AD3-10 Manual - Micro Products Company
Contents
1. MODEL DESCRIPTION ITEM PART NO D 44 Stationary caster special order 48117 D 45 1 shear long handle 64009 D 46 Shear mount bolt 90295 D 47 Standard vise 78112 D 47H Heavy duty vise 78111 D 48 Standard vise bracket 60022 D 48H Heavy duty vise bracket 60005 D 49 Vise bracket mount bolt 90295 D 50 Vise mount bolt 90262 D 51 Flashguard assembly less switch 30656 D 51A Flash shield 30500 D 51B Flash shield bracket assembly 30519 D 5 LC Pivot plate assembly 30639 D 51D Pivot screw 93078 D 52 Flashguard mount bolt 30672 D 53 Flashguard safety switch 57813 D 54 Upset cover 30516 D 55 Upset cover mount screw 90656 D 56 Flash tray AD3 40502 D 56 Flash tray AD4 40500 D 56 Flash tray AD5 40501 D 57 Flash tray mount bolt 90258 D 64A Shoe attaching washer 92754 D 64 Shoe mount bolt 90677 D 65 Die mount bolt 90657 D 70A Transformer weld state voltage serial 50551 number AD3 D 70B Transformer weld state voltage serial 50546 Number AD4 D 70C Transformer weld state voltage amp serial 50547 Number AD5 D 70AP Primary coil state voltage amp serial number AD3 53049 D 70BP Primary coil state voltage serial number AD4 50545 D 70CP Primary coil state voltage2. sure to 90 psi Leaking clamp cylinder Input voltage Check power input Only 5 drop permissible Inadequate wiring Loose transformer secondary Clean and tighten Loose welding dies Clean and tight or replace Binding movable headpiece rod connection Remove all rod ends Clean contact area Preparing rod end Replace rod cutter jaws Require consis tent cuts Weld contactor Replace contac operation ts and check Time delay switch in weld circuit Increase air s time install t units tabilization imer on early 9 1 ELECTRICAL Caution these tests Only persons E 45 treme care should b Dangerous voltages ar amiliar with electrical TROUBLE SHOOTING OF WELDER xercised when making present in the welder 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 met individual st order given thod of to make the tests valid trouble shooting the welder teps of the table should be performed The in the The electrical 14 schema table tic section 10 test poi a different bu corresponding should be connected to nts test points furnished for these tests show The table may be used for welders with the
3. positio 6 7 8 With adjustment 7 completed 1 closed position and make following n adjustments A Mark stem of depressed limi in Figure 1C to hold movab tor to approximately to best tighten 10 PSI locking pi and n in topside av headpiec limit switc swi Release operating lever return to a rest positio ncil mark to specificatio Check pe and 1C Adjust proper switch Important adj successf 6 7 9 Headpiec head adjust 6 7 10Restore correct 6 7 11Should the need arise to reset only the upset adjustments st 5 and 6 may be eliminat to ret limi n switch adjus setting Recheck if ustmen teps 4 Adj t as it determines ul weld Adjustment remai open space may be checked by all urn to rest position ting screw to specifications in 1B UST WELDER ADJUSTMENTS AND LUBRICATION FIG 1 ns san le headpiece in this Adjust head closed adjusting screw specifications shown in Figures 1 to and 1A Tighten locknut in adjusted h tch with pencil as shown to allow movable headpiece to ns shown in Figures 1 ting screw to obtain necessary fusion point of a ne for all sizes Note lowing movable head open t air pressures and power to welder mechanism ted DIMENSION FROM 1 TO ONE DIAMETER OF STOCK DIMENSION WILL VARY W
