THIN-LINE Series 90 Weld and Reflow Solder Heads
Contents
1. 1 3 1 4 Am Actuated Series 90 de vate tu petes 1 4 2 1 Model 90F and MSP Footpedal Installation essere 2 2 2 2 Series 90 Cutaway Illustrates Location and Size of Adjustment Screws 2 3 2 3 Solenoid Air Valve Assembly oe a Ec el ten e tad ensue 2 4 2 4 In line Electrode Holder Modification for Water Cooling 2 5 2 5 Tubing Path for Water Cooling In line Electrode Holder sess 2 5 2 6 Water Cooled HE2000WC Offset Electrode 2 6 2 7 Bottom View of Support Base susto eto aes e te tuas eX eee Pasto ei eed ee du 2 6 2 8 90F and 90A In line Weld Head Connections seen 2 7 2 9 90F DT and 90A DT Offset Weld Head Connections seen 2 7 2 10 9ORF and 90RA Reflow Soldering Head 2 8 2 11 In line Electrode Holder Installation und eio pO EP pa Peso eyes 2 8 2 12 Offset Electrode Holder Installation iiec eee ti pri te rer vig eed ma rd e 2 9 2 13 Blade Thermode Fixed Installation eeeeeeeeeeeeeeeen enne 2 9 2 14 Blade Thermode Pivot Installation eeeeeeeeeeeeen eene enne nnne 2 10 2 15 Fold up Thermode Pivot Installation 2 11 3 1 Welding Force Pressure Defect ee eee rien EE ease te tust2. 3 1 3 2 Using a Force Gauge to Measure the Weld Firing Force 3 2 5 1 Bearing Clearance Ape Eu ooa beoe e o a e aad Grd at cera atrocem ea damen ats 5 1 5 2 Tare Spring AG js wet os ce ense patct tbe Saee tee tate e e sue Ee ase 5 2 5 3 Firing Force Switch Adjustment s oeste aea ete inb teda tah dep abr eti ite ved stas 5 3 5 4 Lower Electrode DisaSsembly itid tes pr eden donde ge t e ae eic e vd edi Rud 5 4 5 5 Upper In line Electrode Holder Exploded View 5 5 5 6 Offset Electrode Holder Exploded View iic de enne edet Eni c c 5 6 5 7 Thermode Adapter Block Exploded sss 5 7 AL Outline Drawn os dette ER REN RE eq e e a aso woud ean A 2 A 2 UNIPULSE Welding Transformers A 14 Tables Table Title Page l 1 Foot Actuated Model Feat tes 5 itii tenet nth P trae Rake E HE 1 2 1 27 Air Actuated Model Features uus idee eben intei dni rior dt d reda POSER RE 1 4 Well SSC UMC AION UR NN UE 1 THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS vi 990 130 CHAPTER 1 DESCRIPTION Section Features Unitek Peco Thin Line Series 90 Welding and Reflow Soldering Heads are precision low inertia force fired designs with a narrow vertical profile Depending on the model their 3 inch width 1 1 2 inch stroke 7 to 100 or 150 pounds force range and 6 1 4 to 10 3 8 inch throat depth allows them to be used in a w
3. 3 8 BT HD 4 5 Tighten the 5 16 18 X 1 0 CAP HEAD SCREW SCREW 625 2 321 item 7 using a 1 4 inch hex key Figure 5 7 Thermode Adapter 6 If Blade Thermodes are to be used insert the Block Exploded View THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 990 130 5 7 CHAPTER 3 OPERATING INSTRUCTIONS INSULATOR PLUG item 8 into the threaded hole located on the front of the THERMODE ADAPTER BLOCK If Fold up Thermodes are to be used go to Step 9 7 Attach WELD TERMINAL LH item 9 and WELD TERMINAL RH item 10 to the THERMODE ADAPTER BLOCK using items 12 13 14 and 15 8 Attach each separate COPPER FLEXURE item 19 Figure 11 to the ends of each WELD TERMINAL Go to Step 11 9 IfFold up Thermodes are used attach WELD TERMINAL item 11 to the THERMODE ADAPTER BLOCK using items 12 13 14 and 15 Go to Step 2 2 10 Attach the LEFT COPPER FLEXURE item 19 Figure 11 to the WELD TERMINAL finger Attach the RIGHT COPPER FLEXURE to the THERMODE ADAPTER BLOCK 11 Reference Chapter 2 Section III for installing Thermodes Section IV Repair Service Telephone Service Call our Repair Department at the telephone number shown in the Foreword of this manual Before calling please obtain the model number and serial number from the name plate on the product Factory Service Repair We provide a quick turn around repair service for both warranty and non warranty repairs Call the Customer
4. Dua RN ERU 2 1 Foot Pedal Actuated Weld Heads esses e eee e eren enne ntn nennen rrr rrr nna 2 1 Adr Actuated Weld Heads edet dt ee Ge a vd ees ede oe a eve 2 4 Additional Attachments ep EI 2 5 Solenoid Air Valve Power 2 5 In line Water Cooled Electrode 1 2 5 Model HE2000WC Offset Water Cooled Electrode 1 2 6 Reducing the Length of Support 2 6 Section Connection to Power SOuUrCE ccc eeeessesessssssssssssssssssssssssssssesssssssssesesssssssesssesesesesesessees 2 6 ET TE EE 1 AEA 2 6 90F 90A 90F DT and 90A DT Weld Head Connections eee 2 7 90 and 90 Soldering Head Connections sese 2 8 Section Electrode and Thermode Installation eese enne 2 8 90F and 90 Electrode Installation 2 8 90F DT and 90A DT Electrode Installation wo 2 9 90RF and 90 Blade Thermode Fixed Installation eee 2 9 90RF and 90RA Blade Thermode Pivot Installation eeeeeeeeceeeeen e 2 10 90RF and 90 Fold up Thermode Pivot Installation sese 2 11 CHAPTER 3 OPERATING INSTRUCTIONS 1 3 1 Section I Weld
5. Linkage and Hardware Kit required to install the Model MSP Footpedal Also included are one pair of 1 4 inch diameter RWMA 2 Electrodes and 2 AWG Welding Cables The In Line Model HEU90 Electrode Holder Housings are designed with cooling fins which radiate heat and reduce the necessity for forced cooling The Electrode Holders can be forced air or water cooled by drilling and tapping a hole in the Housing as illustrated in Figure 13 In Line Electrode Holders use a collet to clamp 1 4 inch diameter ESO800 Series Electrodes Figure 1 1 The Lower Electrode Assembly can be easily aligned with the Upper Model 90F In line Electrode Assembly Electrode Weld Head THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 1 2 990 130 CHAPTER 1 DESCRIPTION Model 90F DT Offset Electrode Weld Head Figure 1 2 shows the Model 90F DT which uses the HE90ABK Offset Electrode Holder Block in both the upper and lower electrode position The offset configuration provides a throat depth of 10 3 8 inches Welding force is limited to 100 pounds The Model HE90ABK Offset Electrode Holder Block accepts 5 8 inch diameter Model HE2000 Electrode Holders which use the 1 4 inch diameter ESO800 Series Electrodes The Model HE2000 Electrode Holders can by replaced with the Model HE2000WC Water Cooled Electrode Holders Figure 1 2 Model 90F DT Offset Electrode Weld Head Model 90RF Reflow Soldering Head Reflow soldering ribbon cables or printed circuit
6. use 0 welding cable or two 2 welding cables in parallel THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 990 130 1 APPENDIX A TECHNICAL SPECIFICATIONS Outline Drawings 5 16 18UNC 28X 0 62 DP 6PI d Es i64 Lgs 1134 131 8 155 8 141 4 Models 90F and 90A Models 90F DT and 90A DT Models 90RF and 90RA Figure A 1 Outline Drawings THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS A 2 990 130
7. Service Department at the telephone number shown in the Foreword of this manual for a Return Material Authorization number All equipment to be returned to us for repair must be shipped PREPAID Please include information concerning the type problem that you are experiencing Include with the shipping information the name and telephone number of the person whom we should call with the estimated cost of repairs THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 5 8 990 130 APPENDIX A TECHNICAL SPECIFICATIONS Specifications Table A 1 Specifications See Outline Drawings Energy Rating 90F 90A 90F DT 90A DT 90RE 90RA Watt Seconds 3 KVA 3 Duty Cycle 3 Air Specifications Air Weld Heads only Air Pressure Line Regulator Output Pressure Gauge Solenoid Voltage Air Cylinder Diameter Air Cylinder Stroke Repetition Rate Nominal 65 psi 100 psi maximum 100 psi maximum 60 psi Scale 2 x 60 psi Either 115 VAC or 24 VAC 50 60 Hz 1 1 8 inch with 1 1 16 inch bore 5 inch 1 weld per second Two 2 AWG Welding Cables both 16 inches long are provided to connect Series 90 Weld Heads to Unitek Peco Stored Energy and AC Power Sources Unitek Peco Weld and Reflow Soldering Heads deliver maximum performance when used with the appropriate Unitek Peco power sources Consider the maximum energy rating of the Weld Head when selecting a Power Source For applications that require more than 16K VA and or duty cycles over 3
