Denyo DN-C-50-4-06 User manual

STATIONARY TYPE
SPOTWELDINGMACHINE
MODEL DN-C-50-4-06
Beforeusingthisequipment,pleasereadthoroughlythesafetyprecautionsforusingthe
equipmentsafely.Afterreadingthemanual, keepit onhand toensureeffectiveuse.
INSTRUCTION MANUAL
DN-C-50-4-06 01
2010/03/25 EN

CONTENTS 〉
1. SafetyInstructions (3)
1 1 Instructions (3)
1 2 SafetyPrecautions (4)
1 3 InstructionsforEnsuringSafety (5)
1 4 DangerousSectionsofProductwhereWarningLabelsareAttached (8)
2. SpecificationsandFunctionsofStationaryTypeSpotWeldingMachine (9)
21 Overview (9)
22 Specifications (9)
23 NameandFunctionsofcomponents (10)
24 Installation (12)
-1Cautionsforinstallationlocation (12)
-2Pipingand connectionmethods (12)
-3Cautionsforpipingand connection (13)
-4Securingthebodyoftheweldingmachine (13)
-5Tableofrequiredequipment (14)
3. Operation (15)
3 1 ControllerofStationaryTypeSpotWeldingMachine (15)
-1Controlmethod (15)
-2Operationsequence (16)
-3 Howtooperatestationaryspotweldingmachine (17)
3 2 Preparation forWelding (19)
3 3 WeldingResultsandCausesofTrouble (20)
3 4 Wiring diagram (21)
3 5 Pipingdiagram (23)
4. Maintenance andInspection (24)
4 1 RegularInspection (24)
4 2 Noteson Inspection (24)
4 3 Maintenance (25)
-1 AirPipingSystem (25)
-2 Cooling WaterCirculationSystem (25)
-3Electrodedressing (25)
-4 Conductorsand OtherComponents (26)
-5 Cylinder (26)
4 4 ElectrodeForceChart (27)
4 5 OtherNotes (27)
4 6 TroubleandActiontobeTaken (28)
4 7 PartsList (29)

1. SafetyInstructions
1－1. Introduction
Beforegettingstarted,readthisinstructionmanualthoroughlyinordertousetheunitcorrectly.
•Inordertoguarantee safety, theinstallation, inspection,maintenance, andrepairing ofthis
welding unitmustbeonlydonebyapersonwhoeitherhasthequalificationsorhasathorough
knowledgeofwelding units.
•Inordertoensuresafety, theoperationofthiswelding unitmustbedonebyapersonwhohas
fullyunderstoodthecontents ofthisinstructionmanualandhastheknowledgeandtechnicalskill
tohandletheunitsafely.
•Afterreadingthisinstructionmanual, storeitcarefullyinaplace whereitcanalwaysbereferred
tobyallrelatedpersons.Thisinstructionmanualshouldbereadagainasandwhentheneed
arises.
•Whenthereisanyitemthatisnotcleartoyou, pleasecontactoursalesofficeorrepresentative's
office.Theaddressesandtelephonenumbersoftheofficestowhichyoucandirectyour
inquiriesaregivenonthebackcoverofthismanual.
(3)

