13 resistance welding

323

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 344

Conductors, Electrodes and Adaptors 345

Weld Analysis 346

Resistance Welding Electrodes & Adaptors 347

Heavy-duty Offset Water Cooled Holder 364

Resistance welding equipment

Section Thirteen

324

SE

CTIO

N T

HIR

TE

EN

– R

ES

ISTA

NC

E W

ELD

ING

EQ

UIP

ME

NT

PEDESTAL RESISTANCE WELDERS

PEDESTAL RESISTANCE WELDERSBUYERS GUIDE

For the ideal balance between quality, reliability and price, the Denka V-Series resistance welders are the solution to your manufacturing needs. Designed to meet the demanding nature of Europe’s production line environment, these welders are ideally suited to all levels of manufacturing, from precision, low-volume spot welding through to high-volume mass production applications. You can choose a weld control system from a range of popular brands, or you can upgrade the standard pneumatic cylinder to double force or two-stage. These options, along with many others, offer you an unparalleled level of diversity and flexibility when choosing a resistance welder to suit your needs. Talk to a Customer Service representative today to discuss your specific requirements.

Thermal Rating At 50% Duty Cycle15 25 35 50 80 100 130 150 200 250 300

Manual Rocker Arm

VRM-15

VRM-25

VRM-35

Pneumatic Rocker Arm

VRP-15

VRP-25

VRP-35

VRP-50

Linear Action Spot

VLP-35

VLP-50

VLP-80

Projection VPP-80

VPP-100

VPP-150

VPP-200

VPP-300

Seam VLS-80

VLS-100

VLS-130

VLS-250

325

SE

CTIO

N T

HIR

TE

EN

– RE

SIS

TA

NC

E W

ELD

ING

EQ

UIP

ME

NT


VRM-SERIES SPECIFICATIONS VRM-15 VRM-25 VRM-35THERMAL RATING @ 50% D/C kVA 15 25 35MAX. SHORT CIRCUIT CURRENT kA 10.4 13.2 16.8ELECTRODE FORCE daN 180 180 180SECONDARY NO LOAD VOLTAGE V 3.0 3.9 4.9PRIMARY VOLTAGE AT 50Hz V 1~415 1~415 1~415SUPPLY AMPERAGE (DELAYED) A 25 42 60ELECTRODE TAPER – ISO 1:10 1:10 1:10ELECTRODES DIAMETER mm 18 18 18THROAT DEPTH mm 400~800 400~800 400~800THROAT HEIGHT mm 220-330 220-330 220-330CYLINDER STROKE mm 50 50 50DIMENSIONS cm 102x30x127 102x30x127 102x30x127WEIGHT kg 120 125 130

15kVA VRM1525kVA VRM2535kVA VRM35For simple operations requiring a manual spot welding system, the Denka VRM-Series 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.FEATURES

‘Rocker’ motion of upper arm•Transformers rated at 50% duty cycle •to AS, DIN & ISO normsManual foot pedal operation •Water-cooled transformer, arms, •electrode holders and electrodesStandard throat depth 400mm •SEE OPTIONS BELOW FOR ALTERNATIVESArms diameter 45mm •Upper and lower electrode holders •can be rotated and used at either 0° or 15°Adjustable lower arm for variable •throat heightDenka S1 analogue weld controller •SEE OPTIONS BELOW FOR ALTERNATIVESMains ON/OFF switch included•High-alloy copper and brass •conductors used throughoutElectrode taper Ø18mm 1:10•Complies with AS2799•Two year warranty •Made in Italy•

DENKA VRM-SERIES MANUAL ROCKER-ARM SPOT WELDERS

SPECIFICATIONSSee table ‘VRM-SERIES SPECIFICATIONS’ opposite.OPTIONS

Additional throat depth - extend to •600mmAdditional throat depth - extend to •800mmLow clearance lower arm – 400mm•Low clearance lower arm – 600mm•Low clearance lower arm – 800mm•Ultra-low clearance lower arm – •400mmUltra-low clearance lower arm – •600mmUltra-low clearance lower arm – •800mmUpgrade weld controller – PX1500•Upgrade weld controller – PX1500P•

326

SE

CTIO

N T

HIR

TE

EN

– R

ES

ISTA

NC

E W

ELD

ING

EQ

UIP

ME

NT


DENKA VRP-SERIES PNEUMATIC ROCKER-ARM SPOT WELDERS

15kVA VRP1525kVA VRP2535kVA VRP3550kVA VRP50The economical choice for general sheetmetal welding, the Denka VRP-Series 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

‘Rocker’ motion of upper arm•Transformers rated at 50% duty cycle •to AS, DIN & ISO normsPneumatic cylinder operation via foot •switchManual foot pedal operation •Water-cooled transformer, arms, •electrode holders and electrodesStandard throat depth 400mm •SEE OPTIONS BELOW FOR ALTERNATIVESArms diameter 45mm •Upper and lower electrode holders •can be rotated and used at either 0° or 15°Adjustable lower arm for variable •throat heightDenka PX1500 digital synchronous •weld controller SEE OPTIONS BELOW FOR ALTERNATIVES

Mains ON/OFF switch included•Quality filter, regulator and lubricator •includedFully enclosed footswitch with safety •leverHigh-alloy copper and brass •conductors used throughoutElectrode taper Ø18mm 1:10 •Complies with AS2799•Two year warranty •Made in Italy•

SPECIFICATIONSSee table ‘VRP-SERIES SPECIFICATIONS’ below.OPTIONS

Additional throat depth - extend to •600mmAdditional throat depth - extend to •800mmLow clearance lower arm – 400mm•Low clearance lower arm – 600mm•Low clearance lower arm – 800mm•Ultra-low clearance lower arm – •400mmUltra-low clearance lower arm – •600mmUltra-low clearance lower arm – •800mmDowngrade weld controller – S1•Upgrade weld controller – PX1500P•

