Operating Instructions Tcbeadmaking Rev02 Alphasensors

7/31/2019 Operating Instructions Tcbeadmaking Rev02 Alphasensors

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THERMOCOUPLE BEAD MAKINGMACHINE

ALPHA SENSORSComplete Thermometry Solutions

Address : Hari Nivas, 2nd

Floor, S.V Road, Khar (W), Mumbai 400 052Ph : 91-22-28682765 Fax : 91-22-28684428

Email : [email protected]/[email protected]

PROPRIETARY : This document and data disclosed herein or herewith is not tobe reproduced, used or disclosed in whole or in part to anyone without thepermission of M/s Precision Sensors Pvt. Ltd., Mumbai

Issue No : IRev : 02

July 2011

MODEL:Dyna.WELD

Author :Ashish Gupta

Page No :Page 2 of 11

INDEX

SR.NO

TOPIC PAGE

1WHAT IS CAPACITANCEWELDING 3

2INTRODUCTION OF Dyna.WELD

and SPECIFICATION3

3

PART DIAGRAM & ACCESORYLIST 4

4 INSTALLATION & SETUP 5

5 OPERATIONS & CONTROLS 5

6 MAINTENANCE7

7 SAFETY &TIPS 8

8. RESISTANCE WELDING 9

9. WARRANTY CERTIFICATE 10

10. ENERGY NOTING SHEET 11


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July 2011

MODEL:Dyna.WELD



OPERATING INSTRUCTIONS1.0 WHAT IS CAPACITANCE WELDING?

In an electrical charge a preset energy level is stored .This charge is then released acrosstwo electrodes the negative electrode being the work piece. This discharge of stored

energy is sufficient to form the weld.

Capacitance welding is generally used for the welding of similar and dissimilar wires(thermocouple junction welds) and for impact welding wires to a conductive material.

2.0 INTRODUCTION OF Dyna.WELD

The DYNAWELD is a versatile welder capable of the rapid production of reliablecommercial and reference Thermocouple junctions and of connecting extension leads toMI Thermocouples, Resistance Thermometer Detectors and other transducers. It may

also be used to attach Thermocouple and other wires to solid metal surfaces, such aspipes, boiler plates, engine blocks, power semiconductors and printed circuit tracks.

No special skills are required for its successful operation and most people will be capableof producing quality work after only a few minutes practice.

2.1 SPECIFICATIONS :

A) TECHNICALWelding System Capacitive Discharge.

Energy Range 4 to 80 Joules.Welding Capacity 0.1 to 1.2mm dia. wires

36 to 20 SWG.

Supply Voltage 220 / 240 VAC 45 / 65 hz.

Power Consumption 170 VA maximum.

Fuse 2 amp / 250 V, 20mm glass.

Duty Cycle Continuous.

Dimensions 215W x 87H x 195D (mm).

Weight Approx. 6 kgs


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PARTS :

.

2.2 ACCESSORIES LIST

Sr,No Description Quantity

1. Dyna.WELDER Main Module 1 nos.

2. Footswitch 1 nos.

3. IEC Mains Cable 1 nos.

4. Spare Electrodes 5 nos.

5. Welding Pliers 1 nos.

6. Magnifying Glass 1 nos.

7. User Manual 1 nos.

8. Allen Key 1 nos.

9 Operation Manual Video CD 1 nos.


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3.0 INSTALLATION AND SETUP.

3.1 MAINS CONNECTION.

The Mains lead supply is connected to the IEC socket at the rear of the Dyna.WELD 80Jand should then be connected to a standard 230V/50HZ supply unless otherwise stated.

3.2 FOOTSWITCH CONNECTION

Plug the supplied footswitch connector into the appropriate socket indicated on the frontpanel of Dyna.WELD 80J.

3.3 WIRE HOLDING PLIERS CONNECTION

Plug the wire holding pliers into one of the Positive (+ve) Electrodes(X1,X2 OR X3)marked on the front panel based on the wire diameter to be welded..

