MD Manual - Micro Products Company
Contents
1. 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 located on welder housing 5 Check nameplate ratings and keep within capacities and material categories stated therein 6 Adjustments or repairs must be made by persons thoroughly familiar with operating principles of welder 7 Welder must be disconnected from power supply prior to maintenance or repair procedures ELECTRICAL 1 Refer to National Electrical Code and local regulations for adequate electrical wiring to power welder Do not operate welder with inadequate electrical power supply cords or cable 2 All welders must be grounded through power supply and welder ground connection terminal securely tightened 3 All welders must be able to be disconnected from power source either by a double breaking disconnect switch or unplugged by standard rated plugs 4 All welders must be fused to pr2. 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 18 9 1 3 TEST LEAD METER PROBLEM IF NO READING PRESS WELD LIMIT PRESS CONNECTION READING OPERATING SWITCH ANNEAL SWITCH ACTUATED SWITCH X1 X2 5 VAC Bad control transformer X2 FU1 1 5 VAC Bad fuse connection X2 FU1 2 5 VAC Open fuse X2 LS3 2 5 VAC Open flashguard switch X2 PB1 2 5 VAC Open stop switch X2 LS1 2 5 VAC 151 open x X2 Lsl 2 5 VAC CRM contacts open X2 PB3 2 5 VAC Bad weld switch x X2 LS2 1 5 VAC Open connection to weld limit switch X2 h82 2 5 VAC Open weld limit switch X2 CRW 2 5 VAC PB4 or CRW defective X X2 PB4 1 5 VAC Open wire to anneal switch X2 PB4 2 5 VAC Bad anneal switch X L2 CRW 3 Line voltage Open wiring to contactor L2 CRW 4 Line voltage Bad contactor x Le Viel Line voltage Open wire to heat switch x NOTE To perform rep
3. head open space head closed space weld limit switch motor speed Pinch cut stock ends clean wire where it makes contact Refer to section 8 0 for approximate Place stock into welding dies so wire ends meet midway between each welding die Clamp into position with foot valve pedals Lower the flashguard to close Press weld button firmly in and release Velder k ends the safety switch After clamping the stock into position there should be approximately 1 16 between stoc Because of the amount of flashing it is advisable to step back from machine will finish the weld cycle without assistance anneal Hard drawn stock mild or high carbon steel Unclamp stock leaving weld burr intact will require an operation See 5 15 Trim off weld burr so welded area is equal to parent material diameter Incomplete burr removal or undercutting weld area will result in subsequent weld breaks of the ANNEAL OPERATION An anneal cycle may be incorporated to process mat improved bending qualities by placing welded st anneal anneal cycle COC terial for k into dies located on welder This may be a standard device activated by a manual Anneal as explained below Bu accessory device that will automatically process ccon or an the anneal 15 OPERATING INSTRUCTIONS PULSA
4. NO MD 01A Basic head assembly 30654 MD 01B Complete head assembly no dies no shoes 30661 MD 04 Shaft wipes felt 30640 MD 04A Shaft wipe retaining ring 48219 MD 05 Head return spring 80059 MD 08L Clamp arm left 30554 MD 08R Clamp arm right 30614 MD 08AL Clamp arm for arm anneal left 30643 MD O8AR Clamp arm for arm anneal right 30644 MD 09 Arm pivot pin steel 30526 MD 10 Arm pin washer 30517 MD 11 Grease zerk 90 degrees 48422 MD 12 Clamp cylinder 50 77706 MD 12A Cylinder replacement diaphragm 77713 MD 12B Cylinder shaft boot 77718 MD 12C Clamp cylinder clevis 77727 MD 13 Foot pedal