S U P E R
W E L D E R
RESISTANCE WELDER SERIES
Highly diversified/advanced various kinds of welding work
Choose your optimal machine t
from our wide serialized produ
your production efficiency.
Nippon Avionics has been producing a various kinds of junction machines for
electronic parts or electrical components, on the basis of the technology
supported by an excellent track record and experience over the years. This
excellent work earns us a reputation and establishes it as a leader in this field.
It is supposed that the welding work in the industrial field such as electron,
electricity or automobile becomes increasingly complicated day by day and
the cost-down is demanded still more with high performance.
Generally speaking, the object to weld includes from thick plates with 10 mm or
so thickness to ultra thin wires in micrometers.
In welding work, there is no suitable machine for all those objects. So, it is
necessary to select a optimal welding machine in accordance with the size,
material, forms and finished accuracy to produce good results on productivity.
A series of "Super Welder" made by Avio has a wide range of machine types
to respond to various kind demands from you.
type
ucts for
Fundamentals of Resistance
Welding and Decision Procedure
of Welding Items
Resistance welding uses the resistance heat (Joule heat)
generated by a large amount of current passing between the
electrodes which also hold the work-piece to weld and apply a
pressure to it.
General conditions in the welding are given as follows;
(a) the material and form of the electrode
(b) the physical weld force applied through the electrode
(c) the amount of energy applied (welding current and weld time)
The item (b) and (c) among the welding conditions are control factors to
the welding unit (a weld head and a welding power supply), and are able
to be got the optimum condition each when the item (a) is fixed.
Accordingly, the decision procedure of the welding items is got in the
following way.
(1) To decide the pass for the welding current, that is, the
weldingmethod.
(2) To decide a mutual material and form from the information of
the work-piece's material and form.
(3) To select a weld head in accordance with the supposed pressurized
force and the work-piece's material and form.
(4) To estimate the welding current and weld time, then select a welding
power supply based on the estimation.
(5) To perform weld test to set final decision on pressurize force,
welding current and weld time.
•A model of Resistance Welding
•WELDING SAMPLES
Battery
Tungsten halogen lamp
Electrical components
Connector
Breaker
Battery
Breaker
Relay
Transistor
Electrical components
Capacitor
Relay
CONTENTS•
WELDING SOURCE ..................... 5
WELDING MONITOR................... 10
Electron gun
WELDING HEAD .......................... 11
WELD HEAD OPTIONS ............... 15
ELECTRODE ................................. 17
Relay
Crystal oscillator
Crystal oscillator
APPLICATION EQUIPMENTS ..... 20
■ LINEUP OF RESISTANCE WELDER
A resistance welding machine is composed of a welding power supply, a weld head and an electrode. The welding power supply
controls a welding current, the weld head exerts a pressure on the material to weld, and the electrode provides welding current and
pressurization force to the part under welding. Since a welding power supply has several characteristics, shown in the table on the
next page, which is based on the control method, you need to select it according to the material and/or shape of the work–piece to
weld. We have been providing various kinds of welding power supplies and weld heads to meet these requirements.
Inverter Type
Weld Head
NT–IN4000A
Welding Timer
Welding Transformer
NT–IN4000A
NRW–IN4000A
NT–IN2000A
NRW–IN4000A
NA–60A
Hand Piece Type
NA–54A
NA–54LA
NA–57A
NA–58A
Transistor Type
Series Type
NA–65
NA–64B
NA–64BT
MCW–650
MCW–650
Straight Pressurization Type
NA–65
NA–41
NA–41B
NA–60C
D.C. Type
NT–100A
NRW–100A
NT–100A
NRW–200A
NT–200A
Extremely Low Pressurization Type
NA–90
VTA–96
NRW–100A
NA–60A
Single–phase A.C. Type
Opposed Type
NT–5A
NA–60A
NA–72
NRW–5A
NT–5A
NRW–25A
NT–8A
NRW–2000/NRW–2000C
NT–5M
NRW–2000/NRW–2500C
NA–60A
3
NRW–5A
Refer to the list shown in the next page
to get suited combination between a
welding source and a weld head.
■ Waveforms and Characteristics of Power Supplies
Table 1. The List of Characteristics of Power Supplies
(
Performance
Type
A.C.
D.C.
No weld splatter*
K
G
Stability to Power Fluctuation
G
Welding Speed(cycle time)
Power Source Capability
Transistor
K
G
G
G
K
K
K
G
Price
Main uses
KGood
Excellent
Between
weldable
plates
For the parts For very thin
requiring no wires
deformation
nor discoloring
•Lead wire of
sensors
•Motor brush
GInferior)
Inverter
G
G
For the parts
requiring no
weld splatter*
•Electronic
•Magnetic
mirror
head
*Weld splatter: Dust or slag which is produced during welding, Welding slag
The Combination of Power Supply and Weld Head
Head
Type
Opposed
Applicable Power Supply
Model
NA-60A
NA-41
Controller
NRW-100A
Uses
Transformer
NT-100A
Relay contact, Lamp, Thermocouple, Electron gun, Micro-motor
NA-41B
NA-60C
NA-60A
MCW-650
NA-60A
NRW-5A
-
NRW-2000/NRW-2000C
NT-5A
NRW-IN4000
NT-IN4000
NA-54A.NA-54LA
NA-57A.NA-58A
NA-65
NA-64B
Very thin wire
NT-5A
NA-41
NA-90
Series
NT-200A
NA-41B
NA-72
Hand Piece
NRW-200A
NRW-25A
NT-8A
NRW-2000/NRW-2500C
NT-8A
NRW-IN4000
NT-IN4000
NRW-100A
NT-100A
MCW-650
-
NRW-100A
NT-100A
NRW-100A
NT-100A
MCW-650
-
NRW-100A
NT-100A
NRW-200A
NT-200A
NRW-5A
NT-5A.NT-5M
NRW-2000/NRW-2000C
NT-5A.NT-5M
NA-64BT
NRW-IN4000
NT-HF2000
Modified NA-90 Series
NRW-100A
NT-100A
VTA-96
MCW-650
-
Stranded cable, Thin plate, Relay contact, Motor, Bimetal
Stranded cable, Relay assembly, Chassis assembly
Lamp, Thermocouple
Lead frame, Thermocouple, Electron gun
Printed circuit board, Hybrid circuit
Battery tab, Magnetic head
Strain gage, Gas sensor, Tungsten halogen lamp, Mini-motor
❉ Call for other combinations.