3.4 OPTIONAL IMPACT WELDING SOCKET :

A separate -ve socket is provided for impact welding or thermocouple attachment function

explained later in the manual.

4.0 OPERATION AND CONTROLS.

4.1 INITIAL SETTING.

STEP I : Switch on the mains Supply with the rocker switch built in on the front panel

STEP II : Connect the footswitch in the appropriate socket of the front panel and plugthe Wire Holding Pliers in the positive socket(+ve) either in X1, X2 or X3 based on wire

diameter . Kindly refer to Energy Setting Table 1 explained in Pt. 4.2 below.

4.2 Energy Setting.

STEP III : Increase the charge voltage reading by moving the potentiometer knob inthe clockwise direction appropriate to the size of wires to be welded. The voltage readingwill be displayed on the LED Display.

There are 3 different energy banks X1, X2, & X3 in the machine which can be selected bythe user based on the wire diameter to be welded. X1 is the low energy bank, X2 is theMid Level Energy bank and X3 is the high energy bank. There may be more than onecombination of Charge voltage and Energy Bank selection which may suit welding for aparticular wire diameter. The user may make some trials and arrive at the bestcombination meeting his application requirements.


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In the table below are some combinations of Capacitor Bank Selection and ChargeVoltage based on trials made by us. This table is for representation purposes only to givethe user a idea of operation. We always advise the user to make his own trials and arriveat suitable combinations suiting his application requirement. We have provided format ofenergy Noting sheet at the back of this manual for recording observations of the user.

TABLE 1

WireDiameter(mm)

Charge Voltage Setting (V)

With X1 With X2 With X3

0.1 25 V 18 V 15 V

0.3 28 V 20 V 18 V

0.5 - 27 V 25 V

0.8 - - 36 V

0.9 - - 40 V

1.0 - - 45 V

**Note: These are few combinations mentioned. Various other combinations can bemade with different banks (X1,X2,X3) and voltage level. The energy combinationdetermines the type of bead formed. Some applications require a round bead for usage ofthermocouple in harsh environments and in some cases the application requires athermocouple bead with minimum mass for fast response.

NEW FEATURE !!!! : In this model we have added a further feature of using the energybanks in combination. You can now combine energy of two or more banks and dischargethem at one time. This will help you in controlling the bead size formed.For Example : By Shorting Banks X1 and X2 together and connecting the plier to eitherX1 or X2 you can harness the combined energy stored in capacitors of bank X1 and X2.Similarly you can short X1 and X3 , X2 and X3 OR X1, X2 and X3 . It is recommendedthat the user analyses various options available and decides on the best combination forthe type of weld required.

STEP IV : Press the Initiate Charging button on the front panel of the machine. The

Charging LED will blink till the charging process is complete. Once the LED stops blinking, it indicates that charging is complete


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4.3 PREPARING WIRES.

STEP V : Insulated wires should have their insulation stripped sufficiently to allow at least5mm protruding when gripped in the pliers. They should be laid side by side and incontact such that the ends square and level. With smaller diameter wires it will be foundadvantageous to twist them together before trimming .This also applies when weldingstranded wires together or stranded wires to solid wires.

4.4 WELD ACTION.

STEP VI : Grip the wires in the holding pliers and bring them near the carbon electrode.Check if the charge voltage is stable or is still increasing value. The wires should be heldtightly so that always there is positive contact. Position the wires such that they areapprox 0.5mm to 1mm away from the carbon electrode. The Purge/Weld Switch mustbe on the WELD side. Initiate weld sequence by pressing the footswitch. WELDSequence will first purge the weld area with argon gas and then within 20 secondsautomatically discharge the stored energy to weld the thermocouple wires together. Afterdischarge the system will automatically charge to preset charge voltage level for nextweld.

