LOW NOISE DIESEL POWEREDLOW NOISE DIESEL POWEREDLOW NOISE DIESEL POWEREDLOW NOISE DIESEL POWERED

WELDERWELDERWELDERWELDER

SALES MANUALSALES MANUALSALES MANUALSALES MANUAL

DGW500DM/ANZDGW500DM/ANZDGW500DM/ANZDGW500DM/ANZ

CERTIFIED

Shindaiwa Corporation

This manual contains brief information for the features and

Benefits of the Shindaiwa diesel welder DGW500DM/ANZ.

Please read this manual carefully, and utilize to enhance your

marketing and new model launch.

INTRODUCTION

ENGINE MODEL ：：：： KUBOTA V1505

1.PRODUCT CONCEPT ……………………………………………….1

1-1. BACK GROUND OF THE DEVELOPMENT……….1

1-2. COMPARISON OF MODEL LINE UP………………4

1-3. COMPETITOR’S SPEC COMPARISON..………….5

1-4. FEATURES AND BENEFIT………………………….6

2.SPECIFICATION ……………………………………………………..9

2-1.TECHNICAL SPECIFICATION ………………………9

2-2. OUTLINE VIEW………………………………………..10

3.FUNCTION ……………………………………………………………12

3-1. CONTROL PANEL ………………..……………….….12

3-2. AUXILIARY AC OUTPUT PANEL .……………….….14

3-3. OPERATION MODE (Single output) .………………..15

3-4. OPERATION MODE (Dual output ) .…………………16

4. MEMO………….………………………………………………………17

CONTENTS

1-1.BACK GROUND OF

THE DEVELOPMENT

�Pipeline welding business

are steadily growing in the

country where has rich

natural resource of

oil & gas area.

1. PRODUCT CONCEPT

World annual oil production(2007) = 29.2 Bb

0.0200.0400.0600.0800.01000.01200.01400.01600.01999 2000 2001 2002 2003 2004 2005 2006 2007

Canadian Oil Sands Former Soviet Union Non-OPEC £ OPEC OECD European Union Reserved oil(2007): over 1,400 Bb

1

World Natural Gas field Map

� Both Pipeline and Mine site construction with periodical maintenance business are steady and the contractors are waiting to procure best performance machine

with reasonable cost against their profit.

1. PRODUCT CONCEPT

Oil/Gas Pipeline maintenance project

Oil plant Mine site

2

� Competitors (Lincoln & Miller) are concentrating with inverter welder and old dated single diesel welders as they are not focusing the necessity of

true Dual Diesel Welder into the industry.

1. PRODUCT CONCEPT

Pipeline dual welding process

Rental single welding machine for pipeline subcontractors

3

1-2.COMPARISON OF MODEL LINE UP

200A

300A

400A

600A

700A

Shindaiwa Miller Lincoln Denyo

1. PRODUCT CONCEPT

New

4

New

500A

5

109.89563Fuel tank (L)

N/A7659Noise level

dB(A) / 7m

115V x1

230V x 1

120V x 1

240V x 1

240 x 3

415 x 1

AC rated

voltage (V)

Single

500A(40V) 60%

400A(40V) 100%

Single

500A(40V) 100%

Single

480A(39V) 60%

Dual

230A(29V)x2 80%

Output /

Duty cycle

35.515AC rated

output (kVA)

Kubota V3800T

3.6L

43.5 KW

2109x711x1273,

928

Lincoln

SAE 500

Deutz

D2011L04i

36.5 kW

1637x724x1092,

769

Miller

Big Blue 500

Kubota V1505

1.5L

24.5 kW

Engine type

1680 x 700 x 950,

613

Dimension (mm)

Dry Weight（（（（KG)

Shindaiwa

DGW500DM/ANZ

Specification

1. PRODUCT CONCEPT

1-3. COMPETITOR’S SPEC COMPARISON

1. PRODUCT CONCEPT

1-4. FEATURES AND BENEFIT

� Comparison spider chart

�Compact Size and Mobility (500A class)

6

LincolnSingle

(928kg x 2)

MillerSingle

(769kg x 2)

ShindaiwaDual

(613kg)