1－2. SafetyPrecautions
•Readthisinstructionmanualthoroughlybeforeusingtheunitanduseitcorrectlyasdescribedin
thismanual.
•Theprecautionsgiveninthisinstructionmanualnotonlyletyouusetheunitsafelybutalso
preventsinjuryandloss toyouortootherpersonsnearby.
•Althoughthiswelding unithasbeendesignedandmanufacturedwithsufficientconsiderations
giventosafety,itisessentialthatyoualwaysfollowtheprecautionsgiveninthisinstruction
manualduringtheuseoftheunit.Iftheseprecautionsarenotfollowedduringtheuseofthe
unit,itcancauseaccidentsofserioushumaninjuryorevendeathofpersons.
•Ifthehandling oftheunitismistaken,itispossiblethatseveraldifferentlevelsoflossesorinjury
canoccur.Theselevelsareclassifiedintothefollowing three ranksinthisinstructionmanual,
andeachoftheselevelsareassigneduniquealertsymbolsasshownbelowalongwith
descriptions. Thesamealertsymbolsarelabeledonthemachineunitalso.
Attentionsymbol Description
Ifthehandling of theunitismistaken,anextremelydangerous
conditioncanoccurwhichcanleadtoseriousinjuryordeath.
Ifthehandling of theunitismistaken,adangerousconditioncanoccur
whichcanleadtoseriousinjuryordeath.
Ifthehandling of theunitismistaken,adangerousconditioncanoccur
whichcanleadtomediumlevelinjuriesorminorinjuriesormay
merelycausemateriallosses.
Thesymbolsaboveareusedingeneralconditions.
"Seriousinjury"mentionedabovearethoseinwhichloss ofsight, bodilyinjury,burns(hot
andcoldburns), electricshock, brokenbones, poisoning, etc., arecaused, andcanbeofthe
typewhichleaveaftereffectsorofthetypewhichrequirehospitalizationorhospitalvisitsover
thelongperiodoftime.Further,theterm"mediumlevelinjuriesorminorinjuries" mentioned
abovearethoseinwhichbodilyinjury, burns, orelectricshockarecaused, althoughtheydonot
requirehospitalizationorhospitalvisitsoverthelongperiodoftime.Theterm"material
losses"usedaboverefertolargelossessuchasbreakageofpropertyordamagetothe
equipment, etc.
(4)
High Danger!
Danger!
Caution!

Inaddition, whatyoumustdoandwhatyoumustnotdoduringthehandlingoftheunitareshownbelow.
Operationyou mustdo.Forexample, "Groundingwork", etc.
Operationyou mustnotdo.
Thesesymbolsareusedingeneralconditions.
1－3. InstructionsforEnsuringSafety
Alwaysfollowtheinstructionsbelowinorderto
avoidserioushumaninjuryaccidents.
1.Althoughthiswelding unithasbeendesignedandmanufacturedwithsufficientconsiderations
onsafety,itisessentialthatyoualwaysfollowtheprecautionsgiveninthisinstructionmanual
duringtheuseoftheunit.Iftheseprecautionsarenotfollowedduringtheuseoftheunit, it
cancauseaccidentsofserioushumaninjuryorevendeathofpersons.
2.Followthegovernmentalregulationsandyourowncompany'sinternalstandardsregardingthe
constructionworkforinputpowersupply, selectionofthelocationofinstallation, handling,
storage,andpiping ofhighpressuregases, storageofproductsafterwelding, andprocessingof
wastematerials, etc.
3.Makesurethatpersonsdo notcomeaccidentallynearthewelding unitorneartheplace of
welding work.
4.Makesurethatpersonswearingcardiacpace makersdo notcomenearanoperatingwelding
unitorneartheplace ofwelding work, unless anduntiltheyhaveobtainedpermissionfrom
theirdoctors.Thewelding unitgeneratesstrongmagneticfieldswhenpowerissuppliedtoit,
andthismagneticfieldcanhavebadeffectsontheoperationofcardiac pace makers.
5.Inordertoguarantee safety, theinstallation,inspection,maintenance, andrepairing ofthis
welding unitmustbedoneonlybyapersonwhoeitherhasthequalificationsorhasathorough
knowledgeofwelding units.
6.Inordertoensuresafety, theoperationofthiswelding unitshouldbedonebyapersonwhohas
fullyunderstoodthecontents ofthisinstructionmanualandhastheknowledgeandtechnical
skilltohandletheunitsafely.
7.Neverusethiswelding unitforanypurposeotherthanwelding.
(5)
Compulsory
Prohibited
Danger!

