model mf40 band saw welder
Contents
1. NN NN NNN NNNNNNNNNN 25375 25377 25378 25379 25380 25381 25382 25383 25384 25385 25386 25388 25389 25390 25391 25392 25393 57910 57810 58589 57600 58085 58091 58559 58543 58544 58495 58497 58494 58143 58142 58132 25237 57123 57695 57840 25116 58080 57572 50102 59554 50100 31920 G 58133 222. Dimensions and Weight tandard Features Width 1 0 in max 25 in min Thickness 060 in max 020 in min Steel Flat Stock Bandsaw Blade Stock 230 VAC 39 amps 10 duty cycles 50 60 Hz 12 amps 100 duty cycle 460 VAC 20 amps 10 duty cycle 50 60 HZ 6 amps 100 duty cycle ct Fusing amperage requirement Choose next larger size of slow blow fuse 4 KVA 50 duty cycle Continuous Spring type Offset Cam Type 15 1 2 45 1 2 12 3 4 42 3 4 DQM TT 28 224 2651bs 3781bs Overall Height Bench Truck Die Height Bench Truck Floor Space Bench Truck Weight Bench Truck ual shaft headpiece with linear ball bearings ptions nneal timer E Operation O C Motor Grinder A S Designed with low maintenance and ease of operator adjustments in mind D B Built in solid state SCR weld control hoice of 575v 460v 415 380v 230v or 208v operation 2 0 GENERAL OPERATING INSTRUCTIONS 2 1 ELECTRICAL HOOK UP INSTRUCTIONS First determine that available electrical service in your plant corresponds to the nameplate rating located on welder housing Electrical wiring to welder must be of sufficient size to deliver full ampere load with no appreciable loss during the weld cycle The welder will not operate properly if there is more than a 10 variation in the line voltage Consult the welder specific
3. patterns on the carbon paper for one of the throughout pattern area Flash material imbedded in die Hand lap dies and take a new carbon paper No pressur Jorn dies Hand lap or replace pattern pattern Heavy pressure line from weld area Dirt under top die dge near weld area dies and take new on heel or edge away Jorn or improperly dimensioned bottom die Remove and towards weld area Dirt under top die clean die Add shims under bottom edge held across the top die is even Heavy pressure pattern die until a straight on top or edge Top die worn from laping Replace top dies or bottom dies until a the two dies bears Remove and clean die remove shims from straight edge across venly on the top die TROUBLE SHOOTING WELDERS A CAUS REMEDY Weld action normal but weld burr doesn t extend beyond blade Molten metal is blown out and ends not jointed Weld has complete burr but is dry and breaks off below surface of blade Welds good but poorly aligned End of blade buckles and may not weld Varying weld results Lack of spacing Weld heat too high Stock is too small Low upset pressure Upset pressure too great High carbon steel blade Welding dies amp shoes Starting space Loose head shafts Upset pressure too great Low weld heat Stock slipping Varying weld voltages Blade condition variation ncreas
4. Base Housing Cylinder Pin Insulator Transformer Strap Spring Insulator Cylinder Insulator Stationary Head Movable Head Stationary End Head Head Base Plate Limit Switch Bracket Spring Adjustment Screw Die Plate Shaft Upset Spring Flash Shield Upset Cam and Handle Shoulder Bolt Stop Insulator Assembly Bearing Sleeve Guide Plates Upset Pin Grinder Option Parts Grinding Wheel Collar Spacer Grinder Motor 230 460V Grinder Bracket Fuse Holder Grinder Shield C E Option Parts C E Fuse Holder 2 Capacitor Clamp SECTION 13 5 ELECTRICAL PARTS LIST Weld Transformer MF40 T1 208V 60Hz 208V 50Hz 230V 60Hz 59555 50101 25372 25373 25374 21 Primary Coil Push but Limit switch LS1 Terminal block Control transformer Fuse F Fuse Holder ure switch Relay CR1 3 Relay Socket Temperat SCR SCR1 2 Fuse FU 3 Control PTR 1000 Potentiometer R5 U 1 Capacitor C1 Resistor 100 ohm Resistor 250 500 ohm Heat sink Timer TR2 Timer Socket GRINDER OPTION Switch Grinder S1 M1 Fuse FU 2 Contactor CR2 C E OPTION Capacitor C4 C C m Di m an Fuse FU 1 Fuse FU 2 ton PB1 2 T2 TS1 R6 R1 R2 R3 R4