4. conveniently located on the lower front of the welder Note The following Section 9 1 items can be located on Print B5800 in 3 1 2 HEADPIECE CLOSED SPACE ADJUSTING BOLT The closed space adj headpiece end plate usting bolt is located on the movable Refer to Item 1A 3 1 3 HEADPIECE OPEN SPACE ADJUSTING BOLT The open space adjusting bolt is located on the upset mechanism on the lever bar Refer to Item E 3 1 4 LIMIT SWITCH ADJUSTING BOLT 3 1 5 TOGGLE LINK The toggle link is 1 Item G The limit switch adjusting bolt is located on the lever bar on the upset mechanism Refer to Item F ocated on the upset mechanism Refer to 3 1 6 UPSET LEVER LIMITING BRIDGE mechanism Refer to 3 1 7 UPSET LEVER ARM Item H The upset lever limiting bridge is located on the upset The upset lever arm is located in the middle of the upset mechanism Refer to tem 4 0 BASIC OPERATING PARTS LOCATION TYPICAL OPERATING SEOUENCE All insulating materials must be removed from conductors where they contact lower welding dies Set weld heat selection switch to recommended chart setting 6 6 6 A W a 0 1 2 3 4 Set upset pressure to recommended chart setting PSI Adjust the head open space to proper chart setting Place the stock into welding dies so wire ends meet midway between ea
5. Grease zerk 90 degrees 48422 D 12 Clamp cylinder 50 77706 D 12A Cylinder replacement diaphragm 50 77713 D 12B Cylinder shaft boot 50 77718 D 12C Clamp cylinder clevis 50 VVZ D 13 Foot pedal 11859 D 13A Hand valve special Suspended weld 77864 D 14 Pedal mount screw 90611 D 20 End plate stationary head AD4 AD5 30548 D 20 End plate stationary head AD3 50502 D 21 End plate mount bolt stationary head AD3 AD5 90664 D 21 End plate mount bolt stationary head AD4 90687 D 22 End plate movable head 30518 D 23 End plate mount bolt movable head 90203 D 24 Push up block 30503 D 25 Closed space bolt adjustable 30506 D 25A Closed space locknut 92107 D 26 Push up block insulating plate 30504 D 11A Grease zerk straight 48423 D 2 6A Insulating tube 30638 D 26B Insulating washer 92906 D 27 Push up block mount bolt 90260 D 30 Stationary anneal extension bar AD3 62078 D 30 Stationary anneal extension bar AD4 AD5 62079 D 31 Front anneal bar 62080 D 32 Anneal bar mount bolts 90260 D 33 Movable anneal extension bar 62081 D 34A Anneal bar bracket AD5 62082 D 35 CA anneal each front 62155 D 36 CAL anneal pair 62020 D 37 Anneal clamp mount bolt 90260 D 40 Complete truck AD3 40599 D 40 Complete truck AD4 40592 D 40 Complete truck AD5 40600 D 41 Truck door 40540 D 43 Swivel caster 48108 24 PARTS LIST AD3 AD4 AD5
6. NOTE To perform repair consult section 13 for parts identification 10 0 ELECTRICAL SCHEMATIC 15 Lust zero an UNLESS OTHERWISE SPECIFIED ALL 120 V CONTROL WIRES TO BE NO 16 AWG RED UNLESS OTHERWISE SPECIFIED ALL NEUTRAL WIRES TO BE NO 16 AWG WHITE WHERE POSSIBLE USE ORANGE WIRE ON HIGH VOL 10 1 PNEUMATIC SCHEMATIC D LIMIT SRPEN SM SWITCH TAGE WIRING ABOVE 200V PB2 USED ON ANNEAL UNITS ONLY FOR 460 VAC OPERATION USE SOLID JUMPERS AS SHOWN FOR 230 VAC OPERATION USE DASHED JUM PERS AS SHOWN 16 WELD TRANSFORMER WATER COOLING TUBES WELD TRANSFORMER WATER COOLING TUBES WATER OUT WATER IN WATER OUT WELD HEADPIECE WELD HEADPIECE 11 0 SAFETY REMINDERS The following accident prevention information is presented to eliminate potential hazards while operating inspecting 17 or repairing Micro Wel equipment Important Welders GENERAL 1 Qualified personnel safety comp iance d electric resistance welding information for Micro Weld malfunction methods prior to using eguipment must instruct an operator on basic operation and 2 Safety eyeglasses must be worn by all personnel operating or servicing welders 3 Use safety eguipment properly and
