13 Resistance Welding
Short Description
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Description
Section Thirteen
Resistance welding equipment
Pedestal Resistance Welders
324
Suspended Spot Welders
330
Nut Welding Systems
333
Other Resistance Welders
334
Transformers
337
Resistance Welding Control Systems
338
Water Cooling Systems
Conductors, Electrodes and Adaptors
344 345
Weld Analysis
Resistance Welding Electrodes & Adaptors
347
Heavy-duty Offset Water Cooled Holder
364
323
PEDESTAL RESISTANCE WELDERS RESISTANCE WELDERS T PEDESTAL N BUYERS GUIDE EFor the ideal balance between quality, and price, the Denka V-Series Mreliability resistance welders are the solution to P manufacturing needs. Designed to I your meet the demanding nature of Europe’s Uproduction line environment, these Qwelders are ideally suited to all levels of Emanufacturing, from precision, lowspot welding through to high Gvolume volume mass production applications. can choose a weld control system N I You from a range of popular brands, or you Dcan upgrade the standard pneumatic L cylinder to double force or two-stage. EThese options, along with many others, you an unparalleled level of Woffer diversity and flexibility when choosing a Eresistance welder to suit your needs. Talk a Customer Service representative Ctotoday to discuss your specific Nrequirements. A T S I S E R – N E E T R I H T N O I T C E S
4 2 3
Thermal Rating At 50% Duty Cycle 15
25
35
50
80
100
130
150
200
VPP150
VPP200
250
300
Manual VRM- VRM- VRMRocker Arm 15 25 35 Pneumatic Rocker Arm Linear Action Spot
VRP15
VRP25
VRP35
VRP50
VLP35
VLP50
VLP80
Projection
VPP80
VPP100
Seam
VLS80
VLS100
VLS130
VPP300 VLS250
PEDESTAL RESISTANCE WELDERS DENKA VRM-SERIES MANUAL ROCKER-ARM SPOT WELDERS
15kVA VRM15 25kVA VRM25 35kVA VRM35 For simple operations requiring a manual spot welding system, the Denka VRMSeries of spot welders will suffice for all applications ranging from low-volume production through to training facilities for apprentices. The simple Denka S1 analogue weld controller makes set-up fast and easy.
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•
• •
• • • •
‘Rocker’ motion of upper arm Transformers rated at 50% duty cycle to AS, DIN & ISO norms Manual foot pedal operation Water-cooled transformer, arms, electrode holders and electrodes Standard throat depth 400mm SEE OPTIONS BELOW FOR ALTERNATIVES Arms diameter 45mm Upper and lower electrode holders can be rotated and used at either 0° or 15° Adjustable lower arm for variable throat height Denka S1 analogue weld controller SEE OPTIONS BELOW FOR ALTERNATIVES Mains ON/OFF switch included High-alloy copper and brass conductors used throughout Electrode taper Ø18mm 1:10 Complies with AS2799 Two year warranty Made in Italy
VRM-SERIES SPECIFICATIONS
See table ‘VRM-SERIES SPECIFICATIONS’ opposite. OPTIONS •
•
• • • •
FEATURES •
SPECIFICATIONS
VRM-15
•
•
• •
Additional throat depth - extend to 600mm Additional throat depth - extend to 800mm Low clearance lower arm – 400mm Low clearance lower arm – 600mm Low clearance lower arm – 800mm Ultra-low clearance lower arm – 400mm Ultra-low clearance lower arm – 600mm Ultra-low clearance lower arm – 800mm Upgrade weld controller – PX1500 Upgrade weld controller – PX1500P
VRM-25
VRM-35
THERMAL RATING @ 50% D/C
kVA
15
25
35
MAX. SHORT CIRCUIT CURRENT
kA
10.4
13.2
16.8
daN
180
180
180
ELECTRODE FORCE SECONDARY NO LOAD VOLTAGE
V
3.0
3.9
4.9
PRIMARY VOLTAGE AT 50Hz
V
1~415
1~415
1~415
SUPPLY AMPERAGE (DELAYED)
A
25
42
60
1:10
1:10
1:10
ELECTRODE TAPER – ISO
S E C T I O N T H I R T E E N – R E S I S T A N C E W E L D I N G E Q U I P M E N T
ELECTRODES DIAMETER
mm
18
18
18
THROAT DEPTH
mm
400~800
400~800
400~800
THROAT HEIGHT
mm
220-330
220-330
220-330
CYLINDER STROKE
mm
50
50
50
DIMENSIONS
cm
102x30x127
102x30x127
102x30x127
WEIGHT
kg
120
125
130
3 2 5
PEDESTAL RESISTANCE WELDERS VRP-SERIES PNEUMATIC T DENKA N ROCKER-ARM SPOT WELDERS E M P I U Q E G N I D L E W E C N A T S I S E R – N E E T R I H T N O I T C E S
15kVA VRP15 25kVA VRP25 35kVA VRP35 50kVA VRP50 The economical choice for general sheetmetal welding, the Denka VRPSeries offer versatility and quality at an affordable price. Capable of spot welding in low to medium production environments, these welders are highly popular with various industries including ducting, refrigeration, metal cabinets, steel shelving and general sheetmetal fabrication. FEATURES • •
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• •
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• •
•
•
VRP-SERIES SPECIFICATIONS
VRP-15
VRP-25
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•
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• • • •
Mains ON/OFF switch included Quality filter, regulator and lubricator included Fully enclosed footswitch with safety lever High-alloy copper and brass conductors used throughout Electrode taper Ø18mm 1:10 Complies with AS2799 Two year warranty Made in Italy
SPECIFICATIONS
See table ‘VRP ‘ VRP-SERIES -SERIES SPECIFICATIONS’ below. OPTIONS •
•
• • • •
•
•
• •
Additional throat depth - extend to 600mm Additional throat depth - extend to 800mm Low clearance lower arm – 400mm Low clearance lower arm – 600mm Low clearance lower arm – 800mm Ultra-low clearance lower arm – 400mm Ultra-low clearance lower arm – 600mm Ultra-low clearance lower arm – 800mm Downgrade weld controller – S1 Upgrade weld controller – PX1500P
VRP-35
VRP-50
THERMAL RATING @ 50% D/C
kVA
15
25
35
50
MAX. SHORT CIRCUIT CURRENT
kA
10.4
13.2
16.8
19.5
daN
250
250
250
250
ELECTRODE FORCE SECONDARY NO LOAD VOLTAGE
V
3.0
3.9
4.9
5.7
PRIMARY VOLTAGE AT 50Hz
V
1~415
1~415
1~415
1~415
SUPPLY AMPERAGE (DELAYED)
A
25
42
60
85
ELECTRODE TAPER – ISO
6 2 3
‘Rocker’ motion of upper arm Transformers rated at 50% duty cycle to AS, DIN & ISO norms Pneumatic cylinder operation via foot switch Manual foot pedal operation Water-cooled transformer, arms, electrode holders and electrodes Standard throat depth 400mm SEE OPTIONS BELOW FOR ALTERNATIVES Arms diameter 45mm Upper and lower electrode holders can be rotated and used at either 0° or 15° Adjustable lower arm for variable throat height Denka PX1500 digital synchronous weld controller SEE OPTIONS BELOW FOR ALTERNATIVES
•
1:10
1:10
1:10
2:10
ELECTRODE DIAMETER
mm
18
18
18
18
THROAT DEPTH
mm
400~800
400~800
400~800
400~800
THROAT HEIGHT
mm
220-330
220-330
220-330
220-330
CYLINDER STROKE
mm
50
50
50
50
DIMENSIONS
cm
102x30x127
102x30x127
102x30x127
102x30x127
WEIGHT
kg
120
125
130
135
PEDESTAL RESISTANCE WELDERS DENKA VLP-SERIES LINEAR ACTION SPOT WELDERS