5. G Numbers with circles wire numbers numbers with squares terminal numbers Note H When anneal timer is NOT used bypass TR2 by connecting 23B amp 24 together NOT 23A Note I Remove strap D12 on PTR 1000 Board for 50Hz service 11 0 SAFETY REMINDERS 18 The following accident Stryco electric resist tance welding equipment t prevention information is presented to eliminate potential hazards while operating inspecting or repairing Important safety compliance information for Stryco Welders GENERAL An operator must be instructed on basic operation and malfunction methods equipment Safety eyeglasses must be worn by all personnel servicing welders Use safety eq welders Determine that power supply located on Ad Fe Wel welder housi Check nameplate ratings a material categories stated both operating voltages and hertz correspond ng by qualified personnel uipment properly and keep safety equipme to rating listed on welder therein prior opera to using ting or nt o cycles name nd keep within capacities and ustments or repairs must be made by persons thoroughly amiliar with operating principles of welder der must be disconnected from power supply prior to maintenance or repair procedures n of plate Report any damage or pote
6. is a problem caused by poor die sets and a major cause of weld breaks 12 7 5 CARE AND MAINTENANCE OF JAWS Welding dies or jaws must be kept in good condition Normal wear and imbedding of flash material will cause weak welds For maximum weld strength two conditions clean dies and proper die pressur must be maintained 7 5 1 CLEAN DIES on the die faces or flash guards circuiting of the welding current a further instructions see page When wear or imbedding becomes failure the dies may be reconditio with valve gri glass or other lapped elkonit Care of It is extremely important to allow NO flash material to build up Flash build up will cause short nd result in weld failure For Die Sets section 7 4 1 on this vident by inspection of weld ned by hand lapping their faces nding compound or 400 wet or dry sand paper on a plate ground surface using a circular motion Ihen properly te faces will have a uniform matte or dull finish Dies should never be belt sanded or filed However when a surface grinder is available discarded 8 0 SUGGESTED WELD SETTINGS they will stand re surfacing several times before being BLADE BLADE WELD VIDTH THICKNESS HEAT INCHES INCHES PERCENT 1 8 020 50 028 50 032 50
7. 1 4 028 65 032 65 035 65 042 65 1 2 028 70 032 70 035 70 042 70 3 4 A035 80 042 80 13 050 80 1 0 035 90 042 90 050 90 8 1 TROUBLE SHOOTING OF POOR WELD QUALITY 8 1 1 PROPER DIE PRESSURE To produce consistent welds the clamping force must be applied evenly to the contact area Uneven pressure may be caused by dirty or worn dies improper tooth relief improper shimming or mechanical failure of the pressure applying mechanism These conditions are easily detected by the following carbon paper pressure test 8 1 2 CARBON PAPER PRESSURE TEST Fold a 4 x 8 piece of clean white paper once lengthwise Fold a 4 x 8 piece of carbon paper once lengthwise with the carbon outside Insert a 12 length of blade being clamped into carbon paper with teeth to the fold See Fig 7 Carbon Paper White Paper FIG 7 Place the blade into its normal clamping position and close both right and left clamps Be certain that pressure is applied evenly especially at the edge closest to the weld area Examine the pressur following appearances Pattern CAUSE REMEDY Appearance Pattern CAUSE REMEDY Appearance Pattern Appearance CAUSI GI REMEDY Pattern Appearance CAUSI GI REMEDY 9 0 DIAGNOSTIC CHART FOR WELD NG ACTION Heavy dots pressure pattern
8. STRYCO PRODUCTS COMPANY MANUFACTURERS OF PRECISION WELDING MACHINES MODEL MF40 BAND SAW WELDER SERVICE MANUAL STRYCO OPERATING MANUAL INTRODUCTION rocess In this process the tryco s MF series band saw welders use the flash butt welding ends are butted together or a small gap allowed between th e material When the o low and is changed in perage to low voltage roug ircuit J Ww 5 3 Freehand nm t is complete n th nds perat the high ti h the secondary of the transformer and nds e small gap betw uts off al he curreni taking place the blades nces too rapidly arc to jump across Af welding an at no charge required arc across the ends of the material t the moment of upset This a transformer from high voli nough to permit an arc to form across ng switch is closed current begins to tage low As current begins to flow through the blade the amperage of the blade causes the current to jump On the very small blades the On the wider heavier remains on for a short period of time while the rcing or flashing process heats up the Arcing causes the bl away the carriage is advanced by control g the same gap so the arc will the gap will If the carriage advances too slow and the arcing will ter reading th
