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Amada THIN-LINE 180 M Series Operation Manual

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WELD HEAD
THINLINE 180 M
SERIES
OPERATION MANUAL
990-133 REV F

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Summary of Contents for Amada THIN-LINE 180 M Series

  • Page 1 WELD HEAD THINLINE 180 M SERIES OPERATION MANUAL 990-133 REV F...
  • Page 2 Copyright © 2002, 2008, 2013-2016 Amada Miyachi America The engineering designs, drawings and data contained herein are the proprietary work of Amada Miyachi America and may not be reproduced, copied, exhibited or otherwise used without the written authorization of Amada Miyachi America.
  • Page 3 We have made every effort to ensure that the information in this manual is accurate and adequate. Should questions arise, or if you have suggestions for improvement of this manual, please contact us at the above location/numbers. Amada Miyachi America is not responsible for any loss due to improper use of this product. ® THIN-LINE...
  • Page 4 SAFETY WARNINGS DANGER DEATH ON CONTACT may result if you fail to observe the safety precautions labeled on the equipment and noted on this page. WARNING HIGH VOLTAGE is used in the operation of this equipment. CAUTION modify the electrode holders or attach additional mechanisms to the moving parts of the head.

  • Page 5: Table Of Contents

    Contents Page Chapter 1: System Description Section I. Features ..........................1-1 Overview ............................1-1 Precision Welding ..........................1-1 Weld Force ............................1-2 Adjustable Stops ..........................1-2 Electrode Holders ..........................1-2 Welding Cables ..........................1-2 Footpedal Actuation ......................... 1-2 EZ-Air Actuation ..........................1-2 Section II.
  • Page 6 Contents (Continued) Page EZ-AIR Installation and Connection ....................2-5 Optics ............................2-5 Section III. Connect Weld Cables ......................2-6 Weld Cables and Energy Losses ...................... 2-6 Connect Cables to Head ........................2-6 Model 180MF, and 180MA Weld Head Connections ..............2-7 Section IV.
  • Page 7 LIMITED WARRANTY 1. (a) Subject to the exceptions and upon the conditions set forth herein, Seller warrants to Buyer that for a period of one (1) year from the date of shipment (“Warranty Period”), that such Goods will be free from material defects in material and workmanship.
  • Page 8 (g) All expendables such as electrodes are warranted only for defect in material and workmanship which are apparent upon receipt by Buyer. The foregoing warranty is negated after the initial use. (h) Subject to Section 1(e) and Section 1(f) above, with respect to any such Goods during the Warranty Period, Seller shall, in its sole discretion, either: (i) repair or replace such Goods (or the defective part) or (ii) credit or refund the price of such Goods at the pro rata contract rate, provided that, if Seller so requests, Buyer shall, at Buyer’s expense, return such Goods to Seller.
  • Page 9 (6) months after the date of shipment, whichever occurs first. Acceptance Tests: Acceptance Tests (when required) shall be conducted at Amada Miyachi America, Inc., Monrovia, CA, USA (the “Testing Site”) unless otherwise mutually agreed in writing prior to issuance or acceptance of the Acknowledgement.
  • Page 10 Seller further warrants that all Services performed by Seller’s employees will be performed in a good and workmanlike manner. Seller’s sole liability under the foregoing warranty is limited to the obligation to re-perform, at Seller’s cost, any such Services not so performed, within a reasonable amount of time following receipt of written notice from Buyer of such breach, provided that Buyer must inform Seller of any such breach within ten (10) days of the date of performance of such Services.

  • Page 11: Chapter 1: System Description

    CHAPTER 1 SYSTEM DESCRIPTION Section I. Features Overview ® This manual is organized to assist you in getting productive quickly with your THIN-LINE Series 180M Weld Head. Chapter 1 describes the equipment, Chapter 2 describes installation, Chapter 3 describes operating procedures so you can run the weld head safely and efficiently, and Chapter 4 describes maintenance and troubleshooting procedures.

