Thinline 80 Technical Manual

Add to my manuals
84 Pages

advertisement

Thinline 80 Technical Manual | Manualzz
USER'S MANUAL
990-121
REVISION G
August 2008
THIN-LINE® Series 80
Weld and Reflow Solder Heads
MODEL
NUMBER
80F
80FLF
80F/DC
80A/115
80A/EZ
80A/24
82A/115
82A/24
83A/24
83F
STOCK
NUMBER
2-142-XX-00
2-142-XX-01
2-142-XX-02
2-143-XX-00
2-143-XX-01
2-1143-XX-00
2-157-XX-01
2-157-XX-00
2-212-XX-00
2-121-XX-00
MODEL
NUMBER
84F
84A/24
84A/115
84SA
86F
86FRE
86A/115
86A/24
86ARE/24
86A/EZ
STOCK
NUMBER
2-206-XX-00
2-207-XX-00
2-207-XX-01
2-181-XX-01
2-181-XX
2-146-XX-00
2-146-XX-01
2-148-XX-00
2-148-XX-01
2-148-XX-02
MODEL
NUMBER
87F
87FLF
87A/115
87A/24
87SA
88A/115
88A/24
88F
89F
89A/24
89A/EZ
STOCK
NUMBER
2-158-XX-00
2-158-XX-02
2-159-XX-03
2-159-XX-03
2-180-XX-01
2-160-XX-00
2-160-XX-00
2-161-XX-01
2-209-XX-00
2-210-XX-00
2-210-XX-00
Copyright © 2001, 2008 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 MIYACHI UNITEK CORPORATION.
Printed in the United States of America.
REVISION RECORD
Revision
EO
Date
A
None
2/96
Basis of Revision
None. Original edition.
Upgrade and add new equipment information.
B
C
17809
3/99
Change Hall Effect switch wire colors.
D
17791
2/99
Add 84SA/24 and 87SA/24.
E
19339
10/01
Major revision/reformat.
F
21776
5/08
Update to Miyachi Unitek logo, and added new CAUTION
information.
G
21853
8/08
Updated reflow information, specifications, & accessories.
CONTENTS
Page
Revision Record
Contents
Contact Us
Safety Warnings
........................................................................................................................................ ii
....................................................................................................................................... iii
....................................................................................................................................... vi
...................................................................................................................................... vii
Chapter 1. System Description ........................................................................................................... 1-1
Section I. Features .......................................................................................................................... 1-1
Overview .................................................................................................................................. 1-1
Preset Firing Force .................................................................................................................... 1-1
Up and Down Stops .................................................................................................................. 1-2
Electrodes ................................................................................................................................. 1-2
Insulation .................................................................................................................................. 1-2
Welding Cables ........................................................................................................................ 1-2
Footpedal Actuation ................................................................................................................. 1-2
Air Actuation ............................................................................................................................ 1-2
Standard Air-Actuation ..................................................................................................... 1-3
EZ-AIR“ ............................................................................................................................ 1-3
Reflow Soldering ...................................................................................................................... 1-3
Section II. System Components ...................................................................................................... 1-4
Model 80A and 80F .................................................................................................................. 1-4
Model 80FLF ............................................................................................................................ 1-4
Model 82A ................................................................................................................................ 1-5
Model 83A and 83F .................................................................................................................. 1-5
Model 84A and 84F .................................................................................................................. 1-5
Model 87A and 87F .................................................................................................................. 1-5
Model 88A and 88F .................................................................................................................. 1-6
Model 89A and 89F .................................................................................................................. 1-6
Models 87SA and 84SA ........................................................................................................... 1-6
Section III. Welding Capabilities ................................................................................................... 1-8
Series Welding .......................................................................................................................... 1-8
Step Welding ............................................................................................................................ 1-8
Section IV. Operating Controls ...................................................................................................... 1-9
Series 80 Air Actuation Specifications .................................................................................... 1-9
Air Cylinders ............................................................................................................................ 1-9
Hall Effect Limit Switch Option .............................................................................................. 1-9
Footswitches ........................................................................................................................... 1-10
THIN-LINE® SERIES 80 WELD HEADS
990-121
iii
Page
Chapter 2. Installation ......................................................................................................................... 2-1
Section I. Introduction .................................................................................................................... 2-1
Overview .................................................................................................................................. 2-1
Mounting Posts ......................................................................................................................... 2-1
Mounting Tube .................................................................................................................. 2-1
Dual-Post ........................................................................................................................... 2-2
Channeled-Post .................................................................................................................. 2-2
Section II. Weld Head Installation ................................................................................................. 2-3
Overview .................................................................................................................................. 2-3
Typical Installation ................................................................................................................... 2-3
Model 80F, 86F, and 87F Model CP Footpedal Installation .................................................... 2-7
Model 83F, 84F, 88F, and 89F Model MSP Footpedal Installation ........................................ 2-8
Model 82A Air Head Installation ............................................................................................. 2-9
Model 80A, 83A, 84A, 86A, 87A, 88A, and 89A Air Head Installation ............................... 2-10
Model 80A/EZ, 86A/EZ, and 89A/EZ EZ-AIR Installation .................................................. 2-12
Optics ................................................................................................................................... 2-12
Section III. Connect Weld Cables ................................................................................................ 2-13
Weld Cables and Energy Losses ............................................................................................ 2-13
Connect Cables to Head ......................................................................................................... 2-13
Section IV. Install Electrodes for Welding ................................................................................... 2-15
Model 80 and 84 ..................................................................................................................... 2-15
Model 82 and 83 ..................................................................................................................... 2-15
Model 88 and 89 ..................................................................................................................... 2-16
Model 86 -- Unibond Electrodes ............................................................................................ 2-16
Model 86 -- Unitip Electrodes ................................................................................................ 2-17
Model 87 -- Unitip Electrodes ................................................................................................ 2-18
Section V. Install Thermodes for Reflow Soldering .................................................................... 2-20
Model 87 -- 17 Fold-Up, 17P Peg, or 17SR Single Point Thermodes ................................... 2-21
Model 87 -- 17BM Blade Thermodes .................................................................................... 2-22
Section VI. Install Optional Equipment ....................................................................................... 2-23
Model 88 and 89 -- Install DFS/88 Series Firing Switch Junction Box ................................. 2-23
Connect Optional Hall Effect Limit Switch ........................................................................... 2-23
Chapter 3. Operating Instructions ..................................................................................................... 3-1
Section I. Getting Started ................................................................................................................ 3-1
Installation Checklists .............................................................................................................. 3-1
Welding Force Theory .............................................................................................................. 3-2
Troubleshooting ........................................................................................................................ 3-2
Reflow Soldering Force ............................................................................................................ 3-4
THIN-LINE® SERIES 80 WELD HEADS
iv
990-121
CONTENTS (Continued)
Page
Section II. Model 80A, 82A, 83A, 84A, 86A, and 87A Standard Air-Actuated Head Setup ........ 3-5
Section III. Model 80A/EZ and 86A/EZ EZ-AIR Air-Actuated Head Setup ................................ 3-7
Section IV. Model 88A and 89A Standard Air-Actuated Head Setup ........................................... 3-9
Section V. Model 89A/EZ EZ-AIR Air-Actuated Head Setup .................................................... 3-12
Section VI. Model 80F, 83F, 84F, 86F, and 87F Manually-Actuated Head Setup ...................... 3-14
Section VII. Model 88F and 89F Manually-Actuated Head Setup .............................................. 3-16
Chapter 4. User Maintenance ............................................................................................................. 4-1
Section I. General Maintenance ...................................................................................................... 4-1
Inspection ................................................................................................................................. 4-1
Lubrication ............................................................................................................................... 4-1
Section II. Standard Resistance Welding Electrode Cleaning ........................................................ 4-1
Section III. Unitip Electrode Maintenance ..................................................................................... 4-2
Section IV. Tare Spring Adjustment -- Model 80, 86, 87, and 88 ................................................. 4-4
Appendix A. Technical Specifications ............................................................................................... A-1
Appendix B. Accessories ......................................................................................................................B-1
THIN-LINE® SERIES 80 WELD HEADS
990-121
v
CONTACT US
Thank you for purchasing a Miyachi Unitek¥ THIN-LINE“ SERIES 80 Weld Head.
Upon receipt of your equipment, please thoroughly inspect it for shipping damage before its installation.
Should there be any damage, please immediately contact the shipping company to file a claim, and
notify us at:
Miyachi Unitek
1820 South Myrtle Avenue
P.O. Box 5033
Monrovia, CA 91017-7133
Telephone: (626) 303-5676
FAX:
(626) 358-8048
e-mail:
[email protected]
The purpose of this manual is to supply operating, maintenance and service personnel with the
information needed to properly and safely operate and service the THIN-LINE“ SERIES 80 Weld
Heads.
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.
Miyachi Unitek is not responsible for any loss due to improper use of this product.
THIN-LINE® SERIES 80 WELD HEADS
vi
990-121
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
Do not modify the electrode holders or attach additional mechanisms to the
moving parts of the head. Doing so may hurt welding performance, damage
the head, and void the warranty.
x
Never work on electronic equipment unless there is another person nearby
who is familiar with the operation and hazards of the equipment, and who is
competent in administering first aid. The technician who is aided by
operators must warn them about the hazards.
x
Whenever possible, turn the power supply to the equipment OFF before
beginning work on it.
x
Do not touch high-voltage connections, including input power connections,
when installing or operating the equipment.
x
Do not be misled by the term "low voltage." Potentials as low as 50 volts can
be lethal under certain conditions.
THIN-LINE® SERIES 80 WELD HEADS
990-121
vii
CHAPTER 1:
SYSTEM DESCRIPTION
Section I. Features
Overview
This manual is organized to assist you in getting productive quickly with your THIN-LINE® Series 80
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.
Series 80 Weld heads come in different sizes and configurations and may be installed on Miyachi
Unitek mounting hardware, custom mounting posts, or installed directly on your equipment using the
two tapped holes on the rear of the weld head. Some heads are manually-actuated, others are airactuated. Mounting templates and all necessary installation hardware are shipped with each weld head.
Miyachi Unitek THIN-LINE Series 80 are precision, low inertia, force-fired Weld Heads with a narrow
vertical profile. The 1-3/4 inch (4.5 cm) width, 1 in. (2.5 cm) stroke, 20-40 pound (89-178 N) maximum
force range, and throat depth allow their use in a wide variety of precision resistance welding
applications. Both in-line and offset electrode holders are available. The dimensions of the mounting
post and the main shaft have been selected to ensure that the electrodes do not "wipe" more than 0.003
in. (0.076 mm) on the 20 lb. (89 N) heads and 0.004 in. (0.102 mm) on the 40 lb. (178 N) heads. This is
an important consideration in critical welding applications such as hermetic seals and pressure
transducers.
The Series 80 is a "production line" head with a bearing life designed for a minimum of 20 million
operations. Miyachi Unitek Weld Heads excel at precisely placing consistent, high quality welds. Their
low inertia, lightweight design assures fast dynamic response, allowing the electrodes to follow the
minute expansion and contraction of the weld joint as it heats and cools during the welding cycle. A
differential motion Force-Firing System initiates the power source at the precise moment the Preset
Firing Force is applied to the workpieces. Linear ball bearing bushings and an oversized, anti-rotational
bearing system provide true, vertical in-line electrode motion, assuring smooth vertical travel of the
upper electrode arm. This system minimizes the wiping action of the electrodes, even at maximum force
settings.
Preset Firing Force
Firing force is continuously adjustable from 8 ounces (0.22 kg), 4 ounces (0.11 kg), 20 lbs. (89 N), or 40
lbs. (178 N) depending on the model. An adjustable Tare Spring on 20 lb. (89 N) models compensates
for the weight of the electrode holders. The Firing Force Adjustment Cam easily adjusts the sensitivity
of the Firing Force Switch.
THIN-LINE® SERIES 80 WELD HEADS
990-121
1-1
CHAPTER 1. SYSTEM DESCRIPTION
Up And Down Stops
Series 80 Heads have adjustable Upstops and Downstops. The Downstop can be used to limit excessive
downward travel. The Upstop controls the stroke, and consequently, the travel time of the head. In
automated machine applications, using a stroke of less than 1/8 in. (3.2 mm) may significantly reduce
bearing life. On air-actuated heads, EZ-Air prevents overforce.
Electrodes
Series 80 Weld Heads accept a wide variety of standard and special purpose electrodes. There are
models available, which accept 1/8 in. (3.2 mm) or 1/4 in. (6.4 mm) diameter electrodes, 0.245 in. (6.3
mm) diameter eccentric electrodes, Unibond7, and Unitip7 Electrodes. The electrode holder on the
Model 87 accepts Unitip electrodes and reflow soldering thermodes. The optional Model ETB4 Table
Electrode fits Models 80, 84, 86, and 87.
Insulation
The Terminal Block, Flexible Copper Strap, and Upper Electrode Assembly are electrically insulated
from the frame of the Weld Head. The Frame, Support Post, and Support Base are grounded to the
bench top.
Welding Cables
Depending upon model, either #2 or #2/0 Welding Cables are provided to connect Series 80 Heads to
the power source. Miyachi Unitek Heads deliver maximum performance when used with the
appropriate Miyachi Unitek power sources.
Footpedal Actuation
The Series 80 Weld Heads, model number suffix "F," are footpedal (manually) actuated. Miyachi
Unitek offers two different footpedal styles:
1 The Model CP Cable Pedal is a treadle-type cable actuator providing an approximate 3 to 1
mechanical advantage. This pedal is used with Models 80F, 86F, and 87F.
2 The Model MSP, Swing Action Footpedal, provides an approximate 5 to 1 mechanical
advantage and is used with the Model 83F, 84F, 88F and 89F.
