Amada ZH-50 User manual

Z06M0871E-06
OPERATION MANUAL
AIR DRIVING UNIT FOR PRESSURE
FOLLOW-UP MECHANISM ELEMENT
ZH-50

ZH-50
Thank you for purchasing our Air Driving Unit for Pressure Follow-Up Mechanism Element
ZH-50.
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 Precautions
(1) Safety Precautions....................................................................... 1
(2) Precautions for Handling.............................................................. 4
2. Features ........................................................................................... 5
3. Name and Functions of Each Section
(1) Explanation of Each Part ............................................................. 6
(2) Follow-Up Mechanism Mounting Plate......................................... 8
4. Installation and Connection
(1) Installation ................................................................................... 9
(2) Connection .................................................................................. 9
(3) Terminal Block Connection Diagram ............................................ 10
5. Operating Method
(1) Introduction.................................................................................. 11
(2) Stroke Adjusting Method .............................................................. 11
(3) Electrode Projection Allowance, Stroke, and Pressure Allowance 13
(4) Service Air Pressure .................................................................... 14
(5) Maintenance Management........................................................... 14
6. Product Specifications
(1) Specifications............................................................................... 15
(2) Component List............................................................................ 15
(3) Functional Options....................................................................... 16
(4) Welding Cable ............................................................................. 17
7. Outline Drawings ............................................................................. 18

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ZH-50
1. Special Precautions
1. Special Precautions
Before using, be sure to read this
operation manual to operate this
machine correctly. This operation
manual may include some items that do
not correspond to your use. However,
you are kindly requested to read only
the items related to your use.
(1) Safety Precautions
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.
！DANGER
Denotes operations and practices that
may imminently result in serious injury
or loss of life if not correctly followed.
！WARNING
Denotes operations and practices that
may result in serious injury or loss of
life if not correctly followed.
Denotes operations and practices
that may result in personal injury or
damage to the equipment if not
correctly followed.
！CAUTION
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 represents
the contents that give
notice of DANGER,
WARNING, or
CAUTION to the
operator.

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ZH-50
Otherwise, an electric shock or injury will occur. When
internal inspection or repair is required, make contact with us.
Do not disassemble, repair, or modify this machine in
any case.
！DANGER
！
！
！
！WARNING
When welding, keep your fingers and hands away from
the electrodes.
Do not put your hands between the electrodes.
The welded part of a workpiece, electrodes and electrode
holder are very hot. Do not touch them; otherwise you may
be burnt.
Do not touch any welded part or electrodes during
welding and just after welding finished.
Application of a voltage out of the specified range can
cause fire and electric shock.
Apply the specified power supply.
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.
Stop the operation if any trouble occurs.
The welding machine generates a magnetic field and has
effects on the operation of the pacemaker while it is turned on.
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.
Persons with pacemakers must stay clear of the welding
machine.
If you look at the surface flash and expulsion directly
during welding, your eyes may be damaged.
Wear protective glasses.
1. Special Precautions

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ZH-50
！
！
！
！
！
！CAUTION
Water splashed over the electric parts can cause electric
shock and short circuits.
Do not splash water on the product.
Do not bend, pull, or pinch any cable forcibly. If the cable is
damaged, it will cause an electric shock, short circuit, or firing.
Do not give excessive force to connecting cables.
Cables of insufficient current-carrying capacities and loose
connections can cause fire and electric shock.
If the welding cable is not connected completely, a spark will occur.
Connect the specified cables securely.
If the product falls or drops, injury may result.
Install the product on firm, level surface.
Do not put any combustible material around the welder. Surface
flash and expulsion can ignite combustible matter.
Keep combustible matter away from the welding machine.
If such a cover is used, it may be overheated and burn.
Do not cover the product with a blanket, cloth, etc.
Keep a fire extinguisher in the welding shop in case of fire.
Keep a fire extinguisher nearby.
Maintain and inspect the product periodically, and repair any
damage near by before starting operation. Tighten the welding
cable connecting section periodically.
Maintain and inspect the product periodically.
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.
Protective gear must be worn.
Use of this product in a manner other than specified can cause
electric shock and fire.
Do not use this product for purposes other than welding.
After a recovery from the outage, the machine may be started or
powered suddenly, resulting in an injury.
When outage occurs, be sure to turn off the power supply.
1. Special Precautions

