model ad 6-10 heavy duty non-ferrous butt welders
Contents
1. This adj tiating ustment is made with the operating lever nothing Item G 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 Angle ground on front end of upset lever pushes against lazy arm roller moving welder headpieces together Item H upset lever restricting bridge which limits movement of upset lever AD 6 AD 8 amp AD 10 ADJUSTMENTS AND DIE INSTALLATION 1To prevent damage to dies or personal injury disconnect power and reduce air pressure gauges to 2 Loosen locknut on closed headpiece space adjusting screw and turn screw in approximately 3 8 to allow clearance between worn welding dies Figure 1 and Designation X 3Loosen locknut on open headpiece space adjusting screw and turn bolt counter clockwise to lower leverage bar Figure 1 and Designation Y 4 Remove welding dies and clamp shoes 5 Brighten with 42 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 Da2. ELECTRICAL Li Adjustments thoroughly or repairs m amiliar with bo la welder Welder must be disconnect mainte Refer to National Electr or to using equipment must nnel ty equipment properly and keep safety welders th operating voltages and hertz supply correspond to rati te located on welder housi te ratings and keep within capacities and tegories stated therein ngs listed ng ical regulations for adequate welder Do QUE A welders welder All wel source or All ders welders ectrical unplugged ectrical power s mu mu b mu malf fused for an stated on we fused using parameters functional specification Electric power cords to welder must be Report any damage or poten maintenance personnel condition th not operate wel ele Code and local ctrical or cable st be able Y ampere load that exceeds Ider nameplate Welders through power s terminal must ust be made by persons operating principles of ted from power supply prior to nance or repair procedures wiring to power der with inadequate upply cords st be grounded ground connection upply and securely tightened to be disconnected from power either by a double breaking disconnect standard rated plugs st be fused to prevent i unction
3. Undersize stoc k Replace worn d ies Set clamp pres sure to 90 psi Leaking clamp cylinder Input voltage Check power in put Only 5 drop p ermissible Inadequate wir ing Loose transformer secondary Clean and tigh cen Loose welding dies Clean and tigh t or replace Binding movable headpiece rod connection Remove all rod ends Clean contact area Preparing rod end Replace rod cu tter 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 15 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 T
4. assembly AD8 30063 D 04 Head return spring 80059 D 07 Clamp arm pivot 30014 D 07A Bell crank pivot 30015 D 07B Clamp arm pivot screw amp washer 30005 D 08 Clamp arm for stationary head left 30037 D 08A Clamp arm for movable head right 30038 D 09 Clamp eccentric leveling block 70005 D 09A Leveling block pin 70006 D 10 Bell crank 70007 D 10A Bell crank block pin 70010 D 10B Bell crank block 70004 D 10C Bell crank retaining screw 90665 D 10D Bell crank block assembly 70012 D 16 Velding die set new style 30029 D 16A Velding die set old style 30024 D 19 Upper die attaching screw washer 30006 D 20 Upper die attaching screw 90691 D 21 Lower die attaching screw 90690 D 22 Upset plate steel 40006 D 23 Upset plate insulation 30007 D 24 Secondary shunt 50002 D 24A Shunt clamp plate 50000 D 24B Shunt attaching screw long 90501 D 24C Shunt attaching screws short 90502 D 25 Closed space adjustment screw 30042 D 25A Closed space locknut 92111 D 26 Open space adjustment screw 30000 D 27 Head closed stop screw 90696 D 27A Head closed stop screw washer 30001 D 28 Upset plate attaching screws 90658 D 29 Anneal clamp bracket CAL anneal clamps 30058 D 30 Weld transformer AD6 50009 D 31 8 tap primary coil 50010 D 32 Transformer secondary 30043 D 33 Transformer H D not taps ADS 50009 D 34 Primary coil 50010 D 35 Secondary 30043 D 36 Clamp cylinder stud AD6 7000 D 36A Clamp cylinder stud ADS8 70011 D 37 Clamp link stop block AD6 70002 D 3
