model br/brg butt welders
Contents
1. Note These setting are approximate and may be varied to suit materials and best weld performance 11 9 0 DIAGNOSTIC CHART FOR TROUBLE SHOOTING WELDERS WELDING ACTION CAUSE REMEDY Weld action normal but weld burr doesn t extend beyond stock Lack of spacing ncrease starting space until desired burr is obtained Molten metal is blown out and ends not joined Weld heat too high Stock is too small Low upset pressure Lower heat settings Check size rating of welder Adjust upset Weld has complete burr but is dry and breaks off below surface of stock Upset pressure too great High carbon steel stock Lower upset pressure Carbon steel stock often appears like this process by annealing weld before removing burr Weld good but poorly aligned Welding dies amp clamps Starting space Loose shafts Replace worn dies and clamps Decrease starting space Return heads to factory Ends of stock buckle and may not weld Upset pressure too great Low weld heat Decrease starting space ncrease weld heat Varying weld results Stock slipping Varying weld voltages Stock condition variations Dies Flashings Check Clamp pressure Check electric lines Clean and tighten transformer connections to heads Clean Stock where clamped in dies Replace dies Clean build up of flash materials Porosity and voids i2. hea Ann can be attained by heati a permanent ted area ttraction corresponds to the exac E erromagnetic the exact magnet is no The exact ng the stock to longer loss of Let material t anneal air cool down and prior to any burr fracturing welded area anneal operation is useful ealing should take place immediately aft removing attempts Some users find t after removing difficult to join materials 6 SPECIAL ADJUSTMENTS LIMIT SWITCH The limit switch can be adjusted with th ter welding cycle to prevent hat an additional the burr on over removed A screw is provided for this 6 2 ALIGNMENT Adjustment B is for correcting alignment Turning to right raises and A very slight movement of this screw to left lowers of welds is suf left jaw ficient AN OPERATOR SHOULD WEAR SAFETY GLASSES WHEN USING THIS UNIT PREVENTIVE MAINTENANCE TECHNIQUE Keep in Mind that these welders are precision built to last many years but will require good maintenance procedures They are designed to be as automatic as possible with a minimum dependence on the ability of the operator Adjustments must be made by those thoroughly familiar with the operating principles of the welders WELDING DIE NOTES 1 Welding dies and die shoes in poor condition are th
3. Sensitive Heavy duty construction amp components to operate controls Low maintenance costs to set welding parameters straight slide movable headpiece assembly Adjustable limit switch Changeable welding dies and clamp shoes Adjustable tension Manual hand clamps Low voltage control circuits Power cord 2 0 GENERAL OPERATING INSTRUCIONS 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 weld cycle The welder will not operate properly if there is more than a 10 variation in the line voltage In general the welder should be fused with a slow blow fuse of the 100 duty cycle rating The minimum power cable size to the welder can be obtained by using this same current rating Refer to National Electrical Code and local electrical regulations for adequate power sizes and fusing guideli Remember line voltages potentially dangerous s severed harm an operator since nes The welding voltages at the welding dies will they do not exceed 10 volts to the welding machine are hould the power cords be damaged or disconnect methods not 2 2 SAFETY PRECAUTIONS See section 11 0 2 2 1 ELECTRICA
4. L 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 befor serving welder high voltages are located within the base of the welder 2 2 2 MECHANICAL Operator while using welder must wear safety glasses Keep all safety guards on welders and use properly Operators must be instructed on basic operation of unit to prevent injury Check 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 weld applications consult the factory for special die and shoe sets 3 0 BASIC OPERATING PARTS 3 1 ALIGNMENT SCREW An access hole is proved in the left panel for this adjustment 3 2 LIMIT SWITCH SETTING The weld limit switch controls the cut off point of current flow to the welding dies Turning a screw located inside the welder allows adjustment of the trip point Access to this adjustment is with the cover removed 3 3 OPERATING SWITCH This switch is located on the front panel 3 6 UPSET PRESSURE Upset pressure is required for each weld and is obtained by a force lever 3 7 CLAMPING SYSTEM This is a dual system consisting of left and right clamping
