13 Resistance Welding

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 344
Conductors, Electrodes and Adaptors 345
Weld Analysis 346
Resistance Welding Electrodes & Adaptors 347
Heavy-duty Offset Water Cooled Holder 364
323
PEDESTAL RESISTANCE WELDERS

SECTION THIRTEEN – RESISTANCE WELDING EQUIPMENT
Thermal Rating At 50% Duty Cycle

BUYERS GUIDE 15 25 35 50 80 100 130 150 200 250 300
For the ideal balance between quality, Manual VRM- VRM- VRM-
reliability and price, the Denka V-Series Rocker Arm 15 25 35
resistance welders are the solution to Pneumatic VRP- VRP- VRP- VRP-
your manufacturing needs. Designed to Rocker Arm 15 25 35 50
meet the demanding nature of Europe’s Linear VLP- VLP- VLP-
production line environment, these Action Spot 35 50 80
welders are ideally suited to all levels of Projection VPP- VPP- VPP- VPP- VPP-
manufacturing, from precision, low- 80 100 150 200 300
volume spot welding through to high-
Seam VLS- VLS- VLS- VLS-
volume mass production applications.
80 100 130 250
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.
324
DENKA VRM-SERIES MANUAL 15kVA VRM15 SPECIFICATIONS

ROCKER-ARM SPOT WELDERS 25kVA VRM25 See table ‘VRM-SERIES
35kVA VRM35 SPECIFICATIONS’ opposite.
For simple operations requiring a manual OPTIONS
spot welding system, the Denka VRM- • Additional throat depth - extend to
Series of spot welders will suffice for all 600mm
applications ranging from low-volume • Additional throat depth - extend to
production through to training facilities 800mm
for apprentices. The simple Denka S1 • Low clearance lower arm – 400mm
analogue weld controller makes set-up • Low clearance lower arm – 600mm
fast and easy. • Low clearance lower arm – 800mm
• Ultra-low clearance lower arm –
FEATURES 400mm
• ‘Rocker’ motion of upper arm • Ultra-low clearance lower arm –
• Transformers rated at 50% duty cycle 600mm
to AS, DIN & ISO norms • Ultra-low clearance lower arm –
• Manual foot pedal operation 800mm
• Water-cooled transformer, arms, • Upgrade weld controller – PX1500
electrode holders and electrodes • Upgrade weld controller – PX1500P
• 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
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 VRM-15 VRM-25 VRM-35

THERMAL RATING @ 50% D/C kVA 15 25 35
MAX. SHORT CIRCUIT CURRENT kA 10.4 13.2 16.8
ELECTRODE FORCE daN 180 180 180
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
ELECTRODE TAPER – ISO 1:10 1:10 1:10
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
325
DENKA VRP-SERIES PNEUMATIC 15kVA VRP15 • Mains ON/OFF switch included

ROCKER-ARM SPOT WELDERS 25kVA VRP25 • Quality filter, regulator and lubricator
included
35kVA VRP35 • Fully enclosed footswitch with safety
50kVA VRP50 lever
The economical choice for general • High-alloy copper and brass
sheetmetal welding, the Denka VRP- conductors used throughout
Series offer versatility and quality at • Electrode taper Ø18mm 1:10
an affordable price. Capable of spot • Complies with AS2799
welding in low to medium production • Two year warranty
environments, these welders are highly • Made in Italy
popular with various industries including SPECIFICATIONS
ducting, refrigeration, metal cabinets, See table ‘VRP-SERIES
steel shelving and general sheetmetal SPECIFICATIONS’ below.
fabrication.
OPTIONS
FEATURES • Additional throat depth - extend to
• ‘Rocker’ motion of upper arm 600mm
• Transformers rated at 50% duty cycle • Additional throat depth - extend to
to AS, DIN & ISO norms 800mm
• Pneumatic cylinder operation via foot • Low clearance lower arm – 400mm
switch • Low clearance lower arm – 600mm
• Manual foot pedal operation • Low clearance lower arm – 800mm
• Water-cooled transformer, arms, • Ultra-low clearance lower arm –
electrode holders and electrodes 400mm
• Standard throat depth 400mm • Ultra-low clearance lower arm –
SEE OPTIONS BELOW FOR 600mm
ALTERNATIVES • Ultra-low clearance lower arm –
• Arms diameter 45mm 800mm
• Upper and lower electrode holders • Downgrade weld controller – S1
can be rotated and used at either 0° • Upgrade weld controller – PX1500P
or 15°
• Adjustable lower arm for variable
throat height
• Denka PX1500 digital synchronous
weld controller SEE OPTIONS
BELOW FOR ALTERNATIVES
VRP-SERIES SPECIFICATIONS VRP-15 VRP-25 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
ELECTRODE FORCE daN 250 250 250 250
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 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
326
DENKA VLP-SERIES LINEAR 35kVA VLP35 • Fully enclosed footswitch with safety

