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Amada MIH-200A Operation Manual

Ac inverter seam welding power supply
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AC INVERTER SEAM WELDING
POWER SUPPLY
MIH-200A
OPERATION MANUAL
AA09OM1158384-07

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  • Page 1 AC INVERTER SEAM WELDING POWER SUPPLY MIH-200A OPERATION MANUAL AA09OM1158384-07...

  • Page 2: Table Of Contents

    MIH-200A Thank you for purchasing our AC Inverter Seam Welding Power Supply MIH-200A. This operation manual describes its method of operation and precautions for use. Read this operation manual carefully prior to use. Store appropriately for ready reference. Contents 1. Special Notes (1) Safety Precautions ·································································...

  • Page 3: Special Notes

    MIH-200A 1. Special Notes (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.
  • Page 4 MIH-200A WARNING Do not insert your fingers or hands between the electrodes. When welding, keep your fingers and hands away from the electrodes. Do not touch any welded part or electrode during welding or just after completion of welding. The welded parts of a workpiece, electrodes, and the arm are very hot.
  • Page 5 MIH-200A CAUTION Apply the specified supply voltage. Application of a voltage outside the specified range may result in fire or electric shock. Do not allow water to come in contact with the equipment. Water on the electric parts can cause electric shock and short circuit.

  • Page 6: Precautions For Handling

    MIH-200A (2) Precautions for Handling  Any work on this Power Supply must be performed only by the personnel with sufficient knowledge and experience regarding an inverter-type welding power supply.  Install this Power Supply on a firm and level surface. Operation on an incline may result in malfunction.

  • Page 7: Warning Label For Safety

    MIH-200A (4) Warning Label for Safety On the main body is warning label for safety. Its location and meaning are as noted below. Location: Output terminal cover. Meaning: Shock hazard. (5) Operation of the OK Signal For products shipped in or after December 2014, the OK signal is not output at WELD OFF.

  • Page 8: Features

    MIH-200A 2. Features The MIH-200A is an inverter-controlled power supply for AC welding. In combination with an AC transformer and a welding head, it can perform excellent welding with less surface flash and expulsion and burns.  Function to monitor current, voltage, power and pulse width for judgment of weld quality ...

  • Page 9: Name And Functions Of Each Section

    MIH-200A 3. Name and Functions of Each Section (1) Front Panel INDICATOR Ｗ Ｅ Ｌ Ｄ Ｐ ＯＷ Ｅ Ｒ WELD POWER READY Ｒ Ｅ Ａ Ｄ Ｙ START Ｓ ＴＡ Ｒ Ｔ WELD TROUBLE POWER Ｗ Ｅ Ｌ Ｄ...
  • Page 10 MIH-200A [START] lamp (Green LED) This lamp remains lit while the 2ND signal is input. [WELD] lamp (Green LED) This lamp remains lit while the welding current is flowing. [TROUBLE] lamp (Orange LED) This lamp lights when an error is detected. At this time, the program unit emits a beeping sound, and the Power Supply operation is interrupted.

  • Page 11: Rear Panel

    MIH-200A (2) Rear Panel terminal cover OUTPUT POWER 200V-240V ～ 50/60Hz I/O power supply cover (With terminal covers mounted) (With terminal covers removed) Connecting terminal block for external input/output signal This terminal block is used to input the SCH signals and output the NG signals.

  • Page 12: Ma-627A (Sold Separately)

    MIH-200A (3) MA-627A (Sold Separately) CURSOR MENU TROUBLE ENTER RESET ⑥ ① ② ③ ④ ⑤ [TROUBLE RESET] key If this key is pressed while the [TROUBLE] lamp on the Power Supply is lit, the lamp goes off. This key has the same function as the [TROUBLE RESET] key on the Power Supply.
  • Page 13 If setting is performed while the 2ND signal is input, the following screen appears. Turn off the 2ND signal and press [TROUBLE RESET] key 1). MIH-200A IS BUSY OR NOT CONNECTED Please RESET key in (Note) While the 2ND signal is input, 1) [TROUBLE RESET] key, [TROUBLE RESET] key on the front panel (see (1) 6)) and the error reset input terminal of the external I/O (see 6.

  • Page 14: How To Operate Screens

    This screen is used to display and set data for the Power Supply. -POWER SUPPLY STATE LCD CONTRAST(T:0 ---> 7:D) CONTROL # PROGRAMMED DATE 2000.01.01 POWER SOURCE FREQUENCY MA-627A ROM VERSION # MIH-200A ROM VERSION # 4. How to Operate Screens...
  • Page 15 (e) MA-627A ROM VERSION # Indicates the ROM version No. of program unit MA-627A. (f) MIH-200A ROM VERSION # Indicates the ROM version No. of the Power Supply. (Note) The Power Supply writes data into FLASH ROM on the control board when a setting is changed or a schedule data is copied.

