KYOKUTOH CDF-200 User manual

High Speed Auto Tip Dresser (CDF)
Instruction Manual
Please read this manual before using KYOKUTOH’s High Speed Tip Dresser.
First Revision: 13.10.2023

Revision
Revision History
Version
Date
Contents
First edition 13.10.2023 First edition issue

Attention to Safety
Please be sure to read ATTENTION TO SAFETY before using CDF.
This product is intended only for the dressing of specified electrodes. This product is not to
be used in any manner other than that which is specified within. We will not be held
responsible for damage or injury caused as a result of misuse of this product.
Symbols
This following symbols “Warning” and “Caution”, are used indicate possible hazards and
to prevent their occurrence.
Be careful to follow directions as specified, as an error could lead to possible
injury or death.
Be careful to foll
ow direction as specified, as an error could lead to
malfunction and serious damage.
The following symbols are explained below.
This symbol indicates operations that should not be done.
This symbol indicates operation that should be done.
※After reading, please the manual to the place where you can check the manual.

Absolutely never disassemble or
reconfigure this machine or its parts.
This could result in operation malfunction,
ignition, or injury.
Do not insert a finger or hand into
gear opening while in operation.
This will result in serious injury.
Avoid as much contact with water
as possible.
This could result in operation malfunction
(short), electrical shock or ignition.
Do not insert metallic article
s such as
a pins or needles in gear or terminal box
opening.
This could result in operation malfunction or
electrical shock.
Be sure to switch off the power
supply, when removing or repairing
wiring.
Will cause electrical shock.
Be sure that spatt
er does cover
any wiring.
This will prevent the melting of wire
membrane and a potential shock hazard.
Remove the spatter, which covers
the tip dresser periodically.
Spatter build-up can cause operation
malfunction or ignition resulting in injury.
Do not use acidic or chlorine
detergents for maintenance purposes.
Poisonous gas may be generated from the
detergents, causing a possible health risk.
Remove any oil that may
accumulate on the tip dresser.
Spatter could cause ignition and possible
Injury.
Do not use voltage other than that
which is specified.
Excess heat could cause operation
malfunction and ignition.
Be sure wire from power supply is
of correct capacity.
Incorrect wiring could result in operation
malfunction or ignition.
Do not allow power supply wiring to
become damaged.
Wiring damage could result in operation
malfunction and ignition.

Firmly fix tip dresser to stand.
If the Tip Dresser is not fixed tightly in
operation, poor dressing and other problems
could occur.
Be sure that the motor is not
locked up.
This could result in overheating and possible
ignition.
Do not use any cutter or holder
other than that which is intended and
specified.
Use of an unspecified cutter or holder,
could result in damage.
Do not install near the thermal
generation source of the welding
machine.
This could cause trouble and accidents.
Do not install between a welding
machine and a transformer.
Strong magnetic forces and heat can be
dangerous and possibly cause malfunctions
or ignition.

Table of Contents
Befo
re Using
Tip Dresser Capability
C
riteria for Dressing Guns
C
autions for Positioning the Dressing
D
resser Floating Amount
C
autions for Wiring
T
iming Chart
D
rawing
P
arts List
H
ow to Change the Cutter
Cautions and Confirmation before the
Operation
A
bnormality and How to Repair
C
onsumption Parts List
P
eriodic Maintenance
C
ontacts
1
2
3
5
8
9
11
12
13
14
19
20
16
17
22

1
Before Using
About QR Code
The high-speed auto tip dresser "CDF" has a QR code pasted on the top of the main
body.
When you scan this QR code with your smartphone, you will be redirected to the product
support page with the latest instruction manual, catalog, teaching videos, etc.

2
Tip Dresser Capability
Feature
1. Dress upper and lower tips simultaneously, therefore, dressing time is reduced.
2. Exclusive cutter enables cap tips to be dressed with the pressure 1,470N.
3. Floating mechanism greatly reduces stress on welding gun and dresser.
Model
Power
FREQ
Current
RPM
Torque
Power
Rated
Time
Weight
CDF-
200
AC200V 50 Hz 4.8 A 363
rpm
29.1
N.m
1kW
RATED
OUTPUT
CONTINOUS
USE TIME 5
MINUTES
16kg
AC200V
60 Hz
4.6 A 435
rpm
25.5
N.m
AC220V 4.2 A 435
rpm
24.4
N.m
CDF-
400
AC380V
50 Hz
3.0 A 363
rpm
28.3
N.m
AC400V 3.3 A 363
rpm
28.1
N.m
AC415V 3.6 A 363
rpm
27.9
N.m
AC400V
60 Hz
2.5 A 435
rpm
24.0
N.m
AC440V 2.7 A 435
rpm
23.2
N.m