ACTION SPOT WELDERS 50kVA VLP50 lever
• Finger guard around moving parts on
80kVA VLP80 upper arm
For demanding, high-volume production • Adjustable lower arm for variable
applications, the Denka VLP-Series throat height
of pneumatic linear-action spot • High-alloy copper and brass
welders offer a multitude of tried and conductors used throughout
proven features, making it the spot • Electrode taper Ø18mm 1:10
welder of choice for many Australian • Reinforcing support on lower arm
manufacturers. A weld control system (optional on VLP-35)
to suit your needs can be fitted to the • Complies with AS2799
Denka VLP-Series spot welders from the • Two year warranty
range of controllers developed by Denka, • Made in Italy
Miyachi and Serratron. SPECIFICATIONS
FEATURES See table ‘VLP-SERIES
• Upper arm descends parallel to SPECIFICATIONS’ below.
lower arm – precise, accurate and
consistent OPTIONS
• Transformers rated at 50% duty cycle • Additional throat depth - extend to
to AS, DIN & ISO norms 630mm
• Pneumatic cylinder operation via foot • Additional throat depth - extend to
switch 830mm
• Water-cooled transformer, arms, • Low clearance lower arms – designed
electrode holders and electrodes to specific requirements
• Standard throat depth 430mm • Upgrade weld controller – PX1500P
SEE OPTIONS BELOW FOR • Upgrade weld controller – Miyachi CT-
ALTERNATIVES 110B or CY-210B
• Arms diameter 60mm (except VLP-80 • Upgrade weld controller – Serratron
has cast section arm) 100
• Can fit optional platens with T-slots • Upgrade pneumatic cylinder – double
to convert to projection welder SEE force
OPTIONS BELOW • Upgrade pneumatic cylinder –
• Denka PX1500 digital synchronous retractable two-stage
weld controller SEE OPTIONS • Optional reinforcing support on lower
BELOW FOR ALTERNATIVES arm
• Mains ON/OFF switch included • Optional platen for projection welding
• Quality filter, regulator and lubricator • Optional two-hand start system
included AS4024.1
• Heavy duty fabricated frame
VLP-SERIES SPECIFICATIONS VLP-35 VLP-50 VLP-80

ELECTRODE Diameter mm 18 18 18
THROAT DEPTH mm 430 430 430
THROAT HEIGHT mm 60-270 60-270 60-270
DIMENSIONS cm 106x30x143 106x30x143 105x52x175
WEIGHT kg 185 190 470
327
DENKA VPP-SERIES PROJECTION FEATURES SPECIFICATIONS

WELDERS • Large, precision-machined brass See table ‘VPP-SERIES

platen on upper and lower arms with SPECIFICATIONS’ below.
T-slots
• Transformers rated at 50% duty cycle OPTIONS
to AS, DIN & ISO norms • Additional throat depth - extend to
• Pneumatic cylinder can be operated 430mm (except VPP-80)
by foot switch or two-hand start • Additional throat depth - extend to
system – fitted standard with both 730mm
• Water-cooled transformer, arms, • Upgrade weld controller – PX1500P
electrode holders and electrodes • Upgrade weld controller – Miyachi CT-
• Generous throat depth – varies 110B or CY-210B
between models • Upgrade weld controller – Serratron
• Maximum distance between platens 100
495mm • Upgrade pneumatic cylinder –
• Solid, cast aluminium upper and lower retractable two-stage
arm (except VPP-80 has cast brass • Upgrade pneumatic cylinder – double
lower arm) force
80kVA VPP80 • Mains ON/OFF switch included
100kVA VPP100 • Quality filter, regulator and lubricator
included
150kVA VPP150 • Heavy duty fabricated frame
200kVA VPP200 • Fully enclosed footswitch with safety
300kVA VPP300 lever
• Finger guard around moving parts on
Designed and manufactured to meet upper arm
the most challenging projection welding • Adjustable lower arm for variable
applications, the Denka VPP-Series throat height
of projection welders are time-proven • High-alloy copper and brass
performers for virtually any application conductors used throughout
between 80kVA and 300kVA. A weld • Reinforcing support on lower arm
control system to suit your needs can • Can easily convert to spot welder with
be fitted to the Denka VLP-Series spot optional electrode holders
welders from the range of controllers • Complies with AS2799
developed by Denka, Miyachi and • Two year warranty
Serratron, and handy options such as • Made in Italy and Spain
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-300

THERMAL RATING @ 50% D/C kVA 80 100 150 200 300
MAX. SHORT CIRCUIT CURRENT kA 29.5 35.0 50 72.0 85.0
ELECTRODE FORCE 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
328
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 T-Series resistance welding