7. devices must not be changed to a new position while a weld operation is in process 12 0 BUYERS GUIDE HOW TO ORDER PARTS You must provide 1 Machine Model 18 2 Machi 3 Voltage Then ide ne Serial Number ntify part s on part list last page in book provide MICRO with the circled number CALL MI OR FAX M Provide number C RO at 800 872 1068 ICRO at 630 787 9360 MICRO with your company name and purchase order 13 0 PARTS LIST and 19 1 20 21 22 N A TM DA ARS NL RR COs DOVO BY RN A E Ls 1 D 2 a 23 PARTS LIST AD3 AD4 AD5 MODEL DESCRIPTION ITEM PART NO D O1A Basic head assembly 30654 D 01B Complete head assembly 30655 D 04 Shaft wipes 30640 D 04A Shaft wipe retaining ring 48219 D 05 Head return spring 80059 D 08L Clamp arm left 30554 D 08R Clamp arm right 30614 D 09 Arm pivot pin bronze 30502 D 10 Arm pin washer 30517 D 10A Arm pin bolt 90258 D 11
8. keep safety eguipment 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 adeguate electrical wiring to power welder Do not operate welder with inadeguate 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
9. serial number AD5 50541 D 70AS Secondary AD3 50550 D 70BS Secondary AD4 50512 D 70CS Secondary AD5 50528 D 71 Transformer ring AD3 50504 D 71 Transformer ring AD4 50506 D 71 Transformer ring AD5 50505 D 71A Lower transformer ring AD4 AD5 50536 D 72 Transformer studs NC 50518 D 73 Transformer studs 327 60 50521 D 75 Auto transformer AD3 AD4 50567 D 75C Auto transformer ring AD3 AD4 42593 D 75P Primary AD3 AD4 50568 D 78 Control circuit step down transformer 57602 25 PARTS LIST AD3 AD4 AD5 MODEL DESCRIPTION ITEM PART NO D 79 8pt heat switch AD5 56548 D 80 12 point heat switch AD3 56547 D 82 Heat switch mount bolt 90294 D 83A Contactor 57611 D 83C Contactor repair kit Application D 85 Pneumatic time delay switch 57661 D 87 Terminal block 53000 D 90 Upset frame 30515 D 91 Upset frame mount bolt 90294 D 92 Lever bar 30513 D 93 Lever bar pivot pin 30508 D 94 Pivot pin bearing amp upset pin 48403 D 95 Pivot pin retaining screw 90015 D 96 Limit switch adjust screw
10. t closely related wiring by using During all tests Il amp L2 of the welder switch should be set to the 1 position 9 1 2 FINAL ELECTRICAL CHECKS Set the heat switch to the number 1 position line voltage The heat 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 Rotate the heat switch through all settings If the voltage is not read at any setting the heat switch may be defective Actuate the weld limit switch observe the reading goes to zero Release the weld limit and operating switches the reading should remain at zero 9 1 3 WELD TEST PROBLEM PRESS LIMIT PRESS LEAD METER IF NO OPERATING SWITCH ANNEAL CONNECTION READING READING SWITCH ACTUATED SWITCH X1 X2 5 VAC Bad control transformer X2 FUl 5 VAC Bad fuse connection X2 FU1 2 5 VAC Open fuse X2 PB1 5 VAC Open wire to operating switch X2 PB1 2 5 VAC Bad operating switch X X2 LS1 2 5 VAC Open flashguard switch X X2 LS2 5 VAC Open wire to weld limit X switch X2 LS2 2 5 VAC Open weld limit switch X X2 PB2 5 VAC Open wire to anneal switch X2 PB2 2 5 VAC Bad anneal switch X X2 TR1 3 5 VAC Bad time delay relay X L2 CR1 Line voltage Open wiring to contactor L2 CR1 2 Line voltage Bad contactor X
11. 53005 D 96A Limit switch screw locknut 92056 D 97 Limit switch 59084 D 99 Open space adjust bolt 30510 D 100 Toggle link 40554 D 101 Upset pin 30511 D 101A Reduced diameter upset pin 92557 D 101B Reduced diameter pin end cap 30507 D 102 Upset pin retaining washer amp bolt 30637 D 104 Toggle link pivot pin 30512 D 105 Toggle pivot pin retaining screw 90015 D 106 Upset cylinder 30 AD3 AD4 77704 D 106A Replacement diaphragm 30 AD3 AD4 77711 D 106B Cylinder shaft boot 30 AD3 AD4 77717 D 106C Upset cylinder clevis 30 AD3 AD4 77727 D 107 Upset cylinder 36 AD5 11105 D 107A Replacement diaphragm 36 AD5 77712 D 107B Cylinder shaft boot 36 AD5 77717 D 107C Upset cylinder clevis 36 AD5 77727 D 159 Clamp cylinder flow control valve 11862 D 210 Air regulator station complete see separate part list 59511 D 211 Muffler 11892 Dies AD 5972 Standard radius groove dies stellite inserts 30595 conical tips state size 0 500 AD 5972 Standard radius groove dies stellite inserts 30596 conical tips state size 500 750 AD Standard radius groove dies stellite inserts 30597 59T2C custom tips state sizes AD 59T3 Standard radius groove dies stellite inserts 3 30598 grooves state sizes AD 59T1 Broach radius groove dies stellite inserts 30624 state size 26 27
