Welding Control Unit TE-500
Contents
1. 34 52 DESCRIPTION OF THE WORK CYCLE The TE500 work cycle is set by the user by adjusting the programming parameters These parameters indicate the operating times and the current adjustments characterizing the work cycle when carried out consecutively The following chart shows the sequence in which the programmed functions are carried out ae eee glanis aeea igs 18 The aforesaid numbers refer to the programming parameters described in the Programming Menu paragraph A For safety reasons the microprocessor does not start the welding cycle if the start cycle device is activated when switching on the welder release it and restart it Any microinterruptions or excessive voltage drops will stop the control unit and do not alter the operation to reset the operation turn the machine off and then turn it on again 35 52 READING OF THE WELDING CURRENT AND THE CONDUCTION ANGLE After every welding operation the display shows the following information e The welding program used e The number of the welding spots carried out as of the last counter reset e The current conduction angle of the last welding spot e The set welding time e The value of the current of the last welding spot PROG 01 SPOT 12340 WELD CYCLE 01 0 CURRENT RMS 43 26 CONDUCTION DEG 142 The value of the current which the control unit measures and which is displayed stands for the average of the RMS values measur2. 52 In any case if a Sequence process error is made it is possible to repeat the last weld or another weld or continue by avoiding some spots Always with the key in RUN position use keys to increase the welds counter to the next spot or to the desired spot Use key El to go back one or more positions of the spots to be carried out Display data OF 013 OF 04 RMS 06 15 007 013 04 RMS 04 31 001 27 52 Display data after key 00 03 11 WEL D J D OF 013 OF 04 RMS 06 15 008 OF 013 OF 04 RMS 04 31 013 CHECK INPUT MENU This menu displays the status of the welding control unit inputs It is activated with the key in PROG position and is used for checking the efficiency and proper operation of the external devices connected to the control unit required for using the welder CHECK INPUT gt START N O START N O START2 N O All the inputs available at the connectors of the control unit are included in the list that is scrolled with keys 4 and V The status of the inputs is shown as active Input closed with COM1 with wording ON not active with wording OFF 28 52 PANEL LEDs a The turning on of this LED indicates that the welder control unit is powered If this LED is switched on it indicates that start cycle 1 command is activated If this LED is switched on it indicates that start cycle 2 command is activated The turning on of this
3. 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 16 52 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 eect 19 1 Chane NOU initialcurrent x100 9 15 initialcurrent x100 26 Consequently the following parameters are set in 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 a 18 INCREMENT PERCENT 26 46 NUMBER OF WELDING SPOTS 2000 E Z 14 12 3 10 o 2 8 O 6 4 2 0 0 500 1000 1500 2000 NUMBER OF WELDING SPOTS Upon having com
4. 17kA If error messages are displayed instead of the aforesaid message proceed as follows e Clear the error by pressing any key e Eliminate the cause that triggered the error see specific paragraph Activate the start cycle device again for repeating the self calibration welding procedure 31 52 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 REC5 REC5 eos st me ess me es BS SE a a re a ee ee e below input active The programs that can be selected are 31 when using input REC5 as additional recall input or 15 if using input REC5 as parity check The use of input REC5 as parity check is activated in the Installation Menu see specific paragraph in which the type of parity is also selected Even or Odd The parity check consists in checking that the number of activated inputs for recalling a program is even or odd Example Recall of Prog N 06 with even parity check To recall program 6 you must activate two inputs REC2 and REC3 but since parity is odd you must also activate input REC5 to obtain an odd number of active inputs To properly recall the welding programs either activate the direct recall inputs before the start cycle signal or simultaneously 32 52 WORK MODES The TE500 weld control unit permits
5. LED indicates that the pressure only stopping command is activated oO The turning on of this LED indicates that the control unit is producing the command V impulses for the SCR It indicates that the solenoid valve 1 which carries out the main cycle is activated It indicates that the solenoid valve which controls back pressure is activated 0 Ng 3 It indicates that the solenoid valve which carries out the pressure or forging cycle is activated It indicates that the solenoid valve which controls the double stroke is activated 29 52 COMMANDS ON THE PANEL Bc Left direction key used for exiting from the programming menu ce Right direction key used for accessing the programming menu a Up direction key used for moving the cursor into the upper parameter Down direction key used for moving the cursor into the lower parameter This key is used for increasing the value of a numeric parameter or for f changing the status of a parameter This key is used 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 is 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 the sta
6. When the key is pressed all the devices connected to the 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 AN injury damage to people or equipment Before starting any welding operations first program the welding data and set some general operating parameters of the vvelder 6 52 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 TE500 VER 2 31 gt PROGRAM DATA SETUP MENU STEPPER MENU The programming parameters of the control unit are divided into different menus as shown in the drawing above _ PROGRAMMING _ CONFIGURATION _ STEPPER _ INSTALLATION PROGRAM COPYING _ INPUT CHECK _ PROGRAM SEQUENCES Arrow gt on the left hand side of the display indicates the cursor s position Use keys 4 and F to move the cursor up and down whereas keys I and Pl are used for entering and exiting from the menu selected by the cursor Use keys l and Hito set the value of the parameter indicated by the cursor PROGRAMMING MENU The Programming 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 CONTROL MODE CUR The first choice to make is the
7. damage to people or equipment AN Keep in mind that only skilled personnel are permitted to edit the FIRST INSERT SERIAL COM NETWORK ADDRESS COIL RATIO LOCKIEND OUT FIRST INSERTION DELAY FUNCTION The FIRST INSERTION parameter shows the first insertion delay This function permits to optimize the balance of the mains consumption of the welder After having selected this parameter the value can be adjusted from 1 to 99 with keys EJ and El For more information refer to the specific chapter SERIAL COMM The user may choose whether to activate the serial data transmission port and how it is to be used connect a printer PRT 232 or connect the control unit to a data supervision network NET 485 or not use this option NONE NETWORK ADDRESS This parameter indicates the identifying address of the control unit when connected in the network activating the aforesaid option 21 52 COIL RATIO This parameter shows the sensitivity of the current transducer installed on the welder OPTIONS SIGNAL RATIO AMMETER CAPACITY pot S oova 40 90KA e oa BT8KA 15 VIKA TOKA LOCK END OUT This parameter indicates interlock LOCK or cycle end END the activation time of the corresponding output RECALL 5 FUNCTION This parameter indicates the function associated to the Recall 5 input _ Input for the direct recalling of the work program up to 31 REC 5 _ EVEN parity test input for the other recalls _ ODD par