Alwaysfollowtheinstructionsbelowtoavoid
electricshockhazards.
*Nevertouchanyelectricallylivepartotherthanthesecondaryconductor.
*Nevertouchbothendsofthesecondaryconductoratthesametime
1.Nevertouchanyelectricallylivepartotherthanthesecondaryconductor.
2.Getgroundingworkdoneforthewelding unitaccordingtogovernmentalregulations(suchas
technicalstandardsforelectricalequipment)byanelectricianhaving thequalificationstocarry
outsuchwork.
3.Duringinstallationormaintenanceinspection, alwaysmakesurethattheinputsidepower
supplyhasbeenswitchedoff bytheswitchinthepowerdistributorbox, andcarryoutthework
atleastfiveminutesafterswitching off thepowersupply.Evenwhentheinputsidepower
supplyhasbeenswitchedoff, therewillbeelectricalenergystoredinthecapacitors, andhence
carryouttheworkafterconfirming thatthereisnochargeonthecapacitors.
4.Neverusecablesthathaveinsufficientvoltage/currentcapacity, orthathavebeendamaged, or
whoseconductorsareexposed.
5.Makesurethattheconnectingpartofcablesarefirmlytightenedandcoveredwithinsulating
sheath.
6.Neverusetheweldingunitwithitscaseorcoverremoved.
7.Neverusetornorwetgloves.Alwaysusedryand insulatinggloves.
8.Carryoutregularmaintenance inspection, andusetheunitafterrepairingthedamagedparts.
9.Forthecoolingwater, besuretousegoodqualitywaterwithlowsedimentcontentandwitha
resistiveof5000Ω-cmorbetter.
10. Whenprocuringthecables, compressedairhose, waterhose,etc., besuretouseitemsthatcan
sufficientlybearthespecifiedloadorpressure.
11. Whennotbeingused, alwaysswitchoff thepowersupplyofall units.
Neverplaceyourhandorfingersinbetweenthe
electrodes.
*Placinganypartofyourbodysuchasahand, fingers, orarm, etc., in
betweentheelectrodescancauseinjuryorbrokenbones.
1.Neverplace anypartofyourbodysuchasahand, fingers, orarm, etc.,inbetweenthe
electrodes.
2.Beforeswitching onthepowerorthecompressedairsupplyofthewelding unit, alwaysconfirm
thesafetyaroundtheweldingunit.
3. Whennotbeingused, switchoff thepowersupplyofall units, andshutoff thesupplyof
compressedairandcoolingwater.
(6)
Danger!
Danger!

Useprotectiveweartoprotectyourselfandother
personsfromthedust(splashesandsputters)
generatedduringweldingandfromnoise.
*Thedustsplashingoutcancausedamagetotheeyesorburnsonthebody.
*Thenoisecancausehearingabnormalities.
1.Toprotectyoureyesfromthedustsplashing outduringwelding, alwayswearprotective
goggles.
2.Wearprotectivegloves,longsleevedclothes, andleatherapron, etc.,forprotection.
3.Place protectivecurtainsaroundtheplace ofweldingoperationsothatthedustdoesnothit
otherpersonsintheneighborhood.
4.Ifthenoiselevelishigh, usesoundprotectiontools.
Alwaysfollowtheitemslistedbelowtoavoidfires
and explosions.
*Thedustsplashingoutduringweldingandthehotworkpiece
immediatelyafterweldingcancausefires.
*Ifthereisanyimperfectconnectionsofcables, theheatgeneratedat
suchpartscancausefires.
1.Removeall flammablematerialsintheneighborhoodofthewelding place sothatthedust
splashing outduringwelding doesnotfallonflammablematerials.Ifitisnotpossibleto
removeflammablematerials, coverthemwithnon-flammablecovers.
2.Nevercarryoutwelding nearflammablegases.
3.Nevertakethehotworkpiecesimmediatelyafterwelding nearflammablematerials.
4.Firmlytightentheconnectingparts ofcablesandcoverthemwithinsulatingsheath.
5. Place afireextinguishernearthewelding workplace foruseinanemergency.
(7)
Caution!
Caution!

