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Instruction manual

ITEM TE550

S.p.A.

TABLE CONSTANT ENERGY OPERATING MODE PARAMETERS

PROGRAM DATA

>PROGRAM N. 001

WORKING MODE ENE

CONTROL MODE CUR

PARAMETER VALUE

RANGE

PROGRAM N.

001 - 250

WORKING MODE

ENE

CONTROL MODE *

NO

QUALITY – T *

OFF

SQUEEZE 1

00.5 - 99.5 cycles

SQUEEZE

00.5 - 99.5 cycles

PRESSURE

00.5 - 10.0 bar

FORGE DELAY

00 - 99 cycles

FORG.PRESS.

00.5 - 10.0 bar

SLOPE UP

00 – 25 cycles

WELD MIN

00.5 - 99.5 cycles

WELD MAX

00.5 - 99.5 cycles

POWER

05 - 99 %

ENERGY 00060-60000

joule

COLD 3

00 – 50 cycles

POST-WELD.

00.0 – 99.5 cycles

POST-POWER

05 – 99 %

HOLD TIME

00.5 - 99.5 cycles

OFF TIME

00.0 - 99.5 cycles

CONTROL MODE *

CURR

CURR. MIN

1.0 - 90.0 kA

CURR. MAX

1.0 - 90.0 kA

CONTROL MODE *

DEG

ANGLE MIN

005°-180°

ANGLE MAX

005°-180°

CONTROL MODE *

ALL

CURR. MIN

0.5 - 90.0 kA

CURR. MAX

0.5 - 90.0 kA

ANGLE MIN

005°-180°

ANGLE MAX

005°-180°

QUALITY - T*

THICK

THICK. MIN

00.00 – 60.00 mm

THICK. MAX

00.00 – 60.00 mm

QUALITY - T*

IDENT

IDENT. MIN

0.000 – 6.000 mm

IDENT. MAX

0.000 – 6.000 mm

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Summary of Contents for TE550

Page 1: ...STRUCTION MANUAL TE550 FROM SOFTWARE RELEASE N 3 31 S p A via Meucci 27 40024 Castel S Pietro Terme Bologna ITALY Tel 390516954411 Fax 390516954490 http www tecna net DOCUMENT NUMBER MAN 4142 DISTRIBUTOR EDITION JANUARY 2012 ...

Page 2: ...Instruction manual ITEM TE550 S p A 2 92 This page intentionally left blank ...

Page 3: ...ERCENTAGE ADJUSTMENT OPERATING MODE 17 2 3 CONSTANT CURRENT OPERATING MODE 20 2 4 CONSTANT ENERGY OPERATING MODE 23 2 5 WORKING PROGRAM PARAMETERS DESCRIPTION 26 2 6 SETUP MENU 34 2 7 STEPPER MENU 36 2 8 CURRENT STEPPER FUNCTION 38 2 9 FEATURES MENU 43 2 10 PROGRAM COPY 48 2 11 CHECK INPUT 49 2 12 PROG SEQUENCE 50 2 13 TIP DRESSING 53 2 14 THICKNESS SENSOR 57 2 15 ADJUSTING THE FIRST INSERT DELAY ...

Page 4: ...L RECALLS 76 CHAPTER 12 DOUBLE STROKE FUNCTION 77 CHAPTER 13 OPTIONS 78 13 1 RS 232 SERIAL INTERFACE 78 13 2 RS 485 SERIAL INTERFACE 80 13 3 INTERFACE FOR PROPORTIONAL VALVE 81 13 4 INTERFACE FOR PRESSURE SENSOR 82 CHAPTER 14 DESCRIPTION OF THE SIGNALS ON THE TERMINAL BOARD 84 14 1 DESCRIPTION OF THE SIGNALS ON THE OPTIONAL BOARDS 50200 OR 50189 86 CHAPTER 15 LIST OF TE550 MESSAGES 87 15 1 SYSTEM ...

Page 5: ...rmation contained in this document is subject to modification without notice No part of this document can be either reproduced or transferred in whatever format neither by electronic nor by mechanic means for whatever purpose without s written permission is a registered brand 5 92 ...

Page 6: ... via 6 keys and a backlit alphanumeric LCD Synchronous control with controlled diodes phase control current adjustment Storage of 250 welding programs 127 recallable from an external drive Up to 33 programmable parameters for each program Slope pulses pre weld post weld functions and adjustment of the welding times in half cycles Display of the RMS welding current measurement in kA and relative an...