8. external network by means of a standard male 9 pin connector with the following signals CONNECTIONS OF CONNECTOR DB9 a a el a ar The card can be connected only when the control unit is not powered It is also advisable to first connect the 6 pin wire which connects the weld control unit and then make the RS485 connection At this point the control unit can be powered and the NET 485 function can be activated in the Installation menu In the network communication an identifying address must be assigned to the weld control unit slave so that it can be recognized by a Master for instance a Personal Computer This parameter called NETWORK ADDRESS is set in the Installation menu A PC software program called tecnaNet is available for handling data and communication among the networked control units for checking the network s structure i e how many and which control units are connected for carrying out for each control unit all the programming functions remotely and for acquiring and storing production data TECHNICAL RECOMMENDATIONS The interface is isolated up to 1500V without the need for any external power supply and works connected to standard RS485 signals in half duplex or full duplex mode The male 9 pin connector has two screws with thread 4 40 UNC with threaded head These screws are to be used for wall mounting purposes max 3mm and for locking the mobile connector The 50209 item is fit with a black protectiv
9. from being stimulated before being properly cooled OFF TIME DWELL TIME The OFF TIME parameter indicates a welder wait time namely the one that elapses from one welder 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 cycle signal When the welder works in automatic cycle the welder goes on executing welding cycles until the start cycle signal is released By programming this parameter to 99 the welding current compensation function is activated see the relevant paragraph 11 52 CURR MIN ANGLE MIN MINIMUM CURRENT LIMIT OR CONDUCTION ANGLE The meaning of this parameter depends on the control mode selected in the CONTROL MODE parameter When the control unit is set to current control mode CONTROL MODE CUR this parameter fixes a minimum current value For each weld the TE500 monitors that the welding current supplied by the welder is higher than the value set at this parameter if it is lower an error message will be displayed see the relevant paragraph When the control unit is set to degree control mode CONTROL MODE DEG this parameter fixes a minimum conduction angle value For each weld the TE500 monitors that the maximum welding cur
10. initialcurrent x100 19 5 17 8 x 100 1095 initialcurrent 17 8 Change segment 3 TE E x100 E 100 490 initialcurrent Spe ona enecurrent initialcurrent x100 20 8 20 2 x100 3 initialcurrent 20 2 The following parameters are consequently set in the Stepper menu INCREMENTS INCREMENT2 Increment percent of second segment 19 52 The 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 increment rule The graph below shows its pattern b SEGMENT 4 SEGMENT 3 SEGMENT 2 CURRENT kA Y SEGMENT 1 o ei N I T T I T T I T T T T T T 0 1000 2000 3000 4000 NUMBER OF WELDING SPOTS 20 52 INSTALLATION MENU The installation menu contains the parameters that determine the complexity and typology of the welder at which the control unit is working Therefore due to their importance the access to this menu is protected by a code 035 ENTER ACCESS CO x kK K If the user is not authorized and consequently does not know the access code the following message is displayed 036 ACCESS CODE ERROR ACCESS DENIED The parameters can be edited only after having typed in the access code following parameters to prevent
11. need to open the electrodes during the process deactivate the input to trigger the deactivation of solenoid valve EV4 45 52 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 Ground connection LOCK END This output is a polarized opto electronic switch Max 30 V 10 mA and 4 LOCK END is used for signaling when a cycle ends if END CYCLE is selected 5 when LOCK in selected the control unit gives an output signal from the 6 7 9 beginning of the welding process to the hold WRONG This output is a polarized opto electronic switch Max 30 V 10 mA that WRONG closes if the set current limits are not respected The contact remains closed for the HOLD and OFF time A max voltage of 24Vdc and a maximum current of 0 1A can be applied to this contact COM2 Output of the trigger signal for the SCRs Output is an impulse train TRIGGER with a 5 KHz frequency duty cycle of 16 20 30V amplitude on a load of 35 S2 It is necessary to use the TECNA firing modules COM1 This input closed on COM1 can have two functions depending on the RIC5 PARITY choice made in the setup menu The first function is external recall the second function is to control the parity during the recall These inputs are used to directly recall the weldin
12. to perform welds with different welding current supply and check methods The table below shows the different modes the operations required for activating them and the compatible functions Rogowski ring sensor Stepper function Program sequence function CUR control mode DEG control mode Current compensation Welding analysis E ae es Only the one with which the Self calibration is performed Only the one with which the Self calibration is performed Rogowski ratio Automatic mains NO compensation First insertion delay Only the one Only the one recommended in Self recommended in Self calibration calibration Ammeter capacity Proportional valve X not compulsory 6 compulsory 33 52 CONSTANT CURRENT OPERATING MODE TE500 allows the user to adjust the welding current in two different operating modes the standard percent adjustment and the constant current adjustment When the control unit works in constant current it is possible to set the welding current value directly During the welding process the control unit measures for each half period the true welding current RMS value and based on a correcting mathematical algorithm keeps the set current In addition to simplifying the programming operations this operating mode also permits to keep the desired welding current even if some factors change such as mains voltage welding circuit dimensions and impedance condition of the welding t
13. 009 CUR OK 0 10 0 06 0 062 00010 CUR OK 0 10 0 06 0 062 00012 CUR MIN 0 10 0 06 0 062 00013 CUR MIN 0 10 0 06 0 062 00014 CUR MAX 0 10 0 06 0 062 00015 CUR MAX 0 10 0 06 0 062 00016 CUR MAX Data printout example during the vveld in DEG Control Mode PROG CYCLES CURRENT DEGREE SPOTS LIMIT 01 10 0 06 0 062 00018 DEG MIN 01 0 0 06 0 062 00019 DEG MIN 01 0 0 06 0 062 00020 DEG MIN 01 0 0 06 0 062 00021 DEG OK 01 0 0 06 0 062 00022 DEG OK 01 0 0 06 0 062 00023 DEG MAX 01 0 0 06 0 062 00024 DEG MAX 01 0 0 06 0 062 00025 DEG MAX Printout example of vvork program parameter values CONTROL UNIT TE500 PROGRAM NUMBER 01 WORKING MODE IK CONTROL MODE DEG SQUEEZE 1 20 SQUEEZE 20 FORGE DELAY 10 PRE WELD 00 0 PRE POWER 05 COLD 1 00 SLOPE UP 00 NELD 10 0 CURRENT 06 0 kA COLD 2 00 IMPULSE N 1 SLOPE DONN 00 COLD 3 00 POST NELD 00 0 POST POWER 05 HOLD TIME 20 OFF TIME 20 ANGLE MIN 053 ANGLE MAX 087 41 52 SERIAL INTERFACE RS 485 ITEM 50209 Option The RS 485 serial expansion card permits the control unit to be networked with other welding control units and with a central PC for programming the control unit or for documenting production data The card interfaces with the control unit by means of a 6 pin connector and with the