  • Page 12: Weld Force

    CHAPTER 1: SYSTEM DESCRIPTION Weld Force The weld force is continuously adjustable from a minimum of 22.2 N (5 pounds) to a maximum of 445 N (100 pounds) Settings are quickly reproduced by using the force adjustment knob and easy-to-read visual scale.

  • Page 13: Section Ii. System Components

    CHAPTER 1: SYSTEM DESCRIPTION Section II. System Components Typical Series 180M Weld Head Model 180MA The Model 180MA is an air-actuated head. The actuation source is the top-mounted, 3.81 cm (1.5-inch) diameter air cylinder. This model provides throat depth of 25.72 cm (10.125 inches) The Model 180MF Weld Head includes the Model HE180KM Offset Electrode Holder Block and the Model HE2000M Electrode Holders.

  • Page 14: Section Iii. Welding Capabilities

    CHAPTER 1: SYSTEM DESCRIPTION Section III. 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.

  • Page 15: Step Welding

    CHAPTER 1: SYSTEM DESCRIPTION Step Welding Series welding is ideal for welding thin resistive parts, 0.15 mm (0.006 inch) maximum thickness, to a larger part that cannot easily accommodate an opposed electrode. In step welding, the size of the weld and the surface marking is frequently controlled by the diameter of the face of each electrode.

  • Page 16: Section Iv. Operating Controls

    CHAPTER 1: SYSTEM DESCRIPTION Section IV. Operating Controls There are several Miyachi Unitek direct energy welding controls, high frequency inverter controls, and microprocessor controlled series of stored energy power supplies that have a 24 VAC valve output for automatically energizing the EZ-AIR solenoid valve. The Model FS1L or FS2L Foot Switch is used to initiate all of these Miyachi Unitek weld energy controls.

  • Page 17: Chapter 2. Installation Section I. Introduction

    CHAPTER 2 INSTALLATION Section I. Introduction Overview Before you start installation, become familiar with the specific model you are using. Series 180M Weld heads come in different sizes and configurations, which require different stands and installation hardware. Despite differences from model-to-model, the installation principle is the same for each head: ...

  • Page 18: Section Ii. Weld Head Installation

    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 Amada Miyachi America at the address shown in the front of the manual.
  • Page 19 CHAPTER 2: INSTALLATION Install the weld head mounting plate onto the weld head using the screws as shown. Install the screws, washers, and T-nuts into the weld head mounting plate as shown. If necessary, remove the end cap from the mounting post to expose the channels in the mounting post.

  • Page 20: Model 180Mf Msp Footpedal Installation

    CHAPTER 2: INSTALLATION Model 180MF MSP Footpedal Installation Screw the head to the bench and Model MSP Footpedal using four (4) screws, washers and nuts supplied with the shipping kit. To adjust the height of the head, loosen two hex head cap screws on the mounting plate adapter, as illustrated, and slide Head up or down the stand.

  • Page 21: Ez-Air Installation And Connection

    CHAPTER 2: INSTALLATION EZ-AIR Installation and Connection Model 180MA-EZ comes with EZ-AIR factory-installed, no further installation is required by the user. For instructions on connecting EZ-AIR to an air supply, follow the procedures in the separate EZ-AIR Operator Manual supplied with the weld head. Optics If you are using any of the optional optics (microscope or illuminator): Verify that the optics mounting post is securely attached to the optics baseplate.

  • Page 22: Section Iii. Connect Weld Cables

    CHAPTER 2: INSTALLATION Section III. Connect Weld Cables Weld Cables and Energy Losses All Miyachi Unitek 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, ...

  • Page 23: Model 180Mf, And 180Ma Weld Head Connections

    CHAPTER 2: INSTALLATION Model 180MF, and 180MA Weld Head Connections Place the welding control, weld energy power supply, or welding transformer approximately 10.2 to 12.7 cm (4 to 5 inch) behind the weld head. Inspect the connections on the weld cables, welding control, weld energy power supply, or welding transformer.

