Amada TL-080B Operation Manual

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Operation manual (92 pages)

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WELD HEAD

TL-080B/BF

OPERATION MANUAL

AA10OM1214700-01

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Page 1 WELD HEAD TL-080B/BF OPERATION MANUAL AA10OM1214700-01...
Page 2: Table Of Contents
TL-080B/BF 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.
Page 3: Special Precautions
TL-080B/BF 1. Special Precautions (1) Safety Precautions CAUTION ！ Before using, read "Safety precautions" carefully to understand the correct method Denotes operations and practices that of use. may result in personal injury or damage to the equipment if not correctly followed.
Page 4 TL-080B/BF WARNING ！ 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.
Page 5 TL-080B/BF CAUTION ！ 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.
Page 6 TL-080B/BF (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,...
Page 7: System Description
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.
Page 8 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.
Page 9 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.
Page 10 TL-080B/BF (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.
Page 11 TL-080B/BF (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...
Page 12: Installation
 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:...
Page 13 TL-080B/BF 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.
Page 14 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.
Page 15 TL-080B/BF -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.
Page 16 TL-080B/BF -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.
Page 17 TL-080B/BF TF-080BF Model CP Footpedal Installation Push down on top of weld ○ head to extend end of pullrod. ○ Secure Electrode Holders with string to hold in place. Position head (and optional ○ baseplate) on bench as shown. Route footpedal cable up ○...
Page 18 TL-080B/BF Adjust footpedal so that the electrode holders move the distance required by ○ the application. Adjust the angle of the treadle so that it provides the electrode stroke necessary ○ for the application and is comfortable for the operator.
Page 19 TL-080B/BF TL-080B Air Head Installation Insert 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"...
Page 20 TL-080B/BF 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).
Page 21 TL-080B/BF (3) Connect Weld Cables Weld Cables and Energy Losses 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 in. (30.5 cm) and #2/0 AWG for longer lengths.
Page 22 TL-080B/BF (4) Install Electrodes and Thermodes Loosen screws and insert ○ electrodes. Loosely tighten screws to hold electrodes in position. Align the electrodes, then ○ tighten into position. NOTE: The maximum distance between the electrode tips is 1.0 in. (25.4 mm).
Page 23: Operating Instructions
TL-080B/BF 4. Operating Instructions (1) Getting Started Installation Checklists INSTALLATION CHECKLIST FOR ALL HEADS Check that the cables are correctly attached at both ends. Verify that the Firing Switch Cable is attached to the welding power supply or control. Set the WELD/NO WELD Switch, located on the front of the welding power supply (control), to the NO WELD position.
Page 24 TL-080B/BF WELDHEAD TROUBLESHOOTING GUIDE SYMPTOM PRIMARY CAUSE PRIORITY* SOLUTION Weldhead-Related Cause PROBLEM Increase current/energy in Insufficient – Current/Energy steps of 5 Clean electrodes and/or parts Dirty Electrodes to be welded Use constant area electrodes Electrode Tip Shape or shape to suit application...
Page 25 TL-080B/BF WELDHEAD TROUBLESHOOTING GUIDE SYMPTOM PRIMARY CAUSE PRIORITY* SOLUTION Weldhead-Related Cause PROBLEM Decrease Welding Time (A.C. Excess Welding Time Welding) Decrease force in steps of Warping Excess Force – Use constant area electrodes Electrode Tip Shape or shape to suit application...
Page 26 TL-080B/BF (2) Air-Actuated Head Setup This Section describes the following adjustments:  Firing force to the value required by the specific application.  Maximum force the electrodes can exert on the workpiece during the welding cycle.  Down stroke limits.
Page 27 TL-080B/BF Use the force gauge reading from the previous step as a starting point. Use the ○ force adjustment knob to increase the indicated force if the initial force reading is less than the required force setting. If the initial force reading is greater than the required force setting, decrease the indicated force.
Page 28 TL-080B/BF (3) Manually-Actuated Head Setup This Section describes the following adjustments:  Firing force to the value required by the specific application.  Maximum force the electrodes can exert on the workpiece during the welding cycle.  Down stroke limits.
Page 29 TL-080B/BF Turn the downstop screw counter-clockwise to its fullest extension without ○ actually disengaging it. This will allow maximum downward travel of the upper arm. The following downstop adjustment should be made only if the workpiece would be damaged if the upper arm travels too far. In most applications, use of the downstop is not recommended.
Page 30: User Maintenance
TL-080B/BF 5. User Maintenance (1) 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 31 TL-080B/BF (3) Unitip Electrode Maintenance To ensure the best possible welds, new Unitip electrodes must be cleaned (or "dressed") before they are first used. This ensures that the electrode tip is flat, which is necessary to make maximum contact with the workpiece surface.
Page 32 TL-080B/BF (4) 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 33: Specifications
TL-080B/BF 6. Specifications ① Specifications Model Name TL-080B-00 TL-080BF-00 Features Actuation — Manual 2.2 to 89 Weld Force N (kgf) (0.23 to 9.0) Maximum Rating (at 5% duty cycle) watt-seconds Electrode Stroke Electrode Diameter Electrode Holder Type — Offset Maximum Distance between Electrodes Max.
Page 34 TL-080B/BF ③ Sold Separately Items  Accessories Model Description Base Plate (For installing Head Base), 432 mm l x 150 mm w x 10 mm t BPTL Cable Pedal (25.4-mm stroke, 6-foot cable (For TL-80BF)) Ceramic Polishing Disks (20 pieces, 25.4 mm square x 0.63 mm t, For polishing electrode) Polishing Disks (50 pieces, 600 grit, 38.1 mm dia., For polishing...
Page 35 TL-080B/BF 7. Outline, Connection and Workbench Drilling (1) Outline TL-080B ○ Dimensions in mm 241( ～252) 1/4-20 UNC 12mm depth (2 places) 135(～146) 4-M6 10mm depth (50.8) 76.2 25.4 38.1 176(～187) 7. Outline, Connection and Workbench Drilling...
Page 36 TL-080B/BF TL-080BF ○ Dimensions in mm 179( ～190) 1/4-20 UNC 12mm depth (2 places) 135( ～146) (50.8) 76.2 25.4 4-M6 10mm depth 176(～187) 38.1 7. Outline, Connection and Workbench Drilling...
Page 37 TL-080B/BF (2) Connection Dimensions in mm Volt-sensing & Thermocouple Cable White White Shield (Thermocouple) Shield Black Black Volt Sensing WARNING ！ Connect the grounding wire to the grounding terminal located near the grounding mark. 7. Outline, Connection and Workbench Drilling...
Page 38 TL-080B/BF (3) Workbench Drilling Dimensions in mm ○ TL-080B 76.2 4- φ7 Electrode Position (9.6) (See Outline Dwg.) (136.6) Welding Head Base Outline TL-080BF ○ (For routing Pedal Cable) φ20～25 20.6 76.2 4-φ7 Electrode Position (9.6) (See Outline Dwg.) (136.6)
Page 39: Metric Screws Location
TL-080B/BF 8. Metric Screws Location Inch screws are used except as shown below. Dimensions in mm Hexagon Socket Head Screw 2-M4 ×6 Hexagon Socket Head Bolt 2-M4 ×10 Hexagon Socket Head Bolt 2-M4 ×10 Hexagon Socket Head Bolt 4-M4 ×15...

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