USER`S MANUAL
Contents
1. HIGH SPEED AUTO TIP DRESSER CDK R 400 USER S MANUAL Please read this manual before using KYOKUTOH S High Speed Tip Dresser CDK R 400 KK KYOKUTOH CO LTD G E Schmidt Inc founded in 1960 is a manufacturer and international distributor of resistance welding machines and components throughout North America We specialize in pedestal welders electrodes tip dressers quality assurance systems and nut bolt loading systems 11236 Williamson Rd Cincinnati OH 45241 Tel 513 489 5130 Fax 513 489 5132 sales geschmidt com geschmidt com Cushway Schmidt Ltd is a UK based distributor providing full system solutions for the resistance welding industry throughout Europe from quality copper consumables to welders and peripheral machines Unit 1 Hastingwood Business Centre Hastingwood Harlow CM17 9 Tel 44 0 1992 713 749 Fax 44 0 1279 436 318 sales cushway schmidt com cushway schmidt co uk ATTENTION TO SAFETY X Please be sure to read ATTENTION TO SAFETY before using CDK R This product is intended only for the dressing of specified electrodes This product is not to be used in any manner other than that which is specified within We will not be held responsible for damage or injury caused as a result of misuse of this product SYMBOLES X This following symbols Caution and Notice are used indicate possible hazards and to prevent their o2. T N N N N Amount mm Number of Dressing 1 sec As seen on above even after 30 000 dressing cycles consistency of our cutter virtually unchanged however cutter life span differs from the condition of cap tip As for average example we set exchange timing when the dressing amount is half compare to the very beginning amount Example Tip material of Electrode Cr Cu new one Type of Electrode 1623 A RR 6 8R Type of Cutter KTW 12T RR 6 8R Number of Revolution 272 rpm Gun Force 1 960 N 200Kgf The Dressing Conditions Dresser Revolution Gun Pressure 1 sec gt Gun release Dresser stop The measuring of one time one second The tip length before dressing The tip length after dressing Above example resulted in the fact that average dressing quantity is 0 2mm for 1 second It means when the dressing quantity gets less than 0 1 mm is the time to change the cutter We used new cap tips for the experiment however how fast cap tips get short actually depends on the situation such as the kind and thickness of steel sheet to weld and the amount of electric current It sometimes happens that the point of cap tip gets crushed and alloyed and extraordinary hard Therefore the life length of cutters is not always same Changing the dressing condition might be effective to make the cutter life longer The most important thing is to choose proper cutter and proper dressing time for each
3. 13 Parts List NO Parts Name Type or Size 1 Tip Dresser CDK R 400 1 2 Terminal Box Include Motor 1 2 Output Bearing 6809DD 2 4 Shaft Plate CDK R 001 2 5 Spring for Vertical Type CDK R 002 2 Spring for Horizontal Type CDK R 003 2 6 Upper Spring CDK R 003 2 T Shaft CDK R 004 2 8 Slide Bearing LM20LUU 2 9 C Ring for Bearing For 32 Axis 4 10 Flat Washer For M20 4 11 Cap Screw M8X25 4 12 Rotation Sensor Optional Extras E2E X1 M5 1 14 How to Change the Cutter 1 Remove M3 screws from the cutter holder 2 Remove the cutter holder from the dresser 3 To remove the cutter from the cutter holder loosen the M3 torque screw With a torque wrench T 10 15 4 Replace a new cutter Confirm cutter is replaced in the proper direction Please install the angle narrows on the side where touches the holder Inscription faced up Recommended torque for M3 screw is to 10 12kgf cm Cutter Holder Cutter Inscription side OK Cutter Holder Cutter NG 5 To install the cutter holder to the dresser please do the reverse order from 1 to 2 16 Mounting arrangement of the Rotation Sensor Optional Extras 1 Remove the nameplate 4 4 2 Remove the M5 panhead screw and install the Rotation Sensor 3 Replace the nameplate 4 Following the wir
