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.

TL-180B
2. System Description
2-5
Step Welding
Series welding is ideal for welding thin resistive
parts, 0.006 inch (0.15 mm) maximum thickness,
to a larger part that cannot easily accommodate an
opposed electrode. Model HE188 Electrode
Holders provide up to 0.75 inch (19.0 mm) of
electrode gap adjustment. 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.

TL-180B
2. System Description
2-6
(4) Operating Controls
Air Cylinders
The top mounted 1.5 inch (3.81 cm) diameter air cylinder is supplied with two
pressure gauges, pressure regulators, and flow controls. The four-way air solenoid,
which controls the direction of air flow to the air cylinder, is available with a 115 V
AC rating. The pressure regulators and flow control valves allow independent
adjustment of the up and down speed of the upper electrode.
The solenoid and regulator assembly is contained in a separate package, which
mounts on the spine of the head.
There are several our direct energy welding controls, high frequency inverter
controls, and microprocessor controlled series of stored energy power supplies
that have a 115 V AC valve output for automatically energizing and controlling the
timing of the air solenoid valve. The Model FS1L or FS2L Foot Switch is used to
initiate all of these our weld energy controls.
Any control that does not supply a valve output requires the use of the 115 V AC
FSAC Foot Switch to provide switched solenoid power to the TL-180B, 115 V AC,
air-actuated heads. TL-180B, 24 V DC air actuated heads can also be used in
automated environments where a programmable logic control (PLC) provides
solenoid power and timing control. The Footswitch can be a single or two level
types, depending on the power supply and the user's preference. Lubricators
should 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-180B
3. Installation
3-1
3. Installation
(1) Introduction
Overview
The installation principle is as follows:
If not already attached, the weld head mounting post is attached to the stand.
The weld head stand is bolted securely to a workbench.
If not already attached, the weld head is attached to the mounting post.
The air head is installed.
Electrodes and weld cables are installed on the weld head.
Requirements
Work Area
We recommend that you install your weld head in a well-ventilated area that is free
from excessive dirt and moisture. The workstation must be stable, free from
vibration, and capable of supporting the combined weight of the head, its
accessories, and the weld energy power supply and welding transformer. The
combined system weight can reach approximately 120 lbs (54.4 kg).
Utilities
AC Power
Included in our weld energy power supplies.
115 V AC required for use with power supplies, which do not supply valve
power.
Compressed Air
65 psi (4.5 bar) minimum.

TL-180B
3. Installation
3-2
(2) Weld Head Installation
Overview
First, this section will give "Typical Installation" instructions that are common to all
TL-180B weld heads. Then, additional instructions for installing specific weld
head models are listed. Before you start installation:
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.
TL-180B weld heads may be purchased with or without mounting hardware. we
provide 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.
Typical Installation
Allow about 8–10 inches (20.32–25.4 cm)
between the front edge of the bench and
the stand so the operator can 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 stand.
○
4Screw the weld head stand to the
workbench.

TL-180B
3. Installation
3-3
○
5Install the weld head mounting plate onto the weld head using the screws as
shown.
○
6Install the screws, washers, and T-nuts into the weld head mounting plate as
shown.
○
7If necessary, remove the end cap from the mounting post to expose the
channels in the mounting post.
○
8Raise 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.
○
9If you are using an air head, install it on the rear of the mounting post following
the procedures in Steps 3 through 7.

TL-180B
3. Installation
3-4
Air Head Installation
Our Air Kits are factory-installed to the TL-180B Weld Heads. User installation
consists of connecting the airhead to an air source and connecting the airhead
power cable to a welding control.
The air input line on each head uses a "quick release" fitting so special tools are
not needed. The hoses simply push into the "quick release" fitting as far as they
will go.
Single-Air Installation
NOTES:
The inside diameter of the main air
supply line must be at least 0.5 inch
(13 mm) to allow sufficient air flow.
The air supply must be properly
filtered at a maximum pressure of
100 psi (690 kPa).
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).
Verify that the air lines are inserted
all the way into the sleeve on the
fittings to prevent inadvertent
blow-outs.
Use the shortest air lines possible to obtain the fastest mechanical response.
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.

