Westken 35kva UN35 Configuration guide

Westken information manuals and technical assistance
General Manual for UN35 Butt Welder
Westken, 190 van Eden crescent, Rosslyn, Pretoria, South Africa.
www.westken.co.za (Tel; 0027 12 541 6064/6065 fax; 0027 12 541 8086)
1
Last update 25th July 2019
“UN35” 35kva butt welder
The 35kva “UN25” butt welder are general purpose air clamping, air upsetting butt
welders fitted with a solid state timer system capable of welding mild steel round material
from 3mmdia up to and including 8mmdia. The transformer is thyristor controlled with
thyristor protection circuits and systems in place. Current/heat control, air clamping
pressure, upsetting pressure & upsetting stroke are all adjustable. Control voltage is
24vdc.
The machine has a CuCrZr copper upper clamping block and “V” cut to suit CuCrZr
copper lower welding electrode. On delivery the lower electrode can be un-machined.
There are two 63mmdia clamping cylinders and a 63mmdia upsetting cylinder. All air
equipment, solenoids & FRL units are 1/4bsp. The machine has a semi encapsulated
transformer which is water cooled. The machine is on a based lifter unit and can be
supplied on a wheel base unit.
The machines are operated by a single foot switch with a latch system to operate the
LH/RH clamping cylinders.
Explaining the Air Operated Butt Welder System
Note: Please read this in conjunction with information on our website.
www.westken.co.za
Congratulations on your purchase of a “Westken”air operated UN35 Butt welder,
marketed by “Westken” in Pretoria, South Africa. Westken manufactures and imports a

Westken information manuals and technical assistance
General Manual for UN35 Butt Welder
Westken, 190 van Eden crescent, Rosslyn, Pretoria, South Africa.
www.westken.co.za (Tel; 0027 12 541 6064/6065 fax; 0027 12 541 8086)
2
full range of welding machines from the 25kva foot pedals up to 450kva Projection
welder.
All air operated butt welding machines use an air cylinder to close the welding electrodes
together and to upset the welding area, whether it’s the “UN35” or “Level-6 100kva butt
welder the method is the same.
The welders utilize a technique called “Resistance Welding”. Resistance welding is a
process where metal is held between two electrodes, lots of amps (thousands) but low
volts (3v –10v) are pushed through the metal causing the metal to get hot and melt in
between the electrodes. Then after the metal melts the supply of the amps is stopped
allowing the metal to cool and bond. Once the metal is cool the electrodes let go of the
metal and you have a weld.
The operator pushes the electric foot switch or, where fitted the two hands start switch,
this switch triggers the welding timer to begin its process.
The first operation the timer undertakes is to send a signal to the air solenoid valve (air
flow switch) to allow air to travel to the air cylinder. This pushes the piston in the
cylinder down and closes the welding tips.
Once the tips are together the timer then switches the Thyristor switch (also call the SCR,
AC switch, Semipack) which allows electricity to flow into the transformer. The
electricity coming into the transformer is normally 380vs at about 80amps. The
transformer changes this (transforms) supply to about 4.5volts at 9000amps output.
Because the clamping electrodes are closed this AC volts/amps will pass through them
and into the steel being welded causing the steel to heat up in the weld area. As the
heated area starts to melt the upset air cylinder pushes the two parts together. This
upsetting pressure ensures that when the weld takes place the wet metals combine to
make a secure weld; this is called follow-up pressure or forging pressure.
An introduction to the machines
We are now looking at the machine with its electronic device with its readout screens,
lights and buttons; it’s a bit confusing, hey! Read this and it will hopefully make things a
bit more clear.
As stated above the air Butt welding machines are all similar but I will highlight machine
specific parts and describe them in a bit more depth.
I will discuss timer setting which can be found further on in this manual. It is important
that you have read the other sections concerning spotwelding and resistance welding, so
now, once again, let’s try and explain in a way that is understandable without using too
many big words, technical terms or baffling phrases.