❉ Old models of NA-60H and NA-60B are equivalent to NA-60A concerning usage.
4
WELDING POWER SUPPLY
Inverter Type Welding Power Supply
NRW-IN4000A/NT-IN4000A
NRW-IN8000A/NT-IN8000A
NRW-IN4000A/NT-IN4000A is the highly efficient welding power
supply that adopted an inverter. It responds to the change
during welding at real time by fast feedback. The highly
stabilized welding current generated by the power supply is
optimal to the resistance welding for precision electronic parts.
Advantages
● High quality welding
• Less weld slag • Steady welding strength
NT-IN8000A
● Multi–mode
• Available 3-modes (current, voltage, power) to its use.
NRW-IN8000A
■ Block Diagram
● A built–in welding monitor
• Powerful tool for welding quality control by monitoring mean
current, voltage or electric power.
• Available observation of current/voltage/power waveforms via
the output connector on the rear panel.
● A wide choice of functions
• Registrable welding conditions up to 15, and possible to
switch from the outside
• Equipped RS232C as an interface with PC.
• Available IC Card (option) to save welding conditions.
● Multi–transformer
• Optional maximum of 4 set transformer control by Switching
Unit (option)
■ Specifications
Welding Timer
Welding Transformer
Model
NRW-IN4000A
NRW-IN8000A
Control Frequency
Control Mode
Range of Heat Control
2KHz
constant current, constant voltage, constant power,fixed pulse width
Current 0.4~4KA(1A unit)
Current 0.4~8KA
Voltage 0.4~4V(0.01V unit)
Voltage 0.4~4V
Power
Power
0.2~8KW(1W unit)
0.2~24KW
UP+WELD+DOWN 1st, 2nd
Each total 0~600ms(1ms unit)
Range of Timer Setting
COOL:0~750ms(1ms unit)
SQ:0.01~9.99s(0.01s unit)
HOLD:0.01~9.99s(0.01s unit)
Monitoring
Number of Conditions
15conditions
Interface
RS-232C(2400~5760bps),I / O 14pins
Power Input
Dimensions/Weight
5
AC2005230V 3ø50/60Hz
170W265H350D 15kg
170W265H420D 17kg
Model
NT-IN4000A
NT-IN8000A
Rated Capacity
8.8KVA(duty cycle: 50%)
30KVA(duty cycle: 50%)
Maximum Current
4.0KA(duty cycle: 5%)
8.0KA(duty cycle: 5%)
Input Frequency
2KHz
2KHz
Transformer Voltage
7V
12V
Dimensions/Weight
150W✕210H✕267D 12kg
210W✕210H✕342D 18kg
Transistor Type Multi-mode Welding Power Supply
MCW-650
MCW-650 is the device that controls a current by power MOS
FET directly. It maintains the welding current, voltage or electric
power within preset values by feedback of the resistance value
change of the work-piece under welding. This type power
supply prevents over weld penetration and brings fewer weld
spattering. Accordingly it is optimal and mighty to weld
precision minute size electronic parts.
MCW-650
Capacitor Unit
Advantages
■ Block Diagram
● High quality welding is possible due to the feedback control
of electrode voltage and welding current.
● The optimal mode can be selected from 3-mode operation
(constant current, constant voltage and constant electric
power) to suit to the object to weld.
● The maximum of 15 welding conditions can be set. They can
be also switched by external control.
● Welding monitor (average current, voltage, electric power)
shows mighty power on controlling welding quality.
● By adopting the capacitor bank (option), the welding time can
be extended up to 3 times.
Note: The maximum time is within the limits of specifications
listed below.
● Remote control or monitoring, used as an input tool of
welding conditions or output tool of measurement values, is
available by use of PC (RS232 C).
● Specifications
Input Power Source ✽1
100V10 50/60Hz 200W 1ø
3600 ( 20W.s )
Maximum Output Power
Maximum Permissible Output Current
Setting Conditions
1800A
10(1800A(1A STEP ) 0.01~4.00V (0.01V STEP)10~3600W (1W STEP)
vary with modes
0~9.9ms (0.1ms STEP)
up
Welding Time
Number of Times of Welding
weld
down
0.1~9.9ms (0.1ms STEP)
0~9.9ms (0.1ms STEP)
By switching, multiplying factor of 10 or 100 is available. However, they are limited by output setting values.
1.5 times/sec at the setting of 100W-5ms (0.5W.s)
0.5 time/sec at the setting of 3600W-5.5ms (20W.s)
Dimension & Weight
480W392D252Hmm32Kg
Applicable Weld Head
NA-65, NA-60A(❉2), NA-90(❉2), NA-62(❉3)
Capacitor Bank (equivalent to 60 W.s)
Options
(❉1) Other input power source of AC115V, 200V, 220V, 230V, 240V are available as an option.
6
WELDING POWER SUPPLY
D.C, Type Welding Power Supply
NRW-100A/NT-100A
NRW-200A/NT-200A
■ Block Diagram
D.C. type welding machine adopts the method that a large
capacitance condenser charges a lot of electric energy and
discharge it in a very short time. In this method, consequently,
the work-piece to weld does not sustain burning or deformation
during the welding as the welding time is very short. It is optimal
for the small parts. Regarding charging energy, there are two
types of 100W•s and 200W•s.