9. ations for fusing and cable hook up sizing Refer to National Electrical Code and local electrical regulations for adequate power sizes disconnect methods and fusing guidelines Remember line voltages to the welding machine are potentially dangerous should the power cords be damaged or severed The welding voltages at the welding dies will not harm an operator since they do not exceed 10 volts 2 1 1 MACHINE HOOK UP INSTRUCTIONS To connect the electrical cables to the welder first remove the right hand access panel see FIG 1 Locate the access port in the rear bottom left hand corner of the housing Then feed the cables through the access port and connect the power cables to L1 and L2 Next connect the safety ground cable to the ground stud Make sure all INPUT TERMINALS ACCESS PORT GROUND STUD RIGHT END PANEL connections are securely fastened and then re attach the right hand access panel 2 2 SAFETY PRECAUTIONS See section 11 0 2 2 1 ELECTRICAL Maintain electrical cable to welder in good repair Welder must be grounded and connections securely tightened Heat switch must not be changed to new position while a weld cycle is in process DISCONNECT ELECTRICAL SERVICE BEFORE SERVICING WELDER high voltages are located within the base of the welder 2 2 2 MECHANICAL An operator must wear safety glasses while using the welder Keep all safety guards on wel
10. ders and use properly Operators must be instructed on basic operation of the unit to prevent injury Check the nameplate rating and keep within material size range for each welder 2 3 WELDING DIES The dies and shoes supplied with the welder will handle most size and material types within the range of the welder For new applications consult the factory for special die and shoe sets 3 0 BASIC OPERATING PARTS 3 1 WELDING HEAT Welding heat is obtained by means of a weld heat selection switch located on the welder housing Accompanying charts will assist in settings for various sizes 3 2 SPACING MECHANISM Operating Lever The welder is capable of welding a variety of blade sizes Spacing is obtained by moving the spacing lever up to engage the first or weld position The spacing lever is located on right hand side of the headpiece and determines the welding starting space Accompanying charts will assist in settings for various sizes 3 3 UPSET PRESSURE Upset pressure adjustments are determined by the size of the material being welded Turning the Upset Force Adjustment bolt clockwise will increase the force while turning it counterclockwise will decrease the force 3 4 WELDING DIES AND DIE SHOES Welding dies serve thr purposes 1 to carry current for welding 2 to align the two ends of stock 3 and prevent material slippage during a weld cycle Welding di
11. e operating manual d annealing a particular blade arrange for you to send samples of your blade stock and give you the specific recomm lade material to burn away as Lled spring pressure not quench If the carriage closed and arcing will cease the gap will be too wide for the stop be LY till have trouble t STRYCO We can to us for welding nded settings should you st contact TABLE OF CONTENTS Pg 1 sO SPBEGTEPTEATLONSE ENGEN ee tl a eae 3 2 0 GENERAL OPERATING INSTRUCTIONS 4 340 BASIC OPERATING PART Ss gedane en wont a i 5 4 0 BASIC OPERATING PARTS LOCATION 6 5 0 TYPICAL OPERATING SEQUENCE aoc eieaa ae aa Ea 7 630 SPECIAL ADJUSTMENTS sao Sa a ae 9 7 0 PREVENTIVE MAINTENANCE 2 22 e eee eee eee ll 82 0 SUGGESTED SETTINGS 2 22 tae Sean een 9 0 DIAGNOSTIC CHART FOR TROUBLE SHOOTING 15 10 207 ELECTRICAL SCHEMATIC 2 2 eae erlernen di 11 202 SABETY REMDNDEIRS seo 42 usa 2 hd le by pate ae bed Yet Wye LB T2407 BUYERS GUEDE rroaren konein ea 13 0 BARTS ELISE 4 0203 oteveherey ee een 20 1 0 SPECIFICATIONS MODEL MF40 Stock Range Material Line Current Single Phase Transformer Heat Selection Upset Pressure Method Clamp Pressure