clamp 77859 MD 13A Hand operated clamp valve 77864 MD 14 Pedal mount screw 90611 MD 20 End plate stationary head 30548 MD 21 End plate mount bolt 90687 MD 22 End plate movable head 40551 MD 23 End plate mount bolt movable head 90203 MD 25 Closed head space adjusting screw 30523 MD 26 End plate insulation 30641 MD 27 Muffler 77892 MD 30 Stationary anneal extension bar 62079 MD 31 Front anneal bar 62080 MD 32 Anneal bar mount bolts 90260 MD 33 Movable anneal extension bar 62081 MD 35 CA anneal clamp each front 62155 MD 36 CAL anneal pair 62020 MD 37 Anneal clamp mount bolt 90260 MD 38 Arm anneal die set 4 pieces 30524 MD 39 Anneal die mount screw 90617 MD 40 Complete truck 40571 MD 41 Truck door 40540 MD 43 Swivel caster 48108 MD 44 Stationary caster special order 48117 MD 45 1 shear 64009 MD 46 Shear mount bolt 90295 MD 47 Standard vise 1
5. UP if so equipped It is important that if a welder is to be operated for an extended period of time and heads 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 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 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 BASIC OPERATING PARTS WELD HEAT SELECTION SWITCH Weld heat is selected by means of a heavy duty tap switch with 6 steps of voltage The switch is conveniently located on the lower front of the welder Number one indicates the high heat number 6 indicates low welding heat Other numbers are equally graduated from high to low to allow just the right amount of voltage for the weld operation Not illustrated HEAD OPEN SPACE STOP BOLT The head open space stop bolt is located on the top plate in the right rear This adjustment is used to set the starting space between the dies HEAD CLOSED SPACE BOLT The
6. ab Adjustments must be made by the operating principles of good maintenance procedures utomatic as possible with a ility of the operator those thoroughly familiar with the welders Brush loose flashings from dies clamp shoes and flash tray Replace both sets if they b to prevent excessive build up Check welding die shoes and dies for excessive wear dies in poor condition is pr com xcessively worn Welding imary cause of poor welds Velding die notes Remove di located on a flat surface d s and clean or replace as necessary By placing welding dies on fine emery cloth ies may be brightly polished Brighten die seats on headpieces by placing emery cloth on a flat file Replace dies and pull down tightly DAILY 1Check for water leaks 2 Check for air leaks X 3Drain airline filter bowl 4 Tighten any loose parts 5 Clean flash pan WEEKLY lRepeat above service items 2 Grease following places with A Clamp arm pivot bearings B Headpiece slide bearings C Upset lever arm bearing hand grease gun QUARTERLY DISCONNECT POWER FROM WELDER lRepeat above service items 2 Tighten transformer clamp retaining ring to prevent transformer laminations from shorting of secondary burned vibrating out of place 3Blow all flashings from top of transformer
7. 0074 MD 23 End plate insulation 30075 MD 24 Secondary shunt 50004 MD 24A Shunt clamp plates 50000 MD 24B Shunt attaching screws long 14 90330 MD 24C Shunt attaching screws short 4 90329 MD 26 Open space adjustment screw 30000 MD 27 Upset pressure plate 30076 MD 27A Upset plate mount screw 90661 MD 27B Upset plate insulation optional 30077 MD 28 End plate mount screws 90660 MD 29 Anneal mount bracket 30058 MD 30 Veld transformer 50005 MD 31 Primary coil 50016 MD 32 Transformer secondary 50017 MD 36 Clamp cylinder stud 70001 MD 36A Cylinder stud nuts 92066 MD 37 Clamp link