Amada Thin-Line TL-080B Series User manual

AA10OM1214700-01
OPERATION MANUAL
WELDHEAD
TL-080B/BF

TL-080B/BF
1
Thank you for purchasing our Weld Head TL-080B/BF.
・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.
Contents
1. Special Precautions ................................................. 1-1 to 1-4
2. System Description.................................................. 2-1 to 2-5
3. Installation ................................................................ 3-1 to 3-11
4. Operating Instructions............................................. 4-1 to 4-7
5. User Maintenance..................................................... 5-1 to 5-3
6. Specifications ........................................................... 6-1 to 6-2
7. Outline and Workbench Drilling.............................. 7-1 to 7-4
8. Metric Screws Location ........................................... 8-1

TL-080B/BF
1. Special Precautions
1-1
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.
Denotes operations and practices that
may result in personal injury or damage
to the equipment if not correctly followed.
Do not touch the inside of the Welding Head unnecessarily
You may receive an electric shock or be burned.
Do not touch the inside of the Welding Head other than for maintenance as
described in the operation manual.
Never disassemble, repair or modify the Welding Head
These actions can cause electric shock and fire. Do not do anything other
than the maintenance described in the operation manual.
Never burn, destroy, cut, crush or chemically decompose the Transformer.
This product incorporates parts containing gallium arsenide (GaAs).
DANGER
！
WARNING
！
CAUTION
！
DANGER
！

TL-080B/BF
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.
Connect the specified cables securely
Cables of insufficient current-carrying capacities and loose connections can
cause fire and electric shock.
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.
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.
When you need any repair or replacement, consult us or your distributor.
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.
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.
Wear protective glasses
If you look at the spatter directly during welding, your eyes may be damaged.
WARNING
！

TL-080B/BF
1. Special Precautions
1-3
Do not splash water on the Welding Head
Water splashed over the electric parts can cause electric shock and
short circuits.
Install the Welding Head on firm, level surface.
If the Welding Head falls or drops, injury may result.
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 Welding Head with a blanket, cloth, etc.
If such a cover is used, it may be heated and burn.
Keep a fire extinguisher nearby.
Keep a fire extinguisher in the welding shop in case of fire.
Maintain and inspect the Welding Head periodically.
Maintain and inspect the Welding Head periodically, and repair any damage
nearby before starting operation.
Do not use this Welding Head for purposes other than welding
Use of this Welding Head in a manner other than specified can cause electric
shock and fire.
CAUTION
！

TL-080B/BF
1. Special Precautions
1-4
(2) Precautions for Handling
■Install this Welding Head on a firm, level, horizontal surface. If it is inclined,
malfunction may result.
■Do not install this Welding Head in the following:
・Damp places where humidity is 90% or higher,
・Dusty places,
・Places where chemicals are handled,
・Places near a high-frequency noise source,
・Hot or cold places where temperatures are above 40C or below 5C, and
・Places where water will be condensed.
■ Clean the outside of the Welding Head 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 Welding Head.
■ Do not put anything other than a workpiece, e.g., a tool, a screw, etc., between
the electrodes. It can cause serious trouble.
■Do not put a screw, a coin, etc., in the Welding Head, since they can cause a
malfunction.
■Operate the Welding Head according to the method described in this operation
manual.
(3) On Disposal
This product incorporates parts containing gallium arsenide (GaAs). At the time of
disposal, separate it from general industrial waste or domestic waste and carry out
the disposal in accordance with applicable laws and regulations.