Westken information manuals and technical assistance
General Manual for UN35 Butt Welder
Westken, 190 van Eden crescent, Rosslyn, Pretoria, South Africa.
www.westken.co.za (Tel; 0027 12 541 6064/6065 fax; 0027 12 541 8086)
3
Some simple explanations of words and terms can be found on our website. Words that
can be found on our website will be in bold italics.
A more in depth explanation of the welding processes and equipment will be covered in
other sections on the Westken info page.
Chapter one
The layout and walk around of an UN35 air operated Butt welder.
(UN35 Butt welder)
1) Front side of the machine
2) Right Hand side of the machine.
3) Rear of the machine
4) Left Hand side of the machine
5) Top of the machine.
Chapter two
The installation of a UN35 air operated Butt welder
Please read Introduction to Spotwelding for newcomers & others on our website
(UN35 Butt welder)
1) Bolting the machine down.
2) Cable sizes and fusing.
3) Water pipes.
4) Machine Fusing with supply cable not exceeding 10m
Chapter three
The operation of a UN35 Butt spot welder
(UN35 Butt welder)
1) How the machine works allowing a weld to take place.
2) Basic startup setting of the timers on an air operated Butt welder.
3) The setup of the solid state control as used on the UN35 Butt welder
4) Info for Customers purchasing spares.
So you have seen what we want to discuss, it helps a bit if you know what machine you
have, look at the list and away we go.

Westken information manuals and technical assistance
General Manual for UN35 Butt Welder
Westken, 190 van Eden crescent, Rosslyn, Pretoria, South Africa.
www.westken.co.za (Tel; 0027 12 541 6064/6065 fax; 0027 12 541 8086)
4
Chapter one
The layout and walk around of a UN35 Butt welder.
(UN35 Butt welder)
1) Front side of the machine
2) Right Hand side of the machine.
3) Rear of the machine
4) Left Hand side of the machine
5) Top of the machine.
6) Electrodes and electrode clamps
7) Welding timers & Thyristors
8) Machine weights and foot prints
These machines are free standing welders. The UN35 machines use 380volt @ 50hz
supply. All machines use water for cooling the transformer and thyristor.
(1) Front side of the machine.
Looking from the front of the machines you will see left hand and right hand clamping
jaws, foot switch on the floor, and the upsetting cylinder on the right hand front. The
timer control is located on the right hand side cover. There are two hinged doors that
allow access to the transformer.
The upper jaws have adjuster bolts which allow height adjustable for different material
sizes. These machines have the lower electrodes fixed to the machine frame where there
is adjusts for leveling lower electrodes. There is also visible the upsetting cylinder
adjuster nut for fine tuning the upsetting travel but this is normally factory set to the
clients specification.
Upper and lower basic electrode dimensions,
1) Upper electrodes 40mm high x 35mm wide x 25mm thick
2) Lower electrode 40mm high x 35mm wide x 25mm thick
(2) Right Hand side of the machine.
Moving around the machine to the right side you will find the timer control system and
the factory fitted program select switch. On the lower side cover you will find the water
inlet and outlet, earthing connection point and the electrical supply access point. The foot
switch plug in connect can be seen below the welding timer.
Welding timer standard on a UN35 butt welder;
1) Six stage Vertical mount

Westken information manuals and technical assistance
General Manual for UN35 Butt Welder
Westken, 190 van Eden crescent, Rosslyn, Pretoria, South Africa.
www.westken.co.za (Tel; 0027 12 541 6064/6065 fax; 0027 12 541 8086)
5
2) 7 selectable programs
3) Solid state membrane facia
(3) Rear of the machine
There are two hinged doors in the rear of the machine that give access to the firing board
and the thyristor unit. The main supply point for electrical power is located behind these
doors. Access to the rear of the clamping cylinders located on the top of the machine.
The FRL (filter/lubricator/regulator) can be seen on top of the machine.
(4) Left hand side of the machine
There is only a blank panel on this side of the machine;
(5) Looking at the top of the machine
Moving to the front of the machine we now look at the top of the machine where we find;
1) Clamping jaws on the left.
2) Upset cylinder on the right side.
3) The 1/4" 5/2 24vdc body port two solenoid valves at the rear of the machine.
4) The FRL (filter/regulator/lubricator) back right hand side.
General Note on machine weights and sizes are for guideline purposes only; due to
machine improvement and client specific requirement Westken reserves the right to
change machine size / mass specifications without notice.
3) UN35 Approximately 200kg 800 wide x 800 deep x 950 high
Chapter two
Installation of a “UN35” air operated Butt welding machine.
(UN35 Butt welder)
1) Bolting the machine down.
2) Cable sizes and fusing.
3) Water pipes
4) Machine Fusing with supply cable not exceeding 10m
Please Note: Installation must only be undertaken by a’
“Qualified electrician”