-4-
(2) Precautions for Handling
Do not install this product in the following:
-Damp places where humidity is higher than 90%,
- Dusty places,
- Places where chemicals are handled,
- Places where corrosive gas is generated,
- Places near a high noise source,
- Hot or cold places where temperatures are above 40C or below 5C, and
- Areas where water will be condensed.
Set the cylinder cover on when operating the cylinder to avoid fingers to be
caught in the cylinder stopper.
In this machine, the linear guide (linear bushing) is used vertically. Accordingly,
grease or oil may drip, but this is not an accident. In particular, when a new
machine is used, lots of grease of oil will drip. In this case, wipe it off properly
during machine operation. If grease or oil sticks on the weldment, this may cause
a defect.
ZH-50
Clean the outside of the product 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 product.
Between electrodes, do not put such a material other than the weldment as tool
and screw. Otherwise, the welding electrode will be damaged or a spark will
occur. When performing maintenance for this machine as a result of replacement
of electrodes, turn off the power supplies of the welder and control device in
advance.
Do not put a screw, a coin, etc., in the product, since they can cause a
malfunction.
Be sure to install the screws, which were removed for maintenance of this
machine, in their original positions. If they are installed in different positions, this
machine will be damaged or go wrong.
Operate the product according to the method described in this operation manual.
1. Special Precautions

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ZH-50
2. Features
All-round unit suitable for diversified production workshops
This model is applicable to your various production environments in the range of
manual operation machine to labor-saving automatic machine.
Applicable to various welding by combining with pressure
follow-up mechanism
By combining with our pressure follow-up mechanism, this model is applicable to
various welding method; direct welding, indirect welding, or series welding.
Most suitable for precision welding
The model is provided with a wide linear guide and adopts an integrated frame
structure, thereby attaining high accuracy and high rigidity.
Lots of options applicable to any shape of weldment
- Combination with our pressure follow-up mechanism
The customer can select an optimum model for your welding in the abundant lineup.
- Options/accessories
The machine can be combined with the precision lower holder (selectable electrode
diameter) for direct welding and the welding cable (ounce copper plate) for high using
ratio.
- Others
A preset holder to simplify projection allowance at replacement of electrodes and base-
less specifications for mounting an automatic machine can be adopted for the machine.
2. Features

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ZH-50
3. Name and Functions of Each Section
(1) Explanation of Each Part
3. Name and Functions of Each Section
1
2
3
9
7
6
10
8
5
4
11
12

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(1) Cylinder stopper fixing nut
Tighten this nut to fix the cylinder stopper after the cylinder stroke adjustment. (Use a
spanner with 32-mm across flats.)
CAUTION Be sure to fix the cylinder stopper during use. Otherwise, the machine
will be damaged.
(2) Cylinder stopper
Adjust the cylinder stroke by moving up and down this part. Set this in consideration
of the pressure allowance. (Adjusting range: 0 to 50 mm)
(3) Safety cover
This cover avoids fingers to be caught in the cylinder stopper.
CAUTION Be sure to mount this cover during operation. Otherwise, an injury will
occur.
(4), (5) Speed controller
This speed controller is used to adjust the operation speed. (4) is used when moving
up and (5) is when moving down. (It has been adjusted before shipment. Be sure to
lock it after re-adjustment.)
CAUTION Avoid excessively fast stroke. Otherwise, screws will be loosened or
parts will be damaged by impact and vibration.
(6) Regulator
This regulator is used to adjust the pressure of the compression air to be supplied to
cylinder. (Adjusting range: 0.3 to 0.7 MPa)
(7) Air connection joint
Connect the air-supplying hose of the primary side. (Refer to page 9.)
(8) Follow-up mechanism mounting plate
This part is used to mount our V-type follow-up mechanism. (Refer to page 8.)
(9) Terminal block
Connect signal lines from the welding power supply or other devices such as
pressure signal, SV signal and cylinder sensor signal. (Refer to page 10.)
(10) M6 screw to supply power (from the electrode holder side)
Connect the welding cable from the electrode holder when mounting our follow-up
mechanism.
(11) M6 screw to supply power (from the transformer or power supply side)
Connect the welding cable from the welding transformer or welding power supply.
(12) Base
This base is used to fix this machine or mount our options. (Refer to page 9.)
！
！
ZH-50
3. Name and Functions of Each Section
！