systems – offer flexibility and
adaptability to different applications
Denka J-Series spot and projection including rotary tables, robot cells,
welders – economical welders offering multi-head and nut welding. Conforms
minimal features for use in automotive to emerging DIN, CNOMO and
production lines, as specified by Asian RWMA requirements in high-volume
car manufacturers. Made in China production environments. Made in
and Taiwan. Spain and USA.
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.
329
Suspended spot welders
DENKA VSR-SERIES SUSPENDED • Fitted with S1 weld controller as standard SEE OPTIONS BELOW FOR
SPOT WELDERS 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
• Includes hose and cable set 5 metres long
• Made in Italy
* Water cooled transformer is optional on Denka VSR-4 spot welder.
SPECIFICATIONS
4kVA VSR4 See table ‘VSR-SERIES SPECIFICATIONS’ below.
6kVA VSR6 OPTIONS
• Arms set (incl. electrode holders) 125mm long 0°
Simple, compact, lightweight and fast are • Arms set (incl. electrode holders) 200mm long 0°
just some of the features of the Denka • Arms set (incl. electrode holders) 300mm long 0°
VSR-Series suspended spot welders. • Arms set (incl. electrode holders) 400mm long 0°
The small and compact design makes • Arms set (incl. electrode holders) 125mm long 15°
spot welding around complex objects • Arms set (incl. electrode holders) 200mm long 15°
easy and fast. The Denka VSR-Series • Arms set (incl. electrode holders) 300mm long 15°
offers either 4kVA or 6kVA, making them • Arms set (incl. electrode holders) 400mm long 15°
attractive to all light-gauge sheetmetal • Upgrade weld controller – PX1500P in separate cabinet
operations, from one-off manufacturing • Upgrade weld controller – Miyachi CT-110B or CY-210B in separate cabinet
through to medium volume production • Upgrade weld controller – Serratron 100 in separate cabinet
lines. Operators can quickly set-up these • Spring balancer 22kg - VSR-Series welders with less than 400mm arms
welders, thanks to the simple Denka S1 • Spring balancer 30kg – VSR-Series welders with 400mm arms
analogue weld controller.
FEATURES
• Suspended spot welder on 3D swivel
gimbal
• X-type gun: scissor action arms
• Integrated on-gun transformer, rated
at 50% duty cycle to AS, DIN & ISO
norms
• Pneumatic cylinder activated lower
arm operation
• Denka SmartStart trigger system
• Water-cooled transformer*, electrode
holders and electrodes
• Various throat depths available
ALTERNATIVES
• Arms available for opposed
electrodes (0°) or angled electrodes
(15°) SEE OPTIONS BELOW FOR
ALTERNATIVES
VSR-SERIES SPECIFICATIONS VSR-4 VSR-6

Pressing the BLACK button allows
THERMAL RATING @ 50% D/C kVA 4.0 6.0
the electrodes to close without
MAX. SHORT CIRCUIT CURRENT kA 9.0 9.0 welding power. This enables the
ELECTRODE FORCE daN 140 140 operator to check the electrodes
SECONDARY NO LOAD VOLTAGE V 3.6 3.6 alignment and position before
PRIMARY VOLTAGE AT 50Hz V 1~415 1~415 welding. If the set-up is correct,
SUPPLY AMPERAGE (DELAYED) A 15 15 pressing the RED button will
introduce the welding current
ELECTRODE TAPER – ISO 1:10 1:10
and release the electrodes when
ELECTRODE Diameter mm 12 12 completed. Or if the alignment is not
THROAT DEPTH mm 170~445 170~445 correct, pressing the BLACK button
THROAT HEIGHT mm 105 105 again will release the electrode
CYLINDER STROKE mm 6~55 6~55 without a weld being created,
DIMENSIONS cm 50x35x25 50x35x25
allowing the operator to easily
realign the electrodes. Alternatively,
WEIGHT* kg 18 18 by pressing the RED button only,
* Weight without arms the welder will go through a normal
welding sequence without the option
of checking the electrode alignment.
330
DENKA VSX-SERIES SUSPENDED • Two different throat heights available • 400mm long 15°

SPOT WELDERS SEE OPTIONS BELOW FOR • 600mm long 15°
ALTERNATIVES • 800mm long 15°
• Arms available for opposed • Increase throat height – from 135mm
electrodes (0°) or angled electrodes to 210mm
(15°) SEE OPTIONS BELOW FOR • Increase electrode force – from
ALTERNATIVES 220daN to 400daN
• Fitted with PX1500 weld controller as • Upgrade weld controller – PX1500P in
standard SEE OPTIONS BELOW FOR separate cabinet
ALTERNATIVES • Upgrade weld controller – Miyachi CT-
• Weld controller is mounted on the 110B or CY-210B in separate cabinet
spot welder for easy programming • Upgrade weld controller – Serratron
8kVA VSX8 • Mains ON/OFF switch on welder 100 in separate cabinet
• Arms diameter: 30mm VSX-8 to • Spring balancer 45kg – VSX-8
12kVA VSX12
VSX25 and 40mm VSX-36 & VSX-42 • Spring balancer 70kg – VSX-12, VSX-
18kVA VSX18 • Quality filter, regulator and lubricator 18, VSX-25
25kVA VSX25 included • Spring balancer 90kg – VSX-36
36kVA VSX36 • High-alloy copper and brass • Spring balancer 105kg – VSX-42
42kVA VSX42 • Electrode taper Ø12mm 1:10
The versatile range of X-type suspended • Heavy-duty machined aluminium
spot welders from the Denka VSX- construction
Series allows you to move the welder • Includes hose and cable set 5 metres
around the work piece in those difficult long
access applications that don’t suit a floor • Complies with AS2799
mounted pedestal spot welder. Fully • Two year warranty
water cooled, ruggedly built and highly • Made in Italy
manoeuvrable, these welders can be SPECIFICATIONS
found in use around Australia in many See table ‘VSX-SERIES
and varied applications. Check out the SPECIFICATIONS’ below.
great fetures of this range along with the
OPTIONS
huge range of optional extras available.
Arm sets (incl. electrode holders)
FEATURES
• 200mm long 0°
• 400mm long 0°
gimbal • 600mm long 0°
• X-type gun: scissor action arms • 800mm long 0°
• Integrated on-gun transformer, rated
at 50% duty cycle to AS, DIN & ISO Arm sets (incl. electrode holders)
norms • 200mm long 15°
• Pneumatic cylinder activated lower • 400mm long 15°
arm operation • 600mm long 15°
• Denka SmartStart trigger system • 800mm long 15°
• Denka XtraBite speedy electrode Low clearance lower arm only (incl.
opening, with manual electrode gap electrode holders)
adjustment • 200mm long 0° Increase the electrode gap at the
• Ergonomic pistol-grip handle • 400mm long 0° press of a button. Get around those
• Water-cooled transformer, arms, • 600mm long 0° awkward flanges and protrusions with
electrode holders and electrodes • 800mm long 0° ease with the pneumatically operated
• Various throat depths available Low clearance lower arm only (incl. XtraBite function. Increase accuracy,
SEE OPTIONS BELOW FOR electrode holders) faster welding and less operator
ALTERNATIVES • 200mm long 15° fatigue … only with Denka XtraBite!
VSX-SERIES SPECIFICATIONS VSX-8 VSX-12 VSX-18 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
ELECTRODE FORCE daN 220 220 220 220 510 510
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 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