  • Page 24: Section Iv. Install Electrode Holders

    CHAPTER 2: INSTALLATION Section IV. Install Electrode Holders Various electrode holders are interchangeable, as required by your weld head application. All Series 180M Weld Heads are shipped with the electrode holders installed. Use the following procedures to change electrode holders. CAUTION Do not modify the electrode holders or attach additional mechanisms to the moving parts of the head.
  • Page 25 CHAPTER 2: INSTALLATION Slip the lower insulating washer over the lower electrode assembly post, followed by the lower insulating tube. Slip 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.

  • Page 26: Section V. Install Electrodes

    CHAPTER 2: INSTALLATION Section V. Install Electrodes Model 180MF and Model 180MA Offset Electrodes Turn the electrode securing screw in the upper electrode holder counterclockwise to loosen it. Insert the electrode in the electrode holder and turn the electrode securing screw clockwise to secure the electrode in the holder.

  • Page 27: Chapter 3. Operating Instructions

    Welding Force Theory Welding force (pressure) is a key variable in the resistance welding process. Excessive or insufficient welding force or pressure can cause a weak weld. More information is available from Amada Miyachi America: A) Resistance Welding Troubleshooting Guide...

  • Page 28: Troubleshooting

    CHAPTER 3: OPERATING INSTRUCTIONS Troubleshooting WELDHEAD TROUBLESHOOTING GUIDE SYMPTOM PRIMARY CAUSE PRIORITY* SOLUTION Weldhead-Related Cause PROBLEM Excess Welding Time Decrease Welding Time (A.C. Welding) Insufficient Force Increase force in steps of 10-20% Wrong Electrode Material Check Electrode/Material Selection Guide Overheating of Weldment Dirty Electrodes Clean electrodes and/or parts to be welded...
  • Page 29 CHAPTER 3: OPERATING INSTRUCTIONS WELDHEAD TROUBLESHOOTING GUIDE SYMPTOM PRIMARY CAUSE PRIORITY* SOLUTION Weldhead-Related Cause PROBLEM Excess Current/Energy Decrease current/energy in steps of 5-10% Insufficient Force Increase force in steps of 10-20% Reduce mass of top electrode holder Poor Weldhead Follow-up assembly*** Sparking Electrode Tip Shape...

  • Page 30: Section Ii. Model 180Mf Manually-Actuated Head Setup

    CHAPTER 3: OPERATING INSTRUCTIONS Section II. Model 180MF Manually-Actuated Head Setup This Section describes the following adjustments for the Model 180MF:  Firing force to the value required by the specific application.  Maximum force the electrodes can exert on the workpiece during the welding cycle. ...
  • Page 31 CHAPTER 3: OPERATING INSTRUCTIONS easily detected by observing the firing switch indicator on the welding power supply or control. For older or non-Miyachi Unitek controls, an ohmmeter or continuity checker can be connected to the pins on the firing switch connector. Use the force gauge reading from the previous step as a starting point.

  • Page 32: Section Iii. Model 180Ma Ez-Air Air-Actuated Head Setup

    CHAPTER 3: OPERATING INSTRUCTIONS Section III. Model 180MA EZ-AIR Air-Actuated Head Setup This Section describes the following adjustments for the Model 180MA-EZ:  Welding force to the value required by the specific application.  Down speed of the electrode approaching the parts. ...
  • Page 33 CHAPTER 3: OPERATING INSTRUCTIONS After setting the required force, particularly in automated applications, remove the force adjustment knob by loosening the two setscrews, which secure it to the shaft. Invert the knob and place it on the shaft. Be sure to insert the locking tab on the knob into the slot on the force tube.

  • Page 35: Chapter 4. User Maintenance Section I. General Maintenance

    CHAPTER 4 USER MAINTENANCE Section I. General Maintenance Inspection Clean all electrical connections every six months to minimize welding circuit resistance. Inspect all bearings and braces for excessive wear every three years and replace as necessary. Lubrication All bearing surfaces are designed for non-lubricated operation. Do not oil any bearings or sleeves except for the use of a dry lubricant on weld heads used in automated, air actuated systems.