  • Page 16: Schedule Screen

    MIH-200A (3) SCHEDULE Screen Up to 255 welding schedules can be set on the Power Supply. These schedules are indicated as SCHEDULE #1 to #255. This screen is used to set the SCHEDULE No., length of weld time, welding current, and so on.
  • Page 17 MIH-200A CO TIME Sets the no-current-carrying time of half cycle. (d in the chart below) Sets the count of half cycle. (5 in the chart below) Sets the current value of the first weld time (HEAT1). (○ in the HEAT...
  • Page 18 MIH-200A Actual current waveform WELD1 WELD2 No. of counts=5 No. of counts=6 １ １ １ No. of counts=5 No. of counts=6 No. of counts=6 UP SLOPE DOWN SLOPE1 DOWN SLOPE2 (j) VALVE # Two valves (welding heads) can be connected to the Power Supply. Use this setting to select which of the two valves to use.

  • Page 19: Monitor1/Monitor2 Screen

    MIH-200A (4) MONITOR1/MONITOR2 Screen In this screen, you can confirm the operational conditions during welding. Monitored data is displayed for each SCHEDULE. -MONITOR1 SCHEDULE #225 CURR1 CURR2 VOLT1 VOLT2 POWER1 POWER2 AVE 000A 000A 0.00V 0.00V 0000W 0000W MAX 000A 000A 0.00V 0.00V 0000W 0000W MIN 000A 000A 0.00V 0.00V 0000W 0000W...
  • Page 20 MIH-200A set count value are displayed. COUNT1, COUNT2 Displays the count values for WELD1 and WELD2. Judged by the item selected in CAUTION ITEM on the MONITOR SET screen. The number of total counts (TOTAL), values within range for judgment (GOOD), values out of upper limit (UPPER) and values out of lower limit (LOWER) are displayed.

  • Page 21: Monitor Set Screen

    MIH-200A (5) MONITOR SET Screen Set the conditions for determining a good or bad weld, including values for welding current, upper or lower limits for the secondary voltage/power, pulse width, etc. If the monitored values do not meet the set conditions, the CAUTION or NG signal is output, and can be used to activate an alarm buzzer, alarm lamp, or similar event.
  • Page 22 MIH-200A (h) CAUTION MODE Note: Common to all schedules Selects the action when the half cycle out of the upper/lower limit range for judgment exceeds the number of counts. Outputs the CAUTION signal and continues the welding sequence. (Can be restarted) Output the NG signal and stops the welding sequence.

  • Page 23: Copy Setup Data Screen

    Power Supply memory is displayed on the Monitor Panel. When the data is changed and the [ENTER] key is pressed, the contents of the memory of the Power Supply are overwritten by the new setting. MIH-200A stores data, MA-627A stores data for one independently from MIH-200A unit.
  • Page 24 Move the cursor () to the required item among (a) to (c), then press the [ENTER] key; the data will be copied. (a) [MIH-200A -----> MA-627A] The data in MIH-200A is copied to the memory of MA-627A. (b) [MIH-200A <----- MA-627A] The data in the memory of MA-627A is copied to MIH-200A.

  • Page 25: Mode Select Screen

    MIH-200A (7) MODE SELECT Screen -MODE SELECT DELAY START SET 20ms START SIG.MODE MAINTAINED SIG.TIME 200 ms PARITY CHECK OFF OUT MODE(END) OUT MODE(OK) OFF COMM CONTROL COMM SPEED 38.4k COMM MODE RS-232C (a) DELAY START SET One welding condition is determined via DELAY START SET, a value corresponding to chatter prevention time, after the 2ND signal is input.
  • Page 26 MIH-200A (b) START SIG.MODE Set the input method of the 2ND signal to activate the Power Supply. (Note) When OUT MODE(END) is OFF 1) At LATCHED  The welding sequence halts if the 2ND signal stops during squeeze time (SQZ).
  • Page 27 MIH-200A (c) END SIG.TIME Sets the length of time for output of the END signal when OUT MODE(END) is OFF. The output time can be set in a range from 10 to 200 ms and in units of 10 ms. The 2ND signal is not received while the END signal is output.
  • Page 28 MIH-200A (Note 1) Schedule Nos. and Schedule Selection Pins ●: Closed Blank: Open SCHEDULE# SCH 1 SCH 2 SCH 4 SCH 8 SCH16 SCH32 SCH64 SCH128 PARITY ● ● ● ● ● ● ● ● ● ● ● ● ●...
  • Page 29 MIH-200A (Note 2) Timer operation and operation between takts 1) Timer operation: Output the signal for the time set for END SIG.TIME. 2) Operation between takts: Outputs the signal at power-on and releases when the 2ND signal is received. 1) Timer operation...