12. ITH HARDNESS OF STOCK AND CUTTER BLADE CONDITION SLIDE SHAFT FITTINGS GREASE LIGHTLY 1 2 TIMES PER YEAR HEAD ADJUSTMENT SCREW CIJ ADJUSTMENT SCREW OH 2 MOVABLE HEADPIECE A CLAMP ARM PIVOT SHAFT FITTINGS GREASE MONTHLY LUBRICATE ADJUSTING SCREW BEARING SURFACE LIGHTLY WITH GREASE MONTHLY REMINDER USE MULTI PURPOSE GREASE USE LOW PRESSURE HAND GREASE GUN GREASE LIGHTLY WIPE OFF EXCESS GREASE FIGURE 1 UPSET ADJUSTMENTS FIG 2 NOTE VIEW SHOWN FROM FRONT OF WELDER TRUCK WITH SAFETY COVER PLATE REMOVED A HEADPIECE CLOSED SPACE ADJUSTING BOLT G TOGGLE LINK H UPSET LEVER LIMITING BRIDGE E HEADPIECE OPEN SPACE BOLT I UPSET LEVER ARM F LIMIT SWITCH ADJUSTING BOLT 7 0 MARK 6 35mm OPEN E CLOSED EQUAL TO THE DIAMETER OF YOUR ROD CLOSED OPEN HEAD ADJUSTMENT SCREW LIMIT SWITCH GREASE LIGHTLY MONTHLY I 1 LUBRICATE CLEVIS PIN LIGHTLY WITH GREASE AIR UPSET MONTHLY NO FITTING ON PART CYLINDER AD 668 TOP VIEW OF UPSET MECHANISM COVER REMOVED RIGHT END OF TRUCK A CLOSED HEAD SPACE ADJUSTMENT B OVER TRAVEL INERTIA LIMITING SCREW C OPEN HEAD SPACE ADJUSTMENT D HIGH PRESSURE TRAVEL STOP SCREW E LOW PRESSURE TRAVEL LIMITING SCREW F LIMIT SWITCH ADJUSTMENT SCREW G TOGGLE LINK H UPSET LEVER LIMITING BRIDGE 1 UPSET LEVER ARM C2723 PREVENTIVE MAINTENANCE TECHNIQUE Keep in Mind that these welders are precision bu
13. MICRO WELD MODEL AD 3 5 HEAVY DUTY NON FERROUS BUTT WELDERS MICRO PRODUCTS COMPANY SERVICE MANUAL TABLE OF CONTENTS 1 0 SPECIFICATIONS 2 0 GENERAL OPERATING INSTRUCTIONS 3 0 BASIC OPERATING PARTS 4 0 BASIC OPERATING PARTS LOCATION 5 0 TYPICAL OPERATING SEQUENCE 6 0 SPECIAL ADJUSTMENTS 7 0 PREVENTIVE MAINTENACE 8 0 SUGGESTED SETTINGS 9 0 DIAGNOISTIC CHART FOR TROULBE SHOOTING 10 0 ELECTRICAL SCHEMATIC 11 0 SAFETY REMINDERS 12 0 BUYERS GUIDE 13 0 PARTS LIST 1 0 SPECIFICATIONS MODEL AD 3 MODEL AD 4 Welding Range Copper Wire 187 to 375 in DIA 250 to 500 in DIA Welding Range Aluminum Wire 250 to 500 in DIA 375 to 750 in DIA Welding Range Copper 232 to 437 in DIA 292 to 547 in DIA Conductors 4ga to 2 0 2ga to 250MCM Welding Range Aluminum 292 to 547 in DIA 437 to 853 in DIA Conductors 2ga to 250MCM 2 0 to 550MCM Maximum Line Demand 460 Volt 62amps 100 duty cycle 115 amps 100 duty cycle 196amps 10 duty cycle 362 amps 10 duty cycle Maximum Line Demand 230 Volt 124amps 100 duty cycle 230 amps 100 duty cycle 390amps 10 duty cycle 724 amps 10 duty cycle Single Phase AC Transformer 40 KVA 8 50 duty cycle 75 KVA 8 50 duty cy
14. bly GENERAL OPERATING INSTRUCTIONS 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 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 SAFETY PRECAUTIONS See section 11 0 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 befor serving welder high voltages are located within the base of the welder 2 2 2 MECHANICAL Operator while using we
15. ch die Clamp into position with foot valve pedals Lower the flash guard and lift the operating lever until it initiates the operation switch hold for 1 to 3 seconds to assure a complete weld cycle Unclamp welded conductors Trim off weld burr so welded area is egual to parent material diameter 1 result Incomplete burr removal or undercutting of the weld area wil in subseguent weld breaks SPECIAL ADJUSTMENTS FIG 2 may have to be adjus this reason it s bes Item A is used for head closed space adjustment This ted as die and shoe inserts wear for t to keep like size grooves in one die set As the ends wear they can be used until an even amount takes place t hen adjust closed headspace again When replacing worn dies with new or rebuilt ones turn bolt A in about or 12 7mm to prevent ends from being damaged when adjusting new closed space To adjust new head closed space after new weld dies and clamp shoes have been installed Lift up on hand operated air valve lever and ears on valve body and hol hold in place with small wire through le in lever Adjust bolt A until there is 005 to 010 to 127 to 254mm between inserts in ends of weld dies Lock bolt A in place with locknut tem E head open space adjustments This also adjusts the amount of low pressure travel