5. does not extend beyond rod Molten metal blown out and High heat Lower heat setting material does not join 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 Low heat Increase heat settings enough to complete weld Transformer secondary connection Clean and tigh ten Welding dies Clean and tigh ten taring space Decrease start ing space Dry looking weld pset pressure Decrease setti ngs imit switch Set to depress 7 4 Misalignment of rod orn die grooves Replace die se ts tarting space Decrease stari ng space elder head loose Return for rec onditioning Rod ends buckle and not welded Increase heat tarting space Decrease start ing space pset pressure Decrease press ure elding dies Clean or repla cement Welder inoperative uses Check power su pply ime delay switch Check continui ty of circuits U L W 5 W Weld heat S U W T perating 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
6. in Weight 4800LBS SPECIFICATIONS MODEL AD 8 MODEL AD 10 Welding Range Copper Wire 550 to l l25 1n dias 500 to 1 300 in dia Welding Range Aluminum Wire 150 tool 750 an dias 500 to 1 750 in dia Welding Range Copper in d as 500 to 1 600 in dia Conductors 250MCM to 1250MCM Welding Range Aluminum JD soda 500 to 1 750 in dia Conductors 500MCM to 2000MCM Maximum Line Demand 460 Volt 784amps 100 duty cycle 784amps 100 duty cycle 1569amps 25 duty cycle 2000amps 15 duty cycle Maximum Line Demand 575 Volt 627amps 100 duty cycle 627amps 100 duty cycle 1255amps 25 duty cycle 1600amps 15 duty cycle Single Phase AC Transformer 510 KVA 50 duty cycle 510 KVA 50 duty cycle Clamp Method Pneumatic Foot Controlled Pneumatic Foot Controlled Upset Method Pneumatic Adjustable Pneumatic Adjustable Mounting 4 Caster Wheels 4 Caster Wheels Dimensions and Weights Height Overall 50 in 50 in Floor Space 85 in x 40 in 85 in x 40 in Welding Die Height 44 in 44 in Weight 5400 LBS 5400 LBS FEATURES m Micro Weld quality and workmanship Heavy duty construction amp components 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 assembly GENERAL OPERATING INSTRUCIONS ELECTRICAL HOOK UP INSTRUCTI
7. travel limiting screw is located on the upset mechanism threaded into the upset lever arm and beneath the upset lever limiting bridge Refer to Item E 7 LIMIT SWITCH ADJUSTING SCREW The limit switch adjusting screw is located on the upset lever arm Refer to Item F 9 TOGGLE LINK The toggle link is located in the middle of the upset mechanism Refer to Item G 10 UPSET LEVER LIMITING BRIDGE The ups the upset lever limiting bridge is located in the middle of mechanism Refer to Item H 11 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 o 6 6 6 0 1 2 3 TYPICAL OPERATING SEQUENCE All insulating materials must be removed from conductors where they contact lower welding dies Set setting Set upset pressure between each die pedals Lower assure Trim off wel material diameter of the weld area wi weld heat selection swit the flash guard and initiates the operation switch hold for a complete weld cycle Unclamp welded conductors d burr so welded area is equal Incomplete burr removal l result to recommended chart setting Adjust the head open space Place the stock into welding dies so wire ends Clamp into position wi to proper chart th foot tch to
