Labfacility L60+ User Manual

CONTENTS

Page

2 Operating Instructions

3 Accessories

4 Front Panel Controls

5 Rear Panel Controls

5 Setting Up Procedure

6 Welding Instructions

7 Impact Welding – Using Impact clip

8 Pen and Plate Resistance Welding

Accessory

9 Energy Settings

9 Electrodes

10 Maintenance

11 Warnings

12 Specications

13 EC Declaration of Conformity

14 Contact information

- 1 -

Operating Instructions

The L60+ 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.

Safety Note

1. Always protect the eyes with a suitable lter 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.

1. Do not allow the hand to directly contact the welding
electrode during operation.

- 2 -

Accessories

Standard: Wire Holding Pliers With Lead

Safety Glasses
Magnifying Eyeglass
Spare Carbon Electrode

Spare 2A Fuse
Impact clip
Pen and plate
Argon Hose
Hexagon key (for electrode change)
Mains Lead

Footswitch (Allows One Handed Operation)

- 3 -

- 3 -

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 owing.

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 point if required.

- 4 -

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
D. IEC power inlet module For selection of 110-120 Vac or 220-

250 Vac power supply. Factory
default setting 220-250 Vac.

Setting Up Procedure

1. Using a suitable connector fused at 5 amps, connect to mains sup-
ply.

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 nger tight.

3. Connect free end of argon hose to the ar-

gon supply via an argon ow regulator.

4. Switch on.

5. Hold welding mode switch in “purge”
position and adjust argon ow to 8 litres
per min.

The apparatus is now ready for use.

- 5 -

Welding Instructions

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 o about 12mm of

insulation and twist together. Then, with side cutters or
scissors cut the wire o square leaving sucient
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 rm contact
with each other and trimmed o 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.

- 6 -

Impact Welding – Using Impact clip

Impact welding is the term used for welding wires to a
conductive metal surface. This process is common when
thermocouples are required to be welded to a test piece/
structure or similar application.

The impact welding clip attachment should be plugged
into the black negative (-) socket on the front of the L60+
welder. The impact clip should then be attached in close
proximity to where the thermocouple is required to be
attached.

The thermocouple wires are then gripped in the holding
pliers and pressed against the surface to which they are
to be welded.

The weld switch or footswitch is then pressed triggering
the L60+ welder discharge that will attach the wires to the
applied surface. Once the thermocouple has be success-

fully welded the impact weld clip can be removed.

- 7 -

Pen and Plate Resistance Welding Accessory

The kit consists of a Copper Plate with a black lead and a Cop­per tipped spring-loaded pen with appropriate red lead. The
leads are terminated in 4mm banana plugs which connect to
the corresponding sockets on the front of the L60+ Welder.

It is suitable for welding ribbon materials of ferrous and higher
resistance metals such as Nickel & Chromium alloys. It will not
weld low resistance metals such as Copper, Silver, Gold or
Brass.

In use, the materials to be joined are placed on top of the oth­er on the copper plate and the pen tip is applied with moder­ate pressure. The weld is then triggered by the switch on the
L60+ or footswitch (if used). Test welds will determine opti­mum settings for material size and composition. We recom­mend that the Operator starts o with a Medium Energy set­ting and check the state of the weld. The energy setting can be
increased if the weld pulls apart easily or lower if the weld is
too severe. With at materials, a pattern of welds may be
made to increase the strength of the joint.

If necessary the plate can be cleaned with ne wire wool, and
the welding pen tip may be cleaned with a nd grade emery
cloth if necessary.

Please note that during welding done using the pen/plate Ar­gon will not be utilised and therefore should be turned o at
the front of the welder.

- 8 -

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 attened bead indicates that the energy setting is too high.

Wire Diameter (mm)

Switch at “LOW” 0.1 Switch at “HIGH” 0.3

0.15 0.5

0.2 0.7

0.25 0.8

Electrodes

To replace or adjust carbon electrode, rst turn the welder on

its side and slacken screw on base of argon shield, which may

be then pulled o. This reveals grub screw which holds carbon
electrode in place.

- 9 -

Maintenance

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

Specications

General

Energy Output 0-60 Joules
Welding Capacity Wires up to 1.1mm diameter
Duty Cycle Minimum 5-10 welds/min
Weld Voltage 49 V

Mechanical

Physical Dimensions 220mm Wide x 120mm High x
250mm Depth
Weight 4kg

Electrical

Power Supply 110-120 Vac or 220-250 Vac,

50-60Hz

Power Consumption Max 170VA dropping to 20VA
during charging
Fuse Characteristics 12A/250V

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

- 10 -

Power Supply 110-120 Vac or 220-250 Vac, 50-60Hz

(220-250 VAC set as default)

- 11 -

Warnings

General Description The Thermocouple Welder,

manufactured by Labfacility, is
a compact, simple-to-use in­strument designed for thermo­couple and ne wire welding.

Dimensions 220mm (W) x 120mm (H) x

250mm (D)

Power Consumption Max 170VA dropping to 20VA

during charging

Power Supply 110-120 Vac or 220-250 Vac, 50

-60Hz

Standards Met CE

Energy Output 0-60 Joules

Duty Cycle Minimum 5-10 welds/min

Welding Capacity Wires up to 1.1mm diameter

Maintenance Apart from keeping the elec-

trode in good order, no other
maintenance is required.

Accessories Wire Holding Pliers & Lead /

Safety Glasses & Magnifying

Eyeglass / Argon Hose / Car­bon Electrodes / Impact clip /
Pen and plate / Spare 2A Fuse
& Mains Lead / Footswitch for
greater ease of use

Specications

- 12 -