3
Criteria for Dressing Guns
Conditions that can be dressed
(Applicable to both X-guns and C-guns; see figure 1 and 2)
1. If A dimension is less than 22mm, this dresser is not suitable, because it may contact
gearbox.
※Some special cutters require up to 25 mm.
2. If B dimension is less than 47mm, this dresser is not suitable, because it may interfere
with gearbox.
3. Cap tip with “C” angle up to 15 degrees can be dressed.
When using the eccentric tips or guns with angle, please contact us.
4. When the length of shank of D dimension is long, contact us for solution.
5. The base tip and insert electrode require a particular cutter. (E dimension)
We will customize the cutter if you could provide us the gun and tip drawings.
6. Recommended dressing force is 1,470N.
High dressing pressure from 1,470N might make the dresser stop or damage the
cutter and holder, depending on the shape of cap tips. In this case, please reduce the
dressing pressure. If it is impossible to reduce the pressure, please contact us.
7. Select a cutter well suited to the tip shape.

4
A: Tip opening needs over 22mm.
B: To avoid interference with gearbox,
47mm.
E: The special cutter should be used
for the shorter tips.
C: Maximum 15 degrees is acceptable.
Figure 1
Figure 2
D: Concentricity guide required,
If this is over 90mm－φ16
70mm－φ13

5
Cautions for Positioning the Dressing
Attention
1. The tip should be set parallel to floating mechanism. (See figure 3)
2. For X-guns, set the dressing location to the pressurization location. (See figure 4)
3. For C-guns, set the dressing location even level with pressurization location,
otherwise it might cause poor dressing or damage gears and bearings.
4. Although the floating mechanism is installed in dresser, we also recommend that you
locate the dressing position as closely as possible.
5. Dressing horizontally C-Guns vertically set with equalizing mechanism is difficult to
keep weight balance of springs, and pressurization point could easily change. So in
this case, please make sure of pressurization point very well when you teach robots.
(See figure 4 and 5)
Figure 3

6
Figure 4
Figure 5

7
Precautions when pressurizing
Attention must be paid to the starting position of pressure on the bottom side of the
holder.
If there is a distance between the tip of the fixed tip and the cutter, there is a possibility
that there will be a large difference in the amount of dressing between the top and
bottom tips.
The starting position of the pressurization should be set at the very end of the contact
between the tip of the fixed tip and the cutter.
Fixed
Movable
NG
OK
Too large gap. The position 1-2 mm
away from light
contact is best.

8
Dresser Floating Amount
※Vertical to Floor
Vertical to floor
Because of gravity on ②, use longer
spring than ①.
※For use of up-side-
down, please
replace ①,②springs.
※Horizontal to Floor
＜Floating amount＞
・Pushing up→18.5
ｍｍ
・Pushing down→22.5
ｍｍ
＜Floating amount＞
・Pushing up→14.5
ｍｍ
・Pushing down→26.5
ｍｍ
Pushing up
Pushing down
Pushing up
Pushing down
②
①

9
Wiring pattern
3pin －T
4pin －S
5pin －R
Earth －FG
Cautions for Wiring
Connector

10
Do NOT operate while the line is live. Shut off the power supply.
Wiring must be performed by a person authorized to handle electrical
work in accordance with electrical work standards.
CDF dresser has a floating device as a standard. Mind the expansion
/contraction when wiring.
Since the dresser has a floating device, be careful not to loosen the
screws on the wiring terminals.、（Creating a loop with cables near the
dresser is effective in absorbing shocks. ）
Install external thermal or other overload protection devices.
Motor Circuit Diagram

11
Timing Chart
ＫC type cutter (Only clockwise rotation)
Gun
Pressure
ON
0.8sec
OFF
Dresser
Rotation
ON
OFF
1. Start motor to clockwise before Gun press.
2. Set the dressing time according to your tip condition. Approximately 0.8sec.
3. Confirm rotate direction (clockwise).
4. To finish dressing, release the gun pressure while dresser is revolving.
◆Before operating, make sure that the forms of cutter and tip are fitting.
◆When dressing is finished and small scrapes are left on the cap tips, both upper and
lower tips should be touched with the cutter of revolving dresser before returning to
original position.

12
Drawing

13
Parts List
NO.
Part Name
Type or Size
QTY
1 Tip Dresser ＣＤF-*** 1
2 Output Gear Bearing 6210 2RS 2
3 Shaft Plate CDF-FP 2
4 Spring for Vertical Type ＣＤＫ－Ｒ－００２ 2
Spring for Horizontal Type ＣＤＫ－Ｒ－００３ 2
5 Upper Spring ＣＤＫ－Ｒ－００３ 2
6 Shaft ＣＤＫ－Ｒ－００４ 2
7 Slide Bearing ＬＭ２０ＬＵＵ 2
8 C-Ring for Bearing For ３２ Axis 4
9 Flat Washer For Ｍ２０ 4
10 Cap Screw Ｍ８×２０ 4

14
How to Change the Cutter
1. Remove the cutter holder from the dresser.
2. To remove the cutter from the cutter holder, loosen the M3 torque screw.
(With a torque wrench T-10)
※Recommended tightening torque: 0.95N・m