Thermocouple Welder

 

• Supplied complete with accessories
• Simple to use
• Designed for the production of commercial grade thermocouple junctions
• Also suitable for other fine wire work
• Front panel or footswitch operation
• Argon gas shield facility

 

Thermocouple Welder Operating Instructions

The L60+ thermocouple welder is designed for sensor manufacturers to produce commercial grade thermocouple junctions, and by users of large numbers of exposed junction thermocouples such as test and development laboratories where multipoint temperature sensing of test pieces is required.

No special skills are required and most people will be capable of producing quality work with minimal practice.A satisfactory thermocouple junction is produced without using argon, but where argon is available a momentary purge is automatically triggered immediately prior to the weld to give optimum weld integrity.

Thermocouple Welder Safety Note

1. Always protect the eyes with a suitable filter during welding – never view the
   weld discharge with the naked eye.
2. Avoid touching the rear of the welder during operation as the power switch heat
   sink may run hot.This is a normal operating condition.
3. Do not allow the hand to directly contact the welding electrode during
   operation.

Thermocouple Welder Accessories

Standard Accessories

• Wire Holding Pliers With Lead
• Safety Glasses
• Magnifying Eyeglass
• Spare Carbon Electrode
• Spare 2A Fuse
• Argon Hose
• Hexagon key (for electrode change)
• Mains Lead
• Footswitch (Allows One Handed Operation)

Optional Accessories

• Spare Carbon Electrodes
• Gas Flow Meter & Valve

Front Panel Controls

A	Arc	Argon gas and weld current controlled by the “Weld” switch. LED indication.
B	Purge	Allows the gas line and electrode shield to be purged of air prior to a new welding period.
C	Weld Switch	Initiates a welding operation (in “arc” mode also opens the Argon valve).
D	Argon LED	Indicates when the Argon control valve is open and gas is flowing.
E	Wait LED	Glows when weld charge is building.
F	Ready LED	“Ready to Weld” indication.
G	Power	Rotary control of the capacitor charge voltage.
H	Level Selector	Selects the total capacitance available giving the following values with LED indication. "LO" = 0 to 6 Joules "MED" = 0 to 28 Joules "HI" = 0 to 64 Joules
I	Electrode Holder	Holds the replaceable carbon electrode which is accessible by removing the outer Argon Shield.
J	Red Socket	Output socket for using the pliers supplied.
K	Black Socket	Output socket, this provides an additional earth.

Rear Panel Controls

A	ON/OFF switch	Power to instrument ON/OFF
B	Weld jack socket	Footswitch connection
C	Argon inlet	For connection to Argon supply

Setting Up the Thermocouple Welder

1. Using a suitable connector fused at 5 amps, connect to mains supply.
2. If Argon is to be utilised, couple argon hose to rear of welder. Do not over-tighten
   as a good seal will be made with the nut slightly more than finger tight.
3. Connect free end of argon hose to the argon supply via an argon flow regulator.
4. Switch on.
5. Hold welding mode switch in “purge” position and adjust argon flow to 8 litres
   per min.

The apparatus is now ready for use.

Welding

Arc Welding

1. Connect the work-holding pliers to the red output socket.
2. Depress the purge switch for 3 or 4 seconds to rid the system of air.
3. Reset the mode to “Arc”.
4. Set the energy level to the desired value.
5. Prepare the wires to be welded and grip in the pliers, leaving about 1mm or more
   protruding.
6. Position the wires 5 or 6mm in front of the carbon, whilst steadying the hand.
7. Press the “weld” switch or foot switch and slowly move the work towards the
   carbon until the arc is struck.
8. Release the switch and remove the work for examination

Preparation of Wires for Arc welding

For small diameter wires, strip off about 12mm of insulation and twist together.Then, with side cutters or scissors cut the wire off square leaving sufficient un-insulated material to give approximately 1mm protruding when gripped in the welding pliers. Larger diameter wires may be held side by side in the welding pliers, but ensure that they are in firm contact with each other and trimmed off square.This method will be found useful for attaching solid leads to resistance thermometer detectors. However, when attaching stranded leads, it will be found more convenient to use the twisting method and then to carefully untwist after welding.

Energy Settings

Arc Welding

The following settings may be used as a guide.The correct setting for a particular metal combination and wire gauge will produce a spherical bead.A flattened bead indicates that the energy setting is too high.

Wire Diameter (mm)

Switch at "LOW"	Switch at "HIGH"
0.1	0.3
0.15	0.5
0.2	0.7
0.25	0.8

Electrodes

To replace or adjust carbon electrode, first turn the welder on its side and slacken screw on base of argon shield, which may be then pulled off.This reveals grub screw which holds carbon electrode in place.

Maintenance

Apart from keeping the electrode in good order, no other maintenance is required.

Specifications

GENERAL
Energy Output	0-60 Joules
Welding Capacity	Wires up to 1.1mm diameter
Duty Cycle	Minimum 5-10 welds/min
MECHANICAL
Physical Dimensions	220mm Wide x 120mm High x 250mm Depth
Weigh	4kg
ELECTRICAL
Power Supply	110-120 Vac or 220-250 Vac, 50-60Hz
Power Consumption	Max 170VA dropping to 20VA during charging
ACCESSORIES
	Wire Holding Pliers & Lead
	Safety Glasses
	Magnifying Eyeglass
	Carbon Electrodes
	Spare 2A Fuse
	Argon Hose
	Mains Lead
	Footswitch for greater ease of use
	Spare Carbon Electrodes (optional)
	Gas Flow Meter & Valve
ORDERING GUIDE
Model No. L60+	Power Supply 110-120 Vac 220-250 Vac

All information given is correct at time of going to press. Please note that specifications and availability of certain items may be subject to change.

Download	Type
L60 Fine Wire Welder Specifications
L60 Operation Instructions

Further Information
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