16. cle Clamp Method Pneumatic Foot Controlled Pneumatic Foot Controlled Upset Method Pneumatic Adjustable Pneumatic Adjustable Mounting 4 Caster Wheels STD 4 Caster Wheels STD Dimensions and Weights Height Overall OU iii 50 in Floor Space SARK 29 iz 62 in x 36 in Welding Die Height 43 in 43 in Weight 1350 LBS 1500 LBS SPECIFICATIONS MODEL AD 5 Welding Range Copper Wire oo Lov 50 117 DIA Welding Range Aluminum Wire 300 to 8 5 in DIA Welding Range Copper 437 to 853 in DIA Conductors 2 0 to 550MCM Welding Range Aluminum 547 to 998 in DIA Conductors 250MCM to 750MCM Maximum Line Demand 460 Volt 228amps 100 duty cycle 727amps 10 duty cycle Maximum Line Demand 575 Volt 184amps 100 duty cycle 582amps 10 duty cycle Single Phase AC Transformer 150 KVA 50 duty cycle Clamp Method Pneumatic Foot Controlled Upset Method Pneumatic Adjustable Mounting 4 Caster Wheels STD Dimensions and Weights Height Overall D An Floor Space 62 in x 36 in Welding Die Height 43 in Weight 1700 LBS FEATURES e Micro Weld quality and workmanship e Heavy duty construction amp components nei 1 Easy to operate controls Low maintenance costs Easy to set welding parameters Safety electrical switch circuits Heavy duty weld heat selection switch Sensitive straight slide movable headpiece assem
17. ilt to last but will require proper maintenance procedures many years designed to be as automatic as possible with a They ar 10 SI W a W a W WUUWUUNNNN N N b amp b eB LD 1 Tighten all 2 Check for w 3 Check for a 4 Drain airli B Tighten all 5 Clean heat minimum dep must make a operating p endence on the ability of the operator Those djustments thoroughly familiar with the rinciples of the welders WELDING DIE NOTES 1 Welding dies and die shoes in poor condition are the primary cause of poor guality welds 2 Check die s 3 Clean weld placed on a 4 Clean die s 5 After clean ets for excessive wear and replace if necessary die bottoms to remove oxides with emery cloth flat surface eats with emery cloth to brighten contact ing of dies be sure to wipe off with soft areas clean act Loch 6 Completely contact 7 Worn dies w tighten dies into seats to assure a good 111 not hold stock during a weld cycle replace worn dies WEEKLY loose parts ater leaks if applicable ir leaks ne filter bowls OUARTERLY 1 Repeat abov loose parts service items 2 Check greas lubrication 3 Check annea assemblies 4 Check conta requirements on clamp arms pivot shafts and points l pa
18. lder 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 WATER HOOK UP If so equipped It is important that if a welder is to be opera extended period of time and head heat up water be connected to the welder Connect hoses to i outlet provided at the back of the welder Shu should be installed in the inlet line and the h outlet should run to an open sight drain Wate turned off when welder is not in use 2 4 AIR HOOK UP Set air regulators for from 20 to 90 lbs A saf valve will be activated when air gauge is set f lbs 2 5 WELDING DIES The dies and shoes supplied with the welder wil most size and material types within the range o welder For new weld applications consult the special die and shoe sets 3 0 BASIC OPERATING PARTS 3 1 MODEL AD 3 4 or 5 3 1 1WELD HEAT SELECTION SWITCH Welding heat is selected by means of a heavy dut ted for an lines must nlet and t off valve ose from the r should be ety pop off or over 100 1 handle f the E factory for ty tap switch with either eight or twelve steps of voli tage Number one indicates the highest heat setting and number eight or twelve indicates th lowest heat setting The switc h is