Air Actuation
Series 80 Weld Heads are equipped with two different types of air-actuation:
x Standard Air-Actuation
x EZ-AIR“
THIN-LINE® SERIES 80 WELD HEADS
1-2
990-121
CHAPTER 1. SYSTEM DESCRIPTION
Standard Air-Actuation
Model 80A/115, 80A/24, 82A/115, 82A/24, 83A/24, 84A/24, 84A/115, 86A/115, 86A/24, 86ARE/24,
87A/115, 87A/24, 88A/115, 88A/24, and 89A/24 are equipped with a top mounted Air Cylinder with
two Flow Controls, one or two Air Pressure Regulators, and a four-way Solenoid, making it easy to
incorporate these weld heads into automated welding systems. The Air Solenoid Valve is available with
either 24 volt, which is standard, or 115 volt AC ratings. Two Flow Controls are used to adjust the up
and down speed of the upper electrode. The Air Solenoid Valve can be energized by most of the
Miyachi Unitek power sources, or by a Model FSAC Footswitch. The Footswitch can be a single or two
level type, dependent upon the power supply and the user's preference. Miyachi Unitek suggests that
lubricators not be used in "clean" environments. However, the user will then be required to periodically
put a few drops of oil in the cylinder. Some users use lubricators, some do not.
EZ-AIR¥
Model 80A/EZ, 86A/EZ, and 89A/EZ weld heads are equipped with factory-installed EZ-AIR, a
Miyachi Unitek pneumatic control that actuates the electrodes and maintains a preset firing force. At a
predetermined firing force, EZ-AIR closes the inlet and outlet valves to the weld head actuation cylinder
and eliminates over-force. Series 80 air-actuated heads are easy to incorporate into automated welding
systems. EZ-AIR can be energized by most of the Miyachi Unitek power sources, or by a Model FSAC
Footswitch. The Footswitch can be a single or two-level type, dependent upon the power supply and the
user's preference. For EZ-AIR instructions, see the separate EZ-AIR Operator Manual supplied with the
weld head.
Reflow Soldering
Models 87SA and 84SA are designed specifically for Reflow Soldering.
If you have questions about reflow soldering contact your Miyachi Unitek representative, or visit the
Miyachi Unitek website listed in the front of this manual for assistance.
THIN-LINE® SERIES 80 WELD HEADS
990-121
1-3
CHAPTER 1. SYSTEM DESCRIPTION
Section II. System Components
Typical Series 80 Weld Head
Model 80A and 80F
These are conventional, 20 lb. (89 N) capacity welding heads with offset, opposed electrodes. Both the
pedestal mounting (post) and lower electrode assembly can be removed and replaced by custom fixtures.
All air actuated heads in the 80 Series are available with either 24 volt, 50/60 Hz. (Model 80A/24) or
115 volt, 50/60 Hz. (Model 80A/115) solenoids. The 24 volt solenoid is the standard option. The 115
volt solenoid does not comply with safety standards in some countries. Model 80 is supplied with one
pair ES0450, 1/8 in. (3.2 mm) diameter Glidcop7 Straight electrodes. Glidcop is a registered trademark
of Glidden Metals Company.
Model 80FLF
This model has a force range which can be set between 4 ounces (1.1 N) and 10 lbs. (45 N). It is
assembled so that it can be used in applications which require very low, precise welding forces.
THIN-LINE® SERIES 80 WELD HEADS
1-4
990-121
CHAPTER 1. SYSTEM DESCRIPTION
Model 82A
This model is designed for automated and special applications requiring custom mounting
configurations and custom lower electrode fixtures. Rugged in-line electrode design eliminates upper
electrode deflection, the cause of wiping action, and permits a maximum welding force of 40 lbs. (178
N). The Model 82 is supplied with one ES0850, Glidcop, 1/4 in. (6.4 mm) diameter Straight Electrode.
Model 83A and 83F
These are 40 lb. (178 N) welding heads with in-line, opposed electrodes. The lower electrode assembly
can be removed and replaced by a custom fixture. Model 83 is supplied with one pair ES0850, 1/4 in.
(6.4 mm) diameter Glidcop Straight electrodes.
Model 84A and 84F
These are 40 lb. (178 N) welding heads with offset, opposed electrodes. The lower electrode assembly
can be removed and replaced by a table electrode or a custom fixture. Model 84 is supplied with one
pair ES0850, 1/4 in. (6.4 mm) diameter Glidcop Straight electrodes.
Model 86A and 86F
These models feature Parallel Gap Weld Heads which are used for fine wire or ribbon bonding and
parallel gap reflow soldering applications. They feature an easily read, high-resolution, digital force
indicator that permits accurate resetting of force values. The Model 86 includes a voltage sensing and
thermocouple adapter cable.
Compliant electrode holders allow the electrodes to conform to uneven workpiece surfaces. The Model
86 is supplied with Model EU1000, RWMA 2 Unibond Electrodes. Unitip Electrodes should not be
used with the air actuated Model 86A, since any misadjustment of the Down Speed Flow Control would
probably damage the delicate tip of the electrode. The Model 86FRE's Electrode Holders hold 1/8 in.
(3.2 mm) diameter EO0400 Series Offset Electrodes. It is supplied with one pair of EO0402 RWMA 2
Offset Electrodes.
Model 87A and 87F
Reflow Soldering Heads use a variety of pulse heated elements, called thermodes, to reflow solder
electronic components to pre-tinned printed circuit boards. The Model 87F can also be used with
Unitips. As previously stated, Unitips are not recommended for use with air actuated heads. Solid
electrode holders provide dimensional stability and high current carrying capacity. The 87F features an
easily read, high resolution, digital force indicator that permits the accurate resetting of force values.
The Model 87A and 87F include a voltage sensing and thermocouple adapter cable, which allows them
to be used with both Unibond and Uniflow Controls. Model 87 Heads are not supplied with electrodes
or thermodes.
THIN-LINE® SERIES 80 WELD HEADS
990-121
1-5
CHAPTER 1. SYSTEM DESCRIPTION
Model 88A and 88F
These are designed to function as either a series or a parallel weld head. The Electrode Holders are
designed to hold eccentric electrodes which can be rotated, parallel to their length and adjusted with the
electrode holders, so that the separation between the electrode faces is from 0.00-0.330 in. (0.0-8.4 mm).
The welding force on each electrode can be independently set between 0.5-20 lbs. (2.2-89 N). The 88A
is supplied with two regulators and four flow controls that allow the force and the speed of each
electrode to be controlled independently. Model 88 Heads are supplied with one pair of ES0850E,
Glidcop Eccentric Electrodes.
Model 89A and 89F
These are designed to function in the same manner as the Model 88 Heads. The force range of the
Model 89A and 89F are adjustable from 6-40 lbs. (27-178 N), and 4-40 lbs. (18-178 N), respectively.
Model 89 Heads are supplied with one pair of ES0850E, Glidcop Eccentric Electrodes.
Models 87SA and 84SA
Models 87SA and 84SA are designed specifically for high-precision reflow soldering. It contains a
Model 17TDLB413 mounting block which can hold any of the TD series of thermodes. It also contains
two co-planarity adjustments for consistent distribution of thermode pressure on the bonding surface.
Models 87SA/84SA with Co-Planarity Adjustments and # 17TDLB413 Mounting Block
THIN-LINE® SERIES 80 WELD HEADS
1-6
990-121
CHAPTER 1. SYSTEM DESCRIPTION
Models 87SA and 84SA are similar to the Models 87A and 84A, respectively, except they are designed
specifically for high-precision reflow soldering. The 87SA includes a Model I7TDSB 177 mounting
block and the 84SA includes a Model 17TDMB256 mounting block. The former can hold any thermode
up to 1.5 in./38.lmm in length; the latter can hold any thermode up to 2.5 in./63.5mm in length. Both
models also contain two co-planarity head adjustments, for consistent distribution of thermode pressure
on the bonding surface, and an air cooling valve assembly, to accelerate cooling of the bonded pieces.
Both head modules incorporate a standard air cooling valve to accelerate cooling of the bonded pieces.
The air cooling valve assembly plugs directly into the Uniflow controller. To actuate the solder cool
valve, the user must turn the solder cool valve on during set up. The solder cool valve will then actuate
the solenoid assembly at the end of the reflow period until the thermode temperature reaches the
previous or cooling temperature, whichever is the lowest.
THIN-LINE® SERIES 80 WELD HEADS
990-121
1-7
CHAPTER 1. SYSTEM DESCRIPTION
Section III. 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.
The work surface, or a user supplied fixture, acts as a support for the
workpieces in series welding. If the Table is insulated from the
workpieces, there is no possibility of shunting current away from the (-)
electrode.
To use the Model 88 or 89 Weld Heads in the series welding mode, you
must use the Model DFS/88 Series Firing Switch Junction Box which is
supplied with the head.
Step welding
In step welding, the size of the weld and the surface marking is frequently
controlled by the diameter of the face of each electrode. If the (+)
Electrode is significantly larger than the (-) Electrode the lower workpiece
will not have any marking and the weld will be under the (-) Electrode.
The Table Electrode, or a user supplied fixture, acts as a support for the
workpieces in step welding.
If the Table is insulated from the workpieces, there is no possibility of
shunting current away from the (-) electrode.
THIN-LINE® SERIES 80 WELD HEADS
1-8
990-121
CHAPTER 1. SYSTEM DESCRIPTION
Section IV. Operating Controls
Series 80 Air Actuation Specifications
PARAMETER / MODEL
Input Air Pressure - Nominal / Maximum
Regulator Output - Maximum
Cycle Rate (full strokes/sec) at Min. Force
at greater than 20% of Rated Force
Solenoid Valve Voltage (AC volts)
Air Cylinder Inside Diameter
80A, 86A, 87A, 88A
82A, 83A, 84A, 89A
65/100 psi (448/690 kPa)
65/100 psi (448/690 kPa)
65 psi (448 kPa)
65 psi (448 kPa)
1.0
2.5
1.0
2.5
24V Standard
115V Optional
24V Standard
115V Optional
0.75 in. (1.9 cm)
1.0625 in. (2.7 cm)
Air Cylinders
The Model 88A and 89A use two air cylinders, two air pressure gauges, two air pressure regulators, and
four flow controls. All other models are supplied with a one air cylinder, one air pressure gauge, one air
pressure regulator, and two flow controls. The Air Solenoid, which controls the direction of air flow to
the Air Cylinder, is available with either 24 volt (standard) or 115 volt 50/60 Hz. ratings. The Flow
Controls allow independent adjustment of the up and downspeed of the upper electrode. The Solenoid
and Regulator Assembly mounts on the spine of the Weld Head.
Hall Effect Limit Switch Option
Air actuated Heads which are equipped with magnetic pistons and a Hall Effect Limit Switch contain an
"HS" in their model number, for example: 80AHS/24. The Hall Effect Switch only operates with
stainless steel pneumatic cylinders equipped with internal magnets on the pistons. By accurately
sensing the magnetic field of the piston when it passes beneath the Sensor, the position of the rod piston
is determined, and a feedback signal is created which can be used by the user to detect when the Head is
in the up position.
The magnetic piston surrounds the rod at the top of the piston. The Hall Effect Sensor, which uses solid
state circuitry, mounts at any position around the exterior of the cylinder. It requires the user to supply 5
to 28 VDC as illustrated. The parts required to retrofit an existing Head to include this feature are
described in Chapter 2, Section IV, Install Optional Equipment.
THIN-LINE® SERIES 80 WELD HEADS
990-121
1-9
CHAPTER 1. SYSTEM DESCRIPTION
ELECTRICAL SPECIFICATIONS HALL EFFECT LIMIT SWITCH
Output Type
Open Collector - current sink
Input Voltage (Vin)
5 to 28 VDC
Input Current
25 Ma maximum
Output Voltage Drop
0.4 VDC maximum
Output Current
0.3 VIN, m00 mA maximum
Power Dissipation
300 mW maximum
Circuit Protection
Reverse polarity, transient voltage and false pulse protected
Footswitches
A one-level Footswitch actuates the head, and the Firing Switch in the head initiates the welding
sequence. The first level of a two-level Footswitch actuates the head. The second level and the Force
Firing Switch initiate the welding sequence. A two-level Footswitch is recommended when the operator
is required to position the workpieces. It also allows the operator to actuate an air head without
initiating the weld cycle since both the Firing Switch and the second level of the Footswitch must close
before the weld portion of the sequence can begin.
THIN-LINE® SERIES 80 WELD HEADS
1-10
990-121
CHAPTER 2
INSTALLATION
Section I. Introduction
Overview
Before you start installation, become familiar with the specific model you are using. As shown below,
Series 80 Weld heads come in different sizes and configurations which require different mounting
baseplates, mounting posts, and installation hardware.
Installation procedures depend on the size and configuration of a specific model, and whether the weld
head, mounting post, and baseplate were shipped as separate pieces requiring assembly or shipped from
the factory fully assembled. Some manually-actuated heads are shipped with foot pedals attached,
others are not. Some air-actuated heads are shipped with the air head attached, others are not.
Despite differences from model-to-model, the installation principle is the same for each head:
x If not already attached, the weld head mounting post is attached to the baseplate.
x The weld head mounting baseplate is bolted securely to a workbench.
x The weld head is attached to the mounting post.
x If necessary, the air head (if used), foot pedal (if used), and optics (if used) are installed.
x Electrodes and weld cables are installed on the weld head.
Mounting Posts
Series 80 weld heads may be purchased with or without mounting hardware. Miyachi Unitek provides
three types of mounting posts (and corresponding installation hardware) designed for different models:
Mounting Tube
Smaller Series 80 Weld Heads are installed
on short mounting tubes. These are factoryinstalled and do not require any assembly by
the user.
Mounting tubes come in fixed lengths, the
height of the weld head is not adjustable.
THIN-LINE® SERIES 80 WELD HEADS
990-121
2-1
CHAPTER 2: INSTALLATION
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.
Channeled Post
This is an extruded aluminum post with channels on the front and back. By inserting TNuts into
the channels, mounting plates can be screwed onto the front (for weld head), back (for air head), or
both sides of the post (only the weld head is shown). This installation allows you to adjust the
height of the weld head and air head separately.
THIN-LINE® SERIES 80 WELD HEADS
2-2
990-121
CHAPTER 2: INSTALLATION
Section II. Weld Head Installation
Overview
First, this section will give "Typical Installation" instructions that are common to all Series 80 weld
heads. Then, additional instructions for installing specific weld head models are listed by model
number. Before you start installation:
x Make sure you are familiar with the mounting configurations and installation hardware described
and illustrated in this section.
x Read the Typical Installation instructions and the instructions for the specific weld head you want
to install.
x 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 Miyachi Unitek at the address shown in the
front of the manual.
Typical Installation
NOTE: Allow sufficient working space, usually 8-10 in. (20.32-25.4 cm), between the front edge of the
bench and the mounting base. This allows the operator to use the bench as a support when positioning
the workpiece.