35kVA VLP35 50kVA VLP50 80kVA VLP80 For demanding, high-volume production applications, the Denka VLP-Series of pneumatic linear-action spot welders offer a multitude of tried and proven features, making it the spot welder of choice for many Australian manufacturers. A weld control system to suit your needs can be fitted to the Denka VLP-Series spot welders from the range of controllers developed by Denka, Miyachi and Serratron. FEATURES •
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•
•
•
•
•
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• •
•
Upper arm descends parallel to lower arm – precise, accurate and consistent Transformers rated at 50% duty cycle to AS, DIN & ISO norms Pneumatic cylinder operation via foot switch Water-cooled transformer, arms, electrode holders and electrodes Standard throat depth 430mm SEE OPTIONS BELOW FOR ALTERNATIVES Arms diameter 60mm (except VLP-80 has cast section arm) Can fit optional platens with T-slots to convert to projection welder SEE OPTIONS BELOW Denka PX1500 digital synchronous weld controller SEE OPTIONS BELOW FOR ALTERNATIVES Mains ON/OFF switch included Quality filter, regulator and lubricator included Heavy duty fabricated frame
VLP-SERIES SPECIFICATIONS
•
•
•
•
• •
• • •
Fully enclosed footswitch with safety lever Finger guard around moving parts on upper arm Adjustable lower arm for variable throat height High-alloy copper and brass conductors used throughout Electrode taper Ø18mm 1:10 Reinforcing support on lower arm (optional on VLP-35) VLP-35) Complies with AS2799 Two year warranty Made in Italy
SPECIFICATIONS
See table ‘VLP ‘ VLP-SERIES -SERIES SPECIFICATIONS’ below. OPTIONS •
•
•
• •
•
•
•
•
• •
Additional throat depth - extend to 630mm Additional throat depth - extend to 830mm Low clearance lower arms – designed to specific requirements Upgrade weld controller – PX1500P Upgrade weld controller – Miyachi CTCT110B or CY-210B Upgrade weld controller – Serratron 100 Upgrade pneumatic cylinder – double force Upgrade pneumatic cylinder – retractable two-stage Optional reinforcing support on lower arm Optional platen for projection welding Optional two-hand start system AS4024.1
VLP-35
VLP-50
VLP-80
THERMAL RATING @ 50% D/C
kVA
35
50
80
MAX. SHORT CIRCUIT CURRENT
kA
14.8
17.2
23.6
ELECTRODE FORCE
daN
180
300
525
SECONDARY NO LOAD VOLTAGE
V
5.2
6.0
6.7
PRIMARY VOLTAGE AT 50Hz
V
1~415
1~415
1~415
SUPPLY AMPERAGE (DELAYED)
A
ELECTRODE TAPER – ISO
60
85
140
1:10
1:10
1:10
18
18
18
ELECTRODE DIAMETER
mm
THROAT DEPTH
mm
430
430
430
THROAT HEIGHT
mm
60-270
60-270
60-270
CYLINDER STROKE
mm
60
60
60
DIMENSIONS
cm
106x30x143
106x30x143
105x52x175
WEIGHT
kg
185
190
470
S E C T I O N T H I R T E E N – R E S I S T A N C E W E L D I N G E Q U I P M E N T
3 2 7
PEDESTAL RESISTANCE WELDERS VPP-SERIES PROJECTION T DENKA N WELDERS E M P I U Q E G N I D L E W E VPP80 C80kVA N100kVA VPP100 A150kVA VPP150 T 200kVA VPP200 S I 300kVA VPP300 SDesigned and manufactured to meet Ethe most challenging projection welding Rapplications, the Denka VPP-Series projection welders are time-proven – ofperformers for virtually any application between 80kVA 300kVA. A weld Ncontrol system toand suit your needs can Ebe fitted to the Denka spot Ewelders from the rangeVLP-Series of controllers T developed by Denka, Miyachi and R and handy options such as I Serratron, the two-stage cylinder and compliant Htwo-hand start system means these T welders can be custom configured to suit the exact needs of your production Nenvironment. O I T C E S
FEATURES •
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VPP-SERIES SPECIFICATIONS
THERMAL RATING @ 50% D/C MAX. SHORT CIRCUIT CURRENT
VPP-80
VPP-100
kVA
80
100
See table ‘VPP ‘ VPP-SERIES -SERIES SPECIFICATIONS’ below. OPTIONS •
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• •
•
•
•
Additional throat depth - extend to 430mm (except VPP VP P-80) Additional throat depth - extend to 730mm Upgrade weld controller – PX1500P Upgrade weld controller – Miyachi CTCT110B or CY-210B Upgrade weld controller – Serratron 100 Upgrade pneumatic cylinder – retractable two-stage Upgrade pneumatic cylinder – double force
VPP-150
150
VPP-200
200
VPP-300
300
kA
29.5
35.0
50
72.0
85.0
daN
735
735
1400
2300
3000
SECONDARY NO LOAD VOLTAGE
V
6.7
8.0
9.3
8.3
10.0
PRIMARY VOLTAGE AT 50Hz
V
1~415
1~415
1~415
1~415
1~415
SUPPLY AMPERAGE (DELAYED)
A
140
170
255
340
510
PLATEN SIZE
mm
150
150
150
200
250
ELECTRODE PITCH
mm
430
395
395
300
300
THROAT HEIGHT
mm
195-495
195-495
195-495
195-645
195-645
CYLINDER STROKE
mm
80
80
80
125
150
DIMENSIONS
cm
106x52x175
106x52x175
106x52x175
125x54x240
131x116x230
WEIGHT
kg
470
500
900
930
1300
ELECTRODE FORCE
8 2 3
SPECIFICATIONS
Large, precision-machined brass platen on upper and lower arms with T-slots Transformers rated at 50% duty cycle to AS, DIN & ISO norms Pneumatic cylinder can be operated by foot switch or two-hand start system – fitted standard with both Water-cooled transformer, arms, electrode holders and electrodes Generous throat depth – varies between models Maximum distance between platens 495mm Solid, cast aluminium upper and lower arm (except VPP-80 has cast brass lower arm) Denka PX1500 digital synchronous weld controller SEE OPTIONS BELOW FOR ALTERNATIVES Mains ON/OFF switch included Quality filter, regulator and lubricator included Heavy duty fabricated frame Fully enclosed footswitch with safety lever Finger guard around moving parts on upper arm Adjustable lower arm for variable throat height High-alloy copper and brass conductors used throughout Reinforcing support on lower arm Can easily convert to spot welder with optional electrode holders Complies with AS2799 Two year warranty Made in Italy and Spain
PEDESTAL RESISTANCE WELDERS Other pedestal resistance welders also available
Denka D-Series resistance welding systems – leading medium frequency DC inverter technology for precision resistance welding applications. Made in Spain and Italy.
Denka J-Series spot and projection welders – economical welders offering minimal features for use in automotive production lines, as specified by Asian car manufacturers. Made in China and Taiwan.
Denka T-Series resistance welding systems – offer flexibility and adaptability to different applications including rotary tables, robot cells, multi-head and nut welding. Conforms to emerging DIN, CNOMO and RWMA requirements in high-volume production environments. Made in Spain and USA.
S E C T I O N T H I R T E E N – R E S I S T A N C E W E L D I N G E Q U I P M E N T
Custom alterations to standard Denka pedestal welders, to improve access to difficult spot locations and to suit unusually shaped objects. Made in Italy.
Denka M-Series spot, projection and seam welders – premium resistance welders for precision applications in military, aerospace, automotive, railcar and research industries. Made in Spain.