Advantages
●Conditions can be also set by an external device like a
sequence controller.
●Welding is interlocked if the charged voltage does not reach
set value.
●The capacity of Condenser Bank can be easily switched to the
other level. (50% or 100%)
●Choosing welding mode from 3 kinds of waveform (refer to the
figure shown right) can set suitable welding time.
●Two conditions of energy levels can be set.
●Automatic condition switching function is available.
●A counter with preset function is built-in.
NT-200A
■ Specifications
Input Power Source ✻1
Capacitance of Condenser
Stored Energy
Mean Value of Max. Output
Short Pulse
At 2M2
Middle Pulse
Load
Long Pulse
Number of times of Welding
Dimensions
Weight
Channel Selection
7
✻3
NT-100A
NRW-200A
NRW-100A/NT-100A
AC100V10% 50/60Hz 1ø 15A
1500µF(750µF/50W•s by changing external connection)
1~100W•s (0.1W•s step) at 1500µF
peak current
base time
4,700A
1.8ms
3,600A
3.2ms
2,200A
6.5ms
setting
continuous rating
✻2
50W•s
60 times/min
✻2
100W•s
30 times/min
(NRW-100A)
(NT-100A)
NRW-100A
NRW-200A/NT-200A
AC100V10% 50/60Hz 1ø 20A
3000µF(1500µF/100W•s by changing external connection)
2~200W•s (0.1W•s step) at 3000µF
peak current
base time
5,500A
3.2ms
4,200A
4.9ms
2,400A
10.5ms
setting
continuous rating
100W•s
50 times/min
200W•s
25 times/min
(NRW-200A)
(NT-200A)
180W424D294Hmm
160W285D220Hmm
220W424D363Hmm
200W324D272Hmm
(NRW-100A) 21 kg
(NT-100A) 16kg
(NRW-200A) 32kg
(NT-200A) 26kg
An external signal can select channels, too.
(1)CH1 or CH2 is selectable freely.
(2)Two modes of automatic switching are available. (CH1/CH2/CH1/CH2…)(CH1/CH2/CH2/CH1…)
(✻1) Other input power source of AC115V, 200V, 220V, 230V, 240V are available as an option.
(✻2) In case of NT-2000A, These value change to 100 times/min. at 50W•s, 50 times/min. at 100W•s.
(✻3) Including protrusion.
Single-phase AC Type Welding Timer
NRW-5A,NRW-25A
■ Block Diagram
General speaking, a single-phase AC type welding machine suits
the welding to thick plate and copper stranded cable as it can adjust
weld time more wide range than an electrostatic stored energy type.
Its characteristic of low peak current gets little effect of dirt or stain
on the surface of the work-piece, accordingly it is effective welding
process when the derivation of the weld spattering and burrs, that
are produced especially in the weld schedule of preheating or up
slope welding, cause troubles. Power is demonstrated.
✻Burr: A protrusion shaping like hairspring produced during
welding. Fin.
Advantages
● Functions of preheating, up slope control, setting cooling time
pave the road to multi-use welding.
● Setting of squeeze time and hold time is available, which is
also useful in the actuation control for the weld head.
● Automatic switching function for 2 kinds of setting conditions
is provided.
● A compensation circuit for the power source voltage is built-in.
● This timer is best suited for automatic operation machines
because of its small size and multi-functions.
Specifications
Type
Input Power Source
Rated Capacity
Dimensions
Weight
Control System
Range of Heat Control
Setting Heat Control
Welding Time
Squeeze Time, Hold Time
Pre-/Main Operation
❉
Channel Selecting Operation
✽ Including protrusion.
NRW-25A
NRW-5A
■ Specifications
NRW-5A
NRW-25A
AC200V, 10%50/60Hz, 1ø(Other input power source of AC100, 110, 115, 120, 220, 230, 240V are available as an option)
3KVA(duty cycle 50%)
6KVA(duty cycle 50%)
9.5KVA (duty cycle 5%)
19KVA (duty cycle5%)
110W315D227Hmm
150W315D227Hmm
6kg
7.8kg
Synchronized, Pre-heating, Up slope control, Setting cooling time, Channel switching function
40~100%
0~99 (2 digit thumb-wheel switch)
1~99cycles (a half cycle energized at 00)
0~99 cycles
(1)Pre-heating Function
(2)Up Slope Control
✽Function that selects a channel by the external signal. (In this case, the functions of pre-heating, up slope
control and cooling time control are not available.)
(1) Both of CH1 And CH2 are selectable freely.
(2) Two modes of automatic switching are available. (CH1/CH2/CH1/CH2…)(CH1/CH2/CH2/CH1…)
8
WELDING POWER SUPPLY
Single-phase AC Type Standard Transformer
NT-5A,NT-5M,NT-8A
NT-8A
NT-5A
NT-5M(custom-made)
Outline Drawing of
Standard Transformer
■ Specifications
W=width
Example of NT-5A, 8A
Standard Transformer
Primary Input Voltage
NT-5A
200V
NT-5M(custom-made)
200V
NT-8A
200V
Rated Input Capacity
3KVA
2.8KVA
6KVA
(duty cycle: 50%)
Primary Short-circuit Current
5,000A
2,400A
11,000A
Secondary Open-circuit Voltage
1.1V, 1.8V, 3V, 5V
6V, 6.5V, 7V, 7.5V
1.8V, 3V, 5V
Dimensions
200W350D265Hmm
200W350D265Hmm
230W566D335Hmm
Weight
29kg
28kg
47kg
Step-Down Transformer
Example of NT-5M
(custom-made)
ST-100,ST-200
■ Specifications
9
ST-100
ST-200
Primary Input Voltage
115V/230V
220V/230V
Rated Power Input
1KVA
6KVA
Secondary Open-circuit Voltage
100V
200V
Dimensions
130W230D193Hmm
130W260D193Hmm
Weight
11kg
12kg
WELDING MONITOR
Welding Monitor
QC-434
Simultaneous monitoring of current /voltage
This monitor measures all sorts of welding conditions (current value, voltage value,
welding time data) simultaneously, which improves defective detection power
revolutionarily. (substantially) Also, it monitors 3 sets of welder or three welding
conditions simultaneously. Furthermore with its printing function, the monitoring
results and/or summarized data are to be print out when they are necessary.
