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tecn@ RESISTANCE WELDERS ITEM 8201 ÷ 8213 INSTALLATION AND USE INSTRUCTION MANU

tecn@ RESISTANCE WELDERS ITEM 8201 ÷ 8213 INSTALLATION AND USE INSTRUCTION MANUAL TECNA S.p.A. Via Grieco 25/27 - 40024 Castel S. Pietro Terme - Bologna ITALY Tel. (051) 941076 - Tlx 520134 TECNA I - Telefax (051) 941887 DOCUMENT NUMBER: MAN 1017 DISTRIBUTOR: EDITION: MAY 1997 tecn@ WELDERS ITEM 8201 ÷ 8213 DOCUMENT NUMBER: MAN1017 EDITION: MAY 1997 PAGE 2 OF 32 INDEX CONTENTS PAGE 1 INTRODUCTION 3 1.1 PRELIMINARY REMARKS 3 1.2 SYMBOLS ON BOTH WELDER AND MANUAL 3 1.3 STANDARD ACCESSORIES 3 2 TECHNICAL FEATURES 4 2.1 IDENTIFICATION DATA 4 2.2 ELECTRICAL DATA 4 2.3 MECHANICAL DATA 5 2.4 COMPRESSED AIR CONNECTIONS DATA 5 2.5 COOLING CIRCUIT CONNECTIONS DATA 6 2.6 ADDITIONAL FEATURES 6 2.7 WELDER MAIN FEATURES 7 2.8 STANDARD WELDING CONTROL UNIT TE 183 DESCRIPTION 8 3 INSTALLATION 9 3.1 PLACE OF INSTALLATION 9 3.2 UNPACKING AND 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 CIRCUIT ADJUSTMENT (OPTIONS 8238-8239) 16 4.3 WORKING PROGRAM ADJUSTMENT 17 4.4 CALCULATION OF THE MAXIMUM WELDING RATING 18 5 SAFETY RULES 19 6 ACCESSORIES AND SPARE PARTS REQUEST 20 7 MAINTENANCE 21 7.1 ORDINARY MAINTENANCE 21 7.2 EMERGENCY CONDITION WARNINGS 23 7.3 EXTRAORDINARY MAINTENANCE 23 7.3.1 LOWERING OF THE WELDING UNIT PERFORMANCES 23 7.3.2 TROUBLESHOOTING 24 7.3.3 REMEDIES FOR WELDS IMPERFECTIONS 27 8 ENCLOSURES 28 8.1 WELDING TABLES 28 8.2 PRODUCTION FORM FACSIMILE 32 tecn@ WELDERS ITEM 8201 ÷ 8213 DOCUMENT NUMBER: MAN1017 EDITION: MAY 1997 PAGE 3 OF 32 1 INTRODUCTION 1.1 PRELIMINARY REMARKS CAREFULLY READ THIS MANUAL BEFORE INSTALLING AND OPERATING WELDER. This manual is addressed to the factory responsible in charge who must release it to the personnel in charge of both welder installation, use and maintenance. He/she must check that the information given in this manual and in the enclosed documents have been read and understood. The manual must be stored in a well-known place, easy to reach, and must be looked up each time even little doubts should arise. This welder has been designed for resistance welding of both ferrous and not ferrous (aluminium, brass) materials. The welder must not been used for other application, i.e. pieces heating, mechanical working carried out by using the electrodes force. The welder has been designed to be used by an operator by means of the foreseen control devices. All modifications, even slight ones, are forbidden because they should invalidate the welder CE certification. The welders described in this manual have been designed to be used only for professional purposes 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 responsible for damages coming from even slight tampering or from the use of not-suitable spare parts, or of spare parts other than the original ones. 1.2 SYMBOLS ON BOTH WELDER AND MANUAL WARNING! Danger of squashing. Double stroke control device. WARNING! Important safety information enclosed in this paragraph. 1.3 STANDARD ACCESSORIES The welder is supplied equipped with the following accessories: N° 1 Allen keys set 4-5-6-8-10 mm. N° 1 Hexagonal key 19 mm. N° 1 Electrodes extractor. N° 1 High conductivity grease pot. N° 1 Straight electrodes, a pair, item 8701. N° 1 Offset electrodes, a pair, item 8703. N° 1 Control unit instruction manual. N° 1 Welder instruction and maintenance manual. N° 1 Technical documentation booklet. N° 1 Wrap-it-ties and hose clamps set. N° 1 Spare silencers set. Check that the welder is equipped with all the standard accessories; immediately inform the manufacturer in case some components should lack. tecn@ WELDERS ITEM 8201 ÷ 8213 DOCUMENT NUMBER: MAN1017 EDITION: MAY 1997 PAGE 4 OF 32 2 TECHNICAL FEATURES 2.1 IDENTIFICATION DATA Item Year of manufacturing Serial number Supply voltage / frequency V / Hz 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. 