4. Release the gun while dresser is revolving and then stop the dresser shapes of the cutter and the cap tips are not fitting Check the cutter shape and replace it if necessary cutter has been damaged Replace the cutter and check the gun pressure Thescrew which fastens the cutter to the holder is loosen Tighten the screw The tip diameter is not at The cap tip has got too short the center or the designated Replace the cap tip to new one location Dressing position is not proper Re do teaching The point of the cap tip is bolts that fasten the motor and the gear box are loosen an oval not a circle Tighten the bolts The bolts that fasten the dresser to the stand are loosen Tighten the bolts Dressing does not complete cutting capability of the cutter has deteriorated or the in the set time cutter has been damaged Replace the cutter and check the gun pressure Dressing time is too short Set the dressing time to the cap tip that has been crushed most The cap tip 18 soften after welding the point of the cap tip gets widened Increase the dressing pressure gradually according to the time of dressing a cap tip when it is with gun voltage valve lt Remarks gt Please be sure the switch is off when you are checking or replacing parts or the cutter When the dresser is out of order please contact us immediately Do
5. Above examples are rough indications for the default If you find cap tips are dressed not enough or too much while using please adjust the setting to your cap tips Average dressing cycle of KTW cutters after 200 welds is 1 to 2 seconds We have various types of cutters with different shapes and different metallic finishing for optimum dressing So even if you changed the length of dressing time or the amount of dressing pressure and still couldn t get better result please contact us Timing Chart KTW type Cutter Only clockwise rotation 1 3 sec Gun Pressure OFF ON Dresser Rotation OFF Start motor to clockwise before Gun press Set the dressing time according to your tip condition Approximately 1 3 sec Confirm rotate direction clockwise e e o To finish dressing release the gun pressure while dresser is revolving Before operating make sure that the forms of cutter and tip are fitting When dressing is finished and small scrapes are left on the cap tips both upper and lower tips should be touched with the cutter of revolving dresser before returning to original position Cutter Replacement Duration data of KTW Cutter 25 30 000 0 5 Upper 0 4 Lower 0 3 0 2 0 1 0 0 L L L L L L 1 1 1 1 1 LO N e e e e e e e e e e e e e e e e e e e e e e e e e e e e N 22 co N
6. dresser For further information please request the cutter instruction manual 10 Procedure for Selecting the Cutter 4XR8 4XR8 KTW 10 KTWH 10 5XRs KTW1IT KTWH H 6XR8 66XRS KTW 12T KTWH 12 8XRS 8XRS KTW 3T KTWH 13 EN B p 19 Ses V EH EN pper m gt 7 NS ye C3 R65 65 KTWST KIWHHS Y Y R8 R8 KTW 6T KTWH 16 7 de L MAX150 Upper hi E 6 R40 arn Lower 11 Lower Upper 2 Lower A x 8 Upper NG gt 12 6 8 16 KTW 23 J KTWH 23 6 8 13 KTW 24 24 ETE 30 KTW 01 01 65X30 5 30 KTW 02 KTWH 02 66X30 6 X30 KTW 03 KTWH 03 8 X 30 8 X30 KTW 04 KTWH 04 4 45 05 KTWH 05 95 45 5 457 KTW 06T KTWH 06 66x45 6X45 KTW 07T KTWH 07 8 X45 8 X45 KTW 08T KTWH 08 Drawing eel Zu elo
7. not take the dresser apart It would not be able to repair if you disassemble it 21 Consumption Parts List Outsourced Product Bearing for tip dresser Type 6809DD 6809DD equivalent Replacement Qty 2pcs Replacement cycle When total dressing time gets 500 hours or 6 months Parts List P14 Figure No Output gear with bearing for KTW cutter Type 4 006 00 TDR E P 006 2 equivalent Replacement Qty 1pc Bearing replacement cycle When total dressing time gets 500 hours or 6 months Gear replacement cycle When total dressing time gets 2000 hours or 2 years Cutter C Type Reference to P11 P12 Replacement Qty 1 pc Replacement cycle Total dressing time 20000sec O Cutter holder Type Reference to P11 P12 Replacement Qty 1 pc Replacement cycle Total dressing time 100000sec The bearing replacement cycle is 6 months Without operation for a long time the grease might resolve inside the bearing In this case please lubricate by a grease spray and the like before operation 22 Periodic Maintenance Maintenance place How to maintenance Remove the nameplate Remove 1 8 screw from the upper side of the gearbox Install grease nipple To the gearbox grease supply Supply the greased with grease gun Grease is MPG 2 equivalent One time per 6 months 20g supply Prevent from dust in
