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Summary of Contents for TECNA 8201N
- 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 DISTRIBUTOR: DOCUMENT MAN 1017 NUMBER: EDITION: MAY 2008...
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Page 2: Table Of Contents
WELDERS ITEM 8201N ÷ 8214N INDEX CONTENTS PAGE INTRODUCTION PRELIMINARY REMARKS SYMBOLS ON BOTH WELDER AND MANUAL STANDARD ACCESSORIES TECHNICAL FEATURES IDENTIFICATION DATA ELECTRICAL DATA MECHANICAL DATA COMPRESSED AIR CONNECTIONS DATA COOLING CIRCUIT CONNECTIONS DATA ADDITIONAL FEATURES WELDER MAIN FEATURES... -
Page 3: Introduction
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... -
Page 4: Technical Features
WELDERS ITEM 8201N ÷ 8214N 2 TECHNICAL FEATURES 2.1 IDENTIFICATION DATA Item Year of manufacturing Serial number Supply voltage Frequency Optional: 8230 Valve to stop the flow of the water cooling when the machine is off and flow switch which makes the welder stop if the cooling water does not circulate. -
Page 5: Mechanical Data
WELDERS ITEM 8201N ÷ 8214N 2.3 MECHANICAL DATA Articolo 8201N-8202N 8206N-8207N 8211N-8212N 8203N-8204N 8208N-8209N 8213N 8214N Electrodes throat depth L = mm Projection plates throat depth D = mm Standard ∅ 32 mm Electrode-holder Special ∅ ..........Standard ∅ 19,05 mm 3/4" 2° 30' BS 807 Electrodes cone Special ∅... -
Page 6: Cooling Circuit Connections Data
WELDERS ITEM 8201N ÷ 8214N Pneumatic cylinder Consumption for 1000 spots at 6 bar (600 kPa) Standard Optional ∅ 125 ∅ 125 × 2 Standard pneumatic circuit with maximum working stroke Nm 3 15,4 21,7 with 20 mm stroke and operating... -
Page 7: Welder Main Features
WELDERS ITEM 8201N ÷ 8214N 2.7 MAIN WELDER FEATURES • Cylinder with chrome plated stem for heavy duty works and long life; adjustable anti-rotation device. • Lubrication free pneumatic components. • Electrodes descent without pressure for set up and service. - Page 8 WELDERS ITEM 8201N ÷ 8214N MAIN TECHNICAL DATA Simplified programming via 6 keys and a backlit alphanumeric LCD. • Synchronous control with controlled diodes, phase control current adjustment. • Storage of 250 welding programs, 31 recallable from an external drive.
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Page 9: Installation
WELDERS ITEM 8201N ÷ 8214N 3 INSTALLATION These paragraphs are addressed to the specialised personnel in charge of both welder transport and installation. The welder dimensions diagram in the technical documentation booklet provides useful information for carrying out these operations. -
Page 10: Cooling Water Connection
WELDERS ITEM 8201N ÷ 8214N The welder has been assembled by using components which do not require lubrication. The insertion of a lubricator in the circuit causes no problems to the welder; nevertheless, pay attention to the fact that this brings the emission of oil mist in the environment. -
Page 11: Working Process
WELDERS ITEM 8201N ÷ 8214N 4 WORKING PROCESS The welder has been designed for being used by an operator placed in front of the unit and working on the same working ground on which the welder is installed. When arranging the working place, always follow the herewith stated instructions: •... - Page 12 WELDERS ITEM 8201N ÷ 8214N Before starting the welding process, check the welding conditions (time, pressure, etc.). If you are operating spot welding, use two off-cuts of the sheet to weld, carry out two spots at the same distance used during the production, then remove the first and check the second: the spot is correct when the pulling test causes the coming out of the weld nugget with the hole of a sheet, and the twist test shows a pure area without porosity or causes the coming out of the nugget.
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Page 13: Mechanical Set Up
WELDERS ITEM 8201N ÷ 8214N 4.1 MECHANICAL SET UP Spot welding electrodes adjustment. With control unit set to NO WELD, the start device is activated; with the electrodes touching, contact between electrodes should be uniform. If required, carry out the adjustment. It is advisable to adjust electrodes with a fine file or with sandpaper. - Page 14 WELDERS ITEM 8201N ÷ 8214N Working Stroke Adjustment Adjust working stroke as short as possible to get: 1) Higher productivity. 2) Faster pressure rise time on the pieces to weld. 3) Higher follow up. 4) Higher working precision. 5) Reduced labour accident possibility.