19. materials will overstress the mechanical abuse S ar replaced ltage E 8 0 SUGGESTED SETTINGS ll wear with use and m y for good welding results lacement parts available clea These parts will An oxidized nd reduc n bottoms of dies tion ffectiv Excessive flash build up causes terial and shorting of die sets ust be changed Keep and adequate Vire and rod lem caused by poor die sets and a major cause of wire breaks Weld Die Die Limit Upset Heat Closed Open Upset Clamp Switch Arm Material Size Setting Space Space Pressure Pressure Setting Movement Model AD 3 Aluminum Rod 315 1 005 359 25 PSI AU PSE 4 Aluminum Rod 250 11 005 250 41 PS 90 PSI 4 Copper Rod 250 5 005 250 30 PSI 90 PSI Y Copper Rod 375 2 005 38 30 PSI 90 PSI l Copper 4 GA 6 005 500 30 PSI 90 PSI l Aluminum 250MCM 1 005 625 40 PSI 90 PSI Y 12 Model AD 4 Aluminum Rod 3 15 4 005 33 25 30 PS 90 PS 4 Aluminum Rod 750 2 005 190 40 PS 90 PS M Copper Rod 375 4 005 315 35 PS 90 PS M Copper Rod 500 1 005 500 45 PS 90 PS Y Copper 350MCM 2 005 500 40 PS 90 PS Y Aluminum 2 11 005 625 35 PS 90 PS Y Aluminum 350MCM 5 005 625 55 PS 90 PS M Model AD 5 Aluminum Rod 315 6 005 35 30 PS 90 PS 4 Aluminum R
20. od 750 1 005 750 35 PS 90 PS Y Copper Rod 23 15 4 005 379 25 PS 90 PS Y Copper Rod 750 005 750 45 PS 90 PS 4 Aluminum 2 8 005 500 30 PS 90 PS l Aluminum 500MCM 4 005 625 35 PS 90 PS Y Copper 500MCM 1 005 625 35 PS 90 PS 4 Copper 2 5 005 500 30 PS 90 PS l 8 1 WELD EXAMPLES EXAMPLES OF GOOD WELDS A GOOD WELD WITH A CORRECT BURR AND EVEN HEAT PENETRATION A POOR WELD WITH IMPROPER UPSET AND A MINIMUM AMOUNT OF HEAT PENETRATION ja Ba BURR REMOVAL EXAMPLES A GOOD WELD WILL BREAK ACROSS WELD ON A BEND TEST GOOD POOR POOR RECOMMENDED SHEAR CUTS Y SHEAR BLADE BC SHEAR BLADE Weld burr must be removed as close A POOR WELD WITH LITTLE FUSION AND NO UPSET BURR to parent metal as possible Incom plete burr removal or excessive grind ing will cause tension breaks on sub sequent wire drawing operations STRANDED CABLE Bend test The weld burr should be the diameter of the rod above vise jaws and bent back forth until rod breaks A good weld will break across or on either side of the weld A POOR WELD WILL BREAK WITH WELD 9 0 DIAGNOSTIC CHART FOR TROUBLE SHOOTING 4 SHEAR BLADE PLACE IN DIE GROOVES AS ILLUSTRATED CROSSING CUT ENDS Welding Action Cause Remedy Welding action normal burr does not extend beyond rod Shear cut Increase stating space Molten metal blown out and mate
21. on Y Remove welding dies and clamp shoes Brighten with 2 0 emery cloth wipe clean A Attaching surfaces of replacement welding dies place on flat surface to brighten B Attaching surfaces of replacement welding die shoes place on flat surface to brighten C Welding die seats on stationary and movable headpieces file with care to eliminate pitted or burnt surfaces Polish with emery cloth Note Damaged die seats indicate poor installation procedures or loose welding dies D Clamp arm die shoe seats polish with emery cloth E Wipe all contact surfaces with quick evaporating low residue cleaner 6 Install new welding dies lower set welding die shoes upper set and align A Place clean welding dies in die seats and lightly tighten into position Note Die sets are marked with a machining code B Attach clean welding die shoes to clamp arms and lightly tighten into position C Select a straight piece of rod that corresponds to one of the exact die grooves and place across and spanning welding dies to assist in alignment t E 7 7 Adj Adjust upset air regulator to approximat clamp aligning rod into place Tap welding dies and die shoes int ten upper die shoes Release clamp arms a tigh ust nd carefully upset air regulat activate operating lever and tely 10 PSI alignment and welding dies place the of air operating lever
