MICRO PRODUCTS COMPANY MANUFACTURES OF PRECISION WELDING MACHINES MODEL SEMT FINE WIRE BUTT WELDER SERVICE MANUAL

Transcription

1 MICRO PRODUCTS COMPANY MANUFACTURES OF PRECISION WELDING MACHINES MODEL SEMT FINE WIRE BUTT WELDER SERVICE MANUAL 1

2 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 SEMT Stock Size Range-Steel Stock Size Range-Aluminum Stock Size Range-Copper Standard Operating Voltages Single Phase Power Type Welding Process Line Demand Heat Selection Switch Single Phase Weld Transformer Truck Mounted Welder Floor Space 24 x 24 Overall Height in. to.025 in. Diameter.0127mm to.635mm.007 in. to.020 in. Diameter.178mm to.508mm.007 in. to.020 in. Diameter.178mm to.508mm 115volts 60 Hertz Capacitor Discharge 5 Duty Cycle 15 Duty Cycle Rheostat 0.8 Duty Cycle 2 Stationary Casters 2 Swivel Casters Height to Welding Dies 44 Welder Weight Approx. 130 LBS MODEL SEMT FEATURES Welding heat is meter indicated Anneal heat is meter indicated Sensitive headpiece Stock clamps foot or hand activated Weld heat, rheostat control Wire shear, square cut Fluorescent lamp Magnifying glass OPTIONAL FEATURES 50 Hertz service step down transformer for line voltages outer than 120 volts Suitable for bench or crane mounting 2

3 2.0 GENERAL OPERATING INSTRUCTIONS 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. 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. 2.2 SAFETY PRECAUTIONS 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 MECHANICAL Operator while 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. 3

4 3.0 BASIC OPERATING PARTS 3.1 WELDING HEAT The welding heat is adjusted by turning the knob on the right hand corner of top panel, and the welding heat that will pass across welding dies when weld is made is indicated by the welding heat meter directly above knob. When knob is turned to the right (clockwise) the voltage is increased. The movement of this knob to the left (counterclockwise) decreases the voltage. CAUTION. Do not force knob at either end of travel for this will result in damage to variable voltage transformer. 3.2 DIE SPACING The welder is capable of welding a variety of wire sizes (capacity shown on nameplate) but for each change in wire diameter a change in space between the dies is needed. This is obtained by rotating index spacing dial located on left of headpiece. Rotation of dial away from operator (counterclockwise) the space is increased. Numbers stamped on edge indicate a definite space. The number 10 (ten) being the largest opening, and number 1 (one) the smallest. In the course of welding the index spacing knob is rotated toward operator until flange on knob comes in contact with operating switch button, and is continued till operating switch button is depressed and weld is made. Spacing operation must therefore be made after each weld. 3.3 UPSET PRESSURE Spring tension setting is obtained by the rotation of the knurled thumbnut located on the left and to the rear of welding head. The spring tension must be changed when size or types of wire to be welded is changed, number 1 (one) being the least tension. 3.4 WELDING DIES To prevent excessive wear on the die grooves, small wires should be placed in small grooves and larger wires in their respective grooves. The does serve three purposes: to carry the current to the wires being welded, align the two ends of the wire and prevent wire from slipping while the pressure is applied during welding. 4

5 3.5 ANNEALING OR TEMPERING DEVICE The annealing or tempering device is located just above and in the center of the lamp reflector. It consists of a U shaped nichrome strip heated by its own transformer. And which is caused to heat by depressing foot pedal all the way. Wires to be welded can be clamped in die grooves by means of raising clamping fingers by hand, or clamping fingers can be raised also by depressing foot pedal a short distance (a further depression on this foot pedal contacts anneal or tempering device switch and causes the nichrome strip to heat). 5

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7 5.0 TYPICAL OPERATING SEQUENCE Wire to be joined must be free of rust, corrosion or other insulating materials, clean wire where it makes contact with welding dies. 1. Adjust weld heat knob to proper setting. 2. Adjust tension-indicating knot to correspond to chart settings. 3. Rotate space-adjusting cam to correspond to chart settings. 4. Square cut each end of wire with cutter provided on unit 5. Place wires in correct welding die groove, so ends touch midway between open jaws. 6. Move magnifying glass away from weld area to prevent lens damage. 7. Rotate the index spacing knob toward the operator until flange on knob contacts and depresses the operating switch. 8. Hold until the weld is completed (less than 2 seconds required.) 9. Release clamp fingers and remove wire. 10. Hard drawn material or high carbon steel will require an anneal operation, handle carefully prior to anneal to prevent fracturing a brittle weld. 5.1 To anneal the weld, follow these instructions: A. Place and hold welded section in U shaped heating element of annealing device. B. Depress foot pedal all the way down to activate anneal switch C. Anneal temperature meter located on left hand control panel, reads directly in degrees Fahrenheit, when reading is multiplied by 100. NOTE: Do not hold foot pedal down too long or the indicating needle on the meter will pass #18 on the scale and damage the meter. 5.2 Trim off upset burr to conform to parent metal diameters. 7

