THERMOCOUPLE WELDER - AMADA MIYACHI AMERICA
Contents
1. 2 4 3 1 Thermocouple Wire Insertion Procedure 3 1 THERMOCOUPLE WELDER vi 990 070 CHAPTER 1 SYSTEM DESCRIPTION Introduction The Miyachi Unitek Model TCW Thermocouple Welder Stock Number 01 196 02 is a manual feed thermocouple welder designed to weld thermocouple wires together to form a thermocouple junction uniform in size and without detrimental oxide layers when used with argon cover gas Four different size Wire Clamp Jaws which are inserted into the TCW Handpiece permit joining of most thermocouple wire materials that ranges in diameter from 38 AWG 0040 inch to 20 AWG 0320 inch The circuitry is solid state with components conservatively rated when used within the maximum specified repetition rates The unique charging circuit uses thyristors to provide high reliability and precise charging intervals Operator safety is ensured through the use of multiple earth ground connections Power Supply Description The Model TCW combines capacitor discharge power supply and Tungsten Inert Gas TIG welding technology to make a thermocouple junction Line Voltage Line voltage is 115 208 or 230 Volts 60 50 Hz The Thermocouple Welder TCW is a multi voltage unit is normally connected for 115V 60 50 Hz operation unless otherwise specified on the nameplate and the label attached to the line cord The actual line voltage should b2. Primary Wiring for 208VAC Models L2 TO 115VAC SOLENOID VALVE CB1 Q 0 03 S1B 1 O Primary Wiring for 230VAC Models L2 TO 115VAC SOLENOID VALVE 2 0 03A 7 S1B 1 O O Figure 2 1 Power Supply Connections THERMOCOUPLE WELDER 2 2 990 070 CHAPTER 2 INSTALLATION Section Il Thermocouple Wire Preparation Insulation Stripping The jacket insulation and the insulation covering both thermocouple wires must be stripped back a MINIMUM distance from the end of the wire where the weld is to take place Proper removal of the insulation allows the bare thermocouple wires to protrude a minimum distance from the end of the Handpiece Wire Clamping Jaws Mechanical strippers with oval shaped cutters work best Do not use Thermal Strippers with Teflon Coated Wires Thermal stripping Teflon leaves a thin Teflon coating on the wires preventing weld current from flowing When properly stripped the bare thermocouple wires will be of equal length parallel and free of insulation residue The table below gives the minimum wire stripping length for each wire size Wire Size Stock No Model No ID No Strip Length Strip Length AWG Inches MM 38 32 10 293 01 TCWCS38 1 200 5 08 31 27 10 294 01 TCWCS31 2 200 5 08 26 23 10 295 01 TCWCS26 B 200 220 5 08 5 59 22 20 10 296 01 TCWCS22 4 200 220 5 08 5 59 The recommend
3. THERMOCOUPLE WELDER 990 070 1 3 CHAPTER 1 SYSTEM DESCRIPTION Physical Dimensions HEIGHT 6 7 8 inch WIDTH 10 inch DEPTH 10 inch WEIGHT 16 2 lbs Handpiece Specifications 17 5 cm 26 0 cm 25 4 cm 7 4 kg Includes Handpiece The Model TCW Handpiece is not supplied with any Wire Clamp Jaw Assemblies A single Wire Clamp Jaw Assembly of the proper gauge is required to operate the TCW Four Wire Clamp Jaw Assemblies are available for use with different gauge wires The table below defines which Wire Clamp Jaw Assembly should be used with each wire diameter size Wire Size AWG 38 32 31 27 26 23 22 20 THERMOCOUPLE WELDER 1 4 10 293 01 10 294 01 10 295 01 10 296 01 990 070 CHAPTER 1 SYSTEM DESCRIPTION Wire Gauge Diameter Specifications The table below defines the maximum outer jacket insulation size for each wire gauge It does not refer to the insulation covering each wire Nominal Wire Size Max Insulation Nominal Wire Size Max Insulation AWG Diameter Diameter AWG Diameter Diameter inch mm inch mm inch mm inch mm 38 0040 11016 038 0 97 28 0126 3200 055 1 40 37 0045 1143 038 0 97 21 0142 3607 055 1 40 36 0050 1270 038 0 97 26 0159 4039 124 3 15 35 0056 1422 038 0 97 25 0179 4547 124 3 15 34 0063 1600 038 0 97 24 0201 5105 124 3 15 33 0071 1803 038 0 97 23 0226 5740 124 3 15 32 0080 2032 038 0 97 22 0253 6426 159 4 04 31 0089 2261 055 1 40 21 028
