Temperature SR80 Operation & Instruction Manual

Temperature Technology Ltd.

SR80 Universal Welder

Operations & Instruction Manual

Whatever stage of development your production line is in, TTL have the products to help you

produce temperature sensors quicker, easier and more efficiently.

Index

What is Capacitance Welding ...............................................................................1.0

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Installation and set up ...............................................................................................

Mains connection ..................................................................................................................2.1

Argon supply connection .................................................................................................2.2

Footswitch connection ......................................................................................................2.3

Wire holding pliers connection .....................................................................................2.4

Viewing filter attachment .................................................................................................2.5

2.0

Operation and controls .............................................................................................3.0

Initial settings ...........................................................................................................................3.1

Energy settings ........................................................................................................................3.2

Preparing wires ........................................................................................................................3.3

Welding action ........................................................................................................................3.4

Specific applications ....................................................................................................4.0

Thermocouple junctions ...................................................................................................4.1

Impact welding .......................................................................................................................4.2

Pt100 elements ........................................................................................................................4.3

Weld quality ...............................................................................................................................4.4

Specifications ....................................................................................................................5.0

Maintenance ......................................................................................................................

Carbon Electrode Replacement ....................................................................................6.1

6.0

Safety and tips ..................................................................................................................7.0

Checklist… .....................................................................................................................................................8.0

SR48 Bench Welde

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Operating Instructions

1.0 What is Capacitance Welding?

An electrical charge at a preset energy level is stored. This charge is then released across two
electrodes, the positive electrode being the workpiece. This discharge of stored energy is sufficient to
weld the workpiece.

Capacitance welding is generally used for the welding of similar and dissimilar wires (thermocouple
junction welds) and for impact welding wires to a conductive material.

2.0 Installation and set up.

2.1 Mains connection.

The mains lead supplied is connected to the IEC socket at the rear of the SR80 and should then be
connected to a standard 240V / 50Hz supply unless otherwise stated.

2.2 Argon supply connection.

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If argon is to be used for welding, connect the argon hose to the spigot at the rear of the instrument
(do not over tighten) and connect the other end to the pressure regulator on an argon supply.

2.3 Footswitch connection.

If using the footswitch, plug the 3.5mm jack into the footswitch socket on the instrument.

2.4 Wire holding pliers connection.

Plug the wire holding pliers into one of the red 4mm sockets on the front panel, labelled x1, x2 or x3
(see initial settings).

2.5 Viewing filter attachment.

Slide the viewing filter over the argon shield housing - this will be easier if the bottom ends of the filter
are pulled slightly apart with thumbs.

Note that the filter must be attached to protect the eyes from welding flashes, even if goggles are worn
the filter should be attached to prevent the possibility of arc-eye from non-operators.

3.0 Operation and controls.

3.1 Initial settings.

BEFORE USE ENSURE THAT THE ROCKER SWITCH ON THE BACK OF THE UNIT IS SET TO ‘DISCHARGE’
FOR CAPACITANCE DISCHARGE WELDING OR TO ‘RESISTANCE’ IF USING THE SR81 RESISTANCE SPOT
WELDING RIG.

Switch on the mains supply with the rocker switch built into the IEC connector on the rear panel - the

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SR80 Universal Welder

Operating Instructions

SR-80 Output Settings

0

10

20

30

40

50

60

70

80

90

1 2 3 4 5 6 7 8 9 10

Dial Setting

Output In Joules

0-20J (x1)
0-40J (x2)
0-80J (x4)

green lamp and the meter light will be illuminated.

If using argon, turn on the supply at the cylinder and adjust the pressure gauge to read 5psi (0.35 Kg/
cm²).
Hold the argon switch in the upper (spring-biased) position and simultaneously adjust the flow meter
to give a reading of 5 litres per minute.

Choose an energy range to suit the size of wires to be welded by plugging the pliers into the

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appropriate red socket x1, x2 or x4. Note that the black socket is only used with accessories such as the
spot welding attachment.

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Adjust the charge meter reading using the potentiometer appropriate to the size of wires to be welded.
The numbers on the potentiometer knob correspond approximately with the meter reading and may
be used for repeating a setting for a particular job.

