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Amada MH-H500D Operation Manual

Motor-driven resistance welding head
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MOTOR-DRIVEN RESISTANCE WELDING HEAD
MH-H500D
OPERATION MANUAL
AA05OM1208874-02

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Summary of Contents for Amada MH-H500D

  • Page 1 MOTOR-DRIVEN RESISTANCE WELDING HEAD MH-H500D OPERATION MANUAL AA05OM1208874-02...

  • Page 2: Table Of Contents

    MH-H500D Thank you for purchasing our Motor-Driven Resistance Welding Head MH-H500D. ・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: Special Precautions

    MH-H500D 1. Special Precautions CAUTION (1) Safety Precautions ！ Before using, read "Safety Precautions" carefully to understand the correct method Denotes operations and practices that of use. may result in personal injury or damage to the equipment if not correctly followed.
  • Page 4 MH-H500D 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 electrode holder are very hot.
  • Page 5 MH-H500D CAUTION ！ Do not splash water on the Welding Head Water splashed over the electric parts can cause electric shock and short circuits. Use proper tools (wire strippers, pressure wire connectors, etc) for termination of the connecting cables Do not cut the conductor of wire. A flaw on it can cause fire and electric shock.

  • Page 6: Precautions For Handling

    MH-H500D (2) Precautions for Handling Do not install this Welding Head in the following: ■ ・Damp places where humidity is higher than 90%, ・Dusty places, ・Places where chemicals are handled, ・Places near a high noise source, ・Hot or cold places where temperatures are above 40°C or below 0°C, and ・Areas where water will be condensed.

  • Page 7: Features

    (length) changes. Also, you don’t need to adjust the electrode opening finely when replacing the electrode. The electrode force of the MH-H500D is 50 to 500 N (approx. 5 to 50 kgf).  Since the electrode-forward/backward speed is adjustable in eight steps (in four steps from Mid-Point to Weld Point), you can fit the electrode-force speed to suit your welding work.

  • Page 8: Name And Functions Of Each Section

    MH-H500D 3. Name and Functions of Each Section (1) Head ⑯ ⑮ ⑭ ⑬ ⑬ ⑭ ⑫ ⑩ ⑪ ① ② ⑧ ⑨ ④③ ⑦ ⑤ ⑤ ⑦ ③ ④ ⑨ ⑧ ⑥ ⑥ 3. Name and Functions of Each Section...
  • Page 9 MH-H500D  Weld Force Adjustment Knob ATTENTION Adjusts the electrode force. If a metal object such as a screw-  Lock Screw driver and wire contacts a part Locks the Weld Force Adjustment Knob. such as Holder through which welding current flows during ...

  • Page 10: Controller Front Panel

    MH-H500D (2) Controller Front Panel  Operation Button Operate the Welding Head by turning the button clockwise/counterclockwise or TROUBLE SPEED pressing it. HOLD TIME By turning the button, the lamp illumination W E L D H E A D READY...
  • Page 11 MH-H500D ⑫ [SPEED HOLD TIME] Display Indicate the “electrode speed” and “HOLD Time after the application of weld force is completed”. The larger number indicates the faster electrode speed and the longer HOLD Time. And the lamp lights up simultaneously with other lamps as follows:...

  • Page 12: Controller Rear Panel

    MH-H500D (3) Controller Rear Panel  [MOTOR CONTROL] Connector It is a connector for controlling a motor to drive the electrode.  I/O Connector It is for input/output of signals.  Connector for Weld Force detecting Sensor It is for inputting the weld force signal of the welding head.

  • Page 13: Interface

    MH-H500D 4. Interface (1) Connection Diagram of External Input/Output Signal Motor Head Controller External Input/Output Connector 24VDC Å -COM SCH1 SCH2 SCH4 SCH8 SCH16 +COM +COM Spare: Do not connect -COM +COM EXT.COM -COM RESET P.LOCK Spare: Do not connect...
  • Page 14 MH-H500D [Example of Connection] ・When contacts are used as input terminal of I/O connector Å 24VDC + C O M -COM +COM EXT.COM -COM ・When NPN transistor (sink type) on PLC is used as input terminal of I/O connector Å...