8 6.1 HEADPIECE CLOSED ADJUSTING SCREW 1. Rotate index spacing cam to #1. 2. Adjust screw A for.001 of clearance between front edges of welding dies. 3. Tighten locknut into position. 4. Clearance is required to prevent possible electrical damage. 6.2 HEADPIECE OPEN ADJUSTING SCREW 1. Rotate index spacing cam to # Adjust screw B so it contacts headpiece casting and at the same time the index spacing cam push rod contacts movable headpiece. 3. Should the adjusting screw be in poor adjustment, it is possible the cam could not be positioned at #10. 8

9 6.3 TENSION CALIBTATING SCREW 1. Rotate tension-adjusting knob E flush with end of adjusting worm. 2. Rotate index spacing cam to #1. 3. Pivot movable headpiece, by hand slightly to right and release. 4. Movable headpiece should just restore to a rest position. 5. Adjust calibrating screw C-1 to obtain correct and initial tension. 6.4 LIMIT SWTICH ADJUSTING SCREW, FOR ACMT ONLY 1. Turn on switch. 2. Place index spacing cam on #2. 3. Push operating switch, only located below index spacing cam. 4. Weld voltage meter located on top panel may or may not indicate a voltage. If meter shows a voltage, turn limit switch adjusting screw D until meter just drops off. If meter doe not show a voltage turn adjusting screw D until meter shows a reading and then back off until meter drops off. 9

10 7.0 PREVENTIVE MAINTENANCE 7.1 AS REQUIRED: Flashings must be removed from between welding dies and clamp fingers with a brush. If flashings are attached so that they cannot be removed by brushing with a soft wire brush, they may be broken loose with a scraper made of fiber or wood. 7.2 DAILY: 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 Check condition of clamp springs. Replace all broken springs or springs that have taken a set 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. 7.3 MONTHLY: Remove welding dies and clean bottom of die surface with #120 emery cloth. Do this by placing the emery cloth on a flat surface plate and rubbing the dies on it, keeping the surface of the die flat. Wipe die and die seat with a clean cloth and replace, taking care not to touch either contact surface with the hand Check anneal dies and replace worn or broken parts Check insulating fiber pin on limit switch adjusting screw for broken or frayed ends Check upset tension spring and clamp springs. Replace if springs have been over-stretched and will not return to normal position. 7.4 QUARTERLY: Disconnect power to welder. Check contacts on operating and limit switch. Replace those that are burned Check anneal dies and replace worn or broken parts Check insulating fiber pin on limit switch adjusting screw for broken or frayed ends Check upset tension spring and clamp springs. Replace if springs have been over-stretched and will not return to normal position. 10

11 7.5 ANNUALLY: Remove the movable headpiece and check condition of slide shafts. Wash slide shafts with low residue cleaner, lightly oil and replace headpiece Check condition of headpiece castings. If worn or broken, replace with new headpiece. If welder is used in an area where there are corrosive fumes, clean off all oxides and paint where possible. 7.6 WELDING DIE INFORMATION Description: Welding dies Lower conducting electrode and clamp jaw. Welding clamp fingers Upper clamping member. WELDING DIES IN POOR CONDITION ARE THE MAIN CAUSES OF BAD WELDS CARE OF DIE SETS 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 Do not attempt to clamp material that is not suited for welder into die sets. Undersize materials will slip and burn die grooves, oversized materials will overstress clamping parts Do not use welding die sets for a vise. These parts will not withstand the mechanical abuse Whenever welding dies are replaces, 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 reduce effective welding voltage 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. 11

12 7.7 FINE WIRE APPLICATIONS SUGGESTED ADJUSTMENTS SEMT MODELS FIG.1 Welding fine wire within the size range of.005 (0.13mm) To.010 (0.26mm) care must be taken in aligning the weld junction to assure dependable welds. Heat selection, pressure adjustments and initial starting space are important variables, but alignment on fine wire ends becomes the most important consideration. We suggest that alignment be observed from two planes, from the topside and also from the front. FIG.2 Welder clamp fingers, upper mechanism, must be in proper adjustment with regard to welding dies, and lower portion of clamp mechanism. Welding clamp fingers may be carefully aligned with attaching screws and polished for correct position with a fine emery cloth placed between fingers and dies. 12