Advantages
● Measuring welding current/electrode voltage simultaneously,
the monitor outputs display /alarm whose measured data is
out of the conditions set beforehand.
● In case of DC type welding machine, data of base time is
measured and monitored instead of welding time cycle.
● A set of monitor is able to control of monitoring up to 3 sets
of welding machines. (In case of simultaneous welding signal
inputs, welding trigger generates sequentially.)
● Easy data extraction is due to flexible print interval setting.
Printout Functions
1) Printout Items
•Measurement results (“#” at no-welding, “#”at failed measurement results)
•Summarized data of judgments (non-defective number vs. total number, a
mean value of current, a mean value of voltage)
•the contents of monitoring conditions
2) Printout Interval
•Every 1~99 times (changeable to 10~990 times by an internal switch)
Welding Monitor
QC-432
For Monitoring on Welding Quality
This unit measures all sorts of monitoring conditions
(current value, voltage value, welding time cycles) and
compare them with optimal welding conditions
preprogrammed beforehand. Those results are
announced by LED lamp or buzzer sound.
Advantages
● Display in digital about welding current
(peak value or effective value), welding
time cycle number and welding voltage
● Flexible setting range about welding
criteria to meet users’ quality requirements
● Easy connection with automatic machines
due to photocoupler-interface of output
signals (HIGH, LOW, CYCLE, NG)
ATTACHMENTS
● Pick-up contact for
welding voltage
measurement
Applicable machine types:
QC-435, 434, 432
■ Specifications & Performance
AC100V~120V
1ø50/60Hz
Electrode voltage: alligator clip
Detecting Means
Welding current: totroidal coil
Measuring object Measuring range Measurement error
(L)500~9990A
Welding current(peak)
2%
(H)5000~99900A
Measured Value
(L)300~7000A
Welding current(RMS)
(H)3600~70000A
Electrode voltage
0.10V~9.99V
1%
AC
0.5~99.5 cycles
no error
Welding time
DC
1~99.9ms
2%
Channel
7-segment LED display Red 1 digit
Measured value 7-segment LED display Red 3 digits
Over-scale indicator: “EEE” display
Welding time
7-segment LED display Red 2 digits
HIGH
LED(red)(welding current>HIGH LIMIT)
Display
GO
LED(red)(LOW LIMIT welding current HIGH LIMIT)
LOW
LED(red)(LOW LIMIT>welding current)
CYCLE N.G
LED(red)(CYCLE≠welding cycle number)
No-welding display LED(red)
NO CURRENT
Service Condition 0˚~40
Dimensions
160W240H380Dmm
Weight
7kg (QC-434 alone)
Input Power Source
The unit is usually set for AC100V~200V input at shipment
■ Specifications & Performance
Input Power Source AV100V* 10% 50/60Hz
Electrode voltage: alligator clip
Detecting Means
Welding current: totroidal coil
Measuring object Measuring range Measurement error
Electrode voltage(peak)
0.1~9.99V
Measured Value Welding current(RMS)
100~999A**
3%
1~9.99KA
Welding current (peak)
10~99.9KA
Welding cycle number
1~99 cycles
LED(red)(welding current/voltage>HIGH LIMIT)
HIGH
GO
LED(green)(LOW LIMIT welding current/voltage HIGH LIMIT)
LOW
LED(red)(LOW LIMIT>welding current/voltage)
HIGH LIMIT
Thumb-wheel switch 3 digits
Display
LOW LIMIT
Thumb-wheel switch 3 digits
LED(red)(CYCLE≠welding cycle number)
CYCLE N.G
CYCLE
Thumb-wheel switch 2 digits
Welding cycle number LCD 2 digits
Indicator for over
“OVER” display
measurement value
Service Condition 0˚~40
Dimensions
110W210H250Dmm
Weight
3.5kg (excluding toroidal coil)
*
**
***
AC input of 115V or 230V is available in modification base.
Measured by LOW-current type toroidal coil (option).
In case of a DC type welding machine, the indication of welding cycle
number is constantly one (1).
OPTIONS
● COIL7
HIGH-current type toroidal coil
1~99.9KA
Applicable machine types:
QC-435, 434, 432
● COIL4,COIL8
LOW-current type toroidal coil
100~999A
Applicable machine types:COIL4, QC432,
COIL8, QC-435, 434
10
WELD HEAD
The weld heads are categorized into 3 groups, as shown in the
figure right side of the page, according to the shape of the
object to weld. In addition to this, it is necessary to vary the
applied electrode force to the object depending on its plate
thickness. You can select an optimal machine from an abundant
lineup according to the purpose.
Series Method
Indirect Method
Direct Method
Opposed Method
Strong Points of Our Product of Weld Head
● Outstanding repeatability of electrode force
Sensing the setting value of applying pressure by using a
●Adjustment Knob
Electrode force is easily adjusted by
only standing the knob at the scale.
micro-switch
● Excellent follow-up ability
Following a slight deformation of the object during the
●Stroke
Maximum stroke of 12 mm is
available for its adjustment.
welding instantly
● Realizing to remove side-to-side rocking motion
Adopting an anti-rotation mechanism
●Leverage
A constant and stable force for the
electrode is applied by impressing
less force.
● Flexible arrangement on electrode setting
Electrodes, horns and clamps are freely located
according to the shape of the object to weld
●Actuating Switch
The welding current flows when the
applied electrode force reached to
the value set by Adjustment Knob.