8. the dresser stop or damage the cutter and holder depending on the shape of cap tips In this case please reduce the dressing pressure If it is impossible to reduce the pressure please contact us We would offer you some other special cutters It is necessary to reduce dressing pressure when it is more than 2 450N Select a cutter well suited to the tip shape For other specifications for the CDK R please contact our sales department Figure 1 D Concentricity guide required If this is over 90mm 16 70mm 13 C Maximum 15 degrees is acceptable B To avoid interference with gearbox 50mm required Figure 2 A Tip opening needs over 30mm E The special cutter should be used for the shorter tips Cautions for Positioning the Dresser 1 The tip should be set parallel to floating mechanism See figure 3 For X guns set the dressing location to the pressurization location See figure 4 For C guns set the dressing location even level with pressurization location otherwise it might cause poor dressing or damage gears and bearings Although the floating mechanism is installed in dresser we also recommend that you locate the dressing position as closely as possible Dressing horizontally C Guns vertically set with equalizing mechanism is difficult to keep weight balance of springs and pressurization point could easily change So in this case please make sure of pressurization p
9. IFU TC 2 equivalent 10 Do not wire when the switch is on Be sure to turn off the switch The operator must have the certification approved as an electrical worker Please take the cable s change shrinkages or slack into consideration when wiring because the floating mechanism is installed on K type dresser Because the floating mechanism is installed make sure the terminal bolt is tightened We recommend that you make a circle with cable beside the dresser in order to absorb the vibration Please wire power cord and thermostat fuse output cord separately for your security When using thermostat fuse make the side hole on the terminal box of dresser When not using the installed thermostat fuse please set the overloading protector beside the dresser Cutter Capacity and Dressing Time Graph of Dressing pressure and Dressing Amount 0 35 0 3 Tip material of Electrode CuCr Tip of Electrode 6 8R 16 0 25 of Cutter KTW 12T 02 Number of Revolution 272 rpm 60Hz 0 15 0 1 0 05 0 1 1 50 100 150 200 250 Amount mm Dressing pressure kgf Estimated Dressing Time Dressing time 1 sec Please adjust dressing time and pressure according to above graph Example 1 to dress 0 1mm Dressing time 1 sec Dressing pressure 110kgf Example 2 to dress 0 1mm Dressing time 0 7 sec Dressing pressure 150 kef
10. ation procedures must be followed with the electric construction standard and also make sure that it is protected from cooling water and spatter Be certain dresser is grounded Make sure dresser is installed in a location with no spatter and cooling water directly Confirm the forms of the cutter and cap tips once again before robot teaching Confirm that cutter and holder are securely fastened Confirm the rotation direction of the KTW cutter is clockwise Make sure there is neither interference to the dresser except for the cap tips nor any allophone when robot teaching When the gun is pressurized make sure that the electric current is not applied and pressure 1s within the setting range Confirm the quality of the dressed tip Be sure that the shank is stable and not shaking during dressing The causes of the failure in dressing gt The gun is not released while the dresser is revolving Scrapes are left on the cap tips The pressure is too high or too low The forms of the cap tip and the cutter are not fitting The dressing time is too short The teaching point differs from the dressing one VV VV ON The shape of used cap tips differs from new ones too much the cap tips can t get dressed properly with any other reason please contact us 19 Abnormality and How to Repair Dresser does not rotate The power switch is OFF Check the power source Wire is cut off or poor contact Ch
11. case of supply 23
