model gp0 ceramic fusion butt welder
Contents
1. This type of we tance heated to a plastic condition and ithin a ceramic tool coalescence cts asa 11 single uctors the a et ld normal burr is not 10 8 2 22 t rp WELDING CRUCIBLE STRAND CONDUCTORS CONDUCTORS HEATED TO PLASTIC CONDITION AND FORCED TOGETHER WELDING CRUCIBLE REMOVED SHOWING WELDED WIRE SECTION 9 0 DIAGNOSTIC CHART FOR TROUBLE SHOOTING SERVICE HINTS FOR STRAND CONDUCTOR WELDERS welding die shoe ceramic tool welding die shoe oe ji welding die lower welding die lower Conductors must be ad to slide freely within ceramic tools during weld cycle therefore rotate and move ceramic tool side to side prior to welding Be sure to center ceramic tool between die sets Example of porosity weld zone 7 3 Example of void in weld zone Porosity and voids in weld zone may be corrected by using one or more of the following suggestions 1 Increase upset pressure 2 Decrease weld heat 3 Readjust timing point of weld heat cut off limit switch adjustment to allow heat to cut off slightly sooner 4 Check to make sure conductor is not binding in ceramic tool Example of poorly fused weld nugget because of small solid area t i Example of properly fused weld nugget approximate solid area of two times diameter of conductor Amount and length of weld nugget solid portion of weld can be varied by one or more2. that se lected on tor diameter ng operation au the timer one is slightly swaging may be required tolerances on subsequent processing tool with his sizing a special swage to assist with t When either auto or manual to the weld time will 6 6 6 0 sl 2 3 4 SPECIAL ADJUSTMENT HEADPIECE CLOSED SPACE ADJUSTMENT between di Closed spac adjusting cam is set a To make this adjustment the to zero then check s should be 7 32 when the space zero first move the space adjusting cam Spacing betw If the space between loosen the locknut on Space OPEN SPACE ADJUSTMENT This adjustment det N the space adj clockwise for more space and counterclockwise Once space has been set tight space adjusting screw rmines th dies is not 7 usting screw n the dies 32 at this time Turn screw or less E adjustment is made reflects for approximate settings WELD LIMIT SWITCH amount LO ten the locknut on the of upset burr The by the space adjusting cam A pointer the cam positioning Refer accompanying charts Do not put any wire in the dies when making this adjustment Set the space adj a voltmeter measure across applied to the welder Press reading should be approxima If no Return tage should shut highest hea
3. MICRO PRODUCTS COMPANY MANUFACTURES OF PRECISION WELDING MACHINES MODEL GPO CERAMIC FUSION BUTT WELDER 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 ADJUSTMENT 7 0 PREVENTIVE MAINTENANCE 8 0 SUGGESTED SETTINGS 9 0 DIAGNOSTIC CHART FOR TROUBLE SHOOTING 10 0 ELECTRICAL SCHEMATIC 11 0 SAFETY REMINDERS 12 0 BUYERS GUIDE 13 0 PARTS LIST 1 0 SPECIFICATIONS MODEL GPO Stock Size Range 26GA to 18GA Type Material Stranded copper conductor Operating Voltage 115 Volts Input Power Cycle 60 Cycle 50 Cycle optional Line Demand 6 Amperes 100 Duty Cycle 19 Amperes 10 Duty Cycle Single Phase Weld Transformer 1 0 KVA 50 Duty Cycle Truck Mounted Welder 2 Stationary Casters 2 Swivel Casters Floor Space 24 x 24 Overall Height Su Height to Welding Dies 44 Welder Weight Approx 120 LBS SUITABLE FOR BENCH MOUNTING Dimensions Overall Height 29 Base Dimensions l1 18 Height from Base to Welding Dies 12 5 Welder Weight Approx 701 5 2 0 GENERAL OPERATING IN
4. OTHERWISE SPECIFIED ALL 115V RETURN WIRES Tl HI Lo HEAT SWITCH 51 NOTE C 5 WHITE NOTE AUNLESS OTHERWISE SPECIFIED ALL 115V CONTROL WIRES TO BE NO16 AWG RED WAZ TO BE 016 AWG WHITE LAMP NOTE C S1 MAY A 6 POINT HEAT SWITCH ON SOME MODELS 51 LIMIT SWITCH WELD CONTACTOR SUPERSEDES DWG B7166 MICRO PRODUCTS COMPANY GP O WIRING DIAGRAM INCH DIMENSIONS 2 PLACES 010 3 PLACES 005 ANGLE 1 nie 14 11 0 SAFETY REMINDERS The following accident prevention information is presented to eliminate potential or repairing Micro Weld equipment Important hazards while operating Welders GENERAL Ta Qualified personnel safety comp inspecting Electric resistance welding information for Micro Weld malfunction methods Safety operati Use safety eg equipment on Determine tha cycles Check namepla th operating voltages and supply correspond to rat on welder nameplate located on welder housing te ratings and keep within capacities and prior to using equipment instruct an operator on basic operation and material categories stated therein Adjustments or repairs m thoroughly familiar with welder We lder must be disconnect tings must yeglasses must be worn by all personnel ng or servicing welders uipmen