TL-080B/BF
2. System Description
2-1
2. System Description
(1) Features
Overview
This manual is organized to assist you in getting productive quickly with your
TL-080B/BF.
TL-080B/BF come in different sizes and configurations and may be installed on
our mounting hardware, custom mounting posts, or installed directly on your
equipment using the two tapped holes on the rear of the weld head. Some heads
are manually-actuated, others are air-actuated.
Mounting templates and all necessary installation hardware are shipped with each
weld head.
TL-080B/BF are precision, low inertia, force-fired Weld Heads with a narrow
vertical profile. The 1-3/4 inch (4.5 cm) width, 1 in. (2.5 cm) stroke, 20 pound (89
N) maximum force, and throat depth allow their use in a wide variety of precision
resistance welding applications. Offset electrode holder is available. The
dimensions of the mounting post and the main shaft have been selected to ensure
that the electrodes do not "wipe" more than 0.003 in. (0.076 mm) on the 20 lb. (89
N) heads. This is an important consideration in critical welding applications such
as hermetic seals and pressure transducers.
TL-080B/BF is a "production line" head with a bearing life designed for a minimum
of 20 million operations. Our Weld Heads excel at precisely placing consistent,
high quality welds. Their low inertia, lightweight design assures fast dynamic
response, allowing the electrodes to follow the minute expansion and contraction
of the weld joint as it heats and cools during the welding cycle. A differential
motion Force-Firing System initiates the power source at the precise moment the
Preset Firing Force is applied to the workpieces. Linear ball bearing bushings and
an oversized, anti-rotational bearing system provide true, vertical in-line electrode
motion, assuring smooth vertical travel of the upper electrode arm. This system
minimizes the wiping action of the electrodes, even at maximum force settings.
Preset Firing Force
Firing force is continuously adjustable from 0.5 lbs (2.2 N) to 20 lbs. (89 N). An
adjustable Tare Spring compensates for the weight of the electrode holders. The
Firing Force Adjustment Cam easily adjusts the sensitivity of the Firing Force
Switch.
Up And Down Stops
TL-080B/BF have adjustable Upstops and Downstops. The Downstop can be used
to limit excessive downward travel. The Upstop controls the stroke, and
consequently, the travel time of the head. In automated machine applications,
using a stroke of less than 1/8 in. (3.2 mm) may significantly reduce bearing life.

TL-080B/BF
2. System Description
2-2
Electrodes
TL-080B/BF accept a wide variety of standard and special purpose electrodes.
There are models available, which accept 1/8 in. (3.2 mm), Unibond®, and Unitip®
Electrodes. The optional Model ETB4 Table Electrode fits TL-80.
Insulation
The Terminal Block, Flexible Copper Strap, and Upper Electrode Assembly are
electrically insulated from the frame of the Weld Head. The Frame, Support Post,
and Support Base are grounded to the bench top.
Welding Cables
#2 Welding Cables is provided to connect TL-080B/BF Heads to the power source.
Our Heads deliver maximum performance when used with the appropriate our
power sources.
Footpedal Actuation
TL-080B/BF Weld Heads, model number suffix "F," are footpedal (manually)
actuated. The Model CP Cable Pedal is a treadle-type cable actuator providing an
approximate 3 to 1 mechanical advantage. This pedal is used with TL-80BF.
Air Actuation
TL-80B is equipped with a top mounted Air Cylinder with two Flow Controls, one
or two Air Pressure Regulators, and a four-way Solenoid, making it easy to
incorporate these weld heads into automated welding systems. The Air Solenoid
Valve is available with 115 V AC ratings. Two Flow Controls are used to adjust the
up and down speed of the upper electrode. The Air Solenoid Valve can be
energized by most of our power sources, or by a Model FSAC Footswitch. The
Footswitch can be a single or two level type, dependent upon the power supply
and the user's preference. We suggest that lubricators not be used in "clean"
environments. However, the user will then be required to periodically put a few
drops of oil in the cylinder. Some users use lubricators, some do not.

TL-080B/BF
2. System Description
2-3
(2) System Components
Typical TL-080 Series Weld Head
These are conventional, 20 lb. (89 N) capacity welding heads with offset, opposed
electrodes. Both the pedestal mounting (post) and lower electrode assembly can
be removed and replaced by custom fixtures.
All air actuated heads in the TL-080B/BF are available with 115 V AC, 50/60 Hz.
(TL-80B-00) solenoids. TL-80 is supplied with 3 mm diameter electrodes.

TL-080B/BF
2. System Description
2-4
(3) Welding Capabilities
Series Welding
In series welding applications, both electrodes contact
the same surface of each workpiece. The weld current
flows from one electrode through the workpiece to the
other electrode. This technique is used to weld
workpieces which have only one surface accessible.
The work surface, or a user supplied fixture, acts as a
support for the workpieces in series welding. If the Table
is insulated from the workpieces, there is no possibility
of shunting current away from the (-) electrode.
Step Welding
In step welding, the size of the weld and the surface
marking is frequently controlled by the diameter of the
face of each electrode. If the (+) Electrode is significantly
larger than the (-) Electrode the lower workpiece will not
have any marking and the weld will be under the (-)
Electrode.
The Table Electrode, or a user supplied fixture, acts as a
support for the workpieces in step welding.
If the Table is insulated from the workpieces, there is no
possibility of shunting current away from the (-)
electrode.

