Amada TC-W100A Operation Manual
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Amada TC-W100A Operation Manual

Thermocouple welder
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THERMOCOUPLE WELDER
TC-W100A
OPERATION MANUAL
990-070 Rev H

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  • Page 1 THERMOCOUPLE WELDER TC-W100A OPERATION MANUAL 990-070 Rev H...

  • Page 2: Revision Record

    Copyright © 1990 – 2021 AMADA WELD TECH The engineering designs, drawings and data contained herein are the proprietary work of AMADA WELD TECH and may not be reproduced, copied, exhibited or otherwise used without the written authorization of AMADA WELD TECH.

  • Page 3: Foreword

    Should questions arise, or if you have suggestions for improvement of this manual, please contact us at the above location/numbers. AMADA WELD TECH is not responsible for any loss due to improper use of this product. TC-W100A - THERMOCOUPLE WELDER...

  • Page 4: Safety Notes

    Disposal Properly handle and dispose of used materials. For the disposal of electronic waste please contact AMADA WELD TECH. TC-W100A - THERMOCOUPLE WELDER 990-070...

  • Page 5: Table Of Contents

    Handpiece Specifications ......................1-4 Wire Gauge Diameter Specifications ................1-4 Initiation ..........................1-5 Safety Features ........................1-5 Physical Dimensions ......................1-5 Argon Purge Gas ....................... 1-5 Gas Flow ........................... 1-5 Argon Purge Gas Shutoff ....................1-5 TC-W100A - THERMOCOUPLE WELDER 990-070...
  • Page 6 Factory Service Repair ...................... 5-2 ILLUSTRATIONS Figure Title Page Front and Back Picture of TC-W100A ................1-2 TC-W100A Schematic, Sheet 2, Power Connections ............2-2 Wire Clamp Jaw Assembly ....................2-4 Thermocouple Wire Insertion Procedure ................3-1 TC-W100A - THERMOCOUPLE WELDER...
  • Page 7 1. Applicability. (a) These terms and conditions of sale (these “Terms”) are the only terms which govern the sale of the goods (“Goods”) by Amada Weld Tech Inc. (“Seller”) to the buyer identified in the Sales Quotation and/or Acknowledgment (as each defined below) to which these Terms are attached or incorporated by reference (“Buyer”).
  • Page 8 Agreement. Buyer shall immediately discontinue use of the Software upon any termination of this license or Agreement. This license shall terminate upon any termination of the Agreement. TC-W100A - THERMOCOUPLE WELDER viii...
  • Page 9 REASONABLY FORESEEN BY BUYER, REGARDLESS OF THE LEGAL OR EQUITABLE THEORY (CONTRACT, TORT OR OTHERWISE) UPON WHICH THE CLAIM IS BASED, AND NOTWITHSTANDING THE FAILURE OF ANY AGREED OR OTHER REMEDY OF ITS ESSENTIAL PURPOSE. TC-W100A - THERMOCOUPLE WELDER 990-070...
  • Page 10 19. Force Majeure. Seller shall not be liable or responsible to Buyer, nor be deemed to have defaulted or breached this Agreement, for any failure or delay in fulfilling or performing any term of this Agreement when and to the extent such failure or delay is caused by or results from acts or circumstances TC-W100A - THERMOCOUPLE WELDER 990-070...
  • Page 11 27. Survival. Provisions of these Terms which by their nature should apply beyond their terms will remain in force after any termination or expiration of this Order including, but not limited to, the following provisions: Compliance with Laws, Confidentiality, Governing Law, Dispute Resolution, Survival, and the restrictions on Software in Sections 10(b), (c) and (d). TC-W100A - THERMOCOUPLE WELDER 990-070...
  • Page 12  ...

  • Page 13: Chapter 1: System Description

    Line Voltage Line voltage is 115, 230, or 100 Volts, 60/50 Hz. The Thermocouple Welder (TC-W100A) is a multi- voltage unit is normally connected for 115V, 60/50 Hz operation unless otherwise specified on the nameplate and the label attached to the line cord.

  • Page 14: Standby Power

    The Line Voltage regulator ensures that the welds are independent of changes in line voltage by maintaining the voltage on the capacitor bank within ± 0.25% of setting for a ± 13% change in line voltage. TC-W100A - THERMOCOUPLE WELDER 990-070...

  • Page 15: Turndown Circuit

    The Line Failure Turndown is a safety feature which ensures that the capacitor bank is automatically discharged whenever the input power is interrupted. Weld Fire Lockout This feature helps prevent poor welds by inhibiting firing of the TC-W100A until the energy stored in the capacitor bank is within 1% of the pre-selected value. Power Switch A rocker switch disconnects both sides of the input power line when switched to the “OFF”...