  • Page 15: I/O Connector

    Input schedule number set on MH-H500D. Before selecting the schedule number by the operation button on MH-H500D, open the circuits of all the Pins of No. 2, 3, 4, 5 and 6 in I/O Connector. Input [SCH] signal at least 2 ms before the welding current flows. During in operation, the schedule number cannot be changed.
  • Page 16 MH-H500D Description Output pins for 24 V DC through 100Ω internal resistor. Input pin for start-up signal. When [1ST] is closed, electrode moves from Start Point to Mid-Point. Input When [2ND] is closed after [1ST] was closed, electrode moves from Mid-Point to Weld Point.
  • Page 17 Close at least for 2 ms. Pin 18 does not work while the circuit of Pin 18 is closed. Input pin for prohibition of setting the operation schedule. When Pin 19 is closed, the operation schedule of MH-H500D cannot be set. (The schedule number can be modified.) Spare pin: Do not connect.
  • Page 18 [ERROR] Output pin for a trouble signal. ERROR When trouble occurs Output MH-H500D, the Pin becomes OUT COM opened until it is reset. or 31 Spare pin: Do not connect. Common terminal to [READY], [START POINT], [MID POINT] and [ERROR] Do not connect to the Pin for [EXT.

  • Page 19: Installation And Connection

    Before using your MH-H500D, install it according to the following procedures. CAUTION ！ Be sure to firmly install MH-H500D on the horizontal place before the use. Do not install it obliquely or vertically. If you use it without being fixed, it may cause either injury due to its dropping, or the degradation of weld quality.
  • Page 20 MH-H500D  Connection of Secondary Cable After installing on the worktable, connect Secondary Cable to MH-H500D. Fix firmly so as not to wobble by the use of appropriate tools for the screws, bolts and nuts for the installation. Power Supply Plate...
  • Page 21 MH-H500D  Connection of Cooling Water Tube ATTENTION A cooling water tube is not contained in MH-H500D . Please purchase it for customer’s use. The recommended tube is “T0604 Nylon tube (manufactured at SMC Corp.)”. Joint Joint Tube Tube Connecting Weld Force Detecting Sensor ...

  • Page 22: Mh-H500D-□□-5□ Head

    Decide where to install MH-H500D, the welding power supply and the welding transformer.  Drilling Holes for Fixing Drill the holes for fixing MH-H500D with reference to the figure below, deciding the location of installation. 2 0 0 Head Base 4 - M 6 S c r e w D e p t h 1 3 m m ...

  • Page 23: Operation

    Downstop A little bit beyond the position from Weld Point. Point It can be set arbitrarily.  Working Mode of Electrode In the model of MH-H500D, it has two working modes. Movement Mode 0 Mode 1 Performed by External Input...

  • Page 24: Mode Setting

    MH-H500D ２ Ｎ Ｄ Start-up １ Ｓ Ｔ Ｏ Ｆ Ｆ SCH No SCH 1 SCH 2 Ｓ Ｃ Ｈ Input S t a r t P o i n t ( S C H 1 ) Electrode S t a r t P o i n t...

  • Page 25: Applying Power And Moving To Start Point

    MH-H500D  Change of ERROR Signal Output Press the operation button while “1” blinks on [SPEED HOLD TIME] Display. Mode No. blinks on [SCH(SCHEDULE)] Display. Rotate the operation button to select “0” or “1”. ・0………means “circuit opened in case of error”...

  • Page 26: Auto-Setting Of Electrode Position

    MH-H500D (4) Auto-Setting of Electrode Position The electrode position can be set automatically by means of the auto-setting function. Turn the operation button to light up [AUTO] Lamp. Press the operation button for 1 second, and [AUTO] Lamp blinks. Close External Input [1ST], and the electrode moves to Original Point.

