Seetrax CIR-KIT WELD 450 Manuel utilisateur
1
CIR-KIT WELD 450
TRACK WELDING MACHINE
INSTRUCTION MANUAL
2
CIR-KIT WELD 450
C O N T E N T S
DECLARATION OF CONFORMITY ...................................................................................... 3
CHECK LIST ............................................................................................................................. 4
SAFETY INSTRUCTIONS ....................................................................................................... 5
INTRODUCTION ...................................................................................................................... 6
TECHNICAL DATA ................................................................................................................. 7
QUICK INSTALLATION PROCEDURE ................................................................................ 8
INSTALLATION PROCEDURE .............................................................................................. 9
MICROSCOPE INSTRUCTION MANUAL .......................................................................... 11
OPERATING INSTRUCTIONS - PART 1 ............................................................................ 12
OPERATING INSTRUCTIONS – PART 2 ............................................................................ 16
RECOMMENDED SETTINGS ............................................................................................... 23
SPARE PARTS LIST .............................................................................................................. 24
MAINTENANCE .................................................................................................................... 27
PROBLEMS? ........................................................................................................................... 28
WARRANTY CLAUSE .......................................................................................................... 29
SERIAL NUMBER:.......................................
Manual Updated December 2008
Seetrax CAE Ltd
Woodstock,
Hangersley Hill,
Ringwood
England
BH24 3JP
Tel +44 (0)1425 489666 Fax +44 (0)1425 461461
Email: [email protected]
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DECLARATION OF CONFORMITY
EC Conformity Mark
Description of Product
TRACKWELDER
Name, Type, Batch or Serial Number
CIRKIT WELD 450
Standards
BS EN 292 Basic Principles of Design 1993
BS EN 60204 Electrical Equipment of Industrial Machines 1993
PR EN 50100 Safety of Machinery Electrosensitive Safety Devices 1993
BS EN 414 Rules for Drafting and Presentation of Safety Standards
BS EN Safety of Machinery – Risk Assessment
Place of Issue
Ringwood, Hants
Name of Authorised Representative
Ian Roper
Position of Authorised Representative
Director
Declaration: I declare that as the authorised representative, the above information in relation
to the supply/ manufacture of this product, is in conformity with the stated standards and
other related documents following the provisions of (89/392/EEC) Directives
Signature of Authorised Representative _____________________________________
Date _______________________
Created by Pilz Lacs Regulations for Machinery Safety
4
CHECK LIST
The following equipment has been packed and checked before despatch.
Please un-crate the CIR-KIT WELD 450 very carefully. Also, please ensure that ALL of the
equipment is unwrapped from its individual packing BEFORE the packaging is discarded.
IMPORTANT NOTE:
THE GUARANTEE ON THIS EQUIPMENT WILL BE INVALIDATED IF DAMAGE
IS CAUSED THROUGH MISHANDLING OR WRONG INSTALLATION.
PACKING LIST
1 x WELDER
1 x BI-OPTIC (With Adjustable Support)
2 x 15x EYEPIECS
1 x EL20 Long Reach Cir-Kit Weld 450 Electrodes (0.020")
1 x MAINS POWER LEAD
1 x REEL OF SAMPLE RIBBON CU40 3M 0.10mm x 0.075mm (Metric)
10’ 0.004"x 0.003" (Imperial)
1 x REEL OF SAMPLE RIBBON CU60 3M 0.15mm x 0.075mm (Metric)
10’ 0.006”x 0.003" (Imperial)
1 x REEL OF SAMPLE RIBBON CU80 3M 0.20mm x 0.075mm (Metric)
10’ 0.008"x 0.003" (Imperial)
1 x FIBER GLASS CLEANING PENCIL
1 x REPAIR TOOLS (Pack of 3 tools)
1 x ELECTRODE SETTING BLOCK
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SAFETY INSTRUCTIONS
The CIR-KIT WELD 450 is an extremely safe machine to use. However, some precautions
must be adhered to when working or repairing it:
• Never connect the CIR-KIT WELD 450 to any voltage or frequency other than that
stated on the label at the back of the machine.
• Never fit a higher current rated fuse than 5 amp
• Never remove the top cover with the mains plug still connected.
• Only a qualified electrician should carry out repair work on the circuitry, etc.
• Use only SEETRAX replacement parts to repair the CIR-KIT WELD 450.
• Never put your face nearer than 6" (152mm) to the Electrodes when a weld is being
made. Splatter from tin/lead deposits, may cause burning or eye damage.
• Do not operate with wet hands.
• Do not leave the machine switched on when not in use other than to charge batteries.
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INTRODUCTION
A few minutes of your time spent now reading through this handbook, could save your many
hours later and will ensure that you will get the very best from your CIR-KIT WELD 450.
