Welding Control Unit TE-600
Contents
1. input active To properly recall the welding programs either activate the direct recall inputs before the start cycle signal or simultaneously 25 42 DESCRIPTION OF THE WORK CYCLE The user decides the work cycle to be run by the TE600 by adjusting the programming parameters These parameters describe the operating times and the current adjustments that run in sequence comprise the work cycle The graph below shows the sequence in which the functions if programmed are carried out ls v A 11 ks 15 ji The numbers shown in the graph refer to the programming parameters outlined in the sections above Due to safety reasons the microprocessor does not start the welding cycle if the start cycle signal is activated on powering up the welder As such clear the control and activate it again Micro cut offs or excessive voltage drops do not alter operations but lock the control unit To restore routine operating conditions simply turn the welder off and then on again 26 42 EXAMPLES OF WELDING PROGRAMS 4 STAGE PLAIN CYCLE NUMBER PARAMETER VALUE wono K 1 iocyces 2 souem 20cyces 4 PRESSURE 04 5 bar 6 PRECURR 8 soru ooms 9 weit 0020 10 CURRENTi 040 0 2 Nouse 9 19 Hop 25eyces 30 OFFTME 00 CYCLE WITH SLOPE UP NUMBER PARAMETER VALUE momoe K 1 squeezet 12. 2 squEEzE 20 4 PRESSURE _ 04 5 bar 6 Precum oroa 8 soeu 10 9 0020 10 CURRENTi 040 0 kA 1 N OFPULSES o 19 Ho 25eyces 30 orrmME 0 cycles Tek Esegui EP 50 0mV 4Plj4 00ms Ch2 f 56 0mvV 19 80 Tek Esegui I 50 0mV PHM 00ms Ch2 7 S6 0mV 9 200 27 42 CYCLE WITH PRE WELD SLOPE UP NUMBER PARAMETER VALUE momoe KX 1 squeezet 1 2 squeeze 20 cycles 4 PRESSURE 045 s PREWELD 0020 6 PRE CURR 0260 7 0M0ms 8 9 0 2 9 0020 10 CURRENTi 040 0 2 N OF PULSES o 19 Hob 25eyces 30 orrrME 00 Tek Esegui Trigger UT a GIC ICT 10 20 CYCLE WITH PRE WELD WITHOUT COLD TIME BETWEEN PRE WELD AND WELD NUMBER PARAMETER VALUE omose K saueze iocyces 2 soueze 20cyces 4 PRESSURE O amp Sba s PREWELD 0020 6 PRECURR 0260 8 9 0 ooms 9 0040 10 CURRENTi mooka 2 vormuss o 19 Hob 25eyces 30 orrmME 00 cycles Tek Esegui 28 42 J 4 120 20 CYCLE WITH PRE WELD WELD AND SLOPE DOWN NUMBER PARAMETER VALUE momoe 1 squeezet 1 2 soueze 20 4
3. PARITY EVEN STOP BIT The control unit runs the data transmission at the beginning of the OFF time Keep in mind that the time used for printing data is approximately 20 ms and such time will be added to the set OFF time A specific parameter in the special functions menu permits to choose whether or not to activate the print The following items are printed for each weld Welding program number Number of cycles with which the weld was carried out Welding current Welding current conduction angle Progressive spot number Out of limit spot signal When the control unit is powered every time a programming value is edited and when the key selector is switched from PROGRAM to RUN the control unit prints the header and the values of the parameters of the selected program 32 42 Data printout example during the weld INVERTER CONTROL UNIT TE600 V 6 0 PROG WTIMEms MEANRMS SPOTS LIMIT 01 0020 10 00 00013 OK 01 0020 10 00 00014 OK 0 0020 09 90 00015 OK 0 0020 09 95 00016 OK 0 0020 10 00 00017 OK 0 0020 10 02 00018 OK 0 0020 10 00 00019 OK 0020 09 97 00020 OK Printout example of work program parameter values CONTROL UNIT TE600 6 08 PROGRAM NUMBER 01 WORKING MODE I SQUEEZE 1 20 SQUEEZE 0 FORGE DELAY 10 PRESSURE 01 0 bar PRE WELD 0000 ms PRE CURR 001 0 kA
4. SLOPE UP The SLOPE UP parameter describes the time for attaining the programmed welding current value The starting value of this slope always corresponds to the minimum current whereas the final value corresponds to the current value set at parameter CURRENT 1 The slope inclination is automatically calculated by the microprocessor based on the set values The SLOPE UP time is added to the welding time WELD 1 This parameter indicates the welding current flow duration It is carried out with the same power value set at parameter CURRENT 1 When the pulse operating mode is activated this parameter indicates the duration of each pulse CURRENT 1 The value indicated in CURRENT 1 shows the current adjustment that is used for carrying out the welding process COLD TIME 2 This parameter indicates the time that elapses from WELD 1 to the pulses where applicable or to WELD 2 N PULSES This parameter indicates the number of pulses used for carrying out the welding process The duration of each pulse corresponds to the time set in parameter WELD 1 WELD 2 This parameter indicates the duration of the flowing of a second weld current which will be run at a power value equivalent to the one indicated in parameter CURRENT 2 CURRENT 2 The value expressed in CURRENT 2 indicates the current adjustment used for carrying out WELD 2 SLOPE DOWN This parameter is a welding time that is added at the end of the welding process during wh
5. PRESSURE _ 04 5 bar s PREWELD 0020 6 PRECURR 0260 8 soeu ooms 9 0020 10 CuRRENT 040 0 kA 2 N OF PULSES o 15 SLOPEDOWN ooms 19 HOLD 25eyces 30 orrrME 00 CYCLE WITH SLOPE UP AND PULSE WELD NUMBER PARAMETER VALUE work moe k 1 20 eycies 2 soueze 20cycs 4 PRESSURE 046 6 Precum oroa s soeur ooms 9 0020 40 CURRENTi 0400 4 090 4 MorPUsE 19 HOLD 25eyces 30 orram 00 Tek Esegui Trigger 50 0mV P 10 0ms Ch2 S6 0mV 9 800 Tek Esegui 50 0 P i0 0ms Ch2 56 0mV 9 200 29 42 READING OF THE WELDING CURRENT AND CURRENT LIMITS The value of the current which the control unit reads and visualizes is the mean of the RMS values read for every weld millisecond time The value displayed always refers to the main adjustment i e to that of the WELD 1 parameter As far as pulse welds are concerned the value of the current will always be that of the last pulse The PRE WELD and POST WELD current as well as the current that circulated during the squeeze times is never read If a test weld is performed in NO WELD mode the visualized current value will be zero and the welding spots counter will not be increased The TE600 is also fitted with a feature for
