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Amada TL-180B Operation Manual

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WELD HEAD
TL-180B
OPERATION MANUAL
AA10OM1214704-01

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Summary of Contents for Amada TL-180B

  • Page 1 WELD HEAD TL-180B OPERATION MANUAL AA10OM1214704-01...

  • Page 2: Table Of Contents

    TL-180B 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.

  • Page 3: Special Precautions

    TL-180B 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-180B 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-180B 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-180B (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,...

  • Page 7: System Description

    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.
  • Page 8 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.
  • Page 9 TL-180B (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). 2. System Description...
  • Page 10 TL-180B (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.
  • Page 11 TL-180B 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.
  • Page 12 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.

  • Page 13: Installation

    TL-180B 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.
  • Page 14 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...
  • Page 15 TL-180B 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 16 TL-180B 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.
  • Page 17 TL-180B Dual-Air Installation Installation Instructions ○ Insert the air supply hose into the "quick release" fitting(s) on the air head(s). Connect the power cord from the air head to the Welding Control following the ○ instructions in the Welding Control Users' Manual.
  • Page 18 TL-180B (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.
  • Page 19 TL-180B Offset Weld Head Connection Place 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. Inspect the connections on the weld cables, welding control, weld energy power ○...
  • Page 20 TL-180B (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 Install the upper insulating washer on the linear bearing rod, followed by the ○...
  • Page 21 TL-180B (5) Install Electrodes 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 22: Operating Instructions

    TL-180B 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 23 TL-180B 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 24 TL-180B 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 25 TL-180B (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 26 TL-180B 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 27: User Maintenance

    TL-180B 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 28 TL-180B (3) 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 29: Specifications

    TL-180B 6. Specifications ① Specifications Model Name TL-180B-00 Features Actuation — Weld Force N (kgf) 22 to 445 (2.3 to 45.4) Maximum Rating (at 5% duty cycle) watt-seconds Electrode Stroke Electrode Diameter Maximum Distance between Electrodes Max. Throat Depth Air Solenoid Voltage V AC Air Pressure for Max.

  • Page 30: Outline And Workbench Drilling

    TL-180B 7. Outline and Workbench Drilling (1) Outline Dimensions in mm 262( ～270) Start cable Support Base (Connector 80-MC2M) 357( ～365) 405( ～413) Slide TEE STUDs into the lowest Tee Slot on the Suport Base. 7. Outline and Workbench Drilling...
  • Page 31 TL-180B (2) Workbench Drilling Dimensions in mm (307) (26) (26) Electrode position Outline of Min.(50) 2-φ10 Support Base 7. Outline and Workbench Drilling...

  • Page 32: Metric Screws Location

    TL-180B 8. Metric Screws Location Inch screws are used except as shown below. Dimensions in mm Hexagon Head Screw 3-M8×25 T Slot Nut M8(3) Internal Thread 2-M8 Hexagon Head Screw 2-M8×20 Hexagon Socket Head Bolt 1-M6×15 Hexagon Socket Hexagon Socket...

This manual is also suitable for:

Tl-180b-00