8. 7A Clamp link stop block AD8 70003 D 38 Clamp cylinder for AD8 50 6 77707 D 38A Clamp cylinder diaphragm 50 6 77714 24 PARTS LIST AD6 AD8 MODEL DESCRIPTION ITEM PART NO D 38B Clamp cylinder boot 50 6 77719 39 Clamp cylinder for Model 50 4 77706 D 39A Clamp cylinder diaphragm 50 4 77713 D 39B Clamp cylinder boot 50 4 77718 D 39C Clamp cylinder clevis 70009 D 48 Upset cover 4002 D 79 Upset frame 40014 D 79A Upset attaching bolts 9067 D 80 Leverage bar 400 D 80A Lever bearings 48404 D 80B Lever down stop screw 30003 D 80C Lever up stop screw 30004 D 81 Toggle mechanism 30012 D 81A Toggle mechanism bearings 48404 D 81B Air upset cylinder boot 77719 D 82 Air upset cylinder 50 6 77707 D 82A Air upset cylinder diaphragm 77714 D 82B Air upset cylinder boot 77719 D 82C Air upset cylinder clevis amp pin 70013 D 82D Cylinder stud amp 3 nuts 70014 D 83 Toggle mechanism pivot pin 30009 D 84 Leverage bar pivot 30010 D 85 Limit switch only 57806 D 85A Limit switch actuator 57814 D 85C Limit switch adjusting screw 53005 D 90A 8 point tap switch 57857 D 91 Quick exh
9. CR1 2 Line voltage Bad contactor X NOTE To perform repair consult section 13 for parts identification 16 10 0 ELECTRICAL SCHEMATIC 460 230V LIMIT FLASHGUARD LIMIT FLASHGUARD sy SAFETY SW SWITCH SAFETY Sw SWITCH SEN UNLESS OTHERWISE SPECIFIED ALL 120 V CONTROL TAGE WIRING ABOVE 200V WIRES TO BE NO 16 AWG RED NOTE D PB2 USED ON ANNEAL UNITS ONLY UNLESS OTHERWISE SPECIFIED ALL NEUTRAL WIRES NOTE E FOR 460 VAC OPERATION USE SOLID JUMPERS AS TO BE NO 16 AWG WHITE SHOWN FOR 230 VAC OPERATION USE DASHED JUM WHERE POSSIBLE USE ORANGE WIRE ON HIGH VOL PERS AS SHOWN 10 1 PNEUMATIC SCHEMATIC WELD TRANSFORMER WATER COOLING TUBES WELD TRANSFORMER WATER COOLING TUBES WATER OUT WATER IN WATER OUT WELD HEADPIECE WELD HEADPIECE 17 11 0 SAFETY REMINDERS The following accident prevention information is presented to eliminate potential hazards while operating inspecting or repairing Micro Wel equipment Important Welders GENERAL l Qualified personnel safety compl iance d electric resistance welding information for Micro Weld pri t an operator on basic operation and yeglasses must be worn by all perso ng or servicing welders instruc malfunction methods 2 Safety operati 3 Use safe equipmen t on 1 Determin cycles on welder namepl Check namepla material ca that of power
10. GHTLY 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 1 UPSET LEVER ARM F LIMIT SWITCH ADJUSTING BOLT DIMENSION WILL VARY WITH HARDNESS OF STOCK AND CUTTER BLADE CONDITION MARK IL _6 35mm OPEN ve EQUAL TO THE DIAMETER OF YOUR ROD CLOSED OPEN HEAD ADJUSTMENT SCREW LIMIT SWITCH GREASE LIGHTLY MONTHLY I LUBRICATE CLEVIS PIN LIGHTLY WITH GREASE AIR UPSET MONTHLY NO FITTING ON PART CYLINDER 1 oa i 1 1 Lis AD6 amp 8 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 UPSET LEVER ARM C2723 11 l 4 Clean die seats wi 1 5 After cleaning of dies be sure to wipe off with soft WWWNHNNDND N au SG aS Keep in Mind that 0 PREVENTIVE MAINTENANCE TECHNIQUE these welders are precision built to las
11. MICRO WELD MODEL AD 6 10 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 SPECIFICATIONS MODEL AD 6 Welding Range Copper Wire 90580 to 1 000 in dia Welding Range Aluminum Wire OZ OREO LSS FOSTER dias Welding Range Copper in dia Conductors 250MCM to 1000MCM Welding Range Aluminum in dia Conductors 400MCM to 1250MCM Maximum Line Demand 460 Volt 584 amps 100 duty cycle 1306 amps 20 duty cycle Maximum Line Demand 575 Volt 467amps8100 duty cycle 1044amps 20 duty cycle Single Phase AC Transformer 380 KVA 50 duty cycle Clamp Method Pneumatic Foot Controlled Upset Method Pneumatic Adjustable Mounting 4 Caster Wheels Dimensions and Weights Height Overall 50 un Floor Space 85 in x 40 in Welding Die Height 44
12. ONS 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 welder must wear safety glasses Keep all safety guards on weld