331
DENKA VSC-SERIES SUSPENDED Denka VSX-Series, these welders are • Quality filter, regulator and lubricator
SPOT WELDERS C-type configuration which means the included

electrodes are directly opposed and • High-alloy copper and brass
operate in a linear motion rather than a conductors used throughout
‘scissor action’. • Electrode taper Ø12mm 1:10
• Heavy-duty machined aluminium
FEATURES
construction
• Includes hose and cable set 5 metres
gimbal long
• Linear action, C-type gun operation • Complies with AS2799
• Integrated on-gun transformer, rated • Two year warranty
at 50% duty cycle to AS, DIN & ISO • Made in Italy
norms
SPECIFICATIONS
• Pneumatic cylinder activated arm
operation See table below.
• Ergonomic pistol-grip handle OPTIONS
• Water-cooled transformer, arms, • Special arms – available on request
12kVA VSC12 electrode holders and electrodes • Increase electrode force – available
18kVA VSC18 • Fitted with PX1500 weld controller as on request
25kVA VSC25 standard SEE OPTIONS BELOW FOR • Upgrade weld controller – Miyachi CT-
The Denka VSC-Series of suspended ALTERNATIVES 110B or CY-210B in separate cabinet
spot welders are designed for • Weld controller is mounted in • Upgrade weld controller – Serratron
continuous, heavy-duty use in high separate cabinet 100 in separate cabinet
• Mains ON/OFF switch on welder • Spring balancer 70kg – Suits all VSC-
volume production environments.
• Arms diameter Series welders
Similar in form and function to the
VSC-SERIES SPECIFICATIONS VSC-12 VSC-18 VSC-25

ELECTRODE DIAMETER mm 12 12 12
THROAT DEPTH mm 110 110 110
THROAT HEIGHT mm 100 100 100
DIMENSIONS cm 72x35X29 72x35X29 72x35X29
WEIGHT* kg 55 58 60
* Weight without arms
OTHER DENKA SUSPENDED SPOT WELDING EQUIPMENT
Custom off-gun suspended spot

welders are available through Denka
Various special configurations of Denka suspended spot welders built to in a range of shapes, sizes and
customer’s specific requirements. configurations.
332
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 WELDING
DENKA NUT WELDERS ELECTRODES
The central point of Denka’s Nut Simple, reliable and affordable is the
Welding System is the welding unit. Denka nut welding electrode system.
Whilst the Denka nut welding system Manufactured from quality chromium
can be retrofitted to virtually any reliable copper, the nut welding electrode is made
spot welder or projection welder, it is from two parts for low-cost replacement.
advisable that you consider the level The nut location pin can sprung via a
of quality and control achievable by coil spring or compressed air. Various
any existing welders when used in back-up electrodes are also available to
conjunction with the highly accurate complement the welding process.
Denka Nut Welding System. Denka DENKA IntelliWeld8000 NUT
has a range of high quality projection
COUNTER
welders specifically designed for use
in combination with Denka’s other nut Developed by Denka in answer to the
welding components. These welders ever-present problem of weld nuts
range from 25kVA through to 200kVA missing from components, the Denka
and are suitable for most styles of weld IntelliWeld8000 is a fully programmable
nuts. These include pedestal welders, counting system that ensures every
bench-mounted weld heads, multi-head nut is welded onto every part. If too few
units and custom-built machines. nuts are welded to the part, an error
DENKA AUTOMATIC NUT FEEDERS signal is output that can flash a light,
sound an alarm or shut down the entire
Several methods of automatic nut manufacturing operation. The plain
feeding exist in today’s manufacturing layout of information on the digital HMI
world but the ‘vibratory bowl’ version panel makes the Denka IntelliWeld8000
has proven to be the most reliable and easy to program and a sure winner with
consistent. Denka’s nut feeders employ quality control departments. Ask us for a
a vibratory bowl to orientate and feed demonstration today.
the weld nuts into the feed tube. Denka’s
Automate your nut welding process DENKA NUT ORIENTATION
quality nut feeders offer a host of great
with Denka’s innovative nut welding features, including: SENSORS
system and experience the speed, • On-board PLC-based control system
efficiency and quality assurance that Denka offers two intelligent systems for
• Precision engineered components detecting when a weld nut is located
major manufacturers rely on. We offer a • Suitable for M4 to M12 nuts
complete end-to-end nut welding solution upside down. The most economical
• Shock absorbers to minimise version is the Denka IntelliWeld500,
for high volume manufacturing operations structure-borne vibration
for almost any nut on any part. which uses a proximity sensor to detect
• Bowls lined with super-quiet the displacement of the upper welding
dampening compound electrode. It also detects if the nut is
• Additional nut storage hopper missing altogether. Being low-cost and
• Easy manual override for setup easy to fit, this is our most popular QA tool
• Overflow cut-out switch for the nut welding industry. The second
• Nuts transported via positive, direct system is the Denka IntelliWeld5000 nut
air thrust sensor, a highly intelligent and interactive
DENKA NUT PLACEMENT system that uses a combination of
COMPONENTS laser and fibre optics to determine the
All shapes…All sizes…All applications presence of a correctly orientated weld
Denka’s precision nut placement nut. Lightning fast and deadly accurate, to
technology uses compressed air flowing within 0.001 millimetres!
333
other RESISTANCE welders
DENKA VTS-SERIES TWIN-SERIES