＜ ＜

Dual output for Pipeline welders

2.588M3

3.818M3

1.117M3

012345Size

Weight

Performance

Fuel consumption

Noise

Reliability

Ease of Control

AC output

Shindaiwa

Miller

Lincoln

� PERFORMANCE

� OPTIMUM WELDING OUTPUT amongst the competitors for the pipeline

Rated output(50Hz): Single: 480A@60% duty cycle

Dual : 230A@80% duty cycle

� CC MODE for stick welding : Low Hydrogen, Cellulose, and Various

Single : 2.6-8.0mm rods

Dual : 2.0-6.0mm rods

� GOUGING capability (CC mode) is enhanced for up- to 9.5mm rods

Single : 3.2-9.5mm rods

Dual : 3.2-5.0mm rods

� CV MODE for optional MIG / MAG / Wire Feeder

� SUPER SOUND PROOF TECHNOLOGY : 57db(A)/7m at no load

� Powerful Kubota V1505 engine complies EPA Interim Tier 4 engine specification

� FEATURES & BENEFIT

� Ease of 1 x Three phase & 3x Single phase OUTPUT RECEPTACLES

for electrical equipment

� SELECTIVE KEY SWITCH for Welding / Generating / Simultaneous mode

� EMERGENCY STOP SWITCH for safety operation

� Internal BATTERY ISOLATOR for ease of operation management

� ARC FORCE control dial can be maximized efficiency with Cellulose rod mode

� 14 pins Dual wire feeder connectors for optional wire feeder with CV mode

� Wire feeder voltmeter switch (+/-) for accurate display at wire feeder meter

� Wire feeder volt selector (42V/115V) for required optional feeder specification

� 9 pins Dual Remote control connectors for individual current control

with optional remotes which can be extended up to 100m

1. PRODUCT CONCEPT

7

1. PRODUCT CONCEPT

� CUSTOMER FRIENDLY & ECONOMY

� Environmental friendly FUEL TANK for 12 hours non-stop running

with lowered position for ease of refueling from the side

� VRD PROTECTION (less than 35V) while actual welding work

� ONE SIDE maintenance is adopted for easy access with tight space

� Hinge type front panel for easy access of electrical components maintenance

� Full digital display for both welding & generating operation

� Fuel meter with illuminating lamp

� Six (6) digits hour meter for up to 100,000hrs without key switch operation

� 20 units will be fit into one 20ft container for maximum load capacity

� Ease of unit handling with reliable lifting eye

� RELIABILITY

� “HEAVY DUTY” quality for reliability and enclosure protection of

internal components from the dust, heat and impact.

� Safety breaker is standard to protect the optional wire feeders

� Enlarged welding terminal nuts for enhanced durability

� Welding duty-cycle over load protection

� AC output duty-cycle over load protection

� Starter motor safety protection

� Fuel inlet rain protection

� Automatic fuel line air extractor

� Complied with IP23 regulation for optimum protection for the customers

� Newly-designed reliable alternator for continuous heavy duty operation

8

2.SPECIFICATION

613Dry Weight (kg)

950Height (mm)

700Width (mm)

1680Length (mm)

63Fuel Tank Capacity (L)

75D31Battery

Starter MotorStarting Method

5.8 (Sub Tank Capacity 0.85 L included)Cooling Water Capacity (L)

6.0 (Effective 2.0)Lubrication Oil Capacity (L)

API Class CD or HigherLubricant Oil grade

ASTM No.2 Diesel Fuel or EquivalentFuel

24.5 / 3000Rated Output (kW/min-1)

1,498Displacement (L)

Vertical, Water-Cooled 4-Cycle Diesel EngineType

Kubota V1505Model

ContinuousRating

1510.8Rated Output ( kVA )

0.81.0Power Factor

415240Rated Voltage (V)

3-Phase(50Hz)1-Phase(50Hz)Phase

3000Rated Speed (min-1 )

50Rated Frequency (Hz)

(Welding rod: 2.0 – 6.0, Gouging rod: 3.2-5.0)Welding Rod (Ф mm)

30 - 280Current Adj. Range (A)Dual

(Welding rod: 2.6 – 8.0, Gouging rod: 3.2-9.5)Welding Rod (Ф mm)

60 - 500Current Adj. Range (A)SingleOutput

MAX 85No Load Voltage (V)

3000Rated Speed (min-1 )

60 / 80Duty Cycle Single / Dual (%)

39.2(CC)- 39.0(CV) / 29.2(CC)-22.5(CV)Rated Voltage Single / Dual (V)

480 / 230Rated Current Single / Dual (A)

Rotating FieldGenerating Method

DGW500DM/ANZModel

Dim

ensio

nE

ng

ine

AC

Ge

ne

rato

rW

eld

ing

Gen

era

tor

9

2-1. TECHNICAL SPECIFICATION

2-2. OUTLINE VIEW

10

2.SPECIFICATION

11

2.SPECIFICATION

12

3. FUNCTION

3-1 CONTROL PANEL

1

2

3

4

5

6

7

8

10 11

9

10 11

12 13

14 15 16 17

18 19 18 1920 21 21

22 23 24 25

Detects Automatic VRD is on (less than 35V) while welding with green lamp, and off (more than 35V) while interval with red lamp for both A

and B output

Voltage Reduction Device indicator

6

Indicates A/B side welding amperage/voltage at actual operation, and

monitor for preset data while interval

Welding output

amperage/voltage meter

5

Production serial number (7digit) for identificationUnit Serial Number (PID)4

Shut off the engine operation when the switch is pressedEmergency stop switch3

Three operational mode (Welder / Generator / Simultaneous) can be selected by switching this key

Operation mode selector key2

Indicates generated AC voltage and frequencyAC Voltage/Frequency meter1

Description of functionNameNO.