3 2 9
SUSPENDED SPOT WELDERS VSR-SERIES SUSPENDED T DENKA N SPOT WELDERS E M P I U Q E G N I D4kVA VSR4 L 6kVA VSR6 E Simple, compact, lightweight and fast are W just some of the features of the Denka VSR-Series suspended spot welders. E The small and compact design makes Cspot welding around complex objects Neasy and fast. The Denka VSR-Series Aoffers either 4kVA or 6kVA, making them T attractive to all light-gauge sheetmetal from one-off manufacturing S I operations, through to medium volume production Slines. Operators can quickly set-up these Ewelders, thanks to the simple Denka S1 controller. Ranalogue weld controller. – FEATURES Suspended spot welder on 3D swivel N gimbal E X-type gun: scissor action arms transformer nsformer,, rated E Integrated on-gun tra T at 50% duty cycle to AS, DIN & ISO norms R I Pneumatic cylinder activated lower H arm operation T Denka SmartStart trigger system Water-cooled transformer*, electrode N holders and electrodes Various throat depths available O I SEE OPTIONS BELOW FOR T ALTERNATIVES C Arms available for opposed (0°) or angled electrodes E electrodes (15°) SEE OPTIONS S ALTERNATIVES BELOW FOR
Fitted with S1 weld controller as standard SEE OPTIONS BELOW FOR ALTERNATIVES Weld controller is mounted on the spot welder for easy programming Arms diameter 25mm Electrode opening is manually adjustable Quality filter, regulator and lubricator included High-alloy copper and brass conductors used throughout Electrode taper Ø12mm 1:10 Includes hose and cable set 5 metres long Complies with AS2799 Two year warranty Made in Italy * Water cooled transformer is optional on Denka VSR-4 spot welder. •
• • • • • • • • • •
SPECIFICATIONS
See table ‘VSR-SERIES SPECIFICATIONS’ below. below. OPTIONS • • • • • • • • • • • • •
Arms set (incl. electrode holders) 125mm long 0° Arms set (incl. electrode holders) 200mm long 0° Arms set (incl. electrode holders) 300mm long 0° Arms set (incl. electrode holders) 400mm long 0° Arms set (incl. electrode holders) 125mm long 15° Arms set (incl. electrode holders) 200mm long 15° Arms set (incl. electrode holders) 300mm long 15° Arms set (incl. electrode holders) 400mm long 15° Upgrade weld controller – PX1500P in separate cabinet Upgrade weld controller – Miyachi CT-110B CT-110B or CY-210B CY-210B in separate cabinet Upgrade weld controller – Serratron 100 in separate cabinet Spring balancer 22kg - VSR-Series welders with less than 400mm arms Spring balancer 30kg – VSR-Series welders with 400mm arms
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•
• •
•
•
VSR-SERIES SPECIFICATIONS
VSR-6
THERMAL RATING @ 50% D/C
kVA
4.0
6.0
MAX. SHORT CIRCUIT CURRENT
kA
9.0
9.0
daN
140
140
SECONDARY NO LOAD VOLTAGE
V
3.6
3.6
PRIMARY VOLTAGE AT 50Hz
V
1~415
1~415
SUPPLY AMPERAGE (DELAYED)
A
15
15
1:10
1:10
ELECTRODE FORCE
ELECTRODE TAPER – ISO ELECTRODE DIAMETER
mm
12
12
THROAT DEPTH
mm
170~445
170~445
THROAT HEIGHT
mm
105
105
CYLINDER STROKE
mm
6~55
6~55
DIMENSIONS
cm
50x35x25
50x35x25
WEIGHT*
kg
18
18
* Weight without arms
0 3 3
VSR-4
Pressing the BLACK button allows the electrodes to close without welding power. power. This enables the operator to check the electrodes alignment and position before welding. If the set-up is correct, pressing the RED button will introduce the welding current and release the electrodes when completed. Or if the alignment is not correct, pressing the BLACK button again will release the electrode without a weld being created, allowing the operator to easily realign the electrodes. Alternatively, by pressing the RED button only, only, the welder will go through a normal welding sequence without the option of checking the electrode alignment.
SUSPENDED SPOT WELDERS DENKA VSX-SERIES SUSPENDED SPOT WELDERS
•
•
•
•
8kVA
VSX8
12kVA 18kVA
VSX12 VSX18
25kVA 36kVA
VSX25 VSX36
42kVA VSX42 The versatile range of X-type suspended spot welders from the t he Denka VSXSeries allows you to move the welder around the work piece in those difficult access applications that don’t suit a floor mounted pedestal spot welder. Fully water cooled, ruggedly built and highly manoeuvrable, these welders can be found in use around Australia in many and varied applications. Check out the great fetures of this range along with the huge range of optional extras available. FEATURES •
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Suspended spot welder on 3D swivel gimbal X-type gun: scissor action arms Integrated on-gun tra transformer nsformer,, rated at 50% duty cycle to AS, DIN & ISO norms Pneumatic cylinder activated lower arm operation Denka SmartStart trigger system Denka XtraBite speedy electrode opening, with manual electrode gap adjustment Ergonomic pistol-grip handle Water-cooled transformer, arms, electrode holders and electrodes Various throat depths available SEE OPTIONS BELOW FOR ALTERNATIVES
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• • •
Two different throat heights available SEE OPTIONS BELOW FOR ALTERNATIVES Arms available for opposed electrodes (0°) or angled electrodes (15°) SEE OPTIONS BELOW FOR ALTERNATIVES Fitted with PX1500 weld controller as standard SEE OPTIONS BELOW FOR ALTERNATIVES Weld controller is mounted on the spot welder for easy programming Mains ON/OFF switch on welder Arms diameter: 30mm VSX-8 to VSX25 and 40mm VSX-36 & VSX-42 Quality filter, regulator and lubricator included High-alloy copper and brass conductors used throughout Electrode taper Ø12mm 1:10 Heavy-duty machined aluminium construction Includes hose and cable set 5 metres long Complies with AS2799 Two year warranty Made in Italy
• • • •
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•
•
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• •
• •
400mm long 15° 600mm long 15° 800mm long 15° Increase throat height – from 135mm to 210mm Increase electrode force – from 220daN to 400daN Upgrade weld controller – PX1500P in separate cabinet Upgrade weld controller – Miyachi CTCT110B or CY-210B in separate cabinet Upgrade weld controller – Serratron 100 in separate cabinet Spring balancer 45kg – VSX-8 Spring balancer 70kg – VSX VS X-12, VSX18, VSX-25 Spring balancer 90kg – VSX-36 Spring balancer 105kg – VSX-42
SPECIFICATIONS
See table ‘VSX-SERIES SPECIFICATIONS’ below. OPTIONS
Arm sets (incl. electrode holders) 200mm long 0° 400mm long 0° 600mm long 0° 800mm long 0° Arm sets (incl. electrode holders) 200mm long 15° 400mm long 15° 600mm long 15° 800mm long 15° Low clearance lower arm only (incl. electrode holders) 200mm long 0° 400mm long 0° 600mm long 0° 800mm long 0° Low clearance lower arm only (incl. electrode holders) 200mm long 15° • • • •
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• • • •
•
VSX-SERIES SPECIFICATIONS
VSX-8
VSX-12
VSX-18
Increase the electrode gap at the press of a button. Get around those awkward flanges and protrusions with ease with the pneumatically operated XtraBite function. Increase accuracy, faster welding and less operator fatigue … only with Denka XtraBite!