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This part is used to various mount follow-up mechanisms.
Model-corresponding table
Part name Supported follow-up mechanism Remarks
V-type mounting plate VP-M
VPW-M mounting plate VP(D)W-M
VTW-M mounting plate VT(D)W-M
(2) Follow-Up Mechanism Mounting Plate
For V-type (standard) : t25
For VTW-M : t20
For VPW-M : t20
ZH-50
3. Name and Functions of Each Section
CAP spot facing, 5.5 deep
CAP spot facing, 5.5 deep
CAP spot facing, 5.5 deep
12 deep (min.)
10 deep (min.)
12 deep (min.)
10 deep
(Can be through holes.)
(Can be through holes.)
10 deep
(Can be through holes.)
12 deep (min.)
(Can be through holes.)

-9-
When fixing the welding head (frame), perform
drilling by referring to the following drawings.
ZH-50
4. Installation and Connection
(1) Installation
(2) Connection
4. Installation and Connection
Example fixing of
standard base
Example direct
fixing of frame
Fix this machine on a firm and flat
surface for use. If not fixed, an injury
may result due to falling or the welding
quality may be lowered.
！CAUTION
Primary-side
air piping
Secondary-side
welding cable wiring Signal line wiring
Connect the welding
cable.
Connect signal cables.
(Refer to page 10.)
Connect the air tube
with external diameter
of 6. Use PT1/8 at
replacement of joint.
CAP spot facing, 6.5 deep
10 deep (min.)
CAP spot facing, 1 deep

-10-
Precautions on connection
- For connection to a terminal block, we recommend you to use our dedicated cable
(between the power supply and ZH).
- For wiring to another control device (other than our product), check the specifications of
the sensor, solenoid valve, etc. and then perform wiring operations.
！
ZH-50
(3) Terminal Block Connection Diagram
4. Installation and Connection
Standard wiring for mounting V-type follow-up mechanism (5-terminal)
1(+5～24V)
2 (LS)
3(COM)
4 (SV+)
5 (SV-)
12345
1: For power supply for the pressure sensor (+5 to 24 V
DC). * Note 1: For connection of the micro switch
specification
2: For connecting the pressure signal line.
3: For connecting the COM line for the pressure sensor.
4: For connecting the head driving SV signal line. (+24
V DC)
5: For connecting the head driving SV signal line. (-24
V DC)
6: For power supply for the cylinder sensor (+24 V DC).
7: For connecting the cylinder sensor signal line. (Up
end side)
8: For connecting the COM line for the cylinder sensor.
(Up end side)
9: For connecting the cylinder sensor signal line.
(Down end side)
10: For connecting the COM line for the cylinder sensor.
(Down end side)
＋24V
LS
COM
LS
COM
678910
1(+5 - 24V)
2 (LS)
3(COM)
4 (SV+)
5 (SV-)
12345
Note1:
When you select a micro switch in the
pressure sensor specification of our follow-up
mechanism, do not connect any line to terminal
1.
Cylinder sensor additional wiring (10-terminal)