●Clamp
Possible to rotate between 90˚.
●Anti-rotation
Adopting a rod and bearings strips
away side-to-side rocking motion
perfectly.
●Horn
Possible to rotate and adjust the angle
along to-and-fro direction.
●Electrode
A lot of varieties are available.
●Jumper
Flexibility is provided.
NA-60A
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11
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Various types of formations are available according to
welding material or purpose of the welding.
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Opposed Type
NA-60A,NA-43,NA-72
NA60A is a general purpose weld head whose application is widened
from various kinds of electronic parts that require reliability and
accuracy, that is, switches, relay contacts, watches, components for
camera etc. to various kinds of mechanical parts. It is also able to make
a flexible combination with a welding power supply, such as transistor
type, electrostatic stored energy type, inverter type or single-phase AC
type.
NA72 is suited to the welding of the mechanical parts or thick stranded
wires that need more strong electrode force. The pressurization system
adopts straight pressurization mechanism in which a pressurization
spring and an air-cylinder are combined in one body. Because of this, it
meets the requirement of not warped welding like projection welding.
NA-43 is used when the work-piece to weld is necessary to be held in
horizontal due to the combination of components. In addition, this head
is also used for automation machines due to the adoption of a floating
system, which rarely does not produce dislocation, and an air drive unit
(CNT-43) as standard equipment.
NA-60A
NA-43(Custom-Made)
NA-72
■ Specifications
NA-60A
Maximum allowable current
NA-43
NA-72
–
AC 5,000A at duty cycle 5%, air cooling
DC200W•s
AC 1,300A at duty cycle 3.5%, air cooling
AC 2,300A at duty cycle 3.5%, air cooling
AC 8,000A at duty cycle 5%, air cooling
Pressurization force
1~13kg
10~60kg
Electrode stroke
8mm(MAX12mm)
MAX 12mm
Space of Pocket
MAX40mm
–
MAX 110mm
Depth dimension of Pocket
98mm
–
MAX 160mm
foot-operation or air-drive system
air-drive system
Pressurization system
A foot-operation pedal and an air-drive unit are sold separately. Air-drive controller/CNT-43 is attached as standard equipment.
10~60kg
MAX
30mm
air-drive system (standard)
Prepare hose for air-circuit whose internal diameter is 9mm.
Diameter of electrode
ø6.4mm
ø6.4mm
ø10mm
Dimensions/Weight
(around)72W175D285Hmm 2.8kg
(around)248W240D319Hmm 11kg
(around)107W345D615Hmm 19kg
❋connection in pneumatic circuit = air hose joint/applicable hose = internal diameter 9mm ø
12
WELD HEAD
Straight Pressurization Type
NA-41,NA-41B,NA-60C
Straight pressurization type head has no warp in electrode and
electrode holder, which gives you high quality welding.
Advantages
● Optimum head for automation machines due to its compact
size(NA41, 41B)
● As a pressure sensor of a microswitch is attached externally,
the maintenance work becomes easy.
NA-41
NA-41B
NA-60C
■ Specifications
Head
Maximum Input Capacity
(duty cycle)
Range of Pressurization Force
Electrode Stroke
Depth Dimension of Pocket
Pressurization System
Diameter of Electrode
Dimensions / Weight
NA-41
1,100A
5%
2~14kg
MAX 15mm
70mm
driving shaft
6.4ø
58W125D255Hmm 1.4kg
NA-41B
720A
5%
2~10kg
any number
70mm
any system
3.2ø
20W110D230Hmm 0.8kg
NA-60C
1,400A
5%
5~34kg
MAX 30mm
72mm
air-drive system
8ø
85W280D470Hmm 7kg
❋connection of pneumatic circuit : air hose joint / applicable hose : internal diameter 8mmø
Extremely Low Pressurization Type
NA-90,VTA-96
This is an optimal ultra-high-precision compact weld head for
the cross wire welding of extra fine wire or welding of ultra-fine
wire to thin (thick) film or semiconductor device. A parallel type
is standard, but a parallel gap type is also available as an option.
Advantages
● A deadweight pressurization system realizes high
reproducibility on extremely low electrode force.
● Fine setting is possible due to digital setting method.
A Kit of Parallel-gap Head
NA-90
■ Specifications
NA-90
Maximum Allowable Energy
Pressurization Force
Depth Dimension of Pocket
Pressurization System
VTA-96
20Ws
0.03~1.0kg
0.06~1.0kg
40mm
224mm
foot-operation system (depending on the flexible cable)
opposed type
Resistance Welding System
parallel gap type
(option: parallel gap type)
155W180D135Hmm
150W280D130Hmm
Dimensions
(not including, Foot Block Riser Block)
(not including Post, Base-plate)
Weight
1kg
2kg
13
VTA-96
Series Type
NA-65,NA-64B
This head is recommended to use when the work-piece cannot
be held with an opposed type head, for example, in case of
welding a wire or plate onto the PCB, or the metal plate one of
whose side is insulated.
Advantages
● The independent suspension system sets the both electrodes’
height independently according to the work-piece height of
the right and left.
● The system that puts it into practice to adjust the gap
minutely (NA65) is adopted.
NA-65
■ Specifications
Maximum Weld Energy
NA-65
NA-64B
equivalent to 40Ws
equivalent to 200Ws
Pressurization Force
0.8~4kg
1~8kg/Head
Electrode Stroke
8mm(MAX 12mm)
8mm(MAX 12mm)
5~30mm
NA-64B
Gap between Electrodes
0.1~1.0mm
Depth Dimension of Pocket
120mm
90mm
Pressurization System
foot-operation system(option air-drive system:CYU-60)
foot-operation system
Dimensions/Weight
75W200D235Hmm 2kg
140W200D295Hmm 6kg
Hand Piece Type
NA-54A,NA-54LA
NA-57A,NA-58A
NA-57A
The welding machine series of an abundant handy type is
arranged to weld a difficult object to weld by a fixed type weld
head like at a jamming area.