VSX-25
VSX-36
VSX-42
THERMAL RATING @ 50% D/C
kVA
8
12
18
25
36
42
MAX. SHORT CIRCUIT CURRENT
kA
9.8
12.8
13.5
15.0
18.0
22.0
daN
220
220
220
220
510
510
ELECTRODE FORCE SECONDARY NO LOAD VOLTAGE
V
2.1
2.7
2.9
5.9
6.0
4.6
PRIMARY VOLTAGE AT 50Hz
V
1~415
1~415
1~415
1~415
1~415
1~415
SUPPLY AMPERAGE (DELAYED)
A
15
15
25
32
63
63
ELECTRODE TAPER – ISO
S E C T I O N T H I R T E E N – R E S I S T A N C E W E L D I N G E Q U I P M E N T
1:10
1:10
1:10
1:10
1:10
1:10
ELECTRODE DIAMETER
mm
12
12
12
12
18
18
THROAT DEPTH
mm
200~800
200~800
200~800
200~800
200~800
200~800
THROAT HEIGHT
mm
135
135
135
135
140
140
CYLINDER STROKE
mm
6~50
6~50
6~50
6~50
6~50
6~50
DIMENSIONS
cm
82x35x30
82x35x30
82x35x30
82x35x30
93x40x35
93x40x35
WEIGHT*
kg
48
50
53
55
75
85
* Weight without arms
3 3 1
SUSPENDED SPOT WELDERS VSX-Series, these welders are Quality filter, regulator and lubricator T DENKA VSC-SERIES SUSPENDED Denka included C-type configuration which means the N SPOT WELDERS High-alloy copper and brass electrodes are directly opposed and E conductors used throughout operate in a linear motion rather than a Electrode taper Ø12mm 1:10 ‘scissor action’. M Heavy-duty machined aluminium P FEATURES construction I Suspended spot welder on 3D swivel Includes hose and cable set 5 metres U gimbal long Linear action, C-type gun operation Q Complies with AS2799 Integrated on-gun transformer t ransformer,, rated E Two year warranty at 50% duty cycle to AS, DIN & ISO Made in Italy G norms SPECIFICATIONS Pneumatic cylinder activated arm N I See table below. operation D OPTIONS Ergonomic pistol-grip handle L Special arms – available on request Water-cooled transformer, arms, E12kVA VSC12 Increase electrode force – available electrode holders and electrodes 18kVA VSC18 on request Fitted with PX1500 weld controller as W25kVA VSC25 Upgrade weld controller – Miyachi CTCTstandard SEE OPTIONS BELOW FOR 110B or CY-210B in separate cabinet EThe Denka VSC-Series of suspended ALTERNATIVES Upgrade weld controller – Serratron Weld controller is mounted in Cspot welders are designed for 100 in separate cabinet separate cabinet Ncontinuous, heavy-duty use in high Spring balancer 70kg – Suits all VSCMains ON/OFF switch on welder production environments. Avolume Series welders Arms diameter T Similar in form and function to the S I VSC-12 VSC-18 VSC-25 SVSC-SERIES SPECIFICATIONS kVA 12 18 25 E THERMAL RATING @ 50% D/C kA 16.0 17.0 18.0 R MAX. SHORT CIRCUIT CURRENT daN 300 300 300 – ELECTRODE FORCE V 2.7 2.9 5.9 N SPRECIMOANRDYAVROYLTNAOGLEOAATD5V0OHLzTAGE V 1~415 1~415 1~415 E SUPPLY AMPERAGE (DELAYED) A 15 25 32 E ELECTRODE TAPER – ISO 1:10 1:10 1:10 T ELECTRODE DIAMETER mm 12 12 12 R I THROAT DEPTH mm 110 110 110 mm 100 100 100 H THROAT HEIGHT T CYLINDER STROKE mm 50 50 50 DIMENSIONS cm 72x35X29 72x35X29 72x35X29 N WEIGHT* kg 55 58 60 O I * Weight without arms T C E S OTHER DENKA SUSPENDED SPOT WELDING EQUIPMENT •
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Various special configurations of Denka suspended spot welders built to customer’s specific requirements.
2 3 3
Custom off-gun suspended spot welders are available through Denka in a range of shapes, sizes and configurations.
NUT WELDING SYSTEM through microscopic venturis within the pneumatic cylinder extension rod to hold the nut steady and firm during placement on the electrode. Various components assembled with meticulous care make up the Denka nut placement system, ensuring your weld nuts are fed positively, orientated correctly and supplied with maximum speed, every time. DENKA NUT LOCATION PINS Denka offers three ranges of hardy nut location pins depending on your exact requirements and the shape of nut being welded: ceramic-coated, tapered toolsteel, ceramic-coated stepped toolsteel and stepped ceramic. Denka nut location pins are manufactured to highly accurate tolerances and have extended usage lifetimes. Standard pins are available ex-stock and custom pins are also available. DENKA NUT WELDERS The central point of Denka’s Nut Welding System is the welding unit. Whilst the Denka nut welding system can be retrofitted to virtually any reliable spot welder or projection welder, it is advisable that you consider the level of quality and control achievable by any existing welders when used in conjunction with the highly accurate Denka Nut Welding System. Denka has a range of high quality projection welders specifically designed for use in combination with Denka’s other nut welding components. These welders range from 25kVA through to 200kVA and are suitable for most styles of weld nuts. These include pedestal welders, welders, bench-mounted weld heads, multi-head units and custom-built machines. DENKA AUTOMATIC NUT FEEDERS
Automate your nut welding process with Denka’s innovative nut welding system and experience the speed, efficiency and quality assurance that major manufacturers rely on. We offer a complete end-to-end nut welding solution for high volume manufacturing operations for almost any nut on any part.
Several methods of automatic nut feeding exist in today’s manufacturing world but the ‘vibratory bowl’ version has proven to be the most reliable and consistent. Denka’s nut feeders employ a vibratory bowl to orientate and feed the weld nuts into the feed tube. Denka’s quality nut feeders offer a host of great features, including: On-board PLC-based control system Precision engineered components Suitable for M4 to M12 nuts Shock absorbers to minimise structure-borne vibration Bowls lined with super-quiet dampening compound Additional nut storage hopper Easy manual override for setup Overflow cut-out switch Nuts transported via positive, direct air thrust • • • •
•
• • • •
DENKA NUT PLACEMENT COMPONENTS All shapes…All sizes…All applications
Denka’s precision nut placement technology uses compressed air flowing
DENKA NUT WELDING ELECTRODES Simple, reliable and affordable is the Denka nut welding electrode system. Manufactured from quality chromium copper, the nut welding electrode is made from two parts for low-cost replacement. The nut location pin can sprung via a coil spring or compressed air. Various back-up electrodes are also available to complement the welding process. DENKA IntelliWeld8000 NUT COUNTER Developed by Denka in answer to the ever-present problem of weld nuts missing from components, the Denka IntelliWeld8000 is a fully programmable counting system that ensures every nut is welded onto every part. If too few nuts are welded to the part, an error signal is output that can flash a light, sound an alarm or shut down the entire manufacturing operation. The plain layout of information on the digital HMI panel makes the Denka IntelliWeld8000 easy to program and a sure winner with quality control departments. Ask us for a demonstration today.
S E C T I O N T H I R T E E N – R E S I S T A N C E W E L D I N G E Q U I P M E N T
DENKA NUT ORIENTATION SENSORS Denka offers two intelligent systems for detecting when a weld nut is located upside down. The most economical version is the Denka IntelliWeld500, which uses a proximity sensor to detect the displacement of the upper welding electrode. It also detects if the nut is missing altogether. Being low-cost and easy to fit, this is our most popular QA tool for the nut welding industry. The second system is the Denka IntelliWeld5000 nut sensor, a highly intelligent and interactive system that uses a combination of laser and fibre optics to determine the presence of a correctly orientated weld nut. Lightning fast and deadly accurate, to within 0.001 millimetres!