22. on the weld cycle Item F limit switch adjus be adjusted to where plunger tment screw This screw should on limit switch is pushed down into threaded tube YA a in welding dies and ini This adjustment is made with nothing tiating the operating lever Item G toggle link This changes the vertical motion of the upset lever to a horizontal movement 6 7 4 5 This lever pivots at the rear with inder pushing front end of lever up Angle ground on AD 3 AD 4 tem I upset lever air cyl front end of moving welder headpieces together Item H upset lever restricting bridge movement of upset lever amp AD 5 ADJUSTMENTS AND DIE INSTALLATION 1 To prevent damage to dies or personal upset lever pushes against lazy arm roller which limits injury disconnect power and reduce air pressure gauges 2 Loosen locknut on closed headpiec and turn screw in approximately 3 8 between worn welding dies Figure 1 to O m space adjusting screw to allow clearance nd Designation X a 3 Loosen locknut on open headpiece space adjusting screw and turn bolt counter clockwise to lower leverage bar Figure and Designati
23. rial does not join High heat Lower heat setting Limit switch adjust Set to depress 4 Small stock Check nameplate rating Low upset pressure Increase upset pressure Air system Clean air filters Weld area does not heat enough to complete weld Low heat Increase heat settings Transformer secondary connection Clean and tighten Welding dies Clean and tighten Staring space Decrease starting space Dry looking weld Upset pressure Decrease settings 13 Limit switch Set to depress Misalignment of rod Worn die grooves Replace die sets Starting space Decrease staring space Welder head loose Return for reconditioning Rod ends buckle and not welded Weld heat Increase heat Starting space Decrease starting space Upset pressure Decrease pressure Welding dies Clean or replacement Welder inoperative Fuses Check power supply Time delay switch Check continui ty of circuits Operating or limit switch Check continui ty of circuits Heat switch Tighten loose connections Contactor Check continui ty of circuits Welding transformer Check continui ty of circuits Auto transformer Check continui ty of circuits Variations in welds Stock slippage Undersize stock Replace worn dies Set clamp pres
24. rts and replace all worn or broken cts on magnetic contactor for worn contacts recoat with ANNUALLY 1 Repeat prev 2 Check for wear in clap arm pivots switch contacts with low residue cleaner and petroleum jelly iously noted items 3 Clean inside and outside of welder 4 Check greas lightly 5 Caution ma requirements on headpiece slide shafts grease ke sure that power supply is disconnected befor servicing welder in anyway WELDING DIES AND DIE SHOES INFORMATION Description Welding dies Lower conducting electrode and clamp jaw 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 11 7 5 1Use a brass or fiber blade to remove particles of flashings that build up o die burns on mat 7 5 2Do n burn ot at welder int die grooves tempt to die sets clamping parts 7 5 3 Do n ot use welding die sets for a vise not withstand 7 5 4 When and corresponding die seats to a bright and clean condit them tightly into place before bolting l insulate the welding dies a surface wil welding vol 7 5 5 Welding die set wil occasional supply of repl slippage is a prob ever welding di n die sets Undersize material s will to clamp material that is not suited for slip and oversize
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