14. 39 SV2 Connect to solenoid valve 2 BACK PRESSURE This is a suitable 40 COM2 command for piloting a 24Vdc coil max 5 W 41 42 SV3 Connect to solenoid valve 3 FORGING and 4 DOUBLE STROKE COM2 This is a suitable command for piloting a 24Vdc coil max 5 W SV4 44 SV PROP This is an output that is connected to the piloting card of the 45 SV PROP proportional solenoid valve Option art 50193 46 47 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 ROG The current transducer Rogowski ring must be connected to this 49 AGND analog input 50 SHIELD Shield for transducer cable NOTE The component indicated with acronym F3 located on the connector side of the control unit is a delayed fuse non resettable which supports a max current of 3 5 A If the ON LED does not light up check the status of the aforesaid component 47 52 TE500 MESSAGES LIST Ver 2 31 MESSAGE pa CAUSE REMEDY The control unit measured a mains frequency of 50 Hz 2 The control unit measured a mains frequency of 60 Hz 3 The control unit was not able to Try to turn on the control unit again measure a steady mains and ensure that power supply is 24 frequency VAC with 50 60 Hz frequency STORING OF 4 The control unit is entering default DEFA
15. ITS Set the CURRENT 1 parameter to a lower value than the max current value of the welder Set the current limits to a lower value than the max current value of the welder Set the min current limit to a lower value than the max current limit Set the minimum conduction angle value to a lower value than the maximum limit STOP MAXIMUM CURRENT LIMIT STOP MINIMUM CONDUCTION LIMIT STOP MAXIMUM CONDUCTION LIMIT NO CURRENT SIGNAL CHANGE AMMETER CAPACITY NO EMERGENCY SIGNAL ZERO SPOTS COUNTER KEY YES ACCESS CODE CODE ERROR NO ENTRY PULSES gt MAX WELDING TIME PRESSURE xx X Bar ERROR SAFETY RELAY STEPPER FUNCTION NOT ACTIVE 28 The control unit counts some faulty Clear the error by pressing any spots the last of which has been Jkey See chapter CURRENT AND carried out with a current value CONDUCTION ANGLE LIMITS higher than the max set limit 29 The control unit counts some faulty Clear the error by pressing any spots the last of which has been key See chapter CURRENT AND carried out with a conduction CONDUCTION ANGLE LIMITS angle value lower than the minimum set limit 30 The control unit counts some faulty Clear the error by pressing any spots the last of which has been Jkey See chapter CURRENT AND carried out with a conduction angle CONDUCTION ANGLE LIMITS value higher than the max set limit 31 During the last welding cycle there Che
16. L MODE DEG if the last welding spot conduction angle is either lower or higher than the limits set in the above stated parameters the display will show one of the following messages 38 52 COMPENSATION OF THE SECONDARY CURRENT The secondary current compensation function is used for facilitating the welding process of oxidized sheets and rods The oxidation of the workpieces blocks the current flow during the first welding phase thus limiting in a different way depending on the type of welding process the real current flow time The compensation function controls the welding current until the current exceeds a pre set threshold equal to 2000 A The welding time is automatically extended up to a limit of 99 periods In this way it is possible to carry out welding processes with a constant real current flow time Keep in mind that this function should be used only in the event of welding conditions that cannot be overcome otherwise since it is not a system that assures welding quality This function is activated by setting the OFF TIME parameter value to 99 when this function is active the control unit works in single cycle In constant current operating mode this function is deactivated 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 cu
17. LORS TECNA 1090 LOUSONS ROAD UNION NEW JERSEY 07083 USA Tel 908 964 9100 Fax 908 964 4492 email sales lors com WELDING CONTROL UNIT TE 500 USER MANUAL RELEASE SOFTWARE No 2 31 DOCUMENT NUMBER MAN 4117 EDITION JUNE 2003 This page is intentionally left blank 2 52 TABLE OF CONTENTS cono wrswenon O O Oo a TIT 3 52 This page is intentionally left blank 4 52 WELDING CONTROL UNIT TE 500 The TE500 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 control It is possible to store up to 63 different welding programs 31 of which are recalled directly from an external device Each program comprises 18 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 MADE IN ITALY MAIN TECHNICAL DATA e Simplified programming via 6 keys and a backlit alphanumeric LCD e Synchronous control with controlled diodes phase control current adjustment e Storage of 63 welding programs 31 recallable from the outside e 26 programmable parameters for each program e Slope pulses pre weld post weld functions and adjustment of the welding times in half periods e Display of the
18. ON OF THE SECONDARY CURRENT e By setting the PRE WELD parameter to zero the pre weld is not carried out e By setting the POST WELD parameter to zero the post weld is not carried out 8 52 DESCRIPTION OF THE PARAMETERS All the following parameters that indicate times are expressed in periods also called mains cycles The mains frequency defines the duration of a period Mains frequency of 50 Hz 1 period 20 ms Mains frequency of 60 Hz 1 period 16 6 ms WORK MODE The WORK MODE parameter defines the mode for adjusting the welding current of the program either power percent PW constant current IK or fixed FIX Welding time WELD 1 is carried out according to the adjustment mode set in this parameter PRE WELD and POST WELD times are always run with the power percent or fixed adjustment CONTROL MODE The CONTROL MODE parameter permits to select the control mode of the desired welding current NO No control is performed on the supplied welding current CUR TE500 permits to set the welding current min and max limits DEG TE500 permits to set the min and max limits of the welding current conduction angle For further information please read the relevant paragraph SQUEEZE 1 The 1 SQUEEZE time or first squeeze determines the time needed by the electrode to move down 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
19. REMENT J 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 n parameters Enter the corresponding percent increment to be achieved in the INCREMENT n parameter The programming procedure is outlined in the Stepper menu paragraph 18 52 Example After a number of welding tests the ensuing life of the electrodes resulted to be 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 kA 3000 20 2 kA 4000 final electrode diameter 20 7 kA Therefore calculate the duration in number of welding spots and the percent increment of each Chie 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 Chase tases endcurrent initialcurrent AE 17 8 15 J 100 19 initialcurrent 15 Caine Gregori 2 endcurrent