VTS-SERIES SPECIFICATIONS VTS-30 VTS-40

SPOT WELDERS 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
ELECTRODE TAPER – ISO 1:10 1:10
ELECTRODES DIAMETER mm 20 20
ELECTRODE PITCH mm 40 – 150mm 40 – 150mm
CYLINDER STROKE mm 60 60
DIMENSIONS cm 59x17x25 59x17x25
WEIGHT kg 58 65
30kVA VTS30
40kVA VTS40
Some 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 norms
• Pneumatic cylinder operation via input
(pushbutton, footswitch or other)
• Water-cooled transformer and
electrodes
• Variable electrode pitch 40 – 150mm
• Heavy duty fabricated frame
• High-alloy copper and brass
• One year warranty
• Made in Italy
SPECIFICATIONS
See 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
334
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

Denka butt welders are available to suit the specific needs of various industries. are also available from Denka.
335
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-
Miyachi has long held a reputuation for
precision weld heads.
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
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.
336
Transformers
DENKA TX-SERIES MACHINE TC-SERIES SUSPENDED • Single-phase AC 415V transformers

TRANSFORMERS TRANSFORMERS • Transformers rated at 50% duty cycle
• 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
• Made in Spain
SPECIFICATIONS
See table below.
100kVA TC100 OPTIONS
150kVA TC150 • Secondary pad lugs for connection to
200kVA TC200 kickless cable
FEATURES • Suspension kit, for suspending
15kVA TX15 • High secondary voltage transformer
• Use with suspended spot welders or • Water manifold system
25kVA TX25 • Air supply system
large secondary circuit
35kVA TX35
50kVA TX50
Model kVA @ Package U1N V20 LPM kg Length
60kVA TX60 50% mm
80kVA TX80 TC-100 100 F 1~415VAC 18.0 8 35 564
100kVA TX100 TC-150 150 F 1~415VAC 20.0 8 110 560
125kVA TX125 TC-200 200 F 1~415VAC 22.0 8 170 485
150kVA TX150
200kVA TX200
250kVA TX250
300kVA TX300
400kVA TX400
FEATURES
• Single-phase AC 415V transformers
• Designed to handle high volume
usage
• Fully water-cooled secondary
windings
• Heavy-duty laminations and frame
• Dimensions meet ISO norms, for easy
interchangability
• Made in Spain, Italy and USADENKA
Model kVA @ 50% Package U1N V20 LPM 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
337
Transformers
DENKA ISO-SERIES AC ROBOT DENKA MFDC-SERIES

TRANSFORMERS DC INVERTER ROBOT

TRANSFORMERS
32kVA ISO32 56kVA MFDC56

54kVA ISO54 150kVA MFDC150 Complete suspended welding
61kVA ISO61 250kVA MFDC250 transformer with weld controller, air &
water systems and gun hanging frame
76kVA ISO76 FEATURES
103kVA ISO103 • Transformers conform to all ISO and
DIN norms
FEATURES
• For medium frequency DC control
• Transformers conform to ISO10656
systems
norms
• Lightweight, compact and powerful
• Lightweight, compact and powerful
• Use with robot guns, suspended
• Use with robot guns, suspended
welders, fixture welders and custom
welders, fixture welders and custom
welders
welders
• Designed to handle high volume usage
• Designed to handle high volume usage
windings
windings
• Made in Spain & India
• Made in Spain OPTIONS
• Other configurations available on
OPTIONS
request
• Transformers available in ISO-K and
• Rear terminal enclosure
ISO-X configuration
• Secondary terminal right angle
• Rear terminal enclosure
brackets
• Secondary terminal right angle
brackets
338
Resistance welding control systems
DENKA S1 ANALOGUE WELD FEATURES • Programmable upper and lower limits