5. MICRO WELD MODEL BR BRG BUTT WELDERS MICRO PRODUCTS COMPANY SERVICE MANUAL TABLE OF CONTENTS SPEC FICAT GEN ERAL OPE NG NSTRUCTI ONS BAS BAS C OPERAT C OPERAT PARTS PARTS LOCATI ON TYPICAL OPE NG SEQUENCE SPECIAL ADJ m ME Di NTS PREVENT NT ENACE SUGGESTE NGS O00 109001 2 0 Por O O O O O OX sO CX DIAGNO D RT FOR TROUL E SHOOTI ELECTR SCHE MATIC S CAL R SAFETY 1 NDE RS BUYE PAI RS G RTS LI OOOO 1 0 SPECIFICATIONS Model BR BRG NG Type of Welding Process Butt welds Welding Range 125 to 500 inch wide flat stock steel Material Suitability steel Standard Operating Voltages 115 Volts Maximum Line Demand 115 Volt 9Yamps 100 duty cycle 29amps 10 duty cycle Single Phase AC Transformer 1 5 KVA Maximum Clamp Method Hand Lever Mounting Bench Dimensions and Weights Height Overall 9 in BR 16 in BRG Bench space 1x EN Weight 50 LBS BR 60 LBS BRG FEATURES OF WELDING EQUIPMENT 2 1 Stryco quality and workmanship Rasy Rasy
6. devices The welding dies and shoes the replaceabl portion of the clamping mechanism hold the stock to be joined during the weld cycle 4 0 BASIC OPERATING PARTS LOCATION A OPERATING BUTTON WELD CONTROL LEVER CLAMPING LEVER WELD CONTROL LEVER OPERATING BUTTON w N 11 12 13 TYPICAL OPERATING SEQUENCE All ins Rotate T C a C b Rotate the f perating switch omplete weld cycl O C lamp stock pproximatel ulating mat where they contact utts and se erials must be removed from conductors welding dies the force lever to proper chart settings rim the stock ends end into welding jaw so that it is y midway between open jaws lamp other stock end into other welding die so that it urely contacts first stock end ever to the desired position Depress the Hold for 1 to 3 seconds to assure a e Unclamp welded stock ANNEAL OPERATION wW eld zone must be annealed prior to If wire is brittle after welding the further processing One reason the weld zone becomes brittle is because the arbon within the chemistry of the stock has been adversely C a e P a tMUNHK MAMA Ga 3 w w g ffected Annealing softening the stock will help liminate brittle weld zones Also when stock has a lot of revious work hardness imparted to it prior to weld
7. devices must not be changed to a new position while a weld operation is in process 16 12 0 BUYERS GUIDE HOW TO ORDER PARTS You must provide 1 Machine Model 2 Machine Serial Number 3 Voltage Then identify part s on part list last page in book and provide STRYCO with the circled number CALL STRYCO at 800 872 1068 OR FAX STRYCO at 630 787 9360 Provide STRYCO with your company name and purchase order number 17 13 0 PARTS LIST 20
8. e primary caused of bad welds 2 Check die sets for excessive wear and replace if necessary 3 Clean weld die bottoms to remove oxides with emery cloth placed on a flat surface 4 Clean die seats with emery cloth to brighten contact 5 After cleaning of dies be sure to wipe off with soft cloth 6 Completely tighten dies into seats to assure a good contact 7 Worn die shoes will not hold stock during a weld cycle change steel faces or replace complete shoes areas clean WEEKLY 1 Tighten all loose parts QUARTERLY lRepeat above service items 2 Check grease requirements on clamp arms pivot shafts and lubrication points 3Check anneal parts and replace all worn or broken assemblies 4 Check contacts on magnetic contactor for worn contacts 5 Clean heat switch contacts with low residue cleaner and recoat with petroleum jelly Y JJ oam aS ANNUALLY 1 Repeat previously noted items 2 Check for wear in clap arm pivots 3 Clean inside and outside of welder 4 Check grease requirements on headpiece slide shafts grease lightly 5 Caution make sure that power supply is disconnected befor servicing welder in anyway WELDING DIES AND DIE SHOES INFORMATION Description Velding dies Lower conducting electrode and clamp jaw Velding die shoes Upper clamping member Velding dies and die sho
9. es in poor condition are the main causes of bad welds Care of die sets lUse 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 2 Do no 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 3Do not use welding die sets for a vise These parts will not withstand the mechanical abuse 4 Whenever welding dies are replaced clean bottoms of dies and corresponding die seats to a bright and clean condition before bolting them tightly into place An oxidized surface will insulate the welding dies and reduc ffectiv welding voltage 5 Welding die shoes must swivel freely within the clamp arm pivots to prevent cracking of die shoes File down die shoe boss if necessary 6Welding die set will wear with use and must be changed occasionally for good welding results Keep and adequate supply of replacement parts available Stock slippage is a problem caused by poor die sets and a major cause of breaks 10 8 0 SUGGESTED SETTINGS Recommended settings for Stryco BR BRG welders Material Size Upset Tension Model BR BRG steel stock Steel 125x 020 1 Steel 25x 030 1 Steel 50x 030 1 Steel 50x 050 2