20. RMS welding current measurement in kA and relative angle of conduction e Dual operating mode standard and constant current e Welding current or angle of conduction limits e Double stroke function e Stepper function to compensate the electrodes wear with programmable curve e Counter for the performed welding spots e Compensation function of the secondary current for welding oxidized sheets and rods e Single and automatic cycle WELD and NO WELD function e Adjustment of first insertion delay e Control of 4 solenoid valves 24 Vdc max 5 W with self protected output e Auto regulation at mains frequency 50 60 Hz e Serial data transmission by means of opto isolated RS232 or RS485 ports e Output for optional proportional solenoid valve e Key for selecting foot control or two hand control e Selectable languages Italian English French German and Spanish e Possibility of upgrading control unit Firmware via appropriate software 5 52 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 TECNA TE500 2 31 WELD CONTROL UNIT After a few seconds the TE500 is set to a waiting condition until the Restart key is pressed This key enables the control units commands and outputs 009 PUSH KEY RESTART TO CONTI It must be pressed every time the control unit is powered
21. ULT VALUES values in its program storage PRESS KEY 5 The control unit s data zeroing Press key to continue otherwise TO ZERO DATA procedure has been activated press any other key or wait a few l seconds DATA ZEROING IN The data zeroing procedure of the PROGRESS control unit is in progress SOFTWARE UPGRADE 7 The upgrade procedure of the IN PROGRESS control unit is in progress PRESS REARM KE The control unit is waiting for the Ensure that the activation of the TO PROCEE rearm key to be pressed so as to VAUX does not cause damage to activate the welding control unit equipment and or people then functions press the key Asynchronism error has occurred Clear the error by pressing any due to the temporary lack of the key If the error occurs frequently reference signal of the power check the working efficiency of the supply line or due to line devices that cut the power supply interferences line and check for any interference TECNA TE500 When the control unit is turned on ERROR MAINS SYNCHRONISM VER 2 31 it displays the type of control unit NFLDING CONTROI and the software version UNIT CALIBRATION IN he The control unit is carrying out the Complete the self calibration PROGRESS pa fa calibration welding procedure vvelding procedure CALIBRATION Current measuring errors occurred Repeat the self calibration CURRENT ERROR during the self cal
22. ac Ground 24 Vac N B _ A red D10 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 for 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 43 52 INTERFACING WITH AUTOMATIC SYSTEMS The TE500 weld control unit can be used in an automated welding system by exploiting a few signal inputs and outputs the activation of which identifies a precise welding process moment Inputs e Start Start cycle command To perform the weld it must be kept active at least until the LOCK contact Is activated e Aux This input locks the cycle in pressure only If activated it locks the welder with electrodes in closed status during one of the squeeze times Outputs e SVI Main solenoid valve output It is activated after the Start and is deactivated at the end of the HOLD TIME e Wrong Error signal for limits or power failure Active for HOLD and PAUSE e Lock This output signals the beginning and the end of the current circulation during the cycle e End cycle This output signals the end of the cycle of one weld for the pause time During the single cycle th
23. ach impulse corresponds to the time set in parameter WELD 1 WELDING TIME COLD 2 COLD 2 TIME The COLD 2 parameter is used in the pulse operating mode it indicates the time that elapses from a welding impulse to the next one SLOPE DOWN The SLOPE DOWN parameter is a welding time that is added at the end of the welding process it enables to decrease the welding current from the value set at CURRENT 1 down to the minimum value The slope inclination is automatically calculated by the microprocessor according to the set values The SLOPE DOWN time is always added to the welding time COLD 3 COLD 3 TIME The COLD 3 parameter indicates the time that elapses from the welding process WELD 1 to the post weld POST WELD POST WELD The POST WELD parameter indicates the duration of a current flow that can be carried out after the welding time in order to enable a more gradual cooling of the welded workpiece This parameter is expressed by three digits since it can be adjusted with half period precision If this parameter is set to 0 the post weld is not carried out The post weld is carried out with the current adjustment set in the POST POWER parameter POST POWER The value expressed in this parameter indicates the post welding power HOLD TIME The HOLD 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
24. aximum set value The control unit counts some faulty spots the last of which has been carried out with a current value lower than the min set limit The set value in CURRENT 1 parameter is higher than the max current value of the welder The set value in one of the current limits parameters 17 18 is higher than the max current value of the welder The set value in MIN CURR 17 is higher than the set value in MAX CURR 18 The set value in ANGLE MIN 17 is higher than the set value in ANGLE MAX 18 49 52 Repeat the self calibration procedure If the error occurs again check the electric connection of the current transducer Check for continuity of the secondary circuit Check the electric wiring of the current transducer Repeat the self calibration procedure Activate the WELD function and repeat the self calibration welding procedure Check that water is flowing inside the welder in the necessary quantity and or check the working efficiency of the thermostat Check the electric wiring of the control unit Check the coil of the solenoid valve The control unit cannot measure the welding current properly Contact the customer service Changethe programming parameters of the welding program or change the ammeter capacity if possible Clear the counter see chapter FUNCTION OF THE WELDS COUNTER Clear the error by pressing any key See chapter CURRENT AND CONDUCTION ANGLE LIM
25. bar 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 FORGE DELAY Optional The FORGE DELAY parameter is used exclusively with pneumatic circuits that contemplate the forging function Such function permits to increase 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 SV3 If the value is set to zero the forging function is disabled valve SV3 will be activated at the beginning of the squeezing phase 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 This parameter is expressed by three digits since it can be set with half period precision If this parameter is set to 0 the pre weld will not be carried out Pre weld is carried out with a current adjustment equivalent to that indicated in the PRE POWER parameter PRE WELD CURRENT PRE POWER PRE WELD CURRENT The value expressed in this parameter indicates the power used for carrying out the pre weld COLD 1 The COLD 1 parameter indicates the time that elapses from the pre weld PRE WELD to the weld WELD 1 If t