1
Place the mounting template in the
desired location on the workbench and
tape it in place.
2
Drill the mounting holes as shown on
the template.
THIN-LINE® SERIES 80 WELD HEADS
990-121
2-3
CHAPTER 2: INSTALLATION
3
If necessary, install the weld head
mounting post to the baseplate.
4
If you are using optics (microscope
and/or illuminator), screw the optics
mounting post to the optics baseplate (if
not already installed).
NOTE: Follow the assembly
instructions provided with the Optics.
If necessary, drill holes in the Optics
baseplate in order to accommodate the
screws used to mount the weld head.
5
If not already attached, install the weld head mounting post to the weld head baseplate.
6
Screw the weld head mounting baseplate (and optics baseplate if used) to the workbench.
NOTE: If you are using optional optics (microscope/illuminator), install the optics
baseplate between the workbench and the weld head mounting baseplate.
THIN-LINE® SERIES 80 WELD HEADS
2-4
990-121
CHAPTER 2: INSTALLATION
7-A Install the weld head on the Dual-Post.
A) Install the mounting screws and washers onto the mounting backplate.
B) 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.
C) Adjust the weld head to the desired height, then tighten the mounting screws.
THIN-LINE® SERIES 80 WELD HEADS
990-121
2-5
CHAPTER 2: INSTALLATION
7-B
Install the weld head on the Channeled-Post.
A) Install the weld head mounting plate onto the weld head using the screws as shown.
B) Install the screws, washers, and T-nuts into the weld head mounting plate as shown.
C) If necessary, remove the end cap from the mounting post to expose the channels in the
mounting post.
D) Raise the weld head and mounting plate above the mounting post, insert the bottom T-nut
into the front channel of the mounting post, and slowly lower the weld head until you can
insert the top T-nut into the channel. Slide the weld head to the desired height, then
tighten the mounting screws.
E) If you are using an air head, install it on the rear of the mounting post following the
procedures in Steps A through D.
THIN-LINE® SERIES 80 WELD HEADS
2-6
990-121
CHAPTER 2: INSTALLATION
Model 80F, 86F, and 87F Model CP Footpedal Installation
1
Push down on top of weld head to extend
end of pullrod.
2
Secure Electrode Holders with string to
hold in place.
3
Position head (and optional baseplate) on
bench as shown.
4
Route footpedal cable up through bench
(and baseplate).
5
Attach cable from footpedal to pullrod (larger hole up) using small screw, which is supplied.
6
Untie string and release the electrode holders.
7
Depress pedal, and push cable sheath into pullrod hole until it is flush with base.
8
Secure sheath with set-screw as illustrated.
THIN-LINE® SERIES 80 WELD HEADS
990-121
2-7
CHAPTER 2: INSTALLATION
9
Adjust footpedal so that the electrode holders move the distance required by the application.
10 Adjust the angle of the treadle so that it provides the electrode stroke necessary for the
application and is comfortable for the operator.
Model 83F, 84F, 88F, and 89F MSP Footpedal Installation
THIN-LINE® SERIES 80 WELD HEADS
2-8
990-121
CHAPTER 2: INSTALLATION
1
Screw the head to the bench and Model MSP Footpedal using four (4) screws, washers and
nuts supplied with the shipping kit.
2
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
mounting stand.
3
Pull out the pin on footpedal adapter
block, as illustrated. Insert the pullrod
and allow the pin to snap back into
place.
5
Attach the pullrod to footpedal.Adjust
the height of head, loosen two Allen
head cap screws on the mounting plate
adapter as shown, and slide Head up or
down the mounting stand.
6
Attach the pullrod to footpedal. Adjust
the angle and length of the footpedal so
that it is comfortable for the operator.
Model 82A Air Head Installation
1
Screw the head to a user supplied
mounting post using two 1/4" - 20
screws.
NOTE: The cross-section of the
mounting plate should be such that the
horizontal movement of the upper
mounting screw should be less than
0.009 in. (0.229 mm) when the
electrode applies 40 lbs. (178 N) to the
workpiece. This should limit the
electrode wiping to 0.004 in. (0.102
mm) at 40 lbs. (178 N), using offset
electrode holders. In order to minimize
deflection, and electrode skidding, the
spine must be fully supported if weld
forces exceed 20 lbs. (89 N).
THIN-LINE® SERIES 80 WELD HEADS
990-121
2-9
CHAPTER 2: INSTALLATION
2
Screw the air gauge assembly to the mounting plate, as illustrated, or in a location, which is as
close as practical to the head. Use 0.25 in. (6.35 mm) outside diameter plastic hose, with a
rated burst pressure of 250 psi (1,724 kPa), to connect the air pressure regulator to the fitting on
the top of the air cylinder, as illustrated.
3
Connect the remaining fitting to the bottom of the air cylinder. Since the cylinder and air
solenoid assembly use "quick release" fittings, special tools are not needed. Simply push the
hose into the "quick release" fitting as far as it will go.
4
Verify that the air lines are inserted all the way into the sleeve on the fittings to prevent
inadvertent blow-outs. The shorter the air lines, the faster the mechanical response of the
Head.
5
Install a user supplied in-line filter lubricator on the air supply line to ensure the maximum life
of the air cylinder, flow controls and regulator.
6
Connect the inlet port of the regulator valve assembly, as illustrated, to a properly filtered air
supply (100 psi/690 kPa maximum). Use the shortest air lines possible to obtain the fastest
mechanical response.
NOTE: The inside diameter of the main air supply line must be at least 0.5 in. (13 mm) to
allow sufficient air flow. Connect the air line to the input air fitting.
Models 80A, 83A, 84A, 86A, 87A, 88A, and 89A Air Head Installation
1
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" fitting so
special tools are not needed. Simply
push the hose into the "quick release"
fitting as far as it will go.
2
Connect the other end to a properly
filtered air supply (100 psi/690 kPa
maximum). Use the shortest air lines
possible to obtain the fastest mechanical
response. The inside diameter of the
main air supply line must be at least 0.5
in. (13 mm) to allow sufficient air flow.
The air supply should be filtered to
ensure the maximum life of the air
cylinder, flow controls, and regulator.
Single-Air Installation
THIN-LINE® SERIES 80 WELD HEADS
2-10
990-121
CHAPTER 2: INSTALLATION
Dual-Air Installation
NOTES:
x
Miyachi Unitek suggests 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.
x
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).
x
To facilitate dressing the electrodes, reduce the air pressure to the top of the cylinder. As
an alternative to changing the setting of the Top Air Pressure Regulator, a customer
supplied bleeder valve connected to the output of the Top Air Pressure Regulator can be
used to reduce the air pressure.
3
Connect the power cord from the solenoid air valve as specified in the Users' Manual for the
appropriate power supply or control.
4
Install the system in accordance with established safety practices and standards. Anti-Tiedown
Palm Buttons are not usually required if the electrode spacing will not allow the operator's
fingers to fit between them.
THIN-LINE® SERIES 80 WELD HEADS
990-121
2-11
CHAPTER 2: INSTALLATION
Models 80A/EZ, 86A/EZ, and 89A/EZ EZ-AIR Installation
These weld heads come equipped with EZ-AIR
factory-installed. Installation consists of bolting
the weld head to the work bench and connection
to an air supply. To connect an air supply to the
EZ-AIR input, follow the instructions in the
separate EZ-Air manual.
NOTES:
x
You must use a properly filtered air
supply, 100 psi (690 kPa) maximum.
Use the shortest air lines possible to
obtain the fastest mechanical response.
x
Install the system in accordance with
established safety practices and
standards. Anti-Tiedown Palm Buttons
are not usually required if the electrode
spacing will not allow the operator's
fingers to fit between them.
Air Connection
Optics
If you are using any of the optional optics (microscope or illuminator):
1
Verify that the optics mounting post is securely attached to the optics baseplate.
2
Install the optics following the instructions provided with the optics.
THIN-LINE® SERIES 80 WELD HEADS
2-12
990-121
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,
x
Use #2 AWG for lengths under 12 in. (30.5 cm) and #2/0 AWG for longer lengths. Tie or tape
cables together to minimize inductive losses. A separation of weld cables surrounding an area of
one square foot could result in losses of up to 65%.
x
Use the shortest possible Welding Cables. It is common to have losses of up to 50% per foot for
#6 cables and 20% for #2 cables.
x
Both cables must always be on the same side
of the head. Route cables so that they do not
surround magnetic materials such as air
solenoids, tooling, or steel weld heads. The
cable routing and weld head design should be
such that the secondary loop does not
encompass magnetic materials (steel) and/or is
not encompassed by any magnetic material.
Connect Cables to Head
1
Model 80, 83, and 84: Connect one of the two cables supplied to the Power Bar.
Model 82A: Only one cable is supplied, connect it to the Power Bar.
Model 86, 87, 88, and 89: Connect one cable to each Power Bar.
THIN-LINE® SERIES 80 WELD HEADS
990-121
2-13
CHAPTER 2: INSTALLATION
2
Place the washer, which is supplied, between the head of the Socket Head Screw and the
Terminal on the Cable. Do NOT place the washer between the Cable and the Power Bar.
Tighten connections securely; they must be free from oxidation, dirt, and/or grease.
3
Connect the other end of the cables to the power supply or output transformer, in accordance
with the instructions in its Users' Manual.
THIN-LINE® SERIES 80 WELD HEADS
2-14
990-121
CHAPTER 2: INSTALLATION
Section IV. Install Electrodes for Welding
CAUTION
Do not modify the electrode holders or attach additional mechanisms to the
moving parts of the head. Doing so may hurt welding performance, damage
the head, and void the warranty.
Model 80 and 84
1
Loosen screws and insert electrodes.
Loosely tighten screws to hold
electrodes in position.
2
Align the electrodes, then tighten into
position.
NOTE: The maximum distance
between the electrode tips is 1.0 in.
(25.4 mm).
Model 82 and 83
1
Fully insert electrodes into electrode
holder(s). Tighten quick release
handle(s).
2
Align electrodes on Model 83 by
adjusting the position of the lower
electrode holder.
NOTE: The maximum distance
between the electrode tips on the Model
83, or the tip of the top electrode on the
Model 82 and the workpiece, is 1.0 in.
(25.4 mm).
THIN-LINE® SERIES 80 WELD HEADS
990-121
2-15
CHAPTER 2: INSTALLATION
Model 88 and 89
1
Insert electrodes into electrode holders.
2
Lower the electrodes onto a flat
workpiece.
3
Align the electrodes so that they are
parallel as well as perpendicular to the
workpiece. Align the electrode tips.
4
Rotate the electrodes to obtain the
desired distance between the tips (gap).
Tighten the screws on the electrode
holders.
NOTE: The maximum distance
between the electrode tips and the
workpiece is 1.0 in. (25.4 mm).
Model 86 -- Unibond Electrodes
1
Check the voltage sensor cable located
on the underside of the electrode arms.
Verify that the two slotted head screws
which attach the sensing cable to the
flexure assemblies are securely
tightened. Erratic operation results if
they are loose.
2
Loosen the electrode holder clamp
screws. Set the electrode gap
adjustment knob for maximum gap
width and insert the Unibond electrodes
into the holders as illustrated.
3
Loosely hold the electrodes in place and
rotate the gap adjustment knob to its
fully-clockwise (closed) position.
4
Orient the electrodes so they contact
each other along their entire length and
are perpendicular to the surface of the
workbench.
THIN-LINE® SERIES 80 WELD HEADS
2-16
990-121
CHAPTER 2: INSTALLATION
NOTE: Position the electrodes vertically in the holder so the electrode tips are aligned.
5
Tighten the electrode holder clamp screws.
CAUTION: Do not over-torque the clamp screws. Doing so will deform the flexure,
dramatically reducing its life.
6
Open the electrodes to the desired operating gap by turning the gap adjustment knob
counterclockwise. The maximum distance between the tip of the electrode and the workpiece
is 1.0 in. (25.4 mm).
Model 86 -- Unitip Electrodes
1
Look at the electrode holders from the
top and verify that the holders are
aligned from front-to-rear.
CAUTION: Unitip electrodes will be
destroyed if the electrode holders are
misaligned. The displacement will
cause the Unitip to be sheared when the
electrode holder clamp screws are
tightened.
2
Assemble Unitip inside the Model
UTA, Unitip Adapter, as shown. The
vertical line (insulation) must be
centered between the edges of the
Unitip Adapter. Insert the assembled
electrode into the electrode holder.
3
Rotate the gap adjustment knob
clockwise until the assembled electrode
is lightly held in place. The Unitip and
Unitip Adapter should be flush with the
top surface of the electrode holder.
NOTE: Unitip electrodes have a fixed gap which can not be adjusted. If necessary, rotate the
Unitip so that the vertical line on the tip formed by the insulation layer is exactly between the
two adapter halves as illustrated. Tighten the two screws on the electrode holder.
THIN-LINE® SERIES 80 WELD HEADS
990-121
2-17
CHAPTER 2: INSTALLATION
CAUTION: Unitips can be severely
damaged by applying excessive
bonding forces. The table on the right
lists the maximum operational force
limits in both kilograms force (kgf) and
ounces (oz). See Chapter 4 for Unitip
cleaning and dressing instructions.
Use of Unibond Electrodes and Unitips
should be limited to footpedal actuated
weld heads. Their use in air-actuated
heads requires great caution in
adjusting electrode forces.
The maximum distance between the tip
of the electrode and the workpiece is
1.0 in. (25.4 mm).
MAXIMUM UNITIP FORCE
Unitip Model
Max. Force
(kgf)
Max. Force
(oz)
UTM111L
0.94
33
UTM112L
0.94
33
UTM152L
0.47
17
UTM222L
3.75
132
UTM111C
0.94
33
UTM112C
0.94
33
TM222C
3.75
132
UTM224C
3.75
132
UTM237C
4.57
161
Model 87 -- Unitip Electrodes
1
Check the voltage sensor cable located
on the underside of the electrode arms.
Verify that the two slotted head screws
which attach the Sensing Cable to the
Flexure Assemblies are securely
tightened.
NOTE: Erratic operation results if the
screws are loose.
2
Loosen the electrode holder clamp
screws. Set the electrode gap
adjustment knob for maximum gap
width.