13 FIG.3 Welding dies with burrs or particles lodged in die groove will also cause poor alignment. FIG.4 When excessive clamp finger pressure indents or deforms wire, light duty torsion springs are available as part number MT-08. Improved upset spring pressure may be obtained by using light duty tension spring assembly, part number MT-16, MT-17, MT-18, MT-19, MT-21, MT SUGGESTED SETTINGS SIZE MATERIAL DIE GROOVE WELDING HEAT RANGE SPACE TENSION ANNEALING TEMPERATURE.005 Ferrous Front 2 Low F.015 Ferrous Third 14 Low F.025 Ferrous Rear 17 High F.007 Non-ferrous Front 1 ½ Low F.010 Non-ferrous Second 10 Low F.020 Non-ferrous Rear 16 High F NOTE: These settings are approximate and may be varied to suit needs. IMPORTANT This is important that this machine be handled carefully as rough usage will result in improper alignment of the abutting wire ends. CARE OF MACHINE Keep in mind that this is a precision machine and as such, requires more than ordinary care. It is constructed to be as nearly automatic as possible, with minimum dependence on ability of operators. A few drops of oil applied occasionally will keep bearings in good condition. Adjustment should be made ONLY by those thoroughly familiar with the operating principles of this welder. 8.1 WELDING DIES INFORMATION Description: Welding dies Lower conducting electrode and clamp jaw Welding clamp fingers Upper clamping member Welding dies in poor condition are the main causes of bad welds. Care of die sets: 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. 2. Do not attempt to clamp material that is not suited for welder into die sets. Undersize materials will slip and burn die grooves, oversized materials will overstress clamping parts. 3. Do not use welding dies seats for a vise. These parts will not withstand the mechanical abuse. 13

14 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 reduce effective welding voltage. 5. Welding die sets will wear with use and must be changed occasionally for good welding results. Keep an 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. 9.0 DIAGNOSTIC CHART FOR TROUBLE-SHOOTING WELDERS WELDING ACTION CAUSE REMEDY Weld action normal but weld burr doesn t extend beyond wire Lack of spacing space obtained Molten metal is blown out and ends not joined Weld has complete burr but is dry and breaks off below surface of wire Weld good but poorly aligned Ends of wire buckle and may not weld Varying weld results Weld heat too high Stock is too small Low upset pressure Upset pressure too great High carbon steel wire Welding dies & clamp fingers Starting space Loose shafts Upset pressure too great Low weld heat Stock slipping Varying weld voltages Rod condition variations Dies Flashings Increase starting space until desired burr is Lower heat settings Check size rating of welder Adjust upset Lower upset pressure Carbon-steel wire often appears like this, process wire by annealing weld before removing burr Replace worn dies and clamp fingers Decrease starting space Return heads to factory Decrease starting space Increase weld heat Check Clamp finger pressure Check electric lines Clean and tighten transformer connections to heads Clean Rod where clamped in dies Replace dies Clean build-up of flash materials 14

15 9.1 ELECTRICAL TROUBLE-SHOOTING OF WELDER (CAUTION! Extreme care should be exercised 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 & L2 of the welder. Set the weld rheostat full clockwise.) FINAL ELECTRICAL CHECKS Set the weld rheostat full clockwise. Connect a 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. The weld meter should show full scale. Actuate the weld limit switch; observe the readings go to zero. Release the weld limit and operating switches, the reading should remain at zero. HOLD THE ANNEAL SWITCH DEPRESSED. The anneal temperature meter will slowly move up scale until full scale is reached. Release the anneal switch, observe that the meter returns to zero after complete cooling of the annealing device TEST LEAD CONNECTION L2 S1-2 L2 PB1-1 METER READING 115VAC 115VAC PROBLEM IF NO READING Bad on/off switch Open wire to operating switch PRESS OPERATING SWITCH RANGE SWITCH ACTUATED PRESS ANNEAL SWITCH L2 PB VAC Bad Operating switch X L2 FS1-1 L2 FS1-2 L2 CR VAC 115VAC 115VAC Open wire to anneal switch Bad anneal switch Open connection or wiring L1 C3+ 420VDC Bad rectifier pack LOW C1+ C1-140VDC D1, C1, or F1 Bad LOW C2+ C2-280VDC D2, C2, or F2 Bad LOW C3+ C3-420VDC D3, C3, or F3 Bad LOW C4+ C4-420VDC C4, C5 or range switch bad HIGH Note: to perform repair consult section 13 for parts identification. X 15