5. STRUCTIONS 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 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 2 2 SAFETY PRECAUTIONS 2 2 1 ELECTRICAL Maintain electrical cables to welder in good repair Welders must be grounded and connections securely tightened Heat switch must not be changed to a new position while a weld cycle is in process Disconnect electrical service before servicing the welder high voltages are located within the base of the welder 2 2 2 MECHANICAL Operator wh
6. are cut conductor ends so no individual wires extend beyond cut Select correct size of ceramic sleeve Thread conductor end into ceramic sleeve so as wire ends are midway wire lay will assi Clamp preset as ceramic sl condu eeve through sleeve is center Rotating ceramic in direction of st threading procedure ctor and sleeve into welding die set d betw open welding dies Thread other prepared conductor into sleeve and allow the y but firmly contact first conductor conduc Clamp Rotate conduc Rota assure arger Positive contact tors duri te spacing lever Depress the operation n additional ntl to wire ends is important for good weld that conduct or into welding dies and center ceramic sleeve to assur ng a complete nclamp welded conduc racture expendabl he inside diameter of ceramic sleeve slightly exceeds the ominal conductor size than conduc 5121 hould weld zone exceed operations Micro exchangeable tooli opera tion The above operatio the auto limited manual sw weld process to 0 weld cycle sl typ therefor fr movement of switch hold for 1 to 3 seconds to tor and remove ceramic sleeve V the weld Products has ng available n applies isin TO to
7. crease weld heat Varying weld results Stock slipping Varying weld voltages Wire condition variations Dies Flashings Check Clamp finger pressure Check electric lines Clean and tighten transformer connections to heads Clean wire where clamped in dies Replace dies Clean build up of flash materials CAUTION these tests Extreme care should b Dangerous voltages ar ELECTRICAL TROUBLE SHOOTING OF WELDER xercised when making Only persons familiar with electrical present in the welder safety precautions should perform these tests 9 1 1 TROUBLE SHOOTING TABLE See section 9 1 3 This electrical trouble shoo suggested method of individual steps of the to make the section 10 furnished points order given schematic table test a different but trouble shooting table tests valid ting table is furnished as a the welder The E should be performed in the The electrical E for these tests show the The table may be used for welders with closely related wiring by using correspon should be switch sh ding connected to Ll amp uld be set to the 1 test points During all tests L2 of the welder position line voltage The heat 9 1 2 FINAL ELECTRICAL CHECKS Set the heat switch to the number 1 position voltmeter across the welding dies Th
8. e meter reading will Consult the weld specification sheet for this value switch VAC connect the Press the operating typically be less than 10 12 Rotate the heat switch through all settings If the VOL switches tage is not read at any setting defective the heat switch may be Actuate the weld limit switch observe the reading goes to zero Release th weld limit and operating the reading should remain at zero 9 1 3 PROBLEM PRESS WELD LMIT AUTO MANUAL TEST LEAD METER IF NO OPERATING SWITCH SWITCH CONNECTION READING READING SWITCH ACTUATED L2 1 5VAC Bad fuse connection MANUAL L2 FU1 2 5VAC Open fuse L2 5VAC Open wire to operating Switch L2 1 2 5 Bad operating switch L2 LS1 5VAC Open connection to weld limit switch X L2 LS1 2 5VAC Open weld limit switch L2 CR1 5VAC Open wire to contactor L2 CR1 2 5VAC Bad contactor X 12 5 Open wire to heat switch 12 TR1 8 115VAC Bad timer circuit momentary AUTO Note to perform repair consult section 13 for parts identification S2 closed for all tests Vol tage present for 1 sec when timer is set to 1 sec 13 RED PE CRI L1 1 15 Le FU 1 1 T TJ S4 LAMP SWITCH 1 2 52 1 41 2 TRI 3 1 53 WELD TRANSFORMER NOTE B UNLESS