  • Page 36: Section Iii. Tare Spring Adjustment

    CHAPTER 4: MAINTENANCE Section III. Tare Spring Adjustment The tare spring adjustment compensates for the varying mass of different upper electrodes and adapters. With the head in a vertical position and the upper arm and electrodes installed, set the force adjustment to minimum by turning the firing force adjustment knob fully counterclockwise.

  • Page 37: Appendix A. Specifications

    APPENDIX A. Technical Specifications 180MF 180MA FEATURES Actuation Manual Air Cylinder Inside Diameter mm (inch) 38.1 (1.5) Air Cylinder Stroke mm (inch) 50.8 (2) Air Pressure for Max. Force kg/cm (psi) 4.57 (65) Air Solenoid Voltage (VAC) Cycle Rate (full strokes/sec) Electrode Diameter mm (inch) 6.4 (0.25)
  • Page 38  ...

  • Page 39: Appendix B. Accessories

    APPENDIX B ACCESSORIES Accessories MODEL DESCRIPTION Fiber Optic Illuminator System, 115V-50/60Hz. Self-Supporting Gooseneck, Bifurcated Light BLFOI Pipes, Focusing Lenses, and Mounting Adapter for Optic Mounting Assembly. Fiber Optic Illuminator System, 230V-50/60Hz. Self-Supporting Gooseneck, Bifurcated Light BLFOI/230 Pipes, Focusing Lenses, and Mounting Adapter for Optic Mounting Assembly. Firing Switch Junction Box.
  • Page 40 APPENDIX B. ACCESSORIES Electrodes MATERIAL DESCRIPTION 83B Rockwell Hardness, 85% conductivity. Used for RWMA 2 -- Copper-Chromium Alloy welding steels, nickel alloys and other high resistance materials. 100B Rockwell Hardness, 48% conductivity. Used for RWMA 3 -- Copper-Beryllium Alloy welding high resistance materials requiring high weld forces.
  • Page 41 APPENDIX B. ACCESSORIES Electrode Holders Electrode Holder, holds 6 mm diameter electrodes. Used on Model 180M weld heads. Electrodes ES0800M 6 MM DIAMETER STRAIGHT ELECTRODES Used with 180M Series Weld Heads Model Material ES0802M RWMA 2 ES0803M RWMA 3 ES0850M GLIDCOP ES0811M RWMA 11 INSERT...
  • Page 43     http://www.amy.amada.co.jp/e/    AMADA MIYACHI AMERICA, INC. 1820 South Myrtle Ave., Monrovia, CA 91016, U.S.A.  TEL. +1‐626‐303‐5676  FAX. +1‐626‐358‐8048               http://amadamiyachi.com  AMADA MIYACHI CO., LTD. 200, Ishida, Isehara‐shi, Kanagawa 259‐1196, Japan    AMADA MIYACHI KOREA CO., LTD. 28, Dongtanhana 1‐gil, Hwaseong‐si, Gyeonggi‐do, 445320, Korea  TEL. +82‐31‐8015‐6810  FAX. +82‐31‐8003‐5995  AMADA MIYACHI SHANGHAI CO., LTD. Room01,15th Floor, SML Center, No.610 Xujiahui Road, Huangpu District, Shanghai 200025, China  TEL. +86‐21‐6448‐6000  FAX. +86‐21‐6448‐6550    AMADA MIYACHI EUROPE GmbH Lindberghstrasse 1, DE‐82178 Puchheim, Germany  TEL. +49‐89‐839403‐0  FAX. +49‐89‐839403‐10    AMADA MIYACHI TAIWAN CO., LTD.
  • Page 44                                                                   AMADA MIYACHI AMERICA, INC.     1820 South Myrtle Ave., Monrovia, CA 91016, U.S.A.     TEL. +1‐626‐303‐5676  FAX. +1‐626‐358‐8048  ...

This manual is also suitable for:

Thin-line 180 maThin-line 180 mfThin-line 180m seriesThin-line 180ma ez-air

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