HIGH SPEED AUTO TIP DRESSER

CDEX

USERS MANUAL

Please read this manual before using KYOKUTOHs

High Auto Tip Dresser (CDEX)

KYOKUTOH CO.,LTD
 ATTENTION TO SAFETY

Please be sure to read this ATTENTION TI SAFETY before using CDEX.

This product is intended only for the dressing of specified electrodes. This product is not to be 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
This following symbols Caution and Notice, are used indicate possible hazards and to prevent
their occurrence.
Be careful to follow directions as specified, as an error could lead to possible

Caution injure or death.

Be careful to follow directions as specified, as an error could lead to malfunction

Notice and serious damage.

The following symbols are explained below.

This symbol indicates operation that should not be done.

This symbol indicates operation that should be done.

After reading, please the manual to the place where you can check the manual.
 Caution

Abolutely never diassemble or reconfiguew this Do noto insert a finger or hand into gear opening ehils
machine or its parts. in operation.
This could result in operation malfunction
This will result in serious injury.
(short), electrical shock or ignition.

Avoid as much contact with water as possible.
This could result in operation malfunction
(short), electrical shock or ignition.
Remove the spatter, which covers the tip dresser
periodically.
Spatter build-up can cause operation
malfunction or ignition resulting in injury.

Be sure to swich off the power supply, when removing Do noto use acidic or chlorine detergents for
or repairing wiring. maintenance purposes.

Will cause electrical shock. Poisonous gas may be generated from the
detergent, causing a possible health risk.
Remove any oil that may occumlate on the tip
dresser.
Spatter could cause ignition and possible injury.

Notice

Firmly fix tip dresser to stand. Be sure that the motor is not locked up.

If the Tip Dresser is not fixed tightly in This could result in overheating and possible
operation, poor dressing and other problems could ignition.
occur

Do not use any autter or holder other than that which Do not install near the themal generation source of the
is intended and specified. welding machine.
Use of an unspecified cutter or holder, could

result in damage. This could cause trouble and accidents.
Do not install between a welding machine and
transformer.
Strong magnetic forces and heat can be
dangerous and possibly cause malfunctions or
ignition.
 INDEX

Servo Dresser Capabilities 1

Servo motor assemble 2

Criteria for Dressing Guns 3

Caution for Positioning the Dresser

5

Cutter Capacity and Dressing time 7

Timing Chart
8

Drawing 9

Parts List 10

How to Change the Cutter 12

Servo Motor Set 14

Optional Extras

15
Wiring diagram

16
Speed Control Mode

17
Cable for Interface

18
Cautions and How to Repair

19
Abnormality and How to Repair

21
Consumption Parts List
 Servo Motor Capabilities

Reduction Geer Rate

Recommended
Servo motors specification
Recommended Revolution
Output revolution
Recommended Torque
Shaft diameter of Motor
Shaft length from flange
Valid shaft length Over
Flange diameter
External dimension of motor Less than

Caution
Please set servos torque less than 3 N
m
Please note that strong torque could break the gear.

90
4-5.5
30
3

1524
5
14
50

90
5

70
.C .D.
P

60

1
 Installation for servo
motor

Please mount the servo motor with 4 pcs of M5 bolts after inserting the servo motor in the motor
flange.

2
 Criteria for Dressing Guns

Applicable to both X-guns and C-guns; see figure 1 and 2

dimension OverIf A dimension is less than 25mm, the dresser is not suitable because it may contact
gearbox.

dimension is over If B dimension is less than 40mm, 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 direction is long, tip could not be held the cutter because of strength of guns. In case,
please contact us for solution.

The base tip and insert electrode requires a particular cutter.dimension

We will customize the cutter if you could provide us the gun and tip drawings.

Recommended dressing force is betweenand Dress up to

When dressing pressure is less than ,there is possibility of dressing defective because of dressing
amount reduction.
In this case, please reduce the dressing pressure. If it is impossible to reduce the pressure, please contact us. We
would offer you some special cutters.

Select a cutter well suited to the tip shape.

3
Figure1

D When the length is over 1690mm and

Over 1370mm,
Please contact us.

C Maximum 15 degrees is acceptable.

B To avoid interference with gearbox, 40mm required.

Figure2

Tip opening needs over 25mm.

The special cutter should be used for shorter cutter,

4
 Cautions for Positioning the Dresser

The tip should be set parallel floating mechanism. ( See figure 3)

For X-guns, set the dressing set the location to the pressurization location. ( See figure4)

For c-guns, set the dressing location even level with pressurization location, otherwise it might cause poor dressing or
damage gears and bearings. (See figure 5)

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 point very well when you
teach robots. (See figure 4 and 5)

Figure3

5
Figure 4

Figure5

6
 Cutter Capacity and Dressing Time

16 Tip Dresing Amount 1sec Dressing 16 Tip Dresing Amount 2sec Dressing

Tip material CuCr

Tip Shape Tip diameter6-8 External dimension16
Cutter KTW-12
Holder KTWEXH-12

Indication of the Dressing Time

Above graph shows amount of dressing amount of new cutter direction to entire length.