13. aust valve 77857 D 99 Weld delay timer 57661 D 102 Welder frame complete 40039 D 104 Step down control transformer 57602 D 105 Air valve 77859 D 106 Standard vise 400R 78111 D 107 Bracket for standard vise 60022 D 108 Vise heavy duty 78112 D 109 Bracket for heavy duty vise 60005 D 111 Control terminal block 53000 D 112 Discharge resistors Thyrite 58132 D 113 Veld contactor AD 6 57615 D 114 Veld contactor housing 58203 D 120 Ignitron contactor 0 6000 tubes w phase 57744 shift heat control price applicable D 12 Flash guard bracket 30519 D 121A Flash guard pivot plate 30639 D 122 Flash guard aluminum 30002 D 122A Complete flashguard assembly less switch 30656 D 123 Flash guard safety switch 57813 23 124 6 angle iron track type wheels stationary Application 125 Flow control valve 77862 126 Stationary mount each 40018 130 X CAL anneal screw 30066 19 Air frame complete 59510 131 Muffler 77892 26
14. ers 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 90 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 3 1 3 1 3 2 3 2 3 2 3 2 3 2 BASIC OPERATING PARTS MODEL AD 6 or 8 1 WELD HEAT SELECTION SWITCH The AD 6 welding heat is selected by means of a heavy duty e Number 1 indicates the Tap switch with 8 steps of voltag highest heat setting and the numb er 8 indicates the lowest heat setting Other numbers are equally graduated from highest to low to allow just the for t
15. he 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 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 152 2 5 VAC Open weld limit switch X X2 PBZ 5 VAC Open wire to anneal switch X2 PBZ 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
16. he weld operation The type of right amount o switch that must be depressed bef This safety switch actually is wi ore turning to f voltage heat switch found on the AD 6 has a safety a new heat red into the control circuit and when the heat switch prohibit the welder welding 1 The AD 8 welding heat is selected control mounted on the side of th located on the control front pane 0 100 0 is the lowest heat set heat setting 2 CLOSED HEAD SPACE ADJUSTMENT is between se by means of a e welder A po l with a scale ting 100 is ttings will n SCR tentiometer designating the highest The closed headspace adjustment bolt is located on the movable headpiec nd plate Refe 3 OVERTRAVEL INERTIA LIMITING SCREW r to Item A The over travel inertia limiting screw is located on the movable headpiec nd plate Refe 4 OPEN HEAD SPACE ADJUSTMENT r to Item B The open headspace adjustment bolt is located on the upset 1 inertia limiting screw mechanism opposite the over trave Refer to Item C 5 HIGH PRESSURE TRACEL STOP SCREW The high pressure travel stop screw is local mechanism threaded into the ups the upset lever limiting bridge ted on the upset t lever arm and beneath Refer to Item D 6 LOW PRESSURE TRAVEL LIMITING SCREW The low pressure
17. i 5 16 2 Copper 1 4 95 32 1 1 16 45 psi 00 psi 5 16 2 Aluminum 783 60 32 13 16 30 psi 00 psi 5 16 3 Aluminum 903 70 32 7 8 30 psi 00 psi 5 16 3 Aluminum 962 70 32 7 8 30 psi 00 psi 5 16 2 Aluminum 1 114 70 32 1 35 psi 00 psi 5 16 2 Aluminum 1 333 75 132 1 35 psi 00 psi 5 16 2 1 WELD EXAMPLES EXAMPLES OF GOOD WELDS LKT A GOOD WELD WILL BREAK ACROSS WELD ON A BEND TEST AZ A POOR WELD WITH IMPROPER A POOR WELD WITH UPSET AND A MINIMUM LITTLE FUSION AMOUNT OF HEAT PENETRATION AND NO UPSET BURR ees A POOR WELD WILL BREAK WITH WELD A GOOD WELD WITH A CORRECT BURR AND EVEN HEAT PENETRATION EXAMPLES OF POOR WELDS BURR REMOVAL EXAMPLES GOOD POOR 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 POOR 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 RECOMMENDED SHEAR CUTS Y SHEAR BLADE X SHEAR BLADE STRANDED CABLE p SHEAR BLADE 4 SHEAR BLADE PLACE IN DIE GROOVES AS ILLUSTRATED CROSSING CUT ENDS 14 9 0 DIAGNOSTIC CHART FOR TROUBLE SHOOTING Welding Action Cause Remedy Welding action normal burr Shear cut Increase stating space