CONTROLLER • Digital synchronous microprocessor- for accurate monitoring
based control technology • Three separate weld current settings
• Works with most SCR and thyristor • Mulitple impulse welding
systems • Can monitor either primary or
• Eleven programmable parameters secondary current
including pulsation welding, upslope • Clear, simple display of welding
and repeat information
• Can be configured for either 240V or • View programmed and actual
415V information together
• Use with manual or pneumatic • Integrated conduction angle monitor
operation • Visual and audible alarm signal for
1~240V S1240 • Various output signals available to bad and suspect welds
integrate with other control devices • Three different sorts of counters for
1~415V S1415
• Uses a current transformer to detect batching & quality control
For a reliable, simple resistance welding current signal • Self diagnostics for controller
controller, the Denka S1 analogue • Does not require separate power supply problems
weld controller will fit the bill. Built to • Complies with AS2799 • Automatic electrode wear
withstand normal workshop wear and • One year warranty compensation current step-up control
tear, this controller is manufactured • Made in Italy • Several input and output contacts for
from components of proven quality and integrating with other processes
SPECIFICATIONS
reliability. Whilst it’s appearance is plain • Various toroidal coil shapes & sizes
and it only offers two variable parameters, See table ‘CONTROL TYPE’ over page. available
this controller is designed to work in DENKA PX1500P DIGITAL WELD • Requires separate 240VAC power
conjunction with the very latest thyristor CONTROLLER supply
technology for retrofitting to almost any • One year warranty
single phase resistance welder. • Made in Japan
FEATURES SPECIFICATIONS
• Simple analogue control system
See table ‘CONTROL TYPE’ over page.
• Incorporates synchronous,
microprocessor technology OPTIONS
• Programmable WELD POWER and • Miyachi MB-400L toroidal coil 400mm
WELD TIME long
• Will work on most single phase 50Hz • Miyachi MB-800L toroidal coil 800mm
resistance welders with a thyristor 1~240V PP1524 long
• Use with manual or pneumatic 1~415V PP1541 • Miyachi MB-500-15 toroidal coil
operation 500mm diameter
The Denka PX1500P weld controller • Miyachi MB-60E toroidal coil 60mm
• Complies with AS2799 is identical to the PX1500 but it offers
• One year warranty diameter
nine schedule memories, for storing • Denka 15 position switch – for remote
• Made in Italy your most popular welding schedules weld schedule setting
SPECIFICATIONS for instant recall at the touch of button.
See table ‘CONTROL TYPE’ over page. Ideal for more welders that are used for
various repetition operations.
DENKA PX1500 DIGITAL WELD
CONTROLLER MIYACHI CT-110 & CY-210 WELD
CONTROLLERS
CT-110 CT110B0008
1~240V PX1524 CY-210 CY210C0008
1~415V PX1541 The weld controller of choice for most
The ever-popular Denka PX1500 manufacturers, the Miyachi range of
digital synchronous resistance weld resistance welding controllers offers
controller is one of the most compact excellent functionability whilst remaining
yet powerful control platforms available the most user-friendly controller available
today. Offering eleven programmable on today’s market. Far more than just
parameters, plenty of handy inputs a weld controller, these units are your
and outputs, and very basic operator key to weld monitoring, quality control
skill, this controller can be retrofitted to management, error alerts, electrode
any AC resistance welding system with redressing warning and a host of other
amazing ease and speed. Fitment of the intelligent and useful functions that will
Denka PX1500 will stop the hit and miss prove beneficial to any manufacturer.
programming of many inferior controllers FEATURES
and bring accuracy and results back into • Constant-current weld control system
your control. • 15 weld schedule memory
339
DENKA DENKA MIYACHI MIYACHI SERRATRON

DENKA S1 PX1500 PX1500P CT-110 CY-210 100
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,
3
TIMERS
340

DENKA DENKA MIYACHI MIYACHI SERRATRON
DENKA S1 PX1500 PX1500P CT-110 CY-210 100
PNEUMATIC CYLINDER CONTROL
SOLENOID VALVE VOLTAGE 24VDC 24VDC 24VDC 240VAC 240VAC 24VDC
OUTPUT FOR PROPORTIONAL VALVE 3

INTERFACE WITH SERVO MOTOR
3
CONTROLS
ADDITIONAL FUNCTIONS
WELD POWER ON/OFF SWITCH • • • 3 3 3

WELD & SQUEEZE - NO WELDING
3 3 3 3 3 3
POWER
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
3
DRESSING
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 To harness these unpredictable This effective value is then analysed by
elements, constant-current technology the weld controller in comparison to
When you program your welder to was developed. So what exactly is the programmed value and a variation
perform a weld of a certain current “constant-current technology”? signal, either up or down, is fed back to
(kA) for a certain period of time the thyristor through phase conversion
(cycles), the actual weld power and The current waveform as programmed
by the operator is reconstructed by the and the trigger pulse oscillation. In
time will almost always differ from effect, the weld current is corrected
that programmed, due to a range of weld controller by monitoring the actual
current passing through the secondary with every half cycle, or up to 100 times
variables present in resistance welding per second, so that the weld current
applications, including material type, loop of the resistance welder, by means
of a toroidal coil. The signal is then remains constant despite the variables
coating variations, electrode diameter, being present. Basically, the weld you
electrode condition, variations in air transformed into the RMS effective
value using the following formula: end up with is the same as you have
supply, mechanical resistance, earth programmed, not just “should be the
leakage, maintenance schedules and same”!
many, many other variables. RMS=
341
342 SECTION THIRTEEN – RESISTANCE WELDING EQUIPMENT
SERRATRON 100 WELD • Accommodates analogue proportional • Power supply