Page 7: ...not cause damage to people or equipment Key for selecting the start cycle device PEDAL or TWO HANDS 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 the 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 w...

Page 8: ... that the pressure only stopping command by means of the AUX1 and AUX2 inlets is activated The turning on of this LED indicates that the control unit is producing the command impulses for the SCR It indicates that the solenoid valve which carries out the main cycle is activated It indicates that the solenoid valve which controls the back pressure is activated It indicates that the solenoid valve w...

Page 9: ...value is displayed both in WELD and in NO WELD mode CURRENT RMS 43 26 kA It indicates the current value used for the last weld sequence In WELD mode it may have a value between 00 00 kA and 90 00 kA In NO WELD mode its value is 00 00 kA It represents the average of the RMS values measured for each welding time half cycle The value shown always refers to the WELD current parameter In case of pulse ...

Page 10: ...he carried out weldings the stepper function status and the last 20 displayed errors In order to enter the welding analysis function of the different carried out half cycles it is necessary to press the key once PRG 001 SPOT 12340 WELD TIME 01 POS 43 26 kA 142 NEG 43 26 kA 142 PRG 001 It indicates the program number used for carrying the last weld sequence SPOT 12340 It indicates the welded spot n...

Page 11: ...n it is possible to carry a further welding analysis out in ENERGY working mode This frame may be displayed by means of the supplementary expansion board item 50200 only PRG 001 SPOT 12340 CYC 01 ENERGY 00000J V 00 00 E 00000J V 00 00 E 00000J PRG 001 It indicates the program number used for the last weld sequence SPOT 12340 It indicates the welded spot number being analysed It always stands for t...

Page 12: ...86 mm Indicates the initial thickness of the material to be welded that the TE550 control unit measures before current flows This value is updated in WELD and NO WELD IDENTATION 0 000 mm Indicates the measurement of the electrode indentation into the welded material at the end of the weld cycle The value is updated only when in WELD and when the IDENTATION measurement is enabled in the welding pro...

Page 13: ... oldest errors are cancelled to be replaced with the most recent ones SPOT 00011 It indicates which welding spot the error is experienced at The number is relevant to the counted welded spots therefore it may happen that the spots number of several consequent errors is not shown in increasing numerical order as in the meantime the counter might have been cleared ERR 0101 It indicates the error rec...

Page 14: ... time the control unit is powered When the RESTART command is activated all the devices connected to the VAUX outlet are powered Before activating the RESTART command it is important to check that it will not cause damage to people or equipment Before starting any welding operations first program the welding data and set some general operating parameters of the welder For safety reasons the microp...

Page 15: ... of them depends either on the options actually inserted in the control unit or on the welder type the control unit is installed onto _ PROGRAM DATA _ SETUP MENU _ STEPPER MENU _ FEATURES MENU _ PROGRAM COPY _ CHECK INPUT _ PROG SEQUENCE It may be activated _ TIP DRESSING It may be activated _ THICKNESS SENSOR It may be activated TE550 VER 3 31 PROGRAM DATA SETUP MENU STEPPER MENU The arrow on the...

Page 16: ...e 250 storable programs using the and keys Then proceed with the next parameters moving with the and keys adjusting the desired value always using the and keys As such all the parameters will be set to the desired value for carrying out the welding process Please beware that the data is saved only and exclusively if the program is exited or if the key is turned in RUN position Here as follows the ...

Page 17: ...be critical to use one of the more complex working modes foreseen in this control unit The correlation map between the set percentage and the controlled diodes SCR closing time is set in TECNA and might not be perfectly linear in order to improve the scale linearity it has been inserted a parameter in the FEATURES MENU allowing to delay the welding process start time For further information check ...

Page 18: ...ar PRES MAX 0 00 10 0 bar Existing particular conditions If the OFF TIME is set to 0 the control unit will work in single cycle By setting the PRE WELD parameter to zero the pre welding process will not be carried out By setting the POST WELD parameter to zero the post welding process will not be carried out By setting the same value for both CURR MIN and CURR MAX the limits of current are disable...

Page 19: ... those with either 1 or 3 sheets The welding current is adjusted by the TE550 control unit However it is necessary to check the welding current value with one sheet so to be set as minimum limit and to check it with 3 sheets so to be set as maximum limit However it is not possible to undoubtedly assure that the piece has been effectively welded as all the conditions and parameters involved in the ...