9. ile using welder must wear safety glasses Keep all safety guards on welders and use properly Operators must be instructed on the 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 5 WELD HEAT SELECTION SWITCH Weld heat is selected by means of a tap switch with 10 steps of voltage Number one indicates the highest setting and number ten the lowest The switch is located in the front and center of the welder Ref 4 0 HEAD CLOSED SPACE SETTING Turning the insulated screw that rides the space adjusting cam located on the top of the headpiece makes this adjustment HEAD OPEN SPACE SETTING A space adjusting cam located on the top of the headpiece makes this adjustment This setting determines the amount of burr that the weld will have See charts for approximate settings LIMIT SWITCH SETTING The weld limit switch controls the cutoff point of current flow to the welding dies Turning an adjusting screw located on the left end of the movable headpiece makes this adjustment See Charts for setting UPSET PRESSURE Upset pressure adjustments are obtained by rotating the knu
10. ion before bolting them tightly into place An oxidized surface will insulate the welding dies and reduc ffective welding voltage 6 5 Welding die sets will wear with use and must be changed occasionally for good welding results Keep and adequate supply of replacement parts available Wire and rod slippage is a problem caused by poor die sets and a major cause of wire breaks 8 0 SUGGESTED SETTINGS HEADPIECE STOCK SIZE OPEN LIMIT STRANDED WIRE HEAT TENSION SPACE SWITCH COPPER 26 GA 10H 1 5 24 9H 1 5 6 COPPER 22 GA 8H 2 6 COPPER 20 GA 7H 3 6 COPPER 18 GA 6H 3355 7 NOTE These settings are approximate and may be varied to suit needs CONDUCTORS WELDED STRAND OR BUNCHED COPPER AND ALUMINUM WIRE THEORY Welds are formed within a ceramic tube of block and fil crucible lire ends are resist hot forged together The resul no filler materials are needed which a weld locks a laments into solid weld 51 strand plastic material wel d have configuration voids on the normally forced 4E is forced con nmon with standard upset welds suitable or sol into the voids fraying to the iminati E surfaces outside on ng the ups id wire
11. k upset tension spring and clamp springs Replace if springs have been over stretched and will not re normal position ES ting screw turn to 5 ANNUALLY 5 1 Remove the movable headpiece and check condition of slide shafts Wash slide shafts with low residue cleaner lightly oil and replace headpiec 5 2 Check condition of headpiece castings worn or broken replace with new headpiece welder is used in an area where there are corrosive fumes clean off all oxides and paint where possible 6 WELDING DIE INFORMATION Description Velding dies Lower conducting electrode and clamp jaw Velding clamp fingers Upper clamping member VELDING DIES IN POOR CONDITION ARE THE MAIN CAUSES OF BAD WELDS 6 0 CARE OF DIE SETS 6 1 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 6 2 Do not attempt to clamp material that is not suited for welder into die sets Undersize materials will slip burn die grooves oversized materials will overstress clamping parts 6 3 Do not use welding die sets for a vise These parts will not withstand the mechanical abuse 6 4 Whenever welding dies are replaces clean bottoms of dies and corresponding die seats to a bright and clean condit