12. e shoes hold the stock firmly within dies during fusion 3 5 CLAMP HANDLES The clamp handles apply force between the upper shoe and the lower die gripping the stock securely The larger the stock clamped the greater the clamp force applied to that stock CAUTION Clamping stock thicker than the recommended maximum size may cause clamp spring failure See welder specifications for stock sizes 4 0 BASIC OPERATING PARTS LOCATION Operating Lever i Spacing Lever Upset Force Adjustment Weld Operating Button Weld Heat Selector Switch Option Anneal Heat F Selector Switch Grinder Switch Anneal Operating Button FIG 2 5 0 TYPICAL OPERATING SEQUENCE Hr Adjust weld heat selection switch to proper setting 2 Adjust flash speed dial If needed 3 Move spacing lever up to open the welding dies to the weld position 4 Place stock into welding dies so the blade ends meet midway between each welding die Hold the blades against the guides Rotate the clamping levers upwards to secure the blades Press weld button located on right side of the welder Release spacing lever by pulling it down After the weld is completed unclamp the stock leaving the weld upset burr intact 8 Hard drawn stock or high carbon blades require an anneal No 0 operation 9 Trim off the weld burr so the weld area is equal to parent material Incomplete burr removal or under cutting w
13. e starting space until desired burr is obtained Lower heat settings Check size rating of welder Adjust upset pressure Lower upset pressure Carbon steel blade often appears like this Process blade by annealing weld before removing burr Replace worn dies and shoes Decrease starting space Return heads to factory Decrease upset pressure Increase weld heat Increase clamp pressure Check electric lines Clean and tighten transformer connections to heads Clean blade where clamped in 15 Dies and die shoes Flashings 9 1 ELECTRICAL TROUBLE SHOOTING OF WELDER WARNING Dangerous voltages ar with electrical dies Replace dies and shoes Clean off build up of flash materials Extreme care should b present 9 1 1 TROUBLE SHOOTING TABLE See section 9 1 2 This electrical trouble shooting method of the table different poin of the welder trouble shooting t table should be performed in The electrical schematic test points but closely related ts During all tests the he welder tion xercised when making in the welder safety precautions should perform these table is f The order give sec The Ti table n wiring by usi ne voltage sho 10 furnished for these nay be used for welders wit urnished as a s these tests Only persons familiar tests uggested individual steps of the n to
14. he cylinder clockwise to increase the trip point distance or turn counterclockwise to decrease the trip point distance See FIG 5 7 0 PREVENTIVE MAINTENANCE 7 1 AS REQUIRED Brush loose flashings from dies clamp shoe and headpieces to prevent excessive build up A soft wire brush may be used to brighten die surfaces Check condition of welding dies and die shoes and replace when worn 1 Welding dies and die shoes in poor condition are primary causes of bad welds Check dies for excessive wear and replace as necessary 3 Clean die bottoms to remove oxides with emery cloth placed on a flat surface Clean die seats with emery cloth to brighten contact areas 5 Completely tighten dies into seats to assure a good contact Replace shoe inserts if they are worn and will not hold stock during a weld cycle N od N 11 7 2 QUARTERLY WN EF Repeat previously noted items Check anneal parts and replace all worn or broken assemblies General lubrication on all oilers and other moving parts 7 3 ANNUALLY Repeat previously noted items Check contacts on magnetic contactors replace if badly worn or Clean transformer secondary connection from transformer to Clean heat selection switch contacts Check limit switch and operating switches replace as Ez 2 poorly aligned 3 movable headpiece Dn required Ox Readjust limit