8. WELD AND REFLOW SOLDER HEADS 990 130 5 1 CHAPTER 3 OPERATING INSTRUCTIONS Tare Spring Adjustment 1 Reference Figure 2 2 Set the WELD FORCE ADJUSTMENT KNOB fully counter clockwise to minimum Place the Weld Head in a vertical position The UPPER ELECTRODE ASSEMBLY item 17 and the Upper Electrode must be in place to adjust the TARE SPRING item 7 2 Adjust the TARE SPRING using a 3 16 inch hex key The TARE SPRING ADJUSTMENT SCREW is recessed in the Center of the SPRING TUBE PLUG not shown on the bottom of the Weld Head Adjust the TARE SPRING ADJUSTMENT SCREW until the bottom edge of the GUIDE ARM ASSEMBLY item 15 reaches its lowest point Mark this position on the SPRING TUBE YOKE item 16 3 Turn the TARE SPRING ADJUSTMENT SCREW clockwise until the GUIDE ARM ASSEMBLY moves up from its lowest point by 06 to 09 inches 1 5 to 2 3 mm as shown in Figure 5 2 SPRING TUBE YOKE GUIDE ARM ASSEMBLY CORRECT SETTING 06 09 INCHES 1 5 2 3 MM LOWEST POINT TARE SPRING ADJUSTMENT SCREW Figure 5 2 Tare Spring Adjustment THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 5 2 990 130 CHAPTER 3 OPERATING INSTRUCTIONS Force Firing Switch Adjustment 1 Reference Figures 2 2 and 5 3 Set the WELD FORCE ADJUSTMENT KNOB fully counter clockwise minimum Welding Force Correct Actuation Lever position Incorrect Actuation Lever position lever hits the switch body Figure 5 3 Firing Force Switch Adjustmen
9. for the Models 90F 90A 90F DT and 90A DT use 1 4 inch diameter ES0800 Series Electrodes These electrodes contain snap ring grooves User ordered snap rings can be put on each electrode to prevent slipping in the electrode holder whenever the welding force exceeds 100 pounds The Model ETB3 Table Electrode can be used with the Offset Electrode Holders Models 90RF and 90RA use the 17BW Series of Blade Thermodes and 17FW2187 Fold up Thermode for reflow soldering applications Foot Actuated Series 90 Heads Targeting of the work pieces is generally easier using foot actuation since foot actuation allows the operator to easily control the rate of electrode descent Table 1 1 lists the features of each model Table 1 1 Foot Actuated Model Features Model Stock Number Electrode Holder Electrode Type Application 90F 2 150 01 HEU90K ES0800 series Welding 90F DT 2 150 01 01 HE90ABK ES0800 series Welding 90RF 2 150 01 02 HE90TAB 17BW or 17FW Reflow Model 90F In line Electrode Weld Head The Model 90F as shown in Figure 1 1 is a conventional opposed In Line electrode welding head The mechanism in the Series 90 provides a three to one mechanical advantage in addition to the three to one advantage provided by the Model MSP Footpedal This means that the operator must apply approximately 17 pounds to the Footpedal in order to obtain a welding force of 150 pounds The Model 90F includes the
10. in Figure 2 7 Figure 2 7 Bottom View of Support Base Section Il Connection to Power Source General The Series 90 Heads come with the necessary fastening hardware for connecting the Welding already installed on the weld head power straps The hardware for connecting the other end of the Welding Cables to the Power Supply or Welding Transformer can be found in the Power Supply or Welding Transformer Ship Kit THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 2 6 990 130 CHAPTER 2 INSTALLATION Connect the Weld Head Firing Switch Cable to the Firing Switch Receptacle located on the front panel of all Stored Energy Power Supplies or to the matching connector cable found on all Direct Energy Power Supplies 90F 90A 90F DT and 90A DT Weld Head Connections 1 Reference Figures 2 8 AND 2 9 Position the Power Supply or Welding Transformer approximately 4 to 5 inch behind the Weld Head Connect one 16 inch WELDING CABLE to the left side of the WELD HEAD POWER STRAP using a 5 16 18 x 1 2 CAP HEAD SCREW The FLAT WASHER goes between the CAP HEAD SCREW and the WELDING CABLE terminal 2 Connect the second WELDING CABLE to the left side of the LOWER ELECTRODE HOLDER using a 5 16 18 x 1 2 CAP HEAD SCREW The FLAT WASHER goes between the CAP HEAD SCREW and the WELDING CABLE terminal 3 Connect the opposite ends of each WELDING CABLE to the Power Supply or Welding Transformer using the hardware supplied with the Welding Transformer Ship Ki
11. the Firing Switch does not close turn the TOP AIR PRESSURE REGULATOR clockwise until the Firing Switch clicks Note the force indication on the Force Gauge when the Weld Head Firing Switch clicks and then release the Footswitch If the Firing Switch closure is inaudible it is easily detected by connecting an Ohmmeter or continuity checker to the Firing Switch Connector pins If THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 990 130 3 3 CHAPTER 3 OPERATING INSTRUCTIONS 14 15 16 more Welding Force is needed go to Step 14 If less Welding Force is required go to Step 15 Reference the force reading from Step 13 as the starting point If more Welding Force is required turn the WELD FORCE ADJUSTMENT KNOB clockwise and then increase the TOP AIR PRESSURE REGULATOR setting until the Firing Switch closes Repeat this trial and error process until the desired Welding Force is reached To provide the most sensitive DOWNSPEED AIR VALVE control the BOTTOM AIR PRESSURE REGULATOR setting should be within 15 to 20 Psig of the TOP AIR PRESSURE REGULATOR Psig final setting Reference the force reading from Step 13 as the starting point If less Welding Force is required turn the WELD FORCE ADJUSTMENT KNOB counter clockwise and then decrease the TOP AIR PRESSURE REGULATOR setting until the Firing Switch opens Slowly increase the TOP AIR PRESSURE REGULATOR setting until the Firing Switch just re closes Repeat this trial and error process u
12. the Welding Transformer Ship Kit The hardware is sized for each REFLOW SOLDERING TRANSFORMER NOTES Do not put a flat or lock washer between the welding cable and the power terminal Do not run welding cables through a steel workbench Doing so could dramatically increase the amount of energy required to make a satisfactory weld because of added inductive losses caused by the table Figure 2 10 90RF and 90RA Reflow Soldering Head Connections Section Ill Electrode and Thermode Installation 90F and 90A Electrode Installation Verify that the COLLET is loose by turning it in the counter clockwise direction Insert the electrode into the COLLET Tighten by turning clockwise as shown in Figure 2 11 Check the alignment of the electrodes Loosen the three cap head screws holding the LOWER IN LINE ELECTRODE HOLDER TEEN ASSEMBLY re align the holder and then tighten the screws Figure 2 11 In line Electrode Holder installation THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 2 8 990 130 CHAPTER 2 INSTALLATION 90F DT and 90A DT Electrode Installation Loosen the 10 32 CAP HEAD SCREW on the side of the HE2000 ELECTRODE HOLDER Insert the electrode into the holder Tighten by turning clockwise as shown in Figure 2 12 Check the alignment of the electrodes Loosen the cap head screw in the SUPPORT BASE and then rotate the LOWER OFFSET ELECTRODE HOLDER ASSEMBLY into alignment with the upper electrode Tighten the