3.2 Energy settings.

The following table is a guide for welding type K thermocouple materials. These may be varied by
experience to give the best weld for this and other material

Meter Reading x1 x2 x4

Wire Diameter (mm)
2 0.1 0.2 0.4
4 0.2 0.35 0.7
6 0.25 0.5 1
8 0.35 0.7 1.2

10 0.45 0.9 1.6

3.3 Preparing wires.

Insulated wires should have their insulation stripped sufficiently to allow at least 2mm to protrude
when gripped in the pliers. They should be laid side by side and in contact and the ends square
and level. With smaller diameter wires it will be found advantageous to twist them together before
trimming. This also applies when welding stranded wires together or stranded wires to solid wires, e.g.
when fitting flexible leads to platinum detectors.

3.4 Weld action.

SR80 Universal Welder

If using an argon shield, put the argon switch in the ‘ARGON’ position. Otherwise move it to the ‘OFF’
position. Press and hold the weld switch or foot switch and with the wires to be welded gripped in the
wire holding pliers, bring the wires up to the carbon electrode (positioned centrally on the front panel).

The argon will flow (yellow lamp lit) for about a second immediately followed by the weld discharge.

Note that the argon shield will continue to be present whilst the weld switch is held down. The weld
switch or foot switch may now be released after which the capacitors will recharge as indicated by the

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Operating Instructions

meter. During recharging the red ‘WAIT’ lamp will be illuminated and welding is prevented before the
recharging is complete.

4.0 Specific applications.

4.1 Thermocouple junctions.

Thermocouple junction welds are the most common application for the SR80
and as such the instructions given under 3.4 should be followed.

Thermocouple

In summary, the thermocouple wires should be prepared as stated in 3.3. The
prepared wires should then be gripped in the wire holding pliers, making sure that they are in contact
with each other and then with the weld switch (or footswitch) depressed, offered to the carbon
electrode. The resulting discharge will weld the wires thus forming the thermocouple junction. See fig

4.1

Junction Weld

Fig 4.1

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4.2 Impact welding.

This is the term used for welding wires to a metal (conductive) surface. This type of application is
common when thermocouples are required to be welded to a chassis or
framework for testing or heat treatment applications.

The optional welding clip attachment should be plugged into the ‘COM’ socket
on the front panel. The clip should then be attached to the surface close to
where the wires need to be attached.

Fig 4.2

The prepared wires are then gripped in the wire holding pliers and then pressed on
to the surface to which they are to be attached.

The weld switch (or footswitch) is then depressed and the resulting discharge will weld the wires to the
surface after which the weld clip can be removed. See fig.4.2.

4.3 Pt100 elements.

The SR80 can be used for attaching wires to Pt100 (or other types of sensing element) to manufacture
resistance thermometers.

Impact Weld

Where possible, the element lead wires should be lightly twisted around the prepared extension in
reversed plane (see fig 4.3a) wires to ensure a good contact. These wires are then gripped in the wire
holding pliers. If the wires cannot be twisted (eg if using a muliticore cable) then hold in pliers in a ‘V’
shape.

The weld switch (or footswitch) should be pressed and the wires offered to the carbon electrode in the
centre of the front panel, the resulting discharge will weld the wires.

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SR80 Universal Welder

Operating Instructions

Fig 4.3a Fig 4.3b

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The element wires can the be straightened (see fig 4.3b) and insulated as appropriate.

4.4 Weld quality.

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Examine the weld using the magnifying glass supplied. A good weld will produce a spherical ball of
metal on the end of the wires. A flat bridge between the wires indicates too low an energy setting. A
flattened hemisphere indicates that the energy setting is too high.

5.0 Specifications.

Parts:

Front Panel:
Argon flow meter 0 - 10 litres per minute.
Power Lamp Green - lit when mains on.
Argon Lamp Yellow - lit when argon valve open.
Wait Lamp Red - lit when capacitors are charging.
Charge Meter Indicates charge level of capacitors, 0 - 10 equivalent to 0 - 100% charge.
Weld Switch Spring-biased initiates weld & argon/weld. Duplicated by the action of the foot

Argon Switch Enables welding with or without argon shield. Spring-biased position purges

Electrode Holder Holds replaceable copper-coated carbon electrode and directs argon
flow.
COM Common socket internally connected to carbon electrode and directs argon

X1 x1 Low energy range - 20Joules.
X2 x2 Intermediate energy range - 40Joules.
X4 x4 High energy range - 80Joules.

switch.

system of air.

flow.

