AUF-8 Manual
Contents
1. Staring space Decrease starting space Dry looking weld Upset pressure Decrease settings Limit switch Adjust 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 continuity of circuits Operating or limit switch Check continuity of circuits Heat switch Tighten loose connections Contactor Check continuity of circuits Welding transformer Check continuity of circuits Auto transformer Check continuity of circuits Variations in welds Stock slippage Undersize stock Replace worn dies Set clamp pressure 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 consistent cuts Weld contactor Replace contacts and check operation2. switch is pushed down when the dies are apart Make final adjustment according to welding chart This adjustment is made with nothing in welding dies and initiating the operating lever T tem toggle link This changes the vertical motion of the upset lever to a horizontal movement T tem upset lever This lever pivots at the rear with air cylinder pushing front end of lever up 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 Those must make adjustments thoroughly familiar with the Operating principles of the welders WWWNHNNDND N as bbe 4 Clean die seats with emery cloth to brighten contact 5 After cleaning of dies be sure to wipe off with soft WELDING DIE NOTES lWelding dies and die shoes in poor condition are the primary caused of bad welds 2 Check die sets for excessive wear and replace if necessary 3Clean weld die bottoms to remove oxides with emery cloth placed on a flat surface areas clean ct c1 E Och 6 Completely tighten dies into seats to assure a good contact 7 Worn dies will not hold stock during a weld cyc
3. twelve steps of voltage Number t heat setting and number eight or conveniently located on st heat setting The switch is E the lower front of the welder Note The following items can be located on Print 4B 7771 in Section 9 1 A 3 1 2 HEADPIECE CLOSED SPACE ADJUSTING BOLT The closed space adjusting bolt is located on the movable headpiece end plate Refer to Item A 3 1 3 HEADPIECE OPEN SPACE ADJUSTING BOLT The open space adjusting bolt is located on the upset mechanism Refer to Item B 3 1 4 LIMIT SWITCH ADJUSTING BOLT The limit switch adjusting bolt is located on the lever bar on the upset mechanism Refer to Item F 3 1 5 TOGGLE LINK The toggle link is located on the upset mechanism Refer to tem 3 1 6 UPSET LEVER ARM The upset lever arm is located in the middle of the upset mechanism Refer to Item 4 0 BASIC OPERATING PARTS LOCATION 6 6 6 0 1 2 3 TYPICAL OPERATING S EQUENCE All insulating materials must be removed from conductors lower welding dies where they contact Set weld heat selec setting Set upset pressure Adjust the head ope n space tion swit ch to recommended chart to recommended chart setting PSI to proper chart setting Place the stock into welding dies so wire ends meet midway between each d
4. D EVEN HEAT PENETRATION Ports A GOOD WELD WILL BREAK ACROSS WELD ON A BEND TEST A POOR WELD WITH IMPROPER A POOR WELD WITH UPSET AND A MINIMUM LITTLE FUSION AMOUNT OF HEAT PENETRATION AND NO UPSET BURR EE A POOR WELD WILL BREAK WITH WELD BURR REMOVAL EXAMPLES GOOD RECOMMENDED SHEAR CUTS SHEAR BLADE CN POOR POOR SHEAR BLADE Weld burr must be removed as close 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 PLACE IN DIE GROOVES AS 9 0 DIAGNOSTIC CHART FOR TROUBLE SHOOTING 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 material 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
5. MICRO WELD MODEL AUF 8 HEAVY DUTY 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 AUF 8 Welding Range Steel Wire 500 80 1 312 vm dia Maximum Line Demand 460 Volt 137amps 100 duty cycle 433amps 10 duty cycle Maximum Line Demand 230 Volt 274amps 100 duty cycle 866amps 10 duty cycle Single Phase AC Transformer 90 KVA 50 duty cycle Clamp Method Pneumatic Foot Controlled Upset Method Pneumatic Adjustable Mounting 4 Caster Wheels Dimensions and Weights Height Overall dne Floor Space 62 an 3 36 dn Welding Die Height 43 in Weight 1700 LBS FEATURES m Micro Weld quality and workmanship Heavy duty construction amp components Easy to operate controls Low maintenance costs Easy to set welding pa
6. NOTE A UNLESS OTHERWISE SPECIFIED ALL I20V CONTROL WIRES TO BE NO I6 AWG RED NOTE Bi UNLESS OTHERWISE SPECIFIED ALL NEUTRAL WIRES TO BE NO I6 AWG WHITE NOTE C WHERE POSSIBLE USE ORANGE WIRE ON HIGH VOLTAGE WIRING ABOVE 200V NOTE D DEPENDING ON LINE VOLTAGE USED TI T2 amp T53 WILL VARY 460V 230V OR OTHER VOLTAGES AVAILABLE NOTE E PB2 USE ON ANNEAL UNITS ONLY 14 10 1 PNEUMATIC SCHEMATIC WELD TRANSFORMER WATER COOLING TUBES WELD TRANSFORMER WATER COOLING TUBES WATER IN WATER OUT WATER IN WATER OUT WELD HEADPIECE WELD HEADPIECE 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 keep safety equipment on welders 1 Determine that both operating voltages and hertz Cycles of power supply correspond to ratings listed on welder nameplate loc
7. Time delay switch in weld circuit Increase air stabilization time install timer on early units 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 The heat switch should be set to th 1 position 9 1 2 FINAL ELECTRICAL CHECKS Set the heat switch to the number 1 position 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 swi