NA-54LA
Advantages
● No side-to-side rocking motion of electrodes
● Operable with light power due to its compact
and lightweight size
NA-54A
NA-58A
■ Specifications
NA-54A
Grip Type Hand Piece
NA-54LA
Grip Type Hand Piece
NA-57A
Pencil Type Hand Piece
Maximum Allowable Energy
100Ws
100Ws
100Ws
100Ws
Pressurization Force
14kg
1~4kg
2~5kg
manual pressurization
Model
Specification
NA-58A
Forceps Type Hand Piece
Pocket Spacing
MAX 10mm
--
--
1mm
Depth Dimension of Pocket
50mm
--
--
75mm
Pressurization System
manual pressurization
manual pressurization
manual pressurization
Applicable Electrode
EL-125 series
EL-54L
specialized for NA-57A
Dimensions
30W195D47Hmm
1,500mm
30W195D47Hmm
1,500mm
36207Dmm
1,500mm
Weld Cable✻
✻We are ready to receive a custom order from you for the cable whose length is based on your requirement. (Max. 2,000mm)
manual pressurization
66.6(length)12(width)1.6(thickness)
(specialized for NA-57A)
24H16W157Dmm
1,100mm
14
HEAD OPTION
Air-Drive Unit
CYU-60
The air drive unit, CYU-60 is the unit that modifies the
weld head of the foot operation system of the NA-60
series to the air drive system easily. Furthermore, the
electrode stroke is expandable to max. 10 mm in the
case of the combination with CYU-60.
Combination example with NA-60
Advantages
● Easy to mount
● No additional work to the cover due to the
attachment of a private head cover
Speed controller (upward)
Air cylinder
Speed controller
Connector for air inlet
■ Specifications
Foot pedal
CYU-60
Input Power Source
Weld Head
& Supplied Air Pressure
AC100V 50/60Hz 0.5A
NA-60A
3kg/cm2
NA-62, NA-62D, NA-65
1.5kg/cm2
Connector for Air Inlet
quick disconnect coupling/applicable tube outer diameter: 6mmø
Cylinder Type
double-acting type(inner diameterø16 stroke 30mm)
Dimensions(✽)
143.5H44W780mm
✽excluding Muffler and Speed Controller
Others
The mounting palette is a decorated surface plate that has two
sets of mounting holes for the special-purpose stand and NA-60
Microscope
series weld head (excluding NA-60C). No more additional work
Mounting Palette
to attach the welding machine on the plate is necessary. The
microscope and the special-purpose stand are powerful tools in
case of tiny part welding. Besides, there is an option of lighting
up unit for the object to weld.
■ Specifications
Special-purpose Stand
15
Microscope
equivalent to SMZ660
Stand
Mounting Palette
RA-07-03
magnification8~50
height 434mm
550W800D20Hmm
Digital Pressurization Gauge
FG-300(body)&TJ Series(sensor)
To measure electrode force precisely with ease
This compact unit measures electrode force, one of three major
factors on welding, accurately and easily.
Advantages
● A small size/light weight and 2 way power supply
(rechargeable battery, AC100V) system allows to use the unit
anytime and anywhere.
● A hold function for measurement data is equipped with.
It is possible to hold the electrode force data at the welding
triggered by an external (synchronous) signal. Or, triggered
freely by the switch on the panel of the gauge.
•Also it is possible to hold the peak data during the welding.
● Easy adjustment is provided.
•Zeroing adjustment is done by only pressing “ZERO” switch
on the panel.
•The sensitivity adjustment at the time of exchanging 3 kinds
of sensors is performed automatically.
● A monitor function is equipped with.
•The measurement data evaluated and determined HI or LOW
to the setting range of the measured value.
● Pressurization force is indicated in Newton.
● The unit of RS-232C is equipped with as a standard interface
for an external device.
● Outline drawing classified by form type of sensor tip
Form type of sensor tip
A Type
R Type
Data in parentheses shows TJ-500R/A's
■ Outline Specifications
<SENSOR>
Model
Measuring Range
Critical Load
Sensing Error
TJ-500R/A
0~4900N(0~500kgf)
7350N(750kgf)
2%(of full scale)
Sensor
TJ-100R/A
0~980N(0~100kgf)
1470N(150kgf)
2%(of full scale)
TJ-20R/A
0~196N(0~20kgf)
294N(30kgf)
2% (offull scale)
<MAIN BODY>
Display (LCD)
Zeroing Adjustment
Hold Function
Output
Power Source
Dimensions/Weight
Composition
4 digit(0000~9999) all dimensions in N (factory default setting) / with unit conversion of Kgf
automatic regulation by auto-zero-switching
external input signal (actuating signal) / HOLD switch / peak-holding
RS-232C interface
Ni-Cd rechargeable battery (continuous duty time: 30 hours) or AC100V (with special purpose AC-adapter)
88W35H152D(mm)520g
the main body, a special purpose AC-adapter, a cable for input signal, a connector for RS-232C, an operation manual, a hard-case
16
ELECTRODE
In the case of Resistance Welding, it is the most important
thing how to concentrate heat at the junction point. So, it is
necessary, as one of means that solves it, to utilize specific
characteristics of the material to weld and the electrode
material proficiently.
Especially it becomes importance with the welding between
the different metal like the figure on the right. By using the
same shape and material electrode, the nugget inclines to
move to a lower electric conductivity material. And to shift
the point of (c) in the figure to the junction interface, it means
maintaining heat balance, is another important necessity.
Solutions are;
(1)As for lower electric conductivity material side: the use of
the water cooling for electrodes, the use of large diameter
electrodes, the use of high electric conductive material of
the electrode
(2)As for higher electric conductivity material side: the use of
small diameter electrodes, the use of low electric
conductive material of the electrode
Materials for Electrode
The list below shows rough standards to choose materials for an electrode, though it may be changed according to its surface treatment or dimensions.