13. 8 inch hex key Use a 1 8 inch hex key to loosen the two BEARING CLEARANCE ADJUSTMENT SCREWS on each side of the UPPER and LOWER BEARINGS If necessary realign each BEARING so that the BEARING split faces forward as indicated in Figure 5 1 If the BEARINGS will not turn easily it can be assumed that the bearings are correctly oriented Carefully tighten the BEARING CLEARANCE ADJUSTMENT SCREWS to reduce bearing play BEARING CLEARANCE SCREWS The object of this adjustment is to reduce the lateral movement of the Main Shaft while maintaining Figure 5 1 Bearing Clearance smooth low friction operation Adjustment Anti Rotation Yoke Adjustment 1 Anti Rotational play in upper the Electrode Arm Assembly is controlled by the ANTI ROTATION ADJUSTMENT item 9 in Figure 2 2 Use a 5 32 inch hex wrench to adjust the YOKE Turn the WELD FORCE ADJUSTMENT KNOB fully counter clockwise to the minimum force position Move the Upper Electrode Assembly slowly up and down by actuating the Footpedal or Footswitch Tighten the YOKE until both ANTI ROTATION BEARINGS start to turn without skidding as the YOKE is moved so that the Upper Electrode travels at least 1 inch Loosen the YOKE 1 turn One of the ANTI ROTATION BEARINGS should stop turning or start to skid Re tighten the YOKE until both ANTI ROTATION BEARINGS just stop skidding The ANTI ROTATION BEARINGS should just barely touch the ANTI ROTATION ALIGNMENT SHAFT THINLINE SERIES 90
14. ADAPTER BLOCK 302100 Assembly over the bottom of the UPPER ELECTRODE SHAFT If installed correctly the UPPER ELECTRODE m T OER et SHAFT will be flush with the bottom of the UPPER 4 30580 01 ELECTRODE ADAPTER BLOCK 5 Tighten the 5 16 18 X 1 0 CAP HEAD SCREW item 9 ful using a 1 4 inch hex key 6 Verify that the LOWER RETAINING RING item 1 1 15 16 SUPPORT M d on the LOWER ELECTRODE SUPPORT POST item m 12 4 30584 02 14 OUTSIDE POST CLAMP 7 Assemble the Support Post Clamp using the INSIDE COMM POST CLAMP item 13 OUTSIDE POST CLAMP E SENI HEAD item 14 and the 5 16 2 1 4 CAP HEAD SCREW item 15 Figure 5 6 Offset Electrode Holder 5 6 Exploded View THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 990 130 CHAPTER 3 OPERATING INSTRUCTIONS 8 Insert the completed Support Post Clamp Assembly into the side of the SUPPORT BASE item 14 The V notch in the Clamp Assembly should face into the 1 inch diameter hole in the SUPPORT BASE 9 Slip the LOWER ELECTRODE SUPPORT POST into the 1 inch diameter hole in the SUPPORT BASE Secure the LOWER ELECTRODE SUPPORT POST by tightening the screw in the end of the SUPPORT POST CLAMP using a 1 4 inch hex key 10 Slip the LOWER ELECTRODE ADAPTER BLOCK item 7 over the top of the LOWER ELECTRODE SUPPORT POST If installed correctly the LOWER ELECTRODE SUPPORT POST will be flush with the top of the LOWER ELECTRODE ADAPTER BLOCK 11 Re attach the COPPER F
15. COLLET NUT item 5 2 UPPER RETAINING RING 2 Actuate the Weld Head and hold in the down position E Adjust the UPSTOP item 1 so that the top of the 102 183 UPPER IN LINE ELECTRODE HOLDER item 17 is approximately 1 5 inches 4 cm from the bottom of the E SASHES C ec gt Weld Head Casting T 3 Remove the COPPER FLEXURE item 19 using a 3 16 inch hex key to remove the socket head screws and brass washers which hold the COPPER FLEXURE to the isi SHEUEEWASHER UPPER IN LINE ELECTRODE HOLDER EA 6 TEFLON WASHER 755 2 274 4 Reference Figure 5 5 Remove the ELECTRODE HOLDER COLLET NUT item 16 from the UPPER IN LINE ELECTRODE HOLDER item 13 5 Use a large wrench to hold the UPPER IN LINE ELECTRODE HOLDER Housing so that it cannot turn al NIT POLDER 6 Rotate the ELECTRODE HOLDER GUIDE NUT item Misa es 8 counter clockwise until it releases the UPPER IN 10 BRASS WASHER 155 2 273 LINE ELECTRODE HOLDER u Lower RETAINING RING lt TH gt 7 Note that the ANTI ROTATION INSULATOR item 12 us 12 ANTI ROTATION is held in the bottom of the UPPER IN LINE INSULATOR 4 30723 01 ELECTRODE HOLDER by a 4 40 x 3 8 CAP HEAD SCREW item 15 and two DOWEL PINS item 14 DA PERERIN Inspect the ANTI ROTATION INSULATOR to ensure 4 30668 01 that the anodized coating has been damaged 8 Remove the LOWER RETAINING RING item 11 from 15 440 X 3 8 CAP H
16. DAPTER BLOCK 4 31247 01 7 INSULATOR SLEEVE 2 WELD TERMINAL 4 31615 01 4 31248 01 6 THERMODE MOUNT L H 4 31616 01 10 THERMODE MOUNT R H 31 10 32X7 8 CAP HEAD SCREW 4 31615 01 9 INSULATOR WASHER 4 31255 01 8 BELLEVILLE WASHER 155 2 285 5 SHOULDER SPACER 4 31253 01 4 10 WASHER 755 2 227 13 8 ITL WASHER 755 2 004 11 THERMODE 17BW STYLE 12 8 32X1 4 CAP HEAD SCREW 625 2 423 Figure 214 Blade Thermode Pivot Installation 2 Assemble items 3 through 10 in numerical order NOTE the convex surface of both BELLEVILLE WASHERS item 8 must be placed against the face of the INSULATOR WASHER item 9 3 Attach the Blade Thermode Pivot Assembly to the THERMODE ADAPTER BLOCK using the single 10 32x7 8 CAP HEAD SCREW item 3 CAUTION Tighten this screw securely or it will weld to the THERMODE ADAPTER BLOCK 4 Attach the BLADE THERMODE item 11 to the WELD TERMINALS using two 8 32x1 4 CAP HEAD SCREWS item 12 and 78 ITL WASHERS item 13 CAUTION Tighten both screws securely or they will weld to the THERMODE PIVOT MOUNTS THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 2 10 990 130 CHAPTER 2 INSTALLATION 90RF and 90RA Fold Up Thermode Pivot Installation 1 Reference Figure 2 15 Verify that the THERMODE ADAPTER BLOCK item 1 has a single separate WELD TERMINAL item 2 18 INSULATOR WASHER 4 31255 01 1 THERMODE ADAPTER BLOCK 4 31557 01 2 WELD TE
17. Dual Firing Switch Junction Box Connects two firing switch cables to a single power source ES0802 Electrode RWMA 2 1 4 inch diameter x 2 inches long ES0803 Electrode RWMA 3 1 4 inch diameter x 2 inches long 50811 Electrode RWMA 11 copper tungsten insert 1 4 inch diameter x 2 inches long 50813 Electrode RWMA 13 tungsten insert 1 4 inch diameter x 2 inches long ES0820 Electrode RWMA 14 molybdenum insert 1 4 inch diameter x 2 inches long ES0850 Electrode Glidcop 1 4 inch diameter x 2 inches long ETB3 3 inch Table Electrode RWMA 2 for use with Offset Electrode Holders FG100 100 Ib Electrode Force Gage 1 lb x 100 scale FG100KG 100 kg Electrode Force Gage 1 kg x 100 kg scale FG200 200 Ib Electrode Force Gage 2 lb x 200 Ib scale FSAC Medium duty Single Level Footswitch which switches 115 VAC to air heads Use with Stored Energy Power Supplies FS2L Footswitch for controlling Phasemaster controls HE2000 Electrode Holders 5 8 inch diameter 2 inch long Holds 1 4 inch diameter electrodes HE2000WC Water Air Cooled Electrode Holders 5 8 inch diameter 2 inch long Holds 1 4 inch diameter electrodes HE90ABK Offset Upper and Lower Electrode Adapter Blocks for 90F Weld Head Not for use over 100 pounds Includes Lower Electrode Mounting Post 1 pair HE2000 Electrode Holders 1 pair ESO802 Electrodes and Hardware HE90C Collet and Nut Assembly for the Model 90 In Line Electrode Holders HE90TAB Thermod
18. EAD the bottom of the UPPER ELECTRODE SHAFT item SCREW 625 2488 1 16 COLLET NUT 9 Remove all of the other parts except the UPPER RETAINING RING item 2 Figure 5 5 Upper In line Electrode Holder Exploded View THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 990 130 5 5 CHAPTER 3 OPERATING INSTRUCTIONS Upper In line Electrode Holder Re assembly To re assemble the UPPER IN LINE ELECTRODE HOLDER reverse the above disassembly procedure CAUTION The six belleville washers item 4 must be re assembled in groups of three with the concave surface of each pair facing inward Section Ill Electrode Thermode UPPER ELECTRODE n 2 UPPER RETAINING RING Holder Conversion d 3 INSULATING SPACER 4 30666 01 Offset Electrode Holder Conversion H TEFLON WASHER Reference Figure 5 5 Remove the In Line Electrode 51 INSULATING WASHER Holders parts by following the procedure outlined in 6 UPPER ELECTRODE Section 8 03 DO NOT REMOVE THE UPPER DATTER BLOCK LL CAP HEAD SCREW RETAINING RING ITEM 2 FROM THE UPPER ay 0 ELECTRODE SHAFT ITEM 1 5 CIT CAP HEAD SCREW 2 Reference Figure 5 6 Install the INSULATING 625 2460 18 SPACER item 3 followed by the TEFLON WASHER item 4 3 Verify that the ELECTRODE SHAFT INSULATOR ADAPTER BLOCK item 5 has been installed in the UPPER ELECTRODE E2000 OR HEZOOWE ADAPTER BLOCK item 6 7 4 Slip the UPPER ELECTRODE