THIN-LINE® SERIES 80 WELD HEADS
2-18
990-121
CHAPTER 2: INSTALLATION
3
Insert the Unitip between the concave
inner surfaces of the electrode arms.
The Unitip should be flush with the top
of the electrode holder. Rotate the
Unitip so that the vertical line on the tip
formed by the insulation layer is exactly
between the two electrode arms when
viewed from the front of the head.
4
Clamp the Unitip by turning the Gap
Adjustment Knob clockwise until the
Unitip is firmly locked.
NOTE: Unitip electrodes have a fixed
gap, which cannot be adjusted.
The table on the right lists the maximum
permissible force limits for Unitips. See
Chapter 4 for Unitip cleaning and dressing
instructions.
Use of Unitips should be limited to footpedal
actuated weld heads. When Unitips are used in
air actuated heads caution is required when
selecting and adjusting electrode forces.
The maximum distance between the tip of the
electrode and the workpiece is 1.0 in. (25.4 mm).
MAXIMUM UNITIP FORCE
Unitip Model
Max. Force
(kgf)
Max. Force
(oz)
UTM111L
0.94
33
UTM112L
0.94
33
UTM152L
0.47
17
UTM222L
3.75
132
UTM111C
0.94
33
UTM112C
0.94
33
TM222C
3.75
132
UTM224C
3.75
132
UTM237C
4.57
161
THIN-LINE® SERIES 80 WELD HEADS
990-121
2-19
CHAPTER 2: INSTALLATION
Section V. Install Thermodes for Reflow Soldering
Models 87SA and 84SA are similar to the Models
87A and 84A, respectively, except they are
designed specifically for high-precision reflow
soldering.
The 87SA includes a Model I7TDSB 177
mounting block and the 84SA includes a Model
17TDMB256 mounting block. The former can
hold any thermode up to 1.5 in./38.lmm in length;
the latter can hold any thermode up to 2.5
in./63.5mm in length.
1.
Slide the thermode up into the groove of
the thermode block.
2.
Adjust the position of the thermode so
that the screw holes in the mounting
block line up with the screw holes in the
thermode.
NOTE: There are screw holes in the
front and back of the thermode block.
You must attach the thermode using all
the screws necessary for the thermode
on both sides of the block.
3.
Insert the thermode screws alternating
between the front and back.
Do not tighten the screws when you
insert them. This allows you to adjust
the position of the thermode so that all
screws will fit into the holes properly.
THIN-LINE® SERIES 80 WELD HEADS
2-20
990-121
CHAPTER 2: INSTALLATION
NOTE: Hot spots can occur on the contact surfaces of 17TD style thermodes if the mounting
screws are not properly tightened. To assure good contact, perform the following steps.
4.
Torque the thermode mounting screws to 18-27 lb.in. (2-3 N.m).
5.
After a few reflow cycles, verify the torque values on the mounting screws.
NOTE: If hot spots occur on the contact faces of the thermode, check the copper surfaces on
the thermode mounting block for damage. Re-surface copper surfaces or replace if they are
extensively damaged.
Model 87 -- 17F Fold-Up, 17P Peg Tip, or 17SR Single Point Thermodes
NOTE: Miyachi Unitek weld heads use two
types of thermocouple connectors. Older models
use telephone-type (or "Phone") plugs, newer
models use Omega plugs. Both plugs work the
same way. Illustrations in the rest of this manual
show "typical" connectors, which represent both
types of plugs. The cable coming from the
thermocouple is plugged into a matching
connector on the weld head.
1
Loosen the electrode holder clamps on
the head. Rotate the electrode gap
adjustment knob counter-clockwise to
its maximum gap opening.
2
Insert the 17F or 17P Thermode into the
holders as illustrated at right. Position
the thermode so that the thermocouple
lead does not interfere with the
workpiece.
3
Return the gap adjustment knob to its
full clockwise position, clamping the
thermode. Tighten the clamp screws.
4
Connect the plug on the thermocouple
to the jack which is located on the side
of the Model 87.
THIN-LINE® SERIES 80 WELD HEADS
990-121
2-21
CHAPTER 2: INSTALLATION
NOTES:
x The maximum width thermode which should be used with the 87 Head is the 17F1000,
which is 1.0 in. (25.4 mm) wide.
x Do not exceed a force of 60 oz. (16.68 N) on either the 17SF or 17SR series Single Point
Fold-Up Thermodes. Forces in excess of 60 oz. (16.68 N) will deform the tips.
x The maximum distance between the tip of the thermode and the workpiece is 1.0 in. (25.4
mm).
Model 87 -- 17BM Blade Thermodes
1
Remove the clamps from the holder. Attach the thermode directly to the face of mounting
block using the lower set of screw holes as illustrated.
2
Rotate the gap adjustment knob, in the appropriate direction, until the lower set of screw holes
are aligned with the holes in the thermode.
3
Attach the blade thermode to the holder using the two screws which are supplied with the
thermode. Position the blade and thermocouple so that they do not interfere with the
workpiece.
4
To ensure efficient even heat transfer to the workpiece, adjust the bottom edge of the thermode so
that it is parallel to the work surface. The maximum distance between the tip of the electrode and
the workpiece is 1.0 in. (25.4 mm).
5
Connect plug on thermocouple to jack which is located on the side of the Model 87.
THIN-LINE® SERIES 80 WELD HEADS
2-22
990-121
CHAPTER 2: INSTALLATION
Section VI. Install Optional Equipment
Model 88 and 89 -- Install DFS/88 Series Firing Switch Junction Box
If the Model 88 or 89 is to be used as a series type welding head, then connect both Firing Switch
Cables to the DFS/88, which is supplied with the head. The DFS/88 connects the Force Firing Switches,
which are located inside the heads, in series. This means that the power source will not be triggered
until both sides of the head exert the preset firing force on the workpiece.
Use the DFS when the Model 88 or 89 are used as parallel type welding heads.
Connect Optional Hall Effect Limit Switch
The Hall Effect Limit Switch cylinder's magnetic
disk surrounds the actuation rod located on the
top of its internal piston.
The magnetic field which is produced when the
piston passes the sensor produces an output
which can be used to control other equipment.
1
Mount the Hall Effect Switch using the
clamp which is supplied.
2
Position the switch at the top (bottom)
of the cylinder to detect when the head
is in the up (down) position.
3
Wire the Hall Effect switch as shown in
the schematic diagram on the right.
NOTES:
x Resistor. Be sure to include a
resistor in series with the output
which limits the output current to a
maximum of 50 mA.
x Wire Colors. Newer versions of
the Hall Effect switch have
different wire colors than older
versions. The table at the right
shows the wire colors for each
version. Verify the colors on your
switch, then connect them
according to the schematic.
Old Version
Red
Black
White
=
=
=
New Version
+
Out
Brown
Blue
Black
=
=
=
+
Out
THIN-LINE® SERIES 80 WELD HEADS
990-121
2-23
CHAPTER 3
OPERATING INSTRUCTIONS
Section I. 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.
Verify that the welding power supply (control) is connected to the
appropriate power source and that the power is switched to ON.
Switch the welding power supply (control) to ON. Follow the
procedures in the manual to program and operate the welding power
supply (control).
INSTALLATION CHECKLIST FOR AIR ACTUATED HEADS
Verify that the air lines are properly connected to the head and the
main air supply (65 psi/448 kPa nominal) is turned ON.
Verify that the line cord from the air solenoid is connected to the
power supply (control) or to a 115 volt source, if required.
Verify that the footswitch is connected to the welding power supply
(control).
THIN-LINE® SERIES 80 WELD HEADS
990-121
3-1
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 (see Model 88F and 89F). Details on the basics of
resistance welding are described in Appendices C and D. More information is available from Unitek
Miyachi:
A) Resistance Welding Troubleshooting Guide
B) Electrode/Material Selection Guide
C) Resistance Welding Spot Welding Applications
D) Technical Service Bulletins on a variety of subjects
Troubleshooting
WELDHEAD TROUBLESHOOTING GUIDE
SYMPTOM
OR
PROBLEM
PRIMARY CAUSE
Weldhead-Related Cause
PRIORITY*
SOLUTION
Overheating of
Weldment
Excess Welding Time
Insufficient Force
Wrong Electrode Material
Dirty Electrodes
Electrode Tip Shape
1
2
2
3
3
Decrease Welding Time (A.C. Welding)
Increase force in steps of 10-20%
Check Electrode/Material Selection Guide
Clean electrodes and/or parts to be welded
Use constant area electrodes or shape to suit
application
Discoloration
Excess Welding Time
Wrong Electrode Material
Insufficient Force
1
1
2
Decrease Welding Time (A.C. Welding)
Check Electrode/Material Selection Guide
Increase force in steps of 10-20%
Weak Weld
Insufficient Current/Energy
Dirty Electrodes
Electrode Tip Shape
1
1
1
Mushroomed Electrodes
1
Excess Force
Insufficient Force
Wrong Electrode Material
Poor Weldhead Follow-up
2
2
2
3
Increase current/energy in steps of 5-10%
Clean electrodes and/or parts to be welded
Use constant area electrodes or shape to suit
application
Replace or reshape electrodes or increase
cleaning schedule
Decrease force in steps of 10-20%
Increase force in steps of 10-20%
Check Electrode/Material Selection Guide
Reduce mass of top electrode holder
assembly
THIN-LINE® SERIES 80 WELD HEADS
3-2
990-121
CHAPTER 3: OPERATING INSTRUCTIONS
WELDHEAD TROUBLESHOOTING GUIDE
SYMPTOM
OR
PROBLEM
PRIMARY CAUSE
Weldhead-Related Cause
PRIORITY*
SOLUTION
Insufficient Current/Energy
Wrong Electrode Material
Electrode Tip Shape
1
1
1
Mushroomed Electrodes
1
Dirty Electrodes
Excess Force
Insufficient Force
2
2
3
Increase current/energy in steps of 5-10%
Check Electrode/Material Selection Guide
Use constant area electrodes or shape to suit
application
Replace or reshape electrodes or increase
cleaning schedule
Clean electrodes and/or parts to be welded
Decrease force in steps of 10-20%
Increase force in steps of 10-20%
Excess Current/Energy
Insufficient Force
Poor Weldhead Follow-up
1
1
1
Dirty Electrodes
Electrode Tip Shape
2
2
Excess Current/Energy
Insufficient Force
Poor Weldhead Follow-up
1
1
1
Electrode Tip Shape
Wrong Electrode Material
Dirty Electrodes
1
2
2
Warping
Excess Welding Time
Excess Force
Electrode Tip Shape
1
1
2
Decrease Welding Time (A.C. Welding)
Decrease force in steps of 10-20%
Use constant area electrodes or shape to suit
application
Electrode Sticking
Insufficient Force
Wrong Electrode Material
Electrode Tip Shape
1
1
1
Dirty Electrodes
Poor Weldhead Follow-up
2
3
Increase force in steps of 10-20%
Check Electrode/Material Selection Guide
Use constant area electrodes or shape to suit
application
Clean electrodes and/or parts to be welded
Reduce mass of top electrode holder
assembly ***
Insufficient Nugget **
Metal Expulsion
Sparking
Decrease current/energy in steps of 5-10%
Increase force in steps of 10-20%
Reduce mass of top electrode holder
assembly***
Clean electrodes and/or parts to be welded
Use constant area electrodes or shape to suit
application
Decrease current/energy in steps of 5-10%
Increase force in steps of 10-20%
Reduce mass of top electrode holder
assembly***
Use constant area electrodes or shape to suit
application
Check Electrode/Material Selection Guide
Clean electrodes and/or parts to be welded
THIN-LINE® SERIES 80 WELD HEADS
990-121
3-3
CHAPTER 3: OPERATING INSTRUCTIONS
WELDHEAD TROUBLESHOOTING GUIDE
SYMPTOM
OR
PROBLEM
Electrode Damage
PRIMARY CAUSE
Weldhead-Related Cause
PRIORITY*
SOLUTION
Excess Current/Energy
Insufficient Force
Electrode Tip Shape
1
1
1
Excess Force
Wrong Electrode Material
Dirty Electrodes
2
2
2
Decrease current/energy in steps of 5-10%
Increase force in steps of 10-20%
Use constant area electrodes or shape to suit
application
Decrease force in steps of 10-20%
Check Electrode/Material Selection Guide
Clean electrodes and/or parts to be welded
*
Priority numbers refer to troubleshooting priority, with 1 as highest priority. Start
troubleshooting with 1 and then proceed to 2 and so on. When there are multiple causes
with the same priority, use personal judgement in determining which is more probable in the
specific application.
**
In most cases capacitor discharge welds do not have a significant nugget.
*** For non-Miyachi Unitek weld heads.
A certain amount of experimentation is necessary to achieve the proper welding force setting for a
specific application. The following are some general rules to make quality welds:
a.
Larger parts require higher force.
b.
Larger diameter electrode faces require higher force.
c.
Higher electrode forces require higher weld currents (energy).
Reflow Soldering Force
The reflow soldering process is not as sensitive to force as resistance welding. Sufficient force or
pressure is necessary to ensure adequate thermal conduction and to hold the workpieces as the solder
solidifies.
THIN-LINE® SERIES 80 WELD HEADS
3-4
990-121
CHAPTER 3: OPERATING INSTRUCTIONS
Section II. Model 80A, 82A, 83A, 84A, 86A, and 87A
Standard Air-Actuated Head Setup
This Section describes the following adjustments:
x
x
x
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.
CAUTION: Excessive force can damage the electrodes and/or the workpiece.
In automated applications, the maximum repetition rate is usually limited by the stroke of the head and
the air pressure on the top of the air cylinder. The higher the pressure, the faster the upper arm will
move. The air pressure on the top of the cylinder will determine the welding, but not the firing force. If
the welding force exceeds the firing force, which is set by the force adjustment knob on the head, by
more than five percent, a noticeable decrease in weld (reflow soldering) quality often results.
1
Use the flow control on the bottom of the cylinder to reduce the down speed.
2
Use the force adjustment knob to set the weld head force indicator to "4". Indicator is located on
the front of the force tube just below the force adjustment knob. Set heads with digital readouts to
"100."
3
Close, but do not tighten, both air flow control valves.
4
Re-open each valve 3 or 4 turns.
5
Adjust the air pressure regulator to an indicated 10 psi (69 kPa).