VRP-SERIES SPECIFICATIONS VRP-15 VRP-25 VRP-35 VRP-50THERMAL RATING @ 50% D/C kVA 15 25 35 50MAX. SHORT CIRCUIT CURRENT kA 10.4 13.2 16.8 19.5ELECTRODE FORCE daN 250 250 250 250SECONDARY NO LOAD VOLTAGE V 3.0 3.9 4.9 5.7PRIMARY VOLTAGE AT 50Hz V 1~415 1~415 1~415 1~415SUPPLY AMPERAGE (DELAYED) A 25 42 60 85ELECTRODE TAPER – ISO 1:10 1:10 1:10 2:10ELECTRODE DIAMETER mm 18 18 18 18THROAT DEPTH mm 400~800 400~800 400~800 400~800THROAT HEIGHT mm 220-330 220-330 220-330 220-330CYLINDER STROKE mm 50 50 50 50DIMENSIONS cm 102x30x127 102x30x127 102x30x127 102x30x127WEIGHT kg 120 125 130 135

327

SE

CTIO

N T

HIR

TE

EN

– RE

SIS

TA

NC

E W

ELD

ING

EQ

UIP

ME

NT

DENKA VLP-SERIES LINEARACTION SPOT WELDERS

35kVA VLP3550kVA VLP5080kVA VLP80For 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

Upper arm descends parallel to •lower arm – precise, accurate and consistentTransformers rated at 50% duty cycle •to AS, DIN & ISO normsPneumatic cylinder operation via foot •switchWater-cooled transformer, arms, •electrode holders and electrodesStandard throat depth 430mm •SEE OPTIONS BELOW FOR ALTERNATIVESArms diameter 60mm (except VLP-80 •has cast section arm)Can fit optional platens with T-slots •to convert to projection welder SEE OPTIONS BELOWDenka PX1500 digital synchronous •weld controller SEE OPTIONS BELOW FOR ALTERNATIVESMains ON/OFF switch included•Quality filter, regulator and lubricator •includedHeavy duty fabricated frame •


VLP-SERIES SPECIFICATIONS VLP-35 VLP-50 VLP-80THERMAL RATING @ 50% D/C kVA 35 50 80MAX. SHORT CIRCUIT CURRENT kA 14.8 17.2 23.6ELECTRODE FORCE daN 180 300 525SECONDARY NO LOAD VOLTAGE V 5.2 6.0 6.7PRIMARY VOLTAGE AT 50Hz V 1~415 1~415 1~415SUPPLY AMPERAGE (DELAYED) A 60 85 140ELECTRODE TAPER – ISO 1:10 1:10 1:10ELECTRODE DIAMETER mm 18 18 18THROAT DEPTH mm 430 430 430THROAT HEIGHT mm 60-270 60-270 60-270CYLINDER STROKE mm 60 60 60DIMENSIONS cm 106x30x143 106x30x143 105x52x175WEIGHT kg 185 190 470

Fully enclosed footswitch with safety •leverFinger guard around moving parts on •upper armAdjustable lower arm for variable •throat heightHigh-alloy copper and brass •conductors used throughoutElectrode taper Ø18mm 1:10•Reinforcing support on lower arm •(optional on VLP-35)Complies with AS2799•Two year warranty •Made in Italy•

SPECIFICATIONSSee table ‘VLP-SERIES SPECIFICATIONS’ below.OPTIONS

Additional throat depth - extend to •630mmAdditional throat depth - extend to •830mmLow clearance lower arms – designed •to specific requirementsUpgrade weld controller – PX1500P•Upgrade weld controller – Miyachi CT-•110B or CY-210BUpgrade weld controller – Serratron •100Upgrade pneumatic cylinder – double •forceUpgrade pneumatic cylinder – •retractable two-stage Optional reinforcing support on lower •armOptional platen for projection welding•Optional two-hand start system •AS4024.1

328

SE

CTIO

N T

HIR

TE

EN

– R

ES

ISTA

NC

E W

ELD

ING

EQ

UIP

ME

NT DENKA VPP-SERIES PROJECTION

WELDERS

80kVA VPP80100kVA VPP100150kVA VPP150200kVA VPP200300kVA VPP300Designed and manufactured to meet the most challenging projection welding applications, the Denka VPP-Series of projection welders are time-proven performers for virtually any application between 80kVA and 300kVA. 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, and handy options such as the two-stage cylinder and compliant two-hand start system means these welders can be custom configured to suit the exact needs of your production environment.


VPP-SERIES SPECIFICATIONS VPP-80 VPP-100 VPP-150 VPP-200 VPP-300THERMAL RATING @ 50% D/C kVA 80 100 150 200 300MAX. SHORT CIRCUIT CURRENT kA 29.5 35.0 50 72.0 85.0ELECTRODE FORCE daN 735 735 1400 2300 3000SECONDARY NO LOAD VOLTAGE V 6.7 8.0 9.3 8.3 10.0PRIMARY VOLTAGE AT 50Hz V 1~415 1~415 1~415 1~415 1~415SUPPLY AMPERAGE (DELAYED) A 140 170 255 340 510PLATEN SIZE mm 150 150 150 200 250ELECTRODE PITCH mm 430 395 395 300 300THROAT HEIGHT mm 195-495 195-495 195-495 195-645 195-645CYLINDER STROKE mm 80 80 80 125 150DIMENSIONS cm 106x52x175 106x52x175 106x52x175 125x54x240 131x116x230WEIGHT kg 470 500 900 930 1300