CONTROLLER valve and load cell • Air pressure monitors
• Numerous error and warning output • Proportional valve
signals • Water flow switches
• Optional modules for field buses and • PLC controllers
servo motor control • Remote control interfaces
• Comes standard with 32 I/O – • Circuit breakers & fuses
expandable up to 516 I/O • Terminal blocks
• Requires separate 24VDC power • HMI panels
supply • Indicator lights & switches
• Two year warranty • Alarms & error processing
• Made in Spain • Ethernet ports
* Optional software required • Cable entry system
• Cooling fans & ventilation
SPECIFICATIONS
See table ‘CONTROL TYPE’ previous
pages.
OPTIONS
• Serratron TP-10 hand-held
programming unit
• Serratron 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 A compact but complex Denka control
diameter cabinet incorporating a Serratron 100
• Serratron BCF-18 toroidal coil 180mm controller.
diameter
• Serratron ‘CPC-Connect’
programming software
• Serratron ‘DeviceNet’ PCB
• Serratron ‘ProfiBus’ PCB
• Serratron ‘Interbus’ PCB
SERRATRON 100 S100 DENKA TC-SERIES CONTROL
For ultimate control of your resistance CABINETS
welding operations, you can’t go past
the Serratron 100. Unrivalled in features, We manufacture a complete range
function and flexibility, this piece of of resistance control cabinets to your
equipment is the culmination of over exact requirements, including your
60 years of research and development preferred controller type, your preferred
brand of electronics and input/output High amperage Denka control
by Serra in Spain, into the needs and
signals to integrate with your existing cabinets with Miyachi CY-210
wishes of major manufacturers around
manufacturing operations. From small, controller and full AS4024.1 compliant
the globe. A huge Intel microprocessor
one-off cabinets through to large safety system.
lies at the heart of this complex PLC-
based control system which controls and quantities of complex control systems,
monitors every conceivable parameter our experienced, in-house technicians
and variable within the resistance can certainly create a control system to
welding experience. The Serratron 100 meet your needs. Just give us a call for
weld controller is an investment that will an obligation free assessment today.
repay itself over and over again. Denka TC-Series Control Cabinet
Component Options Include...
FEATURES
• For welders 10kVA to 1000kVA
• Constant-current, constant-voltage
• Weld controller – Denka, Miyachi or
and phase compensation weld control
Serratron A basic version of the Denka control
system
• Thyristor module – water-cooled or cabinet with the PX1500 controller.
• 127 weld schedule memories
air-cooled Quality Denka TC-Series control cabinets
• Full PLC system with embedded
• Compliant mains ON/OFF disconnect can be retrofitted to most resistance
welding functions
switch welding systems.
• Integrates easily and seamlessly with
• Emergency stop system
QA systems and protocols
• Safety relays
• 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
343
Water cooling systems
DENKA HK-SERIES REFRIGERATED

WATER COOLING SYSTEMS
1kWH HK-250 to provide one of the most robust and • Built-in water storage tank with water
2kWH HK-600 efficient water cooling answers to the level gauge
needs of your welding equipment. • Primary power 3~415V 50Hz
3kWH HK-750 Ideally suited to all forms of resistance • One year warranty
4.3kWH HK-1000 welding, these water coolers are also • Made in Taiwan
5.8kWH HK-2000 used extensively in high-amperage arc SPECIFICATIONS
8.7kWH HK-3000 welding applications such as robotic
mig welding, sub-arc welding and high See table below.
11.6kWH HK-4000 deposition mig welding. OPTIONS
14.5kWH HK-5000 FEATURES Denka water filtration system
Efficient, high-flow water cooling for • Refrigerated water cooling system Denka water flow switch
high amperage welding applications with integrated recirculating pump Denka water flow monitor
is absolutely essential for maximum • Digital water temperature control
productivity and protection of capital • Uses eco-friendly R407C refrigerant
equipment. The Denka HK-Series • Highly efficient radiators and cooling
refrigerated water coolers bring fans
together eco-friendly R407C refrigerant, • Easy to clean air inlet filters
precision high volume pumps and • Compact size – minimum footprint on
digital temperature control technology floorspace
HK-250 HK-600 HK-750 HK-1000 HK-2000 HK-3000 HK-4000 HK-5000

Cooling capacity 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
Heat dissipation --- 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
Inlet/outlet BSP ½ ¾ ¾ ¾ ¾ 1 1¼ 1¼
Tank capacity l 16 43 55 80 80 127 227 227
Dimensions mm 370x450 425x455 490x500 550x620x1205 710x750 885x885x1885
x950 x1110 x1125 x1500
344
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
Laminated shunts manufactured to your

exact requirements.
Call us today for

dimensions and
specifications of our vast
electrodes range.
345
Weld analysis
RESISTANCE WELDING CHECKERS