6
Cycle the weld head by depressing and releasing the footswitch. Adjust the upspeed air flow
control valve located at the top of the air cylinder, so that the upper arm moves up at a reasonable
rate. It should not move so rapidly that it slams against the upstop.
7
If the application is a welding
application, adjust the electrode spacing
so that a Miyachi Unitek Force Gauge
fits between the electrodes, as
illustrated.
THIN-LINE® SERIES 80 WELD HEADS
990-121
3-5
CHAPTER 3: OPERATING INSTRUCTIONS
8
Depress and hold the footswitch. Note the force indication on the force gauge when the head
firing switch "clicks." If the firing switch does not close, increase the pressure from the air
pressure regulator until the firing switch does close. If the firing switch closure is inaudible, it
is 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.
9
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.
10 Release and depress the footswitch. Verify that the welding force applied by the upper arm
does not exceed the force required to close the firing switch by more than five percent (5%). If
necessary, adjust the pressure from the air pressure regulator and/or the force adjustment knob
on the head.
11 After setting the required force, particularly in automated applications, remove the force
adjustment knob by loosening the two set screws 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. Re-tighten both set screws.
12 If necessary, re-adjust the electrodes (thermode) in their holders to accommodate the
workpiece.
13 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.
A) Depress and hold the footswitch. Slowly rotate the downstop counter-clockwise until the
force firing switch in the head closes. Rotate the downstop one or two additional turns
counter-clockwise. The additional turn(s) will allow for electrode wear and/or the slight
variations of the position of the electrode (thermode) in its holder.
B) Re-check that the firing switch consistently closes.
CAUTION: Do not attempt to use the downstop adjustment to limit the force which is applied
to the workpiece. This will result in inconsistent welds (reflow soldering).
14 Depress the footswitch. Adjust the downspeed air flow control valve so that the upper
electrode arm descends slowly enough to prevent impact damage to the workpiece and
electrodes (thermode).
15 Re-adjust upspeed air flow control valve if necessary.
16 Once the required firing force is setup, do not change the regulator setting! Use only the air
flow control valves to control the up and down speed of the upper arm. Changes in the
regulator setting will change the welding (reflow soldering) force.
THIN-LINE® SERIES 80 WELD HEADS
3-6
990-121
CHAPTER 3: OPERATING INSTRUCTIONS
Section III. Model 80A/EZ and 86A/EZ
EZ-AIR Air-Actuated Head Setup
This Section describes the following adjustments:
x
x
x
Welding force to the value required by the specific application.
Down speed of the electrode approaching the parts.
Eliminating any down stop setting.
CAUTION: Excessive force can damage the electrodes and/or the workpiece.
Model 80A/EZ and 86A/EZ air-actuated weld heads are supplied with EZ-AIR, a pneumatic control that
actuates the electrodes and maintains a preset firing force. At a predetermined firing force, EZ-AIR
automatically closes the inlet and outlet valves to the weld head actuation cylinder and eliminates overforce.
Down speed and welding force are the only two adjustments to be made when setting up the EZ-AIR.
Down stops are not required.
NOTE: Before performing the following instructions, get the separate EZ-AIR Operator Manual
supplied with the weld head and follow the detailed procedures for operating and adjusting EZ-AIR.
1
Use the force adjustment knob to set the weld head force indicator to "4." The indicator is located
on the front of the force tube, just below the force adjustment knob. Set heads with digital readouts
to "100."
2
If electrodes are being used, adjust the
electrode spacing so that a Miyachi
Unitek Force Gauge fits between the
electrodes, as shown.
Depress and hold the footswitch. Note
the force indication on the force gauge.
When the head firing switch "clicks"
(closes), the force will stabilize. If the
firing switch does not close, or the force
keeps increasing, verify that all of the
connections have been properly made
as described in the EZ-AIR manual.
3
Cycle the electrode up and down several times and adjust the down speed by turning the knob
that is located on the back of the EZ AIR. The down speed should be adjusted to provide a
comfortable speed for the operator or automation without excessive impact force to the parts.
4
The force gauge will indicate the electrode force. Use the force adjustment knob to increase
the indicated force if the initial force reading is less than the required force setting for the
welding application. If the initial force reading is greater than the required force setting,
THIN-LINE® SERIES 80 WELD HEADS
990-121
3-7
CHAPTER 3: OPERATING INSTRUCTIONS
decrease the indicated force.
5
After setting the required force, particularly in automated applications, remove the force
adjustment knob by loosening the two set screws, 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. Re-tighten both set screws.
6
If necessary, re-adjust the electrodes in their holders to accommodate the work piece.
7
A down stop is never required when using EZ-AIR. Turn the down stop screws counterclockwise to their fullest extension without actually disengaging them. This will allow
maximum downward travel of the upper arms.
THIN-LINE® SERIES 80 WELD HEADS
3-8
990-121
CHAPTER 3: OPERATING INSTRUCTIONS
Section IV. Model 88A and 89A
Standard Air-Actuated Head Setup
This Section describes the following adjustments:
x
x
x
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.
CAUTION: Excessive force can damage the electrodes and/or the workpiece.
In automated applications, the maximum repetition rate is usually limited by the stroke of the head and
the air pressure on the top of the air cylinder. The higher the pressure, the faster the upper arm will
move. The air pressure on the top of the cylinder will determine the welding, but not the firing force. If
the welding force exceeds the firing force, which is set by the force adjustment knob on the head, by
more than five percent, a noticeable decrease in weld (reflow soldering) quality often results. Use the
flow control on the bottom of the cylinder to reduce the down speed.
NOTE: Start with the right side of the head. Do not connect the DFS/88 switch box at this time.
1
Connect the right side firing switch cable to the power supply firing switch connector.
2
Use the force adjustment knob to set the weld head force indicator to "4". Indicator is located
on the front of the force tube just below the force adjustment knob.
3
Close, but do not tighten, both air flow control valves.
4
Re-open each valve 3 or 4 turns. Adjust air pressure regulator to an indicated 10 psi (69 kPa).
5
Cycle the weld head by depressing and releasing the footswitch. Adjust the upspeed air flow
control valve located at the TOP of the air cylinder, so that the upper arm moves up at a reasonable
rate. It should not move so rapidly that it slams against the upstop.
6
Place a Miyachi Unitek Force Gauge
beneath the electrode, as shown. The
force gauge must be supported on the
bottom for proper indication of force.
NOTE: If the application is a welding
application, adjust the spacing so that a
Miyachi Unitek Force Gauge fits
between the right electrode and a
workpiece.
7
Depress and hold the footswitch. NOTE:
the force indication on the force gauge
when the head firing switch "clicks."
THIN-LINE® SERIES 80 WELD HEADS
990-121
3-9
CHAPTER 3: OPERATING INSTRUCTIONS
8
If the firing switch does not close, increase the pressure from the air pressure regulator until the
firing switch does close.
NOTE: If the firing switch closure is inaudible, it is 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.
9
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.
10 Repeat steps 8 and 9 to set the firing force on the left side of the head. Disconnect the power
supply firing switch connector from the right side firing switch cable and connect to the left
side firing switch cable.
11 Release and depress the footswitch. Verify that the welding force applied by the upper arm
does not exceed the force required to close the firing switch by more than five percent (5%). If
necessary, adjust the pressure from the air pressure regulator and/or the force adjustment knob
on the head.
12 After setting the required force, particularly in automated applications, remove the force
adjustment knob by loosening the two set screws 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. Re-tighten both set screws. Reconnect the DFS/88 to both the right/left side firing cables
and attach to the power supply firing switch connector.
13 If necessary, re-adjust the electrodes in their holders to accommodate the workpiece. The faces
of both electrodes should be in the same plane and the gap (spacing) between the electrodes
should be uniform.
14 Turn the downstop screws counter-clockwise to their fullest extension without actually
disengaging them. This will allow maximum downward travel of the upper arms. The
following downstop adjustments should be made only if the workpiece would be damaged if
the upper arms travel too far. In most applications, use of the downstop is not recommended.
A) Start with the right downstop. Place the workpiece in the appropriate position. Rotate the
downstop screw clockwise until the electrode no longer contacts the workpiece. Check the
adjustment by depressing and releasing the footswitch.
B) Depress and hold the footswitch. Slowly rotate the downstop counter-clockwise until the
force firing switch in the head closes. Rotate the downstop one or two additional turns
counter-clockwise. The additional turn(s) will allow for electrode wear and/or the slight
variations of the position of the electrode in its holder. Re-check that the firing switch
consistently closes.
THIN-LINE® SERIES 80 WELD HEADS
3-10
990-121
CHAPTER 3: OPERATING INSTRUCTIONS
C) Repeat this procedure for the left downstop.
CAUTION: Do not attempt to use the downstop adjustments to limit the force which is
applied to the workpiece. This will result in inconsistent welds.
15 Depress the footswitch. Adjust the downspeed air flow control valves so that the upper
electrode arms descend slowly enough to prevent impact damage to the workpiece and
electrodes.
16 Re-adjust upspeed air flow control valves if necessary.
17 Once the required firing force is setup, DO NOT CHANGE THE REGULATOR SETTING!
Use only the air flow control valves to control the up and down speed of the upper arm.
Changes in the regulator setting will change the welding force.
THIN-LINE® SERIES 80 WELD HEADS
990-121
3-11
CHAPTER 3: OPERATING INSTRUCTIONS
Section V. Model 89A/EZ
EZ-AIR Air-Actuated Head Setup
This Section describes the following adjustments:
x
x
x
Welding force to the values required by the specific application.
Down speed of the electrodes approaching the parts.
Eliminating any down stop settings.
CAUTION: Excessive force can damage the electrodes and/or the workpiece.
The Model 89A/EZ air-actuated weld head is supplied with EZ-AIR, a pneumatic control that actuates
the electrodes and maintains a preset firing force. At a predetermined firing force, EZ-AIR
automatically closes the inlet and outlet valves to the weld head actuation cylinder and eliminates overforce.
Down speed and welding force are the only two adjustments to be made when setting up the EZ AIR.
Down stops are not required.
NOTE: Before performing the following instructions, get the separate EZ-AIR Operator Manual
supplied with the weld head and follow the detailed procedures for operating and adjusting EZ-AIR.
1
Start with the right side of the head.
2
Use the force adjustment knob to set the weld head force indicator to "4." The indicator is
located on the front of the force tube just below the force adjustment knob.
3
Place a Miyachi Unitek Force Gauge
beneath the electrode, as shown. The
force gauge must be supported on the
bottom for proper indication of force.
Depress and hold the footswitch. Note
the force indication on the force gauge.
When the head firing switch "clicks"
(closes), the force will stabilize. If the
firing switch does not close, or the force
keeps increasing, verify that all of the
connections have been properly made
per the instructions in the EZ-AIR
manual.
4
Cycle the electrode up and down several times and adjust the down speed by turning the right
hand knob that is located on the back of the EZ AIR. The down speed should be adjusted to
provide a comfortable speed for the operator or automation without excessive impact force to
the parts.
THIN-LINE® SERIES 80 WELD HEADS
3-12
990-121
CHAPTER 3: OPERATING INSTRUCTIONS
5
The force gauge will indicate the electrode force. Use the force adjustment knob to increase
the indicated force if the initial force reading is less than the required force setting for the
welding application. If the initial force reading is greater than the required force setting,
decrease the indicated force.
6
Set the down speed and welding force on the left side of the head repeating steps 2 through 5.
7
After setting each electrode force, particularly in automated applications, remove the force
adjustment knobs by loosening the two set screws that secure them to the shafts. Invert the
knobs and place them on the shafts. Be sure to insert the locking tabs on the knobs into the
slots on the force tubes. Re-tighten the set screws. If necessary, re-adjust the electrodes in
their holders to accommodate the workpiece. The faces of both electrodes should be in the
same plane and the gap (spacing) between the electrodes should be uniform.
8
A down stop is never required when using EZ-AIR. Turn the down stop screws counterclockwise to their fullest extension without actually disengaging them. This will allow
maximum downward travel of the upper arms.
THIN-LINE® SERIES 80 WELD HEADS
990-121
3-13
CHAPTER 3: OPERATING INSTRUCTIONS
Section VI. Model 80F, 83F, 84F, 86F, and 87F
Manually-Actuated Head Setup
This Section describes the following adjustments:
x
x
x
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.
CAUTION: Excessive force can damage the electrodes and/or the workpiece.
1
Use the force adjustment knob to set the
weld head force indicator to "4." The
indicator is located on the front of the
force tube just below the force
adjustment knob. Set heads with digital
readouts to "100."
NOTE: If the application is a welding
application, adjust the electrode spacing
so that a Miyachi Unitek Force Gauge
fits between the electrodes, as
illustrated.
2
Depress and hold the footpedal. Note the
force indication on the force gauge when
the head firing switch "clicks." If the
firing switch closure is inaudible, it is
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.
3
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.
4
Depress and release the footpedal. Verify that the force applied by the operator does not
exceed the force required to close the firing switch by more than five percent (5%).
5
After setting the required force, remove the force adjustment knob by loosening the two set
screws that 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. Re-tighten both set screws.
6
If necessary, re-adjust the electrodes (thermode) in their holders to accommodate the
workpiece.
THIN-LINE® SERIES 80 WELD HEADS
3-14
990-121
CHAPTER 3: OPERATING INSTRUCTIONS
7
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.
A) Place the workpiece in the appropriate position. Rotate the downstop screw clockwise until
the electrode(s) or thermode no longer contacts the workpiece. Check the adjustment by
depressing and releasing the footpedal.
B) Depress and hold the footpedal. Slowly rotate the downstop counter-clockwise until the force
firing switch in the head closes. Rotate the downstop one or two additional turns counterclockwise. The additional turn(s) will allow for electrode wear and/or the slight variations of
the position of the electrode (thermode) in its holder. Re-check that the firing switch
consistently closes.
CAUTION: Do not attempt to use the downstop adjustment to limit the force which is applied to
the workpiece. This will result in inconsistent welds (reflow soldering).
THIN-LINE® SERIES 80 WELD HEADS
990-121
3-15
CHAPTER 3: OPERATING INSTRUCTIONS
Section VII. Model 88F and 89F
Manually-Actuated Head Setup
This Section describes the following adjustments:
x
x
x
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.
CAUTION: Excessive force can damage the electrodes and/or the workpiece.