6. cycle signal When the welder works in automatic cycle the welder goes on executing welding cycles until the start cycle signal is released MIN CURRENT This parameter fixes a minimum current value For each weld the TE600 monitors that the welding current supplied by the welder is higher than the value set at this parameter if it is lower an error condition occurs see the relevant paragraph If this parameter is actually set for the same value of the parameter MAX CURRENT the current limits control is disabled MAX CURRENT This parameter fixes a maximum current value For each weld the TE600 monitors that the welding current supplied by the welder is lower than the value set at this parameter if it is higher an error condition occurs see the relevant paragraph If this parameter is actually set for the same value of the parameter MIN CURRENT the current limits control is disabled 10 42 SETUP MENU In the SETUP menu it is possible to activate certain functions that modify the functionality of the control unit SETUP gt LANGUAGE ENG STOP BAD SPOTS 0 SPOTS MAX 00000 SETUP MENU PARAMETERS TABLE BAD SPOTS Numer of spots arourotimtsep o9 DESCRIPTION OF THE SETUP MENU PARAMETERS LANGUAGE Use the LANGUAGE parameter to select in which language the control unit should visualize the programming parameters STOP BAD SPOTS This parameter permits programming the control uni
7. data Therefore it is advisable to write down all the parameters set in the former menus before proceeding DIAGNOSTIC MENU The diagnostic menu is used for checking the status of the interface signals between the TE600 control unit and the power module that controls the drivers DIAGNOSTIC VERSION N 1 08 ERR DRIVERS NONE CAPACITORS 562 V 20 42 DIAGNOSTIC MENU PARAMETERS TABLE EMERGENCY WELD NO WELD CHECK WELD START BOOSTER THERMOSTAT EV WATER READY BOOSTER WRONG BOOSTER LOCK BOOSTER TEMP BOARD TEMP SINK TRAFO I2T FAIL V SW DRIVER DRIVER LED 1 DRIVER LED 2 DRIVER LED 3 DRIVER LED 4 DRIVER LED 5 This indicates that inverter emergency inlet has OK ERR intervened with ERR Vice versa then OK is displayed If the inverter inlet is on weld then it displays OK OK ERR while if it is on no weld it displays ERR It indicates that the cycle start control has been given OK ERR to the inverter welding inlet with OK or it is on hold with ERR This indicates if the safety thermostat of the inverter OK ERR has tripped by displaying ERR Vice versa then OK is displayed It indicates if the outlet controlling the inverter water ON OFF solenoid valve is active By displaying OK it indicates that the inverter has OK ERR finished charging the capacitors and is ready to weld Vice versa it displays ERR It indicates that the inverter has experienced
8. setting a number of weld current check limits These limits permit to keep the weld current constancy under control for the purpose of helping in achieving a constant qualitative result During the work cycle when the read weld current value is beyond the set limits the weld spot is considered as being out of limits The welder may be stopped when a consecutive series of out of limits spots are welded The number of consecutive welding spots that cause the control unit to stop is adjusted by means of parameter STOP BAD SPOTS in the setup menu the programming function is outlined in the associated section This value may vary from 0 to 9 If set to 0 the function is disabled and therefore when the preset limits are exceeded the welder does not stop However a WRONG outgoing signal is generated see paragraph relevant to DESCRIPTION OF SIGNALS ON TERMINAL BOARD Keep in mind that in order to count the out of limits spots they must come one after the other When the programmed condition takes place if the current value of the last weld is lower or higher than the values set in the aforesaid parameters a message is displayed STOP WRONG SPOTS L Simply press a key to clear this error condition When the values set in the parameters MIN CURRENT MIN CURR and MAX CURRENT MAX CURR are the same the function of limits control is disabled 30 42 THERMOSTAT PRESSURE SWITCH INPUT FUNCTION This inlet is c
9. the start cycle device PEDAL or TWO HAND CONTROL When the nearby LED is switched off the start cycle command is carried out by the PEDAL whereas if the LED is switched on the command is carried out by two hand push buttons TWO HANDS CONTROL In order to work properly the two push buttons must be pressed at the same time or in sequence within a maximum time of 0 5 seconds conforming to the accident prevention regulations WELD NO WELD Key In WELD position LED switched on the control unit runs the programmed welding cycle In NO WELD position LED switched off the control unit runs the programmed cycle without welding current circulation yet keeping all the time parameters unchanged CLEAR Key It is used to clear the error conditions and for zeroing the welds counter and during programming activities for zeroing the parameters PROG RUN Key selector In PROG position key turned to the 4 button position it enables the keyboard and allows the running of all the foreseen programming operations In RUN position it enables the spot welder commands and allows the running of the work program only 22 42 PANEL LEDs ET ed Oo ia Neer only is activated A When this warning light turns ON this means that the control unit is generating command pulses for the IGBT control card This means that solenoid valve 1 which actuates the main cycle is activated This means that the solenoid valve that controls counter pressure is a
10. COLD 1 0000 ms SLOPE UP 000 ms WELD 1 0020 ms CURRENT 1 020 0 kA COLD 2 0000 ms IMPULSE N 0 WELD 2 0000 ms CURRENT 2 001 0 kA SLOPE DOWN 000 ms COLD 3 0000 ms POST WELD 0000 ms POST CURR 001 0 kA HOLD TIME 20 OFF TIME 20 33 42 INTERFACE FOR PROPORTIONAL VALVE ITEM 50220 Option Interface card ITEM 50220 permits the control unit to control a proportional valve and to set as program parameter the welding pressure in bars This interface requires an external power supply The 12 pin terminal strip permits the connection of the proportional valve the control unit and the interface power supply 6 6 6 ALARM IN 74 ALARM1 PIN 33 AUX3 ALARM PIN 34 1 It is possible to program the control voltage range of the proportional valve directly from the weld control unit The PRESSURE TRANSDUCER parameter is in the Installation menu by means of which it is possible to select the bar Volt ratio most suitable for the type of solenoid valve to be used 4 5 7 70 71 72 73 Example WIRING DIAGRAM 64 70 ITEM 50220 PROPORTIONAL 65 71 VALVE 66 67 68 72 Ground 24 Vac Ground 24 Vac N B _ red 010 LED is present on card 50220 near the relay for indicating when 24VDC Pin 71 is present and which goes to the proportional valve If the LED is OFF check for the correct 24VAC wiring Pin66 and Pin67 and ground wiring Pin68 _ Card 50220 also contains a small trimmer fo
