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Denyo DN-C-50-4-06, Instruction Manual, Page: 1 / 30

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STATIONARY TYPE 

SPOT WELDING MACHINE

 

MODEL

    DN-C-50-4-06 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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.

 

 

 

 

INSTRUCTION MANUAL 

DN-C-50-4-06 

01 

2010/03/25 

EN 

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

Page 1: ... MODEL DN C 50 4 06 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 INSTRUCTION MANUAL DN C 50 4 06 01 2010 03 25 EN ...

Page 2: ... of the welding machine 13 5 Table of required equipment 14 3 Operation 15 3 1 Controller of Stationary Type Spot Welding Machine 15 1 Control method 15 2 Operation sequence 16 3 How to operate stationary spot welding machine 17 3 2 Preparation for Welding 19 3 3 Welding Results and Causes of Trouble 20 3 4 Wiring diagram 21 3 5 Piping diagram 23 4 Maintenance and Inspection 24 4 1 Regular Inspect...

Page 3: ...g unit must be done by a person who has fully understood the contents of this instruction manual and has the knowledge and technical skill to handle the unit safely After reading this instruction manual store it carefully in a place where it can always be referred to by all related persons This instruction manual should be read again as and when the need arises When there is any item that is not c...

Page 4: ...n the machine unit also Attention symbol Description If the handling of the unit is mistaken an extremely dangerous condition can occur which can lead to serious injury or death If the handling of the unit is mistaken a dangerous condition can occur which can lead to serious injury or death If the handling of the unit is mistaken a dangerous condition can occur which can lead to medium level injur...

Page 5: ...d piping of high pressure gases storage of products after welding and processing of waste materials etc 3 Make sure that persons do not come accidentally near the welding unit or near the place of welding work 4 Make sure that persons wearing cardiac pace makers do not come near an operating welding unit or near the place of welding work unless and until they have obtained permission from their do...

Page 6: ...ose conductors are exposed 5 Make sure that the connecting part of cables are firmly tightened and covered with insulating sheath 6 Never use the welding unit with its case or cover removed 7 Never use torn or wet gloves Always use dry and insulating gloves 8 Carry out regular maintenance inspection and use the unit after repairing the damaged parts 9 For the cooling water be sure to use good qual...

Page 7: ...s follow the items listed below to avoid fires and explosions The dust splashing out during welding and the hot work piece immediately after welding can cause fires If there is any imperfect connections of cables the heat generated at such parts can cause fires 1 Remove all flammable materials in the neighborhood of the welding place so that the dust splashing out during welding does not fall on f...

Page 8: ...and caught between the electrodes while carrying out work CAUTION Dust causes a fire or explosion Remove any flammable objects CAUTION Flexible conductor can be extremely hot Use extreme caution when handling it CAUTION CAUTION Power supply voltage is applied to stationary control BOX CAUTION CAUTION Power supply voltage is applied to the lowerback surface of the unit Keep back panel and side pane...

Page 9: ...AL Optional equipment 2 2 Specifications Body specifications of the welding machine Model ＤＮ C 50 ４ ０６ Power supply Single phase AC Rated primary voltage 415Ｖ Rated frequency ５０Ｈｚ Primary voltage at maximum contact load ４５０Ｖ １８０００Ａ guaranteed voltage Rated capacity ５０ｋＶＡ Rated max capacity １２６ｋＶＡ Permissible duty cycle ８ ０ Max short circuit current １８０００Ａ Current control range Synchronous method P...

Page 10: ...2 3 Name and Function of components １ Gun body Figure 1 ＤＮ５０ Outline drawing 10 ...

Page 11: ...etic valve to operate pressurizing cylinder Silencer Silencer for exhaust air for pressurizing cylinder Cylinder Move electrode up and down Speed Controller Control upper electrode motion speed by regulating exhaust air flow amount at when pressurized by cylinder Loosening up clockwise will slow down electrode motion speed Welding Controller Control the time for initial pressurizing welding hold a...

Page 12: ...The power equipment must comply with Section 2 4 5 Required equipment table ２ ４ ２ Piping and connection methods Connect earth terminal on welding machine back surface Use a cable of 1４mm2 or more Connect a durable rubber air hose to the air inlet Use a hose that matches the hose port 10 5 in diameter 0 7 MPa Connect water hoses to the cooling water inlet and outlet For the inlet use a hose that ma...

Page 13: ...re over 30 C causes the welding machine to generate heat or fail to start In wintertime be careful that the piping system does not freeze Compressed air If the compressor capacity or piping size is not large enough the welding head becomes slow and the pressure drops which causes many expulsions and surface flashes Use compressed air including only little moisture or mist Compressed air including ...

Page 14: ...machine Lead wire 35 mm2 or more Water pressure 0 2 0 3 MPa Quantity of cooling water 8 Ltr min or more Water temperature 30 C or less Water resistivity 5 kΩ cm or more Water supply hose internal diameter φ10 Cooling water Drain hose internal diameter φ13 Compressor 2 3HP Air pressure 0 5 0 7MPa Compressed air Air hose internal diameter φ10 Grounding Grounding wire 14 mm2 or more 14 ...