4. fluv nei ese dus 1 4 Wire Gauge Diameter Specifications sum adden rtu an E REM Ege 1 5 1 5 SITIS ATE INDE TS NNI T m 1 5 Physical eis pis eivnvhtrh aes ranean ean 1 6 Arpon Purge GaS NUNT SN NO 1 6 arcHdo APA H 1 6 Argon POS Gas SMU err 1 7 THERMOCOUPLE WELDER 990 070 CONTENTS Continued Page CHAPTER 2 INSTALLATION y Hd NGA due 2 1 Section I Power Supply titi copisadsctostheuadeasuiegustasabengasrdahasthecesstsuntantens 2 1 Power SUNY c 2 1 Section II Thermocouple Wire Preparation sb trae debe Maas ad Dd lock De 2 3 HEMP 2255 aad eade Spe Maxi daga dv 2 3 Handpiece Wire Clamping Jaws Installation tl de a o 2 4 Wire Clamp Jaw Removal and Insertion 2 uei einseee 2 4 CHAPTER 3 OPERATING INSTRUCTIONS 3 1 Section I Operation Em 3 1 CHAPTER 4 USER MAINTENANCE 4 1 Section I Handpiece Maintenance babet 4 1 Wire
5. shipped prepaid Please include information concerning the type of problem you are experiencing Include with the shipping information the name and telephone number of the person whom we should call with the estimated cost of repairs THERMOCOUPLE WELDER 5 2 990 070
6. 3 43 mm from the end of the Wire Clamp Jaw See figure 3 1 Clamp the thermocouple wires together by closing the Handpiece Wire Clamp Tube Wires Must Wire Clamp Tube Touch When Clamped NN SSO Thermocouple 4 Thermocouple Y A Wire Clamp Tube Overview B Wire Clamp Tube Close up Figure 3 1 Thermocouple wire insertion procedure NOTE It may be more comfortable to feed the thermocouple wire into the Handpiece with your dominant hand while using the other hand to hold and operate the Handpiece The black Loading THERMOCOUPLE WELDER 990 070 3 1 CHAPTER 3 OPERATING INSTRUCTIONS 3 2 Button can be placed on either side of the Handpiece to accommodate left or right hand operation See Chapter 4 Verify that the WELD READY lamp is on and then gently slide the closed Wire Clamp Jaws into the Weld Chamber When the ends of the thermocouple wires touch the Arc Button located inside the Weld Chamber a solenoid lightly clamps the Wire Clamp Jaws and then automatically fires the power supply Remove the Handpiece after the thump sound has occurred which indicates that the TCW has fired Open the Wire Clamp Jaws and remove the welded thermocouple wire The weld bead should appear round and without oxidation It should not be necessary to change the wire gauge setting more than 2 or 3 wire sizes Adjust the WIRE GAUGE SELECTOR to produce the desired weld bead Turning the Control CLOCKWISE will INCREA
7. 5 7239 159 4 04 30 0100 2540 055 1 40 20 0320 8128 139 4 04 29 0113 2870 055 1 40 Initiation The Handpiece must be correctly inserted into the Weld Chamber to initiate firing The two thermocouple wires loaded in the Handpiece must touch the Arc Button located inside the Weld Chamber in order to initiate a weld The firing sequence ensures that the Handpiece is double earth grounded for maximum operator safety Internal power supply filtering prevents premature firing due to radio frequency interference Safety Features Double earth grounded techniques eliminate the possibility of electrical shock to the operator The Handpiece used to hold the thermocouple wires is earth grounded to the TCW chassis using a non removable cable The length of the cable prevents injury to the Handpiece should it fall off a table or bench that is a minimum of 30 inches high When the Handpiece is placed in the Weld Chamber a solenoid mechanically clamps the Handpiece creating a second earth ground path THERMOCOUPLE WELDER 990 070 1 5 CHAPTER 1 SYSTEM DESCRIPTION Physical Dimensions BODY LENGTH 4 inch 10 16 cm BODY DIAMETER inch 1 91 cm WIRE CLAMP LENGTH inch 1 91 cm WIRE CLAMP DIAMETER Ya inch 0 64 cm WEIGHT 2 Ibs 91 gm Argon Purge Gas Thermocouple welding is performed in an argon filled Weld Chamber which is located on the center upper face of the TCW Argon purge gas is necessary to prevent thermocouple joint oxidat