1－4. DangerousSectionsofProductwhereWarningLabelsareAttached
(8)
Besuretowearsafety
goggleswhen
performingwelding.
Theworktobewelded
maymelt andsplash
ontoyou
CAUTION
DANGER
Becarefulnot toget
yourhandcaught
betweentheelectrodes
whilecarryingout
work.
CAUTION
Dustcausesafireor
explosion.Remove
any flammableobjects.
CAUTION
Flexibleconductor
canbeextremely
hot. Useextreme
cautionwhen
handlingit.
CAUTION
CAUTION:
Powersupply
voltageisapplied
tostationary
controlBOX.
CAUTION
CAUTION:Powersupply
voltageisappliedtothe
lowerbacksurfaceofthe
unit.Keepbackpaneland
sidepanelclosedwhen
operate.

2. SpecificationsandFunctionsofStationaryTypeSpotWeldingMachine
2‐1Overview
This equipment is single-phase ACstationary spot weldingmachine, which consists of
weldingmachine unit,pneumatically operatedpressure device,single-phase transformer
control unit.
Pleaserefertothefollowingspecificationsand instructionmanualsforeachof
theequipment.
(1)Weldingmachine
NUTFEEDERINTEGRATEDSPOTWELDINGMACHINE/MODELDSF50-4IS-01
INSTRUCTIONMANUAL(Thisdocument)
(2)WeldingController
PHASESRESISTANCEWELDINGCONTROLLER 「PHS-1108 SPECIFICATION」
PHASESRESISTANCEWELDINGCONTROLLER 「PHS-1108 INSTRUCTIONMANUAL」
RESETBOX 「RB40-R02A-XXX SPECIFICATION/INSTRUCTIONMANUAL」
TEACHINGBOX 「TB40-P02x INSTRUCTIONMANUAL」Optionalequipment）
2‐2Specifications
◎Body specificationsofthewelding machine
Model ＤＮ-C-50－４－０６
Powersupply Single-phaseAC
Ratedprimaryvoltage 415Ｖ
Ratedfrequency ５０Ｈｚ
Primaryvoltageatmaximumcontactload４５０Ｖ（１８０００Ａ guaranteedvoltage）
Ratedcapacity ５０ｋＶＡ
Ratedmaxcapacity １２６ｋＶＡ
Permissibledutycycle ８．０％
Max shortcircuit current １８０００Ａ
Currentcontrolrange Synchronousmethod（Primaryelectriccurrentunit）
３０～１００％
Max weldingpressure ５９００Ｎ (at ０．５９ＭＰａ)
Airpressure ０．５ＭＰａ
Reference throatdepth ４００㎜
Reference throatgap １９５㎜
Overall stroke １００㎜
Workheight ９００㎜
Workheight ３６０ｋｇ
Quantityofcoolingwater ８Ltr／min（temperatureatwatersupplyoutlet:３０℃
MAX,
waterpressure: ０.１～０.３ＭＰａ）
◎Welding machinecontroller(timer)
Controllerpower Suppliedthroughastepdowntransformerfromthepowersupplyoftheweldingmachine
Thyristor Ｅ-sizeindirectwatercoolingtype
◎Option－TEACHINGBOX(NADEX)･･･TB40-P02X(9)

2‐3NameandFunctionofcomponents
（１）Gunbody
Figure1）ＤＮ５０ Outlinedrawing
(10)