18. imi and 1A Tigh locking pin in topside to hold movable headpiece in this Adjust head closed adjusting screw Specifications shown in Figures 1 to ten locknut av limit switc headpiece in adjusted N swi ever to allow elease opera d 1C Adjus roper switch Important adj S O 0 OH WF 6 7 9 Headpiec head adjust 6 7 10Restore correct 6 7 11Should the need adjustments s ting 1 eturn to a rest positio limi setti n eck pencil mark to specificatio switch adjus ustmen Adj ting screw to specifications in 1 ng Recheck if as it determines fusion point uccessful weld Adjustment remai movable headpiece to ns shown in Figures 1 ting screw to obtain necessary Note t of a open space may be checked by allowing movable to return to rest position ust head open B air pressures and power to welder arise to reset only the upse teps 4 5 and 6 may be elimina mechanism ed a tly tch with pencil as shown ns same for all sizes 10 WELDER ADJUSTMENTS AND LUBRICATION FIG 1 DIMENSION FROM 1 TO ONE DIAMETER OF STOCK SLIDE SHAFT FITTINGS GREASE LIGHTLY 1 2 TIMES PER YEAR HEAD ADJUSTMENT SCREW U ADJUSTMENT SCREW B MOVABLE HEADPIECE CLAMP ARM PIVOT SHAFT FITTINGS GREASE MONTHLY LUBRICATE ADJUSTING SCREW BEARING SURFACE LI
19. maged die seats indicate poor installation procedures or loose welding dies Clamp arm die shoe seats polish with emery cloth Wipe all contact surfaces with quick evaporating low residue cleaner Hu 6 7 6 Ins tall new welding dies lower set upper set and A Place clea tighten into machi Attach clea tighten int Selec of th wel Adj exaci ust upset n wel align di ng dies i position ning code n welding die s O position t a straight piece of t die grooves a ding dies to assis Note oes to clamp arms and lig welding die shoes die seats and lightly Die sets are marked wi th rod t air reg clamp aligning rod i nto place tig E 7 7 Adj welding dies and hten upper die shoes Release clamp arms a ust upset air regula nd carefully activate operating lever cha d place in alignmen ulator to approxima die shoes in tor to approximately t corresponds to o across and spanni tely 10 psi a to best alignment and tighten welding dies 10 psi and place the of air operating lever position 6 7 8With adjustment 7 completed closed position and make following adjustments A Mark st in Figure 1C tem of depressed l
20. ments on clamp arms pivot shafts and 3 4 Check contacts on magnetic contactor for worn contacts 3 5 Clean heat switch contacts with low residue cleaner and grease servicing welder in anyway that power supply is disconnected befor 12 WELDING DIES AND DIE SHOES INFORMATION Description Welding dies Lower conducting electrode and clamp jaw Welding die sho S Upper clamping member Welding dies and die shoes in poor condition are the main causes of bad welds Care of die set 1Use a brass or that build up o 5 fiber blade to remove particles of flashings n die sets Excessive flash build up causes die burns on material and shorting of die sets 2 Do not attempt welder into die burn die groove clamping parts to clamp material that is not suited for sets Undersize materials will slip and S oversize materials will overstress 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 set will wear with use and must be changed occasionally for good welding results Keep and adequate supply of replacement parts a
21. occur switch njury should an never be the ra Normally welders are tings nameplat to The w selec ld heat selection ra ta S switch po tion devices must not be changed position while a weld operat ted load ndard fuses al tial kept tenti ome time lag Llow this in good hazards to ter or range ion is in to a new process 18 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 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 19 13 0 PARTS LIST 20 21 22 rH N A TM DA ARS NL RR COs A Vo Y 1 RN A E fs D a O 5 P 23 PARTS LIST AD6 AD8 MODEL DESCRIPTION ITEM PART NO D 01A Stationary head attaching bolts 90683 D 01B Basic head assembly AD6 30062 D 01D Basic head
