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Summary of Contents for U.S. Solid DN-120T
- Page 1 Manual No. 9319 SPOT WELDING MACHINE MODEL: DN-120T INSTRUCTION MANUAL...
- Page 2 EQUIPMENT FOR RESISTANCE SPOT WELDING FOR INDUSTRIAL AND PROFESSIONAL USE. Thank you for choosing the U.S. Solid spot welding machine. Please check the package firstly to make sure it is not damaged in transit before use. For ques?ons, please contact us at service@ussolid.com for help.
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Page 3: Table Of Contents
CONTENTS 1. SAFETY PRECAUTIONS - READ BEFORE USING 1.1 SYMBOL USAGE………………………………………………………………………………………….1 1.2 RESISTANCE SPOT WELDING HAZARDS……………………………………………………….1 1.3 ADDITIONAL SYMBOLS FOR INSTALLATION, OPERATION, MAINTENANCE…..5 1.4 WARNINGS…………………………………………………………………………………………………7 1.5 EMF INFORMATION……………………………………………………………………………………7 2. INTRODUCTION AND GENERAL DESCRIPTION 2.1 INTRODUCTION………………………………………………………………………………………….8 2.2 STANDARD ACCESSORIES……………………………………………………………………………8 2.3 OPTIONAL ACCESSORIES…………………………………………………………………………….8 3. -
Page 4: Safety Precautions - Read Before Using
1. SAFETY PRECAUTIONS - READ BEFORE USING Protect yourself and others from injury — read and follow these precauXons. 1.1 SYMBOL USAGE DANGER! -Indicates a hazardous situaXon which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. - Page 5 During operaXon, keep everybody, especially children, away. The operator must receive full instrucXons regarding safe use of the spot welding machine and must be informed of the risks related to resistance welding procedures, as well as the related safety measures and emergency procedures. •...
- Page 6 • ELECTRIC SHOCK CAN KILL Touching live electrical parts can cause fatal shocks or severe burns. The input power circuit and machine internal circuits are also live when power is on. Incorrectly installed or improperly grounded equipment is a hazard. •...
- Page 7 • FLYING SPARKS CAN INJURE Very ocen sparks fly off from the joint area. • Wear approved face shield or safety goggles with side shields. • Wear protec?ve garments such as oil-free, flame-resistant leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. Synthe?c material usually does not provide such protec?on.
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Page 8: Additional Symbols For Installation, Operation, Maintenance
Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. • Keep your head out of the fumes. Do not breathe the fumes. • If inside, ven?late the area and/or use local forced ven?la?on at the arc to remove welding fumes and gases. - Page 9 • READ INSTRUCTIONS • Read and follow all labels and the Owner's Manual carefully before installing, opera?ng, or servicing unit. Read the safety informa?on at the beginning of the manual and in each sec?on. • Use only genuine replacement parts from the manufacturer. •...
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Page 10: Warnings
1.4 WARNINGS • Welding or cukng equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. • Banery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproduc?ve harm. -
Page 11: Introduction And General Description
2. INTRODUCTION AND GENERAL DESCRIPTION 2.1 INTRODUCTION Resistance welding is one of the oldest of the electric welding processes in use by industry today. The weld is made by a combina?on of heat, pressure, and ?me. As the name resistance welding implies, it is the resistance of the material to be welded to current flow that causes a localized hea?ng in the part. -
Page 12: Technical Data
3. TECHNICAL DATA 3.1 RATING PLATE The main data rela?ng to use and performance of the spot-welding machine are summarized on the ra?ng plate and have the following meanings: • Norm: Applica?on standards, for example, EN 62135-1:2015. • U1: Rated AC input voltage of the welding power source, 1～,110V. •... -
Page 13: Other Technical Data
3.2 OTHER TECHNICAL DATA General specifica?ons and Weight of the spot-welding machine TAB. 1. TAB.1 GENERAL FEATURES Model DN-120T Power supply voltage and frequency 110V，~AC，1ph，60Hz Electrical protecXon class IP20 Type of cooling Natural Cooling Dimensions (LxWxH) 460x180x100mm Mass with arms 9.6Kg... -
Page 14: Materials Data For Resistance Spot Welding
4. MATERIALS DATA FOR RESISTANCE SPOT WELDING This sec?on of the text will consider methods used for resistance spot welding some of the common metals that are used in fabrica?on work. It is not intended that all the possible problems that could arise will be answered. The purpose of this part of the text is to provide general opera?onal data for use with resistance spot welding machines. - Page 15 The reason is the reactance caused by the ferrous material within the arc welding circuit. Resistance spot welding machines are applicable to low carbon steel welding. They must be used within their rated capacity of total thickness of material for best results. They should not be used over the duty cycle since damage to the contactor and transformer may result.
- Page 16 It is impossible to maintain the integrity of the galvanized coa?ng when resistance spot welding. The low mel?ng point of the zinc coa?ng, compared to the fusion temperature of the steel sheet, causes the zinc to vaporize. Of course, there must be adequate pressure to force the zinc aside at the weld interface to permit steel-to-steel fusion.