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Page 15: Electrode Force Adjustment
WELDERS ITEM 8201N ÷ 8214N 4.2 ELECTRODE FORCE ADJUSTMENT The following paragraphs show how to adjust both the standard pneumatic circuit, and the optional one with a low force squeeze. The welding force must be selected taking into consideration both tables and personal experience, and in relation to the sheets thickness, the desired spot quality, etc. -
Page 16: Low Force Squeeze Pneumatic Circuits Adjustment
WELDERS ITEM 8201N ÷ 8214N 4.2.2 LOW FORCE SQUEEZE PNEUMATIC CIRCUITS ADJUSTMENT (OPTIONS 8238-8239) On request, the welder can be equipped with a pneumatic circuit enabling the low force squeeze, useful especially for projection welding and with light alloys. The pneumatic circuit functioning... -
Page 17: Working Program Adjustment
WELDERS ITEM 8201N ÷ 8214N 4.3 WORKING PROGRAM ADJUSTMENT This operation consist in choosing the welding parameters and entering them directly on the welding control. Select parameters from table or personal experience taking into consideration the plate thickness, the welding desired quality etc.. -
Page 18: Calculation Of The Maximum Welding Rating
WELDERS ITEM 8201N ÷ 8214N 4.4 CALCULATION OF THE MAXIMUM WELDING RATING Before starting the production, it is necessary to check that the welding rating must not exceed the maximum welding rating allowed by the welder in comparison with the set welding conditions (time and current), otherwise causing a too high over heating. -
Page 19: Safety Rules
WELDERS ITEM 8201N ÷ 8214N Example 4: Welds carried out with different welding programs. 2 welds per minute with: × × 30000 3286 Welding current = 30000 A 3000 Welding time = 18 periods 6 welds per minute with: ×... -
Page 20: Accessories And Spare Parts Request
WELDERS ITEM 8201N ÷ 8214N The personnel must wear both safety glasses and gloves. Avoid wearing rings, metal watches and clothes with either metal accessories or components. When operating heavy working, high thickness and pieces with a difficult coupling, wear safety shoes and aprons, and use protection screens to protect the operator from possible split of melted materials. -
Page 21: Maintenance
WELDERS ITEM 8201N ÷ 8214N 7 MAINTENANCE 7.1 ORDINARY MAINTENANCE This chapter states the necessary maintenance operations to be carried out for: 1) keeping the welding unit safe operating and preserving its efficiency; 2) avoiding the most common causes of wrong working worsening the welding quality. -
Page 22: Emergency Condition Warnings
WELDERS ITEM 8201N ÷ 8214N COOLING CIRCUIT MAINTENANCE Cooling circuit maintenance must be carried out only by specialised personnel trained to accomplish it under safety conditions. When possible, maintenance must be carried out with the welder switched off and disconnected from the pneumatic supply, with the circuit free from left air. -
Page 23: Lowering Of The Welding Unit Performances
WELDERS ITEM 8201N ÷ 8214N 7.3.1 LOWERING OF THE WELDING UNIT PERFORMANCES Extraordinary maintenance must be carried out only by specialised personnel equipped with the proper instruments and trained to accomplish it under safety conditions. When possible, the welder must be disconnected from both pneumatic and electric supply. - Page 24 WELDERS ITEM 8201N ÷ 8214N FAULT CAUSE REMEDY pressing foot-control foot-control device Check both foot-control device the electrode descends enables micro-switch connections and corresponding but does not weld. Electrode START micro-switches. Check cams rises up only when releasing AUXILIARY one. The control...
- Page 25 WELDERS ITEM 8201N ÷ 8214N FAULT CAUSE REMEDY slow or not uniform Inadequate welding pressure. It shown by the proper descent. pressure gauge. Adjust correctly means pressure gauge. Faulty RFL2 flow-regulator Adjust it correctly. adjustment. Low electrodes welding force. Low welding pressure.
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Page 26: Remedies For Welds Imperfections
WELDERS ITEM 8201N ÷ 8214N 7.3.3 REMEDIES FOR WELDS IMPERFECTIONS. This chapter has been introduced in order to facilitate the troubleshooting of the most common imperfections caused by a wrong adjustment. Notice that each one can be caused by different causes as there are many parameters affecting the welding process. -
Page 27: Enclosures
WELDERS ITEM 8201N ÷ 8214N 8 ENCLOSURES 8.1 WELDING TABLES In order to facilitate the search for the best welding conditions, we have herewith inserted the following tables stating the approximate adjusting values. Notice that the same weld can be carried out under different working conditions, so much so that the following data are not binding ones. - Page 28 WELDERS ITEM 8201N ÷ 8214N Stainless steel 18/8 spot welding Spots Minimum Electrodes Welding Welding Obtained Thickness Electrodes minimum overlapping Force current time nugget distance cicli 12.5 12.5 10.3 12.5 12.3 1090 15.7 12.7 1500 15.5 7.65 * for stainless steel with tensile strength up to 100 kg/mm...
- Page 29 WELDERS ITEM 8201N ÷ 8214N Aluminium spot welding Welding Class A Electrodes Welding Thickness Welding time Electrodes Obtained nugget force current cycles 0.75 Welding class B Electrodes Welding Thickness Welding time Electrodes Obtained nugget force current cycles 0.75 EDITION: MAY 2008...
- Page 30 WELDERS ITEM 8201N ÷ 8214N Projection welding of low carbon steel Projections dimensions Thickness Projection Minimum distance Minimum Diameter d Height h between projections overlapping 0.75 Welding parameters 1-3 projections 3 or more projections Thickness Single projection (data for each projection)
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Page 31: Production Form Facsimile
WELDERS ITEM 8201N ÷ 8214N 8.2 PRODUCTION FORM FACSIMILE FIRM DATA Firm Department WELDER DATA Welder model Number Welding transformer connecting positioning PIECE TO BE WELDED Description Code Thickness Material Coating WELDING PARAMETER ADJUSTMENT Foreseen working with: FOOT-CONTROL TWO-HANDS CONTROL DEVICE... - Page 32 WELDERS ITEM 8201N ÷ 8214N POSSIBLE STEPPER FUNCTION ADJUSTING PARAMETERS DELTA INCREMENT 1 SPOTS COUNTER 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...
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