1
Start with the right side of the head. Do not connect the DFS/88 switchbox at this time.
Connect the right side firing switch cable to the power supply firing switch connector. Use the
force adjustment knob to set the weld head force indicator to "4." The indicator is located on
the front of the force tube just below the force adjustment knob.
2
Place a Miyachi Unitek Force Gauge
beneath the electrode, as shown. The
force gauge must be supported on the
bottom for proper indication of force.
NOTE: If the application is a welding
application, adjust the spacing so that a
Miyachi Unitek Force Gauge fits
between the right electrode and a
workpiece.
3
Depress and hold the pedal. Note the
force indication on the force gauge
when the head firing switch "clicks." If
the firing switch closure is inaudible, it
is 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.
4
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.
5
Repeat steps 1 through 4 to set the firing force on the left side of the head. Disconnect the
power supply firing switch connector from the right side firing switch cable and connect to the
left side firing switch cable.
6
Depress and release the footpedal. Verify that the force applied by the operator does not
exceed the force required to close the firing switch by more than five percent (5%).
THIN-LINE® SERIES 80 WELD HEADS
3-16
990-121
CHAPTER 3: OPERATING INSTRUCTIONS
7
After setting the required force, remove the force adjustment knob by loosening the two set
screws that 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. Re-tighten both set screws.
8
Reconnect the DFS/88 to both the right/left side firing cables and attach to the power supply
firing switch connector.
9
If necessary, re-adjust the electrodes in their holders to accommodate the workpiece. The faces
of both electrodes should be in the same plane and the gap (spacing) between the electrodes
should be uniform.
10 Turn the downstop screws counter-clockwise to their fullest extension without actually
disengaging them. This will allow maximum downward travel of the upper arms. The
following downstop adjustments should be made only if the workpiece would be damaged if
the upper arms travel too far. In most applications, use of the downstop is not recommended.
11 Start with the right downstop. Place the workpiece in the appropriate position. Rotate the
downstop screw clockwise until the electrode no longer contacts the workpiece. Check the
adjustment by depressing and releasing the footpedal.
A) Depress and hold the footpedal.
B) Slowly rotate the downstop counter-clockwise until the force firing switch in the head closes.
Rotate the downstop one or two additional turns counter-clockwise.
C) The additional turn(s) will allow for electrode wear and/or the slight variations of the position
of the electrode in its holder.
D) Re-check that the firing switch consistently closes.
12 Repeat this procedure for the left downstop.
CAUTION: Do not attempt to use the downstop adjustments to limit the force which is applied to
the workpiece. This will result in inconsistent welds.
THIN-LINE® SERIES 80 WELD HEADS
990-121
3-17
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.
Section II. Standard Resistance Welding
Electrode Cleaning
1
Re-surface tips periodically to remove oxides and welding debris from the electrodes.
2
Set the WELD/NO WELD Switch on the welding power supply, or control, to the NO WELD
position.
3
Clean the electrodes using 400 to 600 grit emery paper. Fold the emery paper over a flat, rigid
backing with the grit surface facing out. The rigid backing will maintain the "flatness" of the
electrode face during cleaning.
4
Place emery paper and backing between electrodes. If the head is air actuated, reduce the pressure
on the top of the cylinder. Actuate the head. The electrodes should contact with the paper with a
force which is low enough to allow the paper to be moved without damaging its surface. Move the
paper in a circular motion while maintaining the contact force.
5
Wipe the electrodes so that they are clean.
THIN-LINE® SERIES 80 WELD HEADS
990-121
4-1
CHAPTER 4: MAINTENANCE
Section III. 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.
During normal welding operations, oxides build up as a natural result of the welding process. Oxide
buildup limits the flow of current to the workpieces, so Unitips must be cleaned periodically. If the
electrode starts to stick to the workpiece, the electrode has become dirty and needs to be cleaned.
CAUTION: The small size of the Unitip makes the electrode tip extremely susceptible to damage during
cleaning. Never apply a force greater than 3 ounces (100 grams) when cleaning, because the, Ceramic
Polishing Squares (Model CPD) have a hard surface which can cause the two halves of the electrode to split
away from the insulator.
1
If necessary, install the Unitip in an electrode holder. Adjust the surface height of the work
holder so that it is at the same level as the workpiece surface.
2
Place a polishing square on the work holder surface, directly beneath the tip of the electrode.
3
Bring the electrode tip into contact with the polishing square by applying a force less than 100
grams (3 ounces). Gently pull the polishing disk forward, keeping the direction of pull in a
straight line parallel to the insulator as shown above. Do not move the polishing square from
side-to-side, or from front-to-back, or the two halves of the electrode will split away from the
insulator.
4
After using the polishing square, clean the electrode tip with a small cotton swab saturated in
alcohol.
5
Examine the electrode tip with a small mirror for flatness and direction of surface scratches. A
properly dressed Unitip will have small scratch marks parallel to the insulator.
THIN-LINE® SERIES 80 WELD HEADS
4-2
990-121
CHAPTER 4: MAINTENANCE
Section IV. Tare Spring Adjustment
Model 80, 86, 87, and 88
The tare spring adjustment compensates for the varying mass of different upper electrodes and adapters.
Tare springs are not used in the model 82, 83, 84 or 89.
1
2
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.
Hold a measuring scale beside the upper electrode adapter block, grasp the block, and move the
block up and down between the tare spring travel limits. The total travel will be about Ɨ inch
(3.2 mm). Push the block down against the bottom limit, then gently release it. The tare spring
should exert enough force to return the electrode to the center of its travel, approximately 1/16
inch (1.6 mm) from either extreme. If the electrode block does not re-center, adjust the tare
spring.
3
If necessary, adjust the tare spring
tension adjustment screw setting with a
Ɨ inch (3.2 mm) Allen wrench. The
adjustment screw is recessed in the
center of the tare spring assembly at the
bottom of the force spring tube.
4
Adjust the screw until the electrode
block centers itself after being
depressed and released. Tightening the
screw increases tare spring tension,
which increases the upward force on the
upper electrode assembly. If the upper
electrode interconnecting flexure
interferes with the adjustment
procedure, temporarily disconnect it
from the upper electrode adapter block.
5
After adjusting the tare spring tension, recheck the firing force adjustment and readjust if
required.
THIN-LINE® SERIES 80 WELD HEADS
990-121
4-3
APPENDIX A.
Technical Specifications
Low-Force Weld Heads: 0.25 to 20 Lbs (2.2 to 89N)
FEATURES
80F(1)
80A
86F(2)
86A(2)
87F(1)
87A
88F
88A
Manual
Air
Manual
Air
Manual
Air
Manual
Air
Max. (lbs/N)
Min. (lbs/N)
20/89
0.5/2.2
20/89
0.5/2.2
20/89
0.25/1.1
20/89
0.5/2.2
20/89
0.25/1.1
20/89
0.5/2.2
20/89
0.5/2.2
20/89
0.5/2.2
(kVA)
(watt-seconds)
2
250
2
250
1
125
1
125
2
125
2
125
5
250
5
250
Electrode Stroke
(in)
(mm)
1
25
1
25
1
25
1
25
1
25
1
25
1
25
1
25
Electrode Diameter
(in)
(mm)
1/8
3.2
1/8
3.2
0.245
6.2
0.245
6.2
Offset
Offset
Series
Series
Actuation
Weld Force
Maximum Rating
Electrode Holder Type
Unibond Unibond Thermodes Thermodes
Unitips
Unitips
Parallel
Gap
Parallel
Gap
Parallel
Gap
Parallel
Gap
Max. Throat Size
Height x Depth
(in) 1.94 x 6.0 1.94 x 6.0 3.38 x 5.2 3.38 x 5.2 2.55 x 5.25 2.55 x 5.25 6.2 x 6.25 6.2 x 6.25
(mm) 49 x 152 49 x 152 86 x 132 86 x 132 65 x 133 65 x 133 157 x 159 157 x 159
Maximum Distance
between Electrodes
(in)
(mm)
Electrode Series
Weld Cable Size:
Length:
-
-
ES-0400 ES-0400
(AWG)
(in/cm)
0.040
1.0
EU
0.040
1.0
0.040
1.0
0.040
1.0
EU or UT 17(3) or UT
17(3)
0.75
44.5
0.75
44.5
ES-0800E ES-0800E
#2
11/28
#2
11/28
#2
11/28
#2
11/28
#2
11/28
#2
11/28
#2/0
11/28
#2/0
11/28
CP
-
CP
-
CP
-
MSP
-
(VAC)
-
24 or 115
-
24 or 115
-
24 or 115
-
24 or 115
Air Pressure for Max. Force (psi)
-
50
345
-
50
345
-
50
345
-
50
345
-
0.75/18.9
-
0.75/18.9
-
0.75/.189
-
0.75/18.9
-
1
2.5
-
1
2.5
-
1
2.5
-
1
2.5
16 /406
7.0/178
2.2/ 56
16.5/419
9.1/231
4.7/119
16 /406
7.0/178
2.2/ 56
16.5/419
9.1/231
4.7/119
5.5
2.5
7
3.2
5.5
2.5
7
3.2
Foot Pedal Model Number
Air Solenoid Voltage
(kPa)
Cylinder Inside Diameter
(in/mm)
Cycle Rate (full strokes/sec) at
Min. Force at greater than 20%
of Rated Force
Max. Dimensions:
Height (in/mm) 13.7/348 16.3/413
Width (in/mm) 7.6/193 9.0/229
Depth (in/mm) 1.7/ 43
4.6/117
Weight
(lbs)
(kg)
5
2.3
7
3.2
16.7/429 19.3/490
13.5/343 13.5/343
4 /102 10.5/267
14
6.4
17
7.7
Add /24 for 24 VAC and /115 for 115 VAC Solenoid. 24 VAC is standard.
1) Model 80FLF and 87FLF have a force range of 0.25 10 lbs (1.1 - 45N).
2) Model 86FRE and 86ARE use 1/8 inch diameter Series E0-0400 35° Offset Electrode Holders and Electrodes.
3) 17BM, 17F, 17M, 17P or 17SR.
THIN-LINE® SERIES 80 WELD HEADS
990-121
A-1
APPENDIX A. TECHNICAL SPECIFICATIONS
Low-Force EZ-AIR Weld Heads: 0.25 to 20 Lbs (2.2 to 89N)
FEATURES
Actuation
80A/EZ
86A/EZ
88A/EZ
Air
Air
Air
Weld Force
Max. (lbs/N)
Min. (lbs/N)
20/89
1/4.4
20/89
1/4.4
20/89
1/4.4
Maximum Rating
(KVA)
(watt-seconds)
2
250
1
125
5
250
Electrode Stroke
(in)
(mm)
1
25
1
25
1
25
Electrode Diameter
(in)
(mm)
1/8
3.2
Unibond
0.245
6.2
Offset
Parallel Gap
Series
Electrode Holder Type
Max. Throat Size
Height x Depth
(in)
(mm)
1.94 x 6.0
49 x 152
3.38 x 5.2
86 x 132
6.2 x 6.25
157 x 159
Maximum Distance
between Electrodes
(in)
(mm)
-
0.040
1.0
0.75
44.5
ES-0400
EU or UT
ES-0800E
#2
11/28
#2
11/28
#2/0
11/28
Foot Pedal Model Number
-
-
-
Valve Driver Input (VAC)
24
24
24
130
896
130
896
130
896
.75/18.9
.75/18.9
.75/18.9
1
2.5
1
2.5
1
2.5
15.9/404
13.3/338
3.4/87
16.0/406
13.3/338
3.4/87
19.3/490
15.6/396
5.6/142
9.4
4.3
9.4
4.3
21.8
9.9
Electrode Series
Weld Cable Size:
Length:
(AWG)
(in/cm)
Air Pressure for Max. Force
[Unlubricated Air]
(psi)
(kPa)
Cylinder Inside Diameter (in/mm)
Cycle Rate (full strokes/sec) at Min. Force
at greater than 20% of Rated Force
Max. Dimensions:
Height (in/mm)
Width (in/mm)
Depth (in/mm)
Weight
(lbs)
(kg)
Add /24 for 24 VAC and /115 for 115 VAC Solenoid. 24 VAC is standard.
4) Model 80FLF and 87FLF have a force range of 0.25 10 lbs (1.1 - 45N).
5) Model 86FRE and 86ARE use 1/8 inch diameter Series E0-0400 35° Offset Electrode Holders and Electrodes.
6) 17BM, 17F, 17M, 17P or 17SR.
THIN-LINE® SERIES 80 WELD HEADS
A-2
990-121
APPENDIX A. TECHNICAL SPECIFICATIONS
High-Force Weld Heads: 4 to 40 Lbs (18 to 178N)
82A
83F
83A
84F
84A
89F
89A
Air
Manual
Air
Manual
Air
Manual
Air
40/178
6/27
40/178
4/18
40/178
6/27
40/178
4/18
40/178
6/27
40/178
4/18
40/178
6/27
(KVA)
(watt-seconds)
5
250
5
250
5
250
5
250
5
250
5
250
5
250
Electrode Stroke
(in)
(mm)
1
25
1
25
1
25
1
25
1
25
1
25
1
25
Electrode Diameter
(in)
(mm)
1/4
6.4
1/4
6.4
1/4
6.4
1/4
6.4
1/4
6.4
0.245
6.2
0.245
6.2
In-Line
In-Line
In-line
Offset
Offset
Series
Series
FEATURES
Actuation
Weld Force
Maximum Rating
ax. (lbs/N)
Min. (lbs/N)
Electrode Holder Type
Max. Throat Size
Height x Width
(in)
(mm)
N/A
1.8 x 3.1
46 x 79
1.8 x 4.8
46 x 122
3.3 x 6.1
84 x 155
3.3 x 7.8
84 x 198
Maximum Distance
between Electrodes
(in)
(mm)
-
-
-
-
-
ES-0800
ES-0800
ES-0800
ES-0800
ES-0800
#2/0
11/28
#2/0
11/28
#2/0
11/28
#2/0
11/28
#2/0
11/28
#2/0
11/28
#2/0
11/28
MSP
-
MSP
-
MSP
-
Electrode Series
Weld Cable Size (AWG)
Length:
(in/cm)
Foot Pedal Model Number
Air Solenoid Voltage
Air Pressure for Max. Force
Cylinder Inside Diameter
8.7 x 5.6 8.7 x 8.2
221 x 142 221 x 208
0.75
44.5
0.75
44.5
ES-0800E ES-0800E
(VAC)
24 or 115
-
24 or 115
-
24 or 115
-
24 or 115
(psi)
(kg/cm2)
50
345
-
50
345
-
50
345
-
50
345
1.0625
-
1.0625
-
1.0625
-
1.0625
1
2.5
-
1
2.5
-
1
2.5
-
1
2.5
16.2/411
17.7/450
4.6/117
17.4/492
7.9/201
2.6/ 66
20.1/511
9.6/244
4.6/117
16.7/424
10.0/254
2.6/ 66
19.3/490
11.9/302
4.6/117
21.9/556
14.6/371
4.9/124
24.5/622
16.0/406
10.5/267
7
3.2
9
4.1
8
3.6
10
4.5
20
9
23
10
(in/mm)
Cycle Rate (full strokes/sec)
At Min. Force
At greater than 20% of Rated Force
Max. Dimensions:
Height (in/mm)
Width (in/mm)
Depth (in/mm)
Weight
(lbs)
(kg)
Add /24 for 24 VAC and /115 for 115 VAC Solenoid. 24 VAC is standard.