stop block 70002 MD 38 Clamp cylinder 77707 MD 38A Clamp cylinder clevis 77714 MD 38B Clamp cylinder boot 77719 MD 39C Clamp cylinder clevis 70009 33 PARTS LIST MD 6 WELDER MODEL PART NO DESCRIPTION ITEM NO MD 120 Upset Cam only 30083 MD 120A Upset cam complete 30085 MD 121 Upset cam insert 30084 MD 122 Upset cam shim 30086 MD 123 Upset lever bar 30087 MD 124 Lever bar rollers 30521 MD 125 Axle for roller 30510 MD 126 Lever bar pivot bushing 30522 MD 127 Lever bar pivot bolt 90687 MD 48 Upset cover 40618 MD 49 Head return assist spring 80045 MD 129 Quadrant plate 30679 MD 129A Qua
8. 8112 MD 47H Heavy duty vise 78111 MD 48 Standard vise bracket 60022 MD 48H Heavy duty vise bracket 60005 MD 49 Vise bracket mount bolt 90295 30 PARTS LIST MD 4 amp 5 WELDERS MODEL PART NO DESCRIPTION ITEM NO MD 50 Vise mount bolt 90262 MD 51 Flashguard assembly 30656 MD 52 Flashguard mount bolt 30672 MD 53 Flash shield safety switch 57813 MD 54 Upset cover 30551 MD 55 Upset cover mount screw 90656 MD 56 Flash tray 40500 MF 57 Flash tray mount bolt 90202 MD 58R2 Contour dies pair 3 grooves 30662 MD 58V2C Standard dies copper 30594 MD 58V2A Standard dies alloy 30618 MD 60R Contour shoes pair 30673 MD 60S Shoes complete w inserts insulation pair 30660 MD 60SL Shoe left 30542 MD 60SR Shoe right 30543 625 Set of inserts 4 pieces 30659 MD 62SA Insert screw 90703 MD 62SL Left insert 30536 MD 62SR Right insert 30537 MD 62SS Straight insert 30535 MD 63S Insulation for shoes set 30671 MD 64 Shoe attaching bolt 90664 MD 65 Die attaching bolt 90657 MD 70F Complete transformer 50558 MD 70FP Primary 50569 MD 70FS Secondary 50515 MD 70S Shunt 50527 MD 71U Transformer ring upper 50506 MD 71L Transform
9. D 159 Flow control valve 778 62 MD 500 DC motor control 57734 MD 501 Gear reducer w motor n s 40616 32 PARTS LIST MD 6 WELDER PART NO DESCRIPTION ITEM NO MD 01B Basic head assembly with shafts shields 30067 MD 01A Stationary head attaching bolts 90683 MD 04 Head return spring 80059 MD 07 Clamp arm pivot pin 30014 MD 07A Bell crank pivot pin 30015 MD 08 Left clamp arm 30080 MD 08A Right clamp arm 30081 MD 09 Clamp eccentric leveling block 70005 MD 10 Bell crank 70007 MD 10A Bell crank block pin 70010 MD 10B Bell crank block 70004 MD 10C Bell crank retaining screw 90665 MD 16MD2 Standard copper dies 2 V groove 30060 MD 16MD3 Standard copper dies 3 V groove 30059 MD MD60S Die shoes standard 30065 MD 19 Shoe attaching screw washer 30068 MD 19A Attaching screw insulating washer 30068 MD 20 Shoe attaching screw 90691 MD 20A Shoe screw insulating tube 30069 MD 20B Shoe boss insulating washer 30070 MD 20C Shoe boss insulating ring 30071 MD 20D Shoe insulating plate 30072 MD 08B Arm insulating spacer 30073 MD 21 Die attaching screw 90689 MD 22 Movable head end plate 3
10. MICRO WELD MODEL MD 4 5 amp 6 FLASH 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 MD 4 MODEL MD5 Type of Welding Process Flash Weld Flash Weld Welding Range 250 to 750 500 to 1 125 Material Suitability Steel Rod Steel Rod Standard Operating Voltages 460 230 Volts 460 230 Volts Maximum Line Demand 460 Volt 115amps 100 duty cycle 137 amps 100 duty cycle 362amps 10 duty cycle 433 amps 10 duty cycle Maximum Line Demand 230 Volt 230amps 100 duty cycle 274 amps 100 duty cycle 724amps 10 duty cycle 866 amps 10 duty cycle Single Phase AC Transformer 75 KVA 50 duty cycle 90 KVA 50 duty cycle Clamp Method Pneumatic Foot Controlled Pneumatic Foot Controlled Upset Method Motor Adjustable Motor Adjustable Mounting 4 Caster Wheels 4 Caster W