Westken information manuals and technical assistance
General Manual for UN35 Butt Welder
Westken, 190 van Eden crescent, Rosslyn, Pretoria, South Africa.
www.westken.co.za (Tel; 0027 12 541 6064/6065 fax; 0027 12 541 8086)
6
The installation of this type of machine is undertaken as follows. The electricity
supply is connected inside the machine to the isolator switch or connection board
only. The power is fed from the client’s distribution board where additional isolation
should be present. This will ensure safety during installation and maintenance. The
connection, to the switch or connection board, is made using two lugs and secured to
the switch by means of a screw or nut and bolt. Connection of phasing is not critical.
The phase requirement of the machine should be checked before installation. This
machine is two-phase equipment and uses two of the three phases. Do not use the
third phase as the earth. This can kill. Ensure that the earth is connected securely to
the earth mounting point on the right hand side of the machine.
1) Locate machine in position and bolt down using the holes provided in the base
plate.
2) Connect electrical power supply to the on/off switch or connection board
provided within the machine, see voltages, cable sizes and supply fusing below.
When using a 380volt machine it is important to note the machine uses two
phases of the three phase supply. It is critically important that the machine is
properly earthed to the earth stud provided on the machine.
3) Connect a minimum 10/12mm water supply/return pipe to the inlet/outlet
connection on the machine. The water supply must be a 3bar supply with a return
back pressure not exceeding 1,5bar or 50% of the supply pressure.
4) Switch on water and inspect for leaks.
5) Connect air supply to air inlet position on the lower right hand side. A supply of 4
to 7 bars is suggested. The pressure to the clamps and upset cylinders is through a
pressure FRL unit and can be adjusted.
6) Switch on electrical supply.
7) Adjust timer settings to minimum time and weld heat/current setting and
undertake a test weld.
8) Adjust machine to suit application.
General Note on machine cable sizes and fusing; due to machine improvement, client
specific requirements Westken reserves the right to change machine specifications
without notice. These cable sizes are calculated on a max supply cable length of 10m.
Longer cable lengths will be a higher mmsq due to volt drop.
1) UN35 Approicmately 60amps cable size 16mmsq supply

Westken information manuals and technical assistance
General Manual for UN35 Butt Welder
Westken, 190 van Eden crescent, Rosslyn, Pretoria, South Africa.
www.westken.co.za (Tel; 0027 12 541 6064/6065 fax; 0027 12 541 8086)
7
Chapter three
Operational system of a “UN35” air operated Butt welding machine.
(UN35).
Please read this in conjunction with section on “spotwelding” on our website.
1) The operator locates the material to be welded within the correct size “V” grooves
in the lower electrodes and brings the two faces of the part to be welded together..
Once located in position the operator presses down on the foot switch. Keep
fingers out of the electrodes clamp area.
2) The downward movement of the foot switch triggers the electric micro switch in
the footswitch and initiates the welding controller.
3) The two electrodes clamp simultaneously onto the parts. The upset cylinder
applies pressure and initiates the welding timer
4) The timer then switches the thyristor (semipak) to allow electrical supply into the
welding transformer for a specified time.
5) When electricity is fed into the welding transformer it is converted (transformed)
from high voltage/low amperage (380v/60amps) into low voltage/high amperage
(10volts/10000amps). This transformed electrical supply is directed from the
transformer, through the machine electrodes butt welding area.
6) Due to a higher resistance to electricity in the steel parts to be welded than in the
copper electrodes heat is formed in the weld area causing the metal to melt, the
molten or wet metal is held together by the electrode clamps and the follow-up
pressure from the upset air cylinder applies additional pressure on the weld.
7) Once the hot red color in the weld area disappears from between the welding tips
the timer will then allow the welding tips/electrodes to open and the completed
welded part can be removed.
Basic startup setting of a UN35 timer system on an air spot welder.
Please read the following on our website.
Westken information manuals and technical assistance
Introduction to setting of Westken timer systems
Welding timers & water cooled Thyristors standard on air operated spot welders are;
1) UN35 7 program vertical 160amp Semipack thyristor
The suggested setup of the UN35 timer controller system
1) Press green run/set button. Then one of the windows will start to flash.