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We recommend you to use this machine (ZH-50) in combination with our pressure follow-up
mechanism as a set.
To obtain the performance of the pressure follow-up mechanism fully, read the "Operation
manual for the pressure follow-up mechanism element" attached to the pressure follow-up
mechanism together with this operation manual.
ZH-50
5. Operating Method
(1) Introduction
5. Operating Method
(2) Stroke Adjusting Method
(1) Remove the safety cover.
(2) Adjust the depressurization knob of
the regulator to make the air
pressure 0 MPa.
(3) Place a weldment (hereinafter
referred to as workpiece) or
something of the same thickness
(gauge, etc.) between electrodes.
(4) Lower the pressure follow-up
mechanism by self-weight and
make the end of upper electrode
contact with the welded surface of
workpiece. (Refer to Figure 1.)
CAUTION
Take care not to apply pressure at
this time.
！
Figure 1
No pressure applied
Workpiece or
gauge of the
same thickness,
etc.

-12-
(5) In a state of (4), adjust the clearance
between the cylinder end face and the
cylinder stopper to 2.5±0.5 mm and fix
it with the cylinder stopper.
Inserting a 2.5-mm gauge etc. in
thickness into the clearance makes
operations easy. (Refer to Figure 2.)
By this adjustment, a proper pressure
allowance (page 13) can be obtained.
(Refer to Figure 3.)
(6) Remove the workpiece or something of
the same thickness (gauge, etc.), and
then adjust the pressure of the
regulator to the specified pressure.
(Refer to page 14.)
(7) After this adjustment, be sure to mount
the safety cover.
No pressure applied
Workpiece or
gauge of the
same thickness,
etc.
Figure 2
Cylinder
stopper
2.5-mm clearance
2.5-mm
gauge,
etc.
Refer to Figure 3.
Cylinder
end face
Figure 3
Ｘ－2.5
Ｘ
Pressure
spring
Before the electrode and
workpiece are brought into
contact, the pressure shaft
is in the full stretched
status.
When the electrode and
workpiece are brought into
contact, the pressure shaft is
pushed upward to bend the
spring, thereby giving
pressure to the workpiece.
Workpiece non-contacted
(no pressure applied)
Workpiece contacted
(pressure applied)
ZH-50
5. Operating Method

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ZH-50
(3) Electrode Projection Allowance, Stroke, and Pressure Allowance
Electrode projection allowance
Determine the electrode projection allowance out of the electrode holder by taking
interference with the workpiece, operational convenience, etc. into consideration.
When a high-resistance electrode of tungsten or molybdenum type is used, the heat
generation amount at the end is changed by electrode projection allowance. Be careful
about projection allowance management at replacement of electrode.
Head stroke
Determine the head up/down stroke according to the pressure allowance of the pressure
follow-up mechanism. (Refer to page 12.)
Make sure that the head stroke does not cause interference with the workpiece (that the
workpiece can be taken out) when the head goes up.
Pressure allowance
The deflection amount of the pressure spring in our follow-up mechanism (V-type series)
is called "pressure allowance.“
Our follow-up mechanism is designed so as to obtain proper pressure when the spring is
bent 2.5 mm. (Refer to Figure 3 on page 12.)
Operate the machine in the pressure allowance range of 2.0 to 3.0 mm.
When the pressure allowance goes below 2.0 mm, a stable pressure signal may not be
obtained or pressure shortage may occur.
When the pressure allowance exceeds 4.0 mm, the internal mechanism of the pressure
follow-up mechanism may be damaged.
Operation management
Normally, determine the electrode projection allowance first, and then adjust the head
stroke. At replacement of electrode after the above adjustment, adjust the electrode
projection allowance again to the value same as that before replacement.
To perform this electrode projection allowance management, an electrode projection
allowance gauge or a removable type holder (preset holder) for the electrode mounting
section is used. These methods are very effective.
It is an important point for pressure management to keep the electrode allowance on a
certain level at precision stop welding. Accordingly, we recommend you to prepare a
work process manual conforming to your management rules.
！CAUTION
<Example of general electrode projection allowance>
When using a copper type electrode with an electrode diameter of 5 5 to 30 mm
！CAUTION
！CAUTION
5. Operating Method

