BEAHM 220-B Split Die Thermal Bonder User Manual

BEAHM 220-B Split Die Thermal Bonder

List of Components

Standard System Components

1) Split Die Thermal Bonder
2) Split Die Thermal Bonder Ship Kit Power cord, U.S. version, 115 VAC Air pressure supply line
3) User’s Manual

Optional Components

General Description

The unique and simple die head design of the Beahm Designs Split Die Thermal Bonder, provides a low cost quick tool alternative to RF die bonding. The three parameter operation is easy to set-up and use and simplifies system calibration and process validation. Upgrade options such as axial compression and cooling further increases versatility and functionality. This system provides you with fast, highly repeatable bonds. Allows you to perform highly precise bonds for demanding applications such as short balloon bonds and ultra smooth lap & butt welds. Adjustable clamp pressure varies compression force on joint. Ultra compact design provides you with greater work-space. Automation and axial compression

Controls

Front Panel Controls

Located on the front panel of the unit (see drawing p/n 170014 (7.1)) are:
System Power
Clamp Pressure
Clamp Pressure Regulator
Tempurature Controllers (front & rear)
Cooling Air Line
Cooling Air Flow Adjust
Cooling Air on/off toggle switch
Timer Reset Button
Process Duration Timer

Rear Panel Controls

Located on the rear panel of the unit are:
Power entry module
Industrial system air connection
System Fuse
Front temperature controller thermocouple calibration port. Rear temperature controller thermocouple calibration port. Pressure gauge calibration port.

Installation

When installing the system, follow the sequence listed below.
Make sure that the system power is in the off position. Connect the system air extension line to 80—100 psi clean dry compressed air source. Connect main AC power to the power entry module on the rear panel.

Parameter Setting

Pressure Regulator Setting

Rotate the regulator knob clockwise to increase air pressure, counter clockwise to decrease air pressure output to the die head actuation cylinder.

Cooling Air Flow Adjust

Rotate the flow meter valve counter clockwise to increase cooling airflow, clockwise to decrease airflow.

Temperature Controller Setting

Depress the up arrow key on the temperature controller to increase the temperature set-point depress the down arrow key to decrease the temperature set-point. Release up or down arrow key when desired temperature is displayed in the upper read out. The new setting will be accepted automatically after 2 seconds.

Process Timer Setting

Depress the upper half of the blue rocker buttons to increase time duration, depress the lower half of the blue rocker button to decrease the time duration. Depress the timer reset button for at least 1.0 seconds to accept the new value.

Temperature Controller Setting

Eurotherm Model 2132
To Set the temperature proceed as follows:
Press and hold “down arrow” to decrease temperature
Press and hold “up arrow” to increase temperature

After 2 secs the readout will ‘blink’ indicating that the new value has been accepted the temperature will automatically ramp to the new value and stabilize.

Auto-Tuning Instructions

Switch main power on
1) Depress the page button until “TUNE LIST” appears in the display
2) Depress the scroll button until “ATUN” appears in the display
3) Depress the “UP” or “DOWN” arrow button twice to initiate tune sequence
4) Unit will resume normal operation automatically

For more details about Eurotherm Temperature Controller, see the manufacturers Insturction Manual in the back of this manual.

System Operation

Facilities Requirements

110/120 v, 50/60 hz
2-3 amps (220 watts)
100-125 psi, clean dry compressed air

Safety Precaution

Hot die jaws will become hot during operation and, depending on temperature set-point, can cause severe skin burns if contact occurs.

System Controls

• Switch main power on.
• Set die temperature on EACH temperature controller by pressing the UP/Down arrow key once to display the set temperature, then again to change it.
• Set timer to desired duration in seconds.
• Position components to be bonded within thermal jaws.
• Depress footswitch.
• To cool assembly when cycle is complete, position the heated area at the tip of the cooling air nozzle and toggle the cooling air switch to the “on” position.

