Product Specification

100KVA Aluminum Spot Welder Projection Resistance Long Arm Welding Machine

Product Overview

Engineered on our proven DTN series platform, this industrial-grade Long Arm Spot Welding Machine delivers a robust 100KVA welding capacity tailored for demanding metal fabrication environments. The defining extra-long C-frame arm is purpose-built to reach deep cavities, enclosed panels, and complex geometries that standard units cannot access, allowing fabricators to handle large-format aluminum workpieces and multi-surface assemblies with ease. Beyond spot welding, this model performs reliable projection welding between sheet metals and onto nuts or bolts, making it a versatile production asset for workshops that process mixed material batches.

Built for sustained throughput, this resistance welding unit provides consistent energy delivery across aluminum, low-carbon steel, stainless steel, and other non-ferrous alloys. The dual-function design combined with a 450mm throat depth and adjustable electrode stroke enables operators to switch between spot and projection modes without re-tooling, cutting changeover time and boosting overall line efficiency. For procurement teams sourcing a high-capacity long-arm welder, this model offers a reliable balance of power, reach, and repeatable weld quality.

Key Technical Advantages

Extended Reach for Hard-to-Access Joints

The deep-throat C-frame structure and custom extra-long arms let operators weld positions beyond the reach of conventional machines, eliminating the need for costly repositioning fixtures. This feature directly reduces setup time for large enclosures, automotive panels, and deep-drawn components.

Capacitor Discharge Precision for Aluminum

Millisecond-level discharge energy delivery concentrates heat precisely at the weld point, minimizing thermal distortion on highly conductive aluminum and copper sheets. This process also reduces visible discoloration and maintains consistent nugget formation across repetitive production cycles.

Digitally Controlled Electrode Force

An electro-pneumatic proportional valve provides linear, high-resolution control of welding force through a digital interface. Operators can store and recall pressure parameters for different material stacks, improving weld repeatability and lowering the risk of expulsion or weak fusion.

Rigid Frame with Fast Actuation

Internal rib reinforcement minimizes frame deflection during heavy loads, while the combination cylinder with aluminum alloy barrel and low-resistance seals enables rapid electrode cycling. This combination promotes high production rates without compromising dimensional accuracy of the weld zone.

Integrated Safety Monitoring System

Built-in air and water pressure switches with audible and visual alarms halt operation automatically if coolant flow drops or air pressure fails. This dual-layer protection safeguards both the transformer and the operator, reducing unplanned downtime and maintenance costs.

Sustained Duty with Full Water Cooling

The welding transformer and rectifier are fully water-cooled at a rated 50% duty cycle, supported by copper and stainless steel lines with an integrated flow sight glass. Thermal stability is maintained even during extended shifts, reducing electrode wear and energy loss.

Applications

Working Principle

Technical Specifications

After-Sales and Support

• 12-Month Warranty — Full coverage on the welding transformer, control board, and core mechanical components for one year from shipment date.
• Video Technical Support — Remote troubleshooting sessions conducted via video call to help your team diagnose issues and restore production quickly.
• Online Assistance — Spare parts availability and documentation access through our digital portal, with response within 24 hours on business days.
• Spare Parts Supply — Genuine electrodes, arms, seals, and water lines shipped promptly to minimize downtime for overseas customers.
• Showroom Inspection — Machine available for live demonstration in Philippines, Brazil, Indonesia, and Pakistan for pre-purchase evaluation.

Frequently Asked Questions

What thickness of aluminum can this spot welder handle?

With the 100KVA power rating and capacitor discharge capability, the machine welds aluminum sheets up to approximately 2.0+2.0mm in spot mode. For steel workpieces, the maximum combined thickness reaches 4.5+4.5mm in A3 mild steel, depending on electrode configuration and welding parameters.

Can this welder perform both spot and projection welding?

Yes. The D(T)N-100 comes with a projection clamping plate and changeable electrode arms, allowing operators to switch between spot welding of large panels and projection welding of sheet-to-nut or sheet-to-bolt configurations within the same production line.

What is the typical lead time for custom electrode arms?

Standard long arms are shipped within 7–10 days. Custom arm lengths or special copper alloy electrodes may add 5–8 days for engineering review and manufacturing. We recommend sending your workpiece drawings for a precise quotation.

How is cooling water supplied to the machine?

The machine requires an external water supply at 2.5 bar with a minimum flow of 8 L/min. Inlet and outlet ports are standard threaded fittings, and a flow sight glass is included to verify circulation at a glance.

Can this unit handle 220V input power?

Yes, a 220V configuration is available upon request. The standard model operates at 380V 50/60Hz, but the transformer can be wired for 220V supply for markets requiring single-phase lower voltage input. Please confirm your local power specification at ordering.

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