3 3 3
OTHER RESISTANCE WELDERS VTS-SERIES TWIN-SERIES T DENKA N SPOT WELDERS E M P I U Q E G N I D L E W30kVA VTS30 E40kVA VTS40 CSome spot welding applications call for Naccess to the welding zone from one Aside of the work piece only, requiring T a ‘single-sided’ spot welder with two adjacent electrodes rather than the S I conventional style spot welder with Stwo opposed electrodes. The Denka EVTS-Series spot welders have been for this specific purpose, Rdeveloped allowing two full strength spot welds – to be created on an object by only one side of the part. One of Naccessing the fantastic features of the Denka VTS ESeries is their ability to be interlinked Ewith several other units to operate in a T cascading sequence which is popular R welding reinforcing mesh, I when wire frames and large expanses of Hsheetmetal. T FEATURES win-series welding, or single-sided N TTransformers rated at 50% duty cycle O to AS, DIN & ISO norms I cylinder operation via input T Pneumatic (pushbutton, footswitch or other) C Water-cooled transformer and E electrodes S Variable electrode pitch 40 – 150mm • •
•
•
• •
• •
• • • •
Denka PX1500 digital synchronous weld controller SEE OPTIONS BELOW FOR ALTERNATIVES Heavy duty fabricated frame High-alloy copper and brass conductors used throughout Electrode taper Ø20mm 1:10 Complies with AS2799 One year warranty Made in Italy
SPECIFICATIONS
See table ‘VTS-SERIES SPECIFICATIONS’ at right. OPTIONS • • •
4 3 3
Electrode holder for flat copper bar Upgrade weld controller – PX1500P Upgrade weld controller – Miyachi CTCT110B or CY-210B
VTS-SERIES SPECIFICATIONS
VTS-30
VTS-40
THERMAL RATING @ 50% D/C
kVA
30
40
MAX. SHORT CIRCUIT CURRENT
kA
16
19
ELECTRODE FORCE
daN
185
185
SECONDARY NO LOAD VOLTAGE
V
6.4
7.5
PRIMARY VOLTAGE AT 50Hz
V
1~415
1~415
SUPPLY AMPERAGE (DELAYED)
A
50
70
1:10
1:10
mm
20
20
ELECTRODE PITCH
mm
40 – 150mm
40 – 150mm
CYLINDER STROKE
mm
60
60
DIMENSIONS
cm
59x17x25
59x17x25
WEIGHT
kg
58
65
ELECTRODE TAPER – ISO ELECTRODES DIAMETER
OTHER RESISTANCE WELDERS DENKA EuroGun ROBOTIC SPOT WELDERS
S E C T I O N T H I R T E E N – R E S I S T A N C E W E L D I N G E Q U I P M E N T
Denka’s EuroGun range of high quality robotic spot weld guns are designed for demanding, high volume production applications where ‘downtime’ is simply not an option. Manufactured in Spain to our customers strict requirements, the Denka EuroGun will perform time and time again with minimal maintenance and maximum efficiency. effic iency. Literally hundreds of variations are available, depending on your needs, including: AC power Medium frequency DC Pneumatic cylinder Electric servo motor X-type C-type Transformers from 36kVA to 1103kVA Almost any arms shape Throat depths up to 1500mm Electrode forces up to 1200daN Contact us now with your needs for a competitive quote on Europe’s most recognized robotic spot welding gun. SPECIFIED BY MAJOR VEHICLE MANUFACTURERS AROUND THE GLOBE • • • • • • • • • •
OTHER DENKA RESISTANCE WELDERS
Denka butt welders are available to suit the specific needs of various vari ous industries.
Custom-built fixture spot weld guns are also available from Denka.
3 3 5
OTHER RESISTANCE WELDERS MICRO-SPOT WELDING T MIYACHI SYSTEMS NSome of Miyachi’s precision power Esupplies and weld control systems. M P I U Q E G Miyachi offers a complete micro-spot N welding system, including power I supply, controller, monitor and ultra D precision weld heads. L E W E C N A T S I S E R – N E E T R I H T N Call today for your FREE comprehensive Miyachi Product Guide O I T A vast array of weld heads are available from Miyachi, including pneumatic, Cservo motor and hand-held. E S
6 3 3
Miyachi has long held a reputuation for leading micro-spot welding technology innovations throughout the world. The focus of Miyachi’s product range is high precision welding of miniature parts in the electronic, IT, IT, medical, aerospace and automotive industries and the broad scope of their technology covers almost every micro-spot welding application. The scope of Miyachi’s micro-spot welding equipment is as follows... AC power 1kVA - 20kVA Capacitor discharge 900µF - 1800µF Transistor power 1,500A – 9,990A DC fine inverter 50A – 5,000A DC inverter 84kVA – 325kVA AC inverter 70A – 500A Miyachi Fineheat technology Bench-mounted weld heads Hand-held welding tongs Call today for your FREE comprehensive Miyachi Product Guide • • • • • • • • •
TRANSfORMERS DENKA TX-SERIES MACHINE TRANSFORMERS
TC-SERIES SUSPENDED TRANSFORMERS
• •
•
• • •
• • • •
Single-phase AC 415V transformers Transformers rated at 50% duty cycle to AS, DIN & ISO norms Designed to handle high volume usage Fully water-cooled secondary windings Heavy-duty laminations and frame High purity copper used on primary and secondary windings Integral thermal overload switch Transformers comply to AS2799 Two year warranty wa rranty Made in Spain
SPECIFICATIONS
See table below. below. 100kVA 150kVA 200kVA
OPTIONS
TC100 TC150 TC200
•
•
FEATURES
15kVA 25kVA 35kVA 50kVA 60kVA 80kVA 100kVA 125kVA 150kVA 200kVA 250kVA 300kVA 400kVA
TX15 TX25 TX35 TX50 TX60 TX80 TX100 TX125 TX150 TX200 TX250 TX300 TX400
• •
High secondary voltage Use with suspended spot welders or large secondary circuit
• •
Secondary pad lugs for connection to kickless cable Suspension kit, for suspending transformer Water manifold system Air supply system
Model
kVA @ 50%
Package
U1N
V20
L PM
kg
Length mm
TC-100
100
F
1~415VAC
18.0
8
35
564
TC-150
150
F
1~415VAC
20.0
8
110
560
TC-200
200
F
1~415VAC
22.0
8
170
485
FEATURES • •
•
•
• •
• •
• • •
Single-phase AC 415V transformers Transformers rated at 50% duty cycle to AS, DIN & ISO norms Designed to handle high volume usage Fully water-cooled secondary windings Heavy-duty laminations and frame High purity copper used on primary and secondary windings Integral thermal overload switch Dimensions meet ISO norms, for easy interchangability Transformers comply to AS2799 Two year warranty wa rranty Made in Spain, Italy and USADENKA
Model
kVA @ 50%
Package
U1N
V20
L PM
kg
Length mm
TX-15
15
A
1~415VAC
3.4
4
25
250
TX-25
25
A
1~415VAC
4.2
4
28
315
TX-35
35
A
1~415VAC
4.9
6
32
340
TX-50
50
B
1~415VAC
6.3
6
60
506
TX-60
60
C
1~415VAC
6.0
6
65
410
TX-80
80
C
1~415VAC
6.7
6
70
450
TX-100
100
D
1~415VAC
9.0
8
75
564
TX-125
125
D
1~415VAC
11.0
8
85
638
TX-150
150
C
1~415VAC
9.5
8
115
560
TX-200
200
E
1~415VAC
10.1
8
200
485
TX-250
250
E
1~415VAC
12.2
12
270
515
TX-300
300
E
1~415VAC
13.1
12
280
550
TX-400
400
E
1~415VAC
13.6
12
335
690
S E C T I O N T H I R T E E N – R E S I S T A N C E W E L D I N G E Q U I P M E N T
3 3 7
TRANSfORMERS ISO-SERIES AC ROBOT T DENKA N TRANSFORMERS E M P I U Q E G N I D L E ISO32 W32kVA ISO36 E36kVA ISO48 C48kVA ISO54 N54kVA ISO61 A61kVA T 76kVA ISO76 S ISO103 I 103kVA SFEATURES Transformers conform to ISO10656 E norms R Lightweight, compact and powerful – Use with robot guns, suspended welders, fixture welders and custom N welders E Single-phase AC 415V transformers E Transformers rated at 50% duty cycle T to AS, DIN & ISO norms to handle high volume usage R I Designed Fully water-cooled secondary H windings T High purity copper used on primary secondary windings N and Integral thermal overload switch comply to AS2799 O I TTransformers wo year warranty wa rranty T Made in Spain COPTIONS E Transformers available in ISO-K and S ISO-X configuration •
• •
• •
• •
•
• • • •
•
• •
8 3 3
Rear terminal enclosure Secondary terminal right angle brackets
DENKA MFDC-SERIES DC INVERTER ROBOT TRANSFORMERS
56kVA 75kVA 100kVA 150kVA 250kVA
MFDC56 MFDC75 MFDC100 MFDC150 MFDC250
FEATURES •
•
• •
• • • •
•
• • • •
Transformers conform to all ISO and DIN norms For medium frequency DC control systems Lightweight, compact and powerful Use with robot guns, suspended welders, fixture welders and custom welders Single-phase AC 415V transformers Transformers rated at 50% duty cycle Designed to handle high volume usage Fully water-cooled secondary windings High purity copper used on primary and secondary windings Integral thermal overload switch Transformers comply to AS2799 Two year warranty Made in Spain & India
OPTIONS •
• •
Other configurations available on request Rear terminal enclosure Secondary terminal right angle brackets
Complete suspended welding transformer with weld controller, controller, air & water systems and gun hanging frame
RESISTANCE WELDING CONTROL SYSTEMS DENKA S1 ANALOGUE WELD CONTROLLER
FEATURES •
•
•
•
•
1~240V S1240 1~415V S1415 For a reliable, simple resistance welding controller, the Denka S1 analogue weld controller will fit the bill. Built to withstand normal workshop wear and tear, this controller is manufactured from components of proven quality and reliability. Whilst it’s appearance is plain and it only offers two variable parameters, this controller is designed to work in conjunction with the very latest thyristor technology for retrofitting to almost any single phase resistance welder.