Page 15: ...e initial pressure SQ １ ９９cyc Weld time WT ０ ９９cyc Hold time HT ０ ９９cyc Off time OT １ ９９cyc Time control Up slope time US ０ ３０cyc Current control method Constant current control and voltage compensation control Supplementary information Power is supplied to the controller from the power supply of the welding machine The controller does not need any external power The control range the minimum curr...

Page 16: ...time Weld time WT Time while the current is flowing Cool time CT Time used for pulsation Hold time HT The hold time varies depending on the material and thickness of the work Off time OT Apply off time when performing continuous welding The welding machine continues welding at intervals of the off time while the operator keeps treading on the foot switch To perform continuous welding turn on the c...

Page 17: ...n activation input signal from foot switch operation of welding will be performed ２ PRESS pressurizing test mode Welding operation test operation won t be performed Only when activation signal from foot switch was input upper electrode is pressurized ３ TEST operation test mode 1 Upon activation input signal from foot switch operation test operation will be performed operation test will perform seq...

Page 18: ...trol Box Welding Machine Control Box Type of switch POWER SW MODE SW Position of switch ON PRESS Activation ON Step on foot switch State of pressurizing Deactivation OFF Turn off foot switch Pattern ３ Testing operation Control Box Welding Machine Control Box Type of switch POWER SW MODE SW Position of switch ON TEST Set work Operator set work This operation will run without work Activation ON Step...

Page 19: ...ing Open the air valve and supply compressed air Read the pressure gauge to check for compressed air is supplied Turning the regulator handle clockwise increases the electrode force Turning it counterclockwise decreases the electrode force Adjustment of welding pressure Be sure to set mode to PRESS at stationary welding machine control box or teaching box Adjust the compressed air Refer to the wel...

Page 20: ...TRUCTION MANUAL and TB40 P02X INSTRUCTION MANUAL optional equipment Confirmation of welding conditions with test pieces Obtain the best welding conditions by welding test pieces several times 3 3 Welding Results and Causes of Trouble Trouble Welding results Cause Electrode force too high Current too high Weld time too long Electrode tips in poor conditions Cracks in welded parts Electrode tips not...

Page 21: ...3 4 Wiring diagram 21 ...

Page 22: ...Circuit diagram 22 ...

Page 23: ...3 5 Piping diagram 23 ...

Page 24: ...e time of Inspection maintenance of welding machine and control box please switch off power from mains Be sure to turn off the power switch of the controller before attempting to inspect form or replace electrode tips Do not modify the welding machine Do not change the specifications If necessary contact the store where you purchased the machine or our sales office Note 1 Condensation When low tem...

Page 25: ...stop air supply when you mount remove the cup Lubricating Supply Turbine oil 90 to 140 if necessary ４ ３ ２ Cooling Water Circulation System Cleaning the cooling water channels Blow compressed air into the water supply port to remove deposit from the cooling water channels about once a month ４ ３ ３ Electrode dressing finish and guide pin Shape of electrode tip is one of the crucial factors for weldin...

Page 26: ...tity of cooling water or more during the weld time ４ ３ ５ Cylinder Oiling Oiling depends on the status of use However supply machine oil from the oil inlet shown in the figure about once a month At detection of an air leak In case you found air leak from cylinder head during upper electrode pressurizing open or stand by mode or in case electrode force was not appropriate for air pressure please tak...

Page 27: ...ric dimension of the welding head when changing the welding pressure mechanism including the upper electrode tip tip holder horn etc When doubling the current eccentric dimension set 0 25 MPa 2 5 kgf cm2 or less as the supply air pressure Air pressure higher than 0 25 MPa may cause the welding head to be damaged The figure at right shows the eccentric dimension Note Be sure to perform the maintena...

Page 28: ...heck if grease is sufficient inside cylinder Apply grease to cylinder Refill lubricator with machine oil Check if lubricator oil is sufficient Refill lubricator with machine oil Check water inside air filter Drain water through drain cock Check if solenoid works Replace solenoid In case lamp won t turn ON or no sound Check if solenoid wiring is cut off Replace wiring Check if foot switch wiring is...

Page 29: ... Ｐ ２１ １ O ring Ｐ １１５ １ Cylinder Packing Denyo Kogyo Refer to figure on Ｐ26 ＰＮＹ ３６ １ Straight tip ＣＤ ０４ ０００１ Upper lower each１ Electrode 1 Straight holder Denyo M E ＣＤ １６ ０００８ Upper lower each１ 1 This specification is a standard In case of any engineering change order from your side this standard specification will be changed to special specification Please refer to Figure 1 DN50 outline drawing on...

Page 30: ...use frequency ４ Any questions regarding product should be address to our sales staff or the head office or sales office indicated below ５ We are not liable for theft and crime prevention DENYO KOGYO CO LTD 2007 55 Shengxi Road Kunshan Economic Development Zone Kunshan Jiangsu China Pref 215334 Phone 0512 57636971 FAX 0512 57909260 Head office 1648 5 Kamanashi Metal Industrial Complex Tsuijiarai Sh...

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