Amada MA-520B User manual

Y02OM1200944-02

OPERATION MANUAL

WELD FORCE SENSOR FOR RESISTANCE WELDING MACHINES

MA-520B/521B/522B

Contents

Thank you for purchasing our MA-520B/521B/522B, Weld Force Sensor for Resistance

Welding Machines.

For correct use, read this Operation Manual carefully. After reading, save it properly for

future reference.

Contents

1. Special Precautions...................................1-1 to 1-4

2. Features......................................................2･3-1

3. Specifications ............................................2･3-1

4. Name of Each Section ...............................4-1

5. Measurement Method ................................5-1

6. Option.........................................................6-1 to 6-2

MA-520B/521B/522B

1. Special Precautions

1-1

Denotes operations and practices that

may result in personal injury or damage to

the equipment if not correctly followed.

1. Special Precautions

(1) Safety Precautions

Before using, read "Safety Precautions"

carefully to understand the correct

method of use.

■These precautions are shown for

safe use of our products and for

prevention of damage or injury to

operators or others. Be sure to read

each of them, since all of them are

important for safety.

■The meaning of the words and

symbols is as follows.

These symbols denote

"prohibition".

They are warnings about

actions out of the scope of

the warranty of the product.

These symbols denote

actions which operators must

take.

Each symbol with a triangle

denotes that the content

gives notice of DANGER,

WARNING or CAUTION to

the operator.

Denotes operations and practices that

may imminently result in serious injury

or loss of life if not correctly followed.

Denotes operations and practices that

may result in serious injury or loss of life

if not correctly followed.

Never disassemble, repair or modify the Sensor.

These actions can cause electric shock and fire. Do not do anything other

than the maintenance described in the operation manual.

DANGER

！

WARNING

！

UTION

！

NGER

！

MA-520B/521B/522B

1. Special Precautions

1-2

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.

Do not touch them; otherwise you may be burnt.

Do not damage the power cable and connecting cables.

Do not tread on, twist or tense any cable. The power cable and connecting

cables may be broken, and that can cause electric shock and fire. If any part

needs to be repaired or replaced, consult us or your distributor.

Connect the specified cables securely.

Cables of insufficient current capacities and loose connections can cause fire

and electric shock.

Stop the operation if any trouble occurs.

Continuous operation after occurrence of a trouble such as burning smell,

abnormal sound, abnormal heat, smoke, etc. can cause electric shock and

fire. If such a trouble occurs, immediately consult us or your distributor.

Persons with pacemakers must stay clear of the welding machine.

A person who uses a pacemaker must not approach the welding machine or

walk around the welding shop while the welding machine is in operation,

without being permitted by his/her doctor. The welding machine generates a

magnetic field and has effects on the operation of the pacemaker while it is

turned on.

Wear protective glasses.

If you look at the surface flash and expulsion directly during welding, your

eyes may be damaged.

ARNING

！

MA-520B/521B/522B

1. Special Precautions

1-3

Use ear protectors.

Loud noises can damage hearing.

Protective gear must be worn.

Put on protective gear such as protective gloves, long-sleeve jacket, leather

apron, etc. Surface flash and expulsion can burn the skin if they touch the

skin.

Keep combustible matter away from the welding machine.

Surface flash and expulsion can ignite combustible matter. If it is impossible

to remove all combustible matter, cover them with non-combustible material.

Do not cover the Sensor with a blanket, cloth, etc.

If such a cover is used, it may be overheated and burn.

Keep a fire extinguisher nearby.

Keep a fire extinguisher in the welding shop in case of fire.

Maintain and inspect the Sensor periodically.

Maintain and inspect the Sensor periodically, and repair any damage nearby

before starting operation.

UTION

！

MA-520B/521B/522B

1. Special Precautions

1-4

(2) Precautions for Handling

■Do not install this Sensor in the following.

Damp places where humidity is higher than 90%, places where the Sensor

may be subjected to vibration or impact, 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 places where water will be

condensed.

■Operate the Sensor according to the method described in this operation

manual.

■Never apply the welding current to the weld force sensor during welding. It can

cause a malfunction or breakage. However, a measurement can be done

while the welding current flows by connecting the optional part for measuring

the weld force of the welding head which has two electrodes such as parallel

gap welding and series welding.

■Do not apply a weld force larger than the rated load of the Sensor. Also, do not

apply a weld force or have an impact on the Sensor suddenly.