8. Clamp cs 4 1 Handpiece Cable Replacement na moa 4 1 Section II Weld Chamber Maintenance cce reine derent ra qe peu ER 4 4 CHAPTER S SERVICE NND RN 5 1 S ction T IN aan atest sdb dera ON 5 1 Section II Troubleshooting 5 1 Thermocouple Weld is Dirty or Inconsistent tir ub estu ius 5 1 Poor Welds or Pate to Weld 5 1 NO UPC is 5 1 Thermocouple Stuck in Wire Clamp Tube sco e AME here Cuin COD PI AREE 5 1 Section Mi Repair SerViCE wei 5 2 Technical Assistance 5 2 Telephone PSTN 5 2 Factory Service 5 2 ILLUSTRATIONS Figure Title Page 1 1 Front and Back Picture of TCW EbUBE SUN GUN MER MS 1 2 2 1 TCW Schematic Sheet 2 Power Connections 2 2 2 2 Wire Clamp Jaw Assembly FM
9. SE the size of the weld bead NOTE If weld bead is too large it cannot be pulled back through the Wire Clamp guide tube See Chapter 5 Section II Troubleshooting THERMOCOUPLE WELDER 990 070 CHAPTER 4 USER MAINTENANCE Section I Handpiece Maintenance Wire Clamp Jaws With use the Upper Wire Clamp Jaw will accumulate wire insulation and metal particles inside the Guide Tube The buildup rate depends on the number of thermocouple welds made the thermocouple insulation material and the thermocouple wire material The larger size wires will accumulate particles at a faster rate To clean both Wire Clamps remove them from the Handpiece and place them in an ultrasonic cleaner Add cleaning solvent such as Micro Model 8790 00 Liquid Lab Cleaner distributed by Cole Parmer WARNING Do not use a wire to clean the upper Wire Clamp guide tube Doing so may cause internal damage to the guide tube Handpiece Cable Replacement The Handpiece Cable is very flexible and should last many years with careful use Should the insulation become cracked at either the Handpiece or Power Supply front attachments return the unit to Unitek Miyachi See Chapter 5 Section III Repair Service Section Weld Chamber Maintenance Over time the thermocouple weld bead will become dirty in appearance signaling an undesirable buildup of thermocouple weld material on the Arc Button located inside of the Weld Chamber If the Arc Button is not periodic
10. USER S MANUAL 990 070 2377 MIYACHI December 2011 CINITEK THERMOCOUPLE WELDER WIRE GAGE SELECTION 30 28 26 32 24 22 MIYACHI WELDER WIN UOT PES Km POWER Copyright 1990 2002 2007 Miyachi Unitek Corporation The engineering designs drawings and data contained herein are the proprietary work of MIYACHI UNITEK CORPORATION and may not be reproduced copied exhibited or otherwise used without the written authorization of MIY ACHI UNITEK CORPORATION Printed in the United States of America Revision Record Basis of Revision Original Manual 1 Add Unitek Peco name 2 Update manual Correct error in Table of Contents and update to Miyachi Unitek corporate logo Updated to Miyachi Unitek labeling THERMOCOUPLE WELDER 990 070 FOREWORD Thank you for purchasing a Miyachi Unitek Thermocouple Welder Upon receipt of your equipment please thoroughly inspect it for shipping damage prior to its installation Should there be any damage please immediately contact the shipping company to file a claim and notify Miyachi Unitek Corporation at 1820 South Myrtle Avenue P O Box 5033 Monrovia CA 91017 7133 Telephone 626 303 5676 FAX 626 358 8048 e mail info unitekmiyachi com The purpose of this manual is to supply operating and maintenance personnel with the information needed to properly and safely operate and maintain the Thermocouple Welder We
11. age Turndown Circuit The Turndown Circuit allows the user to reduce the energy setting by using the Wire Gauge Selection Control The excess energy stored in the capacitor bank is dissipated internally The Turndown Circuit dead band is approximately 0 6 of the full scale voltage Line Failure Turndown The Line Failure Turndown is a safety feature which ensures that the capacitor bank is automatically discharged whenever the input power is interrupted Weld Fire Lockout This feature helps prevent poor welds by inhibiting firing of the TCW until the energy stored in the capacitor bank is within 1 of the pre selected value Power Switch A rocker switch disconnects both sides of the input power line when switched to the OFF position Weld Ready A yellow lamp indicates that the capacitor bank has been charged or discharged to the proper voltage level and is ready to make a weld Wire Gauge Selector The Wire Gauge Selector controls the level of stored energy necessary to make a thermocouple weld Energy levels are indicated for each American Wire Gauge AWG from 38 AWG to 20 AWG Because of variations in the thermocouple wire diameters and in the melting characteristics of the various thermocouple alloys it may be necessary to increase or decrease the WIRE GAUGE SELECTOR setting to produce a good thermocouple weld This control may also be used to increase or decrease the size of the weld bead to meet specific customer requirements
