Amada PU-G User manual

Z08M0896E-06
OPERATION MANUAL
HAND-HELD WELDING HEAD
PU-G

PU-G
Thank you for purchasing our Hand-Held Welding Head PU-G.
This operation manual describes its method of operation and precautions for use.
Read this operation manual carefully prior to use. Store appropriately for ready reference.
Contents
1. Special Precautions
(1) Safety Precautions....................................................................... 1
(2) Precautions for Handling.............................................................. 4
2. Features ........................................................................................... 5
3. Name and Functions of Each Section ............................................ 6
4. Connecting the Pressure Signal Cable .......................................... 8
5. Operating Method ............................................................................ 9
6. Product Specifications .................................................................... 10
7. Outline Drawings ............................................................................. 11

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1. Special Precautions
1. Special Precautions
Before using, be sure to read this
operation manual to operate this
machine correctly. This operation
manual may include some items that do
not correspond to your use. However,
you are kindly requested to read only
the items related to your use.
(1) Safety Precautions
These precautions are shown for safe
use of our products and for prevention of
damage or injury to operators or others.
Be sure to read each of them, since all
of them are important for safety.
The meaning of the words and
symbols is as follows.
！DANGER
Denotes operations and practices that
may imminently result in serious injury
or loss of life if not correctly followed.
！WARNING
Denotes operations and practices that
may result in serious injury or loss of
life if not correctly followed.
Denotes operations and practices
that may result in personal injury or
damage to the equipment if not
correctly followed.
！CAUTION
These symbols denote
“prohibition”.
They are warnings
about actions out of
the scope of the
warranty of the product.
！These symbols denote
actions which
operators must take.
Each symbol represents
the contents that give
notice of DANGER,
WARNING, or
CAUTION to the
operator.

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Otherwise, an electric shock or injury will occur. When
internal inspection or repair is required, make contact with us.
Do not disassemble, repair, or modify this machine in
any case.
！DANGER
！
！
！
！WARNING
When welding, keep your fingers and hands away from
the electrodes.
Do not put your hands between the electrodes.
The welded part of a workpiece, electrodes and electrode
holder are very hot. Do not touch them; otherwise you may
be burnt.
Do not touch any welded part or electrodes during
welding and just after welding finished.
Application of a voltage out of the specified range can
cause fire and electric shock.
Apply the specified power supply.
Continuous operation after occurrence of a trouble such as
burning smell, abnormal sound, abnormal heat, smoke, etc. can
cause electric shock and fire. If such a trouble occurs,
immediately consult us or your distributor.
Stop the operation if any trouble occurs.
The welding machine generates a magnetic field and has
effects on the operation of the pacemaker while it is turned on.
A person who uses a pacemaker must not approach the
welding machine or walk around the welding shop while the
welding machine is in operation, without being permitted by
his/her doctor.
Persons with pacemakers must stay clear of the welding
machine.
If you look at the surface flash and expulsion directly
during welding, your eyes may be damaged.
Wear protective glasses.
1. Special Precautions

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！
！
！
！
！
！CAUTION
Water splashed over the electric parts can cause electric
shock and short circuits.
Do not splash water on the product.
Do not bend, pull, or pinch any cable forcibly. If the cable is
damaged, it will cause an electric shock, short circuit, or firing.
Do not give excessive force to connecting cables.
Cables of insufficient current-carrying capacities and loose
connections can cause fire and electric shock.
If the welding cable is not connected completely, a spark will occur.
Connect the specified cables securely.
If the product falls or drops, injury may result.
Install the product on firm, level surface.
Do not put any combustible material around the welder. Surface
flash and expulsion can ignite combustible matter.
Keep combustible matter away from the welding machine.
If such a cover is used, it may be overheated and burn.
Do not cover the product with a blanket, cloth, etc.
Keep a fire extinguisher in the welding shop in case of fire.
Keep a fire extinguisher nearby.
Maintain and inspect the product periodically, and repair any
damage near by before starting operation. Tighten the welding
cable connecting section periodically.
Maintain and inspect the product periodically.
Put on protective gear such as protective gloves, long-sleeve
jacket, leather apron, etc. Surface flash and expulsion can burn
the skin if they touch the skin.
Protective gear must be worn.
Use of this product in a manner other than specified can cause
electric shock and fire.
Do not use this product for purposes other than welding.
After a recovery from the outage, the machine may be started or
powered suddenly, resulting in an injury.
When outage occurs, be sure to turn off the power supply.
1. Special Precautions