12. of the following suggestions 1 Increase starting space between die sets when weld nugget is small 2 Decrease space between die sets when weld nugget is to large 3 Adjusting limit switch to hold on or cut off current at a different position Fracturing of ceramic tools and bent conductors can be corrected by one or more of the following methods 1 Decrease weld heat to prevent excessive softening of conductors on either side of sleeve 2 Decrease starting space so as decrease length of upset and amount of conductor exposed to heat 3 Decrease upset pressure and still maintain a fused area 4 Afew of the very small stranded and bunched conductors just not have enough mechanical strength to be processed by this process 11 9 0 DIAGNOSTIC CHART FOR TROUBLE SHOOTING WELDERS WELDING ACTION CAUSE REMEDY 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 is complete but is dry and breaks off below surface of wire Upset pressure too great Lower upset pressure Weld good but poorly aligned Welding dies amp clamp fingers Starting space Loose shafts Replace worn dies and clamp fingers Decrease starting space Return heads to factory Ends of wire buckle and may not weld Upset pressure too great Low weld heat Decrease starting space In
13. otentiome LO ter or range new tion is in process 15 12 0 BUYERS GUIDE HOW TO ORDER PARTS You must provide 24 a Machine Model Machine Serial Number Voltage Then identify part s on part list in section 13 and provide MICRO with the circled number CALL MICRO at A C 630 787 9350 Or Toll free at 800 872 1068 Provide MICRO with your company name and purchase order number 16 13 0 PARTS LIST 17 2 27 D CEJ QO N X 2 6 s 22 5 Fh HS 53 HOLIMS LINN HLIM 154 PARTS LIST MODEL PART NO DESCRIPTION ITEM GPO 01A Head assembly 32118 GPO 03 Tray assembly 42051 GPO 04 Transformer cap 52001 GPO 05A Basic head assembly 32133 GPO 05B Interior mounting plate 32132 GPO 05C Cherry micro switch 57851 GPO 06A Basic head assembly 32133 GPO 06B Bearing spacer 32057 GPO 06C Bearing 48400 GPO 06D Limit switch adjusting screw 52008 GPO 06E Shaft cover 32056 GPO 07A Open head stop screw 32028 GPO 14 Housing assembly 42075 GPO 14C Basic head bra
14. rled knob on the right hand side of the stationary headpiece When the outside edge of the adjusting screw is flush with outside edge of the knurled knob the movable headpiece should just close when pulled to the left by hand and released A calibrating screw and nuts located on the opposite left hand headpiece will assist in setting this positioning Accompanying charts will assist in correct settings for various sizes of wire WELD INITIATING KNOB The push button knob that initiates the weld cycle is located on the right front of the welder enclosure 4 0 BASIC OPERATING PARTS LOCATION LAMP OPEN SPACE ADJUSTING SCREW WELD DIES OPEN SPACE LIMIT SWITCH CAM HANDLE ADJUSTING SCREW CLAMP FINGERS TENSION KNOB SQUARE CUT SHEAR HEAT SELECTION SWITCH AUTO MANUAL SWITCH WELO TIMER OPERATING BUTTON POWER ON OFF SWITCH HI LO HEAT RANGE SWITCH o OU OU t0 NH 10 11 12 13 14 15 16 17 18 TYPICAL OPERATING SEQUENCE Wire must be clean and free of dirt and oil Set weld heat switch to recommended setting Ref 8 0 Set hi low range switch Ref 8 0 Set upset pressur Ref 8 0 Rotate space cam to open stop 1 4 between dies Twist conductor end in direction of natural lay Carefully squ
15. roken loose with a scraper made of DAILY 1 Check condition of welding dies and clamp fingers Replace Dies or clamp fingers when they have become so worn that stock does not align or there is slipping of stock in the dies during upset pressure 2 Check condition of clamp springs Replace all broken springs or springs that have taken a set 3 Check movable head for excessive wear Have new slide shafts installed and die seats machined if stock does not line up when placed in die grooves MONTHLY lRemove welding dies and clean bottom of die surface with emery cloth Do this by placing the emery cloth on a surface plate and rubbing the dies on it keeping the 120 flat clea contact surface with the hand k anneal dies and replace worn or broken parts k insulating fiber pin on limit switch adjusting screw for broken or frayed ends k upset tension spring and clamp springs Replace if 2 Chec 3 4 spri n cloth and replace taking care not to touc surface of the die flat Wipe die and die seat with a h either ngs have been over stretched and will not re turn to normal position QUARTERLY 1 Disconnect power to welder Check contacts on operating and limit switch Replace those that are burned 2 Check anneal dies and replace worn or broken part 3 Check insulating fiber pin limit switch adjust for broken or frayed ends 4 Chec