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ZH-50
5. Operating Method
(4) Service Air Pressure
(5) Maintenance Management
It is recommended that the service air pressure is twice or more than use welding
force (Note 1) which can be obtained from the cylinder logic thrust table shown
below. Use the supply pressure in the range of 0.3 to 0.7 MPa.
Lubricate to bearing according to the conditions, in order to demonstrate the best
ability of the machine.
●Recommended lubricant agent
Grease: Lithium type (JIS 2)
Urea type (JIS 2)
Oil: Commingled sliding face or turbine (ISO VG 32 to 68)
Tube
inner dia.
(mm)
Rod dia.
(mm)
Pressure-
receiving
area
(mm2)
Supply pressure (MPa)
0.3 0.4 0.5 0.6 0.7
50 20 1649.3 495 660 825 990 1155
Unit: N
* 1 N ≒0.102 kgf 1 MPa ≒10.2 kgf/cm2
Note 1: “Use welding force” means the force required to welding.
The attached solenoid may not work with 0.2 MPa or less.
！CAUTION
●Cylinder logic thrust table

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ZH-50
6. Product Specifications
(1) Specifications
6. Product Specifications
BD7-MB5IDEC
Rail-type terminal block
(5 terminals)
6
SYJ7120-5L-01SMCSolenoid valve (24 V)5
AW20-01BG-ASMCFilter regulator4
JA25-10-150SMCFloating joint3
CDQ2WB50-50DZSMCThin cylinder2
2SRS12WMUU+190LMTHKLM guide1
Model, part, or drawing number
Manufac-
turer
Part nameNo.
Standard component list
(2) Component List
BD7-MB10IDEC
Rail-type terminal block
(10 terminals)
2
D-M9NVLSMC
Non-contact automatic
switch (3-line type)
1
Optional component list
1 Driving system Air cylinder type
2 Use fluid Dry air (0.2 to 0.7 MPa)
3 Use thrust 495 N (0.3 MPa) to 1155 N (0.7 MPa)
4 Use speed 50 to 200 mm/s
5 Cylinder stroke 0 to 50 mm (excluding pressure allowance)
6Supported follow-up
mechanism VP-M, VP(D)W-M, VT(D)W-M
7 Solenoid valve 5 ports and 2 position valves (single solenoid valve)
8 Weight 15 kg

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Follow-up
mechanism
mounting plate
(Refer to optional
mounting plates
on page 8.)
Used when a mounting plate other than the V-type
mounting plate (standard) is selected.
Raising plate
(1 set (2 pcs.))
Spacer between ZH-50 and base plate.
The body can be raised 50 mm.
XYholder
(precision type
lower electrode
holder with a
water cooling
hole)
(Refer to Fig. 1.)
Like the slide holder, this holder is used at direct
welding.
The XY(vertical/horizontal/inclination) directions
can be finely adjusted. As an electrode diameter,
5, 8or12 can be selected.
Laminated copper
foil specification
(Refer to Fig. 2.)
This specification is for a case where a laminated
copper foil for a high using ratio is installed.
This specification must be specially ordered.
Consult with us when required.
Welding cable on
special order
(Refer to Fig. 3.)
A cable on special order can be manufactured
according to the customer's use.
You are requested to give us instructions about
cable specifications (thickness sq, length,
insulation specification, and terminal hole
diameter) in the table shown on page 17.
Fig. 2
Fig. 3
Fig. 1
(3) Functional Options
ZH-50
6. Product Specifications

-17-
(4) Welding Cable
ZH-50
6. Product Specifications

-18-
With VP-M
ZH-50
Follow-up mechanism
mounting plate
(standard)
ZH-50
7. Outline Drawings
7. Outline Drawings
CAP spot facing, 6.5 deep
polyurethane tube
(for connection)
CAP spot facing, 6.5 deep
2 x M6 (for power supply)
(to electrode holder)
M6 (for power supply)
2 x M6 (for power supply)
(from welder)
10 deep