11. LORS 1090 LOUSONS ROAD UNION NEW JERSEY 07083 USA Tel 908 964 9100 Fax 908 964 4492 email sales lors com WELDING CONTROL UNIT TE 600 USER MANUAL RELEASE SOFTWARE No 6 08 EDITION JUNE 2007 This page is intentionally left blank 2 42 TABLE OF CONTENTS CONTROL UNIT PROGRAMING 8 _ DESCRIPTION OF THE PROGRAM PARAMETERS 3 42 WELDING CONTROL UNIT 600 The TE600 is a microprocessor based welding control unit for resistance welders in inverter technology The task of the welding control unit is to manage the welder s components in particular the IGBT power booster unit which regulates the welding current It is possible to store up to 63 different welding programs all of which can be directly recalled from an external device Each program comprises 22 programmable parameters that describe the work cycle In addition to the basic 4 stage welding cycle the control unit allows the running of welding processes with pre welding current post welding current slopes and pulses The TE600 works in constant current mode it visualizes the weld current and controls the current supplied with settable limits MADE IN ITALY lt MAIN TECHNICAL DATA e Simplified programming by 6 keys and alphanumeric LCD Inverter command with IGBT at medium frequency 1000 Hz e Storage of 63 welding programs all of which are recallable from PLC PC etc 22 programmable parameters for each progra
12. O ZERO DATA RESET MEMORY DATA ZEROING IN PROGRESS SOFTWARE UPGRADE IN PROGRESS PUSH KEY RESTART TO CONTINUE TECNA TE600 VER 6 08 WELD CONTROL UNIT STOP N MAX SPOTS CURRENT 1 2 HIGHER CURMAX The control unit read a mains frequency of 50 Hz The control unit read a mains frequency of 60 Hz The control unit was not able to read a steady mains frequency The control unit s data zeroing procedure has been activated The data zeroing procedure of the control unit is in progress The upgrading procedure of the control unit is in progress Warning DO NOT turn off the control unit during this phase The control unit is waiting for the rearm key to be pressed so as to activate the welding control unit functions When the control unit is turned on it displays the type of control unit and the software version The welds counter has attained the maximum set value One or more welding currents have been set that are beyond the maximum limit CURMAX that is set in the INSTALLATION menu 37 42 Try to turn on the control unit again and ensure that power supply is 24 V AC with 50 60 Hz frequency Press key to continue otherwise press any other key or wait a few seconds Ensure that the activation of the VAUX does not cause injury damage to people equipment and then press the key Clear the counter see chapter FUNCTION OF THE WELDS COUNTER Press the CLEAR key to del
13. and as a consequence the welding current density Ampere mm decreases If the current is maintained at a fixed value throughout the whole electrode life it will be noticed that the quality of the last spots is poorer than the first ones The stepper function is used for overcoming this problem It gradually increases the current adjustment during the welding process when the diameter of the electrodes increases this enables to maintain a constant weld current density An increment curve is programmed to describe the pattern of the current during the electrodes life This curve is described by one or more segments for each of which the number of welding spots and the associated current increment in percent are programmed After it has been set the current increment is applied to all the welding programs used The current limits if used increment by the same percent The same holds true for the pre weld and post weld current adjustments If the set welding current values are changed during the process the control unit re calculates the welding conditions starting from the stepper value reached that far If modifications are made to the programmed stepper curve the control unit clears the counter and therefore the starting diameter of the electrodes must be reset SIMPLIFIED USE OF THE STEPPER FUNCTION LINEAR INCREMENT The stepper function can be used in a simplified manner by programming a simple percent increment for a specific nu
14. control at the power module Connected to TRIGGER contacts 7 and 15 respectively of the power booster COM 1 This input connected to the power module 12 9 detects the Wrong WRONG IN signal i e welding with current beyond the set limits These inputs are used to directly recall the welding program from an external device In order to recall the programs properly these inputs should be enabled before the start cycle signal The inputs are active when closed on the shared COM1 COM 1 Connect to the micro switches of the start cycle pedal START2 START2 NO determines the beginning of the work cycle of the second program chosen during the programming operations This input is active when closed on the shared COM1 AUX2 This input allows an external device to stop the welding cycle during the squeeze phase It may be used as an interlocking input or for connecting safety devices such as for instance flux stats or pressure switches The contact connected to it should be the normally open type and is activated when closed on COM1 LOCK_IN This input connected to the power module pin 8 is used as an interface for checking the flow of current in actual fact COM1 Connect to the micro switches of the start cycle pedal The START START NO determines the beginning of the work cycle This input is active when E closed on the shared COM1 AUX This input allows an external device to stop the welding cycle during the squeeze phase It can be use
15. ctivated L EX 3 This means that the solenoid valve that actuates the pressure or forging cycle is activated This means that the solenoid valve that controls the double stroke is activated RUN After having finished the programming phase the user should turn the Prog Run key to RUN position to run the welding spots lf the start cycle device is activated before the control unit switches from the programming condition to the work condition it will be ignored Simply release the device that commands the cycle start and then activate it again In order to run test cycles without welding current use the WELD NO WELD function When the control unit is in standby with the key turned to RUN position the display visualizes the following data PROGRAM NUMBER 01 WELD TIME 0050 ms MEAN RMS 12 46 kA COUNTER SPOTS 00138 1 2 3 4 This is the selected welding program This is the weld 1 time of the selected program This is the RMS mean value of the current of the last weld This is the counter of the welding spots performed 2 YS NH 23 42 SELECTION OF THE WORK PROGRAM The table below shows which inputs are to be activated to recall the work program directly The selection is made by means of five inputs appropriately activated according to the combinations shown below PROG N RICE Rics Rica RIC RICZ PROG N Rice RIGS Rica RIGS Ricz puc a