10. he reading should remain at zero 13 9 1 3 WELD PROBLEM PRESS LIMIT PRESS TEST LEAD METER IF NO OPERATING SWITCH ANNEAL CONNECTION READING READING SWITCH ACTUATED SWITCH 115 VOLT ONLY REFERENCE TO 9 1 1 L2 PBl 1 115 VAC Open wire to operating switch L2 PB1 2 115 VAC Bad operating switch X L2 LS1 1 115 VAC Open wire to weld limit switch X L2 LS1 2 115 VAC Open weld limit switch X L2 T1 1 115 VAC Open wire to transformer X NOTE To perform repair consult section 13 for parts identification 14 10 0 ELECTRICAL SCHEMATIC A 20 Sw 110 V CORD SY EFE way K i 15 11 0 SAFETY REMINDERS The following accident prevention information is presented to eliminate potential hazards while operating or repairing Micro Wel inspecting d electric resistance welding equipment Important safety compliance information for Micro Weld Welders GENERAL 1 Qualified personnel prior to using equipment must instruct an operator on basic operation and malfunction methods 2 Safety eyeglasses must be worn by all personnel operating or servicing welders 3 Use safety equipment properly and
11. ing PSET PRESSURE nnealing spreads the softness of the weld zone over a reater section ront panel eplaceable por Upset pressure is required nd is obtained by the position of a lever located on the tio or each weld LAMPING SYSTEM This is a dual system consisting of left nd right clamping devices The welding die shoes the n of the clamping mechanism holds the ctivate a weld tock to be joined witch located on or during the weld cycle The operating the front of the welder is used to anneal cycle After annealing remove he upset burr tha t has been created by grinding the weld one to exact parent metal diameter Be careful not to mpart stress areas on the wire with grinding scars which ill lead to breaks Some users are able to hand file the eld zone to proper sizes and others prefer the belt rinder EXPANDED ANNEALING INFORMATION FOR HARD TO PROCESS MATERIALS The correct annealing temperature can vary with materials U w O t sers sometime judge correct anneal temperatures by atching the wire heat up to a point where the wire breaks ut into black flecks Then allowing the wire to air cool o loss of color Since many carbon steels are anneal temperatur a heat range wher attracted to the ho magnetic a temperature for carbon steel prior to removing upset burr
12. keep safety equipment on welders 1 Determine that both operating voltages and hertz Cycles of power supply correspond to ratings listed on welder nameplate located on welder housing 5 Check nameplate ratings and keep within capacities and material categories stated therein 6 Adjustments or repairs must be made by persons thoroughly familiar with operating principles of welder 7 Welder must be disconnected from power supply prior to maintenance or repair procedures ELECTRICAL 1 Refer to National Electrical Code and local regulations for adequate electrical wiring to power welder Do not operate welder with inadequate electrical power supply cords or cable 2 All welders must be grounded through power supply and welder ground connection terminal securely tightened 3 All welders must be able to be disconnected from power source either by a double breaking disconnect switch or unplugged by standard rated plugs 4 All welders must be fused to prevent injury should an electrical malfunction occur Welders must never be fused for an ampere load that exceeds the ratings Stated on welder nameplate Normally welders are fused using the nameplate rated load time lag parameters functional to standard fuses allow this specification 5 Electric power cords to welder must be kept in good condition Report any damage or potential hazards to maintenance personnel 6 The weld heat selection switch potentiometer or range selection
13. n weld more of the following suggestions 1 Increas 2 Decreas 3 Readjust adjustment upset pressure weld heat timing point of weld heat cut off to allow heat to cut off slightly sooner one may be corrected by using one or limit switch 12 9 1 ELECTRICAL TROUBLE SHOOTING OF WELDER Caution Extreme care should b xercised when making these tests Dangerous voltages are present in the welder Only persons familiar with electrical safety precautions should perform these tests 9 1 1 TROUBLE SHOOTING TABLE See section 9 1 3 This electrical trouble shooting table is furnished as a suggested method of trouble shooting the welder The individual steps of the table should be performed in the order given to make the tests valid The electrical schematic section 10 furnished for these tests show the table test points The table may be used for welders with a different but closely related wiring by using corresponding test points During all tests line voltage should be connected to L1 amp L2 of the welder 9 1 2 FINAL ELECTRICAL CHECKS Connect the voltmeter across the welding dies Press the operating switch The meter reading will typically be less than 10 VAC Consult the weld specification sheet for this value Actuate the weld limit switch observe the reading goes to zero Release the weld limit and operating switches t
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