- Page 17 Welding procedures for each type of material must be developed for the most sa?sfactory results. It is possible that shunt currents flowing through a previously made spot weld will take welding current away from the second second spot weld to be made. This will occur if the two spot welds are too close together, and it will happen with all metals.
- Page 18 Test Procedures The test procedures outlined are very simple and require a minimum of equipment to perform. 1. Visual Test Observe the deforma?on and shape of the surface contact points at both sides of the weld. Excessive "dishing" of the surface contact point indicates one or more of the following: a.
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Page 19: Description Of The Spot-Welding Machine
5. DESCRIPTION OF THE SPOT-WELDING MACHINE 5.1 PRINCIPAL COMPONENTS AND ADJUSTMENTS • 1. Electrode force adjustment screw. • 2. Lec/right hand posi?onable handgrip. • 3. Hole for eyebolt if used. • 4. Movable welding arm or Upper Tong. • 5. Fixed welding arm or Lower Tong. •... -
Page 20: Control Panel
5.2 CONTROL PANEL 1-Key for correcXng spot-welding Xme. Adjusts spot-welding ?me with respect to the factory default sekng. 2-Key for selecXng sheet thickness. Selects the thickness of the sheet to be welded. 3-Key for selecXng spot-welding mode. The welding current is pulsed. The length of the pulse is automa?c and requires no regula?on. -
Page 21: Installation
6. INSTALLATION WARNING! CARRY OUT ALL INSTALLATION OPERATIONS AND ELECTRICAL AND PNEUMATIC CONNECTIONS WITH THE SPOT-WELDING MACHINE COMPLETELY SWITCHED OFF AND DISCONNECTED FROM THE POWER SUPPLY OUTLET. THE ELECTRICAL AND PNEUMATIC CONNECTIONS MUST BE MADE ONLY AND EXCLUSIVELY BY AUTHORIZED, SKILLED PERSONNEL. 6.1 PRELIMINARY OPERATIONS Unpack the spot-welding machine, assemble the separate parts included in the package. -
Page 22: Connection To The Main Power Supply
6.4.2 CONNECTION TO THE MAIN POWER SUPPLY Note: The power supply of the welding machine is single phase，110VAC. Connect the power supply correctly when using the welding machine. Connect the power supply cable of the spot-welding machine to the power supply system of appropriate capacity and prepare a power supply switch system fined with fuses or an automa?c circuit-breaker;... -
Page 23: Spot Welding
7. SPOT WELDING 7.1 PRELIMINARY OPERATIONS Before carrying out any spot welding opera?on, it is necessary to carry out a series of checks and tests with the spot welding machine disconnected from the main power supply. • 1-Ensure that the electrical connec?ons are correct, in accordance with the above instruc?ons. -
Page 24: Adjusting The Parameters
7.2 ADJUSTING THE PARAMETERS • Select the thickness of the sheet to be spot welded using the key ( 2-FIG. 2 ) on the spot welding machine control panel. • Select the type of spot welding (conXnuous or pulsed) using the key ( 3-FIG. 2 ). •... -
Page 25: Maintenance
8. MAINTENANCE WARNING! BEFORE CARRYING OUT MAINTENANCE, MAKE SURE THE SPOT WELDING MACHINE IS OFF AND DISCONNECTED FROM THE MAINS. With versions operated with pneumaXc cylinder, the main switch must be locked at “O” using the supplied lock. Dressing Tips... -
Page 26: Routine Maintenance
8.1 ROUTINE MAINTENANCE ROUTINE MAINTENANCE CAN BE CARRIED OUT BY THE OPERATOR. • electrode ?p diameter and profile adapta?on/restora?on; • electrode alignment check; • spring load check (electrode strength); • spot welding machine and clamp power cable integrity check; • electrode and arm replacement; 8.2 SPECIAL MAINTENANCE SPECIAL MAINTENANCE MUST ONLY BE CARRIED OUT BY TECHNICIANS WHO ARE EXPERT OR QUALIFIED IN AN ELECTRIC-MECHANICAL FIELD. -
Page 27: Trouble Shooting Table
9. TROUBLE SHOOTING TABLE Trouble Remedy Not enough tong pressure. Increase tong pressure. Tips overheaXng. Weld ?me too long. Reduce weld ?me. Material too thick for the spot welding machine. Not enough tong pressure. Increase tong pressure. Tips not aligned correctly. Realign ?ps or dress ?ps to proper diameter (see Sec?on 4-2). -
Page 28: Warranty
No responsibility is assumed for any consequen?al damages that may result from the use of a U.S. Solid product, nor for damages due to accident, abuse, lack of care, affixing of unauthorized anachment, loss of parts or subjec?ng this unit to any but the specified voltage. -
Page 29: Contact Info
11. CONTACT INFO Website: www.ussolid.com Email: service@ussolid.com Address: 4560 Johnston Parkway, Cleveland, Ohio 44128 USA...
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