11. N SPACE The headpiece open space is adjusted by a bolt that pushes against the lazy arm See Figure 5 This setting must be made after setting the closed space adjustment Use the method described in Figure 5 to establish the proper open Space 6 3 10n the MD 6 Model please refer to figures 1 5 in conjunction with Section 10 Print 4B 5809 10 4 s5 6 WELD LIMIT SWITCH The weld limit either increase or decreas th tim of Determine which quadrant to maintains the quadrant posi enable the quadrant to be changed graduated scale etched on t Also refer amp 2 change tion MOTOR LIMIT SETTING t switch adjustment will the heat cycle during the weld cycle a Loosening this nut to a new position he quadrant to Section 8 0 for approximate setting single winged nut will on a to Figures 1 Refer The motor limit switch quadrant is factory preset and should no need field adjus Lment adjustmen winged nul Det d t maintains the quadra nut will enable the quadrant to position on a graduated scale rmin Refer to Figure 1 DRIVE MOTOR ADJUSTMENT DC Drive is Standard AC Drive is Optional But which quadrant to nt posi be cha tched o tion if this ever needs change a single Loosening this nged to a new n the quadrant This adjustment is made by turning a potentiome
12. T THE WELD BURR SHOULD BE POSITIONED THE DIAMETER OF THE ROD ABOVE VISE JAWS AND BENT BACK FORTH UNTIL ROD BREAKS A GOOD WELD WILL BREAK ACROSS OR ON 6000 POOR POOR EITHER SIDE OF THE WELD 8 0 SUGGESTED SETTINGS STARTING WELD LIMIT SPACE WELD FLASHING SWITCH BETWEEN CLAMP MATERIAL SIZE HEAT SPEED SETTING DIES GROOVE PRESSURE MD 4 250 750 Steel 4 Dia 6 100 T i Front 00 PS Steel 3 8 Dia 5 90 1 Middle 00 PS Steel gt Dia 5 805 1 5 Middle 00 PS Steel 5 8 Dia 4 70 4 34 Rear 00 PS Steel Dia 2 70 4 Rear 00 PS MD 5 500 1 125 Steel 1 Dia 6 100 1 1 3 8 Front 00 PS Steel Dia 5 100 2 1 3 8 Front 00 PS Steel 1 Dia 2 60 2 34 Rear 00 PS Steel 1 1 8 Dia 1 60 2 34 Rear 100 PSSSI MD 6 500 1 500 Steel 9 16 Dia 6 100 4 34 2 1 8 Front 00 PS Steel 5 8 Dia 6 100 4 4 2 1 8 Front 00 PS Steel Dia 6 90 4 2 1 8 Front 00 PS Steel 1 Dia 4 70 3 3 Rear 00 PS Steel 1 1 8 Dia 4 65 3 37 Rear 00 PS Steel 1 1 8 Dia 4 60 2 37 Rear 65 PSI Steel 1 Dia 2 50 I 3 u Rear 90 PSI 16 9 0 DIAGNOSTIC CHART FOR TROUBLE SHOOTING WELDING ACTION CAUSE REMEDY Starts flashing but cycle is broken and weld if any has large push up or weld may pull apart Weld heat too low Increase weld heat Upset speed too fast for welding heat Slow down flash cycl
13. TING ANNEAL TIMER UNIT To operate the pulsating a Model MD 4 nneal remove the w welding jaws and Reclamp t located in fron t of welder midway between th Operating switc anneal jaws h located o he wire in the anneal The weld burr shou timer incorporated in the MD 5 and MD 6 welder d from the jaws d be placed n front panel Activate automatic anneal Before annealing a weld it would be best to clamp a wire the same size as the wire to be welded in the anneal jaws as a test to determine the approximate timer settings Set the anneal heat switch one heat higher than that used to weld the wire Next set top timer dial total time to around 30 seconds and the On Timer to two seconds and the Off Timer to two seconds Depress and release anneal Switch Timers will complete the time cycle and turn off If settings given above heat the wire too hot any of these three settings may be lowered A Anneal heat switch setting B Overall time C Time on If setting does not heat the rod up enough increase any one or more of the se is used to allow heat being heated temperat P ttings mentioned above ulses to spread out in The ideal settings are those that cause the ure to rise gradually to the correct anneal temperature and then cut o Ef Variations in the te