4.5 OPTIONAL WELD ACTION I IMPACT WELD ACTION

This is the term used for welding wires to a metal (conductive) surface. This type ofapplication is common when the wires are required to be welded to a chassis orframework for testing or heat treatment application.

Connect the surface on which the wires is to be welded to the Impact Welding Socket.Negative (-ve.) socket provided on the front panel of Dyna.WELD 80J using a lead wirewith one end terminated in a banana plug and the other end terminated in a alligator

clip.The alligator clip should then be attached to the surface close to where the wiresneed to be attached.

The prepared wires are then gripped in the wire holding pliers and then pressed on to thesurface to which they are to be attached.

The weld action describe above should be then followed and when the footswitch isdepressed, the resulting discharge will weld the wires to the surface after which the weldclip can be removed.

4.6 WELD QUALITY.

Examine the weld using the magnifying glass supplied. A good weld will produce a strongjoint between the wires and usually forms a round bead. A flat bridge between the wiresindicates too low setting. A flattened hemisphere indicates that energy setting is too high.


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5.0 MAINTENANCE.

Apart from Carbon electrode replacement, the Dyna.WELD 80J contains no userserviceable parts. In the event of failure, please return the welder, carefully packed, to thedistributor from which it was purchased who will arrange for the necessary repair.

5.1 Carbon Electrode Replacement.

After considerable use, the carbon electrode will need attention. The carbon may betrimmed in a drill or lathe chuck using a metal file to give an included angle of about 30 0

with the tip approx. 2mm diameter.

To remove the carbon electrode slacken the grub screw on the argon shield (Allen keyprovided)and pull off the shield. Slacken the grub screw on the the electrode holder andwithdraw the electrode.

When fitting a new or trimmed electrode, insert it loosely until it lines up with the front face

of the shield. Tighten the grub screw & replace the argon shield.

6.0 SAFETY AND TIPS.

Use of Red Welding Glass filter to protect the eyes from the welding flashes isrecommended. A bench lamp positioned over the welder will permit the work and carbonelectrode tip to be easily seen.

Accidental over setting of the energy level can result in flying particles and it is strongly

recommended that welding goggles are used at all times.

If the pliers become pitted or soiled, clean the faces by pulling through a piece of foldedfine emery paper whilst applying slight pressure to the handles.

Keep a note book by the welder and make a record of the setting for each type of job.Noting wire size, materials and energy setting .


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RESISTANCE WELDING KIT OPTIONAL ACCESSORY KIT.

CONSISTING OF 1 COPPER PLATE + 1 ELECTRODE PEN.

The resistance welding attachments are suitable for welding ribbon conductors of up to about 0.3mm thick depending on the resistivity of the materials. It cannot be used successfully with lowresistance materials such as copper, aluminum, silver and gold.

PROCEDURE

Plug the electrode pen in the IMPACT WELD TERMINAL and Copper plate into the welderterminals X1, X2 OR X3. Position the ribbons to be welded on the plate and apply the pen to thepoint where the weld is to be made. Push down the electrode pen until you are sure that the tworibbons are in intimate contact ( use less pressure with fine materials ) and then operate the footSwitch . Test the strength of the weld on the first sample by pulling the ribbons apart. If the weldappears weak, increase the energy setting on the welder. If the ribbons are pierced, reduce theenergy setting. A good weld will show a slightly discoloured disc on the ribbon that was in contactwith the copper plate.

The system is capable of producing a number of welds in close proximity in order to increase thestrength of the joint. A die pattern of five will be found convenient for the wider ribbons.

It can also weld ribbons to solid surfaces such as radiators and engine blocks. In this case thecopper plate should be clamped to a point on the device, using a Mole grip or similar, where it willmake good electrical contact. Alternatively, if a lot of this type of welding is carried out, it will befound more convenient to make up a special lead fitted with a 4mm plug and a heavy dutycrocodile clip - the sort used for car battery jump leads is ideal.