15. ill cause subsequent blade breaks 5 1 PREPARING BLADES FOR WELDING The blade to be joined must be free of rust corrosion or other insulating materials Clean the blade where it contacts the welding dies Refer to section 8 0 for approximate settings When welding saw blades it is sometimes necessary to match the teeth When attempting to match the teeth we recommend that you compensate for the distance traveled during the weld sequence Blade material will burn off during the flashing upset process On some saw blades the set may interfere with the electrical contact across the full width of the blades or it may damage the welding jaws especially on heavier saw blades To avoid this problem it may be necessary to bevel the top and bottom jaws Fig 3 Beveling may be accomplished by grinding the jaws shown Fig 3 4 Blade Stop Top Die Inserts Bottom Dies Inserts FIG 3 FIG 4 5 2 TYPICAL ANNEAL OPERATION 1 Set the anneal timer Option 2 Move spacing lever completely up to open the welding jaws to the anneal position 3 Re clamp welded stock into the welding dies with the upset burr centered midway between dies 4 Press the anneal button with a jogging welded area to the desired temperature 5 3 ADDITIONAL ANNEALING NOTES 1 Steel blades will start to turn a dull 2 Steel blades will start to breakout in flakes at about 1375 degrees F action t
16. itches for 50 read from L2 to 21 should be ge value the SCR control module or weld ss the operating handle down and and anneal button instead of is test should determine if the switches are working properly f tests A thru H above are correc switches for 99 percent Press read across the dies should be 4 J If step I is not correct the weld then set the anneal the anneal button The voltage to 7 VAC transformer may be defective or have poor wiring con 10 0 ELECTRICAL SCHEMATIC nections 17 GRINDER L _ ER2 _ MOTOR N p PE m y2 Bey T1 WELD TRANSFORMER up Baie fa Scien 1 l PEI wen OB aE AULD UI LA w a amp P ef FU 3 5 CRI gt GRINDER AR 12 al _ ae m T i GRINDER CONTACTOR R1 p Fer jP Orc N YEL 7 lala al a ei a7 p BLACK AO EEE Me ORANG eoa Te RED PIR 1000 Zn v GROUND TO HESTSINK fs Note A Unless otherwise specified All 115V control wires are to be 16 AWG red Note B Unless otherwise specified All 115V return wires are to be 16 AWG white Note C Where possible use orange wire on high voltage wiring above 200V Note D Depending on line voltage used T1 amp T2 will vary 460V 230V or other voltages available Note E R2 R3 R4 500 ohms 250 ohms for 230V or less Note F C4 used on CE welder only Note
17. make the Les CS Les ng corresponding uld be connected CS valid show cn a Les Lo Il amp L2 9 1 2 Test lead Press Limit Grinding Press Problem if Connection Weld Switch Switch Anneal Meter Incorrect From To Button Actuated On Button Reading Reading x1 X2 115 VAC Bad T2 X2 LS1 17 X 115 VAC PB1 bad or FU1 X2 LS1 18 X 115 VAC LS1 contact open X2 CRI 7 115 VAC CR1 relay bad X2 CR2 Al X 115 VAC S1 bad L2 CR2 11 X Line voltage FU2 open L2 CR2 12 X Line voltage CR2 bad L2 FU3 15 Line voltage FU3 open Note Operating lever should be in the Weld position to perform tests consult section 13 for parts identification 9 1 3 LINE VOLTAGE TESTS Set Lift uw D If th the weld t the operating lever to C Press the weld the line voltage value correct reading is not button humbwheel switches for 99 percent the weld position The voltage read from L2 to 2 should be obtained the SCR or SCR control 16 module may be defective E If the above test is satisfactory s percent F Press the weld button The voltage approximately of the line volta G If step F reading is not correct thumbwheel switches are defectiv H Repeat steps A thru G above but pre use the anneal thumbwheel switches those for the weld operation Th anneal thumbwheel and push button et the weld sw
18. o heat up red at 1000 degrees F small dark circular 3 The blade should be annealed prior to removing the weld burr Some value may be gained by a second burr is removed 5 4 ANNEAL SETTINGS anneal after weld flash or BAND SAW ANNEAL ANNEAL WIDTH HEAT TIME INCHES PERCENT SECONDS 1 8 1 4 30 2 1 4 1 2 35 2 1 2 3 4 35 3 3 4 1 0 40 4 6 0 SPECIAL ADJUSTMENTS Speed Control Cylinder Limit Switch Closed Space Adjust Plunger Stop Ring Adjustment Screw Plunger Plunger Housing Limit Switch FIG 5 FIG 6 6 1 LIMIT SWITCH ADJUSTMENTS WARNING REMOVE POWER FROM THE WELDER BEFORE MAKING THESE ADJUSTMENTS 6 1 1 Lift the operating lever into the first weld position so that the welding dies are approximately 7 16 9 16 apart at the front edges 6 1 2 Limit switch cut off A With no stock in the dies slowly lower the operating lever down and listen for the limit switch activation B The spacing between the dies at this activation point should be 1 8 of an inch 6 1 3 Should activation not occur at this point adjust limit switch adjusting screw to satisfy this condition See FIG 6 Do not let the plunger stop ring bottom out against the plunger housing This may cause the switch to fail after repeated cycles 6 2 INSTALLATION AND ADJUSTMENT OF WELDER UPSET SPRING Using the operating lever cl