12. ccurrence Be careful to follow directions as specified as an error could lead to possible injury or A Caution death Be careful to follow direction as specified as an error could lead to malfunction and N Notice serious damage The following symbols are explained below N This symbol indicates operations that should not be done This symbol indicates operation that should be done X After reading please the manual to the place where you can check the manual Caution Absolutely never disassemble reconfigure this machine or its parts O This could result in operation malfunction ignition or injury Do not insert a finger hand into gear opening while in operation O This will result in serious injury Avoid as much contact with water as possible O This could result in operation malfunction short electrical shock or ignition Do not insert metallic articles such as a pins or needles in gear or terminal box opening O This could result in operation malfunction or electrical shock Be sure to switch off the power supply when removing or repairing wiring O Will cause electrical shock Be sure that spatter does cover any wiring O This will prevent the melting of wire membrane and a potential shock hazard Or 2 2 Remove the spatter which covers the tip dresser periodically O Spatter build up can cause operation malfunction o
13. e IEC STANDARD Features IP54 APPROVED 1 Dress upper and lower tips simultaneously therefore dressing time is reduced 2 Our KTW cutter enables cap tips to be dressed with the pressure between 1078N 110kgf and 1960N 200kgf furthermore our cutter for high pressure gun makes it possible to use higher pressure between 1960N 200kgf and 2450N 250kgf 3 Floating mechanism greatly reduces stress on welding gun and dresser 4 KTW cutter reduces dressing time Criteria for Dressing Guns Applicable to both X guns and C guns see figure 1 and 2 If A dimension is less than 30mm this dresser is not suitable because it may contact gearbox Ref Some special cutters require up to 35 mm If B dimension is less than 50mm this dresser is not suitable because it may interfere with gearbox Cap tip with C angle up to 15 degrees can be dressed When using the eccentric tips or guns with angle please contact us When the length of shank of D dimension is long contact us for solution The base tip and insert electrode requires a particular cutter E dimension We will customize the cutter if you could provide us the gun and tip drawings Recommended dressing force is between 1 078N and 1 470N Dress up to 110kgf to 150kgf When dressing pressure is less than 1 078N there is possibility of dressing defective because of dressing amount reduction dressing pressure from 1470N to 2450N might make
14. eck the terminal box and control panel The thermostat fuse of motor side is working Check the motor and reset it after cooling down The gun pressure is higher than specified by our company Set gun pressure under 1960N 200kgf Motor is broken Need repair to replace the motor The shapes of the cutter and the cap tip are not fitting and cling each other Check the cutter shape and replace it if necessary The motor is running but Gear in the gear box is broken the cutter does not rotate Need repair to replace the gear The diameter of Dressing time is too short dressed cap tip is different Set the dressing time to the tip that has been from the setting crushed most The cutting capability of the cutter has deteriorated or the cutter has been damaged Replace the cutter and check the gun pressure Dressing point is not proper Re do teaching cutter is not suitable for the cap tip Check the cutter shape and replace it if necessary Gear in the gear box is broken Need repair to replace the gear Thescrew which fastens the cutter to the holder is loosen Tighten the screw Abnormal sound during Dressing point is not proper dressing Re do teaching cutter has been damaged Replace the cutter and check the gun pressure 20 Dresser leaves burr on the The control method is not proper cap tip