12. ally resurfaced the weld quality will deteriorate to where a weld cannot be made The buildup rate depends on the number of thermocouple welds made the thermocouple wire material and the thermocouple wire diameter Buildup occurs faster with large gauge wires such as 20 22 AWG and usually appears as a bright metallic deposit on the face of the Arc Button Should this occur return the unit to Unitek Miyachi See Chapter 5 Section III Repair Service THERMOCOUPLE WELDER 990 070 4 1 CHAPTER 5 SERVICE Section Calibration The Model TCW does not require calibration Component tolerances and stability are such that the Capacitor Bank Voltage will not vary from Power Supply to Power Supply by more than 4 for the same WIRE GAUGE SELECTOR setting Section Il Troubleshooting Thermocouple Weld is Dirty or Inconsistent Return the unit to Unitek Miyachi See Section III Repair Service Poor Welds or Failure to Weld Improper wire gauge selection Wrong Wire Clamp Jaws for the thermocouple wire size Poor electrical contact to thermocouple wires Heavy oxide or corrosion on the thermocouple wires Check gas flow Keep thermocouple in Weld Chamber for one second before removing NOTE dark residue is normal with type J thermocouples e Thermocouple wires are different lengths f Thermocouple wires are not touching each other at the tip g Handpiece is forced past the clamping position during welding No Out
13. d Do not mix Wire Clamp sets The identification code on the upper Wire Clamp Jaw must match the identification code on the lower Wire Clamp Jaw THERMOCOUPLE WELDER 2 4 CHAPTER 3 OPERATING INSTRUCTIONS Section Operation e Turn ON the purge gas supply Set the Pressure Regulator to 50 PSIG Set the Flow Regulator for 3 cubic feet per hour e Switch the POWER SWITCH to ON Purge gas from the reservoir will immediately fill the Weld Chamber making the TCW ready to use When replacing the purge gas tank or if the purge gas line has been opened wait 5 minutes for the purge gas to replace the air in the purge gas line reservoir and Weld Chamber See Chapter 2 e Set the WIRE GAUGE SELECTOR to the desired wire gauge size The WELD READY lamp may flicker and go OFF instead of staying ON when the WIRE GAUGE SELECTOR is turned COUNTERCLOCKWISE The first weld may be safely made and the READY LAMP will turn ON for subsequent welds e Grasp the Handpiece in either hand Slide the black Loading Button back toward the square part of the Handpiece Using the opposite hand insert the stripped end of the thermocouple wire into the large open end on the back of the Upper Wire Clamp Jaw Feed the wire into the large open end on the back of the Upper Wire Clamp Jaw Feed the wire into the tube until it stops If the insulated wire slides through the tube without stopping clamp the BARE wire so that it protrudes a minimum of 135 inches
14. e within 13 of the nominal voltage for which the TCW is connected Line Current Ratings Nominal Line Line Voltage Line Frequency Circuit Breaker of Breakers Voltage Range Hz Size Amps Required VRMS VRMS 115 100 130 50 60 a 208 180 235 50 60 x 2 230 200 260 50 60 3 2 THERMOCOUPLE WELDER 990 070 1 1 CHAPTER 1 SYSTEM DESCRIPTION 1 2 60 50 Hz Operation The TCW is a dual frequency machine that does not require calibration for operation at 50 or 60 Hz Standby Power Standby power is approximately 15 watts Stored Energy Rating 1 5 to 190 watt seconds joules Welding Speed The actual weld time is less than 0 1 seconds and the time for the circuitry to recharge is a maximum of 3 seconds The maximum number of welds per minute is limited to how fast the Handpiece can be loaded and inserted into the Weld Chamber Capacitor Bank The Capacitor Bank is 18 300 5 at 20 degrees Celsius At full rating the Capacitor Bank is operated at 144 volts WIRE GAGE SELECTION WNIT EK w POWER m INERT GAS OFF Figure 1 1 Front and Back Views of Thermocouple Welder THERMOCOUPLE WELDER 990 070 CHAPTER 1 SYSTEM DESCRIPTION Line Voltage Regulator The Line Voltage regulator ensures that the welds are independent of changes in line voltage by maintaining the voltage on the capacitor bank within 0 25 of setting for a 13 change in line volt