19. ION ARM item 8 to the LINK ASSEMBLY item 18 using the 10 32 X 1 00 CAP HEAD SCREW item 19 and KEP NUT item 20 The ADAPTER ARM should be parallel to the bottom of the work bench Re attach the PEDAL ACTUATOR and set it to the desired operating angle THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 2 2 990 130 CHAPTER 2 INSTALLATION 2 DOWNSTOP ADJUSTMENT Limits excess electrode force due to over travel i1 UPSTOP ADJUSTMENT Reduces stroke and travel time 3 WELD FORCE ADJUSTMENT Adjusts Firing Force from 7 150 Lbs 8 FIRING FORCE 16 SPRING SENSITIVITY ADJUSTMENT TUBE YOKE Controls Force Firing switching point 9 64 Hex Driver 15 GUIDE ARM ASSEMBLY i 9 ANTI ROTATION ADJUSTMENT Used to adjust Anti 41 BEARING CLEARANCE m Rotation Bearings for ADJUSTMENT SCREWS n T free play operation Used to adjust Main Shaft I 5 32 Hex Driver Bearings for free play operation 1 8 Hex Driver 13 ANTI ROTATION ALIGNMENT SHAFT 14 FIRING SWITCH Used to trigger welding contro or power supply 17 UPPER IN LINE i ELECTRODE HOLDER 5 ELECTRODE HOLDER COLLET NUT 19 COPPER FLEXURE 10 SUPPORT POST 7 TARE SPRING ADJUSTMENT EE Bee Compensates for weight of Upper Electrode Holder 3 16 Hex Driver 13 LOWER IN LINE ELECTRODE HOLDER 6 LOWER IN LINE ELECTRODE is HOLDER ADJUSTMENT SCREWS Used to position Lower In Line Electrode Holder 12 SUPPO
20. LD or HEAT Switch on all PHASEMASTER and 7500A Direct Energy Power Supplies to the OFF position Set the POWER Switch on Stored Energy Power Supplies to the OFF position Set all PHASEMASTER Power Supplies to the BEAT NON BEAT or ABORT ON Footswitch Operating Mode and 1 LEVEL or 2 LEVEL Disconnect the Weld Head Firing Switch Cable from the Power Supply Adjust the Weld Head Electrode spacing so that a UNITEK Force Gauge just fits between the electrodes NOTE The maximum opening must be less than 1 5 inches 3 8 cm 8 10 11 12 13 Reference Figure 2 2 Using the WELD FORCE ADJUSTMENT KNOB set the Weld Force Indicator to an initial setting of 4 Turn the DOWNSTOP ADJUSTMENT SCREW item 2 fully counter clockwise This will allow maximum downward travel of the Upper Electrode Reference Figure 2 3 Close but do not tighten the UPSPEED AIR FLOW VALVE item 2 and the DOWNSPEED AIR FLOW VALVE item 3 Re open both valves 3 to 4 turns Set the BOTTOM AIR PRESSURE REGULATOR item 5 and the TOP AIR PRESSURE REGULATOR item 4 to 15 Psig Cycle the Weld Head by depressing and releasing the Footswitch Adjust the UPSPEED AIR FLOW VALVE located at the top of the AIR CYLINDER item 1 so that the Upper Electrode moves upward at a reasonable rate It should not move so rapidly that it slams against the Upstop Insert a Force Gauge between the electrodes as shown in Figure 3 2 Depress and hold the Footswitch If
21. LEXURES item 19 Figure 2 2 12 Install a HE2000 Standard 5 8 inch diameter ELECTRODE HOLDER item 8 or a HE2000WC Water Air Cooled 5 8 inch diameter Electrode Holders in the UPPER and LOWER ELECTRODE ADAPTER BLOCKS Secure by tightening the 10 32 X 1 1 8 CAP HEAD SCREWS item 10 with a 5 32 inch hex key 13 Install a 1 4 inch diameter Electrode in each Electrode Holder Use Snap Rings if the operating force is in excess of 50 pounds Thermode Holder Conversion fA SHAFT 4 30569 01 Reference Figure 5 6 Remove the In Line 2 UPPER RETAINING RING 570 2 140 Electrode Holders parts by following the procedure outlined in Section 8 03 DO NOT REMOVE THE 30666 01 UPPER RETAINING RING ITEM 2 FROM THE UPPER ELECTRODE SHAFT ITEM 1 5 INSULATING WASHER 8 INSULATOR 422099001 2 Reference Figure 5 7 Install the INSULATING PLUG 6 THERMODE ADAPTER 4 31557 01 BLOCK 4 31247 01 SPACER item 3 followed by the TEFLON gt WASHER item 4 VJ CAP HEAD SCREW 625 2 684 3 Venfy that the ELECTRODE SHAFT INSULATOR item 5 has been installed in the d 67 THERMODE ADAPTER BLOCK item 6 a EEA TERMINAL 4 Slip the THERMODE ADAPTER BLOCK over a the bottom of the UPPER ELECTRODE SHAFT If installed correctly UPPER ELECTRODE L1 SHOULDER WASHER SHAFT will be flush with the bottom of the 14 WASHER 8 4 THERMODE ADAPTER BLOCK 755 2 021 15 8 32
22. RMINAL 7 BELLEVILLE WASHER F 4 31248 01 755 2 285 4 10 WASHER 9 THERMODE 1553221 oy 17FW2187 gt 6 INSULATOR SLEEVE c A GE 4 31256 01 3 10 32X7 8 CAP HEAD SCREW 5 SHOULDER SPACER 625 2 400 4 31253 01 Figure 2 15 Fold up Thermode Pivot Installation 2 Assemble items 3 through 6 in numerical order 3 Place the convex surface of both BELLEVILLE WASHERS item 7 against the face of the INSULATOR WASHER item 8 Slip this Belleville Sandwich between the top sides of the FOLD UP THERMODE item 9 4 Attach the Fold up Thermode Pivot Assembly to the THERMODE ADAPTER BLOCK using the single 10 32x7 8 CAP HEAD SCREW item 3 CAUTION Tighten this screw securely or it will weld to the THERMODE ADAPTER BLOCK THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 990 130 2 11 CHAPTER 3 OPERATING INSTRUCTIONS Section Welding Force Theory Welding Force Excessive Welding Force Pressure is a key Pressure Overheating of Weldment variable in the resistance welding Weak Weld process Excessive or insufficient welding force or pressure can cause a weak weld as shown in Figure 3 1 For more information Warping on the basics of resistance is Decoloration Insufficient welding a handbook entitled p Electrode Damage M ressure Fundamentals of Resistance Welding is available from Unitek Miyachi Insufficient Nugget Metal Expulsion Figure 3 1 Welding Force Pressure Defe
23. RT BASE 5 32 Hex Driver Figure 2 2 Series 90 Cutaway lllustrates Location and Size of Adjustment Screws THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 990 130 2 3 CHAPTER 2 INSTALLATION Air Actuated Weld Heads 1 3 Position Mounting Template Figure 43 in the desired location on the workbench Make certain that sufficient working space is provided from the front edge of bench to the Support Base This permits operator to use the bench as a support when positioning parts Most applications require about six to ten inches from edge of the bench to front of the Support Base Drill six 3 8 inch diameter mounting holes as shown on the Mounting Template Drill the 2 00 DIA hole for all models Drill the 1 25 DIA hole for the Model 90A DT NOTE All mounting hardware such as screws lock washers and washers are contained in the Ship Kit Reference Figure 2 2 for the following instructions CAUTION use a 1 4 inch hex driver to tighten the support post locking screws location on the back of the right side of the support base to ensure that the weld head does not slip and pinch your fingers Align the SUPPORT BASE item 11 over the mounting holes Attach the SUPPORT BASE to the workbench using four 5 16 18 x 1 1 2 inch hex head bolts with lock washers and washers not shown to secure the front and rear of the SUPPORT BASE 4 2 4 Reference Figure 2 3 for the following instructions Insert a 0 25 inch outside diame