  • Page 27: Manual Setting Of Electrode Position

    MH-H500D (5) Manual Setting of Electrode Position  Selecting Schedule No. Turn the operation button to light up [SCH] Lamp. Press the operation button for 1 second. [SCH] Lamp and [SCH] Display blink. Turn the operation button clockwise and counterclockwise to select a numeral (1 to 31) on [SCH] Display.
  • Page 28 MH-H500D  Changing Moving Speed between Start Point and Mid-Point Turn the operation button to light up both [READY] and [MID] Lamp. Press the operation button for 1 second. [READY] and [MID] Lamp blink. The number of blinking [SPEED HOLD TIME] Lamp indicates the current speed setting.
  • Page 29 MH-H500D When you want to interrupt the operation, Press [ORG/CANCEL] button, and [MID] Lamp blinks fast. Close External Input [1ST]. The electrode returns to the previous position with beeps. In case of Mode 1, it works by pressing the operation button in addition to External Input.
  • Page 30 MH-H500D [In case that the electrode cannot move beyond Weld Point because of a workpiece] Turn the operation button until the electrode stops, then press the operation button. Downstop Point is set 5 mm beyond Weld Point and [WELD] Lamp blinks fast.
  • Page 31 MH-H500D ２ Ｎ Ｄ ２ Ｎ Ｄ Start-up １ Ｓ Ｔ Ｏ Ｆ Ｆ END Signal Ｅ Ｎ Ｄ Input Start Point Electrode Mid-Point Movement Weld Point WELD WELD START START Output Additional Pressing Time  Setting of Hold Time Turn the operation button to light up [HOLD] Lamp.

  • Page 32: Welding Work

    MH-H500D  Setting Moving Speed from Weld Point to Mid-Point Turn the operation button to light up both [MID] and [WELD] Lamp. Press the operation button for 1 second. [MID] and [WELD] Lamp blink. The number of the blinking [SPEED HOLD TIME] Lamp indicates the current speed setting.

  • Page 33: Measuring Weld Force

    MH-H500D After the weld force of the electrode is released, open External Input [both 1ST and 2ND]. Then, the electrode returns to Start Point. In case that External Input [1ST] is closed, the electrode returns to and stops at Mid-Point.

  • Page 34: Fault Indications

    MH-H500D 7. Fault Indications When a trouble occurs at the apparatus, [TROUBLE] Lamp lights up and a fault code is shown on [SCH] Display. Closing External Input [RESET] or continuing to press the operation button can reset the fault signal.

  • Page 35: User's Maintenance

    MH-H500D 8. User’s Maintenance ATTENTION ・Use the appropriate tools for the size of screws for maintenance. After the completion of adjustment, firmly tighten the screws so that there may occur no loosening or wobbling. ・When a caution is given that denotes “Turn off the power switch of the motor controller”, strictly observe it to avoid an electric shock and incorrect operation.
  • Page 36 MH-H500D Weld Force Conversion Graph The weld force conversion graph represents theoretical values. To measure the actual weld force, use a pressing force gauge or spring balance. Weld Force (kgf) 37.8 Scale 8. User’s Maintenance...

  • Page 37: Specifications

    MH-H500D 9. Specifications (1) Specifications Items MH-H500D-□□-0□ MH-H500D-□□-5□ Head Type Horizontal-type Weld Head Electrode Force 50–500 N (Approx. 5 to 50 kgf) Stepless adjustment Weld Force Method Spring forced Electrode Separately sold Electrode-Driving Servomotor Method Electrode Stroke 45 mm Number of Weld-...