14. air consult section 13 for parts identification 19 10 0 ELECTRICAL SCHEMATIC lt xil AMER THYRITE RESISTORS THYRITE RESISTORS NOTE A UNLESS OTHERWISE SPECIFIED ALL 120 V CONTROL WIRES TO BE NO 16 AWG RED NOTE B UNLESS OTHERWISE SPECIFIED ALL NEUTRAL WIRE TO BE NO 16 AWG WHITE NOTE C WHERE POSSIBLE USE ORANGE WIRE ON HIGH VOLTAGE WIRING ABOVE 200 V NOTE D FOR 460 VAC OPERATION USE SOLID JUMPER AS SHOWN FOR 230 VAC OPERATION USE DASHED JUMPERS AS SHOWN 20 MODEL MD 6 WATER LINE DIAGRAM WELD TRANSFORMER WATER COOLING TUBES WATER IN WATER OUT WELD HEADPIECE B 5770 21 MODEL MD 6 UPSET ADJUSTMENTS A HEAD RETURN SPRING B OPEN HEAD SPACE ADJ STOP SCREW C SHIM D INSULATION SHIM E ANVIL F UPSET LAZY ARM G UPSET CAM H CAM INSERT SHIM J CAM INSERT T Tram se ll ga e ill DULL 22 MODEL MD 3 4 amp 5 UPSET ADJUSTMENTS A CLOSED HEAD SPACE ADJ C OPEN HEAD SPACE ADJ G UPSET LAZY ARM J UPSET CAM NOTE VIEW SHOWN FROM FRONT OF WELDER WITH SAFETY COVER PLATE REMOVED C 2795A 23 MODEL MD 4 amp 5 PNEUMATIC SYSTEM 24 MODEL MD 6 PNEUMATIC SYSTEM AIR SUPPLY 23 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
15. alves are used to i nitia te foot valves are located housing arm and the left pedal The right foot a pe E the air cl he bottom dal operated the 1 clamp stock place it i press the top edges of release stock press on pedal CAUTION Care m sure hands are clear of clamp arms gauge is located on the left be adjusted from 80 90 n operates the proper weldi ol X The foot Lamp controlled air cylinders The the welder the right clamp clamp arm To ng die groove and the bot us PSI EI ton Lt pedal on foot val n edge of foot valve be used when clamping An air regul t end of the welder and should Flow control ve To EIIE tock be tor with S a valves are factory installed to keep clamp arm movement slowed MOTOR SPEED CONTROL The motor speed control is located on A potentiometer located on the panel adjust the motor speed potentiometer the right front control box will A scale of 1 10 is found on the 1 is slow and 10 is fast 4 0 BASIC OPERATING PARTS LOCATION 4 0 BASIC OPERATING PARTS LOCATION 10 11 12 13 14 TYPICAL SEQUENCE OF OPERATION Wire to be joined must be free of rust insulating materials with welding dies corrosion or other settings Adjust Adjust Adjust Adjust
16. drant plate spacer 40608 MD 130A Weld switch quadrant limit 50508 MD 130B Motor switch quadrant 50510 MD 131 Quadrant mount bolt 90217 MD 133 Quadrant switch lever 30525 MD 134 Switch lever mount bolt 90262 MD 135 Switch operating cam 30532 MD 136 Cam set screw 90015 MD 137 Cam spacer 30534 MD 138 Limit amp motor switch 57813 MD 139 Motor 3 H P 57743 MD 140 Speed reducer 57746 MD 141 Motor sprocket APPL MD 142 Speed reducer sprocket APPL MD 25 3 8 ship for closed stop 30676 MD 25A 5 16 shim for closed stop 30678 MD 25B shim for closed stop 30678 D C motor control 57736 4 push button control station 57854 Thyrite resistor 57676 8 point heat switch 300 amp 57857 Speed reducer 57746 Motor pulley APPL Speed reducer pulley APPL Chain APPL Belt APPL 34