26. ck for continuity of the was no secondary current secondary circuit Check the circulation in the machine electric wiring of the current 32 3 transducer Change the ammeter capacity or change the program parameter to select a different work mode The welding process is being performed in constant current or with a power percentage using an ammeter capacity different from the one set in the self learning procedure 3 The emergency signal required for Ensure that the emergency contact operating the control unit is is closed missing 34 The CLEAR key was pressed to zero the number of spots and the control unit requests confirmation Press the key to clear the spots counter otherwise press any other keys or wait a few seconds 35 Someone is trying to access the Enter the access code if known menu restricted to installers Otherwise wait a few seconds 36 Someone is attempting to enter the installers only menu without knowing the access password 37 The total pulse welding time is Decrease the pulse vvelding time higher than the maximum value of or the number of impulses 125 periods 38 The measured and displayed Check the air feed circuit or welding pressure is not within the change the pressure limits in the limits set in the execution program program 39 The safety relay that supplies the control unit s outputs is faulty 40 The stepper function is not active and therefore any data enter
27. ction of the program This menu is not always active in the main programming menu It is activated by setting the parameter of the Setup to ON PROG SEQUENCE Program sequence activation oN OE When this menu is activated it can be accessed with key gt and the parameters shown in the figure can be set PROGRAM SEQUENCES gt NUM STEPS 02 PROG STEP 1 03 WELD STEP 1 07 PROGRAM SEQUENCE MENU PARAMETERS TABLE N STEPS The value of this parameter indicates the number of steps i e the number of spot sequences with different work programs STEP PROG 1 2 3 This program indicates the program number that the welder must carry out and is matched to the associated step number WELDS STEP 1 2 3 The value of this parameter indicates the number of welds to be carried out with the program matched to the same step After having activated this mode and having set the parameters of the Program sequences menu as described above the welding spots can be started With the key in RUN position the display shows the sequence data as shown in the figure below 24 52 WELD 008 OF 013 STEP 03 OF 04 PROG 03 RMS 10 45 NEXT WELD 009 Information on the display indicates the following e Line 1 The succeeding number of the last weld performed and the total number of welds of which this sequence is composed e Line 2 The number of the step with which the last weld was performed and the t
28. e cover for protecting it against dust and electrostatic charges It is advisable to always keep it on the connector when the interface is not used Some terminating resistances are present on the cards which should be connected only at the first and last network connector Furthermore it is essential that the ground be connected among all the devices connected to the network The connection cable between the devices must not be longer than 1200m It must be shielded and have metallic or metallized connection connectors such as Belden 8777 cable at 24 AWG 42 52 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 ALARMZ2 PIN 34 COM1 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 JI Ground 24 V
29. e signal closes at the end of the Hold time and reopens on issuing the cycle start signal Ifthe cycle start signal had already been deactivated the contact remains closed for 2 cycles 40ms If the control unit is used in automatic cycle mode OFF pause time other than 0 the cycle will stay closed for the entire OFF time START sv1 LOCK WRONG i m 44 52 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 A The output of the control unit called SV4 controls the double stroke solenoid valve WORK STROKE SHORT C lt lt N I I I 3 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 TE500 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
30. ed for every welding time half period The displayed value always refers to the main adjustment i e to that of the WELD 1 parameter For pulse welding spots the value of the current will always be the average value of all the impulses The control unit also measures the welding current conduction angle The conduction angle stands for the time in which the current was carried during the half period The displayed value stands for the average of the values measured for each welding time half period The displayed value always refers to the main adjustment i e to that of the WELD 1 parameter The conduction angle of the current that circulated during the slope times is never measured For pulse welding spots the value of the angle is related to the last impulse the maximum value of which can be 180 degrees Example of currents with different conduction angles Conduction angle 180 Conduction angle 72 If a test welding stop is performed in NO WELD mode the current and conduction angle values displayed will be zero 36 52 WELDING ANALYSIS The welding pattern can be analyzed exhaustively by means of the welding check It is possible to view in detail the current values and the conduction degrees read at each half cycle of the main WELD1 the values of any pre welds and post welds and if activated the progress status of the stepper function To access these functions turn the key to RUN position perform a weld and pre
31. ed in the associated menu have not been accepted In order to activate the stepper function check the set data and make sure that there are no inconsistencies 50 52 FIRST INSERTION DELAY ADJUSTMENT During the installation phase the first insertion delay is to be adjusted This adjustment allows the optimizing of the welder s line consumption balance Adjust by setting the control unit to maximum power CURRENT 1 99 and carry out loadless welding spots interrupting the secondary circuit e g by placing non conducting material in between the electrodes Adjust the FIRST DELAY parameter see the INSTALLATION paragraph so that positive and negative line consumptions are balanced It is possible to use two different solutions for measuring the primary current Use an ammeter capable of measuring positive and negative maximum peak values such as the TECNA TE1600 In this manner the adjustment will be correct when the positive peak value will be similar to the negative one The value of the current consumed by the welder when loadless might be too low for the instrument s minimum capacity Solve this problem by running the cable on which the measurement is being taken inside the current sensor several times In this case the read value will be multiplied by the same number of cable run through operations performed in the sensor Use an ammeter that allows the displaying of the wave forms on a digital oscilloscope In thi
32. g program from an external device For a correct recall of the programs these inputs should be enabled before the start cycle signal The inputs are active when closed on the shared COM1 COM1 Connect to the microswitches 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 can be used as an interlocking input or for connecting safety devices such as for instance flow regulators or pressure switches The contact connected to it should be the normally open type and is activated when closed on COM1 START_NC COM1 Connect to the microswitches of the start cycle pedal The START START NO determines the beginning of the work cycle This input is active when closed on the shared COM1 AUX This input allows an external device to stop the welding cycle during the squeeze phase It can be used as an interlocking input or for connecting safety devices such as for instance flow regulators or pressure switches The contact connected to it should be the normally open type and is activated when closed on COM1 START_NC BICI 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 closed in sequence within a ma