  • Page 38: Separately Sold Items

    3-pin/2-pin conversion adapter KPR-24(SB)-B (for 100-120V AC) for power cable Electrode Refer to 11. Outline Drawings . * Exclusively for the MH-H500D. Do not use for other devices. (4) Timing Chart  Power ON and Error occurring Switch of Ｏ Ｎ...
  • Page 39 MH-H500D  Operating ２ＮＤ １ＳＴ Start-up ＯＦＦ Original Point Movement Start Point Electrode Mid-Point Weld Point Close Weld Start Open Close Start Point Open Close Mid-Point Open 9. Specifications...

  • Page 40: Data Communication

    MH-H500D 10. Data Communication (1) Communication Specifications RS-232C: RS-232C, Asynchronous, Teletype procedure Method RS-485: RS-485, Asynchronous, Half-Duplex Transmission 9600 bps rate Start bit: --------- 1 Data bit: --------- 8 Data type Stop bit: --------- 1 Parity bit: -------- 1 (Even parity)
  • Page 41 MH-H500D  RS-485 Signals of RS-485 use (RS+) and (RS-). Short-circuit between Pins 7 and 10. MH-H500D MH-H500D External connector Pin No. TRO U BLE SPEE D HOLD TIM E Host Computer REA D Y WELD HEAD CONTROL UNIT WEL D...

  • Page 42: Bidirectional Communication

    When the electrode is at Start Point, the schedule data can be read or written. When the readout/overwrite command is sent from the host computer, MH-H500D sends back the data. When sending the command, do not send the next command until the data are sent back or the timeout time elapses.
  • Page 43 MH-H500D ・MH-H500D→Host Controller Character Item Order Description Range train Communication start 01-01 Fixed (to host) 02-03 Communication ID Fixed 04-06 Schedule No. 001 to 031 07-07 Data start Fixed 00000 to 05000 08-13 nnnnn, Start Point (nnn.nn, unit in mm)
  • Page 44 MH-H500D  Overwrite Command ・Host Controller→MH-H500D Character Item Order Description Range train Communication start 01-01 Fixed (from host) 02-03 Communication ID Fixed 04-04 Overwrite request Fixed 05-07 Schedule No. 001 to 031 08-08 Data start Fixed 00000 to 05000 09-14...
  • Page 45 MH-H500D ・MH-H500D→Host Controller Character Item Order Description Range train Communication start 01-01 Fixed (to host) 02-03 Communication ID Fixed 04-06 Schedule No. 001 to 031 07-07 Data start Fixed 00000 to 05000 08-13 nnnnn, Start Point (nnn.nn, unit in mm)

  • Page 46: Outline Drawings

    MH-H500D 11. Outline Drawings (1) MH-H500D-□□-0□ Head The figure below shows the installation of Electrodes (separately sold). Dimensions in mm Cable for Weld Force Detecting Sensor 6.5 mm dia. Holes 30 23 for fixing Head 300(*1) *1 Approximate center of electrodes 11.

  • Page 47: Mh-H500D-□□-5□ Head

    MH-H500D (2) MH-H500D-□□-5□ Head The figure below shows the installation of Electrodes (separately sold). Dimensions in mm Cable for Weld Force Detecting Sensor 4-M6 Threaded Holes (for fixing MH-H500D） Electrodes (609.5) 11. Outline Drawings 11-2...

  • Page 48: Head Controller

    MH-H500D (3) Head Controller Dimensions in mm TROUBLE SPEED HOLD TIME WELD HEAD READY CONTROL UNIT WELD HOLD AUTO ORG/CANCEL CHECK FORCE 245.5 Connector Connector for Weld Force Motor Control detecting Sensor Cable Power Input 100 to 240 VAC 11. Outline Drawings...

  • Page 49: Electrode (Separately Sold)

    MH-H500D (4) Electrode (separately sold) Dimensions in mm -0.02 -0.05 5 ±0.05 Model Material Z-03037-001 Cr-Cu alloy Z-03037-002 Tungsten 11. Outline Drawings 11-4...

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