•
•
• • • •
Digital synchronous microprocessorbased control technology Works with most SCR and thyristor systems Eleven programmable parameters including pulsation welding, upslope and repeat Can be configured for either 240V or 415V Use with manual or pneumatic operation Various output signals available to integrate with other control devices Uses a current transformer to detect current signal Does not require separate power supply Complies with AS2799 One year warranty Made in Italy
•
•
•
•
• • •
Simple analogue control system Incorporates synchronous, microprocessor technology Programmable WELD POWER and WELD TIME Will work on most single phase 50Hz resistance welders with a thyristor Use with manual or pneumatic operation Complies with AS2799 One year warranty Made in Italy
SPECIFICATIONS
See table ‘CONTROL TYPE’ over page. DENKA PX1500 DIGITAL WELD CONTROLLER
1~240V PX1524 1~415V PX1541 The ever-popular Denka PX1500 digital synchronous resistance weld controller is one of the most compact yet powerful control platforms available today. Offering eleven programmable parameters, plenty of handy inputs and outputs, and very basic operator skill, this controller can be retrofitted to any AC resistance welding system with amazing ease and speed. Fitment of the Denka PX1500 will stop the hit and miss programming of many inferior controllers and bring accuracy and results back into your control.
• • •
•
•
• •
•
•
•
•
SPECIFICATIONS
See table ‘CONTROL TYPE’ over page. DENKA PX1500P DIGITAL WELD CONTROLLER
•
•
• •
FEATURES •
•
Programmable upper and lower limits for accurate monitoring Three separate weld current settings Mulitple impulse welding Can monitor either primary or secondary current Clear, Clear, simple display of welding information View programmed and actual information together Integrated conduction angle monitor Visual and audible alarm signal for bad and suspect welds Three different sorts of counters for batching & quality control Self diagnostics for controller problems Automatic electrode wear compensation current step-up control Several input and output contacts for integrating with other processes Various toroidal coil shapes & sizes available Requires separate 240VAC power supply One year warranty Made in Japan
SPECIFICATIONS
See table ‘CONTROL TYPE’ over page. OPTIONS •
•
1~240V PP1524 1~415V PP1541 The Denka PX1500P weld controller is identical to the PX1500 but it offers nine schedule memories, for storing your most popular welding schedules for instant recall at the touch of button. Ideal for more welders that are used for various repetition operations. MIYACHI CT-110 & CY-210 WELD CONTROLLERS
•
•
•
Miyachi MB-400L toroidal coil 400mm long Miyachi MB-800L toroidal coil 800mm long Miyachi MB-500-15 toroidal coil 500mm diameter Miyachi MB-60E toroidal coil 60mm diameter Denka 15 position switch – for remote weld schedule setting
S E C T I O N T H I R T E E N – R E S I S T A N C E W E L D I N G E Q U I P M E N T
CT-110 CT110B0008 CY-210 CY210C0008 The weld controller of choice for most manufacturers, the Miyachi range of resistance welding controllers offers excellent functionability whilst remaining the most user-friendly controller available on today’s market. Far more than just a weld controller, these units are your key to weld monitoring, quality control management, error alerts, electrode redressing warning and a host of other intelligent and useful functions that will prove beneficial to any manufacturer. FEATURES • •
Constant-current weld control system 15 weld schedule memory
3 3 9
RESISTANCE WELDING CONTROL SYSTEMS
T N E MSYNCHRONOUS P I CONSTANT CURRENT U VOLTAGE FLUCUATION COMPENSATION Q E MEASURE PRIMARY POWER G MEASURE SECONDARY POWER N I D SQUEEZE (TIME) L UPSLOPE (TIME) E WWELD 1 (TIME) E WELD 1 (POWER) C COOL 1 (TIME) N WELD 2 (TIME) A T WELD 2 (POWER) S I COOL 2 (TIME) S WELD 3 (TIME) E R WELD 3 (POWER) – DOWNSLOPE (TIME) N HOLD (TIME) E E OFF (TIME) T PULSATION R I REPEAT H T N MONITOR WELDING CURRENT O I MONITOR CONDUCTION ANGLE T ERROR ALARM FOR BAD WELDS C PROGRAM ERROR TOLERANCE LEVEL E S
DENKA S1
DENKA PX1500
DENKA PX1500P
MIYACHI CT-110
MIYACHI CY-210
SERRATRON 100
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
CONTROL TYPE 3
3
3
3
3
3
WELDING SCHEDULE PARAMETERS 3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
MONITORING FUNCTIONS
WELDING POWER SUPPLY
1~240V
3
3
3
1~415V
3
3
3
3
3
3
AC POWER
3
3
3
3
3
3
MFDC POWER
3
SCHEDULE MEMORY
1
1
9
15
15
DIGITAL
DIGITAL
DIGITAL
BINARY
BINARY
3
3
3
TOTAL NUMBER OF WELDS
3
3
3
NUMBER OF WELDS PER PART
3
3
3
NUMBER OF PARTS
3
3
3
WELDING SCHEDULES MEMORY SETTING FORM SET FROM REMOTE LOCATION
127 BINARY
COUNTER FUNCTIONS
ADDITIONAL COUNTERS, FLIP-FLOPS, TIMERS
0 4 3
3
RESISTANCE WELDING CONTROL SYSTEMS
DENKA S1
DENKA PX1500
DENKA PX1500P
MIYACHI CT-110
MIYACHI CY-210
SERRATRON 100
240VAC
240VAC
24VDC
PNEUMATIC CYLINDER CONTROL SOLENOID VALVE VOLTAGE VOLTAGE
24VDC
24VDC
24VDC
OUTPUT FOR PROPORTIONAL VALVE
3
INTERFACE WITH SERVO MOTOR CONTROLS
3
ADDITIONAL FUNCTIONS WELD POWER ON/OFF SWITCH
•
•
•
3
3
3
WELD & SQUEEZE - NO WELDING POWER
3
3
3
3
3
3
INTERLOCK FUNCTION
3
3
3
LOCK OUT PROGRAMMING FUNCTIONS
3
3
3
LOCK OUT ON ERROR SIGNAL
3
3
3
3
3
3
THYRISTOR DRIVER INCLUDED
3
3
3
OPTIONAL FIELD BUSES
3
PROGRAMMABLE FROM PC
3
INTEGRTED ETHERNET PORT
3
ELECTRODE WEAR COMPENSATION STEPPED CURRENT INCREASE
3
3
INFINITE CURRENT INCREASE
3
PREDIFINED WEAR CURVES
3
AUTOMATIC RESET AFTER TIP DRESSING
3
INPUTS & OUTPUTS THERMAL OVERLOAD MONITORING
3
3
3
3
3
3
WELD ON SIGNAL
3
3
3
3
3
HOLD END SIGNAL
3
3
3
3
3
ERROR SIGNAL
3
3
3
ELECTRODE WORN SIGNAL
3
3
3
INTEGRATED PLC FUNCTIONS
3
ADDITIONAL I/O
32
S E C T I O N T H I R T E E N – R E S I S T A N C E W E L D I N G E Q U I P M E N T
CONTROLLER SPECIFICATIONS CONTROLLER POWER
240V/415V
240V/415V
240V/415V
DIMENSIONS W - D - H (mm) WEIGHT
Constant-Current Feedback Theory When you program your welder to perform a weld of a certain current (kA) for a certain period of time (cycles), the actual weld power and time will almost always differ from that programmed, due to a range of variables present in resistance welding applications, including material type, coating variations, electrode diameter, electrode condition, variations in air supply, mechanical resistance, earth leakage, maintenance schedules and many, many other variables.