17. e Flashing cycle too long for stock size Allow small space between ends of stock when placed in welding dies Does not start flashing Ends of stock too blunt Grind or cut stock to makes big burr or hot chisel point metal drops out before Weld heat too low Increase weld heat or weld cycle is complete slow down upset speed Weld cycle normal yet Weld limit switch set to Increase weld heat or voids found in weld hold on too long slow down upset speed Lack of shims under upset Add extra shims under cam upset cam 1 32 at a time Pinch cut on rod too tapered or flashing cycle is too short Change angle of rod cut or adjust for longer flash cycle Weld action normal until upset occurs then welder stalls Too much shim thickness under upset cam Remove some of upset cam shims Flashing cycle too short Decrease flashing speed or increase weld heat Dirty stock causing poor contact between die and material Clean scale or rust from stock Flashing and weld cycle seem normal but weld is pulled apart while hot Weld limit switch set to hold on too long Readjust limit switch to cut out sooner Too much heat stored in rod during flashing Space ends apart to shorten flash cycle Flashing speed too slow or weld heat too hot Increase flashing speed Weld burns on stock Dirty stock Remove rod scale before welding Dirty dies Wire brush die grooves Va
18. er ring lower 50535 MD 72 Transformer studs 50521 MD 78 Control step down transformer 59525 TS 06 6 point heat switch 56549 MD 82 Heat switch mount bolt 90294 MD 83A Contactor state voltage amp Serial number 57611 MD 83C Contactor repair kit state voltage amp serial APPL number MD 87 Terminal block 53000 MD 88 3 stage anneal timer 50572 MMD 8 9 Anneal timer operating switch 57810 MD 120B Upset cam with insert 30667 MD 121B Insert only for cam 30529 MD 121C Insert shim 30530 MD 122B Insert attaching screw 90619 MD 123B Upset leverage bar w roller 30530 MD 124B Roller 30521 MD 125B Roller axle 30520 31 PARTS LIST MD 4 amp 5 WELDERS MODEL PART NO DESCRIPTION ITEM NO MD 126B Pivot bushing leverage bar 30522 MD 127B Pivot bushing bolt 90687 MD 128B Open stop bolt 90040 MD 129 Quadrant mount plate 50529 MD 129A Quadrant plate spacers 40608 MD 130B Weld switch quadrant 50508 MD 131B Motor switch quadrant 50510 MD 132B Quadrant mount bolt 90021 MD 133B Quadrant switch lever 30525 MD 134B Lever mount bolt 90262 MD 135B Cutoff cam switch 30532 MD 136B Cutoff cam set screw 90015 MD 137B Cutoff cam spacer 30534 MD 138 Limit amp motor cutoff switch 57813 MD 157 Thyrite resistor 58132 MD 158 4 button operating station 57854 M
19. event 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 26 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 27 13 0 PARTS LIST 13 0 PARTS LIST 28 29 PARTS LIST MD 4 amp 5 WELDERS MODEL PART NO DESCRIPTION ITEM
20. head closed space bolt is located on the movable headpiece end plate This adjustment is used to set the closed or finishing space between the weld dies WELD LIMIT SWITCH The weld limit switch is located behind a small door on the lower right of the front panel MOTOR LIMIT SWITCH The motor limit switch is located behind a small door on the lower right of the front panel WELDING DIES The welding dies lower and die shoes upper serve three purposes 1 To carry current for welding 2 To align two ends of stock 3 To prevent material slippage during a weld cycle Small rod is placed in the smaller grooves and the larger rod is placed in the bigger grooves WELDER PUSHBUTTON OPERATING STATION Four pushbutton switches make up th station 1WELD BUTTON This button activates all electrical welder operating circuits and initiates the weld flash cycle after all safety devices have been closed 2 MOTOR BUTTON This button activates the motor drive circuits only and is used in adjusting welder spacing without activating the weld transformer 3 ANNEAL BUTTON This button activates the manually operated anneal circuit only 4 STOP BUTTON This button terminates all used with the motor button to aid in making welder adjustments CLAMP ARMS The clamp arms are air operated electrical Cycles and can be v