（２）Namesandfunctionsofmaincomponents
WeldTransformer ：Convertinputvoltage(primary)tolowvoltage(secondary)forresistance welding.
FootSwitch：Switchtooperatenutwelding operationcycle.
①AirFilter ：Eliminatemoistureanddustfromcompressedair.Turnthelowerknobcounterclockwisetodrain
theaccumulatedwaterifany.
②AirRegulator ：Regulateelectrodeforcebyregulating airpressure. Turningregulatorknob clockwisewill
increaseelectrodeforce proportionately.
③Lubricator ：Automaticlubrication systemforpressurizingcylinderandsolenoidvalve.Usetheupper
redknobtocontrollubricantflowsothatthelubricantwill dropevery40 movementsof
cylinder.
④PressureGauge：Indicatesupplyairpressuretopressurizing cylinder. Refertothevalueshownatpressure
gaugeandtable4-9 “Electrodeforcetable”tosetelectrodeforce.
⑤Air ：Airinlet
⑥SolenoidValve ：Airelectromagneticvalvetooperatepressurizingcylinder.
⑦Silencer ：Silencerforexhaustairforpressurizingcylinder.
⑧Cylinder ：Moveelectrodeup anddown.
⑨SpeedController：Controlupperelectrodemotionspeedbyregulatingexhaustairflowamountatwhen
pressurizedbycylinder.Looseningupclockwisewill slowdownelectrodemotion
speed.
⑩Welding Controller ：Controlthetimeforinitialpressurizing, welding, holdand open.Also
(NADEX) controlweldingcurrent.
Pleasereferto 「PHS-1108 SPECIFICATION」，「 PHS-1108 INSTRUCTION MANUAL」
⑪FootSwitchConnector：Connectfootswitch.Steppingontheswitchwill sendoff thesignaltoactivate
controlunit.
⑫FlexibleConductor :FlexibleCurrentcarryinglink
⑬Electrode :WeldingElectrode
⑭WaterMeter ：Indicatorforcoolingwatercirculation.
⑮ControlBox ：Switch「POWER」ON/OFF atcontrolunit.Alsoswitchmodebetween「PRESS」「 WELD」
「TEST」.
⑯SwitchBox ：Switchweldingconditionnumber(betweencondition number1 ~15)
(NADEX)
⑰ResetBox ：Thisequipmenthasfunctionssuchasmonitor(partial)and resetweldingcontrol (NADEX)
unit. Pleasereferto ｢RB40-R02A-XXX SPECIFICATION/INSTRUCTION MANUAL｣
(11)

2‐4Installation
２‐４‐1Cautionsforinstallationlocation
①Usetheeyebolt onthetopofthebodyoftheweldingmachinewhensuspendingthemachine.
②Donotinstall theweldingmachineinadustyplace oraplace wheretemperatureandhumidityarealways
high.
③Besuretoremovetheframefortransport, andfirmlysecuretheweldingmachineonto
asolidfloorbyanchorboltstopreventvibrationduringweldoperation
④Install theweldingmachineasclosetothetransformerofthepowerequipmentaspossible.
⑤ThepowerequipmentmustcomplywithSection2-4-5 (Requiredequipmenttable).
２‐４‐２ Pipingandconnectionmethods
①Connectearthterminalonwelding machinebacksurface.
Usea cableof1４mm2ormore.
②Connectadurablerubberairhosetothe"airinlet."
Useahosethatmatchesthehoseport(10.5 indiameter).(0.7 MPa)
③Connectwaterhosestothe"cooling waterinletandoutlet."
Fortheinlet, useahosethatmatchesthehoseport(10.5 indiameter).
Fortheoutlet,useahosethatmatchesthehoseport(14 indiameter).
④Connectthefootswitchtothe" footswitch"metalreceptacle.
⑤Connectthepowercabletothecableonthebackofthebodyoftheweldingmachine.
Thecablemustbeequalto thespecifieddiameterormore.
(12)