■Do not bend the flexible joint part of the Sensor unnecessarily. When bending,

do not bend it over 60° from right to left or up and down. Also, do not pull the

flexible joint part of the Sensor over 5 mm. The internal signal line may be

broken.

■Do not put anything other than a workpiece, e.g., a tool, a screw, etc., between

the electrodes. It can cause a malfunction.

■Clean the outside of the Sensor with a soft, dry cloth or one wet with a little

water. If it is very dirty, use diluted neutral detergent or alcohol. Do not use

paint thinner, benzine, etc., since they can discolor or deform the Sensor.

MA-520B/521B/522B

2. Features / 3. Specifications

2･3-1

2. Features

MA-520B/521B/522B is an electrode force sensor for resistance welding machine.

By connecting this sensor to the special weld force gauge sold separately (MM-400A),

the weld force over a wide range can be measured easily.

This sensor can be carried easily, since it is both small and light.

Use the force sensor so that the welding current does not flow on it since it is not

insulated, otherwise the sensor will be broken.

3. Specifications

Model No. MA-520B MA-521B MA-522B

Rated load 9.8daN (10kgf) 98daN (100kgf) 980.6daN (1000kgf)

Effective measurement

range

0.2daN–9.8daN

(0.2kgf–10kgf)

2.0daN–98daN

(2.0kgf–100kgf)

20daN–980.6daN

(20kgf–1000kgf)

Acceptable load 1.5 times of rated load

Measurement accuracy ±3% of rated load

Using temperature range 0 – +40°C

Overall length

of body Approx. 170 mm Approx. 177 mm

Diameter of

sensor unit x

thickness

φ25 mm x 9 mm φ33 mm x 16 mm

External

dimensions

Cable length Approx. 1000 mm

Weight

(including cable and connector) 200 g 250 g

Option (See Chapter 6.)

Jig for simultaneous force

application and welding

(A-04860-001)

！

CAUTION

MA-520B/521B/522B

4. Name of Each Section

4-1

4. Name of Each Section

(Dimensions in mm)

Cable to connect

weld force gauge

Flexible joint Handle

Weld force

sensor unit

φ20

170(MA-520B,MA-521B) / 176.5(MA-522B)

φ25

φ5

φ3

φ33

MA-520B/521B MA-522B

φ12

φ10

Connector for weld force gauge

[Detail of weld force sensor unit]

MA-520B/521B/522B

5. Measurement Method

5-1

5. Measurement Method

(1) Connection to Weld Force Gauge

Confirm that the weld force to be measured is in the effective measurement range of

the sensor, then connect the sensor to the weld force gauge securely.

(2) Application of Weld Force

●Preparation of weld force sensor

Hold the weld force sensor so that it will be aligned with the electrodes of the

welding machine and the weld force will be applied to the sensor normally (see

figure below).

●Application of weld force

Slowly apply the weld force. Avoid applying any large shocks to the sensor.

Weld force sensor

Electrode

Line the axis of

the electrodes

Perpen-

dicular

force

In case of pointed

electrodes, turn the

sensor unit to the fixed

side to make a measurment

more accurate.

Before measuring the weld force, be sure to turn off the welding machine and confirm

that the power is not applied. If the welding power is applied while the weld force is

measured, the sensor may be broken.

Do not apply the weld force to any part other than the sensor unit. Do not apply a

weld force larger than the rated load of the sensor. If they are applied, the sensor

may be broken.

For the details of the measurement method, see the Operation Manual for the Weld

Force Gauge.

For weld force gauges other than MM-601, there are setting items of sensor

type and span value. The span value is indicated on the seal attached to each

weld force sensor. For details, refer to the Operation Manual for the Weld Force

Gauge to be connected.

MA-520B/521B/522B

6. Option

6-1

6. Option

In this chapter, we will explain about the optional jig for simultaneous force application

and welding (A-04860-001).

This jig can be used for MA-520B/521B only. (This cannot be mounted to MA-522B.)

(1) Introduction

This is a jig for measuring the weld force of the welding head which has two

electrodes such as parallel gap welding and series welding.

Also, when this jig is mounted, a measurement can be done even if the welding

current flows.

(2) Mounting Method

Fix the sensor with three setscrews (M3)

so that it will be set at the center of the jig.

M3 setscrew Copper

plate Insulation sheet

Parallel gap welding Series welding

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