15. ing color wire the sensor Brown 24V Blue OV Black Signal wire Before wiring please make sure of the type of your sensor NPN or PNP 17 Timing Chart for the Rotation Sensor 0 1 sec ON Rotation Sensor OFF Rotation of ON Dresser OFF While the dresser is revolving the sensor sends out signals 1 pulse 0 1 sec We recommend that more than 0 5 sec input or cutting of signal including initiation delay should be considered as abnormal rotation Example Ladder Program for the Rotation Sensor PLC Robot Input side PLC Robot Output side 1000 Startup Signal of Dresser 1500 Abnormal 1000 Signal of Rotation Sensor Rotation R1000 R1001 1 TI Dresser Start Signal of Rotation Sensor Signal Input R1000 R1001 T2 Dresser Start Signal of Rotation Sensor Signal disconnect T1 R1500 Signal Input Abnormal Rotation T2 Signal disconnect 5 0 5 sec 18 10 11 12 Cautions and Confirmation before the Operation Confirm the specification again Voltage option etc Make sure of the conformity between the forms of cutter and cap tips Install the dresser in the place where the operator can not touch it directly during the operation Make sure dresser and stand bolts are tightened firmly Also confirm stand is fixed securely to the floor When connecting wires to the dresser oper
16. oint very well when you teach robots See figure 4 and 5 Figure 3 Figure 4 Figure 5 Cautions for Positioning the Dresser 2 Perpendicular to Floor Horizontal to Floor Upper Lower Perpendicular to Floor CDK R T Horizontally CDK R Y DSpring Spring CDK R 003 CDK R 003 Spring Spring CDK R 002 CDK R 003 Because spring takes dresser weight in the Upper 2 use the spring Full length which is 20mm longer than lower Use same spring for 3 and 4 When it is installed upside down the spring of the D 2 must be replaced and used When you place order please let us know installation method Perpendicular to Floor or Horizontal to Floor If not we would supply you standard type Vertical mounting Wiring to the Dresser THERMOSTAT FUSE OUTPUT Terminal Box Circuit Diagram of The Motor LID Dresser CDK E ERR TE 71 U v W 404 1 1 SEAL CONNECTOR Use over 2sq power wire AWG Gauge NO14 equivalent Strip coating and wire directly Recommended stripping length is 10 mm If it is difficult to wire use pin terminal NICH
17. ong magnetic forces and heat can be dangerous and possibly cause malfunctions or ignition Do not use rotation direction beside set O This could cause trouble and accidents INDEX CDK R Tip Dresser Capabilities Criteria for Dressing Guns Cautions for Positioning the Dresser 1 Cautions for Positioning the Dresser 2 Wiring to the Dresser Cutter Capacity and Dressing Time Timing Chart Cutter Replacement Procedure for Selecting the Cutter Drawing Parts List How to Change the Cutter Mounting arrangement ofthe Rotation Sensor Optional Extras Timing Chart for the Rotation Sensor Example Ladder Program for the Rotation Sensor Cautions and Confirmation before the Operation Abnormality and How to Repair Consumption Parts List Periodic Maintenance 10 13 14 15 17 18 18 19 20 22 23 CDK R Tip Dresser Capability Output Mass Model Power Freq Current Rpm Torque Rad Rated Time Ke 227 AC380V 50Hz 24A 34 6 N m rpm 50Hz 24 228 343Nm 400 rpm CDR R 60Hz 22A 277 ogaN 2 4 0 0 7 rpm 2 N M deu 1k Mead ACAISV 50 24 230 34 1 continuous 17 8 rpm kg use time AC440V 60Hz 2 0A sin 28 0 N m 5minute 460 60Hz 20A 282 1278 CDK R rpm 400 c480v 60Hz 21 id 28 0 N m X Dresser motor and terminal box have protection structur
18. r ignition resulting in injury Do not use acidic or chlorine detergents for maintenance purposes O Poisonous gas may be generated from the detergents causing a possible health risk Remove any oil that may accumulate on the tip dresser O Spatter could cause ignition and possible Injury GOO 919 Do not use voltage other than that which is specified O Excess heat could cause operation malfunction and ignition Be sure wire from power supply is of correct capacity 10A lunit O Incorrect wiring could result in operation malfunction or ignition Use wiring of enough thickness 2 sq mm or more O Incorrect wiring could result in operation malfunction or ignition 22 Do not allow power supply wiring to become damaged O Wiring damage could result in operation malfunction and ignition A Notice Firmly fix tip dresser to stand O If the Tip Dresser is not fixed tightly in operation poor dressing and other problems could occur Be sure that the motor is not locked up O This could result in overheating and possible ignition 2 Do not use any cutter or holder other than that which 1s intended and specified O Use ofan unspecified cutter or holder could result in damage 22 Do not install near the thermal generation source of the welding machine O This could cause trouble and accidents Do not install between a welding machine and a transformer O Str
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