& MONITORS
Miyachi MM-326B full function weld

checker with built-in printer, capable
of simultaneously measuring and
monitoring weld current, weld voltage
and weld cycles.
Need to double-check your electrode

The Miyachi MM-315A is a handy, force? The Denka Force Checker is a
simple weld checker for obtaining ecomonical and accurate way to make
quick confirmation of weld current and sure those electrodes are closing
weld cycles. correctly. It will also help the visual
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.
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.
346
Resistance welding Electrodes & Adaptors

Part
Number
347
Part
Number
348

Part
Number
349
Part
Number
350

Part
Number
351
Part
Number
352

Part
Number
353
Part
Number
354

Part
Number
355
Part
Number
356

Part
Number
357
Part
Number
358

Part
Number
359
Part
Number
360

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.
5 221315 Electrode 12mm flat 30mm 1:10 ext.
6 221410 Electrode 12mm dome R5 1:10 ext.

7 221510 Electrode adaptor 18mm-12mm

5 221520 Electrode adaptor 20mm-12mm
361

1 243530 22mm lower arm adaptor 90 deg. suits VSR
2 243540 22mm lower arm adaptor 15 deg. suits VSR

1 243515 30mm upper arm adaptor 90 deg. suits VSX
2 243535 30mm lower arm adaptor 90 deg. suits VSX

362
heavy-duty offset water cooled holder

1 243310 Offset electrode holder 20mm dia. x 70mm long
363
364 SECTION THIRTEEN – RESISTANCE WELDING EQUIPMENT

13 Resistance Welding

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13 Resistance Welding

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Section Thirteen

Resistance welding equipment

Pedestal Resistance Welders 324

Suspended Spot Welders 330

Nut Welding Systems 333

Other Resistance Welders 334

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

PEDESTAL RESISTANCE WELDERS

Thermal Rating At 50% Duty Cycle

DENKA VRM-SERIES MANUAL 15kVA VRM15 SPECIFICATIONS

SECTION THIRTEEN – RESISTANCE WELDING EQUIPMENT

VRM-SERIES SPECIFICATIONS VRM-15 VRM-25 VRM-35

DENKA VRP-SERIES PNEUMATIC 15kVA VRP15 • Mains ON/OFF switch included

VRP-SERIES SPECIFICATIONS VRP-15 VRP-25 VRP-35 VRP-50

SECTION THIRTEEN – RESISTANCE WELDING EQUIPMENT

VLP-SERIES SPECIFICATIONS VLP-35 VLP-50 VLP-80

DENKA VPP-SERIES PROJECTION FEATURES SPECIFICATIONS

WELDERS • Large, precision-machined brass See table ‘VPP-SERIES

VPP-SERIES SPECIFICATIONS VPP-80 VPP-100 VPP-150 VPP-200 VPP-300

Other pedestal resistance welders also available

SECTION THIRTEEN – RESISTANCE WELDING EQUIPMENT

Denka T-Series resistance welding

Custom alterations to standard Denka

Denka M-Series spot, projection and seam welders –

SPOT WELDERS ALTERNATIVES

VSR-SERIES SPECIFICATIONS VSR-4 VSR-6

SECTION THIRTEEN – RESISTANCE WELDING EQUIPMENT

VSX-SERIES SPECIFICATIONS VSX-8 VSX-12 VSX-18 VSX-25 VSX-36 VSX-42

* Weight without arms

SPOT WELDERS C-type configuration which means the included

VSC-SERIES SPECIFICATIONS VSC-12 VSC-18 VSC-25

OTHER DENKA SUSPENDED SPOT WELDING EQUIPMENT

Custom off-gun suspended spot

through microscopic venturis within the

SECTION THIRTEEN – RESISTANCE WELDING EQUIPMENT

DENKA VTS-SERIES TWIN-SERIES

VTS-SERIES SPECIFICATIONS VTS-30 VTS-40

DENKA EuroGun ROBOTIC SPOT

SECTION THIRTEEN – RESISTANCE WELDING EQUIPMENT

OTHER DENKA RESISTANCE WELDERS

Custom-built fixture spot weld guns

MIYACHI MICRO-SPOT WELDING

Miyachi offers a complete micro-spot

Call today for your FREE comprehensive Miyachi Product Guide

DENKA TX-SERIES MACHINE TC-SERIES SUSPENDED • Single-phase AC 415V transformers

SECTION THIRTEEN – RESISTANCE WELDING EQUIPMENT

Model kVA @ 50% Package U1N V20 LPM kg Length mm

DENKA ISO-SERIES AC ROBOT DENKA MFDC-SERIES

TRANSFORMERS DC INVERTER ROBOT

32kVA ISO32 56kVA MFDC56

DENKA S1 ANALOGUE WELD FEATURES • Programmable upper and lower limits

SECTION THIRTEEN – RESISTANCE WELDING EQUIPMENT

DENKA DENKA MIYACHI MIYACHI SERRATRON

VOLTAGE FLUCUATION COMPENSATION 3 3 3

MEASURE PRIMARY POWER 3 3 3

MEASURE SECONDARY POWER 3 3 3 3 3 3

WELDING SCHEDULE PARAMETERS

MONITOR WELDING CURRENT 3 3 3