21. heels Dimensions and Weights Height Overall 30 1 50 in Floor space 60 in x 37 in 60 in x 37 in Welding Die Height 43 in 43 in Weight 2025 LBS 2325 LBS 2 0 SPECIFICATIONS MODEL MD 6 Type of Welding Process Flash Weld Welding Range 750 to 1 500 Material Suitability Steel Rod Standard Operating Voltages 460 230 Volts Maximum Line Demand 460 Volt 472amps8100 duty cycle 944amps 10 duty cycle Maximum Line Demand 230 Volt 944amps 100 duty cycle 888amps 10 duty cycle Single Phase AC Transformer 308 KVA 50 duty cycle Clamp Method Pneumatic Foot Controlled Upset Method Motor Adjustable Mounting 4 Caster Wheels Dimensions and Weights Height Overall d Floor space 40 in x 85 in Welding Die Height 44 in Weight 5400 LBS FEATURES 2 2 1 Micro Weld quality and workmanship Heavy duty construction components East 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 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 suff
22. icient 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 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 WATER HOOK
23. m be caused by not star temperature or variat Ed ions ratur ng wi in electrical rod and anneal jaw a particular si may be repeated Once e and alloy settings have b The Off Time to the wire from one time to another can th approximately the same rod contact between the n determined for a chart can be made so they UPSET ROLLERS ADJUSTING CAM ROTATION 1 PS IS Z lt 34WELD MOTOR LIMIT SWITCH D CONTROL CAM LIMIT SWITCH 35 MOTOR CONTROL GEAR BOX SHAFT CAM 2 4 LIMIT SWITCH OPERATING LEVERS AND CAM FOLLOWER PINS POINT A ADJUSTMENT POINT WHERE LIMIT SWITCH CUTS OFF ADJUSTMENT AREA OF UP 3 16 WHERE LIMIT FOR STOCK SIZES 3 8 SWITCH CUTS OFF FOR 5 8 SIZES OVER 5 8 STOCK FIGURE 1 amp 2 6 0 SPECIAL ADJUSTMENTS 6 1 HEAT SWITCH SETTINGS This setting determines the amount of heat available for welding In general use higher heat settings for larger stock and lower heat settings for smaller stock Number one heat is the highest setting and number six heat is the lowest heat 6 2 HEADPIECE CLOSED SPACE The closed space bolt should be adjusted to equal the diameter of the rod as measured between the dies at the groove being used to weld that particular stock size The closed space should be set prior to setting the open space adjustment Refer to Figure 4 for this setting 6 3 HEADPIECE OPE
24. n condi before bolting them tightly into place surface wil welding voltage 5 Wel lding die shoes must swivel insulate the welding dies a freely wit These parts will bottoms of dies tion An oxidized d reduc ffeci tiv in clamp arm pivots to prevent cracking of die shoes boss if necessary 6Welding die set wil occasionally supply of replacement parts available slippage is a probl lem caused by poor die cause of wire breaks File down die shoe 1 wear with use and must be changed or good welding results Keep and adequate Wire and rod sets and a major 15 7 6 RECOMMENDED SHEAT CUTS FOR PINCH CUT SHEAR EXAMPLE SHEAR BLADE SHEAR BLADE LX PLACE IN DIE GROOVES AS ILLUSTRATED CROSSING CUT ENDS weg 9 Y E T A GOOD WELD WITH CORRECT BURR AND EVEN HEAT PENETRATION V OW occi Az A POOR WELD WITH IMPROPER UPSET AND A MINIMUM AMOUNT OF HEAT PENETRATION IEEE BURR REMOVAL EXAMPLES WELDERS NOTE A DESIGNATION INDICATES POSITION OF FRAYING SURFACES FOR OPTIMUM WELD ALIGNMENT WELD HEAT AND UPSET PRESSURE UTILIZATION AGOOD WELD WILL BREAK ACROSS WELD ON A BEND TEST A POOR WELD WITH LITTLE FUSION AND NO UPSET BURR WELD BURR MUST BE REMOVED AS CLOSE TO PARENT METAL AS POSSIBLE INCOMPLETE BURR REMOVAL OR EXCESSIVE GRINDING WILL CAUSE TENSION BREAKS ON SUBSEQUENT WIRE DRAWING OPERATIONS BEND TES