24. SOLDER HEADS 990 130 5 3 CHAPTER 3 OPERATING INSTRUCTIONS Section Il Disassembly Re assembly Electrode Holder Disassembly Re assembly Lower In line Electrode Holder Disassembly 1 Reference Figure 5 4 Remove the Lower Electrode from the ELECTRODE COLLET NUT item 1 2 10 32 X 5 8 CAP HEAD SCREW 3 625 2 137 1 ELECTRODE COLLET NUT HE90C 13 410 ITL WASHER 3 755 2 006 5 LOWER IN LINE ELECTRODE HOLDER 4 30669 01 4 10 WASHER 3 755 2 135 7 ELECTRODE HOLDER BASE 6 8 32 X 3 8 CAP HEAD SCREW 3 4 30724 01 625 2 155 Figure 5 4 Lower Electrode Disassembly 2 Remove all three 10 32 x 5 8 CAP HEAD SCREWS item 2 10 ITL WASHERS item 3 and 10 FLAT WASHERS item 4 Lift the LOWER IN LINE ELECTRODE HOLDER item 5 from the BASE SUPPORT 4 Remove all three 8 32 x 3 8 CAP HEAD SCREWS item 6 from the ELECTRODE HOLDER BASE item 7 to separate the LOWER IN LINE ELECTRODE HOLDER from the ELECTRODE HOLDER BASE Lower In line Electrode Holder Re assembly To re assemble the LOWER IN LINE ELECTRODE HOLDER reverse the above disassembly procedure THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 5 4 990 130 CHAPTER 3 OPERATING INSTRUCTIONS Upper In line Electrode Holder Disassembly CAUTION Turn the flange not the housing of the upper electrode assembly in order to remove it 1 UPPER ELECTRODE SHAFT 1 Reference Figure 2 2 Remove the Upper Electrode from the ELECTRODE
25. USER S MANUAL 990 130 N REVISION A January 2002 EX UNITEK PECO WORLD LEADER IN RESISTANCE WELDING THIN LINE Series 90 Weld and Reflow Solder Heads MODEL STOCK MODEL STOCK MODEL STOCK NUMBER NUMBER NUMBER NUMBER NUMBER NUMBER 90F 2 150 XX 90F DT 2 150 01 90RF 2 150 XX 02 90A 2 151 XX 90A DT 2 151 XX 01 90RA 2 151 XX 02 Copyright 1998 2001 Unitek Miyachi Corporation The engineering designs drawings and data contained herein are the proprietary work of UNITEK MIYACHI CORPORATION and may not be reproduced copied exhibited or otherwise used without the written authorization of UNITEK MIY ACHI CORPORATION Printed in the United States of America REVISION RECORD Revision EO Date Basis of Revision pT Original Release 19161 1 02 Added Unitek Peco name THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 990 130 FOREWORD Thank you for purchasing a Unitek Peco THIN LINE SERIES 90 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 Unitek Miyachi Corporation 1820 South Myrtle Avenue P O Box 5033 Monrovia CA 91017 7133 Telephone 626 303 5676 FAX 626 358 8048 e mail info unitekmiyachi com The purpose of this manual is to supply operating maintenance and service personnel with the inform
26. ation needed to properly and safely operate and service the THIN LINE SERIES 90 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 Unitek Miyachi Corporation is not responsible for any loss due to improper use of this product THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 990 130 iii CONTENTS Revision Recordant naue uei Bequiediitaeieaniequiteiittdui a eiit ii Foreword a a mean iii CHAPTER 1 DESCRIPTION ene eR Rc tet ere cete ede t 1 1 Section Tis Eeat tes e ex E Eee eue Ted ee vt e Dna e ege ee us 1 1 Foot Actuated Series 90 Head sese 1 2 Model 90F In line Electrode Weld Head sees 1 2 Model 90F DT Offset Electrode Weld Heads 1 3 Model 90 Reflow Soldering Head ee e ee eire cus PR ue eco heater ee 1 3 Air Actuated Series 90 Heads eese nene n ne ne n nr rr rre rrr rrr nna 1 3 Section IE AGCeSSOFPIeS o edere de enden c Feet eee ee e 1 5 CHAPTER 2 INSTALLATION eter eiecti cote bres Tu Enc 2 1 Section T Physical Installatiogti irato ui Pda da tea e esp Ete
27. cap head screw Figure 2 12 Offset Electrode Holder installation 90RF and 90RA Blade Thermode Fixed Installation Reference Figure 2 13 Verify that the THERMODE ADAPTER BLOCK item 1 has two separate WELD TERMINALS item 2 and 3 The INSULATOR PLUG item 4 should be positioned between the THERMODE ADAPTER BLOCK and both WELD TERMINALS Attach the BLADE THERMODE item 5 to the WELD TERMINALS using two 8 32x1 4 CAP HEAD SCREWS item 6 and 8 ITL WASHERS item 7 Leave the screws loose 4 INSULATOR PLUG 2 WELD TERMINAL L H 4 31557 01 4 31619 02 fe 11 THERMODE ADAPTER BLOCK 4 31247 01 3 WELD TERMINAL R H 4 31619 01 6 8 32 1 4 CAP HEAD SCREW 5 BLADE THERMODE 625 2423 17BW STYLE Figure 2 13 Blade Thermode Fixed Installation 2 Reference Chapter 3 for operating instructions Bring the BLADE THERMODE down onto the workpiece CAUTION do not heat the thermode at this time or the loose screws will weld to the thermode and or weld straps 3 While applying pressure against the workpiece tighten each 8 32x1 4 CAP HEAD SCREW This action will ensure that the bottom of the BLADE THERMODE is parallel to the workpiece THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 990 130 2 9 CHAPTER 2 INSTALLATION 90RF and 90RA Blade Thermode Pivot Installation 1 Reference Figure 2 4 Verify that the THERMODE ADAPTER BLOCK item 1 has a single separate WELD TERMINAL item 2 1 THERMODE A
28. connectors can be accomplished by using the Model 90RF Reflow Soldering Head with Blade Thermodes as shown in Figure 1 3 The 17BW Series of Blade Thermodes can be mounted using pivot or fixed mounting hardware attached to the Model HE90TAB Thermode Adapter Block The single 17FW2187 Fold up Thermode only uses the pivot mounting hardware See Chapter 2 Section III for detailed thermode mounting instructions Air Actuated Series 90 Heads All Series 90 Foot Actuated Heads can be ordered with air actuation already installed Air actuation makes it easier to incorporate the Series 90 Heads into automated systems An air cylinder replaces Model 90RF Thermode Adapter the Model MSP Footpedal as the actuation source The speed of the Reflow Soldering Head air actuation system is limited by the speed at which the electrode holder can move without damaging the electrodes thermodes or workpieces as a result of the impact Welding rates of 1 per second are possible Table 1 2 lists the features of each model shown in Figure 1 4 THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 990 130 1 3 CHAPTER 1 DESCRIPTION Table 1 2 Air Actuated Model Features Model Stock Number Electrode Holder Electrode Type Application 90A 2 151 01 HEU90K ES0800 series Welding 90A DT 2 151 01 01 HE90ABK ES0800 series Welding 90RA 2 151 01 02 HE90TAB 17BW or 17FW Reflow The top mounted 1 1 16 inch diamete
29. ct Diagram A certain amount of experimentation is necessary to achieve the proper Welding Force setting for a specific application Larger parts require higher force The greater the diameter of electrode face the higher force required Generally higher electrode force requires a greater amount of energy to make a weld Reflow Soldering Force The reflow soldering process is not as force sensitive as resistance welding Sufficient force or pressure is necessary to ensure adequate thermal conduction and to hold the workpieces as the solder solidifies Section Il Operation Foot Actuated Heads Reference Figure 2 2 Rotate the WELD FORCE ADJUSTMENT KNOB item 3 located on the top of the Weld Head clockwise to increase the Welding Force and counterclockwise to decrease force The maximum Welding Force is reached when the indicator reads 10 at the bottom of scale 4 or 5 on the Welding Force Scale represents a good initial setting 2 Check the alignment of the electrodes Adjust the vertical work opening by either lowering the height of the lower Offset Electrode Holder or by lowering the position of the SUPPORT POST in the SUPPORT BASE using a 1 4 inch hex key THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 990 130 3 1 CHAPTER 3 OPERATING INSTRUCTIONS NOTE The vertical work opening must be less than 1 5 inch 3 8 cm or the weld head firing switch may not function properly 4 As the actual Welding Force may vary slightl
