Amada TL-180B User manual

AA10OM1214704-01
OPERATION MANUAL
WELDHEAD
TL-180B

TL-180B
1
Thank you for purchasing our Weld Head TL-180B.
・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 2-6
3. Installation ................................................................ 3-1 to 3-9
4. Operating Instructions............................................. 4-1 to 4-5
5. User Maintenance..................................................... 5-1 to 5-2
6. Specifications ........................................................... 6-1
7. Outline and Workbench Drilling.............................. 7-1 to 7-2
8. Metric Screws Location ........................................... 8-1

TL-180B
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.
DANGER
！
WARNING
！
CAUTION
！
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
！

TL-180B
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-180B
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 overheated 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-180B
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 higher than 90%,
・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 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-180B
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-180B Weld Head.
Our TL-180B Weld Heads are production line heads having a narrow vertical
profile. They are characterized by low inertia, force fired operation. Their primary
operational features allow them to be used in a wide variety of precision resistance
welding applications.
1.75 inch (4.44 cm) width (actual head module)
1.25 inch (3.17 cm) stroke
5 to 100 pound (22.2 to 445 N) force range
6.031 to 10.125 inch (15.32 to 25.72) throat depth
Bearing life is designed for a minimum of 20 million operations when the head is
used according to specifications.
The design of the aluminum extrusion mounting system and main shaft ensures
that the offset electrodes do not slide from side to side more than 0.015 inch
(0.381 mm) at 100 pounds (445 N). The four mounting holes on the head spine
allow you to easily incorporate the head into your custom welding machines. In
addition, you can modify the aluminum extrusion used for the base of the head to
accommodate your custom fixtures and tooling.
Precision Welding The weld heads excel in their ability to deliver repeatable weld
force and electrode placement on your parts. The low inertia, lightweight design
ensures fast dynamic response. This allows the top electrode to follow the minute
expansion and contraction of the weld joint as it heats and cools. A "differential
motion" force-firing system triggers the weld energy power source at the precise
moment when the electrodes reach the preset firing force applied on the
workpieces.
Rugged construction, linear ball bearing bushings, and an over-sized anti-rotation
system provide perfect in-line electrode travel, which assures smooth vertical
travel of the upper electrode arm. This system minimizes the "wiping" (side-to-side
sliding) action of the electrodes during welding, even at maximum force settings.
Weld Force
The weld force is continuously adjustable from a minimum of 5 pounds (22.2 N) to
a maximum of 100 pounds (445 N). Settings are quickly reproduced by using the
force adjustment knob and easy-to-read visual scale. An adjustable tare spring
allows you to compensate for the weight of non-standard electrode holders. An
adjustment screw allows you to adjust the sensitivity of the force-firing switch.
Weld force is applied via an air cylinder.
Adjustable Stops
TL-180B Weld Heads have adjustable upstops and downstops. You can use the
downstop to limit excessive over-travel. You can use the upstop to reduce the
stroke and, therefore, the travel time of the head. This is a particularly useful
feature when using the head in an automated system.

TL-180B
2. System Description
2-2
Electrode Holders
Electrode holders use 0.25 inch diameter, ES0800 Series Electrodes.
Welding Cables
#2/0 Welding Cables is provided to connect TL-180B Heads to the power source.
Our Heads deliver maximum performance when used with the appropriate our
power sources.
Air Actuation
TL-180B heads come with factory-installed air actuation kits. Air actuation
facilitates incorporation of these heads into automated welding systems. The
speed of the air-actuated system is limited by the speed at which the upper
electrode can move without damaging both the electrode or work pieces as a
result of the impact. A repetition rate of one weld per second is possible.
For Air Head instructions, see the separate Operator Manual supplied with the Air
Kit installed on the weld head.

TL-180B
2. System Description
2-3
(2) System Components
TL-180B Weld Head
TL-180B is an air-actuated head. The actuation source is the top-mounted,
1.5-inch (3.81 cm) diameter air cylinder. This model provides throat depth of
10.125 inches (25.72 cm).

TL-180B
2. System Description
2-4
(3) Welding Capabilities
Opposed Welding
With opposed welding, the top and bottom
electrodes are used to hold the parts and provide
the current path. Weld current flows from one
electrode through both parts to the other electrode.
An opposed weld is preferred over other
configurations because it is easier to set up and
the current path is more easily controlled. It should
be used whenever possible.
Dual-Opposed Welding
This method of welding uses two opposed welds
being made on a single part, using two separate
weld energy power supplies. Weld energy can be
delivered in a simultaneous or alternate fashion,
depending on your manufacturing requirements.
Opposed welding provides maximum weld
strength repeatability.
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.
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.