13

Select Cellulose (for pipe welding) or Others (for general welding) Welding rod selector switch11

Indicates total operating hours of the welder unitHour meter12

Lights when an equipment malfunction occursWarning indicator 13

Always stay ON while in operation, unless toggle switch is flipped down for test purpose

Voltage Reduction Device switch

14

Select the idling speed by switching HIGH or AUTO positionIdling rpm control15

STOP: Stops an engine operationRUN : Continue an engine operation

PREHEAT: Warm-up for control operation and starts pre-heatingSTART: Starts an engine operation

Starter switch16

Indicates remaining diesel fuel in the fuel tankFuel gauge17

Select the output control by switching this toggle switch for CC(Welding terminal ON) and CV (Wire Feeder remote control)

Welding terminal output selector

18

Select the pole by switching this toggle for accurate indication of

optional Wire Feeder voltage meter

Pole selector for optional

Wire Feeder

19

Select the pole by switching this toggle for optional Wire Feeder power source (42V or 115V)

Voltage selector for optional Wire Feeder

20

Protect the internal circuit of optional Wire Feeder by tripping this breaker

Safety breaker21

Connect 9 pins optional remote control for extended welding cablesRemote control connector

(output A)

22

Connect optional 14 pins Wire Feeder for CV operationsWire Feeder connector(output A)

23

Connect 9 pins optional remote control for extended welding cablesRemote control connector

(output B)

24

Connect optional 14 pins Wire Feeder for CV operationsWire Feeder connector(output B)

25

Adjust Arc force effect while welding cellulose rodsArc force dial10

Select CV (Wire feeder) or CC (Stick/Gouging) for both A and B

output individually

CV/CC selector switch9

Select the Single (output A) or Dual (output A/B) by flipping this toggle switch

Single/Dual Mode selector switch

8

Adjust amperage (CC) and voltage (CV) for desired outputAmperage/Voltage dial7

Description of functionNameNO.

3. FUNCTION

2627

27 27

2829

30 31

3-2 AUXILIARY AC OUTPUT PANEL

3. FUNCTION

14

Turns the power supply to load equipment ON (closed) and OFF (open)

Single Phase circuit breaker30

Ground the bonnet to prevent the electrical shockBonnet grounding terminal32

Turns the power supply to load equipment ON (closed) and

OFF (open)

Three phases circuit breaker31

Detects electric leakage in the 3 phase,4wire output, and turns

the circuit breaker OFF when activated

Earth leakage relay29

Indicates rotating speed of the engine, and indicates Total operating hours of the generator unit

Main Circuit Breaker28

3 x 240V output receptaclesSingle phase receptacles27

1 x 415V output receptacle Three phase receptacle26

Description of functionNameNO.

32

3. FUNCTION

3-3. OPERATION MODE (Single output)

<CC Cellulose>

Cellulose rod : 2.6 -8.0mm

89 9

10 11 10 11

14 15

A Terminal

1

2

3

4

5

7

6

1213

718 19 20 21 18 19 21

22 23 24 25

<CC Gouging and others>

Gouging : 3.2-9.5mm

Other rod : 2.6 -8.0mm

<CV with optional wire feeder>

Voltage : 14 - 40V

89 9

10 11 10 11

14 15

A Terminal

1

2

3

4

5

7

6

1213

718 19 20 21 18 19 21

22 23 24 25

Remote Control (Option)

15

Remote Control (Option)

89 9

10 11 10 11

14 15

Wire Feeder A (Option)

1

2

3

4

5

7

6

1213

7

22 23 24 25

18 19 20 21 18 19 21

3. FUNCTION

3-4. OPERATION MODE (Dual output )

<CC Cellulose>

Cellulose rod : 2.0 - 6.0mm x 2

<CC Gouging and Other rod>

Gouging : 3.2 - 5.0mmx 2

Other rod : 2.0 - 6.0mm x 2

<CV with optional wire feeder>

Voltage : 14 - 29V x 2

22 23 24 25

8

9 9

10 11 10 11

14 15

B TerminalA Terminal

1

2

3

4

5

7

6

1213

718 19 20 21 18 19 21

Remote Control (Option)

22 23 24 25

8

9 9

10 11 10 11

14 15

B TerminalA Terminal

1

2

3

4

5

7

6

1213

718 19 20 21 18 19 21

22 23 24 25

16

Remote Control (Option)

Remote Control (Option)

Remote Control

(Option)

8

9 9

10 11 10 11

14 15

1

2

3

4

5

7

6

1213

718 19 20 21 18 19 21

22 23 24 25

Wire Feeder A (Option)

Wire Feeder B (Option)

April, 200971923-00000

Shindaiwa Corporation

4. MEMO

17