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TECNA 8201N, Instruction Manual

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TECNA 8201N Instruction Manual Download Page 1

 

 

                                         

     

     

     

 

 
 
 
 
 
 

RESISTANCE WELDERS 

 

ITEM 8201N ÷ 8214N 

 

INSTALLATION AND USE 

 INSTRUCTION MANUAL  

 
 
 
 
 
 

TECNA S.p.A. 

Via Grieco 25/27 - 40024 Castel S. Pietro Terme - Bologna  ITALY  

 

Pho.+39.051.6954400 – Tel.051.6954410 – Fax.+39.051.6954490 

DOCUMENT 
NUMBER: 

MAN 1017 

DISTRIBUTOR: 

EDITION:  

MAY 2008 

 

Summary of Contents for 8201N

Page 1: ...01N 8214N INSTALLATION AND USE INSTRUCTION MANUAL TECNA S p A Via Grieco 25 27 40024 Castel S Pietro Terme Bologna ITALY Pho 39 051 6954400 Tel 051 6954410 Fax 39 051 6954490 DOCUMENT NUMBER MAN 1017 DISTRIBUTOR EDITION MAY 2008 ...

Page 2: ...TRANSPORT 9 3 3 PNEUMATIC INSTALLATION 9 3 4 COOLING WATER CONNECTION 10 3 5 ELECTRICAL INSTALLATION 10 4 WORKING PROCESS 11 4 1 MECHANICAL SET UP 13 4 2 ELECTRODE FORCE ADJUSTMENT 15 4 2 1 STANDARD PNEUMATIC CIRCUIT ADJUSTMENT 15 4 2 2 LOW FORCE SQUEEZE PNEUMATIC CIRCUITS ADJUSTMENT 16 4 3 WORKING PROGRAM ADJUSTMENT 17 4 4 CALCULATION OF THE MAXIMUM WELDING RATING 18 5 SAFETY RULES 19 6 ACCESSORI...

Page 3: ...urposes in industrial environments They must not be installed on public low voltage network which supplies domestic premises This can cause electromagnetic interferences TECNA S p A is not responsible for any damage to both people animals things and to the welder itself caused by either a wrong use or the lack or the superficial observance of the safety warnings stated on this manual nor it is res...

Page 4: ...n aluminium kA 36 40 47 49 26 30 35 37 18 22 23 59 Maximum welding current on steel kA 32 35 41 43 20 27 31 32 16 20 20 52 Secondary thermal current at 100 A 6200 6800 7000 8400 6200 6800 7000 8400 6800 7000 8400 9300 Secondary no load alternate voltage V 7 1 6 3 5 6 5 0 8 3 7 5 6 7 6 1 10 9 8 7 1 10 5 9 8 7 3 7 1 6 3 5 6 5 0 8 3 7 5 6 7 6 1 10 9 8 7 1 10 5 9 8 7 3 8 3 7 5 6 7 6 1 10 9 8 7 1 10 5 ...

Page 5: ...odes cone Standard 19 05 mm 3 4 2 30 BS 807 Special Projection plate Standard centreline 63 mm for M12 nuts Special Pneumatic circuit Standard 125 Optional 125 2 Electrode force per bar 100 kPa daN 123 207 Electrode force at 6 bar 600 kPa daN 736 1242 Maximum stroke mm 100 100 Double stroke mm 60 60 Adjustable Double stroke options 8236 8237 mm 0 80 0 80 2 4 COMPRESSED AIR CONNECTIONS DATA Minimum...

Page 6: ...e bar 4 kPa 400 Hoses inside diameter input output mm 12 Minimum consumption for nominal power l min 8 2 6 ADDITIONAL FEATURES Item 8201N 8202N 8203N 8204N 8206N 8207N 8208N 8209N 8211N 8212N 8213N 8214N Net weight of the machine kg 510 525 540 555 530 545 560 575 585 600 615 555 Aerial noise produced Continuous eqivalent acoustic pressure level A weighed value dB A 71 73 76 77 72 72 75 75 76 76 7...

Page 7: ...uires it 8235 Cylinder 1242 daN 125 double stage total stroke 100 mm 8236 Adjustable double stroke for cylinder 736 daN 8237 Adjustable double stroke for cylinder 1242 daN option 8235 8238 Low pressure squeeze for cylinder 736 daN 8239 Low pressure squeeze for cylinder 1242 daN option 8235 8240 Proportional valve Allows to adjust the working pressure directly from the control unit and to combine a...

Page 8: ...oid valves 24 VDC max 5 W with self protected output Self adjustment at mains frequency 50 60 Hz Serial data transmission by means of optional insulated RS232 or RS485 ports Output for proportional solenoid valve Key for selecting foot control or two hand control Selectable languages Italian English French German Spanish Hungarian Swedish or Portuguese Possibility of upgrading control unit Firmwar...