22. recommended chart PSI setting meet midway valve lift the operating lever until it in subsequent SPECIAL ADJUSTMENTS FIG 2 may have to be adjus this reason it s bes set As amount takes place t When replacing worn dies with new or rebuilt ones ec Item A is used for head closed space adjustment ted as die and shoe inserts wear e grooves in one die the ends wear they can be used until an even hen adjust closed headspace again O keep like si bolt A in about damaged when adjusti To adjust new head c clamp shoes have bee valve lever and hold on valve body and ho there is 005 to 01 ends of weld dies M to 3 seconds to to parent or undercutting weld breaks This Lor turn 12 7mm to prevent ends from being r new weld dies and or ng new closed space losed space aft n installed in le in lever 0 to 127 to Lock bol E head open space adjustments This also adj Lift hand operated air place with small wire through ears Adjust bolt A until 254mm between inserts in t A in place with locknut USTS be adjusted into threaded tube in welding dies and ini the amount of low pressure travel Item F limit switch adjustment J to where plunger on on the weld cycle Screw limit switch is pushed This screw should down n
23. t many years but will require good maintenance procedures They are designed minimum dependence on the ability of the operator must make adjustments thoroughly familiar with the Operating principles of the welders 1 WELDING DIE NOTES 1 1Welding dies and die shoes in poor condition are the primary caused of bad welds xcessive wear and replace if necessary 1 2 Check die sets for 1 3 Clean weld die boti placed on a flat surface th emery cloth to brighten contact cloth 1 6 Completely tighten contact 1 7 Worn dies will not worn dies WEEKLY dies into seats to assure a good O to be as automatic as possible with a Those toms to remove oxides with emery cloth areas clean hold stock during a weld cycle replace 1 Tighten all loose parts 2Check for water leaks if applicable 3Check for air leaks 4 Drain airline filter bowls QUARTERLY 5 Tighten all loose parts lRepeat above service items lubrication points 3Check anneal parts assemblies and replace all worn or broken recoat with petroleum jelly ANNUALLY lRepeat previously noted items 2 Check for wear in clap arm pivots 3Clean inside and outside of welder lightly 4 5 Caution make sure 4 Check grease requirements on headpiece slide shafts 2 Check grease require
24. vailable ire and rod slippage is a problem caused by poor die sets and a major cause of wire breaks 13 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 Model AD 6 Stranded Material Aluminum 565 6 or 7 32 5 8 30 psi 00 psi 5 16 1 Copper 565 5 32 5 8 30 psi 00 psi 5 16 1 Aluminum 670 5 32 34 30 psi 00 psi 5 16 1 Copper 670 4 32 34 30 psi 00 psi 5 16 1 Aluminum 795 4 32 3 16 30 psi 00 psi 5 16 1 Copper 795 3 32 3 16 30 psi 00 psi 5 16 1 Aluminum 985 3 32 7 8 35 psi 00 psi 5 16 3 Copper 985 3 32 7 8 35 psi 00 psi 5 16 3 Aluminum 1 140 2 32 5 16 40 psi 00 psi 5 16 3 Copper 1 140 1 32 5 16 45 psi 00 psi 5 16 3 Aluminum 1 1245 2 32 45 psi 00 psi 5 16 3 Copper 112275 1 32 50 psi 00 psi 5 16 3 Solid Material Copper 4 32 3 16 30 psi 00 psi 5 16 1 Copper 34 2 7 32 7 8 40 psi 00 psi 5 16 1 1 27 07 32 45 psi 00 psi 5 16 3 Aluminum 5 8 5 32 3 16 30 psi 00 psi 5 16 1 Aluminum 34 3 32 7 8 40 psi 00 psi 5 16 L Aluminum 1 1 8 2 32 45 psi 00 psi 5 16 3 Model AD 8 Copper 5 8 60 32 1 16 30 psi 00 psi 5 16 3 Copper 3 70 32 3 16 30 psi 00 psi 5 16 3 Copper 7 8 70 32 7 8 35 psi 00 psi 5 16 2 Copper 1 75 32 7 8 35 psi 00 psi 5 16 2 Copper 1 1 8 80 32 1 40 psi 00 ps
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