Please adjust dressing time and pressure according to above graph.

Adjust by the pressure. In case of dressing time 2 sec, and to 0.10mm.
Set the pressure about 150kgfnumber of revolution150RPM.

Recommended Pressure

Recommended
Revolution


Motor rotation frequency

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.
We have various types of cutters with different shapes and different metallic finishing for
optimum dressing.
7
 Timing Chart

KTW type Cutter (Only clockwise rotation)

ON
Gun Pressure
2seconds
OFF

ON
Dresser Rotation
OFF

Start motor to clockwise before Gun press.

Set the dressing time according to your tip condition. Approximately 2 sec.

Confirm rotate direction (clockwise).

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.

8
 Drawing

4-M8 penetration

9
 Parts List

No
1 Dresser CDEX 1
2 Output Gear CD-SVR-VM1-P-005 1
3 Boll Bearing 6809LLB 1
4 Input Gear CDEX-R-P-004 1
5 Boll Bearing 6002LLB 1
6 Boll Bealing 6905LLB 1
7 Floating Unit EXFLU-15-01 1
8 Servo MotorPanasonic MSMD042G2S 1

10
Parts List Floating Unit
No Name Type Qty
1 Floating Block CDEXFLU-15-01-002 1
2 Floating Plate CDEXFLU-15-01-003 2
3 Special Slide CDEXFLU-15-01-005 2
shaft
4 Slide Cover CDEXFLU-15-01-006 1
5 Samini Spring 11-2243 2
6 E Ring STW-20 4
7 Slide Bearing SM12WUU 2
8 SUS Cap Bolt M515 4
9 SUS Cap Bolt M815 2
10 Dowel Pin 57-25L 2

11
 How to Change the Cutter

Remove M3 screws from the cutter holder.

Remove the cutter holder from the dresser.

To remove the cutter from the cutter holder, loosen the M3 torque screw.

12
 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

Cutter Holder Cutter

To install the cutter holder to the dresser, please do the reverse order from 1 to 2.

13
 Servo Motor Set
SetOptional Extras
Extras

No Parts Name Type or Size PC

Servo motor MSMD042G2S
Amplifier MBDHT2510
Motor Cable FMCA0015EED
Encoder cable MFECA0015EAM
Interface Cable DV0P4360

14
 Wiring Diagram
Diagram

Thermostat with a built-in

outside-attachment
regenerative resistor
(Light yellow)
Coil Serge aspirator
Nozzle Filter

Main Power Supply

Please power on MC

In case of single phase,

Control
L2 pin is not used.
Power supply

Arrange circuit shut off L1, L3

for emergency stop.

Red
White Motor
Black Connectio
Green

Motor

Insulated Power

15
 Speed Control Mode

Input internal order speed selection1 Connect weir

Input internal order speed selection2
left column7
33
29
31

Input servo on
37
41.
Input gain conversion
Input internal order speed selection3

Input zero cramp speed A aspect output

Divider
Input control mode conversion

Input alarm clear B aspect output

Input forbid right rotate drive
Input forbid minus rotate drive Z aspect output

Output servo leady

Output servo alarm

Z aspect output (Open Collector)

Output speed arrival

Output out brake release

Output during torque limit Input speed order

(0~10V)
Output zero speed detection Input forward direction
torque limit (0~10V)
Input minus direction
Torque limit (-10~0V)
Output speed monitor
Output torque monitor

Twist Pair

ON Recommended 2 sec
Gun Pressure

OFF

ON
Internal order speed
selection1 input (33)
OFF

ON
Input Servo on
29
OFF

During this signal is set, dresser is keeping revolute.

Servo on does not work when input signal without servo on
release the alarm
Output Alarm
For error code, please refer to amplifier annual (basic) p34, 35

Set 4,000rpm before delivering.

16
Cable for interface

Pin Array of Connecter I/F (50 Pin) (case of seeing side of soldering)

Pin No Line Color (Mark) Pin No Line Color (Mark) Pin No Line Color (Mark)
Pin No Green (Mark) Pin No Line Color (Mark) Pin No Line Color (Mark)
1 - 21 - 41 White (Red1)
2 - 22 - 42 -
3 - 23 - 43 -
4 - 24 - 44 -
5 - 25 - 45 -
6 - 26 White (Black3) 46 -
Yellow (Red1)
7 Yellow (Red1) 27 Yellow (Red3) 47 -
Peace (Red1)
8 Peach (Red1) 28 Yellow (Black3) 48 -
9 Peach (Black1) 29 Peach (Red3) 49 -
10 Orange (Red2) 30 Peach (Black3) 50 White (Black1)
11 Orange (Black2) 31 Orange (Red4)
12 Yellow (Black1) 32 Orange (Black4)
13 - 33 Gray (Red4)
14 - 34 White (Red4)
15 - 35 White (Black4)
16 - 36 Orange (Red1)
17 - 37 Orange (Black1)
18 - 38 Gray (Red1)
19 - 39 Gray (Black1)
20 - 40 Grey (Black4)

