MICRO PRODUCTS GP0 Service Manual Download | Manualshive

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MICRO PRODUCTS COMPANY

MANUFACTURES OF PRECISION

WELDING MACHINES

MODEL GP0 CERAMIC FUSION BUTT WELDER

SERVICE MANUAL

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Summary of Contents for GP0

Page 1: ...MICRO PRODUCTS COMPANY MANUFACTURES OF PRECISION WELDING MACHINES MODEL GP0 CERAMIC FUSION BUTT WELDER SERVICE MANUAL 1 ...

Page 2: ...CATIONS MODEL GP0 Stock Size Range 26GA to 18GA Type Material Stranded copper conductor Operating Voltage 115 Volts Input Power Cycle 60 Cycle 50 Cycle optional Line Demand 6 Amperes 100 Duty Cycle 19 Amperes 10 Duty Cycle Single Phase Weld Transformer 1 0 KVA 50 Duty Cycle Truck Mounted Welder 2 Stationary Casters 2 Swivel Casters Floor Space 24 x 24 Overall Height 57 Height to Welding Dies 44 We...

Page 3: ...ally 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 2 2 1 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 Disc...

Page 4: ...TING The weld limit switch controls the cutoff point of current flow to the welding dies Turning an adjusting screw located on the left end of the movable headpiece makes this adjustment See Charts for setting 3 5 UPSET PRESSURE Upset pressure adjustments are obtained by rotating the knurled knob on the right hand side of the stationary headpiece When the outside edge of the adjusting screw is flu...

Page 5: ...4 0 BASIC OPERATING PARTS LOCATION 5 ...

Page 6: ...but firmly contact first conductor Positive contact to wire ends is important for good weld Clamp that conductor into welding dies 5 12 Rotate and center ceramic sleeve to assure free movement of conductors during weld process 5 13 Rotate spacing lever to 0 5 14 Depress the operation switch hold for 1 to 3 seconds to assure a complete weld cycle 5 15 Unclamp welded conductor and remove ceramic sle...

Page 7: ...eter measure across the clamp fingers with power applied to the welder Press the weld button The voltmeter reading should be approximately one VAC with welder at the highest heat setting If no voltage is read move the space cam to higher number Return the cam to 1 while watching the voltmeter The voltage should shut off at 1 on the cam Loosen locknut on the limit switch adjusting screw and adjust ...

Page 8: ...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 7 3 2 Check anneal dies and replace worn or broken parts 7 3 3 Check insulating fiber pin on limit switch...

Page 9: ...ie sets Excessive flash build up causes die burns on material and shorting of die sets 7 6 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 7 6 3 Do not use welding die sets for a vise These parts will not withstand the mechanical abuse 7 6 4 Whenever welding dies are...

Page 10: ...med within a ceramic tube of block and no filler materials are needed Wire ends are resistance heated to a plastic condition and hot forged together within a ceramic tool which acts as a crucible The resultant coalescence weld locks all single filaments into a solid weld zone Since strand conductors have configuration voids on the fraying surfaces the plastic material normally forced to the outsid...

Page 11: ...8 2 CERAMIC FUSION TECHNIQUE 11 ...

Page 12: ... build up of flash materials 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 9 1 1 TROUBLE SHOOTING TABLE See section 9 1 3 This electrical trouble shooting table is furnished as a suggested method of trouble sho...

Page 13: ...AUTO MANUAL SWITCH L2 FU1 1 115VAC Bad fuse connection MANUAL L2 FU1 2 115VAC Open fuse L2 PB1 1 L2 PB1 2 L2 LS1 1 115VAC 115VAC 115VAC Open wire to operating switch Bad operating switch Open connection to weld limit switch X X L2 LS1 2 115VAC Open weld limit switch L2 CR1 1 115VAC Open wire to contactor L2 CR1 2 115VAC Bad contactor X L2 S1 1 L2 TR1 8 115VAC 115VAC Open wire to heat switch Bad ti...

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Page 15: ...ected 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...

Page 16: ...hine 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 630 787 9350 Or Toll free at 800 872 1068 Provide MICRO with your company name and purchase order number 16 ...

Page 17: ...13 0 PARTS LIST 17 ...

Page 18: ...18 ...

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Page 20: ...djusting worm 32087 GPO 23 Tension screw nylon 35516 GPO 24 Tension spring 32059 GPO 25A Space cam assembly 32003 GPO 26 Repeating cam stop 32000 GPO 27 Cam bushing 32002 GPO 28 Space cam attaching bolt 90203 GPO 29 Closed space adjusting screw 32082 GPO 34 Insulating sleeve 37709 GPO 38 End cover plate 32054 GPO 39 End cover attaching screw 91055 GPO 51A Omron timer 57693 GPO 51B Omron socket 576...

Page 21: ...ating switch 57843 GPO 106 Hi low switch 57843 GPO 107 Auto manual nameplate 52034 GPO 108 Operating switch plate 52035 GPO 109 On off switch 57839 GPO 109A Auto manual switch 57840 GPO 110 Hi low nameplate 48306 GPO 111 On off nameplate 48305 GPO 112 Truck assembly 42026 GPO 119 Shear 64002 GPO 138 Lamp 58164 GPO 141 Transformer 52049 GPO 142 Transformer ring 54512 GPO 143 Rod 93000 GPO 185 Conta...

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