Page 20: ... tools or surface condition of the materials being processed CONSTANT CURRENT BEHAVIOUR READINGS Welding current changes I according to the mains voltage V variation in standard operating mode Welding current changes I according to the mains voltage V in constant current operating mode It is advisable to activate the CONTROL MODE in DEG and to check before proceeding with production the limit use ...

Page 21: ... 99 5 cycles PRE POWER 05 99 COLD 1 00 50 cycles SLOPE UP 00 25 cycles WELD 00 5 99 5 cycles CURRENT 00 5 90 0 kA IMPULSE N 01 09 COLD 2 00 50 cycles SLOPE DOWN 00 25 cycles COLD 3 00 50 cycles POST WELD 00 0 99 5 cycles POST POWER 05 99 HOLD TIME 00 5 99 5 cycles OFF TIME 00 0 99 5 cycles CONTROL MODE CURR CURR MIN 0 5 90 0 kA CURR MAX 0 5 90 0 kA CONTROL MODE DEG ANGLE MIN 005 180 ANGLE MAX 005 ...

Page 22: ...g the PRE WELD parameter to zero the pre welding process will not be carried out By setting the POST WELD parameter to zero the post welding process will not be carried out By setting the same value for both CURR MIN and CURR MAX the limits of current are disabled By setting the same value for both ANGLE MIN and ANGLE MAX the limits of the conduction angles are disabled By setting the same value f...

Page 23: ...ood execution of the spot quality control that the welding machine it is applied to has adequate specifications relating to power electrode force and welding current for the execution of high A and B class spots To ensure correct use of the control unit in this operating mode we recommend following the procedure below step by step 1 adjust the welding pressure the welding current and the diameter ...

Page 24: ...P 00 25 cycles WELD MIN 00 5 99 5 cycles WELD MAX 00 5 99 5 cycles POWER 05 99 ENERGY 00060 60000 joule COLD 3 00 50 cycles POST WELD 00 0 99 5 cycles POST POWER 05 99 HOLD TIME 00 5 99 5 cycles OFF TIME 00 0 99 5 cycles CONTROL MODE CURR CURR MIN 1 0 90 0 kA CURR MAX 1 0 90 0 kA CONTROL MODE DEG ANGLE MIN 005 180 ANGLE MAX 005 180 CONTROL MODE ALL CURR MIN 0 5 90 0 kA CURR MAX 0 5 90 0 kA ANGLE M...

Page 25: ...value for both THICK MIN and THICK MAX the limits are disabled By setting the same value for both IDENT MIN and IDENT MAX the limits are disabled It is advisable to activate the CONTROL MODE in CUR and to check before proceeding with production the limit use conditions For instance if the use is meant with 2 sheets the limit conditions would be those with either 1 or 3 sheets The constant energy i...

Page 26: ... max limits of the welding current conduction angle ALL It is possible to set the minimum and maximum value of both the welding current and the conduction angle QUALITY T Use this parameter to select if and which check should be carried out on the mechanical qualities of the welded material Checks are run before the weld current flow to measure the initial thickness of the material to be welded an...

Page 27: ...e correct indentation values are outlined in the specific weld tables according to the type of material to be welded TH ID Both measurements are carried out before and after the weld and the minimum and maximum limits may be set in both By setting parameter QUALITY T to THICK or TH ID the user activates the limits on the material s initial thickness In this case two new parameters are displayed TH...

Page 28: ...cuit with low pressure squeeze the SQUEEZE 1 time is combined with the SQUEEZE time where the SQUEEZE 1 time is the one determining the duration of the interval of time that elapses from the beginning of the head descent to the application of the welding pressure The set value must be long enough to allow the electrodes to reach the work piece to be welded During the SQUEEZE 1 time it is possible ...

Page 29: ... is present The set value must be such that it guarantees a proper clamping force during the forging An inadequate adjustment of such value produces sparks between electrodes and sheet during the welding process This parameter may be activated through the FORGE DELAY and PROP VALVE parameters in the FEATURES MENU MOTOR DELAY This parameter describes the time elapsing between the start of the weldi...

Page 30: ...above or equal to the programmed rating This parameter is only displayed when ENE Constant Energy operating mode is selected WELD MAX The maximum weld time parameter WELD MAX is expressed in cycles and represents the welding duration maximum time It is carried out with the same power value set at parameter POWER Welding will stop also if the energy measured at the end of this period of time is bel...

Page 31: ...This parameter may be activated through the relevant function in the SETUP MENU COLD 3 The COLD 3 parameter indicates the time that elapses from the WELD time to the POST WELD time This parameter may be activated through the relevant function in the SETUP MENU POST WELD The POST WELD parameter indicates the duration of a current flow that can be carried out after the welding time in This parameter...

