PUK U5 User manual

1
Instruction Manual
PUK – Mold & Die
Guiding Principles
1. Weld surface and wire must be clean. Use alcohol periodically to
wipe the welding surface. Any contaminants such as dust or grease
can contaminate the weld.
2. Argon gas regulator must have output flow of ca. 2 l/min (fig.1)
3. Electrode tip must be sharp and clean. Sharpen tip periodically,
especially before advanced welding applications.
4. Always overlap the welded area. Failure to overlap properly will
create voids in the welded surface (fig.2)
The Electrode
1. Sharpen electrode periodically to maintain a fine clean tip.
2. Remove electrode before sharpening. Hold at 15 degree angle and roll
electrode tip to produce even point (fig.3)
3. Electrode tip should extend aproximately 5mm from the front ceramic
cover. This is the sweet spot for the flow of argon (fig.4)
fig.1
fig.2
fig.3
The Handpiece
1. Do not press the handpiece down with force. If so, the pulse arc
will not fire. Simply make contact with metal piece and the handpeice
will fire automatically.
2. Position the angle of the handpiece in the direction of the weld area.
For deep penetration, hold handpeice at 90 degree angle to work
surface. In general, 45 degree angle is best for most weld applications
(fig.5)
fig.5
1
⁄4”
fig.4

2
Tack Welding
1. The tack welding handpiece is used to temporarily tack a
piece of wire to the work surface. (fig.9)
2. Connect handpiece cable to the blue output (fig.10)
3. Press the black knob and hold until “Settings Screen” is
displayed. (fig.11)
4. Touch the “fixing button” to activate the tack welding feature.
The icon will turn blue.
5. Press and hold black knob until welding screen is displayed.
Then press and hold black knob again until “fixing screen” is
displayed. (fig.12)
6. Select desired power for tack welding.
7. Connect magnetic grounding cable to your work piece. (fig.13)
8. Position wire on your work piece and place the copper tack
welding handpiece on wire.
9. Now, step on foot pedal to fire a tack weld. (fig.14)
fig.10
Display Settings
1. Touch screen display allows the user to choose
preprogrammed settings for steel, aluminum, and copper.
Time setting controls the penetration depth of weld, power
percentages control diameter of weld (fig.8)
2. To override the preset, begin by adjusting the power up
or down. Then adjust the time setting if necessary.
3. Usually presets work perfectly.
Welding Wire
1. It is recommended to use a wire holder to prevent finger grease from
contaminating wire (fig.6)
2. Wipe wire with alcohol periodically.
3. For best results, try to position the wire flat to the working
surface, thus making more contact with the base material (fig.7)
fig.6
fig.7
fig.8
fig.11
Power
Setting
Power
Setting
Time
Setting
Metal and Wire
Selection
fig.13
Item# 830-2500
Item# 820-4650
fig.17
fig.12
fig.9

3
The Microscope
1. 10X microscope
2. Fix microscope directly to mold base or scrap metal on bench by
using on/off switch (fig.15)
3. Adjust microscope in any position using the adjustment knob (fig.16)
4. Get comfortable with microscope. Position it so that your hand can
rest comfortably on the work surface.
5. Internal shutter protects eyes from weld spark picture (fig.17)
6. Change light intensity in settings: 50% – 75% – 100% (fig.18) fig.18
fig.15
fig.16
fig.17
Welding applications
PUK – Mold & Die
Preparation of Surface
1. Wipe surafce clean with alcohol.
2. If necessary, “burn out” worksurface. Without using wire, weld directly
on top of worksurface to burn out any impurities.
Flat Surface
1. Try to lay wire flat to the surface, thus creating maximum contact.
2. Start with electrode at the end of the wire, electrode points to the
work surface at 45 degree angle. Do not place electrode directly
above wire. Do not place electrode to the side of the wire (fig.19)
3. Overlap each weld by moving electrode in the direction of the wire
(fig.20)
4. Continue until weld area is completely overlapped.
fig.19
fig.20

4
Parting Line
1. Begin by applying protective wire below the parting edge, using the
resistance welder (fig.21)
2. After protective wire is in position, place a new wire above and begin
to weld a straight seam (fig.22)
3. Weld another wire slightly above previous seam, making sure the new
weld spots are overlapping 50% of the previous weld spots (fig.23)
4. Continue until the welds go over the parting area.
Filling Deep Grooves
1. In this application, the user must weld wire on top of wire to fill up
the groove.
2. Before welding, determine if groove needs to be opened completely.
Any cracks or crevices will create voids.
3. Begin welding wire at base. Make sure all welds are overlapping.
4. An adjustment in the power and time settings may be necessary
depending on the size of the groove.
5. Smooth welds by welding in opposite dirction at 15% reduced power.
6. Apply second layer of wire in same manner.
7. Apply soft welding wire every third layer to prevent cracking in
welding surface (fig.24)
fig.21
fig.22
fig.24
Soft Wire
Welding applications
PUK – Mold & Die (continued)