TL-080B/BF
2. System Description
2-5
(4) Operating Controls
TL-80 Series Air Actuation Specifications
Input Air Pressure – Nominal / Maximum 65/100 psi (448/690 kPa)
Regulator Output – Maximum 65 psi (448 kPa)
Cycle Rate (full strokes/sec)
at Min. Force
at greater than 20% of Rated Force
1.0
2.5
Solenoid Valve Voltage 115 V AC
Air Cylinder Inside Diameter 0.75 in. (1.9 cm)
Air Cylinders
All air models are supplied with one air cylinder, one air pressure gauge, one air
pressure regulator, and two flow controls. The Air Solenoid, which controls the
direction of air flow to the Air Cylinder, is available with 115 V AC 50/60 Hz. ratings.
The Flow Controls allow independent adjustment of the up and downspeed of the
upper electrode. The Solenoid and Regulator Assembly mounts on the spine of
the Weld Head.
Footswitches
A one-level Footswitch actuates the head, and the Firing Switch in the head
initiates the welding sequence. The first level of a two-level Footswitch actuates
the head. The second level and the Force Firing Switch initiate the welding
sequence. A two-level Footswitch is recommended when the operator is required
to position the workpieces. It also allows the operator to actuate an air head
without initiating the weld cycle since both the Firing Switch and the second level
of the Footswitch must close before the weld portion of the sequence can begin.

TL-080B/BF
3. Installation
3-1
3. Installation
(1) Introduction
Overview
Before you start installation, become familiar with the specific model you are using.
As shown below, TL-080B/BF Weld heads come in different sizes and
configurations which require different mounting baseplates, mounting posts, and
installation hardware.
Installation procedures depend on the size and configuration of a specific model,
and whether the weld head, mounting post, and baseplate were shipped as
separate pieces requiring assembly or shipped from the factory fully assembled.
Some manually-actuated heads are shipped with foot pedals attached, others are
not. Some air-actuated heads are shipped with the air head attached, others are
not.
Despite differences from model-to-model, the installation principle is the same for
each head:
If not already attached, the weld head mounting post is attached to the
baseplate.
The weld head mounting baseplate is bolted securely to a workbench.
The weld head is attached to the mounting post.
If necessary, the air head (if used) and foot pedal (if used) are installed.
Electrodes and weld cables are installed on the weld head.
Mounting Posts
TL-080B/BF weld heads may be purchased with or without mounting hardware. we
provide three types of mounting posts (and corresponding installation hardware)
designed for different models:
Mounting Tube
Smaller TL-080B/BF Weld Heads
are installed on short mounting
tubes. These are factory-installed
and do not require any assembly
by the user.
Mounting tubes come in fixed
lengths, the height of the weld
head is not adjustable.

TL-080B/BF
3. Installation
3-2
Dual-Post
This consists of two parallel posts connected at the top and bottom, leaving an
open slot for the full length of the post. The mounting screws are installed from the
back of the post and screwed directly into the weld head. The mounting screws
can be loosened from the back of the post for adjusting the height of the weld
head.
Channeled Post
This is an extruded aluminum post with channels on the front and back. By
inserting T-Nuts into the channels, mounting plates can be screwed onto the front
(for weld head), back (for air head), or both sides of the post (only the weld head is
shown). This installation allows you to adjust the height of the weld head and air
head separately.

TL-080B/BF
3. Installation
3-3
(2) Weld Head Installation
Overview
First, this section will give "Typical Installation" instructions that are common to all
TL-080B/BF weld heads. Then, additional instructions for installing specific weld
head models are listed by model number. Before you start installation:
Make sure you are familiar with the mounting configurations and installation
hardware described and illustrated in this section.
Read the Typical Installation instructions and the instructions for the specific
weld head you want to install.
Make sure you have all necessary parts and mounting hardware. Use the
shipping list as a reference. Verify that the paper mounting template
corresponds to the model number of the weld head. If you do not have the
correct template, contact us at the address shown in the rear of the manual.
Typical Installation
NOTE: Allow sufficient working space, usually 8–10 in. (20.32–25.4 cm), between
the front edge of the bench and the mounting base. This allows the operator to use
the bench as a support when positioning the workpiece.
○
1Place the mounting template in the
desired location on the workbench
and tape it in place.
○
2Drill the mounting holes as shown
on the template.
○
3If necessary, install the weld head
mounting post to the baseplate.
○
4If not already attached, install the weld head mounting post to the weld head
baseplate.
○
5Screw the weld head mounting baseplate to the workbench.