FEATURESLarge, precision-machined brass •platen on upper and lower arms with T-slotsTransformers rated at 50% duty cycle •to AS, DIN & ISO normsPneumatic cylinder can be operated •by foot switch or two-hand start system – fitted standard with bothWater-cooled transformer, arms, •electrode holders and electrodesGenerous throat depth – varies •between modelsMaximum distance between platens •495mmSolid, cast aluminium upper and lower •arm (except VPP-80 has cast brass lower arm)Denka PX1500 digital synchronous •weld controller SEE OPTIONS BELOW FOR ALTERNATIVESMains ON/OFF switch included•Quality filter, regulator and lubricator •includedHeavy duty fabricated frame •Fully enclosed footswitch with safety •leverFinger guard around moving parts on •upper armAdjustable lower arm for variable •throat heightHigh-alloy copper and brass •conductors used throughoutReinforcing support on lower arm•Can easily convert to spot welder with •optional electrode holdersComplies with AS2799 •Two year warranty •Made in Italy and Spain•

SPECIFICATIONSSee table ‘VPP-SERIES SPECIFICATIONS’ below.OPTIONS

Additional throat depth - extend to •430mm (except VPP-80)Additional throat depth - extend to •730mmUpgrade weld controller – PX1500P•Upgrade weld controller – Miyachi CT-•110B or CY-210BUpgrade weld controller – Serratron •100Upgrade pneumatic cylinder – •retractable two-stageUpgrade pneumatic cylinder – double •force

329

SE

CTIO

N T

HIR

TE

EN

– RE

SIS

TA

NC

E W

ELD

ING

EQ

UIP

ME

NT

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.

Denka D-Series resistance welding systems – leading medium frequency DC inverter technology for precision resistance welding applications. Made in Spain and 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.

Custom alterations to standard Denka pedestal welders, to improve access to difficult spot locations and to suit unusually shaped objects. Made in Italy.

Other pedestal resistance welders also available

330

SE

CTIO

N T

HIR

TE

EN

– R

ES

ISTA

NC

E W

ELD

ING

EQ

UIP

ME

NT DENKA VSR-SERIES SUSPENDED

SPOT WELDERS

4kVA VSR46kVA VSR6Simple, compact, lightweight and fast are just some of the features of the Denka VSR-Series suspended spot welders. The small and compact design makes spot welding around complex objects easy and fast. The Denka VSR-Series offers either 4kVA or 6kVA, making them attractive to all light-gauge sheetmetal operations, from one-off manufacturing through to medium volume production lines. Operators can quickly set-up these welders, thanks to the simple Denka S1 analogue weld controller.FEATURES

Suspended spot welder on 3D swivel •gimbalX-type gun: scissor action arms•Integrated on-gun transformer, rated •at 50% duty cycle to AS, DIN & ISO normsPneumatic cylinder activated lower •arm operationDenka SmartStart trigger system•Water-cooled transformer*, electrode •holders and electrodesVarious throat depths available •SEE OPTIONS BELOW FOR ALTERNATIVESArms available for opposed •electrodes (0°) or angled electrodes (15°) SEE OPTIONS BELOW FOR ALTERNATIVES

Fitted with S1 weld controller as standard SEE OPTIONS BELOW FOR •ALTERNATIVESWeld 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.SPECIFICATIONSSee table ‘VSR-SERIES SPECIFICATIONS’ 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 or 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•

SUSPENDED SPOT WELDERS

VSR-SERIES SPECIFICATIONS VSR-4 VSR-6THERMAL RATING @ 50% D/C kVA 4.0 6.0MAX. SHORT CIRCUIT CURRENT kA 9.0 9.0ELECTRODE FORCE daN 140 140SECONDARY NO LOAD VOLTAGE V 3.6 3.6PRIMARY VOLTAGE AT 50Hz V 1~415 1~415SUPPLY AMPERAGE (DELAYED) A 15 15ELECTRODE TAPER – ISO 1:10 1:10ELECTRODE DIAMETER mm 12 12THROAT DEPTH mm 170~445 170~445THROAT HEIGHT mm 105 105CYLINDER STROKE mm 6~55 6~55DIMENSIONS cm 50x35x25 50x35x25WEIGHT* kg 18 18

* Weight without arms

Pressing the BLACK button allows the electrodes to close without welding 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, the welder will go through a normal welding sequence without the option of checking the electrode alignment.

331

SE

CTIO

N T

HIR

TE

EN

– RE

SIS

TA

NC

E W

ELD

ING

EQ

UIP

ME

NT

DENKA VSX-SERIES SUSPENDED SPOT WELDERS

8kVA VSX812kVA VSX1218kVA VSX1825kVA VSX2536kVA VSX3642kVA VSX42The versatile range of X-type suspended spot welders from the Denka VSX-Series 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

Suspended spot welder on 3D swivel •gimbalX-type gun: scissor action arms•Integrated on-gun transformer, rated •at 50% duty cycle to AS, DIN & ISO normsPneumatic cylinder activated lower •arm operationDenka SmartStart trigger system•Denka XtraBite speedy electrode •opening, with manual electrode gap adjustmentErgonomic pistol-grip handle •Water-cooled transformer, arms, •electrode holders and electrodesVarious throat depths available •SEE OPTIONS BELOW FOR ALTERNATIVES

Two different throat heights available •SEE OPTIONS BELOW FOR ALTERNATIVESArms available for opposed •electrodes (0°) or angled electrodes (15°) SEE OPTIONS BELOW FOR ALTERNATIVESFitted with PX1500 weld controller as •standard SEE OPTIONS BELOW FOR ALTERNATIVESWeld controller is mounted on the •spot welder for easy programmingMains ON/OFF switch on welder•Arms diameter: 30mm VSX-8 to •VSX25 and 40mm VSX-36 & VSX-42Quality filter, regulator and lubricator •includedHigh-alloy copper and brass •conductors used throughoutElectrode taper Ø12mm 1:10 •Heavy-duty machined aluminium •construction Includes hose and cable set 5 metres •longComplies with AS2799•Two year warranty •Made in Italy•