TIP MAINTENANCE

To remove the welding tip for replacement or reshaping, remove the tip from the plastic handle byunscrewing the same.

To reshape, grip the copper body and sharpen the tip of the electrode on a grinding wheel. Thetip should not be very pointy and should have some relief on the top. Always wear protective eyegear as copper is brittle and is liable to break off if too much side force is applied.


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Page No :Page 10 of

11

WARRANTY CERTIFICATE

All equipment sold by Alpha Sensors is warranted by Alpha Sensors for the period of twelve months, whichperiod will commence upon date of shipment or invoicing whichever occurs first, to be free from any defects inmaterial and workmanship disclosed under normal use and service, provided such goods have been properlyinstalled, maintained and operated in accordance with Alpha Sensors specifications for such goods. IfPurchaser, within such period, notifies Alpha Sensors in writing of any claimed defect in goods delivered by AlphaSensors and such goods are found by Alpha Sensors, after appropriate tests and inspection, not to be inconformity with this warranty, Alpha Sensors will at its option and expense either repair the same or provide areplacement for installation at Purchasers expense. With respect to services performed hereunder, AlphaSensors sole liability for any defect therein shall be to perform again, at Alpha Sensors expense, such services.

EXCEPT AS AFORESAID, ALPHA SENSORS MAKES NO WARRANTY OF MERCHANTABILITY, FITNESSFOR A PARTICULAR PURPOSE, OR ANY OTHER OR FURTHER WARRANTY, EITHER EXPRESS ORIMPLIED OR BY TRADE USAGE, IN CONNECTION WITH THE DESIGN, SALE, INSTALLATION, OR USE OFANY OF THE GOODS REFERRED TO HEREIN, AND LIABILITY FOR THE WARRANTY MADE HEREINSHALL IN NO EVENT EXCEED THE COST OF CORRECTING DEFECTS IN THE GOODS SOLD OR, ATALPHA SENSORS OPTION, OF REPLACING SAME WITH NONDEFECTIVE GOODS.

WITHOUT LIMITING THE GENERALITY OF THE FOREGOING, THE FOREGOING WARRANTY DOES NOTCOVER, AND NO WARRANTY IS MADE WITH RESPECT TO :

A. Failures not reported within the warranty period above specified.

B. Failures or damage due to negligence (other than that of Alpha Sensors ), accident, improper installation,improper operation or abnormal conditions of temperature, moisture, dirt or corrosion.

C. Goods which have been tampered with, repaired or altered by anyone other than an authorizedrepresentative of Alpha Sensors

D. Goods damaged in shipment or otherwise without fault of Alpha Sensors.

E. Expenses incurred by Purchaser in an attempt to correct or repair any alleged defect, unless approved byAlpha Sensors in writing.

F. Components and other materials purchased by Alpha Sensors from other manufacturers and resold toPurchaser either in the form acquired by Alpha Sensors or in assembly with other components andmaterials. As an accommodation to Purchaser, Alpha Sensors will, upon request of Purchaser, assign toPurchaser any rights it may have arising out of warranties given by any manufacturer of suchcomponents, materials or standard equipment purchased by Alpha Sensors and so resold to purchaser

G. Any goods manufactured by Alpha Sensors in response to Purchasers specifications therefor which gobeyond the existing state of the art. Alpha Sensors assumes no liability for any failure of such goods so tomeet such specifications.

H. Failure or defects attributable to design or specifications requested by Purchaser.

I. Specifications and dimensions shown in this quotation which are approximate and are subject to minordeviations or tolerances in accordance with industry standards.

J. Such components which by their nature in normal usage of the goods in accordance with Alpha Sensorsspecifications therefor, have a life expectancy shorter than the warranty period, referred to as consumables,.

K. If original seals on instrument are tampered with then all warranties on the equipment are immediatelyterminated.

Any representation or warranty beyond that expressly contained herein, whether made prior to or subsequent tothe date hereof, are not authorized by Alpha Sensors and shall have not force or effect and shall not be bindingupon Alpha Sensors.