16 10. ELECTRICAL SCHEMATIC 16

17 11.0 SAFETY REMINDERS The following accident prevention information is presented to eliminate potential hazards while operating, inspecting or repairing Micro-Weld 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. 4. 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 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 fuse 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 head selection switch, potentiometer or range selection devices must not be changed to a new position while a weld operation is in process. 17

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 in section 13 and provide MICRO with the circled number CALL MICRO at A.C Or Toll free at Provide MICRO with your company name and purchase order number. 18

19 13.0 PARTS LIST 19

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22 PARTS LIST SEMT MODEL/ PART NO. DESCRIPTION ITEM NO SEMT-01 Welding dies.005 to.025 wire cap SEMT-03A Head assembly, stat. & movable Castings SEMT-03 matched machined w/pivots & center Head assembly, complete w/all operating parts SEMT-04 Bearing for movable headpiece SEMT-05 Center for movable headpiece SEMT-06 Operating switch cover SEMT-07 Arm stop and screw SEMT-08 Arm torsion spring.080 square SEMT-09 Arm torsion spring collar SEMT-10L Arm torsion, left SEMT-10R Arm torsion, right SEMT-11R Clamp fingers, right SEMT-11L Clamp fingers, left SEMT-12 Space & operating knob SEMT-13A Space knob mount bolt SEMT-14 Push rod, space cam SEMT-14A Space adjusting screw SEMT-15 Welding die attaching screw SEMT-16 Tension adjusting nut SEMT-17 Tension adjusting worm SEMT-18 Tension calibrating barrel SEMT-19 Tension calibrating spring SEMT-20 Tension spring SEMT-21 Insulating tube SEMT-22 Transformer clamp ring SEMT-23 Headpiece open stop screw SEMT-23A Closed headpiece stop screw SEMT-24 Clamp finger, retaining screw SEMT-25 Operating switch, short stem SEMT-28 Tension calibrating screw SEMT-30 Top panel (meter) SEMT-35A Truck w/foot pedal mechanism SEMT-35 Truck plain SEMT-37 Push rod tube, foot pedal SEMT-38 Push rod spacer SEMT-39 Push rod roller SEMT-40 Lamp shade w/set screw SEMT-41 Lamp tube SEMT-42 Lamp socket SEMT-44 Lamp ballast SEMT-45 Magnifying glass

23 MODEL/ PART NO DESCRIPTION ITEM NO SEMT-46 Magnifying glass frame w/ring SEMT-47A Magnifying glass clamp ring gasket SEMT-48 Lamp post SEMT-49 Transformer lug cap SEMT-50 Transformer lug cap insulating Plate SEMT-51 Weld heat rheostat SEMT-52 Line switch w/off-on plate SEMT-53 Welding transformer, state voltage SEMT-53P Welding transformer, primary coil SEMT-53S Welding transformer, secondary ribbon SEMT-55 H.D. Step down transformer complete w/caps SEMT-56B Anneal transformer lugged cap insulating screws SEMT-57 Diode SEMT-58B Fuse, 2 amp SEMT-62 Weld heat meter 0-45 VDC SEMT-63A Capacitor SEMT-67 Resistor SEMT-69 Anneal heat meter SEMT-72 Anneal switch, heavy duty kit SEMT-73 Caster swivel SEMT-73A Caster rigid SEMT-74 Wire shear, square cut.005 to SEMT-75 Magnetic contactor SEMT-75A Contactor mounting bracket SEMT-82 Standard insulating panel SEMT-84 Power pack bracket SEMT-85 Power pack complete SEMT-86 Power pack, extra capacity complete Application SEMT-88 Secondary insulating sleeve SEMT-90A Fluorescent light switch SEMT-92 Anneal arm attaching bolt & nut SEMT-93 Meter lead wire insulating bushing SEMT-94 High-low range switch SEMT-100L Anneal arm, left SEMT-100R Anneal arm, right SEMT-101 Anneal arm clamp clevis w/screw SEMT-102 Anneal heater unit w/thermocouple SEMT-103 Anneal heat unit insulating block SEMT-104 Line cord assembly SEMT-109 Annealing transformer SEMT-109P Anneal transformer primary coil SEMT-109S Anneal transformer secondary ribbon SEMT-116 Anneal meter lead wire