THIN-LINE® SERIES 80 WELD HEADS
990-121
A-3
APPENDIX A. TECHNICAL SPECIFICATIONS
High-Force EZ-AIR Weld Heads: 4 to 40 Lbs (18 to 178N)
83A/EZ
84A/EZ
89A/EZ
Air
Air
Air
Max. (lbs/N)
Min. (lbs/N)
40/178
4/17.8
40/178
4/17.8
40/178
4/17.8
(KVA)
(watt-seconds)
5
250
5
250
5
250
Electrode Stroke
(in)
(mm)
1
25
1
25
1
25
Electrode Diameter
(in)
(mm)
1/4
6.4
1/4
6.4
0.245
6.2
In-line
Offset
Series
FEATURES
Actuation
Weld Force
Maximum Rating
Electrode Holder Type
Max. Throat Size
Height x Width
(in)
(mm)
1.8 x 4.8
46 x 122
3.3 x 7.8
84 x 198
8.7 x 8.2
221 x 208
Maximum Distance
between Electrodes
(in)
(mm)
-
-
0.75
44.5
ES-0800
ES-0800
ES-0800E
#2/0
11/28
#2/0
11/28
#2/0
11/28
Foot Pedal Model Number
-
-
-
Valve Driver Input (VAC)
24
24
24
130
896
130
896
130
896
1.0625
1.0625
1.0625
1
2.5
1
2.5
1
2.5
20.25/514
14.5/368
4.6/117
20.25/514
15.55/395
4.6/117
21.5/546
21.4/544
10.5/267
11.4
5.17
12.4
5.62
27.8
12.6
Electrode Series
Weld Cable Size (AWG)
Length
(in/cm)
Air Pressure for Max. Force
[Unlubricated Air]
Cylinder Inside Diameter
(psi)
(kPa)
(in/mm)
Cycle Rate (full strokes/sec)
At Min. Force
At greater than 20% of Rated Force
Max. Dimensions:
Height (in/mm)
Width (in/mm)
Depth (in/mm)
Weight
(lbs)
(kg)
THIN-LINE® SERIES 80 WELD HEADS
A-4
990-121
APPENDIX A. TECHNICAL SPECIFICATIONS
Model 87SA and 84SA Reflow Soldering Heads
Feature
87SA (Low Force)
84SA (Medium Force)
Air
Air
20/88.96
40/ 177.92
2/8.9
5 / 22.2
5
5
250
250
inch
1
1
mm
25
25
N/A *
N/A *
Thermode Style
Mounting Block
Thermode Style
Mounting Block
Actuation
Weld Force - Maximum (lbs/N))
Minim urn (lbs/N)
Maximum Rating
KVA
watt-second
Electrode Stroke
Electrode Diameter
-- inch / mm
Electrode Holder Type
Max. Throat Size
Height x Depth
-- (inch)
-- (mm)
2.55 x 5.25
65 x 133
3.3 x 7.8
84 x 198
Maximum Distance
between Electrodes
-- (inch)
-- (mm)
---
---
Electrode Series
17TD
17TD
Weld Cable Size - (AWG)
and Length - (inch/cm)
#2/0
11 / 28
#2/0
11 / 28
Foot Pedal Model Number
--
--
Air Solenoid Voltage - (Vac)
24
24
Air Pressure for Max. Force (psig)
80
80
0.75 / 0.189
1.0625
1
2.5
1
2.5
-- Height (inch / mm)
16.5 / 419
19.3 /490
-- Width (inch / mm)
9.1 / 231
11.9 / 302
-- Depth (inch / mm)
4.7 / 119
4.6 / 117
-- (Ibs)
7
10
-- (kg)
3.2
4.5
-- VAC
24
24
Cylinder Inside Diameter (inch / mm)
Cycle Rate (full strokes/sec) at Min. Force
at greater than 20% of Rated Force
Max. Dimensions
Weight
Cooling Valve
* Thermodes range in lengths starting from 1.0 in. / 25.4mm up to 1.5 in. / 38.1 mm (for the 87SA) or up to 2.5 in. / 63.4
mm (for the 84SA) and in width from 0.059 in / 1.5mm to 0.118 in. / 3.0 mm (both units).
NOTE: Add /24 for 24 VAC and /115 for 115 VAC Solenoid. 24 VAC is standard.
THIN-LINE® SERIES 80 WELD HEADS
990-121
A-5
APPENDIX B
ACCESSORIES
Accessories
MODEL
DESCRIPTION
80AK/24
Air Kit, 24V-50/60Hz. Includes Regulators, Gauges, Flow Controls, Cylinder, and Hardware.
80AK/115
Air Kit, 115V-50/60Hz. Includes Regulators, Gauges, Flow Controls, Cylinder, and Hardware.
Converts Model 80F, 86F or 87F to Model 80A, 86A, 87A, respectively.
BLFOI
Fiber Optic Illuminator System, 115V-50/60Hz. Self-Supporting Gooseneck, Bifurcated Light
Pipes, Focusing Lenses, and Mounting Adapter for Optic Mounting Assembly.
BLFOI/230
Fiber Optic Illuminator System, 230V-50/60Hz. Self-Supporting Gooseneck, Bifurcated Light
Pipes, Focusing Lenses, and Mounting Adapter for Optic Mounting Assembly.
BPTL
Base Plate, Teflon Coated. Supports Optic Mounting Assembly.
CP
Cable Pedal, 1 in. stroke, with 6 foot cable. (Model 80F, 86F, or 87F)
CPD
Polishing Disks, Ceramic, 1 inch square x 0.025 in. thick, 20 pieces. Use to polish electrodes.
DFS
Firing Switch Junction Box. Connects 2 Firing Switch Cables to one Power Supply.
DFS/88
Series Firing Switch Junction Box. Connects two firing switch cables in Series.
(Model 88 or 89)
FG100
Electrode Force Gage, 100 lb, SCALE 100 lb x 1 lb.
FG20
Electrode Force Gage, 20 lbs, SCALE 20 lb x 0.2 lb
FG10KG
Electrode Force Gage, 10 kg, SCALE 10 kg x 0.1 kg.
FSAC
Footswitch, Single Level. Switches 115V-50/60Hz to air heads. USE with UB2 and HFIC
power supplies and/or any power supply or control which does NOT have a built-in Valve
Driver.
FS1L
Footswitch, Single Level, for PM4.
FS2L
Footswitch, Two Level, for PM7 and 125DP, 250DP, 500HV or 875DP Power Supplies.
HS20
Hall Effect Sensor Kit for 20 lb. cylinders. Includes, Cylinder, Clamp and Sensor. Use on 80A,
86A, 87A. 88A requires two (2) Kits.
HS40
Hall Effect Sensor Kit for 40 lb. cylinders. Includes, Cylinder, Clamp and Sensor. Use on 82A,
83A, 84A. 89A requires two (2) Kits.
KR207
Kovar Ribbon, Gold Plated, 0.002 in. x 0.007 in. x 20 ft. spool.
KR310
Kovar Ribbon, Gold Plated, 0.003 in. x 0.010 in. x 20 ft. spool.
KR315
Kovar Ribbon, Gold Plated, 0.003 in. x 0.015 in. x 20 ft. spool.
KR320
Kovar Ribbon, Gold Plated, 0.003 in. x 0.020 in. x 20 ft. spool.
MSP
Footpedal, Medium Force Swing Type, 100 lb maximum, 5:1 mechanical advantage. (Model
83F, 84F, 88F, or 89F)
THIN-LINE® SERIES 80 WELD HEADS
990-121
B-1
APPENDIX B. ACCESSORIES
Accessories (Continued)
MODEL
DESCRIPTION
OMA
Optic Mounting Assembly. Use with SZO and BPTL.
PD
Polishing Disks, 600 grit, 1.5 in. diameter, 50 pieces. Use to polish electrodes.
SMZ-660
Nikon SMZ 660 Stereo Zoom Microscope, 10X wide eyepieces, object lens 0.5X wide field,
195 mm maximum working distance. Includes C-Bonder arm.
VDAC-24P
Valve Driver Adapter Cable, 115 V Receptacle, 4 pin Plug. Allows for Connection of OLD
Style 115V Air Head Valve to NEW Type 115/24V Receptacle.
VDAC-115P
Valve Driver Adapter Cable, 4 pin Receptacle, 115 V Plug. Allows for Connection of Standard
24/115V Plug on NEW Style Air Head Valve to OLD Type 115V Receptacle.
WP
Work Positioner, 3 inch diameter, Height Adjustable from 1-7/16 to 2 inches.
Electrodes
MATERIAL
DESCRIPTION
RWMA 1 -- Copper-Cadmium-Alloy
70B Rockwell Hardness, 90% conductivity. Used for
welding aluminum and tin plate. Difficult to obtain in
diameters under 1/2 inch. Gildcop is a substitute.
RWMA 2 -- Copper-Chromium Alloy
83B Rockwell Hardness, 85% conductivity. Used for
welding steels, nickel alloys and other high resistance
materials.
RWMA 3 -- Copper-Beryllium Alloy
100B Rockwell Hardness, 48% conductivity. Used for
welding high resistance materials requiring high weld
forces.
GLIDCOP -- AL-15 -- Dispersion Strengthened Copper
With 0.15% Aluminum Oxide
68B Rockwell Hardness, 92% conductivity. Longer life,
greater thermal stability, higher strength than RWMA 2.
Generally interchangeable with RWMA 2 without
changing schedules. GLIDCOP is a trademark of SCM.
RWMA 11 -- Copper-Tungsten Alloy
90B Rockwell Hardness, 46% conductivity. Usually
inserted into an RWMA 2 shank. Used for welding
cuprous and precious metals. Used for light projection
welding dies.
RWMA 13 -- Tungsten
70A Rockwell Hardness, 32% conductivity. Usually
inserted into an RWMA 2 shank. Cannot be machined but
may be ground to the desired shape. Used to weld nonferrous metals such as copper and brass.
RWMA 14 -- Molybdenum
90B Rockwell Hardness, 31% conductivity. Usually
inserted into an RWMA 2 shank. Machineable. Used for
welding copper, silver, gold, and their alloys.
THIN-LINE® SERIES 80 WELD HEADS
B-2
990-121
APPENDIX B. ACCESSORIES
1/8 Inch Electrodes
EO0400 1/8 INCH DIAMETER OFFSET ELECTRODES
Used with Series 80 Weld Heads
Model
Material
EO0402
RWMA 2
EO0403
RWMA 3
EO0411
RWMA 11 INSERT
EO0413
RWMA 13 INSERT
EO0420
MOLY INSERT
* Copper Alloy
** Refractory Alloy Insert
ES0400 13 mm DIAMETER STRAIGHT ELECTRODES
Used with 80 and 82 Series Weld Heads
Model
Material
ES0402
RWMA 2
ES0403
RWMA 3
ES0450
GLIDCOP
ES0411
RWMA 11 INSERT
ES0413
RWMA 13 INSERT
ES0420
MOLY INSERT
* Copper Alloy
** Refractory Alloy Insert
THIN-LINE® SERIES 80 WELD HEADS
990-121
B-3
APPENDIX B. ACCESSORIES
ES0800 6 mm DIAMETER STRAIGHT ELECTRODES
Used with 82, 83, and 84 Series Weld Heads
Model
Material
ES0802
RWMA 2
ES0803
RWMA 3
ES0850
GLIDCOP
ES0811
RWMA 11 INSERT
ES0813
RWMA 13 INSERT
ES0820
MOLY INSERT
ES0820A
1/8 IN. DIAMETER
MOLY INSERT
* Copper Alloy
** Refractory Alloy Insert
ES0800E 0.245 INCH DIAMETER ECCENTRIC STRAIGHT ELECTRODES
Used with 88 Weld Heads and HE38V and HE88 Holders.
Model
Material
ES0802E
RWMA 2
ES0803E
RWMA 3
ES0850E
GLIDCOP
ES0820E
MOLY INSERT
ES0820E
GLIDCOP
(0.062 FACE)
THIN-LINE® SERIES 80 WELD HEADS
B-4
990-121
APPENDIX B. ACCESSORIES
ETB2 AND ETB3 TABLE ELECTRODES
Used with 80 and 86 Series Weld Heads
Model
ETB2 *
A
B
2 in.
C
1-3/4 in. 3/8 in.
ETB4 TABLE ELECTRODE
Used with 80 and 86 Series Weld Heads
Model
ETB4
A
B
3 in.
3-3/4 in.