TL-180B
3. Installation
3-5
Dual-Air Installation
Installation Instructions
○
1Insert the air supply hose into the "quick release" fitting(s) on the air head(s).
○
2Connect the power cord from the air head to the Welding Control following the
instructions in the Welding Control Users' Manual.
○
3Install 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.

TL-180B
3. Installation
3-6
(3) Connect Weld Cables
Weld Cables and Energy Losses
All our weld heads are supplied with the correct weld cables to provide maximum
weld energy. If you need to install longer cables, or replace damaged cables,
Use #2 AWG for lengths under 12 inch (30.5 cm) and #2/0 AWG for longer
lengths. Tie or tape cables together to minimize inductive losses. A separation
of weld cables surrounding an area of one square foot could result in losses of
up to 65%.
Use the shortest possible Welding Cables. It is common to have losses of up
to 50% per foot for #6 cables and 20% for #2 cables.
Connect the welding cables on the same side of the head. Otherwise, the
inductive losses added by the intervening support post could substantially
increase the amount of energy required to join metal satisfactorily
Connect Cables to Head
Place the washer securing the
welding cable terminal between
the screw head and the welding
cable terminal, not the welding
cable terminal, and the terminal to
which the cable is being attached.
Make sure the connections are
free of oxidation, dirt and grease.
Use 2/0 AWG cable for lengths
under 18 inches (45 centimeters),
and 4/0 AWG for longer lengths.
Use the shortest possible welding cables. Energy losses can range up to 20%
per foot for 2/0 AWG cables.
Tie the welding cables together to minimize weld energy losses caused by
unwanted welding cable inductance.
Route the welding cables so that they do not run adjacent to magnetic materials
and devices such as air solenoids, tooling and steel heads. Run the welding
cables through a single hole in a steel plate.

TL-180B
3. Installation
3-7
Offset Weld Head Connection
○
1Place the welding control, weld energy power supply, or welding transformer
approximately 4 to 5 inch (10.2 to 12.7 cm) behind the weld head.
○
2Inspect the connections on the weld cables, welding control, weld energy power
supply, or welding transformer. Remove any oxidation, dirt, or grease.
○
3Connect the short welding cable to one terminal on the weld head power bar,
using a 5/16-18 x 1/2 inch hex head bolt, and flat washer. Place the washer
between the bolt head and the welding cable terminal, do not place the washer
between the Cable and the Power Bar because you will get an unstable
connection and, consequently, unstable current flow. Tighten connections
securely.
○
4Connect the longer welding cable to the lower electrode holder, or
user-supplied welding fixture, using the procedures in Step 3.
○
5Connect the other end of the cables to the welding control, weld energy power
supply, or welding transformer in accordance with the instructions in its Users'
Manual.
○
6Connect the firing switch cable to the welding control, weld energy power
supply, or welding transformer in accordance with the instructions in its Users'
Manual.

TL-180B
3. Installation
3-8
(4) Install Electrode Holders
Various electrode holders are interchangeable, as required by your weld head
application. TL-180B Weld Heads are shipped with the electrode holders installed.
Use the following procedures to change electrode holders.
Offset Electrode Holders
○
1Install the upper insulating washer on the linear bearing rod, followed by the
upper insulating tube.
Note: Do not remove the upper retainer ring from the linear bearing rod.
○
2Slip the upper electrode adapter block over the upper insulating tube. The linear
bearing rod should now be flush with the bottom of the upper electrode adapter
block.
○
3Secure the upper electrode adapter block on the linear bearing rod by
tightening the upper electrode adapter block securing screw.
○
4Slip the lower insulating washer over the lower electrode assembly post,
followed by the lower insulating tube.
○
5Slip the lower electrode adapter block over the lower insulating tube. Secure
the lower electrode adapter block on the lower electrode post by tightening the
lower electrode adapter block securing screw.
○
6Insert one finger into the lower electrode post mounting hole in the support
base until you feel the plug screw. Turn the plug screw counter-clockwise until it
no longer protrudes from the mounting hole.
○
7Insert the lower electrode assembly post into the support base mounting hole.
Secure the assembly by turning the plug screw clockwise.
○
8To remove the offset electrode holder assembly, reverse the installation
procedure.