8. achine Model 2 Machine Serial Number 3 Voltage Then identify part s on part list last page in book and provide MICRO with the circled number CALL MICRO at 800 872 1068 OR FAX MICRO at 630 787 9360 Provide MICRO with your company name and purchase order number 17 13 0 PARTS LIST 18 19 20 pa N A TM DA NL RR COs A Vo Y 1 RN A E fs D a O 5 P 21 22
9. ated 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 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 M
10. ectrical 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 WATER HOOK UP If so equipped It is important that if a welder is to be operated for an extended period of time and head heat up water lines must be connected to the welder Connect hoses to inlet and outlet provided at the back of the welder Shut off valve should be installed in the inlet line and the hose from the outlet should run to an open sight drain Water should be turned off when welder is not in use 2 4 AIR HOOK UP Set air regulators for from 20 to 80 lbs A safety pop off valve will be activated when air gauge is set for over 100 lbs 2 5 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 MODEL AUF 8 3 1 1 WELD HEAT SELECTION SWITCH Welding heat is selected switch with either eight one indicates the highes twelve indicates the low by means of a heavy duty tap or
11. ials will slip and burn die grooves oversize materials will overstress clamping parts 7 5 3Do not use welding die sets for a vise These parts will not withstand the mechanical abuse 7 5 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 7 5 5 Welding die set will wear with use and must be changed occasionally for good welding results Keep and adequate supply of replacement parts available ire and rod slippage is a problem caused by poor die sets and a major cause of wire breaks 8 0 SUGGESTED SETTINGS Weld Die Die Limit Upset Heat Closed Open Upset Clamp Switch Arm Material Size Setting Space Space Pressure Pressure Setting Movement inches inches inches Model AUF 8 Steel Rod 500 7 x5 Tes 30 psi 90 psi 2 Steel Rod 750 6 5 1 5 30 psi 90 psi 245 Steel Rod 1 000 5 1 5 40 psi 90 psi 3 Steel Rod i212 1 9 14 50 psi 90 psi 3 10 FJLMIT SWITCH ADJUSTMENT SCREW LIMIT SWITCH ADJUSTMENT NUT AND LOCK NUT MICRO MODEL AUF 8 PRODUCTS UPSET ADJUSTME COMPANY HEAD CLOSED ADJUSTMENT SCREW a OPEN HEAD STOP BOLT E TP 11 8 1 WELD EXAMPLES EXAMPLES OF GOOD WELDS A GOOD WELD WITH A CORRECT BURR AN
12. ie Clamp into position with foot valve pedals Lower the flash guard and raise up on the operating lever until it initiates the operation switch hold for 1 to 3 complete weld cycle Seconds to assure a Unclamp welded conductors Trim off weld burr material diameter of the weld area wil So welded area is equal to parent Incomple l resul e burr removal or undercutting in subsequent weld breaks SPECIAL ADJUSTMENTS FIG 9 1 A may have to be adju this reason it s be Item A is used for head closed space adjustment This sted as die and shoe inserts wear for st to keep like size grooves in one die set As the ends wear they can be used until an even amount takes place then adjust closed headspace again When replacing worn dies with new or rebuilt ones turn bolt A in about to prevent ends from being damaged closed space when adjusting new 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 hold in place with small wire through ears on valve body and hole in lever Adjust bolt A 0 between ends of weld dies Lock bolt until there is 01 A in place with 1 M ocknut E head open space adjustments Item F limit switch adjustment The trip nuts should be adjusted to where plunger on limit
13. le replace worn dies WEEKLY 1 Tighten all loose parts 2 Check for water leaks if applicable 3 Check for air leaks 4 Drain airline filter bowls 5 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 ANNUALLY lRepeat 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 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 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 7 5 2 Do ot attempt to clamp material that is not suited for welder into die sets Undersize mater
14. rameters Safety electrical switch circuits Heavy duty weld heat selection switch Sensitive straight slide movable headpiece assembly 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 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 el
15. tch 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 CR1 5 VAC Bad relay x Coil L2 CR1 Line voltage Open wiring to contactor L2 CR1 2 Line voltage Bad contactor x NOTE To perform repair consult section 13 for parts identification 13 10 0 ELECTRICAL SCHEMATIC DRAWING NUMBER DATE 5 31 FH MAT L DRAWN JS MODEL AUF AUF 9 PRODUCT S WIRING DIAGRAM Cp SCALE THE INFORMATION MERLON IS THE PROPERTY OF MICRO PRODUCTS COMPANY ANO SOMMER ri ANY A r 1014411 TMOUT WATT Y YING fn ITAL FO OTHER Y er THAT von Wm to HEAT CONTROL AUTO TRANSFORMER WELD OPERATING X X2 T3 m PBI LSI LS2 BN m 2 I 2 LIMIT SW WELD NOTEE PB ut d CONTACTOR ANNEAL FLASH GUARD e SAFETY SW
Download Pdf Manuals
Related Search