12 INCH ELECTRODE RODS
MODEL
MATERIAL
DIAMETER
(Inch)
MODEL
MATERIAL
DIAMETER
(Inch)
ER0213
RWMA 13
1/16
ER0450
GLIDCOP
1/8
ER0220
MOLY
1/16
ER0802
RWMA 2
1/4
ER0402
RWMA 2
1/8
ER0803
RWMA 3
1/4
ER0403
RWMA 3
1/8
ER0850
GLIDCOP
1/4
ER0413
RWMA 13
1/8
ER1202
RWMA 2
3/8
ER0420
MOLY 1/8
1/8
ER2002
RWMA 2
5/8
THIN-LINE® SERIES 80 WELD HEADS
990-121
B-5
APPENDIX B. ACCESSORIES
UNITIP ELECTRODES
FACE
Width
Depth
Gap
Length
MAXIMUM
FORCE (oz)
MAXIMUM
FORCE (kgf)
UTM111L
0.010
0.0009
0.001
0.025
33
0.94
UTM112L
0.010
0.010
0.002
0.025
33
0.94
UTM152L
0.010
0.005
0.002
0.025
17
0.47
UTM222L
0.018
0.020
0.002
0.050
132
3.75
UTM237L
0.020
0.030
0.007
0.050
161
4.57
UTM111C
0.009
0.010
0.001
0.025
33
0.94
UTM112C
0.010
0.010
0.002
0.025
33
0.94
UTM222C
0.018
0.020
0.002
0.050
132
3.75
UTM224C
0.020
0.020
0.004
0.050
132
3.75
UTM224L
0.020
0.020
0.004
0.050
132
3.75
UTM112CS
0.010
0.010
0.002
0.015
33
0.94
UTM112LS
0.010
0.010
0.002
0.015
33
0.94
MODEL
All dimensions in inches unless noted.
NOTE: Refer to Unitip and Unibond Electrodes Data Sheet 991-461
THIN-LINE® SERIES 80 WELD HEADS
B-6
990-121
APPENDIX B. ACCESSORIES
Electrode Holders
MODEL HE87
Holders, Unitip/Thermode.
Used on Model 87A and 87F weld heads.
MODEL HE88
Electrode Holder Blocks. Holds 0.245 inch diameter electrodes. Adjusts CenterCenter distance from 3/32 inch to 15/32 inch.
Used on Model 88 weld heads.
MODEL HE1208
Electrode Holder, 3/8 inch diameter x 2 inch long, for 1/4 inch diameter electrodes.
Used on Model 80 weld heads.
MODEL HE127SF
Flexure Set.
Used on Model 86 weld heads.
MODEL HE127SFRE
Flexure Set, 1/8 inch diameter round electrodes.
Used on Model 86 weld heads.
MODEL HE0435
Offset Electrode Holder, 35-degree for EO0400 Series electrodes.
MODEL HE0804
Sleeves, 5/8 in. outside diameter, 3/8 in. inside diameter. Convert large weld heads
from 5/8 in. to 3/8 in. diameter holders for 1/8 in. diameter electrodes.
Used on Model 88 weld heads.
THIN-LINE® SERIES 80 WELD HEADS
990-121
B-7
APPENDIX B. ACCESSORIES
Electrode Holders (Continued)
MODEL HE1200L
Electrode Holder, 3/8 inch diameter x 3.5 inch long, for 1/8 inch diameter
electrodes.
Used on Model 80 weld heads.
MODEL 1200S
Electrode Holder, Standard, 3/8 inch diameter x 3.5 inch long, for 1/8 inch
diameter electrodes.
Used on Model 80 weld heads.
MODEL 1208
Electrode Holder, 3/8 inch diameter x 2 inch long, for 1/4 inch diameter electrodes.
Used on Model 80 weld heads.
MODEL 1600
Standard Electrode Holder, 1/2 inch diameter x 2.312 inch long, for 1/4 inch
diameter electrodes.
Used on Model 84 weld heads.
MODEL UTA
Unitip Adapter.
Used on Model 86 weld heads.
Thermode Blocks
NOTE: Thermodes are normally supplied with Type K Thermocouples attached. You may order either
Type E or Type J Thermocouples instead. Contact Miyachi Unitek for details.
THIN-LINE® SERIES 80 WELD HEADS
B-8
990-121
APPENDIX B. ACCESSORIES
Thermodes
17TD
THREE-DIMENSIONAL THERMODES
CATALOG #
TYPE
MATERIAL
SIZE (W x L)
Used With 87, 84, and 180 SA Reflow Heads (Fits Small, Medium, and Large Blocks)
17TDS1000/059
3-DIMENSIONAL
Special alloy
0.059” x 1.0” (1.5 mm x 25.4 mm)
17TDS1000/079
3-DIMENSIONAL
Special alloy
0.079” x 1” (2.0 mm x 25.4 mm)
17TDS1000/098
3-DIMENSIONAL
Special alloy
0.098” x 1” (2.5 mm x 25.4 mm)
17TDS1000/l18
3-DIMENSIONAL
Special alloy
0.118” x 1” (3.0 mm x 25.4 mm)
I7TDS1500/059
3-DIMENSIONAL
Special alloy
0.059” x 1.5” (1.5 mm x 38.1 mm)
I7TDS1500/079
3-DIMENSIONAL
Special alloy
0.079” x 1.5” (2.0 mm x 38.l mm)
I7TDS1500/098
3-DIMENSIONAL
Special alloy
0.098” x 1.5” (2.5” / 38.l mm)
17TDS 1500/118
3-DIMENSIONAL
Special alloy
0.118” x 1.5” (3.0 mm x 38.1 mm)
Used With 87, 84, and 180 SA Reflow Heads (Fits Medium and Large Blocks)
17TDM2000/059
3-DIMENSIONAL
Special alloy
0.059” x 2” (1.5 mm x 50.8 mm)
17TDM2000/079
3-DIMENSIONAL
Special alloy
0.079” x 2” (2.0 mm x 50.8 mm)
I7TDM2000/098
3-DIMENSIONAL
Special alloy
0.098” x 2” (2.5 mm x 50.8 mm)
17TDM2000/118
3-DIMENSIONAL
Special alloy
0.118” x 2” (3.0 mm x 50.8 mm)
17TDM2500/059
3-DIMENSIONAL
Special alloy
0.059” x 2.5” (1.5 mm x 63 mm)
CATALOG #
TYPE
MATERIAL
SIZE (W x L)
Used With 87, 84, and 180 SA Reflow Heads (Fits Medium and Large Blocks)
17TDM25001079
3-DIMENSIONAL
Special alloy
0.079” x 2.5” (2.0 mm x 63 mm)
17TDM2500/098
3-DIMENSIONAL
Special alloy
0.098” x 2.5” (2.5mm x 63 mm)
17TDM2500/118
3-DIMENSIONAL
Special alloy
0.118” x 2.5” (3.0 mm x 63 mm)
Used With 84, and 180 SA Reflow Heads (Fits Large Block)
17TDL3000/059
3-DIMENSIONAL
Special alloy
0.059” x 3” (1.5 mm x 76.2 mm)
17TDL3000/079
3-DIMENSIONAL
Special alloy
0.079” x 3” (2.0 mm x 76.2 mm)
17TDL3000/098
3-DIMENSIONAL
Special alloy
0.098” x 3” (2.5 mm x 76.2 mm)
17TDL3000/118
3-DIMENSIONAL
Special alloy
0.118” x 3” (3.0 mm x 76.2 mm)
THIN-LINE® SERIES 80 WELD HEADS
990-121
B-9
APPENDIX B. ACCESSORIES
17B MULTIPLE LEAD
BLADE THERMODE
Used With 87 Reflow Heads
Model
Material
Size
17BM070
Molybdenum
0.075 inch wide x 0.030 inch thick (1.905 mm x 0.762 mm)
17BM180
Molybdenum
0.220 inch wide x 0.030 inch thick (5.588 mm x 0.762 mm)
17BM360
Molybdenum
0.400 inch wide x 0.030 inch thick (10.16 mm x 0.762 mm)
17BM770
Molybdenum
0.810 inch wide x 0.030 inch thick (20.574 mm x 0.762 mm)
17BM031/030
Molybdenum
0.031 inch wide x 0.030 inch thick (0.787 mm x 0.762 mm)
176M135/30
Molybdenum
0.135 inch wide x 0.030 inch thick (3.429 mm x 0.762 mm)
17BM400/60
Molybdenum
0.400 inch wide x 0.060 inch thick (10.16 mm x 1.524 mm)
17BM400/90
Molybdenum
0.400 inch wide x 0.090 inch thick (10.16 mm x 2.286 mm)
17BM600/30
Molybdenum
0.600 inch wide x 0.030 inch thick (15.24 mm x 0.762 mm)
17BM650/30
Molybdenum
0.650 inch wide x 0.030 inch thick (16.51 mm x 0.762 mm)
17BM770/60
Molybdenum
0.810 inch wide x 0.060 inch thick (20.574 mm x 1.524 mm)
17BM770/90
Molybdenum
0.810 inch wide x 0.090 inch thick (20.574 mm x 2.286 mm)
17BN870/30
Molybdenum
0.870 inch wide x 0.030 inch thick (22.098 mm x 0.762 mm)
17BM870/60
Molybdenum
0.870 inch wide x 0.060 inch thick (22.098 mm x 1.524 mm)
17BM900/30
Molybdenum
0.900 inch wide x 0.030 inch thick (22.86 mm x 0.762 mm)
17BM950
Molybdenum
0.950 inch wide x 0.030 inch thick (24.13 mm x 0.762 mm)
17BM1000
Molybdenum
1.000 inch wide x ,030 inch thick (25.4 mm x .762 mm)
17BMll00
Molybdenum
1.100 inch wide x 0.030 inch thick (27.94 mm x 0.762 mm)
17BM1300/30
Molybdenum
1.300 inch wide x 0.030 inch thick (33.02 mm x 0.762 mm)
17BM300/30
Molybdenum
0.300 inch wide x 0.030 inch thick (7.62 mm x 0.762 mm)
THIN-LINE® SERIES 80 WELD HEADS
B-10
990-121
APPENDIX B. ACCESSORIES
17P SINGLE POINT
PEG TIP THERMODE
Used With 87 Reflow Heads
Model
Material
Size
17P20
Brazed Tungsten
0.020 inch diameter x 0.070 inch long (0.508 mm x 1.778 mm)
17P40
Brazed Tungsten
0.040 inch diameter x 0.070 inch long (1.016 mm x 1.778 mm)
17P50
Brazed Tungsten
0.050 inch diameter x 0.200 inch long (1.27 mm x 5.08 mm)
17P75
Brazed Tungsten
0.075 inch diameter x 0.070 inch long (1.905 mm x 1.778 mm)
17P93
Brazed Tungsten
0.093 inch diameter x 0.250 inch long (2.362 mm x 6.35 mm)
17P40/200D
Brazed Tungsten
0.40 inch diameter x 0.200 inch long (10.16 mm x 5.08 mm)
17P50/180
Brazed Tungsten
0.050 inch diameter x 0.180 inch long (1.27 mm x 4.572 mm)
17P50E
Brazed Tungsten
0.050 inch diameter x 200 inch long (1.27 mm x 5.08 mm)
17P062/10
Brazed Tungsten
0.062 inch diameter x 0.010 inch long (1.575 mm x 0.254 mm)
17P110/70
Brazed Tungsten
0.070 inch diameter x 0.110 inch deep (1.778 mm x 2.794 mm)
17P93-50
Brazed Tungsten
0.093 inch diameter x 0.500 inch long (2.362 mm x 12.7 mm)
17P93/E
Brazed Tungsten
0.93 inch diameter x 0.250 inch long (2.362 mm x 6.35 mm)
17T "T" TIP THERMODE
Used With 87 Reflow Heads
Model
Material
Size
17T08/10
Molybdenum
0.008 inch wide x 0.010 inch deep face (0.203 mm x 0.254 mm)
17T085/25
Molybdenum
0.0085 inch wide mm x 0.025 inch deep face (0.216 mm x 0.635 mm)
17T08/30
Molybdenum
0.008 inch wide x 0.030 inch deep face (0.203 mm x 0.762 mm)
17T04/04
Molybdenum
0.004 inch wide mm x 0.004 inch deep face (0.102 mm x 0.102 mm)
THIN-LINE® SERIES 80 WELD HEADS
990-121
B-11
APPENDIX B. ACCESSORIES
16SR SINGLE LEAD
ROUNDED FOLD-UP THERMODE
(Replaces 17SR)
Used With 87 Reflow Heads
Model
16SR40
Material
Molybdenum
Size
0.040 inch wide x 0.010 inch thick (1.016 mm x 0.254 mm)
NOTE: Part Number 16SR40 replaces Part Number 17SR40.
16 & 17M FINELINE
MINIBAR THERMODE
Used With 87 Reflow Heads
Model
Material
Size
16M300
Nichrome Alloy
0.010 inch wide x 0.300 inch thick (0.254 mm x 0.762 mm)
17M300/20
Nichrome Alloy
0.020 inch wide x 0.300 inch thick (0.508 mm x 0.762 mm)
NOTE: Part Number 16M300 replaces Part Number 17M300.
THIN-LINE® SERIES 80 WELD HEADS
B-12
990-121
APPENDIX B. ACCESSORIES
17F MULTIPLE LEAD
FOLD-UP BAND THERMODE
Used With 87 Reflow Heads
Model
Material
Size
17F1000
Nichrome Alloy
0.1 inch wide x 0.075 inch thick (25.4 mm x 1.905 mm)
17F250
Nichrome Alloy
0.250 inch wide x 0.075 inch thick (6.35 mm x 1.905 mm)
17F350
Nichrome Alloy
0.350 inch wide x 0.075 inch thick (8.89 mm x 1.905 mm)
17F380
Nichrome Alloy
0.375 inch wide x 0.075 inch thick (9.525 mm x 1.905 mm)
17F380K
Nichrome Alloy
0.375 inch wide x 0.075 inch thick (9.525 mm x 1.905 mm)
17F400
Nichrome Alloy
0.400 inch wide x 0.075 inch thick (10.16 mm x 1.905 mm)
17F500
Nichrome Alloy
0.500 inch wide x 0.075 inch thick (12.7 mm x 1.905 mm)
17F550
Nichrome Alloy
0.563 inch wide x 0.075 inch thick (14.30 mm x 1.905 mm)
17F630
Nichrome Alloy
0.625 inch wide x 0.075 inch thick (15.88 mm x 1.905 mm)
17F750
Nichrome Alloy
0.750 inch wide x 0.075 inch thick (19.05 mm x 1.905 mm)
17F850
Nichrome Alloy
0.850 inch wide x 0.075 inch thick (21.59 mm x 1.905 mm)
THIN-LINE® SERIES 80 WELD HEADS
990-121
B-13

advertisement

Was this manual useful for you? Yes No
Thank you for your participation!

* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project

Related manuals

Download PDF

advertisement