Denyo DN-C-50-4-06 Instruction Manual
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Denyo DN-C-50-4-06 Instruction Manual

Denyo DN-C-50-4-06 Instruction Manual

Stationary type spot welding machine
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INSTRUCTION MANUAL
STATIONARY TYPE
SPOT WELDING MACHINE
DN-C-50-4-06
MODEL
Before using this equipment, please read thoroughly the safety precautions for using the
equipment safely. After reading the manual, keep it on hand to ensure effective use.
DN-C-50-4-06
01
2010/03/25
EN

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Summary of Contents for Denyo DN-C-50-4-06

  • Page 1 INSTRUCTION MANUAL STATIONARY TYPE SPOT WELDING MACHINE DN-C-50-4-06 MODEL Before using this equipment, please read thoroughly the safety precautions for using the equipment safely. After reading the manual, keep it on hand to ensure effective use. DN-C-50-4-06 2010/03/25...

  • Page 2: Table Of Contents

    〈 CONTENTS 〉 1. Safety Instructions ············································································································· (3) 1‐1 Instructions ··············································································································· (3) 1‐2 Safety Precautions ····································································································· (4) 1‐3 Instructions for Ensuring Safety ·················································································· (5) 1‐4 Dangerous Sections of Product where Warning Labels are Attached ······························ (8) 2. Specifications and Functions of Stationary Type Spot Welding Machine ································· (9) 2‐1 Overview ·················································································································...

  • Page 3: Safety Instructions

    1. Safety Instructions 1－1. Introduction Before getting started, read this instruction manual thoroughly in order to use the unit correctly. • In order to guarantee safety, the installation, inspection, maintenance, and repairing of this welding unit must be only done by a person who either has the qualifications or has a thorough knowledge of welding units.

  • Page 4: Safety Precautions

    1－2. Safety Precautions • Read this instruction manual thoroughly before using the unit and use it correctly as described in this manual. • The precautions given in this instruction manual not only let you use the unit safely but also prevents injury and loss to you or to other persons nearby.

  • Page 5: Instructions For Ensuring Safety

    In addition, what you must do and what you must not do during the handling of the unit are shown below. Operation you must do. For example, "Grounding work", etc. Compulsory Operation you must not do. Prohibited These symbols are used in general conditions. 1－3.
  • Page 6 Always follow the instructions below to avoid Danger! electric shock hazards. * Never touch any electrically live part other than the secondary conductor. * Never touch both ends of the secondary conductor at the same time 1. Never touch any electrically live part other than the secondary conductor. 2.
  • Page 7 Use protective wear to protect yourself and other Caution! persons from the dust (splashes and sputters) generated during welding and from noise. The dust splashing out can cause damage to the eyes or burns on the body. The noise can cause hearing abnormalities. 1.

  • Page 8: Dangerous Sections Of Product Where Warning Labels Are Attached

    1－4. Dangerous Sections of Product where Warning Labels are Attached CAUTION: CAUTION Power supply voltage is applied to stationary DANGER Be careful not to get control BOX. your hand caught between the electrodes while carrying out work. Flexible conductor CAUTION can be extremely CAUTION hot.

  • Page 9: Specifications And Functions Of Stationary Type Spot Welding Machine

    Specifications and Functions of Stationary Type Spot Welding Machine 2‐1 Overview This equipment is single-phase AC stationary spot welding machine, which consists of welding machine unit, pneumatically operated pressure device, single-phase transformer control unit. Please refer to the following specifications and instruction manuals for each of the equipment.

  • Page 10: Name And Functions Of Components

    2‐3 Name and Function of components （１）Gun body Figure 1） ＤＮ５０ Outline drawing (10)
  • Page 11 （２）Names and functions of main components Weld Transformer ：Convert input voltage (primary) to low voltage (secondary) for resistance welding. Foot Switch： Switch to operate nut welding operation cycle. ① Air Filter ： Eliminate moisture and dust from compressed air. Turn the lower knob counterclockwise to drain the accumulated water if any.

  • Page 12: Installation

    2‐4 Installation ２‐４‐1 Cautions for installation location ① Use the eye bolt on the top of the body of the welding machine when suspending the machine. ② Do not install the welding machine in a dusty place or a place where temperature and humidity are always high.

  • Page 13: Cautions For Piping And Connection

    ２‐４‐３ Cautions for piping and connection ① Grounding ： Grounding is mandatory for protecting operators from an electric shock when the insulation resistance of the welding machine drops. Use a grounding conductor having a cross-sectional area of 14mm more, and ground the welding machine complying with the following: With source voltage 400 V: Special Class III grounding (grounding resistance 10Ω...

  • Page 14: Table Of Required Equipment

    ２‐４‐５ Table of required equipment Model DN-C-50 380V ± 10 (400V or more during weld time) Source voltage Power supply of Power capacity 50 kVA the welding Power switch capacity 415V 125A machine Lead wire 35 mm or more Water pressure 0.2 - 0.3 MPa Quantity of cooling water 8 Ltr/min or more...