SR80 Universal Welder

Rear Panel.
IEC CONN. Mains in & on/off with spare fuse.
ARGON CONN. 1/4” BSP (G1/4).
JACK For connecting foot switch and trigger lead for resistance welding accessory.

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Operating Instructions

General Specifications:

Energy output: 0 to 80Joules via selectable outputs.
Weld capacity: Up to 2 x 1.6mm dia.
Power supply: 220/240Vac or 100/120Vac to order.
Power cons. Max. 360VA, quiescent 5VA.
Argon cons. 300l/Hr @5psi.
Weight: 5Kg.
Dimensions: 310 x 230 x 120mm.

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Indicators and Controls:

LED indication: Mains on, Charging and Argon flow.
Meter: Percent of max. charge
Weld switch: Activates weld & selects Argon
Purge switch: Clears air from Argon circuit.
Potentiometer: Sets energy level.

Accessories included:

Plier electrodes, Spare Carbon electrodes, Viewing filter glass, Magnifying glass, Argon hose with

end fittings, Hands Free footswitch, welding goggles and Mains lead.

Accessories optional:

Spot Welding Rig model SR81, Impact weld pad, Impact weld clip, Tweezer Electrodes for very fine
wires and Mini argon bottle and regulator.

6.0 Maintenance.

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Apart from carbon electrode replacement, the SR80 contains no user serviceable parts. In the event of
failure, please return the welder, carefully packed, to the distributor from which it was purchased who
will arrange for the necessary repair.

6.1 Carbon Electrode Replacement.

After considerable use, the carbon electrode will need attention. The carbon may be trimmed in a drill
or lathe chuck using a metal file to give an included angle of about 30° with the tip approx. 2mm dia.

To remove the carbon electrode, slide off the viewing filter, slacken the grub screw on the underside
of the argon shield (2mm Allen key provided) and pull off the shield. Slacken the grub screw on the
right-hand side of the electrode holder and withdraw the electrode. When fitting a new or trimmed
electrode, insert it loosely and offer up the argon shield to the front panel at the side of the electrode
holder and, using a straight edge, push the electrode in until it lines up with the front face of the shield.
Tighten the grub screw, replace the argon shield and viewing filter.

SR80 Universal Welder

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Operating Instructions

7.0 Safety and tips.

Always use the red viewing filter to protect the eyes from the welding flashes. A bench lamp positioned
over the welder will permit the work and carbon electrode tip to be easily seen.

Accidental over-setting of the energy level can result in flying particles and it is strongly recommended
that the welding goggles supplied are used at all times.

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Before starting a welding session when using argon, purge any air from the shield system by holding

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the argon switch in the ‘PURGE’ position for a few seconds.

If the pliers become pitted or soiled, clean the faces by pulling through a piece of folded fine emery
paper whilst applying slight pressure to the handles.
Keep a notebook by the welder and make a record of the settings for each type of job, noting wire size,
materials, energy range and meter reading.

Where a particular size of wire can be welded on one of two or even three energy ranges, choose the
range that will give the highest meter reading.

SR80 Universal Welder

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8.0 MODEL SR-80 UNIVERSAL WELDER

Checklist

WELDER UNIT FUNCTION CHECK ............................................................................................................

1 x MAINS LEAD ..................................................................................................................................................

1 x SET OF WELDING PLIERS .......................................................................................................................

1 x FOOTSWITCH ................................................................................................................................................

1 x INSTRUCTION MANUAL .........................................................................................................................

1 x VIEWING FILTER ...........................................................................................................................................

1 x MAGNIFYING GLASS ................................................................................................................................

1 x SET OF ARGON HOSE AND END FITTINGS .................................................................................

2 x SPARE CARBON ELECTRODES ............................................................................................................

1 x 2mm ALLEN KEY .........................................................................................................................................

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SERIAL NO.: .................................................................................

CHECKED BY: .............................................................................

DATE: ...............................................................................................

CE Marked.

SR80 Universal Welder

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