SPECIFICATIONSSee table ‘VSX-SERIES SPECIFICATIONS’ below.OPTIONSArm 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°•

400mm long 15°•600mm long 15°•800mm long 15°•Increase throat height – from 135mm •to 210mmIncrease electrode force – from •220daN to 400daNUpgrade weld controller – PX1500P in •separate cabinetUpgrade weld controller – Miyachi CT-•110B or CY-210B in separate cabinetUpgrade weld controller – Serratron •100 in separate cabinetSpring balancer 45kg – VSX-8•Spring balancer 70kg – VSX-12, VSX-•18, VSX-25Spring balancer 90kg – VSX-36•Spring balancer 105kg – VSX-42•


VSX-SERIES SPECIFICATIONS VSX-8 VSX-12 VSX-18 VSX-25 VSX-36 VSX-42THERMAL RATING @ 50% D/C kVA 8 12 18 25 36 42MAX. SHORT CIRCUIT CURRENT kA 9.8 12.8 13.5 15.0 18.0 22.0ELECTRODE FORCE daN 220 220 220 220 510 510SECONDARY NO LOAD VOLTAGE V 2.1 2.7 2.9 5.9 6.0 4.6PRIMARY VOLTAGE AT 50Hz V 1~415 1~415 1~415 1~415 1~415 1~415SUPPLY AMPERAGE (DELAYED) A 15 15 25 32 63 63ELECTRODE TAPER – ISO 1:10 1:10 1:10 1:10 1:10 1:10ELECTRODE DIAMETER mm 12 12 12 12 18 18THROAT DEPTH mm 200~800 200~800 200~800 200~800 200~800 200~800THROAT HEIGHT mm 135 135 135 135 140 140CYLINDER STROKE mm 6~50 6~50 6~50 6~50 6~50 6~50DIMENSIONS cm 82x35x30 82x35x30 82x35x30 82x35x30 93x40x35 93x40x35WEIGHT* kg 48 50 53 55 75 85


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!

332

SE

CTIO

N T

HIR

TE

EN

– R

ES

ISTA

NC

E W

ELD

ING

EQ

UIP

ME

NT DENKA VSC-SERIES SUSPENDED

SPOT WELDERS

12kVA VSC1218kVA VSC1825kVA VSC25The Denka VSC-Series of suspended spot welders are designed for continuous, heavy-duty use in high volume production environments. Similar in form and function to the

Denka VSX-Series, these welders are C-type configuration which means the electrodes are directly opposed and operate in a linear motion rather than a ‘scissor action’. FEATURES

Suspended spot welder on 3D swivel •gimbalLinear action, C-type gun operation•Integrated on-gun transformer, rated •at 50% duty cycle to AS, DIN & ISO normsPneumatic cylinder activated arm •operationErgonomic pistol-grip handle •Water-cooled transformer, arms, •electrode holders and electrodesFitted with PX1500 weld controller as •standard SEE OPTIONS BELOW FOR ALTERNATIVESWeld controller is mounted in •separate cabinetMains ON/OFF switch on welder•Arms diameter •

Quality filter, regulator and lubricator •includedHigh-alloy copper and brass •conductors used throughoutElectrode taper Ø12mm 1:10 •Heavy-duty machined aluminium •construction Includes hose and cable set 5 metres •longComplies with AS2799•Two year warranty •Made in Italy•

SPECIFICATIONSSee table below.OPTIONS

Special arms – available on request•Increase electrode force – available •on requestUpgrade weld controller – Miyachi CT-•110B or CY-210B in separate cabinetUpgrade weld controller – Serratron •100 in separate cabinetSpring balancer 70kg – Suits all VSC-•Series welders


VSC-SERIES SPECIFICATIONS VSC-12 VSC-18 VSC-25THERMAL RATING @ 50% D/C kVA 12 18 25MAX. SHORT CIRCUIT CURRENT kA 16.0 17.0 18.0ELECTRODE FORCE daN 300 300 300SECONDARY NO LOAD VOLTAGE V 2.7 2.9 5.9PRIMARY VOLTAGE AT 50Hz V 1~415 1~415 1~415SUPPLY AMPERAGE (DELAYED) A 15 25 32ELECTRODE TAPER – ISO 1:10 1:10 1:10ELECTRODE DIAMETER mm 12 12 12THROAT DEPTH mm 110 110 110THROAT HEIGHT mm 100 100 100CYLINDER STROKE mm 50 50 50DIMENSIONS cm 72x35X29 72x35X29 72x35X29WEIGHT* kg 55 58 60


OTHER DENKA SUSPENDED SPOT WELDING EQUIPMENT

Various special configurations of Denka suspended spot welders built to customer’s specific requirements.

Custom off-gun suspended spot welders are available through Denka in a range of shapes, sizes and configurations.

333

SE

CTIO

N T

HIR

TE

EN

– RE

SIS

TA

NC

E W

ELD

ING

EQ

UIP

ME

NT

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.

All shapes…All sizes…All applications

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, bench-mounted weld heads, multi-head units and custom-built machines.

DENKA AUTOMATIC NUT FEEDERS

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 vibrationBowls lined with super-quiet •dampening compoundAdditional nut storage hopper•Easy manual override for setup•Overflow cut-out switch•Nuts transported via positive, direct •air thrust

DENKA NUT PLACEMENT COMPONENTS

Denka’s precision nut placement technology uses compressed air flowing

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 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.

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!