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(2) Precautions for Handling
Do not install this product in the following:
-Damp places where humidity is 90% or higher,
- Dusty places,
- Places where chemicals are handled,
- Places where corrosive gas is generated,
- Places near a high noise source,
- Hot or cold places where temperatures are above 40C or below 5C, and
- Areas where water will be condensed.
Caution must, therefore, be made against damage that could happen if subjected
to heavy shock such as when dropped down.
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Clean the outside of the product with a soft, dry cloth or one wet with a little
water. If it is very dirty, use diluted neutral detergent or alcohol. Do not use paint
thinner, benzine, etc., since they can discolor or deform the product.
Between electrodes, do not put such a material other than the weldment as tool
and screw. Otherwise, the welding electrode will be damaged or a spark will
occur. When performing maintenance for this machine as a result of replacement
of electrodes, turn off the power supplies of the welder and control device in
advance.
Do not put a screw, a coin, etc., in the product, since they can cause a
malfunction.
Be sure to install the screws, which were removed for maintenance of this
machine, in their original positions. If they are installed in different positions, this
machine will be damaged or go wrong.
Operate the product according to the method described in this operation manual.
1. Special Precautions
Welding with large electric current may cause the body of this unit and welding
cable to get heated. In such case, consult our sales person for help.
Be careful so that no horizontal load should be applied to this hand-set. Take
note that the following cases may possibly occur by chance.
- Normal pressure force is not obtained.
- Damage or bend of electrode and/or main shaft.

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2. Features
Grip-held push type hand-set
Free point welding irrespective of welded object
Pressurization for stable welding
2. Features

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3. Name and Functions of Each Section
3. Name and Functions of Each Section
4
2
1
7
8
65
3

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3. Name and Functions of Each Section
(1) Pressure adjusting knob
This knob is used to adjust the pressure at welding. Turn the pressure knob to set
the required pressure.
(2) Pressure scale
This scale is used to read the pressure at welding. For the relation of pressure
between "Pressure scale" and "Pressure spring specification", refer to the pressure
diagram (page 13).
CAUTION The pressure diagram represents theoretical values. To measure actual
pressure, use a pressure gauge or spring balance.
(3) Pressure sensor
The pressure sensor is used to make sure that pressure is applied to the weldment
at welding. This sensor outputs a signal when the electrode makes contact with the
weldment and the specified pressure is reached.
(4) Pressure spring
This pressure spring gives the pressure required for welding to the weldment.
Pressure spring specification (S series): Maximum pressure 25/50/80/120 (N)
(5) Electrode holder
This part is used to give a welding current to the welding electrodes and fix the
electrodes.
(6) Welding electrode
This is an electrode rod for welding. Select a material and an end shape suitable for
your use. We prepare welding electrodes for various uses.
(7) Welding electrode fixing screw
This screw is used to remove or mount the welding electrode.
(8) Screw to supply power (from the transformer or power supply side)
Connect the welding cable from the welding transformer or welding power supply.
！

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4. Connecting the Pressure Signal Cable
4. Connecting the Pressure Signal Cable
LS.
NC
COM
12
[Pressure signal cable terminal]
Microswitch
(WT)
(BK)
2: BK (COM) 1: WT (NC)
2P connector
Selecting F terminal
Selecting 2P connector
COM.

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(1) How to set electrode
Set electrode, with 10mm sticking out upward (see figure below), to the electrode terminal.
Insert the electrode into the electrode holder in such way that the D-cut of the electrode on
the electrode terminal should come right to face the set screw position of the electrode
holder. Fix the set screw seeing that the electrode holder and the electrode terminal are flat
in touch leaving no clearance between them.
(2) Setting of pressure force
Set the pressure force by rotating the pressure force regulation knob. Clock-wise rotation
(turning to the right) will increase the pressure force. Pressure force graduation is engraved
on the body for your reference guide.
Use an independent pressure force gauge to get the actual exact pressure force. (A
pressure gauge measuring up to 10 kgs is ready for supply.)
(3) How to weld
Hold the grip and press the hand-set straight in axial direction to strike on the object to be
welded.
The pressure force signal is set to on and welding current starts running when the shaft
which fixed the electrode holder gets into the body by about 1.5 mm deep.
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5. Operating Method
5. Operating Method
Electrode holder
Electrode terminal
Electrode

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6. Product Specifications
6. Product Specifications
1 Electrode diameter 5
2Signal output Microswitch
3Pressure force 1 to 9 kg
4Welding cable (2 pcs.)
(option)
H-050-1000-06-08-N (Item No.: 1006016)
50 sq φ6-φ8
L = 1 m Nylon mesh sleeve
5Weight 700 g
6Terminal copper bus bar 30 x 180 x 5t Material: Cu

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7. Outline Drawings
7. Outline Drawings
Standard electrode
Material: Alumina dispersion copper
(for mounting secondary
conductor)
(for mounting secondary
conductor)