TECNA 8201N User manual

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.[phone] – Fax.[phone]
DOCUMENT
NUMBER: MAN 1017 DISTRIBUTOR:
EDITION: MAY 2008

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EDITION: MAY 2008 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 TE550 DESCRIPTION 7
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 CIRCUITS ADJUSTMENT 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 22
7.3 EXTRAORDINARY MAINTENANCE 22
7.3.1 LOWERING OF THE WELDING UNIT PERFORMANCES 23
7.3.2 TROUBLESHOOTING 23
7.3.3 REMEDIES FOR WELDS IMPERFECTIONS 26
8 ENCLOSURES 27
8.1 WELDING TABLES 27
8.2 PRODUCTION FORM FACSIMILE 31

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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.

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2 TECHNICAL FEATURES
2.1 IDENTIFICATION DATA
Item
Year of manufacturing
Serial number
Supply voltage V
Frequency 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.
8232 Rotary selector for the welding program recalling.
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).
8240 Proportional valve.
8241 Constant energy operating mode.
2.2 ELECTRICAL DATA
Item
8201N 8202N 8203N 8204N 8206N 8207N 8208N 8209N 8211N 8212N 8213N 8214N
Nominal power at 50 %
duty cycle kVA
63 80 100 125 63 80 100 125 80 100 125 160
Maximum welding power kVA 230 295 420 460 170 230 315 350 135 205 225 650
Short circuit secondary
current kA
40 44 52 54 29 34 39 41 20 25 26 65
Maximum welding current
on 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
9
8
7.3
12.1
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
315
-
Mains cables section *
380÷415V - L=10m
380÷415V - L=30m
380÷415V - L=60m
220÷240V - L=10m
220÷240V - L=30m
mm
2
mm
2
mm
2
mm
2
mm
2
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
2×70
2×70
2×120
-
-
Supply transformer
minimum power ** kVA
266 341 480 532 197 266 364 405 156 237 260 727
* 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.

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2.3 MECHANICAL DATA
Articolo 8201N-8202N
8203N-8204N
8214N
8206N-8207N
8208N-8209N 8211N-8212N 8213N
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 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 pressure bar 6,5
kPa 650
Maximum pressure bar 10
kPa 1000
Hoses minimum inside diameter mm 15

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Pneumatic cylinder
Consumption for 1000 spots at 6 bar (600 kPa) Standard
∅125 Optional ∅125 ×2
Standard pneumatic circuit
with maximum working stroke Nm315,4 21,7
with 20 mm stroke and operating
with maximum double stroke Nm34,6 9,4
Pneumatic circuit with low force squeeze (options 8238 - 8239)
with maximum working stroke Nm39,2 15,5
with 20 mm stroke and operating
with maximum double stroke Nm32,9 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
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 76 78
Measurement position h=1,60 m L=0,5 m
Measurement conditions
working stroke (mm)
welding time (cycles)
welding current (kA)
working rating (welds/min.)
50
13
29
6
50
11
34
6
50
10
39
6
50
12
41
6
50
22
22
6
50
21
25
6
50
17
29
6
50
22
30
6
20
23
15
15
20
16
19
15
20
20
20
15
50
11
47
6
Machine painting colour
Grey RAL7035
..............................................

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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.
• Built-in compressed air filter unit and tank.
• Silencers for compressed air discharge.
• Two stage electric foot control for clamping and welding pieces only if correctly positioned.
•Pre-setting for additional double stage electric foot connection for the direct recalling of
welding program no.2.
• Water-cooled transformer, plates, electrode-holders and electrodes; transformer with epoxy
resin coated windings.
• Synchronous SCR contactor insulated from cooling water circuit with protection thermostat.
• Two-hand safety control with timer for maximum safety, and removable key selector, standard
on all models.
• Emergency push-button to stop the machine immediately.
• Constant current control unit.
OPTIONS:
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.
8232 - Rotary selector for recalling the welding programs.
8234 - Double stroke control device with pneumatic foot instead of key one. To be used only for
spot welding when the work necessarily requires 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 proper pressure value to each program.
8241 - Constant energy operating mode.
2.8 WELDING CONTROL TE550 DESCRIPTION
The TE550 is a microprocessor-based welding control unit for resistance welders. The task of the
welding control unit is to manage the welder components, in particular the controlled diodes that
carry out the welding current adjustment.
The TE550 is a particularly versatile welding control unit as it may be adjusted to different types
of welders; it may be installed not only on spot and projection welders but on seam welders too. It
may work with power adjustment: both in constant current and in constant energy (optional). The
number of inputs and outputs may be increased so to better adjust the welding control unit to
automatic machines.
It is possible to store up to 250 different welding programs, 31 of which are recalled directly from
an external device. Each program comprises several programmable parameters that describe the
work cycle. In addition to the plain 4-stage welding cycle, the control unit allows the running of
welding processes with pre-welding current, post-welding current, slope and pulses.