16. d as an interlocking input or for connecting safety devices such as for instance flux stats or pressure switches The contact connected to it should be the normally open type and is activated when closed on COM1 READY IN This input connected to the power module Pin 10 detects the ON status of said module 40 42 c BIC1 NO This input can be connected to the hand operated start cycle push buttons The welding cycle starts when BIC1_NO and BIC2_NO are closed simultaneously or in sequence within a maximum time of 0 5 secs This value has been chosen in accordance to the international safety rules RIC5 These inputs are used to directly recall the welding program from an RIC6 external device In order to recall the programs properly these inputs should be enabled before the start cycle signal The inputs are active when closed on the shared COM1 D STROKE This input is used for the manual control of the double stroke in welders 2 COM1 fitted with this function 7 PRESS FLU This input is used for connecting a pressure switch and or a flux stat COM1 AUX3 This input allows an external device to stop the welding cycle during the COM1 squeeze phase It can be used as an interlocking input or for connecting safety devices such as for instance flux stats or pressure switches The contact connected to it should be the normally open type and is activated when closed on COM1 BIC2_NO Input for the hand operated start cycle
17. e 4000 welding spots and the following current values are required during the different moments of the electrodes life SPOTS PERFORMED REQUIRED CURRENT 1800 19 5 3000 20 2 4000 end electrode diameter 20 7 kA Therefore calculate the duration in number of welding spots and the percent increment of each that the percent increment must always be calculated in relation to the beginning of the segment being examined Duration of segment 1 700 0 700 spots Duration of segment 2 1800 700 1100 spots Duration of segment 3 3000 1800 1200 spots Duration of segment 4 4000 3000 1000 spots initi 17 8 1 endcurrent initialcurrent xi 178 15 100 199 initialcurrent 15 Chains vi sehen endcurrent initialcurrent x100 19 5 17 8 x100 10 initialcurrent 17 8 Change 96 segment 3 TE REO OH 100 me 100 4 initialcur rent enecurrent initialcurrent x100 20 8 20 2 100 3 initialcur rent 20 2 The following parameters are consequently set in the Stepper menu INCREMENTS INCREMENT2 Increment percent of second segment 17 42 welding program should be adjusted for carrying out the first welding spot followed by the adjustment that allows the achieving of the required current with the starting diameter of the electrodes 15 KA Now the welding process can begin Current will change according to the programmed increme
18. ed out by switching the key to WORK position and the values of the run weld at the end of each spot PRINTER SPOTS with optional card If the previous parameter is activated the user may choose by means of this parameter which welding spots to print It is possible to print all spots ALL or choose to print only those whose current value remains within the programmed limits GOOD or those whose value is beyond the limits BAD 12 42 STEPPER MENU The Stepper menu contains parameters associated with the current stepper operations STERPPER gt gt NUM INCREMENTS O1 SPOTS 1 INCREMENT 1 4000 12 STEPPER MENU PARAMETERS TABLE NUM OF INCREMENTS This parameter indicates how many segments are to be created for implementing the stepper curve Only the parameters that describe the desired function will be displayed in relation to the set value SPOTS 1 2 3 Each of these parameters indicates the number of spots of which the associated segment is composed INCREMENT 1 2 3 These parameters indicate the current stepper percent to be attained upon the completing of the spots set in the associated segment 13 42 CURRENT STEPPER FUNCTION The stepper function enables to compensate the wear of the electrodes that affects the quality of the welding spots When the electrode diameter is enlarged the contact section area between the electrode and the workpiece to be welded increases
19. ed to the authorized personnel only The user is accessing the menu reserved to the installers only A wrong password has been entered 39 42 Check that water is circulating inside the welder in the correct quantity and or check the working efficiency of the thermostat Check the wiring of the control unit Check the coil of the solenoid valve Press the key if you wish to zero the spots otherwise press any other key and wait a few seconds Enter the access code if known otherwise wait a few seconds Enter the access code if known otherwise wait a few seconds DESCRIPTION OF SIGNALS ON TERMINAL BOARD This is the control unit s power supply which must be 24 Vac The power supply transformer should be at least 50 VA and must supply the control unit only in order to avoid possible sources of interference LOCK END This output is used to signal when the control unit reaches the end of the LOCK END cycle if END CYCLE function was selected when LOCK in selected the control unit gives an output signal from the beginning of the welding process to the hold A max voltage of 30Vdc and a maximum current of 10mA can be applied to this contact This output is a contact that closes if the set current limits are not respected The contact remains closed for the HOLD and OFF time A max voltage of 30Vdc and a maximum current of 10 mA can be applied to this contact Output the IGBT activation
20. either an OK ERR out of limit or excessive or faulty current supply OK while if the current supply is within the limits the parameter is correct on the outlets ERR During the welding process the inverter is in the OK OK ERR condition while in the welding hold phase it is in the ERR condition the welding transformer s primary The data is displayed only if the communication cable item 22890 is connected Please refer to the installation menu for further information FACTORY RESERVED MENU This menu is reserved to and can be accessed by authorized personnel only 21 42 PANEL CONTROLS Left direction key used for exiting from the programming menu Right direction key used for accessing the programming menu Up direction key used for moving the cursor into the upper parameter Down direction key used for moving the cursor into the lower parameter Key for increasing the value of a numeric parameter or for changing the status of a parameter Key for decreasing the value of a numeric parameter or for changing the status of a parameter RESTART key It enables the commands and the control unit s outputs It must be pressed every time the control unit is powered When this key 1 pressed all the devices connected to VAUX are powered such as for example any double stroke valves Before pressing the key it is important to check that it will not cause injury damage to people or equipment Key for selecting