  • Page 30: Monitor Mode Screen

    MIH-200A (8) MONITOR MODE Screen -MONITOR MODE NO CURRENT CUT COUNT 000CNT NO CURRENT LEVEL 000A MONITOR FIRST TIME 0.0ms (a) NO CURRENT CUT COUNT The absence of welding current will not be detected as a no-voltage error (see 11.

  • Page 31: I/O Check Screen

    MIH-200A (9) I/O CHECK Screen This screen is used to check the status of the external I/O signals. You cannot move to another screen while the 2ND signal is input. -I/O CHECK SCH01* SCH128* ERR RST* NG 0 SOL1 0...

  • Page 32: Reset To Default Screen

    MIH-200A (10) RESET TO DEFAULT Screen This screen is used to initialize the Power Supply’s memory (i.e., to restore the initial settings). Initialization will not clear the memory of the MA-627A. To initialize, move the cursor () over YES or NO and press the [ENTER] key.

  • Page 33: Over Write / Down Load Screen

    MIH-200A 3) Turn off the power supply and turn on it again, or disconnect the MA-627A with the power supply turned on and connect to the circuit cable again. When PROGRAM PROTECT is ON, the display of the MENU screen changes.
  • Page 34 It takes about 5 minutes to rewrite the memory. After rewriting, the MA-627A can be used. CONNECT MEMORY MIH-200A-M [V00-01A] IS-470B-MA [V00-01A] MIH-200A-S [V00-01A] TEST [V00-02A] CONNECT IMPOSSIBLE!! OVER WRITE : YES 2) DOWN LOAD screen This screen is for downloading a program from the product connected to the MA-627A.

  • Page 35: Connection Procedures

    MIH-200A 5. Connection Procedures (1) Basic Configuration 627A Power Supply front Welding head MENU Secondary INDICATOR cable WELD POWER READY START WELD TROUBLE POWER TROUBLE RESET Circuit Voltage cable WELD ON/OFF detecting PROGRAM RS-232C/485 MONITOR cable Earth Welding leakage transformer...

  • Page 36: Connecting

    MIH-200A (2) Connecting 1) Connecting to the transformer’s input terminal block and the voltage detecting cable Use the output cable to connect the welding power output terminal block on the Power Supply’s rear panel with the welding transformer’s input terminal block.

  • Page 37: Interface

    MIH-200A 6. Interface (1) Connection Diagram for External Input/Output Signals 24V DC INT.24V EXT.COM STOP SCH 1 SCH 2 SCH 4 SCH 8 SCH16 SCH32 SCH64 SCH128 WE1 STOP/PARITY WE2 STOP/WELD COUNT WELD ON THERMOSTAT FLOWSWITCH ERROR RESET STEP RESET WE3 STOP 6.
  • Page 38 MIH-200A CAUTION READY STEP END WELD SIGNAL OUT COM SOL POWER SOL COM SOL 1 SOL 2 VOLT SENS Terminal block specifications Terminals connectable Two pieces max. Pressure wire connectors M3 or M3.5 (7.1 mm wide) 0.75 mm min. for pin nos. 34 to 37 Recommended wire size 0.5 mm...

  • Page 39: Description Of External I/O Signals

    MIH-200A (2) Description of External I/O Signals Pin No. Name Description 24 V DC present. When using a contact, open collector (sink type), or PLC (programmable logic controller) as an input signal (e.g., for INT.24V startup or schedule selection), connect pins 1 and 2.
  • Page 40 MIH-200A Pin No. Name Description Flow switch input pin. Opening this pin will result in a flow rate FLOWSWITCH error. COM pin. This pin is internally connected to the GND chassis. Error/caution reset input pin. ERROR Eliminate the cause of error or caution and close this pin to RESET reset the error or caution indication.
  • Page 41 MIH-200A Pin No. Name Description Common pin for output pins. OUT COM This pin is the common pin for the NG, CAUTION, END, OK, READY, STEP END, and WELD SIGNAL pins. Power input pins to drive the solenoid valve. SOL POWER Input 120 V AC or 24 V AC/DC power.

  • Page 42: Connection Of Input Signals

    MIH-200A (3) Connection of Input Signals Connection with equipment having a contact input Connect pins 1 and 2. (Internal) (External) Internal power supply Connection with equipment featuring NPN open collector output (when using internal power supply) Connect pins 1 and 2.
  • Page 43 MIH-200A Connection with equipment featuring PNP current output (when using external power supply) Connect the negative side of an external 24 V DC power supply to pin 2. (External) (Internal) Internal power supply Connection with equipment featuring NPN open collector output (when using external power supply) Connect the positive side of an external 24 V DC power supply to pin 2.