33. he 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 15 52 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 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 current density This function is suitable especially when using the control unit in constant current mode Nevertheless it also works when the control unit operates in percent adjustment mode but it is not active in FIX mode 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 appl
34. he pre weld is deactivated that is when PRE WELD time 0 this cooling time is not carried out 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 WELDING CURRENT The slope inclination is automatically calculated by the microprocessor according to the set values The SLOPE UP time is added to the welding time WELD 1 WELD 1 WELDING TIME The WELD 1 parameter indicates the welding current flow duration It is carried out with the same power value set at parameter CURRENT 1 WELDING CURRENT When the pulse operating mode is activated this parameter indicates the duration of each pulse This parameter is expressed by three digits since it can be adjusted with half period precision 10 52 CURRENT 1 WELDING CURRENT The value indicated in CURRENT 1 shows the current adjustment used for carrying out the welding process Depending on the adjustment mode selected by means of the WORK MODE parameter this value indicates either the current percent adjustment PW power percent adjustment or the required welding current value expressed in kA IK constant current adjustment N IMPULSE NUMBER OF IMPULSES The N IMPULSE parameter indicates the number of impulses used for carrying out the welding process The duration of e
35. ibration procedure If the error occurs E procedure again contact the customer service measured a too high current which current supplied by the machine is cannot be measured correctly within this value Contact the customer service CALIBRATION 14 During the self calibration The capacity of the built in OVERFLOW ERROR procedure the control unit ammeter is 36kA Ensure that the 48 52 CALIBRATION SAMPLING ERROR CALIBRATION NO CURRENT ERROR CALIBRATION TE500 IN NO WELD THERMOSTAT ACTIVATED SOLENOID VALVES OVERHEATING ALARM CURRENT ERROR ALARM CURRENT OVERFLOW STOP MAX SPOTS N STOP MINIMUM CURRENT LIMIT CURRENT gt MAX CURRENT CURRENT LIMITS gt MAX CURRENT MIN CURRENT gt MAX CURRENT DEG MIN gt DEG MAX The self calibration welding was not carried out or current measurement errors occurred during the self calibration procedure This error occurs when the control unit does not measure the current during the self calibration welding procedure This error occurs when performing the self calibration welding procedure in NO WELD The protection thermostat inside the welder has been activated The short circuit safety device of the control unit outputs has tripped During the welding process an error occurred during the current measurement procedure A weld with a too high current signal has occurred The welds counter has attained the m
36. ied to all the welding programs used The current or conduction angle 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 or power current values are changed during the process the control unit takes them into consideration and re calculates the welding conditions 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 number 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
37. 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 Optional The SQUEEZE time is a wait time like that of the 1 SQUEEZE It is necessary for welding machines with low pressure squeeze functions In this case such time determines the interval from the application of the welding force onto the electrodes energizing of the SV2 valve to the beginning of the welding It should be long enough to allow the electrodes to achieve the proper clamping force before the welding begins An inadequate adjustment of such time produces sparks among the electrodes and the sheet when the welding begins causing quality inconsistencies If the welding machine does not contemplate low pressure squeeze deactivate this parameter see Installation Menu Otherwise it will be added to the 1 squeeze time If the start cycle signal is deactivated during the squeeze time the sequence is interrupted 9 52 PRESSURE Optional This parameter expressed in
38. ity test input for the other recalls LOW FORCE SQUEEZE This parameter is activated for welders that envisage the low pressure squeeze function Its enabling adds the Squeeze parameter to the welding program FORGE FUNCTION This parameter is used for enabling the forging for pneumatic circuit welders that envisage this function Its enabling adds the Forge Delay 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 PRESSURE TRANSDUCER With this parameter it is possible to select if the above parameter is activated the most suitable BAR VOLT ratio for the type of solenoid valve the user intends using 22 52 PROGRAM COPY MENU The Program copy menu is used for copying the values of the parameters of a program to other programs without having to set one parameter at a time PROGRAMS COPY gt SOURCE PROGRAM 03 FROM PROGRAM 06 TO PROGRAM 10 PROGRAM COPY MENU PARAMETERS TABLE PARAMETER DESCRIPTION VALUE RANGE SOURCE PROGRAM FROM PROGRAM Program start copy target 01 63 TO PROGRAM Copy end program 00 63 SOURCE PROGRAM This program indicates the number of the program to be copied to other programs The value of this parameter may vary from 01 to 63 COPY FROM PROGRAM This program indicates the first program into which the source program is c
39. le limit ANGLE MAX maximum conduction angle limit These two parameters enable to set the welding current conduction angle limit values When working if the measured value of the welding current or its conduction angle is beyond the set limits the welding spot is considered as out of limits If consecutive out of limits welding spots occur it is possible to stop the welder The number of the consecutive out of limits welding spots after which the control unit blocks can be adjusted by means of the BLOCK SPOTS parameter placed in the set up menu see the relevant paragraph for the programming operations This value can be included between 0 and 15 By setting it to 0 this function is deactivated so that the welding process is not blocked in case of out of limits welding spots Bear in mind that in order to be effectively considered and counted the out of limits welding spots must follow each other When the set error condition takes place the control unit locks and the displays show an error message The error message refers to the last welding spot When working with the current control mode CONTROL MODE CUR if the last welding spot current is either lower or higher than the limits set in the above stated parameters the display will show one of the following messages STOP LIMIT STOP LIMIT NIMUM CURRENT MAXIMUM CURRENT When working with conduction angle control mode CONTRO