19. ose the welder headpiec Remove the upset force adjuster Remove the old upset spring and replace it with a new one Re install the upset force adjuster vawe 6 3 JAW SPACING A The weld open spacing is the distance the right end of the left jaw is from the left end of the right jaw when the operating lever is in the cocked or weld position 10 B To check for the weld closed spacing pull the operating lever down Once closed this spacing should be between 1 32 and 1 16 of an inch This is a factory setting and normally requires no adjustment If needed this space can be changed by use of the closed space adjuster See FIG 5 6 4 FLASHING SPEED ADJUSTMENT POWER OFF WARNING DANGEROUS VOLTAGES ARE PRESENT WITHIN THE WELDER THIS ADJUSTMENT IS TO BE MADE ONLY BY QUALIFIED ELECTRICAL MAINTENANCE PERSONNEL A Pull the operating handle down and observe the speed of the moveable headpiec BE Turn the flashing speed adjustment clockwise to slow the head movement This adjustment should be made so that the head moves it s slowest without causing any hesitation during the full cycle 6 5 SPEED MECHANISM TRIP POINT POWER OFF A Pull the operating lever down and observe the point at which the Headpiece snaps closed This trip point should be approximately 3 16 of an inch between the dies B To adjust this trip point loosen the locknut turn t
20. personnel The weld heat selection S lection switch po devices must not ntial t be c rate ged by sed for an hazards t o maintenance tentiome Cer or range weld operation is in process 12 0 BUYERS GUIDE tion ELECTRICAL Refer to National Electrical Code and local regulations for adequate electrical wiring to power welder Do not ope welder with inadequate electrical power supply cords or cable All welders must be grounded through power supply and welder ground connection terminal securely tightened All welders must be able to be disconnected from power source either by a double breaking disconnect switch or unplug standard rated plugs All welders must be fused to prevent injury should an electrical malfunction occur Welders must never be fu ampere load that exceeds the ratings stated on welder nameplate Electric power cords to welder must be kept in good condi hanged to a new position while a 19 HOW TO ORDER PARTS The following information will be needed before processing your order Company Name Purchase Order Number Machine Model Machine Serial Number Voltage Part Number s and U b w o He mH After acquiring this information 13 0 PARTS LIST Clamp Handle Guide Pin Call Micro at 1 800 872 1068 23330 23418 20 Weld Jaws Clamping Jaws Clamping Shim Shoulder Screw Ball Knob Linear Bearings
21. switch to specifications m NOTE All adjustments and maintenance services must be made only by those thoroughly familiar with operating principles of the welder 7 4 WELDING DIES AND DIE SHOES INFORMATION Welding dies Lower conducting electrode and clamp jaws Welding die shoes Upper clamping member Welding dies and die shoes in poor condition are the main causes of bad welds Care of die sets Iy Use a brass or fiber blade to remove particles of flashings that build up on die sets Excessive flash build up causes die burns on material and shorting of die sets Do not attempt to clamp material that is not suited for welder into die sets Undersize materials will slip and burn die grooves oversize materials will overstress clamping parts Do not use welding die sets for a vise These parts will not withstand the mechanical abuse Vhenever welding dies are replaced clean bottoms of dies and corresponding die sets to a bright and clean condition before bolting them tightly into place An oxidized surface will insulate the welding dies and reduc ffective welding voltage Welding die shoes must swivel freely within the clamp spring sleeve mounting to prevent shoe from binding Sand rear of shoe if necessary Welding die set will wear with use and must be changed occasionally for good welding results Keep an adequate supply of replacement parts available Blade slippage
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