15. ed tolerance on Strip Length is 0 010 inches 0 0 25 mm Any strip length greater than those shown above is acceptable The TCW Handpiece can be used with non insulated thermocouple wire Non insulated wire must protrude a MINIMUM of 135 inches 3 43 mm from the closed Wire Clamp Jaws THERMOCOUPLE WELDER 990 070 2 3 CHAPTER 2 INSTALLATION Handpiece Wire Clamping Jaws Installation Wire Clamp Jaw Removal and Insertion Loosen the set screws that hold each Wire Clamp Jaw in place Pull each jaw straight out of the Handpiece See figure 2 2 Upper Setscrew Align Here Upper Wire Handpiece Lower Setscrew Body Align Here Lower Wire Clamp Jaw Figure 2 2 Wire Clamp Jaw Assembly To replace the Upper Wire Clamp Assembly open the Handpiece by sliding the black Loading Button back toward the square part of the Handpiece Insert the Wire Clamp Jaw CONTAINING THE GUIDE TUBE into the upper half of the Handpiece Line up the flat wedge shaped face on the Wire Clamp Jaw with the flat surface on the upper Handpiece face Tighten the set screw To replace the Lower Wire Clamp Assembly insert the remaining Wire Clamp Jaw into the lower half of the Handpiece Line up the flat wedge shaped face on the Wire Clamp Jaw with the flat surface on the upper Handpiece face Tighten the set screw Close the Handpiece by sliding the black Loading Button forward Both halves should be flush at the tip when the tip is close
16. 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 Miyachi Unitek Corporation is not responsible for any loss due to improper use of this product THERMOCOUPLE WELDER 990 070 SAFETY NOTES This instruction manual describes how to operate maintain and service the Thermocouple Welder and provides instructions relating to its SAFE use Procedures described in this manual MUST be performed as detailed by QUALIFIED and TRAINED personnel For SAFETY and to effectively take advantage of the full capabilities of the tester please read these instruction manuals before attempting to use the workstation Procedures other than those described in this manual or not performed as prescribed in it may expose personnel to electrical hazards After reading this manual retain it for future reference when any questions arise regarding the proper and SAFE operation of the tester Please note the following conventions used in this manual WARNING Comments marked this way warn the reader of actions which if not followed might result in immediate death or serious injury CAUTION Comments marked this way warn the reader of actions which if not followed might result in either damage to the equipment or injury to the individual if subject to long term exposure to the indica
17. ion during the welding process NOTE Nitrogen is not effective as a purge gas Gas Flow 3 cubic feet per hour nominal Argon Purge Gas Shutoff An internal solenoid valve blocks the flow of argon purge gas to the Weld chamber when input power to the TCW is turned off NOTE For this system to be economical the user must eliminate all leaks in the gas system feeding the Model TCW When the input power is on gas flow is continuous An internal gas reservoir located between the purge gas input connector and the shutoff solenoid stores a sufficient amount of argon purge gas to immediately clear out the Weld Chamber when the TCW is turned back on THERMOCOUPLE WELDER 1 6 990 070 CHAPTER 2 INSTALLATION Section Power Supply Installation Power Supply CAUTION Do not connect the Thermocouple Welder to the power line at this time Check the voltage label on the line cord At the time of shipment the voltage for which the Thermocouple Welder was connected was marked on the line cord Do not connect the Thermocouple Welder to any voltage without properly changing the internal connections The TCW was assembled at the factory for operation at a specific line voltage If the TCW is used on a line voltage other than the one for which it is connected serious damage can result Most Thermocouple Welders are shipped from the factory wired for 115 volt 50 60 Hz operation To check whether the TCW is connected for 115 or 230 volts f