The CIR-KIT WELD 450 is a complete Repair Station with all the necessary equipment
needed to repair open circuits and reduced width tracks on populated and bare PCB’s. No
other equipment is required. The CHECK LIST on page 4 of this handbook contains a
detailed check list of what the CIR-KIT WELD 450 package contains.
The welder - a constant current, microprocessor controlled, parallel gap type - used in
conjunction with SEETRAX CU Series Plated Copper Ribbons is a very cost effective means
of repairing the faults that so often occur during the manufacture of PCB’s.
Repairs to track with open circuits are made by welding a short length of ribbon across the
track break, thereby bridging the defect. Different widths of ribbon are supplied to suit most
track widths. Adhesive should be used to ensure a long length of ribbon (10mm and above) if
used, is held firmly to the substrate. The advantage of repairing open circuits by welding
copper ribbon across the defect is that it is an extremely fast, flux free, permanent repair.
Welds can be made onto electroplated copper (of varying quality) and tin/lead plated tracks if
the solder is bared back to the copper track beneath. Please note, welding through a tin/lead
deposit should be avoided, as some splatter or 'side ways' spreading of tin/lead will almost
definitely occur and could possibly short track the track and a good copper to copper weld
will not be achieved.
Copper ribbon cannot be detected electrically; being copper it is the same as the damaged
track.
Repairs to open circuits on PCB’s carried out on the CIR-KIT WELD 450 will meet numerous
manufacturing specs, including BS6221.
Repairs can be Roller Tinned, Hot Air Levelled or Tin/Lead Plated and fused without fear of
lifting, fracturing or peeling.
In addition to repairs PCB’s, fine wires, such as motor and solenoid winding tails can be
successfully welded to terminals and pads, using the CIR-KIT WELD 450.
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TECHNICAL DATA
MACHINE SPECIFICATION
MACHINE BASE SIZE 31" x 26" (786mm x 656mm)
MAXIMUM HEIGHT (INCL OPTICS) 20" (500mm)
WEIGHT 128lbs (58Kgs)
MAXIMUM PANEL SIZE 30" x 30" (762mm x 762mm)
WELD HEAD PRESSURE 0.6 - 1.5 Kgf
1.25 - 3.5 Ibf
6 - 15 NEWTONS
(MANUAL SETTING)
BASE FRAME STEEL BOX TUBE
WORK TABLE OPAQUE GLASS
CONTROL COVER GLASS-FIBRE
WELD HEAD MOVEMENT FOOT PEDAL ACTUATOR
ELECTRODES MOLYBDENUM (OVER PLATED)
POWER INPUT 100/110 or 220/240 VAC
(SELECTABLE)
50/60 Hz
3.0 / 1.5 AMP 1 PHASE
+ NEUTRAL + GROUND
OUTPUT CURRENT 0 - 500 A MAX (SELECTABLE)
WELD TIME 0.2 - 29.0 m/sec (SELECTABLE)
CONTROLS
PROGRAMMABLE MEMORY MODE 99 SETTINGS
MANUAL POWER MODE MANUAL OVERRIDE
WORK LIGHT 12 VOLT MULTI-POSITIONAL
(VARIABLE OUTPUT)
OPTICS FIXED 7.5X - 15X
TOOLS SUPPLIED
3 X DIFFERENT RIBBON SIZES
3 X TOOLS
1 X FIBRE GLASS CLEANING PENCIL
1 X PAIR ELECTRODES EL20
1 X ELECTRODE SETTING BLOCK
See check list on page 4 for a full list of parts supplied.
8
QUICK INSTALLATION PROCEDURE
For people with previous experience of the Cir-Kit Weld 450. Inexperienced people should
refer to the full instructions in the INSTALLATION PROCEDURE on page 9.
To adjust the foot cable and electrodes
Set the height adjustment on the front of the machine to 0 mm adjust the electrodes so there is
a 4 mm gap between the bottom of the electrodes and the glass table. Make sure that the
electrodes are both at the same height by bringing them down gently on to a piece of abrasive
paper and if you gently pull the paper forward, 2 equal lines should be made on the paper.
Next with the height setting still at 0 mm put a piece of paper under the electrodes and gently
push down on the foot pedal until the paper is clamped, this should be firmly clamped
without trying to weld and the adjusting screw will have stopped moving. You should still
have approximately ¼ of the downward foot pedal movement left. Now pushing a little more
on the foot pedal, the white arm below the height adjustment screw should continue to move
down giving a gap of 2-3 mm between the nut and the white arm, compressing the spring and
putting clamping pressure on the electrodes, the welder should now try and weld, beep and
show the clean light.