Die Head Sizing and Replacement

Required Tools and Equipment

Milling Machine
.25” diameter end mill
reamer as required
Caliper or micrometer

• Assemble components to be bonded over mandrel(s).
• Measure bond length, tubing overlap or balloon sleeve length.
• Position the protective sleeve over the bond area.
• Measure the O.D. of the protective sleeve. Set timer to desired duration in seconds.
• Position components to be bonded within thermal jaws.
• Depress footswitch.
• To cool assembly when cycle is complete, position the heated area at the tip of the cooling air nozzle and toggle the cooling air switch to the “on” position.

Die Head Replacement

Caution: ensure that the die heads are cooled to within 15 degrees f of ambient temperature before proceeding with replacement.

• Loosen the set screw located on the top of each die head and withdraw the thermocouple.
• Remove the two screws at the base of each die head
• Position new die heads in place of removed die heads, install two screws at the base of each die head. Do not overtighten the screws.
• Install the thermocouple in the rear of each die head and gently tighten the set screw to hold them in place.

Maintenance

Calibration

Calibration Method:

Calibration ports are provided at the rear of the main control unit to prevent the need to open the enclosure and disconnect wiring or plumbing.
Calibrate every 12 months. Send unit to an NIST certified calibration service (this service can be coordinated by Beahm Designs for an additional fee).
Calibration procedures are carried out by certified services. Their procedures are derived from the N.I.S.T. (National Institute of Standards and Technology). http://www.nist.gov/index.html

System Specifications Range Resolution Accuracy
6.1.1 Temperature 200-500 deg f 1.0 degree +/- .25% F.S.
6.1.2 Timer 1-9999 sec 1.0 second +/- .1 seconds
6.1.3 Pressure 0-100 psi 5 psi +/- 3.5% F.S.

Calibration

Calibrate the temperature controller annually.
Calibrate the process timers annually.
Calibrate the pressure gauges annually.

Replacement Parts List

(the below items are available through Beahm Designs)

Die Head Replacement

Loosen the thermocouple set screw in each die head and slide the thermocouple out of each head.
Remove the fasteners at the base of each die head and remove the die heads.
Position the replacement die heads on the die bases with the thermocouple mounting holes facing away from each other.
Re-install the fasteners at the base of each die head, DO NOT tighten the fasteners.
Manually close the die heads and ensure that they are aligned left-to-right and, while holding the heads together, tighten the base fasteners.
Fully insert each thermocouple into each die head and lightly tighten each set screw.

Warranty Information

Beahm Bonders are backed by a 1 year warranty on parts and labor.
BDI will have no liability for any Product returned if BDI determines that:

• The asserted defect:
  1. is not present,
  2. is attributable to misuse, improper installation, alteration (including removing or obliterating labels and opening or removing external covers (unless authorized to do so by Beahm Designs), accident or mishandling while in the possession of someone other than Beahm Designs, Inc.
  The Product was not sold to you as new.

Return Material Authorization (RMA)

No Product may be returned directly BDI without first contacting BDI for a Return Material Authorization (“RMA”) number. If it is determined that the Product may be defective, you will be given an RMA number and instructions for Product return. End Users are required to include a copy of the RMA receipt inside the return box to receive replacement product under warranty. An unauthorized return, i.e. one for which an RMA number has not been issued, will be returned to you at your expense. To request an RMA, please call 408-871-2351.

List of Drawings

1502 Gladding Ct. Milpitas, Ca. 95035.
408-395-5360
www.beahmdesigns.com

Equipment User Manual

1700-14 Front Panel Controls

6066 Blank Die Head

Document 10125-20

3018 System Schematic

List of Component Data Sheets

Eurotherm 2132 Temperature Controller
Split Die Thermal Bonder

Bonding Systems Catheter Balloon and Shaft Bonds

Customer Service

Visit us at www.BeahmDesigns.com or contact our soles deportment for product specifications and pricing.
568 Division street compbell CA 95008 tel 408-871-2351
Fax 408-871-8295
for complete line of machine designs

References

• Beahm Designs - catheter manufacturing equipment solutions - tipping, bonding, fusing, necking, forming, shrinking, flaring
• Beahm Designs - catheter manufacturing equipment solutions - tipping, bonding, fusing, necking, forming, shrinking, flaring
• National Institute of Standards and Technology

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