25. riations in welding Loose upset cam Tighten cam check locking key Input voltage variations Check input voltage only 5 drop permissible Loose welding die or Clean and tighten transformer secondary connection secondary connections Misalignment of rods Worn die grooves Replace dies Starting gap between dies Reduce starting space too great either with motor limit switch or space adjusting screw Loose headpiece slid Return to factory for re shafts cementing Ends or rod bent Straighten 6 of material where rod meets dies 17 1 1 2 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 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 the 1 position
26. ter on the front of on the po the cam i the welder tentiometer larger stock nsert 1 During a weld cycle not happe n ngages th A graduated scale of 1 10 is located is slowest speed and is used for there should be flashing when the ends of stock begin to touch and until lazy arm roller If this does refer to Section 9 0 11 HEADPIECE AND WELDING DIE ADJUSTMENTS FIGURE 3 STARTING POSITION OF WELDING DIES LENGTH OF PINCH CUT PLUS 14 EQUALS SPACE BETWEEN WELDING DIES EXAMPLE A 1 2 A Va B or G Ve 1 4 Ya LARGE ROD SMALL ROD FIGURE 4 CLOSED POSITION OF WELDING DIES SPACE BETWEEN WELDING DIES EQUAL TO DIAMETER OF ROD WELDED CHECK WITH MOVABLE HEADPIECE IN MAXIMUM UPSET POSITION LAZY ARM HEADPIECE OPEN MOVABLE ADJUSTING SCREW HEADPIECE UPSET PLATE ROTATION OF CAM UPSET CAM MODELS HEADPIECE CLOSED MD4 and MD5 ADJUSTING SCREW FIGURE 5 ADJUSTING FOR STARTING POSITION AND ADJUSTING FOR CLOSED POSITION ON THE MD4 and 5 THE STARTING POSITION IS ADJUSTED BY THE LAZY ARM STOP SCREW AND THE LARGE SCREW AND NUT ON UPSET PLATE ADJUST THE CLOSED POSITION 1 PPP Pp PREVENTIVE MAINTENANCE TECHNIQUE MAINTENANCE PROCEDURES AS REQUIRED Keep in mind that these welders are precision built to last many years but will require They are designed to be as a minimum dependence on the
27. to prevent 4 Check contacts on magnetic contactor replace if worn badly 5 Wash contacts on heat selection switch with carbon tetrachloride dry with a clean cloth and place a thin coat of petroleum jelly on contacts 14 ANNUALLY DISCONNECT POWER FROM WELDER causes of bad welds CARE OF DIE SETS 1 Repeat above service items 2 Check for wear in clamp arm bearings replace when needed 3Check for excessive headpiece wear die seats not lining up properly 4 Check pop safety valve on air system to be sure they ar operative 5Clean inside of welder housing WELDING DIES AND DIE SHOES INFORMATION Description Velding dies Lower conducting electrode and clamp jaw Velding die shoes Upper clamping member Velding dies and die shoes in poor condition are the main lUse a brass or fiber blade to remove particles of flashings tha die t build up o burns on ma 2Do not at welder ini burn die grooves clamping parts tempt 3 Do not ot use welding 4 Whenever wel n die sets to clamp material that to die sets oversize materials will ding di is Undersize materia Excessive flash build up causes terial and shorting of die sets not suited for s will slip and overstress die sets for a vise withstand the mechanical abuse clea s are replaced and corresponding die seats to a bright and clea
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