２‐４‐３ Cautionsforpipingandconnection
①Grounding ：
Groundingismandatoryforprotectingoperatorsfromanelectricshockwhentheinsulation
resistance oftheweldingmachinedrops.Useagrounding conductorhavingacross-sectionalareaof14mm2or
more, andgroundtheweldingmachinecomplyingwiththefollowing:
Withsourcevoltage400 V:SpecialClass IIIgrounding(groundingresistance 10Ωorless)
②Coolingwater ：
Usecoolingwaterofwhichtemperatureisalways30 °Corless.Becarefulofthewatertemperature
particularlywhenusingaforciblycirculatedwatercoolingsystem.Notethataninsufficientquantityof
coolingwaterorwatertemperatureover30 °Ccausestheweldingmachinetogenerateheatorfail tostart.
Inwintertime, becarefulthatthepipingsystemdoesnotfreeze.
③Compressedair：
If thecompressorcapacityorpipingsizeisnotlargeenough,thewelding headbecomesslowandthe
pressuredrops,whichcausesmanyexpulsionsandsurfaceflashes.Usecompressedairincludingonlylittle
moistureormist.Compressedairincludingexcess moistureormistinfluencesthelifeofequipment.
④Powersupply ofthewelding machine：
Theratedsource voltageis380V.Usea600 VACpowercablethathasacross-sectionalareaof35 mm2or
more.
PleaserefertoSection2-4-5 (Requiredequipmenttable).
２‐４‐４ Securingthebodyoftheweldingmachine
①Securethebodyontoaflatfloorusinganchorbolts(12 mm indiameter).
②Dimensionsofthebody(Seethefigurebelow.)
（Bottomsurface ofthemainbody）
(13)

２‐４‐５ Tableof requiredequipment
Model DN-C-50
Source voltage 380V ±10 (400Vormoreduringweldtime)
Powercapacity 50 kVA
Powerswitchcapacity 415V125A
Powersupplyof
thewelding
machine Leadwire 35 mm2ormore
Waterpressure 0.2 -0.3 MPa
Quantityofcoolingwater 8 Ltr/minormore
Watertemperature 30 °Corless
Waterresistivity 5 kΩ・cmormore
Watersupplyhoseinternaldiameter φ10
Coolingwater
Drainhoseinternaldiameter φ13
Compressor 2 -3HP
Airpressure 0.5-0.7MPaCompressedair
Airhoseinternaldiameter φ10
Grounding Groundingwire 14 mm2ormore
(14)

3. Operation
3‐1ControllerofStationaryTypeSpotWeldingMachine
３‐１‐１ Controlmethods
《Important》Use「TB40-P02X(TEACHINGBOX)」tosetcondition.Forconnectingteachingbox, unplug
connectorfromResetBoxand connectittotheteaching box.
「PHS-1108 SPECIFICATION」「 PHS-1108 INSTRUCTION」「 RB40-R02A-XXXSPEC./INST.」
Pleasereferto 「TB40-P02XINSTRUCTION」（ optionalequipment）
Controlmethod Synchronousphasecontrolbythethyristorfortheweldingmachine
Squeezetime(initialpressure)(SQ) １～９９cyc
Weldtime(WT) ０～９９cyc
Holdtime(HT) ０～９９cyc
Offtime(OT) １～９９cyc
Timecontrol
Up-slopetime(US) ０～３０cyc
Currentcontrol
method Constantcurrentcontrolandvoltagecompensationcontrol
(Supplementaryinformation)
•Powerissuppliedtothecontrollerfromthepowersupplyoftheweldingmachine.Thecontrollerdoes
notneedanyexternalpower.
•Thecontrolrange(theminimumcurrentandmaximumcurrent)isdeterminedforeachsetvaluebythe
connectedload.Therefore, thelimitvaluesvarydependingon theload.
•When0%ofthesetcurrentisspecified, themachineissubjectedtoabout30%ofthecurrenteffective
when100%isspecified.
(15)