This 2-3 mm movement of the white arm will ensure that there is pressure on the electrodes
which is needed to give a good electrical contact to measure the current flow / resistance. If
there is insufficient pressure, the machine will not sense the correct welding times. To
increase the spring pressure wind the 2 knurled nuts upwards.
If it welds early or not at all adjust the foot pedal cable to achieve this setting.
Welding settings
The settings on the welding machine can be very difficult to control if you start changing
both amps and time settings. We have found that if you leave the time setting always at 3.40
mil seconds and always adjust the amps up or down this gives much better results.
The machine is designed to adjust the time setting for itself, therefore it will not always use
the 3.40 mil seconds set but will sense the welding resistance and cuts the time accordingly to
its threshold setting.
Only for experienced operators
If the threshold is set to 65 this will give a weak weld, 70 is normal and 75 is a very
aggressive weld. To adjust threshold setting push both amps and time button together and
adjust with + or - (on older machines, the version number of the software will display on
power up. version 5 or before the threshold setting was 120).
For normal welding the time should be 3.40, threshold 70 and only adjust the amps starting
low and working up to achieve a good weld.
Approximate values
Cu40 (0.004”) 0.10mm Time 3.40 Amps 80 Threshold 70
Cu60 (0.006”) 0.15mm Time 3.40 Amps 100 Threshold 70
Cu80 (0.008”) 0.20mm Time 3.40 Amps 130 Threshold 70
Cu10 (0.010”) 0.25mm Time 3.40 Amps 160 Threshold 70
9
INSTALLATION PROCEDURE
• Having unpacked the CIR-KIT WELD 450 from its crate, check all of the components
against the Packing Check List, and familiarise yourself with all parts listed.
• Place the CIR-KIT WELD 450 on a solid table or workbench, (recommended height
30ins (760mm), depth 34ins (860mm)) with an open back, i.e. not against a wall. The
machine must be out of direct sunlight, free from vibration and not near chemicals,
i.e. plating tanks.
• Bring the Foot Pedal Switch around the back of the machine to a comfortable position
under the table or bench.
• IMPORTANT NOTE: Do not have the Foot Pedal Switch cable laying on top of
the table or bent at an angle from the machine back. It must lie in a straight,
vertical line from the machine to the floor, otherwise the operation of the Weld
Head will be jerky.
• Assemble the Microscope, as instructed in the Microscope Instruction Manual ().
• Mount the Microscope onto the CIR-KIT WELD 450's Support Bracket and secure by
locking the screws on the Microscope Bracket Assembly. Plug in work lamp.
• To adjust the foot cable and electrodes slacken the brass clamp plates and slide the
electrodes under the clamps. Lift the electrodes and position the Setting Block under
the electrodes so that the tips of the electrodes touch the lower step (4mm from the
base). Hold the electrodes against the 0.25mm shim to keep them parallel. Tighten
the clamps plate screws. Remove the Setting Block.
• Set the height adjustment on the front of the machine to 0 mm adjust the electrodes so
there is a 4 mm gap between the bottom of the electrodes and the glass table. Make
sure that the electrodes are both at the same height by bringing them down gently on
to a piece of abrasive paper and if you gently pull the paper forward, 2 equal lines
should be made on the paper.
• With the height setting still at 0 mm put a piece of paper under the electrodes and
gently push down on the foot pedal until the paper is clamped, this should be firmly
clamped without trying to weld and the adjusting screw will have stopped moving.
You should still have approximately ¼ of the downward foot pedal movement left.
Now pushing a little more on the foot pedal, the white arm below the height
adjustment screw should continue to move down giving a gap of 2-3 mm between the
nut and the white arm, compressing the spring and putting clamping pressure on the
electrodes, the welder should now try and weld, beep and show the clean light. This 2-
3 mm movement of the white arm will ensure that there is pressure on the electrodes
which is needed to give a good electrical contact to measure the current flow /
resistance. If there is insufficient pressure, the machine will not sense the correct
welding times. To increase the spring pressure wind the 2 knurled nuts upwards.
10
• If it welds early or not at all adjust the foot pedal cable to achieve this setting.
• Place the repair tools in the front cover pockets.
• Connect mains lead into the sockets at rear of machine.
• Check voltage switch on the machine back is showing the corresponding voltage to
your mains supply.
• IMPORTANT NOTE: If voltage is wrong, DO NOT proceed with installation
and DO NOT switch the machine on. Contact SEETRAX or your local
SEETRAX Distributor. If the voltage is correct SWITCH ON O/I. See Figure 2,
page 20).
• Adjust the Work Light position.
• YOUR CIR-KIT WELD 450 IS NOW READY TO WORK!!
• PLEASE TURN TO OPERATING INSTRUCTIONS - PART 1, page 12.
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