NUT WELDING SYSTEM

334

SE

CTIO

N T

HIR

TE

EN

– R

ES

ISTA

NC

E W

ELD

ING

EQ

UIP

ME

NT

OTHER RESISTANCE WELDERS

DENKA VTS-SERIES TWIN-SERIES SPOT WELDERS

30kVA VTS3040kVA VTS40Some spot welding applications call for access to the welding zone from one side of the work piece only, requiring a ‘single-sided’ spot welder with two adjacent electrodes rather than the conventional style spot welder with two opposed electrodes. The Denka VTS-Series spot welders have been developed for this specific purpose, allowing two full strength spot welds to be created on an object by only accessing one side of the part. One of the fantastic features of the Denka VTS-Series is their ability to be interlinked with several other units to operate in a cascading sequence which is popular when welding reinforcing mesh, wire frames and large expanses of sheetmetal.FEATURES

Twin-series welding, or single-sided •Transformers rated at 50% duty cycle •to AS, DIN & ISO normsPneumatic cylinder operation via input •(pushbutton, footswitch or other)Water-cooled transformer and •electrodesVariable electrode pitch 40 – 150mm •Denka PX1500 digital synchronous •weld controller SEE OPTIONS BELOW FOR ALTERNATIVESHeavy duty fabricated frame •High-alloy copper and brass •conductors used throughoutElectrode taper Ø20mm 1:10•Complies with AS2799•One year warranty •Made in Italy•

SPECIFICATIONSSee table ‘VTS-SERIES SPECIFICATIONS’ at right.OPTIONS

Electrode holder for flat copper bar•Upgrade weld controller – PX1500P•Upgrade weld controller – Miyachi CT-•110B or CY-210B

VTS-SERIES SPECIFICATIONS VTS-30 VTS-40THERMAL RATING @ 50% D/C kVA 30 40MAX. SHORT CIRCUIT CURRENT kA 16 19ELECTRODE FORCE daN 185 185SECONDARY NO LOAD VOLTAGE V 6.4 7.5PRIMARY VOLTAGE AT 50Hz V 1~415 1~415SUPPLY AMPERAGE (DELAYED) A 50 70ELECTRODE TAPER – ISO 1:10 1:10ELECTRODES DIAMETER mm 20 20ELECTRODE PITCH mm 40 – 150mm 40 – 150mmCYLINDER STROKE mm 60 60DIMENSIONS cm 59x17x25 59x17x25WEIGHT kg 58 65

335

SE

CTIO

N T

HIR

TE

EN

– RE

SIS

TA

NC

E W

ELD

ING

EQ

UIP

ME

NT


DENKA EuroGun ROBOTIC SPOT WELDERS

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.

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

Custom-built fixture spot weld guns are also available from Denka.Denka butt welders are available to suit the specific needs of various industries.

336

SE

CTIO

N T

HIR

TE

EN

– R

ES

ISTA

NC

E W

ELD

ING

EQ

UIP

ME

NT


MIYACHI MICRO-SPOT WELDING SYSTEMS

Some of Miyachi’s precision power supplies and weld control systems.

Miyachi offers a complete micro-spot welding system, including power supply, controller, monitor and ultra-precision weld heads. 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, 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

A vast array of weld heads are available from Miyachi, including pneumatic, servo motor and hand-held.

Call today for your FREE comprehensive Miyachi Product Guide

337

SE

CTIO

N T

HIR

TE

EN

– RE

SIS

TA

NC

E W

ELD

ING

EQ

UIP

ME

NT

DENKA TX-SERIES MACHINE TRANSFORMERS

15kVA TX1525kVA TX2535kVA TX3550kVA TX5060kVA TX6080kVA TX80100kVA TX100125kVA TX125150kVA TX150200kVA TX200250kVA TX250300kVA TX300400kVA TX400FEATURES

Single-phase AC 415V transformers•Transformers rated at 50% duty cycle •to AS, DIN & ISO normsDesigned to handle high volume •usageFully water-cooled secondary •windingsHeavy-duty laminations and frame •High purity copper used on primary •and secondary windingsIntegral thermal overload switch•Dimensions meet ISO norms, for easy •interchangability Transformers comply to AS2799•Two year warranty •Made in Spain, Italy and USA• DENKA

TC-SERIES SUSPENDED TRANSFORMERS

100kVA TC100150kVA TC150200kVA TC200FEATURES

High secondary voltage •Use with suspended spot welders or •large secondary circuit

Single-phase AC 415V transformers•Transformers rated at 50% duty cycle •to AS, DIN & ISO normsDesigned to handle high volume •usageFully water-cooled secondary windings•Heavy-duty laminations and frame •High purity copper used on primary •and secondary windingsIntegral thermal overload switch•Transformers comply to AS2799•Two year warranty •Made in Spain•

SPECIFICATIONSSee table below. OPTIONS

Secondary pad lugs for connection to •kickless cableSuspension kit, for suspending •transformerWater manifold system•Air supply system•

TRANSfORMERS

Model kVA @ 50% Package U1N V20 LPM kg Length mmTX-15 15 A 1~415VAC 3.4 4 25 250TX-25 25 A 1~415VAC 4.2 4 28 315TX-35 35 A 1~415VAC 4.9 6 32 340TX-50 50 B 1~415VAC 6.3 6 60 506TX-60 60 C 1~415VAC 6.0 6 65 410TX-80 80 C 1~415VAC 6.7 6 70 450TX-100 100 D 1~415VAC 9.0 8 75 564TX-125 125 D 1~415VAC 11.0 8 85 638TX-150 150 C 1~415VAC 9.5 8 115 560TX-200 200 E 1~415VAC 10.1 8 200 485TX-250 250 E 1~415VAC 12.2 12 270 515TX-300 300 E 1~415VAC 13.1 12 280 550TX-400 400 E 1~415VAC 13.6 12 335 690