8231 Welding adaptive control model TE250 item 1311. 8232 Rotary selector for the welding program recalling. 8233 Constant current welding model TE185. 8234 Double stroke control device with pneumatic foot instead of key one. 8235 Cylinder 1242 daN (∅ 125 double stage) total stroke 100 mm. 8236 Adjustable double stroke for cylinder 736 daN (standard). 8237 Adjustable double stroke for cylinder 1242 daN (option 8235). 8238 Low pressure squeeze for cylinder 736 daN (standard). 8239 Low pressure squeeze for cylinder 1242 daN (option 8235). 2.2 ELECTRICAL DATA Item 8201 8202 8203 8204 8206 8207 8208 8209 8211 8212 8213 Nominal power at 50 % duty cycle kVA 63 80 100 125 63 80 100 125 80 100 125 Maximum welding power kVA 230 295 420 460 170 230 315 350 135 205 225 Short circuit secondary current kA 40 44 52 54 29 34 39 41 20 25 26 Maximum welding current on aluminium kA 36 40 47 49 26 30 35 37 18 22 23 Maximum welding current on steel kA 32 35 41 43 20 27 31 32 16 20 20 Secondary thermal current at 100 % A 6200 6800 7000 8400 6200 6800 7000 8400 6800 7000 8400 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 9 8 7.3 Delayed fuses (380÷415V) (220÷240V) A A 125 200 160 250 200 315 250 400 125 200 160 250 200 315 250 400 160 250 200 315 250 400 Mains cables section * 380÷415V - L=10m 380÷415V - L=30m 380÷415V - L=60m 220÷240V - L=10m 220÷240V - L=30m mm2 mm2 mm2 mm2 mm2 50 50 95 2x35 2×70 70 70 2×70 2x70 2×95 95 95 2×50 2x95 2×120 2×50 2×50 2×95 2x120 2×150 50 50 70 2x35 2×50 70 70 95 2x70 2×70 95 95 2×35 2x95 2×95 2×50 2×50 2×70 2x120 2×120 70 70 70 2x70 2x70 95 95 95 2x95 2x95 2×50 2×50 2×50 2x120 2x120 Supply transformer minimum power ** kVA 266 341 480 532 197 266 364 405 156 237 260 * Section for every phase, calculated for PVC insulated, single conductor cables, considering the welder working at the maximum welding power and a 4% voltage drop on cables. ** Approximate value, calculated for a three phase transformer with a 4% short circuit voltage, with 6% voltage drop on transformer and a 4% voltage drop on cables, with the welder adjusted for the maximum welding power. tecn@ WELDERS ITEM 8201 ÷ 8213 DOCUMENT NUMBER: MAN1017 EDITION: MAY 1997 PAGE 5 OF 32 2.3 MECHANICAL DATA Item 8201-2-3-4 8206-7-8-9 8211-12-13 Electrodes throat depth L = mm 390 540 800 Projection plates throat depth D = mm 270 420 - Electrode-holder Standard ∅ 32 mm Special ∅ ................................................. Electrodes cone Standard ∅ 19,05 mm 3/4" 2°30' BS 807 Special ∅ ................................................. Projection plates 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 pressure bar 6,5 kPa 650 Maximum pressure bar 10 kPa 100 Hoses minimum inside diameter mm 15 tecn@ WELDERS ITEM 8201 ÷ 8213 DOCUMENT NUMBER: MAN1017 EDITION: MAY 1997 PAGE 6 OF 32 Pneumatic cylinder Consumption for 1000 spots at 6 bar (600 kPa) Standard ∅ 125 Optional ∅ 125 × 2 Standard pneumatic circuit with maximum working stroke Nm3 15,4 21,7 with 20 mm stroke and operating with maximum double stroke Nm3 4,6 9,4 Pneumatic circuit with low force squeeze (options 8238 - 8239) with maximum working stroke Nm3 9,2 15,5 with 20 mm stroke and operating with maximum double stroke Nm3 2,9 6 2.5 COOLING CIRCUIT CONNECTIONS DATA Maximum water pressure bar 4 kPa 400 Hoses inside diameter - input/output mm 12 Minimum consumption for nominal power l/min. 8 2.6 ADDITIONAL FEATURES Item 8201 8202 8203 8204 8206 8207 8208 8209 8211 8212 8213 Net weight of the machine kg 510 525 540 555 530 545 560 575 585 600 615 Aerial noise produced (Continuous eqivalent acoustic pressure level; A weighed value) dB(A) 71 73 76 77 72 72 75 75 76 76 76 ........ Measurement position h=1,60 m uploads/s3/ spot-welding-guide.pdf