40. number 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 keys adjusting the desired value always using the EH 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 7 52 WORK PROGRAM PARAMETERS TABLE PARAMETER DESCRIPTION VALUERANGE contol mone contRoL woe NO GuRR DES e JereroneR prewe cunan Jos ses Ce soeu Jskope up rave oozes TI Co wo weon TJ oossoo TI ue If CONTROL MODE is activated it will be possible to have additional parameters namely CURR MIN MIN LIMIT IN CURRENT 1 0 90 0 KA 20 CURR MAX MAX LIMIT IN CURRENT 1 0 90 0 kA if the CONTROL MODE parameter is set to CURR otherwise ANGLE MIN MIN LIMIT IN DEGREES 001 180 ANGLE MAX MAX LIMIT IN DEGREES 001 180 if the parameter is set to DEG There are few special conditions e If OFF TIME is set to 0 the welding control unit will work in single cycle e If OFF TIME is set to 99 the welding control unit will carry out the min current compensation with a value lower than 2 0 kA see paragraph COMPENSATI
41. onnection 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 7 BIT 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 e Welding program number e Number of cycles with which the weld was carried out e Welding current e Welding current conduction angle e Progressive spot number e 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 40 52 Data printout example during the weld PROG CYCLES CURRENT DEGREE SPOTS LIMIT 01 10 0 06 0 061 00001 01 10 0 06 0 061 00002 01 10 0 06 0 061 00003 01 10 0 06 0 061 00004 Data printout example during the weld in CUR Control Mode PROG CYCLES CURRENT DEGREE SPOTS LIMIT 01 10 0 06 0 062 00
42. ools surface conditions of the materials being processed CONSTANT CURRENT BEHAVIOR READINGS art Welding current changes I according to the mains VVelding current changes 1 according to the mains voltage V variation under standard operating mode voltage V variation under constant current operating mode The selection of the current adjusiment mode is independent for each vvelding program and is set by means of the VVORKING MODE parameter e By setting the PW value the welding current adjustment is carried out in percent values Please notice that the set value stands for the real percent value of the welder maximum current e By setting the IK value the program in progress carries out the adjustment mode in constant current TE500 monitors the welder characteristics by means of the self calibration procedure The values measured during this operation are used for the correct functioning of the working mode in constant current In order to get a better adjustment precision we recommend to repeat this procedure in case the arms are replaced with other having different dimensions This procedure is described in the relevant paragraph When operating in constant current mode and if during the welding process for any reasons there is no current circulation the control unit does not carry out the adjustment it blocks the welding process and displays the following error message NO SECONDARY CURRENT SIGNAL
43. opied in the case of a multi program copying operation Ifit concerns an individual copying it represents the target program to which the source program is to be copied The value of this parameter may vary from 01 to 63 TO PROGRAM This program indicates the last program into which to copy the source program The value of this parameter may vary from 00 to 63 Programmed value 00 indicates that the source program vvill be copied to the target program only To copy programs access the copy menu from the main menu using key gt set the desired values in the aforesaid parameters and then press key I Now the confirmation message of the copying action is displayed COPY PROGRAM lt 03 gt FROM lt 06 gt TO lt 10 gt PRESS KEY OK PERRET Press key to copy conforming to the parameters displayed in the video page shown above The operation is completed when the last line of the display is filled and the control unit shows the main programming video page If any other key is pressed or if you wait a few seconds the operation will not be carried out and the main programming video page is returned to 23 52 PROGRAM SEQUENCE MENU This menu includes the parameters required for activating the program sequence operations In this work mode the weld control unit commands the welder to perform a series of spots deciding automatically the work program for each spot and the spots order without having to make an external sele
44. otal number of steps e Line 3 The program number and the RMS current value of the last weld e Line 4 The progressive number of the next weld 25 52 PROGRAM SEQUENCE MENU Let s take for example the sequence operation after having set the following values in the parameters NUMBER SEQUENCE Joe step rere Jem epi wes steze step zvueios J TI stese J step svueios Je TI jsvep arre J TI srepawens Je For each start cycle signal a spot is carried out vvith the vveld program associated vvith the current step In this specific case as shown in the chart below the following welds are performed in sequence 4 welds with program 03 2 welds with program 07 6 welds with program 11 1 weld with program 04 wao rjejsjejslejrl ejo tojn se alrftjilzlejsjelslejsjejal gt gt gt E E E E _ tC sos o o Je es or or r n e e e fo Usually this type of operation is applied to one manual welder where the operator always performs weld spots in the same order but with different work parameters By means of this system the operator does not need to change the program manually which would cause his her attention to be distracted from the workpiece to be welded or does not have to change pedal or other start cycle device However the operator must pay utmost attention during the process not to perform fewer spots than those programmed overlapping spots or not in the same order 26
45. pleted all 2000 welding spots the TE500 stops the production cycle and displays the following message 22 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 TE500 resets the initial work parameters and begins a new increment phase 17 52 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 in 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 1 VVITH SET INC
46. rent conduction angle supplied by the welder is higher than the value set at this parameter if it is lower an error message will be displayed see the relevant paragraph If the CONTROL MODE parameter is set to NO no control on the welding current the parameter is not displayed during the programming phase CURR MAX ANGLE MAX MAXIMUM CURRENT LIMIT OR CONDUCTION ANGLE This parameter expresses different data according to the control mode selected at the CONTROL MODE parameter When the control unit is set to current control mode CONTROL MODE CUR this parameter fixes a maximum current value For each weld the TE500 monitors that the welding current supplied by the welder is lower than the value set in this parameter if it is higher an error message will be displayed see the relevant paragraph When the control unit is set to degree control mode CONTROL MODE DEG this parameter fixes a maximum conduction angle value For each weld the TE500 monitors that the maximum welding current conduction angle supplied by the welder is lower than the value set in this parameter if it is higher an error message will be displayed see the relevant angle If the CONTROL MODE parameter is set to NO no control on the welding current the parameter is not displayed during the programming phase 12 52 CONFIGURATION MENU The Configuration menu contains those parameters that are used for enabling or disabling a function of the cont