３‐１‐２ Operationsequence
①Pre-squeezetime(PSQ)
Timestartfromwhentheoperatorpress thefootswitchto thesolenoidvalveworks.
②Squeezetime(SQ)
Timefromwhen thesolenoidvalveworksto when thecurrentstartsflowing. Setatimelongenoughfor
theupperelectrodeto reach thelowerlimit. Otherwise, an excessloadappliedto thecylindermay cause
theweldingmachinetofail.Atfirstsetatimelongerthanthestandard,anddecreaseit gradually.The
timemustbesetinaccordance withtheelectrodespeed.
③Upslope(US)
Thecurrentgraduallyincreasesduring theup slopetime.
④Weldtime(WT)
Timewhilethecurrentisflowing.
⑤Cooltime(CT)
Timeusedforpulsation.
⑥Holdtime(HT)
Theholdtimevariesdependingonthematerialand thickness ofthework.
⑦Off time(OT)
Applyoff timewhenperformingcontinuouswelding.Theweldingmachinecontinuesweldingat
intervalsoftheoff timewhiletheoperatorkeepstreadingonthefootswitch.Toperformcontinuous
welding, turnonthecontinuousswitch.
⑧Repetitiveoperation
Togettheweldingmachinetocontinueworkingatintervalsofthesetoff time,selecttherepetitive
operationmodeand keeptreadingonthefootswitch.
(16)
Basicoperationsequence
Startinput
Welding pressure
Current
Welding
completion
output
Repetitionofpulsation
During repetitive operation
OFF
OFF
OFF
OFF
OT
HT
WT2
CT
WT1
US
SQ
PSQ

３‐１‐３ Howto operatestationary spotwelding machine
（１）ControlBoxOperating Console
①「POWERSW」
・SwitchON/OFF ofControlBox
・SwitchON will turnthe[POWER]lampON.
・WhentheswitchisturnedON, youcanselectthemodeofoperation
thrufootswitch.
②「MODESW」
・Setoperationmodetoeitherof[WELD](welding), [PRESS]
(Pressurizingtest), or[TEST](operationtest)
・[WELD]lampgoeson onlywhen「WELD」(welding)modewasselected.
・Abouteachmode
－１「WELD」（ welding）mode （*1）
Uponactivationinputsignalfromfootswitch,operationof
「welding」will beperformed.
－２「PRESS」(pressurizing test) mode
[Welding],[operation test]operationwon’tbeperformed.Onlywhenactivationsignalfromfootswitch
wasinput,upperelectrodeispressurized.
－３「TEST」(operationtest)mode （*1）
Uponactivationinputsignalfromfootswitch, [operationtest]operation will beperformed.
[operationtest]will performsequentialoperationonly. Nopowerdistribution.
（*1）Pleasekeepthisswitchto “AUTO”otherthanwhenyou tune-upyourweldingmachine.
CONTROLBOX
(17)
POWER
OFFON
WELD TEST
PRESS
MODESW
WELD
TEST
PRESS
MODE
POWER
OFF
ON
POWER
WELD
RESETBOX
SCHEDULEN ．

（２）Sequence of Operation
Pattern1 Welding operation
ControlBox WeldingMachineControlBox
Typeofswitch POWERSW MODESW
Position ofswitch ON”WELD”
①Setwork･･････ Operatorsetwork
↓
②Activation(ON)･･････ Steponfootswitch
↓
③Spotwelding･･････ Weldingmachinestartsweldingoperation.
↓
④Deactivation(OFF)･･････ Turnoff footswitch.
↓
Oneprocess completed.
Pattern ２Pressurizing operation
ControlBox WeldingMachineControlBox
Typeofswitch POWERSW MODESW
Position ofswitch ON”PRESS”
①Activation (ON)･･････ Stepon footswitch
↓･･････（Stateofpressurizing）
②Deactivation(OFF)･･････ Turnofffootswitch
Pattern ３Testing operation
ControlBox WeldingMachineControlBox
Typeofswitch POWERSW MODESW
Position ofswitch ON”TEST”
①Setwork･･････ Operatorsetwork. (Thisoperationwill runwithoutwork.)
↓
②Activation(ON)･･････ Steponfootswitch
↓
③Sequentialoperation･･････weldingmachinestartssequentialoperation.
↓(Nopowerdistribution)
④Deactivation(OFF)･･････ Turnoff footswitch
↓
Oneprocess completed.
(18)

