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Summary of Contents for MICRO PRODUCTS MICRO WELD MD 4
- Page 1 MICRO WELD MODEL MD 4, 5 & 6 FLASH BUTT WELDERS MICRO PRODUCTS COMPANY SERVICE MANUAL...
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Page 2: Table Of Contents
TABLE OF CONTENTS SPECIFICATIONS GENERAL OPERATING INSTRUCTIONS BASIC OPERATING PARTS BASIC OPERATING PARTS LOCATION TYPICAL OPERATING SEQUENCE SPECIAL ADJUSTMENTS PREVENTIVE MAINTENACE SUGGESTED SETTINGS DIAGNOISTIC CHART FOR TROULBE-SHOOTING 10.0 ELECTRICAL SCHEMATIC 11.0 SAFETY REMINDERS 12.0 BUYERS GUIDE 13.0 PARTS LIST SPECIFICATIONS MODEL MD 4 MODEL MD5 Type of Welding Process... - Page 3 FEATURES • 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...
- Page 4 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-UP (if so equipped) It is important that if a welder is to be operated for an...
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Page 5: Basic Operating Parts
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. - Page 6 WELDER PUSHBUTTON OPERATING STATION Four pushbutton switches make up the welder operating station. 3.7.1 WELD BUTTON This button activates all electrical circuits and initiates the weld flash cycle after all safety devices have been closed. 3.7.2 MOTOR BUTTON This button activates the motor drive circuits only and is used in adjusting welder spacing without activating the weld transformer.
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Page 7: Basic Operating Parts Location
BASIC OPERATING PARTS LOCATION... - Page 8 TYPICAL SEQUENCE OF OPERATION Wire to be joined must be free of rust, corrosion or other insulating materials, clean wire where it makes contact with welding dies. (Refer to section 8.0 for approximate settings.) Adjust head open space. Adjust head closed space. Adjust weld limit switch.
- Page 9 5.15 OPERATING INSTRUCTIONS – PULSATING ANNEAL TIMER UNIT To operate the pulsating anneal timer incorporated in the Model MD-4, MD-5 and MD-6 welder, remove the weld from the welding jaws and Reclamp the wire in the anneal jaws located in front of welder. The weld burr should be placed midway between the anneal jaws.
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Page 10: Special Adjustments
SPECIAL ADJUSTMENTS 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. - Page 11 WELD LIMIT SWITCH The weld limit switch adjustment will either increase or decrease the time of the heat cycle during the weld cycle. Determine which quadrant to change; a single winged nut maintains the quadrant position. Loosening this nut will enable the quadrant to be changed to a new position on a graduated scale etched on the quadrant.
- Page 14 PREVENTIVE MAINTENANCE TECHNIQUE MAINTENANCE PROCEDURES AS REQUIRED 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. Adjustments must be made by those thoroughly familiar with the operating principles of the welders.
- Page 15 ANNUALLY – DISCONNECT POWER FROM WELDER 7.4.1 Repeat above service items. 7.4.2 Check for wear in clamp arm bearings, replace when needed. 7.4.3 Check for excessive headpiece wear (die seats not lining up properly). 7.4.4 Check pop safety valve on air system to be sure they are operative.
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Page 16: Suggested Settings
RECOMMENDED SHEAT CUTS FOR WELDERS SUGGESTED SETTINGS STARTING WELD LIMIT SPACE WELD FLASHING SWITCH BETWEEN CLAMP MATERIAL SIZE HEAT SPEED SETTING DIES GROOVE PRESSURE MD-4 .250-.750 Steel ¼” Dia 100% 1 ½” Front 100 PSI Steel 3/8” Dia 1 ½” Middle 100 PSI Steel... -
Page 17: Diagnoistic Chart For Troulbe-Shooting
DIAGNOSTIC CHART FOR TROUBLE-SHOOTING WELDING ACTION CAUSE REMEDY Starts flashing but cycle Weld heat too low Increase weld heat is broken and weld, if Upset speed too fast for Slow down flash cycle any, has large push-up or welding heat weld may pull apart. -
Page 18: Troubleshooting Table
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.) 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. - Page 19 9.1.3 TEST LEAD METER PROBLEM IF NO READING PRESS WELD LIMIT PRESS CONNECTION READING OPERATING SWITCH ANNEAL SWITCH ACTUATED SWITCH X1 X2 115 VAC Bad control transformer X2 FU1-1 115 VAC Bad fuse connection X2 FU1-2 115 VAC Open fuse X2 LS3-2 115 VAC Open flashguard switch...
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Page 20: Electrical Schematic
10.0 ELECTRICAL SCHEMATIC... -
Page 26: Safety Reminders
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. -
Page 27: Buyers Guide
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. -
Page 28: Parts List
13.0 PARTS LIST... -
Page 30: Model Md
PARTS LIST MD 4 & 5 WELDERS MODEL/ PART NO DESCRIPTION ITEM 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... - Page 31 PARTS LIST MD 4 & 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...
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Page 32: Model Md
PARTS LIST MD 4 & 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... - Page 33 PARTS LIST MD 6 WELDER MODEL/ 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...
- Page 34 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...
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