Model kVA @ 50%

Package U1N V20 LPM kg Length mm

TC-100 100 F 1~415VAC 18.0 8 35 564TC-150 150 F 1~415VAC 20.0 8 110 560TC-200 200 F 1~415VAC 22.0 8 170 485

338

SE

CTIO

N T

HIR

TE

EN

– R

ES

ISTA

NC

E W

ELD

ING

EQ

UIP

ME

NT DENKA ISO-SERIES AC ROBOT

TRANSFORMERS

32kVA ISO3236kVA ISO3648kVA ISO4854kVA ISO5461kVA ISO6176kVA ISO76103kVA ISO103FEATURES

Transformers conform to ISO10656 •normsLightweight, compact and powerful•Use with robot guns, suspended •welders, fixture welders and custom weldersSingle-phase AC 415V transformers•Transformers rated at 50% duty cycle •to AS, DIN & ISO normsDesigned to handle high volume usage•Fully water-cooled secondary •windingsHigh purity copper used on primary •and secondary windingsIntegral thermal overload switch•Transformers comply to AS2799•Two year warranty •Made in Spain•

OPTIONSTransformers available in ISO-K and •ISO-X configurationRear terminal enclosure•Secondary terminal right angle •brackets

DENKA MFDC-SERIES DC INVERTER ROBOT TRANSFORMERS

56kVA MFDC5675kVA MFDC75100kVA MFDC100150kVA MFDC150250kVA MFDC250FEATURES

Transformers conform to all ISO and •DIN normsFor medium frequency DC control •systemsLightweight, compact and powerful•Use with robot guns, suspended •welders, fixture welders and custom weldersSingle-phase AC 415V transformers•Transformers rated at 50% duty cycle •Designed to handle high volume usage•Fully water-cooled secondary •windingsHigh purity copper used on primary •and secondary windingsIntegral thermal overload switch•Transformers comply to AS2799•Two year warranty •Made in Spain & India•

OPTIONSOther configurations available on •requestRear terminal enclosure•Secondary terminal right angle •brackets

TRANSfORMERS

Complete suspended welding transformer with weld controller, air & water systems and gun hanging frame

339

SE

CTIO

N T

HIR

TE

EN

– RE

SIS

TA

NC

E W

ELD

ING

EQ

UIP

ME

NT

DENKA S1 ANALOGUE WELD CONTROLLER

1~240V S12401~415V S1415For 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.FEATURES

Simple analogue control system•Incorporates synchronous, •microprocessor technologyProgrammable WELD POWER and •WELD TIMEWill work on most single phase 50Hz •resistance welders with a thyristorUse with manual or pneumatic •operation Complies with AS2799•One year warranty •Made in Italy•

SPECIFICATIONSSee table ‘CONTROL TYPE’ over page.

DENKA PX1500 DIGITAL WELD CONTROLLER

1~240V PX15241~415V PX1541The 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.

FEATURESDigital synchronous microprocessor-•based control technologyWorks with most SCR and thyristor •systemsEleven programmable parameters •including pulsation welding, upslope and repeatCan be configured for either 240V or •415VUse with manual or pneumatic •operation Various output signals available to •integrate with other control devicesUses a current transformer to detect •current signalDoes not require separate power supply•Complies with AS2799•One year warranty •Made in Italy•

SPECIFICATIONSSee table ‘CONTROL TYPE’ over page.

DENKA PX1500P DIGITAL WELD CONTROLLER

1~240V PP15241~415V PP1541The 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

CT-110 CT110B0008CY-210 CY210C0008The 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•

Programmable upper and lower limits •for accurate monitoringThree separate weld current settings•Mulitple impulse welding•Can monitor either primary or •secondary currentClear, simple display of welding •informationView programmed and actual •information togetherIntegrated conduction angle monitor•Visual and audible alarm signal for •bad and suspect weldsThree different sorts of counters for •batching & quality controlSelf diagnostics for controller •problemsAutomatic electrode wear •compensation current step-up controlSeveral input and output contacts for •integrating with other processesVarious toroidal coil shapes & sizes •availableRequires separate 240VAC power •supplyOne year warranty • Made in Japan•

SPECIFICATIONSSee table ‘CONTROL TYPE’ over page.OPTIONS

Miyachi MB-400L toroidal coil 400mm •longMiyachi MB-800L toroidal coil 800mm •longMiyachi MB-500-15 toroidal coil •500mm diameterMiyachi MB-60E toroidal coil 60mm •diameterDenka 15 position switch – for remote •weld schedule setting

