０...
  • Page 68 MEA-100B (3) Model No.-Spec Reference Table Sub- Power supply used number Power for [CAUTION], MEA- Supply Solenoid Output CE Marking [STP/WELD END] 100B- Voltage and [READY] Photo-MOS relay 00-00 220V Internal power supply Not applicable output Photo-MOS relay 00-10 200V...
  • Page 69 MEA-100B 14. External Communication Function (1) Introduction MEA-100B can be used to set schedules from an externally-connected personal computer (abbreviated as PC) or to read monitored data and several kind of status data. Prepare the program and its development environment for controlling the Power Supply on the customer side.
  • Page 70 MEA-100B (3) Configuration Host computer Device No.01 Device No.02 Device No.31 RS-232C RS-485 … … RS-232C/RS-485 Conversion Adapter 31 Devices Max. (Note 1) When controlling two or more devices with one host computer, register the device No. for each device.
  • Page 71 MEA-100B (4) Protocol  Single-directional Communication Mode 1) Monitor Data (sent after each welding) Data strings: !01 01 :0,10,1.20,050,20,2.10,110,1,0000,1,0000,00005555 [CR][LF] A B C D Character Item Contents Range string Device No. 01 to 31 Schedule No. 01 to 31 0: Secondary constant-current...

  • Page 72: Error Code 1

    MEA-100B 2) Error Data Data strings: !01 01:E03,04,05,06,07,08,09,10[CR][LF] C D E F G H I J Character Item Contents Range string Device No. 01 to 31 Schedule No. 01 to 31 Error code 1 nnn, E01 to E15 Error code 2...
  • Page 73 MEA-100B  Bi-directional Communication Mode Reading of data Code: # Device No. R Schedule No. S Screen No. * Host Data MEA-100B 1) ID1 and ID2 are device numbers. 2) SH1 and SH2 are schedule numbers. 3) SC1 and SC2 are screen numbers.

  • Page 74: Range

    MEA-100B (5) Data Code Table  Screen 01 (SCHEDULE data) Specific data in accordance with Schedule No. (Schedule No.: 01 to 31) Character Item Contents Range string [SQ] Squeeze 00 to 99 (CYC) [UP1] Upslope 1 0 to 9 (CYC)

  • Page 75: Character String

    MEA-100B  Screen 03 (Stepper data) Common data (Schedule No.: 00) Character Item Contents Range string SOL1 STEP1 Count nnnn, 0000 to 9999 SOL1 STEP2 Count nnnn, 0000 to 9999 SOL1 STEP2 Stepper Rate nnn, 050 to 150 (%) SOL1 STEP3 Count...
  • Page 76 0: OFF 1: ON 0: Skips to the next sequence [WS] Determines how the (Skips to COOL (CO) if MEA-100B functions when the WELD1 (W1) is underway) WELD2 SKIP signal is input 1: Skips to HOLD (HLD) 00: Until the START input circuit...
  • Page 77 MEA-100B Character Item Contents Range string [NCL] No-current detecting 00 to 10 (%) level CC:2 1ST [NCL] No-current detecting 00 to 10 (%) level CC:2 2ND [NCL] No-current detecting 00 to 10 (%) level CC:3 HALF [NCI] No-current neglecting 00.0 to 10.0 (CYC) nn.n,...
  • Page 78 MEA-100B Character Item Contents Range string Error code 6 01 to 15 Error code 7 01 to 15 Error code 8 01 to 15 The number of error codes is of eight max. In the case of only one error code, the items 2 to 8 are omitted.
  • Page 79 1) ID1 and ID2 are device numbers “01.” 2) On the host side, SH1 and SH2 are schedule numbers “00.” On the MEA-100B, SH1 and SH2 are those of the last welding “08.” 3) SC1 and SC2 are screen numbers “06.”...
  • Page 80 MEA-100B Reading of data Code: # Device No. R Schedule No. S Screen No. * Example: Read all data of Screen No. “01” of Schedule No. “08” of the specified device No. 01. Host 0 1 0 8 0 1 :...
  • Page 81 To write settings in the bi-directional communication, be careful of followings. 1) Data is checked if it is within a correct range after received by the MEA-100B. When correct, the received data is transmitted as it is. During that time, the READY signal is turned off.
  • Page 82 MEA-100B 15. Outline Drawing (Dimensions in mm) Front Side Rear Cable Dia. : 18mm max. Cable Dia. : 14mm max. 15. Outline Drawing 15-1...
  • Page 83 MEA-100B 16. Schedule Table 16. Schedule Table 16-1...
  • Page 84 MEA-100B 16. Schedule Table 16-2...
  • Page 85 MEA-100B Count Stepper-Up (-Down) Rate 0000–9999 050%–150% STEP1 STEP2 SOL1 STEP3 STEP4 STEP5 STEP1 STEP2 SOL2 STEP3 STEP4 STEP5 16. Schedule Table 16-3...
  • Page 86 MEA-100B Screen Item Range Setting SET1 #1 MAX CURR 0.5–9.9 kA SET1 #2 LCD CONTRAST 01–16 0–1 0–3 SET2 #1 0–3 0–3 01, 05, 10, 20 0–1 0–1 SET2 #2 0–1 0–1 DEF, 0–10.0 CYC 00%–10% CC:0 00%–10% 00%–10% CC:1 SET2 #3 00%–10%...

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