21. eriod Mains frequency of 50 Hz 1 period 20 ms Mains frequency of 60 Hz 1 period 16 6 ms WORK MODE This parameter defines the mode for adjusting the welding current at constant current IK SQUEEZE 1 If a pneumatic circuit is present with low pressure squeeze such time is that which determines the duration of the squeeze at low pressure i e the interval of time that elapses from the beginning of the head descent to the application of the welding force The set value must be long enough to allow the electrodes to reach the workpiece to be welded In a standard pneumatic circuit such time is the interval from the beginning of the head descent to the beginning of the welding The set value must be long enough to allow the electrodes to achieve the proper clamping force before the welding begins During the first squeeze time it is possible to end the cycle if the start cycle signal is deactivated SQUEEZE The SQUEEZE determines the closing time of the electrodes i e the time interval between the beginning of the closing of the electrodes and the beginning of the weld The set value must be long enough to permit the electrodes to reach the workpiece to be welded and to attain the correct clamping force before the weld begins An inadequate adjustment of such time produces sparks among the electrodes and the sheet when the welding begins causing quality inconsistencies If the start cycle signal is deactivated during the squeeze
22. ete the message and change the wrong current value as compared to the correct value set in the PROGRAMMING menu to below the CURMAX STOP WRONG SPOT LIMIT SUPPLY SYNC ERROR CAPACITORS SUPPLIED PLEASE WAIT CAPACITORS ARE NOT SUPPLIED CORRECTLY CHECK 14 POWER SUPPLY WARNING BOOSTER NOT READY SYSTEM ERROR COMMUNICATION ERROR CHECK CONNECTION PRESS ANY KEY TO RETRY DEVICE NOT FOUND CHECK CONNECTION PRESS ANY KEY TO RETRY CHECKING DEVICE PLEASE WAIT PLEASE RELEASE START AND SECURITY EMERGENCY OPEN CHECK INPUT The counter that counts the out of limit welding spots has attained the set value or the set wrong spots limit has been attained A synchronism error has occurred due to the temporary lack of the reference signal of the power supply line or due to line interferences The control unit warns that it is running the procedure for charging the capacitors battery The control unit warns that the capacitor battery charging procedure was not run correctly A fault has occurred at the power module or a connection between the power module and the welding control unit has been cut There is a communication error between the TE600 and the booster There is a communication error between the TE600 and the power module A key was pressed to reactivate the communication after a serial communication error The Restart key was pressed when the star
23. ich the weld current decreases as compared to the value set during the last weld that comes before said time down to the minimum value The slope inclination is automatically calculated by the microprocessor based on the set values The SLOPE DOWN time is always added to the welding time COLD TIME 3 This parameter indicates the time that elapses from the previous welding time and the POST WELD time If the POST WELD parameter is not programmed said time is not run 9 42 POST WELD This parameter indicates the duration of the flowing of the POST WELD current which will be run at a power value equivalent to the one indicated in parameter POST CURR POST CURRENT The value expressed in POST CURR indicates the current adjustment with which the POST WELD is run HOLD This parameter indicates the time that elapses from the end of the welding process to the opening of the electrodes It allows a quicker cooling of the welding spot and prevents the spot from being stimulated before being properly cooled OFF TIME This parameter indicates a welder wait time namely the one that elapses from one welding cycle to the next one when the welder is working in automatic cycle When this value is set to zero the welder always works in single cycle if it is set to another value the welder will work in the automatic cycle When the welder works in single cycle the control unit carries out a single welding cycle each time it receives a start
24. m Stepper function for compensating the electrodes wears with programmable curve Weld times adjustable in 1ms increments Visualization of the welding current in kA and limits of the welding current Automatic double stroke function for the applicable welders Proportional valve for controlling the welding pressure Welds performed counter e Single and automatic cycle WELD NO WELD function Control of 4 solenoid valves 24 Vdc 7 2 W with output protected against short circuit Welding current limits with output for signalling out of limits welds Outputs for interfacing with external devices Interlock End cycle Automatic voltage compensation Five languages can be selected Possibility of updating the control unit hardware 4 42 CONTROL UNIT SWITCH ON As soon as the welding control unit is turned on the display shows the primary mains frequency and the software version of the program SUPPLY FREQUENCY 50 Hz TE600 6 08 WELD CONTROL UNIT After a few seconds the TE600 switches to standby status PUSH KEY RESTART TO CONTI Press the restart key for one second to enable the controls and the outputs of the control unit It must be pressed every time the control unit is powered When the key is pressed all the devices connected to the VAUX are powered such as for example the double stroke valve and then the procedure for charging the bat
25. mber of the program to be used Choose among the 63 storable programs using the and El keys Then proceed with the next parameters moving with the 4 and v keys adjusting the desired value always using the l and El keys As such all the parameters will be set to the desired value for carrying out the welding process Keep in mind that there is no need to confirm the set data item that is stored automatically after the adjustment Parameters can have several values according to the type of parameter The minimum and maximum limits of each parameter are shown in the following table 6 42 PROGRAM DATA PARAMETERS TABLE s_ PRE CURRENT PREWELO CURRENT 0009 12004 s 0 50 s _ In order to view these parameters in the welding program they must be activated in the installation menu see specific section There are few special conditions f OFF TIME is set to 0 the welding control unit will work in single cycle When parameters PRE WELD and or WELD 2 and or POST WELD are set to 0 said cycles will not be run 7 42 DESCRIPTION OF THE PROGRAM PARAMETERS As far as the parameters that indicate times expressed in milliseconds are concerned the mains frequency 50 60 Hz does not change the duration of the set time whereas for all those parameters that indicate times expressed in periods also called mains cycles the main frequency determines the duration of one p
