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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