Electrode Number
Alloy Components
Electric Conductivity
(IACS%)
Applicable Metal
02(equivalent to RWMA-2)
Cu-Cr-Zr
around 80%
iron, nickel, chrome and their alloys
03(equivalent to RWMA-3)
Cu-Ni-Be
around 50%
phosphor bronze, brass
00
pure Mo
around 39%
Dumet wire, tinned copper wire, solder plating copper wire
11(equivalent to RWMA-11)
Cu(30%)-W(70%)
around 46%
noble metal
13(equivalent to RWMA-13)
pure W
around 33%
copper
RWMA stands for Resistance Welder Manufacturer’s Association.
IACS stands for International Anneald Copper Standard.
● Copper Alloy
As for the alloy of this group the sufficient welding
strength is obtained, by finding a correct welding
condition, although it has been said that to weld it is
difficult in general.
If the electrode of No. 00, No. 11 or No. 13 is used for
pure copper, or No. 2 or No. 3 for the copper alloy of
phosphorus bronze/brass etc., the fine welding result is
obtained.
● Nickel Alloy, Cobalt Alloy, Chrome Alloy
For the low electric conductivity/low thermal conduction
materials, the welding result becomes fine by setting high
electrode voltage, making the welding energy to low and
using No. 2 electrode.
● Iron Alloy
The weldability is good except for cast iron and iron high
in carbon content. In general, the fine welding result is
obtained if No.2 electrode is used with high electrode
voltage and low welding energy settings.
17
● Noble Metal and its Alloy
Though it is difficult to explain the welding results
sweepingly due to many kinds of alloy materials, it is
generally recommended to use No.11 or No. 13 electrode
and to set low electrode voltage and high welding energy
in order to obtain good result.
However, the silver is one of the most difficult materials
to weld.
● Aluminum Alloy
If the work-piece is very thin, the weldability is very good.
The fine welding result is obtained by setting low
electrode voltage, making the welding energy to high and
using No. 2 electrode that has high electric conductivity.
How to read Electrode Number(example) : EH
–
Shape
250
– 02
Diameter or Material
Dimension of head
The Shape of Various kinds of Electrodes
Each electrode is described in the order of shape, dimension and material.
Applicable Weld Head
Electrode Number
Shape
Applicable Weld Head
NA-60A
EL-125 Series
NA-54A
EL-54L Series
NA-54LA
(Material: only 02)
EH-125-03
EH-125-00
EH-250 Series
NA-60A
EH-125-11
EH-125-13
EL-125-02
EL-125-03
EL-125-00
NA-90
Parallel Gap Type
EH-250-00
EH-250-11
EO-250-02
EO-250 Series
NA-60A
EL-125-11
EL-125-13
EO-250-03
EO-250-00
EO-250-11
EO-250-13
EH-062
EL-54L
EP-507-02
NA-90
EH-062-02
Opposed Type
(Material: only 02)
EH-60C
EP-507-00
EP-711F Series
Printed Wiring Board
Repair Welding Unit
EH-250-03
EH-250-13
NA-60C Tip
EP-507 Series
Shape
EH-250-02
EH-125-02
EL-125 Series
Electrode Number
Tip for NA-72
EHF-02
NA-72
EHF-00
EP-711-02F
EP-711-00F
HPC-596,ELP-696
Ribbon material 0.1 mm
EP-406-02F
EP-406-00F
in width
Cooling Holder for
Electrode
NA-72 Head
EHC-F
Applicable electrode is
EH-F-02 or EH-F-00
Note:The diameter of the coolimg
holder for EHM-72 is ø6.0.
EP-711 Series
NA-65 Head
Ribbon material 0.1 mm
in width
EP-711-02
EP-711-00
Cooling Holder for
Electrode
NA-60A Head
EHC-250M4
EP-406-02
Applicable electrode is
WT-M25M4-00
or WT-M25M4-02
18
ELECTRODE
■Weldability and Selection Criteria for Weld Materials
W
Ni
Ni SUS Cr
•
•
Mo alloy
Fe Tin Fe PB Ni--Ag Cu-Ni Bs
•
(Zn)
(C.R)
A
Ti(C.P)
Al
Al-alloy
Cu
Bs(R)
Bs(Y)
Cu-Ni
Ni-Ag
PB
Fe(C.R)
Tin
Fe(Zn)
Cr
SUS
Ni
Ni-alloy
W•Mo
Al
23
23 1
E 2 H 2 H 2 D 2 D 2 E 2 D 2
D 2 E 2 H V C 2 C 2
2 32 10 2 342 2 3 8 2 3 49 2 3 49 2 3 4 2 5 2
2 5 2 2 2 2 2 1 2 1
D 2 E 2 E V D 2
E 2 H 2 H 2 D 2 D 2 E 2 D 2
3
V 210 2 3 42 2 3 8 2 3 49 2 3 49 2 3 4 2 5 2
2 6 2 2 2 2 2 1
E 2 E 2 H 2 H 2 H 2 D 2 D 2 D 2 D 2 D 2 E 2 E V
V 3610 V 342 V 3 4 V 349 V 349 V 3 4 V 5 6 V 6 V 6 V 6 V 6 V 2
D 2 D 2 E 2 H 2 H 2 H 22 H 2 D 2 D 2 D 2 E 2 E 2
2 56
2
V 6 V 6 10 V
V 6 V 6 2 34 V 6 V 6 V
V
2
E
E
C
C
C
C
E
H
E
2
2
2
D
2
2
2
2
2
2
D 2
2
V
4 6 4 6 4 34 4 1 4 1 4 1 21
V 6 2 6 10 4
C 2 C 4 E 2 E 2 E 2 E 22 E 2 C 2 C 2 C 2
2
2 22 822 2 2 22 3 2 3 2
2
21
C 2 C 4 E 21 E 2 E 2 E 1 2 E 2 C 2 B 2
Weldability Electrode
2 2 2 82 2 22 2 2 3 2 1 2 1
2
2
D 2 D 2 E 22 E 2 E 2 E 22 D 2 B 2
Special
Electrode Mention
2 8 2
2
23 21
2
2 10 2
Items
D 2 D 2 D 2 B 2 B 2 C 2 B 22 A 2
3
3
6
1
3
8
2
2
2 10 3
2
2
2
2
E 2 D 2 D 2 C 2 2 C 2 C 2 D 22
29 239 29 2
Special Mention Items
28 269 269
1 . Having enough welding strength.