26. mber of welding spots that are to be carried out with the same electrodes The user must know the service life of the electrodes in order to adjust these parameters To do this run some welding tests with new electrodes before they are replaced Under these two conditions the currents required for carrying out the welding spots of the required quality are assessed The change in percent is calculated and then it is set in the control unit The parameters that allow the carrying out of the stepper function are entered in the Stepper menu The instructions for programming these parameters are outlined in the relevant paragraph For the simplified use of the stepper function always set parameter STEPS INCREM to 1 since the segment to be programmed is only one Enter the number of welding spots to be carried out in parameter SPOTS 1 i e the foreseen life span of the electrodes Enter the percent increment to be achieved in parameter INCREMENT 1 14 42 Example After having run the welding tests the result was that the usable life of the electrodes 2000 welding spots Another fact that ensued was that the required current for new electrodes 15 kA whereas after 2000 welding spots the diameter increase of the electrodes requires a current of 19 kA Therefore calculate the change in percent as follows mu 19 1 Chaiige initialcur rent 100 9 15 initialcurrent x100 26 Consequently the following parame
27. mits to select the type of communication The parameters are NONE PRT 232 when using a printer and NET 485 when using the network NETWORK ADDRESS This parameter selects the address that will allow the network to recognize the control unit INVERTER SIZE This parameter indicates the capacity of the power module to which the control unit is connected The value may vary from 100 to 2000 and it is expressed in terms of primary current PRIMARY COIL This parameter indicates the number of primary coils that make up the welding transformer connected to the power module used It must be set to the same number as the transformer s actual number of coils If it is set a different primary coil number than the transformer s real one then one may experience excessive current supplies Therefore the value stated on the transformer s plate may be experienced T CURR MAX This parameter indicates the maximum current value at which the welding transformer may work To prevent breakdowns or irreparable damage to the transformer it is essential that this data item be programmed very carefully without making any mistakes RESET DATA When the user selects ON and exits from the installation menu the following message is visualized PRESS KEY TO RESET MEMORY PREMERE TASTO 4 PER AZZER DATI WARNING if you press all programming setup and installation data will be deleted and will be replaced by the default
28. n the graph below IDEL PATTERN lt gt REAL PATTERN WITH LINEAR INCREMENT CURRENT NUMBER OF WELDING SPOTS As such the use of the linear increment is an approximation which nonetheless permits to achieve good results in most applications However when the user wishes to achieve utmost constancy during work conditions a non linear increment curve can be set that is described by defining a certain number of segments This type of adjustment requires an adequate knowledge on how electrodes wear and on the parameters required during their life Consequently many welding spot tests are necessary for assessing the work conditions in different moments of the electrodes life IDEAL PATTERN lt REAL PATTERN WITH SET INCREMENT CURVE CURRENT NUMBER OF WELDING SPOTS The increment curve is set by assessing a certain number of linear segments The number of welding spots and the desired increment are assessed for each segment The STEPS INCREM parameter determines the number of segments to be inserted in the increment curve Enter the number of welding spots that make up the segment in the SPOTS parameters Enter the corresponding percent increment to be achieved in the INCREMENT parameter The programming procedure is outlined in the Stepper menu paragraph 16 42 Example After a number of welding tests the ensuing life of the electrodes resulted to b
29. nt rule The graph below shows its pattern 22 20 a uaria O we Noe WR Um b 19 SEGMENT 4 SEGMENT 3 SEGMENT 2 CURRENT kA v 16 SEGMENT 1 o N T T T T T T T T T T 0 1000 2000 3000 4000 NUMBER OF WELDING SPOTS WELDING SPOTS COUNTER FUNCTION The control unit contains a weld counter with the possibility of programming the maximum number of welding spots During the welding process the control unit displays the value currently attained by the counter The counter is updated after each welding spot with the only exception of welding tests carried out in NO WELD To clear the counter press the CLEAR key The display will show the following message CLEAR COUNTER SPOTS KEY YES Press the key to clear the counter otherwise wait 8 seconds or press another key to end the procedure without clearing the counter The maximum welds number to be carried out is set in the set up menu as formerly described When the counter attains the set number of welds the control unit displays the following message STOP N MAX PUNTI Welder operations are interrupted until the counter is cleared If the parameter is set to zero the stop function is deactivated To clear this error condition it is sufficient to press any key 18 42 INSTALLATION MENU The installation menu contains the parameters that determine the complexity and typology of the welder at which the control unit is wo