30. ct Energy Power Supplies and switch on Stored Energy Power Supplies 12 Make several welds If the welding application requires more Welding Force as typically indicated by heavy electrode or workpiece sparking increase the Welding Force and re measure 13 If the welding application requires less Welding Force as indicated by heavy electrode marking accompanied by a cold weld decrease the Welding Force and re measure THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 3 2 990 130 CHAPTER 3 OPERATING INSTRUCTIONS Air Actuated Heads 1 This system should be installed in accordance with your established safety standards Anti Tie Down Palm Buttons are not usually required if the electrode spacing is not sufficient to allow the operator s fingers to fit between them Review Air Actuated Weld Heads and Solenoid Air Valve Power Connections in Chapter 2 Installation to verify that the air lines and solenoid power cord have been correctly installed It is very important to adjust the Bottom Air Pressure Regulator to a pressure level that just triggers the Firing Switch in the Weld Head Proper adjustment of the Bottom Air Pressure ensures that the Actual Welding Force as experienced by the workpieces will be identical to the user Set Welding Force The typical user mistake is to set the Bottom Air Pressure at maximum for the fastest electrode travel This action results in inconsistent welds workpiece and electrode damage Set the WE
31. d Secret 5 1 Blectrode Holder Disassembly Re assetibly iet e eget n te oe oa es 5 4 Lower In Line Electrode Holder Disassembly 5 4 Lower In Line Electrode Holder Re assembly sse 5 4 Upper In line Electrode Holder Disassembly 5 5 Upper In line Electrode Holder 5 5 Section HI Electrode Thermode Holder Conversion 5 6 Offset Electrode Holder onverst0 ep reet Re rer o a E Ee dva ttd repa o e RR eg NUES 5 6 Thermode Holder GOnVerstOlba Soo a Sin oceans a caret tana de fco Liu e afa 5 7 Section TV ntes damp aA Cetus boe 5 8 Telephone 1 uie Dio ee ve tis tet i doped eu e uin Pec ud te aod bi suut ob aste i n 5 8 Pactory Service Repatto us dE 5 8 APPENDIX A TECHNICAL SPECIFICATIONS eene 1 SOCCINCATONS ent cages atic DURS 1 Qutline DrawWIDBS ate a 2 THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 990 130 ILLUSTRATIONS Figure Title Page 1 1 Model 90F In line Electrode Weld eere ertet eterna 1 2 1 2 Model 90F DT Offset Electrode Weld Head oe dee merde deett dade ens 1 3 1 3 Model 90RF Thermode Adapter Reflow Soldering
32. e Adapter Block for 90RF and 90RA Reflow Soldering Heads HEL90K In Line LOWER Electrode Holder Assembly for 90 Series Weld Head Includes hardware HEU90K In Line UPPER Electrode Holder Assembly for 90 Series Weld Head Includes hardware MSP Medium Force Swing type Footpedal Rated 100 pounds OMAA90 Allows the use of Model BLCS Microscope with Series 90 Heads THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 990 130 1 5 CHAPTER 1 DESCRIPTION PD Polishing Disks package of 50 17BW1200 Blade Thermode 1 20 inches wide x 060 inches thick with thermocouple and air cooling tube 17BW2187 Blade Thermode 2 18 inches wide x 060 inches thick with thermocouple and air cooling tube 17BW2500 Blade Thermode 2 50 inches wide x 060 inches thick with thermocouple and air cooling tube 17FW2187 Fold up Thermode 2 18 inches wide x 060 inches thick with thermocouple and air cooling tube Not for use over 350 C 2AA16 Welding Cable 2 16 inches long 570 2 040 Retaining Ring for 1 4 inch diameter electrodes 325 1 119 1 4 inch O D Plastic Tube Fitting with 1 4 NPT pipe thread Use to convert HEL90K and HEU90K In Line Electrode Holders for water cooling THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 1 6 990 130 CHAPTER 2 INSTALLATION Section Physical Installation Foot Pedal Actuated Weld Heads 1 Position Mounting Template located in the Ship Kit in the desired location
33. g the electrodes Additional Attachments Solenoid Air Valve Power Connection Stored Energy Power Supplies require a 115 VAC Solenoid P Air Valve Assembly for plugging directly into a Model We NPT THREAD FSAC Foot Switch receptacle ON BOTH ENDS 7500A Both the 115 VAC and 24 VAC Solenoid Valve Assemblies plug directly into the 115 VAC receptacle on the back of the 7500A An internal switch set by the user applies 115 or 24 VAC to the receptacle PHASEMASTER Controls The 115 VAC Solenoid Air Valve Assembly plugs directly into the 115 VAC VALVE receptacle on the rear panel The 24 VAC Solenoid Valve Assembly requires that the user replace the 115 VAC connector with the 24 VAC connector provided in the Phasemaster Shipping Kit The new connector plugs into the 24 VAC VALVE located on the rear panel Figure 2 4 In line Electrode Holder Modification for Water Install the system in accordance with established safety Cooling practices and standards Anti Tie Down Palm Buttons are not usually required if the electrode spacing is insufficient to allow the operator s fingers to fit between them In line Water Cooled Electrode Holders If forced cooling is required drill a 399 inch diameter hole in the Upper and Lower In Line Electrode Holder as shown in Figure 2 4 Tap a 1 4 NPT standard pipe thread into both ends of the hole Order four 1 4 inch O D Plastic Tube Fittings from Unitek Peco P N 325 1 119 Apply pi
34. hould be limited to electrode dressing and cleaning Procedures for changing electrodes and thermodes are contained in Chapter 2 Section Electrode and Thermode Installation Electrode Dressing 1 Depending on use periodic tip resurfacing is required to remove oxides and welding debris from electrodes Set the WELD or HEAT Switch on all PHASEMASTER and 7500A Direct Energy Power Supplies to the OFF position Set the POWER Switch on Stored Energy Power Supplies to the OFF position Cleaning of the electrodes on production line should be limited to use of 400 600 grit emery paper In addition the emery paper should have a solid backing so that it will not distort flat electrode surfaces Reference Figure 2 3 Temporarily reduce the TOP AIR PRESSURE Place the emery paper between the electrodes and actuate the Footpedal or Footswitch to bring the electrodes into light contact with paper Move the paper in a rotary motion Wipe the electrode tips so that they are clean THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 990 130 4 1 CHAPTER 5 SERVICE Section Adjustments Linear Ball Bearing Bushing Adjustment CAUTION Do not adjust bearings unless the side play in the shaft exceeds 0 001 inch Do not over tighten the bearings If you can feel the balls move as the shaft is moved the bearings are too tight This will dramatically reduce bearing life 1 Remove the Covers from both sides of Weld Head with a 1
35. ide variety of precision resistance welding and reflow soldering applications The Series 90 is a production line head Bearing life is designed for a minimum of 10 million operations when used according to the specifications The diameter of the mounting post and the main shaft have been selected to ensure that the electrodes do not wipe more than 001 inch at 150 pounds This is an important consideration in critical welding applications such as hermetic seals and pressure transducers Series 90 Thin Line Heads have six mounting holes on the spine which allow them to be easily incorporated into custom welding machines The aluminum base of the Model 90 can be modified by the user in order to provide additional space to accommodate custom fixtures and tooling The Series 90 Head is available in three different electrode configurations Each configuration can be foot pedal or air actuated Unitek Peco Series 90 Heads excel in their ability to precisely place consistent high quality welds even in complex welding applications They feature low inertia light weight designs which ensure fast dynamic response This allows the electrodes to follow the minute expansion and contraction of the weld joint as it heats and cools A differential motion Force Firing System initiates the power source at the precise moment when the Preset Firing Force is applied to the workpieces Rugged construction linear ball bearing bushings and an over sized anti rotation bea
