GP-0 Ceramic Fusion Butt Welder for Fine Stranded Copper & Aluminum
Aluminum, Brass, Bronze, Copper, Nickel
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Butt Welder
HP-1.1 Heavy-Duty Ceramic Fusion Butt Welder for Large Stranded Copper & Aluminum
The HP-1.1 sits at the top of Micro Weld’s Ceramic Fusion Series, built for the largest stranded non-ferrous conductors the GP series cannot reach — copper from 8 AWG through 4/0 AWG and aluminum up to 250 MCM. It delivers the same burr-free ceramic fusion weld quality found across the GP line, but scaled up to heavy conductor demands: solenoid-controlled pneumatic actuated clamps, air upset at 100 psi, 99-step SCR heat control, and robust fixed and movable interlocked guarding. At 640 lbs on a heavy-duty 4-wheel truck, the HP-1.1 is a production floor machine — heavy-duty in construction, yet movable on its caster-mounted truck. It runs on 240V, 480V, or 600V single phase and draws up to 234A — built for facilities with the power infrastructure to support heavy conductor joining at volume. Groove sizes for the radius groove weld die set must be specified at time of order.
- 240V, 480V, or 600V, 60Hz, single phase
- Robust fixed & movable interlocked guarding
- Solid state heat control; Pneumatic upset
- Solenoid controlled, pneumatic actuated clamps
- Radius groove weld die set with 3 to 4 grooves (groove sizes must be stated at time of order)
- Heavy duty truck with casters
Metal:
Aluminum, Brass, Bronze, Copper, Nickel
Construction:
Stranded
Stranded Copper Welding Range:
8 AWG (10 mm²) - 4/0 AWG (120 mm²)
Solid Aluminum Welding Range:
8 AWG (10 mm²) - 250 MCM (150 mm²)
Max Current Draw:
234/117/92
Single Phase Transformer:
Yes
Heat Selection Method:
99 STEPS SCR
Upset Method:
Air
Air Requirements:
100psi
Mounting Truck Type:
4 Wheels
Dimensions & Weight:
Welding Die Height: 41 in (104.14 cm)
Width Across the Front: 39 in (99.06cm)
Depth to the Back: 29 in (73.66 cm)
Height: 46 in (116.84 cm)
Weight: 640 lbs (290.24 kg)
Width Across the Front: 39 in (99.06cm)
Depth to the Back: 29 in (73.66 cm)
Height: 46 in (116.84 cm)
Weight: 640 lbs (290.24 kg)
- Standard Filing Vise
- AQ-5 Shear
Butt Welder Upgrades to Improve Your Precision and Productivity
Upgrade your Micro Weld butt welders with world-class safety & technology accessories. You’ll get the same quality, rugged welders with the safety features you need, creating uniformity with every machine and consistency with every training.
- New Finger Safe Covers & Components
- 24V Control Circuit
- Interlock Switch on Rear Access Panel
- Solid-State Heat Control
Applications
Welding large stranded copper conductor from 8 AWG through 4/0 AWG on high-volume wire and cable production lines where a burr-free ceramic fusion joint is required without post-weld grinding or finishing
Joining large stranded aluminum conductor up to 250 MCM on power cable manufacturing lines ahead of insulating, jacketing, or armoring operations where joint geometry and surface finish directly affect downstream tooling performance
Splicing heavy stranded conductor on pay-off stands, stranders, and take-up equipment to maintain continuous production feed and eliminate the downtime of re-threading large conductor through in-line equipment
Joining large non-ferrous conductor for utility, construction, and industrial power distribution cable applications where weld strength, conductor integrity, and joint appearance are quality and safety requirements
Real-World Benefits
- Pneumatic upset with solenoid-controlled clamps delivers consistent, repeatable clamping force and upset pressure on large stranded conductor — eliminating the operator variability that hand-operated clamps introduce at this conductor size and weight.
- 99-step SCR heat control provides the fine resolution needed to weld cleanly across the full 8 AWG–4/0 AWG copper and up to 250 MCM aluminum range — letting operators select the appropriate heat setting for each conductor size in mixed-size production runs.
- Ceramic sleeve flash containment produces a burr-free joint on heavy stranded conductor — protecting insulating and jacketing tooling downstream and eliminating the secondary grinding operation that conventional butt welders require at this cross-section.
- Robust interlocked guarding keeps operators safe at the high energy levels required to weld large non-ferrous conductor, aligning the HP-1.1 with modern plant safety standards for heavy industrial welding stations.
- 240V / 480V / 600V input flexibility covers the full range of heavy industrial plant power configurations, including 600V facilities common in Canadian and international manufacturing environments.
Comparison to Similar Models
The HP-1.1 is the top of the five-machine GP/HP Ceramic Fusion Series. Below it, the GP-3 covers stranded copper and aluminum up to 4 AWG with hand-operated mechanical upset and no air requirement — the GP-3 is the right choice when conductor stays at or below 4 AWG and air supply isn’t available. The HP-1.1 takes over where the GP series leaves off, starting at 8 AWG and reaching 4/0 AWG copper and 250 MCM aluminum. The shift from mechanical to pneumatic upset, the addition of interlocked guarding, the 600V input option, and the 640 lb floor-mounted footprint all reflect the demands of joining conductor at this cross-section and current level.
If your production runs large stranded non-ferrous conductor and requires a burr-free finish, the HP-1.1 is the only ceramic fusion option in the Micro Weld lineup built for it.
Best For
High-volume wire and cable producers, power distribution cable manufacturers, and utility cable operations joining large stranded copper (8 AWG–4/0) or aluminum (to 250 MCM) who require ceramic fusion burr-free joints, pneumatic upset consistency, and full interlocked guarding in a heavy industrial production environment.