30. onnected to a flow switch and or pressure switch normally closed placed on the welder If when starting the welding cycle the control unit displays the following error it means that the protection FLOW SWITCH PRESSURE SW ACTIVATED flow switch pressure switch has intervened It is not possible to carry any welding spot out before it is restored In case this error occurs check that the cooling water actually flows in the required quantity and temperature Also verify that the duty cycle is not too high for the machine The message is displayed only when the start cycle signal is activated Once the correct water flow is restored press the CLEAR key for restarting the work 31 42 SERIAL INTERFACE RS 232 ITEM 50214 ITEM 50190 Option Use expansion card ITEM 50214 to connect the TE600 with a printer or a PC fitted with RS232 serial interface to document production data The card interfaces with the control unit by means of a 6 pin connector and with the printer or computer by means of a standard female 9 pole connector The 9 pole connector is wired as follows On request cable Art 70377 is available for the connection with standard serial printers that as a rule are equipped with a female 25 pole connector as follows The control unit does not execute any type of handshaking at the serial port The serial port of the printer must be configured with the following values SPEED 9600 BAUD WORD LENGTH
31. push buttons The welding cycle starts when BIC1_NO and BIC2_NO are closed simultaneously or closed in sequence within a maximum time of 0 5 secs VAUX 24 Vdc output It indicates that the control unit is powered and ready to receive a start cycle command This output can be used to connect a valve for the opening of the cooling circuit It is also connected to the power module Pins 17 and 18 This is a suitable command for piloting 24Vdc coil 5 W EV1 Connect to the solenoid valve that actuates the main cycle This is a suitable command for piloting 24Vdc coil 5 W EV2 Connect to solenoid valve 2 BACK PRESSURE This is a suitable 40 command for piloting a 24Vdc coil max 5 W EV3 Connect to solenoid valve 3 FORGING and 4 DOUBLE STROKE COM2 This is a suitable command for piloting a 24Vdc coil max 5 W EVA EV PROP This is an output that is connected to the piloting card of the proportional 45 EV solenoid valve Option art 50193 EMERGENCY Emergency input An emergency button can be connected to these EMERGENCY inputs the contacts of which should open if faults occur The emergency procedure and consequently the opening of these inputs cut voltage to all the outputs 37 26 28 30 32 33 34 38 39 42 43 44 47 48 49 50 51 Not connected 41 42 NOTES 42 42
32. r regulating the voltage output full scale Pin70 This regulation is performed when the required tests are run and therefore MUST NOT be shifted from its default position so that the value at output will always be exact 34 42 LOCK END AND WRONG SIGNALS FUNCTIONING Choose either LOCK or END in the INSTALLATION MENU The END signal remains activated as long as the HOLD time lasts or in case of hold 00 as long as the start is disabled n order to enable the WRONG signal set the MIN and MAX current LIMITS Every out of limit spot the TE600 control unit activates the WRONG signal as long as the HOLD time lasts or in case of hold 00 as long as the START signal is disabled f it is needed that the machine stops and displays the out of limit spot set the STOP BAD SPOTS parameter differently than 0 in the CONFIGURATION menu Having the HOLD 00 the WRONG signal remains enabled as long as the START signal is removed Then at the following spot the TE600 control unit does not allow the welding and displays STOP BAD SPOTS Having the HOLD different than 00 the WRONGi signal remains enabled as long as the CLEAR key is pressed Incase the start is released during the welding process a WRONG END signal lasting 12 msec will be generated Example of Lock connection on the TE600 control unit OUT 24 VDC In the automatic systems it is recommended to select the HOLD time equal to 00 and to keep the START c
33. rking Therefore due to their importance the access to this menu is protected by a code ENTER ACCESS CO ky Ske sak 9e If the user is not authorized and consequently does not know the access code the following message is displayed ACCESS CODE ERROR ACCESS DENIED It is important to keep in mind that the followin arameters may be AN changed exclusively by AUTHORIZED personnel to prevent injury damage to people equipment FEATURES MENU PARAMETERS TABLE DESCRIPTION OF THE INSTALLATION MENU PARAMETERS LOW PRESSURE SQUEEZE This parameter activates for welders that envisage the low pressure squeeze function The enabling adds the SQUEEZE parameter to the welding program FORGE This parameter enables the forging for pneumatic circuit welders that envisage the forging function The enabling adds the FORGING parameter to the work program PROPORTIONAL VALVE This parameter is used for welders that envisage the use of a proportional valve and the parameter that is activated in the program is the PRESSURE parameter 19 42 PRESSURE RATIO Use this parameter if the previous parameter is activated to select the VOLT PRESSURE ratio that is most suitable for the type of solenoid valve that is to be used OUT LOCK END This parameter indicates by means of interlock LOCK or cycle end END the activation mode of this output during the welding cycle SERIAL COM This parameter per
34. t cycle command had already been given The emergency input was activated 38 42 Press the CLEAR key to delete the message Clear the error by pressing any key If the error occurs frequently check the working efficiency of the devices that cut the power supply line and check for any interference Wait a few seconds for the procedure to be completed Check that there aren t any cable interruptions between the TE600 and the power module and that the latter is not damaged or faulty If faulty a warning light blinks Check the RS485 serial connection Check that the serial cable is not damaged and that it is connected correctly and then press any key Wait a few seconds Deactivate the start cycle command Check the status of the emergency input and rearm the contact if no emergency situations exist FLOW SWITCH PRESSURE SWITCH ACTIVATED FOR RESET OUTPUT VALVE FAIL OVER TEMP FAULT AT SOLENOID VALVE OUTPUT PUSH CLEAR COUNTER SPOTS KEY 5 FACTORY USE ONLY ENTER ACCESS CODE kK kK kK kK kK ENTER ACCESS CODE kK ACCESS CODE ERROR ACCESS DENIED The thermostat and or the safety pressure switch located inside the welder tripped The short circuit safety device of the control unit outputs has tripped The CLEAR key was pressed to zero the number of spots and the control unit requests confirmation The user is accessing the menu reserv
