BEAHM DESIGNS Bonder 220B User manual

Equipment User Manual
1502 Gladding Ct. Milpitas, Ca. 95035.
408-395-5360
www.beahmdesigns.com
1 | P a g e
Split Die Thermal Bonder User Manual
(Model 220-B)
(Beahm Bonder 220B)

Equipment User Manual
1502 Gladding Ct. Milpitas, Ca. 95035.
408-395-5360
www.beahmdesigns.com
2 | P a g e
TABLE OF CONTENTS
1.0 List of Components
2.0 General Description
2.1 System Data Sheet
3.0 Controls
3.1 Front Panel Controls
3.2 Rear Panel Controls
3.3 Installation
4.0 Parameter Setting
4.1 Pressure Regulator Setting
4.2 Cooling Air Flow Setting
4.3 Temperature Controller Setting
4.4 Process Timer Setting
4.5 Temperature Controller Layout
4.6 Auto-Tuning Instructions
5.0 System Operation
5.1 Facilities Requirements
5.2 Safety Precaution
5.3 System Controls
5.4 Die Head Sizing
5.5 Die Head Replacement
6.0 Maintenance
6.2 Calibration
6.3 Replacement Parts List:
6.4 Tool Change
7.0 Warranty Information
8.0 List of Drawings
8.1 1700-14 Front Panel Controls
8.2 1700-09 Blank Die Head
8.3 Document 10125-20 Process Instructions –Die Head Sizing.
8.4 System Schematic

Equipment User Manual
1502 Gladding Ct. Milpitas, Ca. 95035.
408-395-5360
www.beahmdesigns.com
3 | P a g e
9.0 Component Data Sheets
9.1 Eurotherm 2232 Temperature Controller
9.2 Split Die Thermal Bonder
1.0 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
Blank Die Heads p/n SD220C
2.0 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
3.0 Controls
3.1 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

Equipment User Manual
1502 Gladding Ct. Milpitas, Ca. 95035.
408-395-5360
www.beahmdesigns.com
4 | P a g e
Timer Reset Button
Process Duration Timer
3.2 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.
3.3 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.
4.0 Parameter Setting
4.1 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.
4.2 Cooling Air Flow Adjust
Rotate the flow meter valve counter clockwise to increase cooling airflow, clockwise to
decrease airflow.
4.3 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.

Equipment User Manual
1502 Gladding Ct. Milpitas, Ca. 95035.
408-395-5360
www.beahmdesigns.com
5 | P a g e
4.4 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.
4.5 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.
4.6 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.
5.0 System Operation
5.1 Facilities Requirements
110/120 v, 50/60 hz
2-3 amps (220 watts)
100-125 psi, clean dry compressed air

Equipment User Manual
1502 Gladding Ct. Milpitas, Ca. 95035.
408-395-5360
www.beahmdesigns.com
6 | P a g e
5.2 Safety Precaution
Hot die jaws will become hot during operation and, depending on temperature set-point, can cause severe
skin burns if contact occurs.
5.3 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.
5.4 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.
5.5 Die Head Replacement
Caution: ensure that the die heads arecooled 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.

Equipment User Manual
1502 Gladding Ct. Milpitas, Ca. 95035.
408-395-5360
www.beahmdesigns.com
7 | P a g e
•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.
6.0 Maintenance
6.1 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.
6.2 Calibration
6.2.1 Calibrate the temperature controller annually.
6.2.2 Calibrate the process timers annually.
6.2.3 Calibrate the pressure gauges annually.
6.3 Replacement Parts List: (the below items are available through Beahm Designs)
Description
P/N
Delivery
Heater Cartridge
5018
1 week
Thermocouple
5071
1 week
Blank Die Heads
6066
1 week
Air Pressure Gauge
5021
1 week
Temperature
Controller
5347
1 week

Equipment User Manual
1502 Gladding Ct. Milpitas, Ca. 95035.
408-395-5360
www.beahmdesigns.com
8 | P a g e
6.4 Die Head Replacement
6.4.1 Loosen the thermocouple set screw in each die head and slide the thermocouple out of
each head.
6.4.2 Remove the fasteners at the base of each die head and remove the die heads.
6.4.3 Position the replacement die heads on the die bases with the thermocouple mounting
holes facing away from each other.
6.4.4 Re-install the fasteners at the base of each die head, DO NOT tighten the fasteners.
6.4.5 Manually close the die heads and ensure that they are aligned left-to-right and, while
holding the heads together, tighten the base fasteners.
6.4.6 Fully insert each thermocouple into each die head and lightly tighten each set screw.
7.0 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.
8.0 List of Drawings

Equipment User Manual
1502 Gladding Ct. Milpitas, Ca. 95035.
408-395-5360
www.beahmdesigns.com
9 | P a g e
8.1 1700-14 Front Panel Controls

Equipment User Manual
1502 Gladding Ct. Milpitas, Ca. 95035.
408-395-5360
www.beahmdesigns.com
10 | P a g e
8.2 6066 Blank Die Head

Equipment User Manual
1502 Gladding Ct. Milpitas, Ca. 95035.
408-395-5360
www.beahmdesigns.com
11 | P a g e
8.3 Document 10125-20

Equipment User Manual
1502 Gladding Ct. Milpitas, Ca. 95035.
408-395-5360
www.beahmdesigns.com
12 | P a g e
8.4 3018 System Schematic

Equipment User Manual
1502 Gladding Ct. Milpitas, Ca. 95035.
408-395-5360
www.beahmdesigns.com
13 | P a g e
9.0 List of Component Data Sheets
9.1 Eurotherm 2132 Temperature Controller
9.2 Split Die Thermal Bonder