RESISTANCE WELDING CONTROL SYSTEMS

340

SE

CTIO

N T

HIR

TE

EN

– R

ES

ISTA

NC

E W

ELD

ING

EQ

UIP

ME

NT


DENKA S1DENKA PX1500

DENKA PX1500P

MIYACHI CT-110

MIYACHI CY-210

SERRATRON 100

CONTROL TYPE

SYNCHRONOUS 3 3 3

CONSTANT CURRENT 3 3 3

VOLTAGE FLUCUATION COMPENSATION 3 3 3

MEASURE PRIMARY POWER 3 3 3

MEASURE SECONDARY POWER 3 3 3 3 3 3

WELDING SCHEDULE PARAMETERS

SQUEEZE (TIME) 3 3 3 3 3

UPSLOPE (TIME) 3 3 3

WELD 1 (TIME) 3 3 3 3 3 3

WELD 1 (POWER) 3 3 3 3 3 3

COOL 1 (TIME) 3 3 3 3 3

WELD 2 (TIME) 3 3 3

WELD 2 (POWER) 3 3 3

COOL 2 (TIME) 3 3 3

WELD 3 (TIME) 3 3 3

WELD 3 (POWER) 3 3 3

DOWNSLOPE (TIME) 3 3 3

HOLD (TIME) 3 3 3 3 3

OFF (TIME) 3 3 3 3 3

PULSATION 3 3 3 3 3

REPEAT 3 3 3

MONITORING FUNCTIONS

MONITOR WELDING CURRENT 3 3 3

MONITOR CONDUCTION ANGLE 3 3 3

ERROR ALARM FOR BAD WELDS 3 3 3

PROGRAM ERROR TOLERANCE LEVEL 3 3 3

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

WELDING SCHEDULES 1 1 9 15 15 127

MEMORY SETTING FORM DIGITAL DIGITAL DIGITAL BINARY BINARY BINARY

SET FROM REMOTE LOCATION 3 3 3

COUNTER FUNCTIONS

TOTAL NUMBER OF WELDS 3 3 3

NUMBER OF WELDS PER PART 3 3 3

NUMBER OF PARTS 3 3 3

ADDITIONAL COUNTERS, FLIP-FLOPS, TIMERS 3

341

SE

CTIO

N T

HIR

TE

EN

– RE

SIS

TA

NC

E W

ELD

ING

EQ

UIP

ME

NT

DENKA S1DENKA PX1500

DENKA PX1500P

MIYACHI CT-110

MIYACHI CY-210

SERRATRON 100

PNEUMATIC CYLINDER CONTROL

SOLENOID VALVE VOLTAGE 24VDC 24VDC 24VDC 240VAC 240VAC 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

THYRISTOR DRIVER INCLUDED 3 3 3 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

CONTROLLER SPECIFICATIONS

CONTROLLER POWER 240V/415V 240V/415V 240V/415V 240V 240V 24VDC

DIMENSIONS W - D - H (mm) 110-250-355 355-250-110 62-182-295

WEIGHT 4.5KG 4.5KG 2.0KG


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 welder, by means of a toroidal coil. The signal is then transformed into the RMS effective value using the following formula:

RMS=

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”!

342

SE

CTIO

N T

HIR

TE

EN

– R

ES

ISTA

NC

E W

ELD

ING

EQ

UIP

ME

NT


343

SE

CTIO

N T

HIR

TE

EN

– RE

SIS

TA

NC

E W

ELD

ING

EQ

UIP

ME

NT

SERRATRON 100 WELD CONTROLLER

SERRATRON 100 S100For 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 PLC-based 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 system127 weld schedule memories•Full PLC system with embedded •welding functionsIntegrates easily and seamlessly with •QA systems and protocolsWorks with AC and MFDC welders•Input data via hand-held programmer •or PC*Ethernet networking for centralised •programming up several controllersView programmed and actual •information togetherVarious counters, timers, flip-flops, etc •for aiding manufacturing processesComprehensive electrode wear •compensation system

Accommodates analogue proportional •valve and load cellNumerous error and warning output •signalsOptional modules for field buses and •servo motor controlComes standard with 32 I/O – •expandable up to 516 I/ORequires separate 24VDC power •supplyTwo year warranty • Made in Spain•

* Optional software requiredSPECIFICATIONSSee table ‘CONTROL TYPE’ previous pages.OPTIONS

Serratron TP-10 hand-held •programming unitSerratron UPT-8A HMI panel•Serratron MES-32 I/O expansion unit •(additional 32 I/O)Serratron BCF-06 toroidal coil 60mm •diameterSerratron BCF-12 toroidal coil 120mm •diameterSerratron BCF-18 toroidal coil 180mm •diameterSerratron ‘CPC-Connect’ •programming softwareSerratron ‘DeviceNet’ PCB•Serratron ‘ProfiBus’ PCB•Serratron ‘Interbus’ PCB•

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 •SerratronThyristor module – water-cooled or •air-cooledCompliant mains ON/OFF disconnect •switchEmergency stop system•Safety relays•

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 •

A compact but complex Denka control cabinet incorporating a Serratron 100 controller.

High amperage Denka control cabinets with Miyachi CY-210 controller and full AS4024.1 compliant safety system.

A basic version of the Denka control cabinet with the PX1500 controller.Quality Denka TC-Series control cabinets can be retrofitted to most resistance welding systems.


344

SE

CTIO

N T

HIR

TE

EN

– R

ES

ISTA

NC

E W

ELD

ING

EQ

UIP

ME

NT

WATER COOLING SYSTEMS

HK-250 HK-600 HK-750 HK-1000 HK-2000 HK-3000 HK-4000 HK-5000Cooling capacity kWH 1 2 3 4.3 5.8 8.7 11.6 14.5

BTU 3300 6700 10000 15000 20000 30000 40000 50000Water temp °C 10~30 10~30 10~30 10~30 10~30 10~30 10~30 10~30Ambient °C 10~40 10~40 10~40 10~40 10~40 10~40 10~40 10~40Water cut off °C 45 45 45 45 45 45 45 45Primary 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 22Heat dissipation --- Air cooled Air cooled Air cooled Air cooled Air cooled Air cooled Air cooled Air cooledPump kW 0.7 0.7 0.7 0.7 0.7 1.5 1.5 1.5Maximum flow LPM 40 40 40 40 40 120 120 120Max. lift (head) m 28 28 28 28 28 36 36 36Inlet/outlet BSP ½ ¾ ¾ ¾ ¾ 1 1 ¼ 1 ¼Tank capacity l 16 43 55 80 80 127 227 227Dimensions mm 370x450

x950425x455 x1110

490x500 x1125

550x620x1205 710x750 x1500

885x885x1885

DENKA HK-SERIES REFRIGERATED WATER COOLING SYSTEMS

1kWH HK-2502kWH HK-6003kWH HK-7504.3kWH HK-10005.8kWH HK-20008.7kWH HK-300011.6kWH HK-400014.5kWH HK-5000Efficient, high-flow water cooling for high amperage welding applications is absolutely essential for maximum productivity and protection of capital equipment. The Denka HK-Series refrigerated water coolers bring together eco-friendly R407C refrigerant, precision high volume pumps and digital temperature control technology