Page 32: ...uring the programming phase CURR MAX This parameter fixes a maximum current limit value For each weld the control unit monitors that the welding current supplied by the welder is lower than the value set at this parameter if it is higher an error message will be displayed see the relevant paragraph This parameter may be activated by setting the CONTROL MODE in CUR If the CONTROL MODE parameter is ...

Page 33: ...t at the end of the weld Otherwise an error message is displayed Activate this parameter by setting QUALITY T in IDENT or in TH ID otherwise the parameter will not be displayed during programming IDENT MAX This parameter fixes a higher limit for the maximum electrode indentation measurement at the end of the weld The measurement of the indentation value should be less than the set limit at the end...

Page 34: ... 0 which if set allows the control unit to work with the program selected in the programming frame START 2 PRG This parameter indicates the program number to be run when the cycle is activated from the start cycle 2 command PRINTER SPOTS With this parameter if the serial port is setup for print see FEATURES MENU paragraph the user can choose which welding spots to be printed It is possible to disa...

Page 35: ...sensitiveness of the connected transducer in the SET UP MENU 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 One may select the following languages ITALIAN ENGLISH SPANISH GERMAN FRENCH HUNGARIAN PORTUGUESE SWEDISH DUTCH POLISH PRE WELD By setting it on ON it activates the following parameters...

Page 36: ...4 0001 5000 INCREMENT 4 Percent increment step 4 00 60 SPOTS 5 Spots step 5 0001 5000 INCREMENT 5 Percent increment step 5 00 60 SPOTS 6 Spots step 6 0001 5000 INCREMENT 6 Percent increment step 6 00 60 SPOTS 7 Spots step 7 0001 5000 INCREMENT 7 Percent increment step 7 00 60 TOTAL STEPS This parameter indicates how many segments are to be created for implementing the stepper curve When it is set ...

Page 37: ...er indicates the current stepper percentage to be attained upon the completing of the spots set in the associated segment SPOTS 5 This parameter indicates the number of spots of which the associated segment is composed INCREMENT 5 This parameter indicates the current stepper percentage to be attained upon the completing of the spots set in the associated segment SPOTS 6 This parameter indicates th...

Page 38: ... post welding current and the energy level to attain During the welding process it is possible to correct the stepper curve trend by changing the parameters determining its trend In order to start a new stepper curve it is necessary to clear the counter and restore the starting diameter of the electrodes SIMPLIFIED USE OF THE STEPPER FUNCTION LINEAR INCREMENT The stepper function can be used in a ...

Page 39: ...ed by the adjustment that permits to obtain the required current with the starting electrode diameter 15 kA It does not matter whether the TE550 is programmed for a percent adjustment or a constant current adjustment since the stepper function is operational in both modes Now the welding process can begin Current will vary conforming to the set increment rule The graph below shows its pattern CURR...

Page 40: ... 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 CURRENT NUMBER OF WELDING SPOTS IDEAL PATTERN REAL...

Page 41: ...pots 1000 3000 4000 4 segment of Duration 19 100 15 15 8 17 100 1 rent initialcur rent initialcur endcurrent segment Change 10 100 8 17 8 17 5 19 100 2 rent initialcur rent initialcur endcurrent segment Change 4 100 5 19 5 19 2 20 100 3 rent initialcur rent initialcur endcurrent segment Change 3 100 2 20 2 20 8 20 100 4 rent initialcur rent initialcur enecurrent segment Change The following parame...

Page 42: ...h below shows its pattern CURRENT INCREASE DURING THE PRODUCTION WELDING CURRENT kA NUMBER OF WELDING SPOTS SEGMENT 4 SEGMENT 3 SEGMENT 2 SEGMENT 1 Once the 4000 welding spots have been carried out the control unit stops the production and displays the following message ERR 104 MAX SPOTS NUMBER At this point the operator replaces the electrodes or resets their original diameter and clears the spot...

Page 43: ...communication 232 485 USB OFF NETWORK ADDRESS Network address 01 31 COIL RATIO Rogowski ratio X 0 5 X1 X5 X10 LOCK END OUT Output function END LOCK FUNCTION RIC6 7 Recall function 6 and 7 RIC BIC LOW FORCE SQ Low force squeeze ON OFF FORGE Forging ON OFF PROP VALVE Proportional valve ON OFF PRESSURE RATIO Proportional ratio 0 1 2 0 AUTORETAIN Start Autoretain ON OFF NC CONTACTS Also NC functions o...