To harness these unpredictable elements, constant-current technology was developed. So what exactly is “constant-current technology”? The current waveform as programmed by the operator is reconstructed by the weld controller by monitoring the actual current passing through the secondary loop of the resistance resi stance welder, by means of a toroidal coil. The signal is then transformed into the RMS effective value using the following formula:
RMS=
240V
240V
24VDC
110-250-355
355-250-110
62-182-295
4.5KG
4.5KG
2.0KG
This effective value is then analysed by the weld controller in comparison to the programmed value and a variation signal, either up or down, is fed back to the thyristor through phase conversion and the trigger pulse oscillation. In effect, the weld current is corrected with every half cycle, or up to 100 times per second, so that the weld current remains constant despite the variables being present. Basically, the weld you end up with is the same as you have programmed, not just “should be the same”!
3 4 1
RESISTANCE WELDING CONTROL SYSTEMS
T N E M P I U Q E G N I D L E W E C N A T S I S E R – N E E T R I H T N O I T C E S
2 4 3
RESISTANCE WELDING CONTROL SYSTEMS SERRATRON 100 WELD CONTROLLER
Accommodates analogue proportional valve and load cell Numerous error and warning output signals Optional modules for field buses and servo motor control Comes standard with 32 I/O – expandable up to 516 I/O Requires separate 24VDC power supply Two year warranty Made in Spain * Optional software required •
•
•
•
•
• • • • • • • • • •
•
•
•
•
SPECIFICATIONS
• •
Power supply Air pressure monitors Proportional valve Water flow switches PLC controllers Remote control interfaces Circuit breakers & fuses Terminal blocks HMI panels Indicator lights & switches Alarms & error processing Ethernet ports Cable entry system Cooling fans & ventilation
See table ‘CONTROL TYPE’ previous pages. OPTIONS •
• •
•
•
•
•
• • •
SERRATRON 100 S100 For ultimate control of your resistance welding operations, you can’t go past the Serratron 100. Unrivalled in features, function and flexibility, this piece of equipment is the culmination of over 60 years of research and development by Serra in Spain, into the needs and wishes of major manufacturers around the globe. A huge Intel microprocessor lies at the heart of this complex PLCbased control system which controls and monitors every conceivable parameter and variable within the resistance welding experience. The Serratron 100 weld controller is an investment that will repay itself over and over again. FEATURES •
• •
•
• •
•
•
•
•
Constant-current, constant-voltage and phase compensation weld control system 127 weld schedule memories Full PLC system with embedded welding functions Integrates easily and seamlessly with QA systems and protocols Works with AC and MFDC welders Input data via hand-held programmer or PC* Ethernet networking for centralised programming up several controllers View programmed and actual information together Various counters, timers, flip-flops, etc for aiding manufacturing processes Comprehensive electrode wear compensation system
Serratron TP-10 hand-held programming unit Serratron UPT-8A UPT-8A HMI panel Serratron MES-32 I/O expansion unit (additional 32 I/O) Serratron BCF-06 toroidal coil 60mm diameter Serratron BCF-12 toroidal coil 120mm diameter Serratron BCF-18 toroidal coil 180mm diameter Serratron ‘CPC-Connect’ programming software Serratron ‘DeviceNet’ PCB Serratron ‘ProfiBus’ PCB Serratron ‘Interbus’ PCB
A compact but complex Denka control cabinet incorporating a Serratron 100 controller.
DENKA TC-SERIES CONTROL CABINETS We manufacture a complete range of resistance control cabinets to your exact requirements, including your preferred controller type, your preferred brand of electronics and input/output signals to integrate with your existing manufacturing operations. From small, one-off cabinets through to large quantities of complex control systems, our experienced, in-house technicians can certainly create a control system to meet your needs. Just give us a call for an obligation free assessment today. Denka TC-Series Control Cabinet Component Options Include... For welders 10kVA to 1000kVA Weld controller – Denka, Miyachi or Serratron Thyristor module – water-cooled or air-cooled Compliant mains ON/OFF disconnect switch Emergency stop system Safety relays
High amperage Denka control cabinets with Miyachi CY-210 CY-210 controller and full AS4024.1 compliant safety system.
S E C T I O N T H I R T E E N – R E S I S T A N C E W E L D I N G E Q U I P M E N T
• •
•
•
•
A basic version of the Denka control cabinet with the PX1500 controller. controller. Quality Denka TC-Series control cabinets can be retrofitted to most resistance welding systems.
•
3 4 3
WATER WAT ER COOLING SYSTEMS DENKA HK-SERIES REFRIGERATED T WATER COOLING SYSTEMS N E M P I U Q E G N I D L E W E C N A T S I S E R – HK-250 N1kWH E2kWH HK-600 E3kWH HK-750 T 4.3kWH HK-1000 R I 5.8kWH HK-2000 H8.7kWH HK-3000 T 11.6kWH HK-4000 N14.5kWH HK-5000 Efficient, high-flow water cooling for O I high amperage welding applications T is absolutely essential for maximum and protection of capital Cproductivity The Denka HK-Series Eequipment. refrigerated water coolers bring Stogether eco-friendly R407C refrigerant, precision high volume pumps and digital temperature control technology
Cooling capacity
•
• • •
SPECIFICATIONS
See table below. below. OPTIONS
FEATURES •
• • •
• •
Built-in water storage tank with water level gauge Primary power 3~415V 50Hz One year warranty Made in Taiwan
Refrigerated water cooling system with integrated recirculating pump Digital water temperature control Uses eco-friendly R407C refrigerant Highly efficient radiators and cooling fans Easy to clean air inlet filters Compact size – minimum footprint on floorspace
Denka water filtration system Denka water flow switch Denka water flow monitor
HK-250
HK-600
HK-750
HK-1000
HK-2000
HK-3000
HK-4000
HK-5000
kWH
1
2
3
4.3
5.8
8.7
11.6
14.5
BTU
3300
6700
10000
15000
20000
30000
40000
50000
Water temp
°C
10~30
10~30
10~30
10~30
10~30
10~30
10~30
10~30
Ambient
°C
10~40
10~40
10~40
10~40
10~40
10~40
10~40
10~40
Water cut off
°C
45
45
45
45
45
45
45
45
Primary power
---
3~415V
3~415V
3~415V
3~415V
3~415V
3~415V
3~415V
3~415V
A
10
10
10
10
10
14
18
22
---
Air cooled
Air cooled
Air cooled
Air cooled
Air cooled
Air cooled
Air cooled
Air cooled
Pump
kW
0.7
0.7
0.7
0.7
0.7
1.5
1.5
1.5
Maximum flow
LPM
40
40
40
40
40
120
120
120
Max. lift (head)
m
28
28
28
28
28
36
36
36
BSP
½
¾
¾
¾
¾
1
1¼
1¼
80
80
127
227
227
Heat dissipation
Inlet/outlet Tank capacity Dimensions
4 4 3
to provide one of the most robust and efficient water cooling answers to the needs of your welding equipment. Ideally suited to all forms of resistance welding, these water coolers are also used extensively in high-amperage arc welding applications such as robotic mig welding, sub-arc welding and high deposition mig welding.
l
16
43
55
mm
370x450 x950
425x455 x1110
490x500 x1125
550x620x1205
710x750 x1500
885x885x1885
CONDUCTORS, ELECTRODES AND ADAPTORS RESISTANCE WELDING CONDUCTORS
High quality seam welding wheels manufactured to suit your needs.