47. rol unit CONFIGURATI gt START CYCLE1 START CYCLE2 SPOTS PRINT CONFIGURATION MENU PARAMETERS TABLE stop BAD SPOT Nomberofspasioreutotimtsop 0 8 START CYCLE 1 This parameter indicates the program number to be run when the cycle is activated from 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 START CYCLE 2 This parameter indicates the program number to be run when the cycle is activated from the start cycle 2 command SPOTS PRINT With this parameter if the serial port is setup for print see Installation paragraph the user can choose which welding spots to be printed It is possible to print all spots or only the spots whose current value remains within the set limits or those with out of limits values OUT OF LIMITS SPOTS STOPPING FUNCTION Parameter STOP SPOTS permits to program the control unit so that it stops when out of limits welding spots are performed 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 CURR MIN and CURR MAX To set the value use keys 4 and El the value can be set from 0 to 9 If the value is set to zero this function is deactivated in this case the welder does no
48. rrently 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 in RUN mode the CLEAR key The display will show the following message CLEAR COUNTER SPOTS YES Press the MINUS key to clear the counter otherwise wait 8 seconds to end the procedure without clearing the counter The maximum welds number is set by following the same procedure described for the stepper function For example if you want to carry out 2840 welding spots without using the stepper function set the following parameters in the setup menu When setting these parameters the counter is automatically cleared When the counter attains the set number of welds the control unit displays the following message STOP N MAX SPOTS Welder operations are interrupted until the counter is cleared If SPOTS 1 parameter is set to zero the stop function is deactivated 39 52 SERIAL INTERFACE RS 232 ITEM 50214 Option Use expansion card ITEM 50214 to connect the TE500 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 bin Jers SSS PINS JNOT CONNECTED On request cable Art 70377 is available for the c
49. rt 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 30 52 SELF CALIBRATION PROCEDURE This procedure allows the control unit to read the welder s characteristics and also to optimize the current adjustment The values measured with this procedure are used for the correct working of the welding current adjustment We recommend to repeat this procedure if the welder arms are replaced with others ha
50. s case perform the adjustment so that all the half waves of the primary current have the same amplitude The graphs below show the wave forms achieved both with an incorrect and a correct adjustment Unbalanced consumption Balanced consumption 51 52 NOTES 52 52
51. ss key Ya to display the first data video page Then you may continue in the succeeding video pages as shown below Welding example with these parameters e Pre Weld Time 4 cycles e WELD1 Time 8 cycles e Post Weld Time 0 cycles e Incremental step 1 10000 spots 18 PROG 03 SPOTS 05148 WELD TIME 08 0 CURRENT 09 52 kA RMS CONDUCTION DEG 110 PROG 03 SPOTS 05148 PREW 068 POSTW 000 04 0 00 0 05 90 kA 00 00 KA 03 SPOTS 05148 03 SPOTS 05148 03 SROTS 10 51 CYCLE N 02 lt D CYCLE N 1 D CYCLE N 08 09 32 kA 106 08 92 kA 09 60 kA 09 10 kA 1 09 56 kA 09 40 kA 110 SPOTS MAX 10000 SPOTS 05148 INCREMENT 09 OF 1 STEP NUMBER 1 OF 1 37 52 WELDING CURRENT AND CONDUCTION ANGLE LIMITS TE500 enables to set some control limits on the welding current The purpose is that of monitoring the stability of the welding current so to improve a constant welding quality The control unit enables to select two different control modes Welding current limits To activate this control mode set parameter CONTROL MODE to CUR Two new parameters will be displayed CURR MIN minimum current limit CURR MAX maximum current limit These two parameters enable to set the welding current limit values Conduction angle limits To activate this control mode set parameter CONTROL MODE on DEG Two new parameters will be displayed ANGLE MIN minimum conduction ang
52. t stop even in case of out of limits welding spots PROGRAM SEQUENCE The sequence type operation is activated with this parameter If this parameter is set to ON the menu for setting the program sequences will appear in the list of the main menus 13 52 AMMETER CAPACITY This parameter indicates the ammeter capacity of the control unit Keep in mind that the capacity refers to simple harmonic currents and as such overflow conditions might occur even with effective current values lower than the nominal value of the carrying capacity and this depends on the sensitiveness of the connected transducer CALIBRATION Set this parameter to ON for starting the self calibration procedure For further information refer to the relevant paragraph LANGUAGE With this parameter the user programs the language in which the control unit should display both the parameters to be set and the error messages 14 52 STEPPER MENU The Stepper menu contains parameters associated with the current stepper operations gt gt STEPPER gt NUM INCREMENTS 01 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 t
53. ving different dimensions especially when working in constant current mode This permits to obtain the best adjustment precision to standard work conditions In this phase a very short weld is carried out with high welding currents therefore the electrodes must have a proper diameter and the welder must be adjusted to an adequate electrode force A Before carrying out this procedure both the control unit and the welder must be set A pressure of at least 4 bar is recommended The self calibration welding procedure must be carried out in short circuit The following operations are to be carried out in the following order Enter the setup menu by turning the key to PROG position and selecting the SETUP item 2 Select the CALIBRATION parameter by means of keys 4 and set it to ON by means of keys and El 8 Turn the key to RUN position to end the programming phase At this point the display shows the standard work data associated with the last spot performed Ensure that the WELD NO WELD function is set to WELD LED must be on Activate the start cycle device The control unit displays the following message and carries out one welding spot which lasts for a few periods with different current adjustments ore CALIBRATION IN PROGRESS When this procedure is completed the control unit displays the maximum current value supplied and the machine s cos value CALIBRATION OK Fi 34
54. ximum time of 0 5 secs This value has been chosen in accordance to the international safety rules BIC1_NC Not used COM1 46 52 D STROKE This input is used for the manual control of the double stroke in welders 27 COM1 fit with this function 29 BIC2_NC Not used 28 COM1 29 30 TERM This input can be used for connecting a thermostat pin 30 32 If a flow FLUX TERM regulator is also present the input must be connected in series with the COM1 thermostat i e the thermostat with pin 30 31 and the flow regulator with pin 31 32 AUX3 This input allows an external device to stop the welding cycle during COM1 the squeeze phase It can be used as an interlocking input or for connecting safety devices such as for instance flow regulators 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 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 This is a suitable command for piloting a 24Vdc coil max 5 W SVI Connect to the solenoid valve that actuates the main cycle This is a 38 COM2 suitable command for piloting a 24Vdc coil max 5 W
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