Westken information manuals and technical assistance
General Manual for UN35 Butt Welder
Westken, 190 van Eden crescent, Rosslyn, Pretoria, South Africa.
www.westken.co.za (Tel; 0027 12 541 6064/6065 fax; 0027 12 541 8086)
8
2) Press right hand arrow to move to the next window. At this point you will be able to
adjust units. To adjust tens then utilize the left hand arrow.
3) Use the “plus” or “minus” buttons to increase or decrease the flash window.
4) Once completed press the right hand arrow to access the next window.
Please note* that under normal setting procedures you will only need adjustment on the
time “1” and heat”1”
5) Once programming has been completed then press run/set to return the timer controller
to run condition.
There are three switches on the lower facia that allow;
1st switch clamps the part.
2nd switch upsets the part without welding.
3rd switch is for timer only and does not isolate the machine.
Basic setting and set up:
1) The timer allows for the selection of 7 individual programs depending on the setup of
the controller.
2) Squeeze time; keep this time setting short between 2 and 6 cycles.
3) Upslope; 1 to 3 cycles to minimize sparking during welding.
4) Weld one; allow sufficient welding to achieve a cosmetically good weld without
excessive expulsion of weld area. Please note* weld time must always be longer that the
upslope time.
5) Heat one; this adjusts the percentage of weld heat going into the weld area as a
percentage of the total machine output. Too much heat and the part will disintegrate
during welding, to little will cause a cold weld and the joint will not fuse properly and
will break.
6) All other setting set to “0” zero. Only hold is set to 5 to allow the weld to dry in the
weld area.
GENERAL DISCLAIMERS:
West Kennett Corporation is not liable for damages resulting from, or attributable to the
non-compliance of the user of the procedures and recommendations in this manual.
Failure to observe these instructions may cause serious injury or death and may result in
the warranty being declared null and void.
Read and understand the entire contents of this user manual, with special emphasis on the
safety instructions and procedures throughout the user manual, before installing,
operating, or maintaining this equipment. This machine and user manual is for use only
by persons trained and experienced in the safe operation of welding equipment. Do not

Westken information manuals and technical assistance
General Manual for UN35 Butt Welder
Westken, 190 van Eden crescent, Rosslyn, Pretoria, South Africa.
www.westken.co.za (Tel; 0027 12 541 6064/6065 fax; 0027 12 541 8086)
9
allow unqualified persons to install, operate, or maintain this machine. Contact your
distributor if you do not fully understand this user manual. Wear safety clothing and use
safety equipment at all times.
If you are not sure, please phone and ask, we will help.
West Kennett Corporation retains the right to modify, improve, and upgrade our products
at any time without prior notice due to ongoing improvements of our products and
services.
And finally,
This is another in a set of documents that hopefully will help you understand the
equipment better. There will be a more in-depth study of the timer, air system, cooling
system and how and why a weld takes place. Look on our website www.westken.co.za
for the following
1) Introduction to set-up of Westken spotwelding timers for newcomers & others.
2) Cooling water for welding machines.
3) Explanation of clever words & terms concerning Resistance welding & timer
systems.
4) Introduction to Spotwelding for newcomers and others.
5) Introduction & a basic explanation to Timer control systems.
6) Manuals for other machines in our range of equipment.
If you have any questions concerning the above or others question concerning
resistance welding please do not hesitate to contact one of our really clever people at
Westken. Try the following people who might be able to give a helping hand or some
good advice. Remember they do it almost every day, I am talking resistance welding.
Really technical stuff concerning the mechanical and electrical layout and workings
of the machines
………….. Mr. Stuart Dorling. [email protected]
Stuff concerned with machining the copper, brass, soldered type electrodes etc and
the setup and usage of brickforce machinery
……………. Mr. Dean Nicholson. [email protected]
When you can get stuff and how much stuff costs
……………………… Mr. Altus Van Der Walt. [email protected]

Westken information manuals and technical assistance
General Manual for UN35 Butt Welder
Westken, 190 van Eden crescent, Rosslyn, Pretoria, South Africa.
www.westken.co.za (Tel; 0027 12 541 6064/6065 fax; 0027 12 541 8086)
10

Westken information manuals and technical assistance
General Manual for UN35 Butt Welder
Westken, 190 van Eden crescent, Rosslyn, Pretoria, South Africa.
www.westken.co.za (Tel; 0027 12 541 6064/6065 fax; 0027 12 541 8086)
11
UN-
35Butt
Welder
3
380 V in
1
380 V in
13
12
AV2
11
AV1
10
AV Com
8
G1
PCB
5
K1
7
G2
4
K2
61
60
42
41
40
Thermo
_________
20
Gnd com
_________
Thermo
24
Bit 8
23
Bit 4
22
Bit 2
21
Bit 1
_________
20
Gnd com
_________
Foot Sw
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