  • Page 16: Handpiece Specifications

    The Model TC-W100A Handpiece is not supplied with any Wire Clamp Jaw Assemblies. A single Wire Clamp Jaw Assembly of the proper gauge is required to operate the TC-W100A. Four Wire Clamp Jaw Assemblies are available for use with different gauge wires. The table below defines which Wire Clamp Jaw Assembly should be used with each wire diameter size.

  • Page 17: Initiation

    NOTE: For this system to be economical, the user must eliminate all leaks in the gas system feeding the TC-W100A. When the input power is on, gas flow is continuous. An internal gas reservoir, located between the purge gas input connector and the shutoff solenoid, stores a sufficient amount of argon purge gas to immediately clear out the Weld Chamber when the TC-W100A is turned back on.
  • Page 18  ...

  • Page 19: Chapter 2: Installation

    The TC-W100A was assembled at the factory for operation at a specific line voltage. If the TC-W100A is used on a line voltage other than the one for which it is connected, serious damage can result. Most Thermocouple Welders are shipped from the factory wired for 115 volt, 50/60 Hz operation.
  • Page 20 0.005 0.01 Primary Wiring for 208VAC Models (L2) TO 115VAC SOLENOID VALVE 0.03A 0.005 0.01 0.03A Primary Wiring for 230VAC Models (L2) TO 115VAC SOLENOID VALVE 0.03A 0.005 0.01 0.03A Figure 2-1. Power Supply Connections TC-W100A - THERMOCOUPLE WELDER 990-070...

  • Page 21: Section Ii. Thermocouple Wire Preparation

    The recommended tolerance on Strip Length is –0/+0.010 inches (-0/+0.25 mm). Any strip length greater than those shown above is acceptable. The TC-W100A Handpiece can be used with non-insulated thermocouple wire. Non-insulated wire must protrude a MINIMUM of 0.135 inches (3.43 mm) from the closed Wire Clamp Jaws.

  • Page 22: Handpiece Wire Clamping Jaws Installation

    Button forward. Both halves should be flush at the tip when the tip is closed. Do not mix Wire Clamp sets. The identification code on the upper Wire Clamp Jaw must match the identification code on the lower Wire Clamp Jaw. TC-W100A - THERMOCOUPLE WELDER 990-070...

  • Page 23: Chapter 3: Operating Instructions

    • Switch the POWER SWITCH to “ON”. Purge gas from the reservoir will immediately fill the Weld Chamber, making the TC-W100A ready to use. When replacing the purge gas tank or if the purge gas line has been opened, wait 5 minutes for the purge gas to replace the air in the purge gas line, reservoir, and Weld Chamber.
  • Page 24 Control CLOCKWISE will INCREASE the size of the weld bead. NOTE: If the weld bead is too large, it cannot be pulled back through the Wire Clamp guide tube. See Chapter 5, Section II, Troubleshooting. TC-W100A - THERMOCOUPLE WELDER 990-070...

  • Page 25: Chapter 4: User Maintenance

    The Handpiece Cable is very flexible and should last many years with careful use. Should the insulation become cracked at either the Handpiece or Power Supply front attachments, return the unit to AMADA WELD TECH. See Chapter 5, Section III, Repair Service.

  • Page 26: Section Ii. Weld Chamber Maintenance

    Buildup occurs faster with large gauge wires such as 20-22 AWG and usually appears as a bright metallic deposit on the face of the Arc Button. Should this occur, return the unit to AMADA WELD TECH. See Chapter 5, Section III, Repair Service. TC-W100A - THERMOCOUPLE WELDER...

  • Page 27: Chapter 5: Service

    SERVICE Section I: Calibration The Model TC-W100A does not require calibration. Component tolerances and stability are such that the Capacitor Bank Voltage will not vary from Power Supply to Power Supply by more than 4% for the same WIRE GAUGE SELECTOR setting.

  • Page 28: Section Iii. Repair Service

    Telephone Service Call the AMADA WELD TECH 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 identification plate on the rear panel.
  • Page 29 TEL. +1-626-303-5676 FAX, +1-626-358-8048 http://www.amadaweldtech.com AMADA WELD TECH CO., LTD. 200, Ishida, Isehara-shi, Kanagawa 259-1196, Japan AMADA WELD TECH KOREA CO., LTD. 28, Dongtanhana 1-gil, Hwaseong-si, Gyeonggi-do, 18423, Korea TEL. +82-31-8015-6810 FAX. +82-31-8003-5995 AMADA WELD TECH SHANGHAI CO., LTD. Unit 401, A206(C8), No. 77, Hongcao Road, Xuhui District, Shanghai, China TEL.
  • Page 30 AMADA WELD TECH INC. 1820 South Myrtle Ave., Monrovia, CA 91016, U.S.A. TEL. +1-626-303-5676 FAX. +1-626-358-8048...

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