36. ing Force Theory ms esr 3 1 Welding Forcen coast ecu eon E E qute Pump an 3 1 Reflow SCC MITT aote ede tru aene hi ads ED Rete e Md aU 3 1 THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS iv 990 130 Section TT qoo ne aera rrt Ob lcd a Rr adde dri deoa Ob ad ata 3 1 Foot Actuated iu asse Nia iia uta C tec et eiae 3 1 Ait Actuated Heads E 3 3 Dosynstop Adjustment so E en napa R 3 4 CHAPTER 4 USER MAINTENANCE 4 1 a en 4 1 Electrode Dressid Tero image Uh cas teta echar RD eee 4 CHAPTER 5 SERVICE tci a He bak be BU electo des AM 5 1 Sectomd Adjustments ede reo devi 5 1 Linear Ball Bearing Bushing Adjustment aos ese nila daa deu rese 5 1 Anti Rotation Yoke Adjustment eerie tei dte ro eda decken interni ede Rev 5 1 MEME nens ud ages qa addu deque poa utes a e Mas Pe ur ad P UAE ETE edo 5 2 Force Firing Switch ge iecore eiecit aa tags 5 3 Minim m Firing ORCS e d cent Sb Ne PDA Dr In ni abre umi 5 3 Spring PUBS Bat OS bes ocius ru er NN NE 5 3 Section TT Disassembly Re asserbly is o
37. must pass through the clearance hole in the Bellcrank Arm 7 Line up the weld head with the correct holes in the Mounting Template CAUTION Be careful not to bend the LINK ASSEMBLY item 18 Attach the SPACER PLATE item 10 to the WORKBENCH item 11 using two 5 16 18 x 2 3 4 CAP HEAD SCREWS item 13 LOCK WASHERS item 14 and WASHERS item 15 NOTE The CAP HEAD SCREWS must pass through the SPACER PLATE and WORKBENCH and thread into the two rear mounting holes on the weld head support base 8 Attach the FOOTPEDAL MOUNTING PLATE item 12 to the SPACER PLATE item 10 using two 5 16 18 x 3 4 HEX HEAD SCREWS item 16 ITL WASHERS item 17 and WASHERS item 15 THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 990 130 2 1 CHAPTER 2 INSTALLATION 211 5 16 18 X 2 13 5 16 18 X 2 3 4 HEX HD BOLT CAP HD SCREW 14 LOCK 14 LOCK WASHER WASHER 15 WASHER 116 5 16 18 X 3 4 WELD HEAD FRONT 12 MOUNTING PLATE 19 10 32 X 1 CAP HD SCREW 110 SPACER PLATE 9 10 32 X 3 4 CAP HD 201 10 32 KEP SCREW 4 BUSHING NUT FARSIDE RM BOLT 15 BUSHING WASHER 18 LINK FARSIDE 9 l ASSEMBLY 7 BUSHING 6 BELLCRANK x SPRING 2 BELLCRANK NUT 1 PEDAL ACTUATOR Figure 2 1 Model 90F and MSP Footpedal installation 9 Secure the front of the weld head to the WORKBENCH using two 5 16 18 x 2 HEX HEAD BOLTS item 21 LOCK WASHERS item 14 and WASHERS item 15 10 Connect the EXTENS
38. ntil the desired Welding Force is reached To provide the most sensitive DOWNSPEED AIR VALVE control the BOTTOM AIR PRESSURE REGULATOR setting should be within 15 to 20 Psig of the TOP AIR PRESSURE REGULATOR Psig final setting Readjust both the TOP AIR FLOW and BOTTOM AIR FLOW VALVES to provide smooth Upper Electrode motion CAUTION Using the air pressure regulators to control electrode speed can result excess welding force being applied to the workpieces 17 Readjust the electrodes in their holders as necessary to accommodate the actual workpiece 18 3 4 Reconnect the Weld Head Firing Switch Cable to the Power Supply Downstop Adjustment 1 The DOWNSTOP ADJUSTMENT should only be used to prevent excessive workpiece deformation In most applications use of the DOWNSTOP ADJUSTMENT is unnecessary 2 Depress and hold the Footswitch closing the electrodes on the workpiece Loosen the JAM NUT at the base DOWNSTOP ADJUSTMENT SCREW Rotate the DOWNSTOP ADJUSTMENT SCREW until it just bottoms out 3 Release the Footswitch and then turn the DOWNSTOP ADJUSTMENT SCREW counter clockwise one or two turns to allow for electrode wear 4 Donotattempt to use the DOWNSTOP ADJUSTMENT to limit the Welding Force Doing so will cause inconsistent weld quality THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 990 130 CHAPTER 4 USER MAINTENANCE Maintenance Series 90 Weld Heads are designed to minimize routine maintenance Daily maintenance s
39. on the workbench Make certain that sufficient working space is provided from front edge of the bench to the Mounting Base This permits operator to use the bench as a support when positioning parts Most applications require about six to ten inches from edge of the bench to front of the Support Base NOTE All dimensions use inches and all mounting hardware is American standard unless specified otherwise 2 Drill six 3 8 inch diameter mounting holes as shown on the Mounting Template Drill the 2 00 DIA hole for all models Drill the 1 25 DIA hole for the Model 90F DT CAUTION Use a 1 4 inch hex driver to tighten the support post locking screws location on the back of the right side of the support base to ensure that the weld head does not slip and pinch your fingers NOTE mounting hardware such as screws lock washers and washers are contained in the Ship Kit 3 Reference Figure 2 1 for the following instructions Remove the PEDAL ACTUATOR item 1 by removing the BELLCRANK NUT item 2 and the BELLCRANK BOLT item 3 4 Remove the BUSHING BOLT item 4 and BUSHING WASHER item 5 5 Remove the BELLCRANK SPRING item 6 Slip the BUSHING item 7 inside the BELLCRANK SPRING replace the BELLCRANK SPRING and secure in position using the BUSHING WASHER and BUSHING BOLT 6 Slide the EXTENSION ARM item 8 over the end of the Bellcrank Arm and secure with two 10 32 X 3 4 CAP HEAD SCREWS item 9 NOTE The middle screw
40. pe sealant to each tread and then thread two fittings into the Upper and Lower Electrode Holders Connect 1 4 inch O D plastic tubing to the fittings as shown in Figure 2 5 Support the tubing on the Upper In Line Electrode Holder using a cable clamp placed under one of the weld head side cover screws Be sure to leave an Figure 2 5 Tubing Path for adequate service loop Water Cooling In line Electrode Holder THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 990 130 2 5 CHAPTER 2 INSTALLATION Model HE2000WC Offset Water Cooled Electrode Holders Models 90A DT and 90F DT use the HE90ABK Offset Electrode Holders which in turn use Model HE2000 5 8 inch diameter by 3 3 4 inch long solid electrode holders for extending the weld head throat depth In those applications where the duty cycle approaches 10 percent or where the electrodes are too hot to comfortably touch the HE2000WC Water Cooled Electrode Holders should be used in place of the solid HE2000 holders Electrode life is inversely proportional to Electrode Temperature These holders can be cooled by connecting them to an air supply or a water supply as illustrated in Figure 2 6 Figure 2 6 Water Cooled HE2000WC Offset Electrode Holders Reducing the Length of the Support Base The Support Base can be cut to provide additional room for tooling It can be reduced to 5 5 inch by cutting the Base just in front of the support web that contains the mounting holes as shown
41. r Air Cylinder is supplied with two gauges Pressure Regulators and Flow Controls The four way Air Solenoid which controls the direction of air flow to the Air Cylinder is available with either 24 standard or 115 VAC ratings The Pressure Regulators and Flow Controls allow independent adjustment of the up and downspeed of the upper electrode The Solenoid and Regulator Assembly is contained in a separate package that mounts on the spine of the Weld Head The Models 250 500 and 800 Stored Energy Power Supplies require that the Model FSAC Footswitch be used to energize the Four Way Air Solenoid Valve Model 90A In Line Model 90A DT Model 90RA Thermode Electrode Weld Offset Electrode Adapter Reflow Soldering Head Weld Head Head Figure 1 4 Air Actuated Series 90 Models THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 14 990 130 CHAPTER 1 DESCRIPTION The Phasemaster IV Time At Temperature Control PM4 the Phasemaster series of direct energy welding controls and the microprocessor controlled series of stored energy power supplies Each of these controls or power supplies has a 24 115 VAC Valve Output for energizing and controlling the timing of the Air Solenoid Valve The Model FS2L Footswitch is used to initiate all controls Section Il Accessories BLCS Microscope 3X objective 20X eyepieces 4 to 18X magnification Includes Arm and Porthole Assembly DFS