Page 9: ...roaching to the devices and or making inaccessible or ineffectual the safety devices 3 2 UNPACKING AND TRANSPORT On receipt of the welder verify the perfect integrity of the outer package communicate to a responsible in charge possible anomalies which should be noticed Possible damages on the outer package should arise some doubts on the integrity of its content Remove the package and visually ver...

Page 10: ...ruct or reduce the water channels in the welder causing damages If the machine is operated in a re circulating water supply the water softener must be placed on the supply of the tank an insertion before the machine generate damages 3 5 ELECTRICAL INSTALLATION The welders described in this manual have been designed to be used only for professional purposes in industrial environments They must not ...

Page 11: ...lowing adjustments 1 Mechanical set up 2 Electrode force adjustment 3 Welding parameters adjustment 4 Calculation of the maximum welding rating The following paragraphs carefully explain these different phases Before starting the working process Check that all the safety instructions have been operated Check that the correct device have been selected by means of the TWO HANDS FOOT CONTROL selector...

Page 12: ...ctrodes which must always be clean without any deformation and must have the proper diameter according to the work to be carried out Check that there are not strong changing in the welder supply pressure as they could modify the force on the electrodes and thus the welding quality Do not use sealing products to remove water losses on the electrodes conic connection To facilitate the electrode remo...

Page 13: ...parison with the thickness to be welded produces spatter of melted material sheets over mark low spot quality If the electrode diameter is too large longer welding times are necessary causing a higher heating of the welder and a shorter life of electrodes For aluminium spot welding we suggest to use spherical electrodes radius value varies according to the thickness to be welded and the kind of qu...

Page 14: ...the piece Remind that both electrodes and tools wear increases the working stroke When operating large sized pieces spot welding it can be necessary to use a high stroke to be able to insert pieces among the electrodes To allow the use of a reduced stroke even when operating in this way this unit is equipped with a control device called double stroke A key switch placed on the welder and marked wi...

Page 15: ...able outside surface If the welding to be carried out requires low or precise force values it is advisable to use a dynamometer 4 2 1 STANDARD PNEUMATIC CIRCUIT ADJUSTMENT The electrodes force adjustment is carried out by means of the pressure control REG1 This carries out the pressure P1 adjustment displayed by pressure gauge MAN1 modifying the welding force Upon demand it is possible to have a p...

Page 16: ...ied in order to obtain the welding force The electrodes force adjustment is carried out by means of the pressure regulator REG1 This carries out the pressure P1 adjustment displayed by pressure gauge MAN1 modifying both the welding and the squeeze force Upon demand it is possible to have a proportional valve EVP to adjust the working pressure directly from the control unit and to combine a proper ...

Page 17: ...ing control unit instruction manual When working in automatic cycle as long as the start cycle control device is activated the welder will repeat welding cycles at the settled off time In single cycle even though the start device is kept activated the welding unit will stop after having carried out a single cycle to carry out the next one it is necessary first to release the device and then press ...

Page 18: ... paragraph On the contrary it is necessary to reduce the welding rate When different welding programs are employed or when using a welding cycle with pre weld and post weld the value of these different currents must be calculate separately then added in order to obtain the equivalent total value Example 1 Cycle simple Welding current 41000 A Welding time 18 periods 5 welds per minute A 7101 3000 2...

Page 19: ...n the WORKING PROCESS chapter It is forbidden to have more people working on the welder at the same time No admittance allowed to the working area to people other than the operator The welder main risk is the squashing of the upper limbs caused by the moving of the mobile components electrodes electrode holder projection plate tools etc For this reason it is necessary to pay great attention and to...

Page 20: ...PARTS REQUEST When ordering accessories spare parts or expendable material please state type of machine year of manufacture serial number the voltage and frequency Available accessories 70379 Additional electric foot control for carrying out welding processes with direct recall of welding program No 2 equipped with stirrup for the connection with the main foot switch Cable length 1 4 m 70462 Addit...

Page 21: ...achine plastic components ELECTRODES MAINTENANCE Electrodes maintenance must be carried out with the welder switched off When operating the electrodes must be kept clean and their diameter must be kept suitable for the work to be carried out Too worn electrodes must be replaced When replacing electrodes check that the tube bringing water to the electrode inside stops at a few mm from the bottom of...

Page 22: ...NCY CONDITIONS WARNINGS In case of emergency push the emergency push button immediately stopping the welder working This push button is placed close to the welding cylinder and it is red on a yellow background Once it has been activated before restart the working it is necessary first to rotate this push button to deactivate it If there take place any water leakage which could enter the welder imm...

Page 23: ...equipped with the proper instruments and trained to accomplish it under safety conditions When possible disconnect both electric and pneumatic supply In case of a wrong operating welder use the following table for find out both fault cause and remedy FAULT CAUSE REMEDY The control unit does not switch on Control unit led ON keeps off Either connectors or cables disconnected Check Fuses FU1 FU2 blo...