E 2 D 2 D 2 C 2 C 2 C 2 C 2
2 9
2 . Possible to weld under a special condition.
23 2 9 2
2 8 2 6 2 6
2
3 . Not enough welding strength.
2
D 2 D 2 D 2 D 2B 2
4 . Generating a stick instead of a nugget.
8
8
8
8
8
2
2
2
2
2
5 . Welding conditions should be adjusted
Weldability
D 2 D 2 C 3 A 22
precisely.
2
2 1
6 . Clean electrode generates no stick.
A- Excellent
25 2 2
2 10 2
Electrode
7 . Scrubbing before welding.
B- extremely
D 2 C 2 B 2
8 . Flat electrode to prevent deforming.
good
2-RWMA No.2
5
1
1
10
2 22
2
9 . Coating has a chance to melt or burn.
C- very good
3-RWMA No.3
D 2 B 2
10. Pay attention on polarity.
D- good
4-RWMA No.11
E- poor
5-Moly or No.13
2 510 2 2 1
Note:The criteria of weldability of (A) is based on
H- failed
6-RWMA No.11
D 2
the weldability of stainless steel.
K- rejected
orNo.13
2
2 5
E 2
2 52
E 2
2 2
H 2 E 2
V 3 V
: Aluminum
Al•alloy : Aluminum alloy
: Brass (zinc 25.4%)
Bs(R)
: Brass (zinc 5.25%)
Bs(Y)
Ni
:Nickel
Ni alloy : Nickel alloy
Ni-Ag : Nickel silver
PB
: Phosphor bronze
Cr
: Chrome plating
SUS
: Stainless steel
Cu
: Copper
Ti(C.P)
: Titanium
Tin
: Tinning plate
: Tungsten, Molybdenum
Cu-Ni : Cupro Nickel
Fe(C.R) : Cold finished steel
Fe(Zn) : Galvanized steel plate
19
Bs Cu Al Al Ti
•
•
•
(Y) (R)
(C.P)
alloy
W, Mo
APPLICATION EQUIPMENT
Nippon Avionics manufactures the equipment applying the junction unit provided with high quality and high reliability.
To protect internal chips and wiring of semiconductors or quartz device, hermetic sealing in N2 gas atmosphere with
high quality and high reliability is necessary process, whose technique is an application of the resistance welding. For
example, a seam welding equipment is based on micro-parallel seam welding process, and a can sealing equipment is
based on opposed welding process. In addition, ELP-696 is the best machine to repair printed wiring on PCB’s.
Seam Welding Equipment
The inline type automatic seam welding equipment
is the automatic device that seals in high speed
small sized rectangular packages like a quartz
oscillator or a SAW filter used in phones, cellular
phones, pagers etc. It has been showing high
reliability and productivity. A specialized tack
welder and a manual welder are at a line-up of this
series.
Inline Type Automatic Seam Welding Equipment
Can Sealing Equipment
The can sealing equipment is the welding machine that seals metal
packages (cap and stem) used mainly in transistors, quartz oscillators
etc. The welding machine sandwiches the package between opposed
electrodes, arranged up and down, then welds it. In this series, there
are a semi-automatic device and a manual device etc.
Manual Can Sealing Equipment
Minute Lead Wire Welding Equipment ELP-696
This is the device that welds a minute lead wire to the substrate by the
parallel gap welding process. It adopts the deadweight method for
pressurization mechanism, transistor control system for power supply,
and now is ready for fine patters caused by high-density packaging.
20
We have prepared various kind of welding machines in the welding laboratory in Yokohama
Workshop of Avio with some expert engineers to give advice to our customers who have
problems about welding or questions how to select optimal machines for their processes.
Please contact us, or our sales offices shown below, if you need to consult on any welding
matter with us....
YOKOHAMA WORKSHOP: 28-2 Hongoh 2-chome Seya-ku Yokohama
!
CAUTION
To operate this unit correctly, read the operation manual
carefully. The unit should be situated away from the place
filled with water, moisture, steam, dust or soot, which.
may cause a fire, an electric shock, troubles etc.
❉ Customer-made products are out of ISO9000 standards
❉ The appearance and specifications are subject to change without notice.
URL http://www.avio.co.jp/ Our products are introduced in our home page
Second Marketing Department (Head Office)
Second Sales Division (taking charge of electronic equipment)
20-1, Nishi-shimbashi 3-chome, Minato-ku,Tokyo 105-0003
Telephone: 81-3-5401-7379
Osaka Branch
1-11-16, Nishi-nakajima 1-chome, Yodogawa-ku, Osaka 532-0011
Telephone: 81-66-304-7361
Nagoya Branch 7-9, Nishiki 3-chome, Naka-ku, Nagoya 460-0003
Telephone: 81-52-951-2926
Fukuoka Office 8-36, Hakataeki-chuogai, Hakata-ku, Fukuoka 812-0012
Telephone: 81-92-411-7371
The contents of this catalog are based on the information as of Dec. 2000. ●To safeguard the environment, this catalog is made of recycled paper.
CAT.NO.410-067-E 0012-15-CO