16. ss pin 93144 GPO 14E Basic head groove pin 92608 GPO 14FP Front door 42050 GPO 14BP Back door 42033 GPO 18 Shunt insulator 37728 GPO 21 Tension adjusting knob 35564 GPO 22 Tension adjusting worm 32087 GPO 23 Tension screw nylon 35516 GPO 24 Tension spring 32059 GPO 25A Space cam assembly 32003 GPO 26 Repeating cam stop 32000 GPO 27 Cam bushing 32002 GPO 28 Space cam attaching bolt 90203 GPO 29 Closed space adjusting screw 32082 GPO 34 Insulating sleeve 37709 GPO 38 End cover plate 32054 GPO 39 End cover attaching screw 91055 GPO 51A Omron timer 57693 GPO 51B Omron socket 57695 GPO 51C Omron adapter 57694 GPO 51D Omron cover 57696 GPO 53 Fuse holder 58091 GPO 54 Fuse 58083 GPO 62 Tap switch plate 55510 GPO 63 Tap switch 57800 GPO 64 Heat switch plate 55510 GPO 68 GPO radius groove dies 20 amp 18 ga 32123 GPO 69 GPO radius groove dies 22 24 26 ga 32124 GPO 70 Clamp finger left wide 32016 GPO 71 Clamp finger right wide 32017 GPO 74 Finger stop pin 32020 GPO 75 Clamp finger return spring 80007 GPO 76 Basic head spring screw 91026 20 PARTS LIST MODEL PART NO DESCRIPTION ITEM GPO 77 Finger attaching screw 32064 GPO 90 Cable 86006 GPO 91 Kellum grip 86100 GPO 100 Back panel knob 48216 GPO 101 Terminal block assembly 42509 GPO 105 Operating swi
17. t properly and keep sa welders bo of power fety hertz listed ust be made by persons maintenance or repair procedures ELECTRICAL Refer to national Electrical regulations for adequate el welder Do n ot electrical power s ect trical wiring operate wel All welders m welder All wel source or unplugged All welders m electrical ma ders m us us by us lf fused for an stated on welder using th upply cords or cable t be grounded ground connection t be able through power terminal to be disconnected from power either by a double breaking disconnect securely Standard rated plugs t be fused to prevent injury should an unction occur We lders must operating principles of ted from power supply prior to Code and local to power der with inadequate supply and tightened switch never be ampere load that exceeds the ratings nameplate condition nameplat functional to standard fuse allow Electric power cords to wel maintenance personnel The w ld head selection swit selection devices must not be changed position while a weld operat Normal ly welders are fused rated load time lag parameters this specification must be t any damage or potential t in good hazards to tch p
18. t setting cam to higher number the cam Loosen locknut on the limit swit the welder shuts off at 1 on adjust until voltmeter The volt the cam usting cam at the clamp fingers with power the weld button tely one VAC with welder at the voltage is read move the space 1 cam With The voltmeter o 1 while watching off at 1 on the tch adjusting screw and the space adjusting cam After setting tighten locknut on the limit switch adjusting screw UPSET PRESSURE Upset pressure adjustments are obtained by rotating knurled knob on right outside edge edge of when pulled nut the neutral position correct will assist hand side of stationary headpiec of upset adjusting screw is flush with outside thumb knob movable headpiece should just to the left by hand A calibrating screw and located on right hand headpiece will j When close assist in setting Accompanying charts will setting for neutral position assist in Accompanying charts in correct setting for various sizes of wire AS REQUIRED Flashings must be removed fron clamp fingers with a brush n between welding dies and If flashings are attached so that they cannot be removed by brushing with a soft wire brush fiber or wood they may be b
19. tch 57843 GPO 106 Hi low switch 57843 GPO 107 Auto manual nameplate 52034 GPO 108 Operating switch plate 52035 GPO 109 On off switch 57839 109 Auto manual switch 57840 GPO 110 Hi low nameplate 48306 GPO 111 On off nameplate 48305 GPO 112 Truck assembly 42026 GPO 119 Shear 64002 GPO 138 Lamp 58164 141 Transformer 52049 GPO 142 Transformer ring 54512 143 93000 185 Contactor 57613 21
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