Page 24: ...ng module wrong functioning Firing modules led shows the presence of SCR trigger signals Identify the faulty component and replace it Faulty contact in the secondary circuit Check and tighten all the secondary connections Do not forget the electrode and electrode holder connection No electrode descent Control unit led START is on Welding control unit display shows THERMOSTAT ACTIVATED Inadequate o...

Page 25: ...sure Too closed flow regulator RFL1 Correctly adjust it Faulty solenoid valve EV2 optional pneumatic circuit Replace it Spots or electrodes overheating Insufficient cooling Check that water circulates in the required quantity and at a low temperature Too high welding current or welding time Reduce them Too high post heating time and or current Change them Electrodes reduced life Insufficient cooli...

Page 26: ...ng pieces Clean the pieces Inadequate electrodes cooling Check the cooling circuit Faulty pieces contact or pieces and electrodes faulty contact Increase the electrodes force by increasing pressure Spatter of melted Too high welding current Reduce it material Too high welding time Reduce it Too small electrodes diameter Adjust diameter to the value shown on the table Inadequate welding force Incre...

Page 27: ...3 90 4 4 3 0 5 9 5 11 9 5 4 5 136 7 5 4 0 75 12 5 11 9 5 4 5 181 8 7 5 1 0 19 5 12 5 13 6 5 225 9 5 8 5 5 1 25 22 5 15 13 6 5 294 10 5 10 6 1 5 27 16 13 6 5 362 12 12 6 5 2 0 35 18 16 8 498 14 18 7 3 2 5 42 19 16 8 590 15 5 22 8 3 2 8 48 21 16 9 725 17 5 24 9 3 2 50 23 22 9 820 19 25 10 Welding class B Thickness Spots minimum Minimum overlapping Electrodes Electrodes force Welding current Welding ...

Page 28: ... 1 8 28 16 16 6 770 12 3 10 10 6 3 2 32 18 16 7 860 14 11 12 7 2 5 35 20 19 8 1090 15 7 12 7 13 7 2 3 50 22 19 10 1500 18 15 5 17 7 65 for stainless steel with tensile strength up to 100 kg mm 2 for stainless steel with tensile strength over 100 kg mm 2 Crossed rods welding of cold drawn low carbon steel Rod Welding time Set down 15 Set down 30 diameter Electrodes Force Welding current Electrodes ...

Page 29: ... 75 230 24 6 16 50 4 0 1 0 250 30 7 16 50 4 5 1 5 320 35 9 19 100 5 5 2 0 400 40 10 19 100 6 5 2 5 520 49 11 19 100 7 5 3 0 600 58 12 25 100 8 5 Welding class B Thickness Electrodes force Welding current Welding time Electrodes Obtained nugget a D R d1 mm daN kA cycles mm mm mm 0 5 140 16 6 16 50 3 0 0 75 160 18 7 16 50 3 5 1 0 180 21 8 16 50 4 0 1 5 240 25 10 19 50 5 0 2 0 280 29 12 19 50 6 0 2 5...

Page 30: ...21 Welding parameters Thickness Single projection 1 3 projections data for each projection 3 or more projections data for each projection a Time Current Force Time Current Force Time Current Force mm cycles kA daN cycles kA daN cycles kA daN 0 5 3 4400 68 5 3850 68 5 2900 36 0 75 3 5500 88 5 4450 68 7 3300 45 1 0 4 8000 150 8 6000 90 12 4300 70 1 5 8 10300 250 16 7650 166 20 5400 150 2 0 12 11850 ...

Page 31: ...ycle foreseen working SINGLE REPEAT Is during production foreseen the use of double stroke YES NO Welding pressure adjustment bar Reached welding current kA Working stroke adjustment mm Double stroke adjustment mm WELDING CONTROL UNIT TE550 PARAMETERS PARAMETER VALUE WORK MODE CONTROL MODE SQUEEZE 1 SQUEEZE PRESSURE PRE WELD FORGE DELAY FORGE PRESSURE PRE POWER COLD 1 SLOPE UP WELD 1 POWER 1 CURRE...

Page 32: ...ER 1 DELTA INCREMENT 2 SPOTS COUNTER 2 DELTA INCREMENT 3 SPOTS COUNTER 3 DELTA INCREMENT 4 SPOTS COUNTER 4 DELTA INCREMENT 5 SPOTS COUNTER 5 DELTA INCREMENT 6 SPOTS COUNTER 6 DELTA INCREMENT 7 SPOTS COUNTER 7 NOTES CONCERNING EITHER ELECTRODES OR WELDING TOOLS Electrodes type and diameter maintenance and electrodes replacement terms etc ...

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