Page 44: ...he corresponding output interlock LOCK or end of cycle END FUNCTION RIC6 7 This parameter indicates the function associated to the two inputs RIC6 BIC1 NC pin 26 and RIC7 BIC2 NC pin 28 By setting the parameter FUNCTION RIC6 7 on RIC the two inputs are used to directly recall the working program from an external drive up to 127 programs By setting the parameter FUNCTION RIC6 7 on BIC the two input...

Page 45: ...cle start signal allowing the weld cycle start However this is possible only if the exchange double contact is present This contact would enable the following operation the normally open contact would close while the normally closed one would open up At present this function is always on OFF and therefore it is disabled SEAM WELD MODE By means of this parameter it is possible to enable the functio...

Page 46: ...ter is set on OFF this function is disabled When this parameter is set on ON the head lock function is enabled in case of error To unlock the TE550 it is necessary to press the CLEAR key or to use the ERROR RESET input when the extra board is present When the parameter is set on KEY a second function for locking the head is enabled In this very case in order to unlock the TE550 it is necessary fir...

Page 47: ... procedure for restoring the data relevant to the parameters of all the control unit s menus from an external USB memory The control unit displays this parameter only when the USB optional board item 50288 is present and if the SERIAL COM parameter is set on USB For further information please refer to the installation and user manuals of the USB board item 50288 SET DATE TIME By pressing the key l...

Page 48: ...en the copying procedure is finished the main programming frame is displayed TE550 VER 3 31 STEPPER MENU FEATURES MENU PROGRAM COPY PROGRAM COPY MENU PARAMETERS TABLE PARAMETER PARAMETER DESCRIPTION VALUE RANGE SOURCE PROGRAM Source program 001 250 COPY FROM PRG Program start copy target 001 250 TO PROGRAM Copy end program 001 250 SOURCE PROGRAM This program indicates the number of the program to ...

Page 49: ...signal ON OFF PRG RECALL 1 It indicates the status of the recall 1 signal ON OFF PRG RECALL 2 It indicates the status of the recall 2 signal ON OFF PRG RECALL 3 It indicates the status of the recall 3 signal ON OFF PRG RECALL 4 It indicates the status of the recall 4 signal ON OFF PRG RECALL 5 It indicates the status of the recall 4 signal ON OFF SAFETY START 1 It indicates the status of the two h...

Page 50: ...n the step 3 001 250 STEP 3 WELDS Number of spots to be carried out with step 3 00 25 STEP 4 PRG Program to be carried out in the step 4 001 250 STEP 4 WELDS Number of spots to be carried out with step 4 00 25 STEP 5 PRG Program to be carried out in the step 5 001 250 STEP 5 WELDS Number of spots to be carried out with step 5 00 25 STEP 1 PRG This parameter indicates the program number that the we...

Page 51: ...rt carrying the welding spots out By turning the key on RUN position the display will show the sequences data as per the below picture WELD N 008 TOTAL 013 WELD N 008 TOTAL 013 PROG N 003 RMS 10 45 TIME 10 0 SPOT 00050 NEXT 009 NEXTPRG 002 It indicates the progressive number of the last carried out welding spot and the welding spots total number the sequence is composed of PROG N 003 RMS 10 45 It ...

Page 52: ...erator must pay great attention while working so not to carry less welding spots out than the programmed ones neither overlapped spots nor welding spots in a different order However should any error occur in the sequence operating mode it is possible to repeat either the last or another welding spot or to go ahead avoiding certain spots By always turning the key in RUN position by means of the key...

Page 53: ...unction allows interfacing the welding control unit with the dresser and may be used with automated equipment Once it is programmed the current stepper is applied to all the used welding programs This menu allows programming the tip dressing number to be carried out during the electrodes life TIP DRESSING DRESSING NUMBER 02 SPOT DRESSING 003 DRESSING STEPS 07 This function is displayed only if the...

Page 54: ...control unit has not received the accomplished tip dressing signal it stops and displays the following message ERR 0116 SPOTS FINISHED DRESS ELECTRODES In order to restore operations first clear the screen via the ERROR RESET input followed by the activation of the signal that indicates that the dressing was done ELECTRODES ALARM This parameter indicates the notice welding spots number during whic...

