Amada AH Series User manual

Z07M0875E-07
OPERATION MANUAL
WELDING HEAD
AH Series

AH Series
Thank you for purchasing our Welding Head AH Series.
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. Installation and Connection
(1) Installation ................................................................................... 6
(2) Connection .................................................................................. 7
4. Operating Method
(1) Stroke and Welding Force Adjustments........................................ 8
(2) Adjustment of Cylinder Descending Speed .................................. 9
(3) Lower Electrode Alignment .......................................................... 10
(4) Adjustment of the Timing to Start a Welding Current Flow............ 10
(5) Pressure Diagram........................................................................ 11
(6) Maintenance Management........................................................... 11
5. Product Specifications
(1) Specifications............................................................................... 12
(2) Welding Cable ............................................................................. 13
6. Outline Drawings ............................................................................. 14

-1-
AH Series
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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AH Series
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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AH Series
！
！
！
！
！
！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

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(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.
AH Series
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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AH Series
2. Features
In AH series welding heads, the air cylinder and the pressure follow-up mechanisms are
integrated into signal housing for compact design.
The AH series welding heads offer great quality of welding by improving the accuracy and
reliability, and ease of mounting onto the automatic welding machine.
2. Features

Drill some holes to mount the welding head on the mounting surface of your existing desk,
shelf, or bench as shown below.
Mounting Base Mounting Frame
Note: For installation without a base, the mounting surface must have an enough structural
strength.
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AH Series
3. Installation and Connection
(1) Installation
3. Installation and Connection
ABCDEFGH I J M N
70 180 450 10 160 270 160 145 122 226 For 6-M10 For M10
Center of
electrode

(1) Air Piping
The speed controller with one-touch joint is mounted at the main unit of cylinder. The outer
diameter of urethane tube is φ10.
(2) Connection of the Welding Cable
Connect the bus bar on the rear of the welding head to the welding transformer with a
welding cable of adequate square millimeter.
(3) Connection of the Pressure Signal Cable
Connect the terminal or connector of the pressure signal cable to the welding power supply.
Note: See also the operation manual for the welding power supply.
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AH Series
(2) Connection
3. Installation and Connection

-8-
Home (Released) Touch Press
A = B + C
Full stroke Stroke to touch Stroke to press
AH Series
4. Operating Method
4. Operating Method
(1) Stroke and Welding Force Adjustments
Rod
Stopper spacer
Cylinder rod
Lock nut
Adjustment nut
Scale
Workpiece

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AH Series
4. Operating Method
Referring to the Pressure Diagram, adjust the upper adjustment nut until the desired press
force can be obtained. Depending upon the thickness of the workpiece to be welded, if it is
impossible to have an enough stroke for the head to press the workpiece, adjust the
thickness of the stopper spacer. (The stopper spacer can be disassembled.)
Four stopper spacers are assembled by default.
To add the stopper spacer, purchase the required number of following item (1 piece)
separately.
When changing the thickness of stopper spacer, refer to the table below to change the fixing
bolt.
* M4-35 for the standard 4 pieces is already assembled.
The cylinder descending speed is adjusted by two speed controllers on the side of cylinder.
The speed becomes slow whichever speed controller you turn. The cylinder ascending
speed is adjusted by the upper speed controller.
(2) Adjustment of Cylinder Descending Speed
Item No. Model No.
1035809 0007302
Number of stopper
spacers 12345678
Hexagon bolt M4-10 M4-20 M4-30 M4-35 M4-45 M4-50 M4-60 M4-70

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AH Series
(3) Lower Electrode Alignment
4. Operating Method
The lower electrode holder base can be adjusted horizontally, from front to back and from
side to side.
■Centering Adjustment
Loosen the fixing screws for the X and Y stages.
While applying a pressure, adjust the upper and lower
electrodes for centering.
①~④Fixing Screws
1~4 Jack Screws
■Parallel Alignment
Set the press force to “1” on the stroke scale. Visually center
the upper and lower electrodes and tighten the screws for the
X, Y and θstages. Next, prepare a sheet of white paper and
copy carbon paper. Place them on the lower electrode, and
give a press with the upper electrode. Perform a parallel
adjustment with the jack screws until a satisfactory uniform
stamp is obtained.
(4) Adjustment of the Timing to Start a Welding Current Flow
The timing to start a welding current flow is adjusted by the position of cylinder sensor.
Normally, set the sensor so as to be ON when the stopper spacer reaches the bottom
(constant welding force application types).
Also, tangential welding force application type, which is the welding force is increased while
a welding current flows, can be set by accelerating the timing of sensor ON.
* When using a non-contact two-wire sensor, adjust the position of sensor ON/OFF with a
tester.
Non-parallel Parallel

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AH Series
4. Operating Method
(6) Maintenance Management
This product cannot be disassembled by customers. If abnormal noise is generated
during an up-and-down motion of cylinder or the movement becomes non-smooth,
consult us. For preventing dew condensation in the cylinder, use dry air as much as
possible.
The pressure diagram is provided as a rough guide. For an accurate
pressure measurement, use a pressure gauge.
Cylinder thrust: 1814 [N] at 0.4 MPa of air pressure, 2268 [N] at 0.5 MPa
(5) Pressure Diagram
！CAUTION
AH-100 (200-kg spring spepcification)
AH-100
0
3000
2500
2000
567
Pressure (N)
1500
1000
8910
Stroke
500
01234
* AH-100 (200-kg spring specification) is
a special specification.

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AH Series
5. Product Specifications
(1) Specifications
5. Product Specifications
1Electrode Diameter φ20
2Welding Force 1250 N max., 2150 N max. (200-kg spring specification)
3Max. Stroke 80 mm
4Welding Force Stroke 30 mm max.
5Factor of Spring 41.8 N, 88.2 N max. (200-kg spring specification)
6Throat Depth 120 mm
7Solenoid Valve (24V) Koganei; 300-4LE1-SR-DC24V
8Air Regulator Koganei; FR-300-02
9C.S (non-contact
three-wire type) ZE155B-CDAS
10 Weight 55 kg

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(2) Welding Cable
AH Series
5. Product Specifications

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AH Series
6. Outline Drawings
6. Outline Drawings
20 108 79 89 (34) 270 160
491
760
270 160
450
30 230 119
887 97 8
20
160
180
55
48 32
8
(80)
50
20(39)20
2×2-Rc 1/8
2×2-Rc 1/8
10
O20
O20
(80)
Ascending speed
adjusting knob
Descending speed
adjusting knob
Max. stroke
6-9 DRILL,14 CBORE 8.5 DEEP
φ10
one-touch tube joint
2×φ10.1
Overall
Note: There are screw holes not shown in the figure above, but do not use them since they
are option mounting holes.

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AH Series
6. Outline Drawings
48 32
8
(80)
50
O20
20 89 270 160
2
10 80 80
50
48 ±0.02
(34)
2×2-Rc 1/8 Descending speed
adjusting knob
Ascending speed
adjusting knob
Stroke 80
φ10.1
From rear
2-φ6 H7, 6 DEEP
From rear
6-M8x1.25, 21 DEEP
Cylinder part