  • Page 44: Basic Operation

    MIH-200A 7. Basic Operation (1) Turn on the welding power. Turn on the welding power. The [WELD POWER] lamp lights; the [READY] lamp blinks for 7 seconds, then goes off. (2) Set the program unit. Call up the MENU screen. If another screen is displayed, press the [MENU] key.

  • Page 45: Timing Chart

    MIH-200A 8. Timing Chart A: DELAY START SET WELD1 WELD2 DOWN1 DOWN2 HOLD WELD SIGNAL Valve output B: END signal output time When OUTPUT MODE(END) is OFF Welding current (Note 1) To stop the sequence during SQZ (possible only when LATCHED or MAINTAINED is selected for START SIG.

  • Page 46: Specifications

    MIH-200A 9. Specifications (1) Specifications *: Selectable for every 255 schedule Welding power 3-phase, 200–240 V AC (50/60 Hz) ±10% 200 A (peak value) Max. output current Duty cycle: 4% (at 40°C of ambient temperature) Number of schedules Control frequency...
  • Page 47 MIH-200A Cooling method Air-cooled (fan motor) Ambient temperature +5 to +40°C Operating Humidity 90% max. (no condensation) environment Altitude 1000 m max. (Note 2) Protection degree IP20 Transportation and Ambient temperature -10 to +55°C storage conditions Humidity 90% max. (no condensation)

  • Page 48: Options (Sold Separately)

    MIH-200A (2) Options (Sold Separately) 1) Input Cables Customer-procured cables must meet the specifications at right. Model No. Length Specifications PK-03300-002 2 m Rated Voltage 300 V AC min. PK-03300-005 5 m Section Area 2 mm min. PK-03300-010 10 m No.

  • Page 49: Duty Cycle Graph

    MIH-200A (3) Duty Cycle Graph Ambient temperature: 40°C Ambient temperature: 30°C 5.4%(200A) 8.3%(150A) 5.6% 13.8%(100A) 13.2% 20%(80A) 38.2% 54.4%(35A) Duty cycle (%) 9. Specifications...

  • Page 50: Schedule Data Table

    MIH-200A (4) Schedule Data Table SCHEDULE Screen, MONITOR SET Screen ○ Note: As needed, copy and use this page. 　　　 SCHEDULE# Item TIME CO TIME (HEAT) TIME CO TIME WELD1 HEAT TIME CO TIME WELD2 HEAT TIME CO TIME DOWN1...
  • Page 51 MIH-200A ○ MONITOR SET Screen CAUTION ITEM CAUTION COUNT CAUTION MODE COUNT MODE Other Screens ○ POWER SUPPLY STATE LCD CONTRAST CONTROL # PROGRAMMED DATE MODE SELECT DELAY START SET START SIG. MODE END SIG. TIME OUT MODE(END) OUT MODE(OK) COMM CONTROL OFF , -->...

  • Page 52: Outline Drawing

    MIH-200A 10. Outline Drawing (Dimensions in mm) INDICATOR WELD POWER READY START WELD TROUBLE POWER TROUBLE RESET WELD ON/OFF PROGRAM RS-232C/485 MONITOR OUTPUT POWER 200V-240V ～ 50/60Hz With terminal covers removed 10. Outline Drawing 10-1...

  • Page 53: Troubleshooting

    MIH-200A 11. Troubleshooting (1) Fault Code List In the event of a problem with the Power Supply, the MA-627A displays the fault code and message. In such cases, read this section carefully, then inspect the equipment and take the necessary countermeasures. If you have any questions, consult us or your distributor.
  • Page 54 MIH-200A Fault Contents Cause Measures code HEAT setting > 10 P/S RATIO Schedule setting E-10 Correct each setting. HEAT setting error < 0.2 P/S RATIO The UP, WELD1, WELD2, DOWN1 and DOWN2 values are all “0.” External emergency stop input Rectify cause of emergency stop, and circuit is open.

  • Page 55: When A Welding Does Not Start Even If The 2Nd Signal Is Input

    MIH-200A (2) When a Welding Does not Start Even if the 2ND Signal is Input When a welding does not start even if the 2ND signal is input, the following causes can be thought.  READY does not light up.
  • Page 56 MIH-200A The next 2ND signal is not received while the monitor data is transferred. Also, on every screen, the data is transferred to the MA-627A from the Power Supply to display the monitor error when the monitor data is beyond/below the upper/lower limit (data communication time Tb2).

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