Sr. No : ALPHA/2012/TBM/1196Month of Manufacture : May. 2012


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Dyna.WELD


USER MANUAL


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INDEX

SR.NO

TOPIC PAGE

1WHAT IS CAPACITANCEWELDING 3

2INTRODUCTION OF Dyna.WELD

and SPECIFICATION3

3

PART DIAGRAM & ACCESORYLIST 4

4 INSTALLATION & SETUP 5

5 OPERATIONS & CONTROLS 5

6 MAINTENANCE7

7 SAFETY &TIPS 8

8. RESISTANCE WELDING 9

9. WARRANTY CERTIFICATE 10

10. ENERGY NOTING SHEET 11


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July 2011

MODEL:Dyna.WELD



OPERATING INSTRUCTIONS1.0 WHAT IS CAPACITANCE WELDING?

In an electrical charge a preset energy level is stored .This charge is then released acrosstwo electrodes the negative electrode being the work piece. This discharge of stored

energy is sufficient to form the weld.

Capacitance welding is generally used for the welding of similar and dissimilar wires(thermocouple junction welds) and for impact welding wires to a conductive material.

2.0 INTRODUCTION OF Dyna.WELD

The DYNAWELD is a versatile welder capable of the rapid production of reliablecommercial and reference Thermocouple junctions and of connecting extension leads toMI Thermocouples, Resistance Thermometer Detectors and other transducers. It may

also be used to attach Thermocouple and other wires to solid metal surfaces, such aspipes, boiler plates, engine blocks, power semiconductors and printed circuit tracks.

No special skills are required for its successful operation and most people will be capableof producing quality work after only a few minutes practice.

2.1 SPECIFICATIONS :

A) TECHNICALWelding System Capacitive Discharge.

Energy Range 4 to 80 Joules.Welding Capacity 0.1 to 1.2mm dia. wires

36 to 20 SWG.

Supply Voltage 220 / 240 VAC 45 / 65 hz.

Power Consumption 170 VA maximum.

Fuse 2 amp / 250 V, 20mm glass.

Duty Cycle Continuous.

Dimensions 215W x 87H x 195D (mm).

Weight Approx. 6 kgs


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July 2011

MODEL:Dyna.WELD



PARTS :

.

2.2 ACCESSORIES LIST

Sr,No Description Quantity

1. Dyna.WELDER Main Module 1 nos.

2. Footswitch 1 nos.

3. IEC Mains Cable 1 nos.

4. Spare Electrodes 5 nos.

5. Welding Pliers 1 nos.

6. Magnifying Glass 1 nos.

7. User Manual 1 nos.

8. Allen Key 1 nos.

9 Operation Manual Video CD 1 nos.


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In the table below are some combinations of Capacitor Bank Selection and ChargeVoltage based on trials made by us. This table is for representation purposes only to givethe user a idea of operation. We always advise the user to make his own trials and arriveat suitable combinations suiting his application requirement. We have provided format ofenergy Noting sheet at the back of this manual for recording observations of the user.

TABLE 1

WireDiameter(mm)

Charge Voltage Setting (V)

With X1 With X2 With X3

0.1 25 V 18 V 15 V

0.3 28 V 20 V 18 V

0.5 - 27 V 25 V

0.8 - - 36 V

0.9 - - 40 V

1.0 - - 45 V

**Note: These are few combinations mentioned. Various other combinations can bemade with different banks (X1,X2,X3) and voltage level. The energy combinationdetermines the type of bead formed. Some applications require a round bead for usage ofthermocouple in harsh environments and in some cases the application requires athermocouple bead with minimum mass for fast response.