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.FEATURES

Refrigerated water cooling system •with integrated recirculating pumpDigital water temperature control•Uses eco-friendly R407C refrigerant•Highly efficient radiators and cooling •fansEasy to clean air inlet filters•Compact size – minimum footprint on •floorspace

Built-in water storage tank with water •level gaugePrimary power 3~415V 50Hz•One year warranty • Made in Taiwan•

SPECIFICATIONSSee table below.OPTIONS

Denka water filtration systemDenka water flow switchDenka water flow monitor

345

SE

CTIO

N T

HIR

TE

EN

– RE

SIS

TA

NC

E W

ELD

ING

EQ

UIP

ME

NT

CONDUCTORS, ELECTRODES AND ADAPTORS

RESISTANCE WELDING CONDUCTORS

Denka high-quality water-cooled cables.

Denka long-lasting ‘kickless’ cables

Denka heavy-duty air-cooled cables

Laminated shunts manufactured to your exact requirements.

Electrodes of all shapes an sizes to the following RWMA, ISO and Morse tapers.

A huge range of electrode holders, welding arms and adaptors are available to suit your needs.

Call us today for dimensions and specifications of our vast electrodes range.

High quality seam welding wheels manufactured to suit your needs.

346

SE

CTIO

N T

HIR

TE

EN

– R

ES

ISTA

NC

E W

ELD

ING

EQ

UIP

ME

NT

WELD ANALYSIS

RESISTANCE WELDING CHECKERS & MONITORS

The Miyachi MM-315A is a handy, simple weld checker for obtaining quick confirmation of weld current and weld cycles.

Compact, light, exact and fast are the outstanding attributes of the Miyachi MM-122A weld checker, which monitors weld current and weld time against preset limits and outputs an alarm signal for failed or suspicious welds.

Miyachi MM-326B full function weld checker with built-in printer, capable of simultaneously measuring and monitoring weld current, weld voltage and weld cycles.

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.

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. It will also help the visual appearance of your welds!

347

SE

CTIO

N T

HIR

TE

EN

– RE

SIS

TA

NC

E W

ELD

ING

EQ

UIP

ME

NT

RESISTANCE WELDING ELECTRODES & ADAPTORS

Part Number

348

SE

CTIO

N T

HIR

TE

EN

– R

ES

ISTA

NC

E W

ELD

ING

EQ

UIP

ME

NT


Part Number

349

SE

CTIO

N T

HIR

TE

EN

– RE

SIS

TA

NC

E W

ELD

ING

EQ

UIP

ME

NT


Part Number

350

SE

CTIO

N T

HIR

TE

EN

– R

ES

ISTA

NC

E W

ELD

ING

EQ

UIP

ME

NT


Part Number

351

SE

CTIO

N T

HIR

TE

EN

– RE

SIS

TA

NC

E W

ELD

ING

EQ

UIP

ME

NT


Part Number

352

SE

CTIO

N T

HIR

TE

EN

– R

ES

ISTA

NC

E W

ELD

ING

EQ

UIP

ME

NT


Part Number

353

SE

CTIO

N T

HIR

TE

EN

– RE

SIS

TA

NC

E W

ELD

ING

EQ

UIP

ME

NT


Part Number

354

SE

CTIO

N T

HIR

TE

EN

– R

ES

ISTA

NC

E W

ELD

ING

EQ

UIP

ME

NT


Part Number

355

SE

CTIO

N T

HIR

TE

EN

– RE

SIS

TA

NC

E W

ELD

ING

EQ

UIP

ME

NT


Part Number

356

SE

CTIO

N T

HIR

TE

EN

– R

ES

ISTA

NC

E W

ELD

ING

EQ

UIP

ME

NT


Part Number

357

SE

CTIO

N T

HIR

TE

EN

– RE

SIS

TA

NC

E W

ELD

ING

EQ

UIP

ME

NT


Part Number

358

SE

CTIO

N T

HIR

TE

EN

– R

ES

ISTA

NC

E W

ELD

ING

EQ

UIP

ME

NT


Part Number

359

SE

CTIO

N T

HIR

TE

EN

– RE

SIS

TA

NC

E W

ELD

ING

EQ

UIP

ME

NT


Part Number

360

SE

CTIO

N T

HIR

TE

EN

– R

ES

ISTA

NC

E W

ELD

ING

EQ

UIP

ME

NT


Part Number

361

SE

CTIO

N T

HIR

TE

EN

– RE

SIS

TA

NC

E W

ELD

ING

EQ

UIP

ME

NT


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.












5 221520 Electrode adaptor 20mm-12mm


362

SE

CTIO

N T

HIR

TE

EN

– R

ES

ISTA

NC

E W

ELD

ING

EQ

UIP

ME

NT



1 243515 30mm upper arm adaptor 90 deg. suits VSX

2 243535 30mm lower arm adaptor 90 deg. suits VSX









1 243530 22mm lower arm adaptor 90 deg. suits VSR

2 243540 22mm lower arm adaptor 15 deg. suits VSR

363

SE

CTIO

N T

HIR

TE

EN

– RE

SIS

TA

NC

E W

ELD

ING

EQ

UIP

ME

NT

HEAvY-DUTY OffSET WATER COOLED HOLDER


1 243310 Offset electrode holder 20mm dia. x 70mm long




364

SE

CTIO

N T

HIR

TE

EN

– R

ES

ISTA

NC

E W

ELD

ING

EQ

UIP

ME

NT

13 resistance welding

Documents