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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.
• Up to 25 programmable parameters for each program.
• Slope, pulses, pre-weld, post-weld functions and adjustment of the welding times in half-
cycles.
• Display of the RMS welding current measurement in kA and relative angle of conduction.
• 3 operating modes: standard, constant current and constant energy.
• Welding current or angle of conduction limits.
• Double stroke function.
• Stepper function to compensate the electrodes wear with programmable curve.
• Single and automatic cycle. WELD and NO-WELD function.
• Adjustment of first insertion delay.
• Control of 5 solenoid 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 Firmware via appropriate software.
• Activation and control of the electrodes dressing (optional)
PARAMETER RANGE
WORK MODE IK - FIX
CONTROL MODE NO - CURR - DEG
SQUEEZE 1 01 - 99
SQUEEZE 00 - 99
PRESSURE 1.0 - 10 bar
FORGE DELAY 00 - 99
FORGE PRESSURE 1.0 - 10 bar
PRE-WELD 00.0 - 99.5
PRE-POWER 05 - 99
COLD 1 00 - 50
SLOPE UP 00 - 25
WELD 1 00.5 - 99.5
POWER 1
CURRENT 1 01 - 99 01.0 - 90.0 kA
COLD 2 00 - 50
N. IMPULSE 00 - 09
SLOPE DOWN 00 - 25
COLD 3 00 - 50
POST-WELD 00.0 - 99.5
POST-POWER 05 - 99
HOLD TIME 01 - 99
OFF TIME 00 - 99
CURR. MIN 1.0 - 90.0 kA
ANGLE MIN 001°- 180°
CURR. MAX. 1.0 - 90.0 kA
ANGLE MAX. 001°- 180°
For further information concerning TE550 see the relevant instruction manual.

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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.
3.1 PLACE OF INSTALLATION
The welder must be installed in a position fulfilling the following features:
•In an inner place. The use of the welder in an open place is not foreseen.
•Room temperature included between 0 and 40 °C (If water is removed, storage is allowed
down to 20°C below 0); 1000 m. maximum altitudes.
•In a well ventilated area, free from dust, steam, and acid exhalations.
•The working place must be free from inflammable materials because the working process can
produce spatter of melted metal.
•Around the welder there must be enough room to carry out both working and maintenance in a
comfortable manner and without any risk.
•In a place with a suitable lighting system in comparison with the work to be carried out.
•The place of installation must necessarily be flat and the ground must be without unevenness
which can be dangerous during the working.
If the welder is used to carry out welding processes which can cause smoke exhalations, there
must be installed a proper aspirator. The welder must be properly fixed to the ground through the
proper holes placed on the welder basement. Do not install nearby the welder neither supporting
tables nor equipment limiting the approaching 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 verify the welder integrity. Check that the welder is equipped with all the standards
components; immediately inform the manufacturer in case some components should lack. All the
material forming the package must be removed according to the present environmental
protection regulations.
The welder barycentre is high from ground. For this reason, the welder must be moved only by
means of the proper attachment placed on the unit upper side. Consider the welder weight stated
on the “TECHNICAL FEATURE” paragraph.
3.3 PNEUMATIC INSTALLATION
For a correct compressed air supply to the welder, it is necessary either a centralised system or a
compressor capable of supplying dry air cooled within the maximum pressure and in the quantity
stated in the paragraph “Technical Features”. Pay attention to the hoses minimum diameter
stated in the same paragraph.
In case the line is subject to great pressure variations, it is advisable to supply the welder by
means of a tank of at least 50-100 litres equipped with a gauge-pressure supplied by means of a
one-way valve.
The machine is equipped with a filter unit, the moisture of which must be discharged periodically.
Periodically discharge also the moisture eventually present in the built-in small air tank, by means
of the tap placed on the bottom of the tank itself.

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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.
3.4 COOLING WATER CONNECTION
For a correct cooling of the welder it is necessary clean water at a maximum temperature of 30°C
at the quantity stated on the paragraph “Technical features”. When connecting the unit to the
water line check for dirt or packing scraps in the hoses and connect the supply to the inlet, and
the drain to the outlet, this to allow that still cool water immediately reaches the parts of the
welder most subject to heating.
Different cooling circuit systems are available: with city supply water, with re-circulating water,
with heat exchanger (air-water) and with refrigerator. If the circuit is with city supply or refrigerator
and you are working in presence of high humidity, we suggest to avoid the use of low
temperature water, as this could produce moisture inside the machine. In presence of hard water
it is necessary to install a water softener at the inlet hose, this to avoid that deposits obstruct 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 be installed on public low voltage network
which supplies domestic premises. This can cause electromagnetic interferences.
Installation must be carried out by specialised personnel, aware of all safety rules.
As this unit can be supplied for different power supply versions, before connecting the unit to the
power line, check if the voltage shown on the features plate corresponds to the one of your
power supply.
Consult the “technical features” paragraph to determine the cables section to be used, according
to their length. On this paragraph you find also the values of fuses which must be placed on the
welder supply input. Fuses must be delayed type. Connect machine to earth by using a cable
having the same section of the mains cable. In order to facilitate the maintenance operation, we
recommend you to supply the welder machine by means of a mains disconnecting switch. The
welder has not been designed for different voltages supply. If a voltage change is necessary
consult your supplier for the replacement of required parts and new set ups.