35. t so that it stops when welding spots are performed with current values that are beyond the limits set in the weld program The set value indicates the number of consecutive out of limits welding spots after which the machine stops The limit error occurs when a welding spot is carried out with values either higher or lower than the limits set in parameters MINIMUM CURRENT MIN CURR and MAXIMUM CURRENT MAX CURR To set the value use keys and 5 the value can be set from 0 to 9 When the value is set to zero this function is disabled therefore the welder does not stop even in case of out of limits welding spots SPOTS MAX This parameter indicates the maximum number of welding spots The function is to allow the operator to run the desired number of welding spots When the pre set number of welds is attained the control will stop welding If this parameter is set to zero the function is disabled START 1 PRG This parameter indicates the program number to be run when the cycle is activated via the start cycle 1 command The value of the program also includes 0 which if set allows the control unit to work with the program that is active in the setting 11 42 START 2 PRG This parameter indicates the program number to be run when the cycle is activated via the start cycle 2 command PRINTER with optional card This parameter enables disables the printing both of the values of the welding parameters that is carri
36. ters are set the Stepper menu PARAMETER DESCRIPTION VALUE Number of segments for stepper function SPOTS 1 First segment spots number 2000 INCREMENT1 First segment increment percent The welding program should be adjusted for carrying out the first welding spot followed by the adjustment that permits to obtain the required current with the starting electrode diameter 15 kA Now the welding process can begin Current will vary conforming to the set increment rule The graph below shows its pattern CURRENT INCREMENT DURING PRODUCTION INITIAL CURRENT 15 kA 20 END CURRENT 19 kA lt 18 INCREMENT PERCENT 26 46 NUMBER OF WELDING SPOTS 2000 2 14 12 3 10 o 3 8 6 4 2 0 0 500 1000 1500 2000 NUMBER OF WELDING SPOTS Upon having completed all 2000 welding spots the TE600 stops the production cycle and displays the following message STOP MAX N of SPOTS At this point the operator replaces the electrodes or resets their original diameter and clears the spots counter to clear stepper calculations The TE600 resets the initial work parameters and begins a new increment phase 15 42 COMPLETE USE NON LINEAR INCREMENT CURVE In the aforesaid work method a linear welding current increment is used during the whole life span of the electrodes In actual fact the increase of the contact section of the electrode on the sheet is not linear but has a pattern that is similar to the one shown i
37. tery of the capacitors is activated Before pressing the key it is important to check that it will not cause injury damage to people or equipment CAPACITOR SUPPLIE PLEASE WAIT It takes about 20 seconds for the device to charge the capacitors and be ready either to begin the welding operations or program the values of the parameters On powering up the control unit and before starting any welding operations first program the welding data and set some general operating parameters of the welder 5 42 CONTROL UNIT PROGRAMMING To begin the programming operations turn the key in the PROG position and be aware of some of the fundamental features of the control unit TE600 VER 6 08 PROGRAM DATA SETUP MENU FEATURES MENU The programming parameters of the control unit are divided into different menus _ PROGRAM DATA _ SETUP MENU _ STEPPER MENU _ FEATURES MENU _ DIAGNOSTIC _ FACTORY RESERVED MENU Use keys and M to select the desired menu identified by symbol gt next to the caption Use keys gt and 4 to enter and exit the menu whereas you should use keys and to set the parameters The Program DATA menu contains all the parameters associated with the welding cycle the times and the currents by means of which to carry out the welding process PROGRAM DATA gt PROGRAM NUMBER 01 WORK MODE IK SQUEEZE 1 30 The first choice to make is the nu
38. time the sequence is interrupted FORGE DELAY The FORGE DELAY parameter is used exclusively with pneumatic circuits that have a forging function capability Such function permits increasing the electrode force during the welding cycle The parameter describes the time that elapses from the beginning of the welding process to the application of the forging force onto the electrodes by means of solenoid valve EV3 If the value is set to zero the forging function is disabled and valve EV3 will be activated at the beginning of the squeezing phase PRESSURE This parameter expressed in bar or psi expresses the welding pressure value The set value must be such that it guarantees a proper clamping force during the welding cycle An inadequate adjustment of such value produces sparks between electrodes and sheet when the welding begins PRE WELD The PRE WELD parameter indicates the duration of a current flow that can be carried out before the welding process so as to pre heat the workpiece to be welded If this parameter is set to 0 the pre weld will not be carried out Pre weld is carried out with a current adjustment equal to that stated in the PRE CURR parameter 8 42 PRE CURRENT The value expressed in this parameter indicates the current used for carrying out the PRE WELD COLD TIME 1 This parameter indicates the time that elapses from the PRE WELD to the weld If the PRE WELD is deactivated this cooling time is not carried out
39. ycle activated as long as the automation acknowledges either the END or the WRONG signal 35 42 DOUBLE STROKE FUNCTION When the machine is powered it is always disabled even if the D STROKE input is active and the electrode is in position A The control unit sets it to position B when the first weld is performed as shown in the figure below The output of the control unit called SV4 controls the double stroke solenoid valve lt lt WORK STROKE SHORT A POSITION OF THE MOBILE ELECTRODE WITH DOUBLE STROKE DEACTIVATED LONG STROKE B POSITION OF THE MOBILE ELECTRODE WITH DOUBLE STROKE ACTIVATED SHORT STROKE During this first weld the TE600 activates solenoid valve EV4 that shifts the electrode from position A to position B waits a fixed time of 0 6 seconds and performs the programmed weld cycle At the end of the weld solenoid valve EV4 is not deactivated and the electrode remains in position B The succeeding welds will be performed starting from this position When input D STROKE is activated solenoid valve EV4 is kept activated and the electrode in rest status will be in position B Should the operator need to open the electrodes during the process deactivate the input to trigger the deactivation of solenoid valve EVA 36 42 LIST OF MESSAGES MESSAGE CAUSE REMEDY SUPPLY FREQUENCY 50 HZ SUPPLY FREQUENCY 60 HZ SUPPLY FREQUENCY ERROR PRESS KEY F TO RESET MEMORY PRESS KEY T
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