  • Page 15: Operation

    3. Operation 3‐1 Controller of Stationary Type Spot Welding Machine ３‐１‐１ Control methods 《Important》Use「TB40-P02X(TEACHING BOX)」to set condition.For connecting teaching box, unplug connector from Reset Box and connect it to the teaching box. 「PHS-1108 SPECIFICATION」 「PHS-1108 INSTRUCTION」 「RB40-R02A-XXX SPEC./INST.」 Please refer to 「TB40-P02X INSTRUCTION」 （optional equipment） Control method Synchronous phase control by the thyristor for the welding machine １～９９cyc...

  • Page 16: Operation Sequence

    ３‐１‐２ Operation sequence Basic operation sequence Start input Welding pressure C urrent Welding com pletion output W T1 W T2 R epetition of pulsation During repetitive op eration ① Pre-squeeze time (PSQ) Time start from when the operator press the foot switch to the solenoid valve works. ②...

  • Page 17: How To Operate Stationary Spot Welding Machine

    ３‐１‐３ How to operate stationary spot welding machine （１）Control Box Operating Console ①「POWER SW」 POWER ・Switch ON/OFF of Control Box ・Switch ON will turn the [POWER] lamp ON. ・When the switch is turned ON, you can select the mode of operation thru foot switch.
  • Page 18 （２）Sequence of Operation Pattern 1 Welding operation Control Box Welding Machine Control Box Type of switch POWER SW MODE SW “ON” “WELD” Position of switch ① Set work･･････ Operator set work ↓ ② Activation (ON)･･････ Step on foot switch ↓ ③...

  • Page 19: Preparation For Welding

    3‐2 Preparation for Welding When the cable connection and piping are completed, check them again. （Caution）During the process of ①～⑧, be sure to keep [PRESS] mode at welding control box or teaching box for safety purpose. ① Timer initialization (Set condition 1 at condition switch box.) ・Set the following values for the timer at startup.

  • Page 20: Welding Results And Causes Of Trouble

    ⑥ Adjustment of the distance between tip holders Adjust the distance between the electrodes so that Horns the dimensions of the upper and lower horns shown in the figure are obtained when pressure is applied after the work to be welded is inserted between the electrodes.

  • Page 21: Wiring Diagram

    3‐4 Wiring diagram (21)
  • Page 22 Circuit diagram (22)

  • Page 23: Piping Diagram

    3‐5 Piping diagram (23)

  • Page 24: Maintenance And Inspection

    4. Maintenance and Inspection For maintenance and inspection of nut feeder and welding control equipment, please refer to instruction manual of each unit. 4‐1 Regular Inspection （１）Pre-shift inspection ① Check the machine for abnormal vibration, swell, or odor. ② Check the cable connections for abnormal heat output. ③...

  • Page 25: Maintenance

    4‐3 Maintenance ４－３－１ Air Piping System Air piping diagram ① Cleaning air filter (as necessary) Push down the drain cock to drain water and impurities accumulated in the air filter before the accumulation level reaches the baffle plate (the permissible upper limit). Use a neutral detergent to clean the filter cup. Be sure to stop air supply when you mount/remove the cup.

  • Page 26: Conductors And Other Components

    ４－３－４ Conductors and Other Components ① Conductors－Disassemble the connections of the secondary side of the welding transformer, the secondary conductor, and the horn feeders about twice a year, and polish the contact faces. Imperfect contact causes the welding capacity to lower. To prevent the problem, regularly polish the contact faces.

  • Page 27: Electrode Force Chart

    ◎ O-ring and packing used for cylinder ＮＯ Cylinder capacity 5900N cylinder ① Ｓ－１２５ O-ring ② Ｐ－２１ O-ring ③ Ｐ－１１５ O-ring ④ ＰＮＹ－３６ Packing 4‐４ Electrode Force Chart ◎Electrode force 5.9KN (KN) Electrod Force 4‐５ Other Notes ① Diversion of current Before mounting a welding jig on the welding machine, completely insulate between the jig/electrode and conductor or between the jig and the housing of the body.

  • Page 28: Trouble And Action To Be Taken

    4‐６ Trouble and Action to be Taken Trouble Confirmation Item Action Check fuse melt down Replace fuse. Please refer to 「 」 fore more PHS-1108 INSTRUCTION MANUAL inside welding control details. equipment Power supply Check welding power Operate switch on primary distribution panel (provided by customer) and lamp won’t supply turn on power supply.

  • Page 29: Parts List

    4‐７ Parts List (Consumable supplies) ＮＯ Part name Manufacturer Specification ＤＳＴ５０－４０５ １ Denyo Kogyo Welding Transformer ① ＳＭＣ ＡＦ４０－０４Ｄ １ Air Filter ② ＳＭＣ ＡＲ４０－０４ １ Air Regulator ③ ＳＭＣ ＡＬ４０－０４ １ Lubricator ⑥ ＳＭＣ ＶＱ７－８－ＦＧ－Ｓ－３Ａ０４ １ Solenoid Valve ⑦ ＳＭＣ...
  • Page 30 ● Cautions on use （１） Read the instruction manual before using the equipment. （２） Do not insert hands, etc. Between electrodes of the gun when connecting the power supply to the controller. （３） Check, clean, re-tighten, and re-lubricate each section, and replace perishable items as required according to the use frequency.

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