17
 Cautions and Confirmation before the Operation
1. Confirm the specification again. (Voltage, option, etc)
2. Make sure of the conformity between the forms of cutter and cap tips.
3. Install the dresser in the place where the operator can not touch it directly during the operation.
4. Make sure dresser and stand bolts are tightened firmly. Also, confirm stand is fixed securely to the floor.
5. When connecting wires to the dresser, operation procedures must be followed with the electric
construction standard and also make sure that it is protected from cooling water and spatter.
6Make sure that the torque setting is proper.
7Make sure dresser is installed in a location with no spatter and cooling water directly.
8Confirm the forms of the cutter and cap tip once again before robot teaching.
Confirm that cutter and holder are securely fastened.
9Confirm the rotation direction of the KTW cutter is clockwise.
10. Make sure there is neither interference to the dresser except for the cap tips, nor any allophone when
robot teaching.
11When the gun is pressurized, make sure that the electric current is not applied and pressure is within the
setting range.
12. Be sure that the shank an cutter are stable and not shaking during dressing. Confirm the quality of the
dressed tip.

The causes of the failure in dressing.

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 differ from the dressing one.
The shape of used cap tips differs from new ones too much.

If the cap tips cant get dressed properly with any other reason, please contact us.

18
 Abnormality and How to Repair

Abnormal Condition Cause and Countermeasure

Dresser does not rotate. Servo motor is not rotating

Check the power source.

The gun pressure is higher than specified by our company.

Set gun pressure under 1960N(200kgf).

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 the 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.

The 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.

The screw which fastens the cutter to the holder is loosen.

Tighten the screw.

Abnormal sound during Dressing point is not proper.

dressing. Re-do teaching.

The cutter has been damaged.

Replace the cutter and check the gun pressure.

19
 Abnormal Condition Cause and Countermeasure

Dresser leaves burr on the The control method is not proper.

cap tip. Release the gun while dresser is revolving, and then stop
the dresser.

The shapes of the cutter and the cap tips are not fitting.
Check the cutter shape and replace it, if necessary.
The cutter has been damaged.
Replace the cutter and check the gun pressure.

The screw 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 bolts that fasten the motor and the gear box are loosen.
The point of the cap tip is Tighten the bolts.
an oval, not a circle The bolts that fasten the dresser to the stand are loosen.
Tighten the bolts

Dressing does not complete Dressing time is too short.

in the set time Set the dressing time to the cap tip that has been
crushed most.
The cutting capability of the cutter has deteriorated or the
cutter has been damaged.
Replace the cutter and check the gun pressure.
The cap tip is 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.
<Remarks>
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 not take the dresser
apart. It would not be able to repair if you disassemble it.

20
Consumption Parts List

Output Gear Bearing for KTW

Type: 6809LLB
Replacement Qty:pcs

Input Gear Bearing for

Type: 6002LLB
6002LLB6905LLB
Replacement Qty: pcs

Replacement cycle
50,000sec or 6 months

Input Gear for KTWEXH holder

Type: CDEX-
CDEX-R-R-P-004F

Replacement Qty: pcs

Replacement cycle
2years or100,000sec

Output Gear KTWEXH holder

Type: CD
CDSVR
SVRVM1
VM1P005
With Ring stopper
DSVR
SVRVM1
VM1P006
006
Replacement Qty: pcs
Replacement cycle
2years or100,000sec

Cutter
Type: KTW
KTW
Replacement Qty: pcs
Replacement cycle 10,000 sec

Cutter Holder
Type KTWEXH
KTWEXH
Replacement Qty: pcs
Replacement cycle 30,000 sec

21
 HEAD OFFICE

2-2225, HIGASHIKAMINOKURA MIDORI-KU NAGOYASHI

AICHI 458-0808 JAPAN
TEL 052-879-2223 FAX 052-879-6223
E-mailsales@kyokutoh.com

http://www.kyokutoh.com

KANTOH OFFICE
TEL 04-2968-9228 FAX 04-2968-9224
HIROSHIMA OFFICE
TEL 082-847-2170 FAX 082-847-2170

CHANGER DRESSER CORPORATION

CORPORATION

1527 ITC Way, Anniston, AL 36207 U.S.A

TEL +1-256-832-4392 FAX +1-256-832-4393
http://www.changer-dresser.com

KYOKUTOH CHINA

Xinzhuang Village Section Furong Town,Furong Street.

Huadu District Guangzhou City,China 510860
TEL +86-20-86980880 FAX +86-20-86980890
http://www.kyokutoh.com.cn

KYOKUTOH EUROPE

#003, Radlkoferstr.2; 81373 Munchen; Germany

TEL +49-89-7411-85313 FAX +49-89-7411-85315

KYOKUTOH TAILAND

52 soi Bangna-Trad 25 Bangna-Trad km3

Road Bangkok 10260 Thailand
TEL +66-80-970-8111
2012.11.12

22 2012.08.08