TL-080B/BF
3. Installation
3-4
○
6-A Install the weld head on the Dual-Post.
i) Install the mounting screws and washers onto the mounting backplate.
ii) Place the weld head on the front of the mounting post, then insert the
mounting screws through the slot in the back of the mounting post and screw
them into the weld head.
iii) Adjust the weld head to the desired height, then tighten the mounting
screws.

TL-080B/BF
3. Installation
3-5
○
6-B Install the weld head on the Channeled-Post.
i) Install the weld head mounting plate onto the weld head using the screws as
shown.
ii) Install the screws, washers, and T-nuts into the weld head mounting plate as
shown.
iii) If necessary, remove the end cap from the mounting post to expose the
channels in the mounting post.
iv) Raise the weld head and mounting plate above the mounting post, insert the
bottom T-nut into the front channel of the mounting post, and slowly lower
the weld head until you can insert the top T-nut into the channel. Slide the
weld head to the desired height, then tighten the mounting screws.
v) If you are using an air head, install it on the rear of the mounting post
following the procedures in Steps i through iv.

TL-080B/BF
3. Installation
3-6
TF-080BF Model CP Footpedal Installation
○
1Push down on top of weld
head to extend end of pullrod.
○
2Secure Electrode Holders
with string to hold in place.
○
3Position head (and optional
baseplate) on bench as
shown.
○
4Route footpedal cable up
through bench (and
baseplate).
○
5Attach cable from footpedal to pullrod (larger hole up) using small screw, which
is supplied.
○
6Untie string and release the electrode holders.
○
7Depress pedal, and push cable sheath into pullrod hole until it is flush with
base.
○
8Secure sheath with set-screw as illustrated.

TL-080B/BF
3. Installation
3-7
○
9Adjust footpedal so that the electrode holders move the distance required by
the application.
○
10 Adjust the angle of the treadle so that it provides the electrode stroke necessary
for the application and is comfortable for the operator.

TL-080B/BF
3. Installation
3-8
TL-080B Air Head Installation
○
1Insert a 0.25 in. (6.35 mm)
outside diameter plastic hose,
with a rated burst pressure of
250 psi (1,724 kPa), into the
Air Input of the air solenoid
valve assembly, as illustrated.
The air input line uses a
"quick release" fitting so
special tools are not needed.
Simply push the hose into the
"quick release" fitting as far as
it will go.
○
2Connect the other end to a
properly filtered air supply
(100 psi/690 kPa maximum).
Use the shortest air lines
possible to obtain the fastest
mechanical response. The
inside diameter of the main air
supply line must be at least
0.5 in. (13 mm) to allow
sufficient air flow. The air
supply should be filtered to
ensure the maximum life of
the air cylinder, flow controls,
and regulator.
Dual-Air Installation
Single-Air
Itllti

TL-080B/BF
3. Installation
3-9
NOTES:
We suggest that in-line lubricators only be used in automated applications,
since excess oil can blow-by worn seals in the Air Cylinder and be deposited on
the workpieces.
If an in-line lubricator is not used, then the air line should be removed from the
top of the cylinder(s) once every 1 million cycles, and several drops of a light
machine oil should be squirted into the top of the cylinder(s).
To facilitate dressing the electrodes, reduce the air pressure to the top of the
cylinder. As an alternative to changing the setting of the Top Air Pressure
Regulator, a customer supplied bleeder valve connected to the output of the
Top Air Pressure Regulator can be used to reduce the air pressure.
○
3Connect the power cord from the solenoid air valve as specified in the Users'
Manual for the appropriate power supply or control.
○
4Install the system in accordance with established safety practices and
standards. Anti-Tiedown Palm Buttons are not usually required if the electrode
spacing will not allow the operator's fingers to fit between them.