42. ring system provide perfect in line electrode travel which assures smooth vertical travel of the upper electrode arm This system minimizes the wiping action of the electrodes during welding even at maximum force settings The Firing force is continuously adjustable from a minimum of 7 to a maximum of 150 pounds using In Line Electrode Holders or Thermode Adapter Block and a maximum of 100 pounds using Offset Electrode Holders Settings are quickly reproduced by using the Force Adjustment Knob and easy to read visual scale An adjustable Tare Spring allows the user to compensate for the weight of non standard electrode holders An adjustment screw is provided which allows the user to adjust the sensitivity of the Force Firing Switch All Series 90 Heads have adjustable Up Stops and Down Stops The Down Stop can be used to limit excessive over travel The Up Stop can be used to reduce the stroke and therefore the travel time of the Weld Head The stroke of these Weld Heads should not be reduced to less than 1 4 inch when used in automated machines in order to obtain long bearing life and ensure that the ball bearings recirculate properly THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 990 130 1 1 CHAPTER 1 DESCRIPTION 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 Electrode Holders
43. t 2 Adjust the FIRING FORCE SENSITIVITY ADJUSTMENT SCREW item 8 with a 9 64 inch hex wrench so that Actuation Lever on Firing Switch is horizontal as shown in Figure 5 3 3 Set the WELD FORCE ADJUSTMENT KNOB fully clockwise maximum Welding Force The Actuation Lever should not touch the body of the Firing Switch Minimum Firing Force The minimum Welding Force at which the Firing Switch closes is 7 lbs If the Welding Head fails to meet this specification repeat the above four adjustments Spring Tube Bearings The bearings which guide the SPRING TUBE YOKE item 16 Figure 2 2 are bronze bushings with a Teflon lead bearing surface During normal operation these bearings quickly seat and transfer a small amount of material an average of 0 0005 inch 0 013 mm thick to the tube housing forming a physically bonded gray green lubricant film The rubbing surface of the Bronze Bushing also acquires a gray green color as the Teflon lead coating wears Any excess of the Teflon lead surface layer will be shed as fine feathery particles Following the break in period the wear rate becomes extremely low The Bronze Bushings should last at least 10 million operations After an extended period of operation the wear rate increases as the Bronze Bushings approach the end of their useful life as a self lubricating bearings When the radial wear exceeds 0 0025 inch 0 064 mm replace both Bronze Bushings THINLINE SERIES 90 WELD AND REFLOW
44. t The hardware is sized for each WELDING TRANSFORMER NOTES Do not put a flat or lock washer between the welding cable and the power terminal Be sure to place both cables on the same side of the support post Failure to do so could dramatically increase the amount of energy required to make a satisfactory weld because of added inductive losses caused by the support post For the same reason do not run welding cables through a steel workbench WELDING TRANSFORMER 516 18 X 1 2 H CAP S d HEAD Screw Figure 2 8 90F and 90A In line Weld Figure 2 9 90F DT amp 90A DT Offset Weld Head Connections Head Connections THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 990 130 2 7 CHAPTER 2 INSTALLATION 90RF and 90RA Reflow Soldering Head Connections 1 Reference Figure 2 10 Position the Power Supply or Welding Transformer approximately 4 to 5 inch behind the Weld Head Connect one 16 inch WELDING CABLE to the left side of the WELD HEAD POWER STRAP using a 5 16 18 x 1 2 CAP HEAD SCREW The FLAT WASHER goes between the CAP HEAD SCREW and the WELDING CABLE terminal 2 Connect the second WELDING CABLE to the right side of the POWER STRAP using a 5 16 18 x 1 2 CAP HEAD SCREW The FLAT WASHER goes between the CAP HEAD SCREW and the WELDING CABLE terminal 3 Connect the opposite ends of each WELDING CABLE to the Power Supply or Welding SER UNE Transformer using the hardware supplied with TRANSFORMER ROTA SIDEN C
45. ter plastic hose with a rated burst pressure of 250 psi into the AIR INPUT item 6 located on the bottom of the Solenoid Air Valve Assembly The AIR INPUT uses a quick release connector so specials tools are not needed Simply push the hose into the quick release fitting as far as it will go Connect the other end to a FILTERED AIR SUPPLY 100 psig maximum UNITEK suggests that in line lubricators not be used since excess oil can blow by worn seals in the AIR CYLINDER item 1 ending up on the workpieces Every one million cycles the user should put a few drops of oil in the AIR CYLINDER The tubing connecting the TOP AIR PRESSURE REGULATOR item 4 with the UPSPEED AIR FLOW VALVE item 2 and BOTTOM AIR PRESSURE REGULATOR item 5 with the DOWNSPEED AIR FLOW VALVE item 3 has been pre assembled at the factory 4 TOP AIR PRESSURE REGULATOR aby 17 POWER CORD 2 UPSPEED AIR FLOW VALVE 3 DOWNSPEED AIR FLOW VALVE 5 BOTTOM AIR PRESSURE REGULATOR 6 INPUT AIR Figure 2 3 Solenoid Air Valve Assembly THINLINE SERIES 90 WELD AND REFLOW SOLDER HEADS 990 130 CHAPTER 2 INSTALLATION 6 dressing electrodes the TOP AIR PRESSURE REGULATOR must be turned down An auxiliary regulator or a customer supplied bleeder valve connected to output of the of the TOP AIR PRESSURE REGULATOR can also be used to lower air pressure to facilitate dressin
46. y between similar weld heads due to manufacturing tolerances we recommend that a Force Gage be used to precisely measure the Welding Force at which the Power Supply is triggered 5 Figure 3 2 shows how a Unitek Peco Force Gauge can be used to set up and measure the actual Welding Force Force Gauges are available in 100 Ibs FG100 200 Ibs FG200 and 100 Kgs Figure 3 2 Using a Force FG100KG models Gauge to Measure the Weld 6 Set the WELD or HEAT Switch on all PHASEMASTER and Firing Force 7500A Direct Energy Power Supplies to the OFF position Set the POWER Switch on Stored Energy Power Supplies to the OFF position 7 Disconnect the Weld Head Firing Switch Cable from the Power Supply 8 Adjust the Weld Head Electrode spacing so that a UNITEK Force Gauge just fits between the electrodes NOTE The maximum opening must be less than 1 5 inches 3 8 cm 9 Reference Figure 2 2 Turn the DOWNSTOP ADJUSTMENT SCREW item 2 fully counter clockwise This will allow maximum downward travel of the Upper Electrode 10 Depress the Footpedal and note the force indication on the Force Gauge when the Firing Switch inside of the Weld Head clicks then release the Footpedal If the Firing Switch closure is inaudible it is easily detected by connecting an Ohmmeter or continuity checker to the Firing Switch Connector pins 11 Reconnect the Weld Head Firing Switch Cable turn on the WELD or HEAT Switch on all PHASEMASTER and 7500A Dire
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