NEW FEATURE !!!! : In this model we have added a further feature of using the energybanks in combination. You can now combine energy of two or more banks and dischargethem at one time. This will help you in controlling the bead size formed.For Example : By Shorting Banks X1 and X2 together and connecting the plier to eitherX1 or X2 you can harness the combined energy stored in capacitors of bank X1 and X2.Similarly you can short X1 and X3 , X2 and X3 OR X1, X2 and X3 . It is recommendedthat the user analyses various options available and decides on the best combination forthe type of weld required.

STEP IV : Press the Initiate Charging button on the front panel of the machine. The

Charging LED will blink till the charging process is complete. Once the LED stops blinking, it indicates that charging is complete


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MODEL:Dyna.WELD



4.3 PREPARING WIRES.

STEP V : Insulated wires should have their insulation stripped sufficiently to allow at least5mm protruding when gripped in the pliers. They should be laid side by side and incontact such that the ends square and level. With smaller diameter wires it will be foundadvantageous to twist them together before trimming .This also applies when weldingstranded wires together or stranded wires to solid wires.

4.4 WELD ACTION.

STEP VI : Grip the wires in the holding pliers and bring them near the carbon electrode.Check if the charge voltage is stable or is still increasing value. The wires should be heldtightly so that always there is positive contact. Position the wires such that they areapprox 0.5mm to 1mm away from the carbon electrode. The Purge/Weld Switch mustbe on the WELD side. Initiate weld sequence by pressing the footswitch. WELDSequence will first purge the weld area with argon gas and then within 20 secondsautomatically discharge the stored energy to weld the thermocouple wires together. Afterdischarge the system will automatically charge to preset charge voltage level for nextweld.

4.5 OPTIONAL WELD ACTION I IMPACT WELD ACTION

This is the term used for welding wires to a metal (conductive) surface. This type ofapplication is common when the wires are required to be welded to a chassis orframework for testing or heat treatment application.

Connect the surface on which the wires is to be welded to the Impact Welding Socket.Negative (-ve.) socket provided on the front panel of Dyna.WELD 80J using a lead wirewith one end terminated in a banana plug and the other end terminated in a alligator

clip.The alligator clip should then be attached to the surface close to where the wiresneed to be attached.

The prepared wires are then gripped in the wire holding pliers and then pressed on to thesurface to which they are to be attached.

The weld action describe above should be then followed and when the footswitch isdepressed, the resulting discharge will weld the wires to the surface after which the weldclip can be removed.

4.6 WELD QUALITY.

Examine the weld using the magnifying glass supplied. A good weld will produce a strongjoint between the wires and usually forms a round bead. A flat bridge between the wiresindicates too low setting. A flattened hemisphere indicates that energy setting is too high.


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July 2011

MODEL:Dyna.WELD



5.0 MAINTENANCE.

Apart from Carbon electrode replacement, the Dyna.WELD 80J contains no userserviceable parts. In the event of failure, please return the welder, carefully packed, to thedistributor from which it was purchased who will arrange for the necessary repair.

5.1 Carbon Electrode Replacement.

After considerable use, the carbon electrode will need attention. The carbon may betrimmed in a drill or lathe chuck using a metal file to give an included angle of about 30 0

with the tip approx. 2mm diameter.

To remove the carbon electrode slacken the grub screw on the argon shield (Allen keyprovided)and pull off the shield. Slacken the grub screw on the the electrode holder andwithdraw the electrode.

When fitting a new or trimmed electrode, insert it loosely until it lines up with the front face

of the shield. Tighten the grub screw & replace the argon shield.

6.0 SAFETY AND TIPS.

Use of Red Welding Glass filter to protect the eyes from the welding flashes isrecommended. A bench lamp positioned over the welder will permit the work and carbonelectrode tip to be easily seen.

Accidental over setting of the energy level can result in flying particles and it is strongly

recommended that welding goggles are used at all times.

If the pliers become pitted or soiled, clean the faces by pulling through a piece of foldedfine emery paper whilst applying slight pressure to the handles.

Keep a note book by the welder and make a record of the setting for each type of job.Noting wire size, materials and energy setting .


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