18. ollow steps below e Turn the WIRE GAUGE SELECTOR fully counter clockwise to 40 Verify that the POWER switch is in the OFF position and that the line cord is disconnected If power was previously applied wait one minute to ensure that the Capacitor bank is fully discharged e Loosen the four screws which secure the cover and lift the cover straight up to remove it The different transformer connections and circuit breakers for each specific line voltage are illustrated in figure 2 1 e Replace the cover and tighten the screws Change the line cord plug if necessary If necessary change or replace the voltage label on the line cord to show the correct operating voltage Miyachi Unitek recommends that the Thermocouple Welder TCW be installed in a well ventilated area free of dirt and moisture The Thermocouple Welder is a self contained unit designed to minimize installation and setup time Connect the Purge Gas Inlet Port located on the rear panel of TCW to a PROPERLY FILTERED ARGON GAS SUPPLY using 0 25 O D x 0 17 LD 120 PSI plastic tubing Turn ON the purge gas supply Set the Pressure Regulator to 50 PSIG Set the Flow Regulator for 3 cubic feet per hour Repair leaks 1f necessary THERMOCOUPLE WELDER 990 070 2 1 CHAPTER 2 INSTALLATION Primary Wiring for 115VAC Models L2 TO 115VAC SOLENOID VALVE 0 01 S1B 1 O CB1 A 0 05 77 S1A 4 6 C1
19. put Bad Control Board Assembly Weld Capacitor or Arc Button or Wire Clamp Solenoid malfunction Unitek Miyachi strongly recommends that the Power Supply be returned to the factory for service See Section III Repair Service Thermocouple Stuck in Wire Clamp Tube If the weld bead is larger than the inside of the Wire Clamp Tube the thermocouple wire cannot be removed without first cutting off the weld bead using a flush cutting wire cutter or a sharp knife Avoid cutting or nicking the Wire Clamp Tube THERMOCOUPLE WELDER 990 070 5 1 CHAPTER 5 SERVICE Section Ill Repair Service Technical Assistance If you need further technical assistance please contact either your authorized service agent or Unitek Miyachi at the postal or e mail address or telephone or FAX number shown in the Foreword of this manual Before calling please obtain the model number stock number and the serial number from the name plate on the product Telephone Service Call the our Repair Department at the telephone number shown in the Foreword of this manual Before calling please obtain the model number and serial number from the identification plate on the rear panel Factory Service Repair We provide a repair service for both warranty and non warranty repairs Call our Customer Service Department at the telephone number shown in the Foreword of this manual for a Return Material Authorization number All equipment to be returned to us for repair must be
20. ted hazard THERMOCOUPLE WELDER iv 990 070 CONTENTS Page REAS OI SCOR MD ii POLS WOT M iii Safety NOTES THO rr PHP iv CHAPTER 1 SYSTEM DESCRIPTION 1 1 NR 1 1 Power e 1 1 932 91 10 basa ae M LU M dE 1 1 Voltag ree n 1 1 Li e uten Bat gesis riria iep i Rd deese APO 1 1 60 50 HZ Op ration us osten Qe bise duse busta kese En uita t Ga cif ESE Lua usd Ds 1 2 Standby POWET 1 2 Stored Energy M Ute 1 2 Welding Speed MR E TT 1 2 Capacitor Bank de 1 2 Line Voltage Regulator MMC S 1 3 T rmmdown CCAD sratine M 1 3 Line Failure Tid Wat 1 3 deiecit 1 3 SWIC EH Ecc 1 3 Weld Reddy TERRAIN 1 3 Wire Gauge Selector RR Cc uUu 1 4 1 4 Handpiece Specifications asec cnes sp
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