Denka high-quality water-cooled cables.
Electrodes of all shapes an sizes to the following RWMA, ISO and Morse tapers.
Denka long-lasting ‘kickless’ cables
A huge range of electrode holders, welding arms and adaptors are available to suit your needs.
Denka heavy-duty air-cooled cables
S E C T I O N T H I R T E E N – R E S I S T A N C E W E L D I N G E Q U I P M E N T
Laminated shunts manufactured to your exact requirements.
Call us today for dimensions and specifications of our vast electrodes range.
3 4 5
WELD ANALYSIS WELDING CHECKERS T RESISTANCE N & MONITORS E M P I U Q E G N I D L E W E C NThe Miyachi MM-315A is a handy, Asimple weld checker for obtaining T quick confirmation of weld current and weld cycles. S I S E R – N E E T R I H T N O I T C E SCompact, light, exact and fast are the outstanding attributes of the Miyachi MM-122A weld checker, checker, which monitors weld current and weld time against preset limits and outputs an alarm signal for failed or suspicious welds.
6 4 3
Miyachi MM-326B full function weld checker with built-in printer, printer, capable of simultaneously measuring and monitoring weld current, weld voltage and weld cycles. Need to double-check your electrode force? The Denka Force Checker is a ecomonical and accurate way to make sure those electrodes are closing correctly. correctly. It will also help the visual vi sual appearance of your welds!
The new Miyachi MM-380A sets a new benchmark in monitoring welds and diagnosing system faults with speed and ease. A range of options are available to compliment this amazing piece of machinery. machinery.
RESISTANCE WELDING ELECTRODES & ADAPTORS
Part Number
S E C T I O N T H I R T E E N – R E S I S T A N C E W E L D I N G E Q U I P M E N T
3 4 7
RESISTANCE WELDING ELECTRODES & ADAPTORS
T N E M P I U Q E G N I D L E W E C N A T S I S E R – N E E T R I H T N O I T C E S
8 4 3
Part Number
RESISTANCE WELDING ELECTRODES & ADAPTORS
Part Number
S E C T I O N T H I R T E E N – R E S I S T A N C E W E L D I N G E Q U I P M E N T
3 4 9
RESISTANCE WELDING ELECTRODES & ADAPTORS
T N E M P I U Q E G N I D L E W E C N A T S I S E R – N E E T R I H T N O I T C E S
0 5 3
Part Number
RESISTANCE WELDING ELECTRODES & ADAPTORS
Part Number
S E C T I O N T H I R T E E N – R E S I S T A N C E W E L D I N G E Q U I P M E N T
3 5 1
RESISTANCE WELDING ELECTRODES & ADAPTORS
T N E M P I U Q E G N I D L E W E C N A T S I S E R – N E E T R I H T N O I T C E S
2 5 3
Part Number
RESISTANCE WELDING ELECTRODES & ADAPTORS
Part Number
S E C T I O N T H I R T E E N – R E S I S T A N C E W E L D I N G E Q U I P M E N T
3 5 3
RESISTANCE WELDING ELECTRODES & ADAPTORS
T N E M P I U Q E G N I D L E W E C N A T S I S E R – N E E T R I H T N O I T C E S
4 5 3
Part Number
RESISTANCE WELDING ELECTRODES & ADAPTORS
Part Number
S E C T I O N T H I R T E E N – R E S I S T A N C E W E L D I N G E Q U I P M E N T
3 5 5
RESISTANCE WELDING ELECTRODES & ADAPTORS
T N E M P I U Q E G N I D L E W E C N A T S I S E R – N E E T R I H T N O I T C E S
6 5 3
Part Number
RESISTANCE WELDING ELECTRODES & ADAPTORS
Part Number
S E C T I O N T H I R T E E N – R E S I S T A N C E W E L D I N G E Q U I P M E N T
3 5 7
RESISTANCE WELDING ELECTRODES & ADAPTORS
T N E M P I U Q E G N I D L E W E C N A T S I S E R – N E E T R I H T N O I T C E S
8 5 3
Part Number
RESISTANCE WELDING ELECTRODES & ADAPTORS
Part Number
S E C T I O N T H I R T E E N – R E S I S T A N C E W E L D I N G E Q U I P M E N T
3 5 9
RESISTANCE WELDING ELECTRODES & ADAPTORS
T N E M P I U Q E G N I D L E W E C N A T S I S E R – N E E T R I H T N O I T C E S
0 6 3
Part Number
RESISTANCE WELDING ELECTRODES & ADAPTORS
ITEM
PART NUMBER
DESCRIPTION
1
221110
Electrode 12mm off-centre point 1:10 ext.
2
221010
Electrode 12mm centre point 1:10 ext.
3
221210
Electrode 12mm swivel 22mm 1:10 ext.
4
221215
Electrode 12mm swivel 30mm 1:10 ext.
5
221315
Electrode 12mm flat 30mm 1:10 ext.
6
221410
Electrode 12mm dome R5 1:10 ext.
ITEM
PART NUMBER
DESCRIPTION
1
221020
Electrode 18mm centre point 1:10 ext.
2
221120
Electrode 18mm off-centre point 1:10 ext.
4
221325
Electrode 18mm flat 30mm 1:10 ext.
5
221220
Electrode 18mm swivel 30mm 1:10 ext.
7
221510
Electrode adaptor 18mm-12mm
8
221410
Electrode 12mm dome R5 1:10 ext.
ITEM
PART NUMBER
DESCRIPTION
1
221030
Electrode 20mm centre point 1:10 ext.
2
221130
Electrode 20mm off-centre point 1:10 ext.
3
221335
Electrode 20mm flat 30mm 1:10 ext.
5
221520
Electrode adaptor 20mm-12mm
6
221410
Electrode 12mm dome R5 1:10 ext.
S E C T I O N T H I R T E E N – R E S I S T A N C E W E L D I N G E Q U I P M E N T
3 6 1
RESISTANCE WELDING ELECTRODES & ADAPTORS
T N E M P I U Q E ITEM G 1 N I 2 D L E W E C N A T S I S E R – ITEM N 1 E 2 E 3 T 4 R I H T N O I T C E S
2 6 3
PART NUMBER
DESCRIPTION
243530
22mm lower arm adaptor 90 deg. suits VSR
243540
22mm lower arm adaptor 15 deg. suits VSR
PART NUMBER
DESCRIPTION
243515
30mm upper arm adaptor 90 deg. suits VSX
243535
30mm lower arm adaptor 90 deg. suits VSX
243525
30mm upper arm adaptor 15 deg. suits VSX
243545
30mm lower arm adaptor 15 deg. suits VSX
ITEM
PART NUMBER
DESCRIPTION
1
243555
40mm upper arm adaptor 90 deg. suits VSX
2
243575
40mm lower arm adaptor 90 deg. suits VSX
3
243565
40mm upper arm adaptor 15 deg. suits VSX
4
243585
40mm lower arm adaptor 15 deg. suits VSX
HEAvY-DUTY OffSET WATER COOLED HOLDER
S E C T I O N T H I R T E E N – R E S I S T A N C E W E L D I N G E Q U I P M E N T
ITEM
PART NUMBER
DESCRIPTION
1
243310
Offset electrode holder 20mm dia. x 70mm long
2
243311
Offset electrode holder 20mm dia. x 125mm long
3
243410
Offset electrode holder 25mm dia. x 70mm long
4
243411
Offset electrode holder 25mm dia. x 125mm long
3 6 3
T N E M P I U Q E G N I D L E W E C N A T S I S E R – N E E T R I H T N O I T C E S
4 6 3
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