3‐2PreparationforWelding
Whenthecableconnectionandpipingarecompleted,checkthemagain.
（Caution）During theprocess of ①～⑧, besureto keep[PRESS]modeatwelding controlboxor
teaching boxforsafety purpose.
①Timerinitialization (Setcondition1 atconditionswitchbox.)
・Setthefollowingvaluesforthetimeratstartup. (setatteachingbox [TB40-P02X])
・Forthefollowing conditions, setto conditionNo.1 whichis X1”.
Squeezetime (SQ)Y1 ：60 CYCLEUpslope (US)Y3 ：0 CYCLE
Weldtime (WT1)Y4 ：10 CYCLECurrent (CC)Y5 ：6.0 KA
Holdtime (HT)Y12 ：10 CYCLE Offtime (OT)Y14 ：10 CYCLE
（Note）For Y20 of TURNS RATIO, set “54”for all schedule No. 1 ～15.
②Openthewatersupply valveandsupply coolingwater.
Checkwaterflowmetertomakesurecoolingwaterisflowing.
③Opentheairvalveandsupply compressedair.
Readthepressuregaugetocheckforcompressedairissupplied.Turningtheregulatorhandleclockwise
increasestheelectrodeforce.Turningit counterclockwisedecreasestheelectrodeforce.
④Adjustmentofweldingpressure
Besuretosetmode to[PRESS]atstationaryweldingmachinecontrolboxorteachingbox. Adjust
thecompressedair.Refertotheweldingconditiontable,andadjusttheregulatortoobtaintheelectrode
forcethatissuitableforthematerialandthickness oftheworktobewelded.Usefootswitchtomove
upperelectrodeforadjustingcompressedair. (Pleasereferto「4-9 ElectrodeForce Chart」)
⑤Electrodes:Adjustmentofup/downoperation
Adjusttheelectrodesby treadingonthefootswitch andpushinginorpulling outtheworkwhiletheupper
electrodeisatthelowestposition.Theelectrodesmustbeadjustedinaccordance withtheshapeofthe
worktobewelded.
(19)

Electrode
tipholders
Electrode
tips
Horns
⑥Adjustmentofthedistance betweentipholders
Adjustthedistance betweentheelectrodessothat
thedimensionsoftheupperandlowerhorns
showninthefigureareobtainedwhenpressureis
appliedaftertheworktobeweldedisinserted
betweentheelectrodes.
⑦Adjustmentofelectroderising/lowering speed
Thelowering speedcanbeadjustedbyturningthespeed
controllerbesidetheweldingheadcylindercover.
Turning thespeedcontrollerclockwisedecreases
thespeed.Turningit counterclockwise.
⑧Setting ofwelding conditions
Setthevalues(e.g., current)forthetimeroneafteranother
according totheweldingconditiontable
Referto 「PHS-1108 SPECIFICATION 」「 PHS-1108
INSTRUCTION MANUAL」and 「TB40-P02XINSTRUCTION MANUAL」（ optionalequipment）
⑨Confirmationofwelding conditionswithtestpieces
Obtainthebestweldingconditionsbyweldingtestpiecesseveraltimes.
3‐3WeldingResultsand CausesofTrouble
Trouble Weldingresults Cause
Electrodeforce toohigh
Currenttoo high
Weldtimetoolong
Electrodetipsinpoorconditions
Cracksinweldedparts
Electrodetipsnotcooledenoughbycoolingwater
Currenttoo low
Electrodeforce toolow
Weldtimetooshort
Lowweldstrength
Electrodetipsinpoorconditions
Weldedworksurfacesinpoorconditions
Oil orruststuck
Initialpressuretimetooshort
Electrodeforce toolow
Currenttoo high
Many weldsplatters
Weldtimetoolong
Holdtimetooshort
Electrodeforce toolow
Gapsinweldedparts Weldingheadoperationnotsmooth(insufficient
lubrication)
Poorwelding
Notwelded Squeezetimetooshort(Electrodesdonotreachthe
work.)
(20)