Page 55: ...R VALUE DRESSING NUMBER 3 SPOT DRESSING 200 DRESSING STEPS 30 DRESSING ALARM 20 ELECTRODES ALARM 20 DRESSING OFFSET 5 The chart below shows the pattern of how the current increased during the electrodes dressing run mode Notice that the initial current of the first dressing starts at 10KA whilst a percentage is added to the starting current value of the subsequent dressings parameter DRESSING OFFS...

Page 56: ...rt for dressings 1 3 and 4 In the example the last DRESSING spot was reached for DRESSING n 2 without clearing the DRESSING ALARM In this case the control unit stops and displays the relevant message ERROR 116 In this case first delete the screen from the control unit either using the ERROR RESET input or using the CLEAR key and then clear the DRESSING ALARM output The same is applicable to clear ...

Page 57: ...eyed in the correct access code THICKNESS SENSOR LINEAR SENSOR OFF SENSOR S N_P1 0000 SENSOR S N_P2 0000 If the position sensors are activated the position sensors initialize each time the control unit is switched on If an initialization error occurs it is displayed on the control unit through the following message CAN LINE NOT INITIALIZABLE and the sensors disable automatically Therefore solve th...

Page 58: ...ameter contains the first part of the serial number of the linear sensor which can be read on the sensor s body SENSOR S N_P2 This parameter contains the second part of the serial number of the linear sensor which can be read on the sensor s body SENSOR ID CAN This parameter is for setting the sensor s ID in the CAN network In order to work efficiently the sensors present in the CAN network must h...

Page 59: ...o determine the minimum wait time before executing the measurement 1 Configure the linear position sensor for use 2 Set parameter DELAY IDENT to ZERO 3 Go to the PROGRAM DATA menu set parameter QUALITY T to ZERO in the weld program Weld a short circuited spot to zero the coordinate electrodes with no material in between 4 Go to the PROGRAM DATA menu set parameter QUALITY T to IDENT in the weld pro...

Page 60: ... the FEATURES MENU so that positive and negative line absorptions are balanced Use an ammeter allowing measuring the maximum positive and negative peak values The adjustment will be correct when the positive peak value is similar to the negative one It is necessary to use a proper current measurement device providing CAT III 600V insulating class and operate with suitable insulating gloves for int...

Page 61: ...suggest using short weld times to prevent the control unit from finishing a long weld time when the cycle start command is cleared In the seam operating mode output EV3 is used as the roller start command instead of being used for the forging On selecting the seam weld function the control unit may work either in WORKING MODE in FIX or in IK SEAM WELD MODE PARAMETERS TABLE Below you may see the 2 ...

Page 62: ... PROGRAM N 001 250 WORKING MODE IK CONTROL MODE NO SQUEEZE 1 00 5 99 5 cycles SQUEEZE 00 5 99 5 cycles PRESSURE 00 5 10 0 bar MOTOR DELAY 00 99 cycles SLOPE UP 00 25 cycles WELD 00 5 99 5 cycles CURRENT 00 5 90 0 kA COLD 2 00 50 cycles CURRENT 3 00 5 90 0 kA HOLD TIME 00 5 99 5 cycles OFF TIME 00 0 99 5 cycles CONTROL MODE CURR CURR MIN 0 5 90 0 kA CURR MAX 0 5 90 0 kA CONTROL MODE DEG ANGLE MIN 0...

Page 63: ...led by means of the closing of RIC5 Pin12 input The external recalls RIC5 RIC6 and RIC7 are not activated in the function of recall from an external device program When the SEAM WELD MODE is set to ON the butt welding BUTT WELD MODE and high speed welding SER SPOT MODE functions are disabled Should one activate them this will make a programming error be displayed ...

Page 64: ...value corresponds to the last carried out pulse BUTT WELD MODE PARAMETERS TABLE Below you may see the 2 possible programming screens according to the parameter selected in the WORKING MODE The screens contain all the programmable parameters PROGRAM DATA PROGRAMME N 001 WORKING MODE FIX CONTROL MODE CUR PARAMETER VALUE RANGE PROGRAM N 001 250 WORKING MODE FIX CONTROL MODE NO SQUEEZE 1 00 5 99 5 cyc...

Page 65: ...CONTROL MODE NO SQUEEZE 1 00 5 99 5 cycles SQUEEZE 00 5 99 5 cycles PRESSURE 00 5 10 0 bar FORGE DELAY 00 99 cycles FORG PRESS 00 5 10 0 bar PRE WELD 00 0 99 5 cycles PRE POWER 05 99 COLD 1 00 50 cycles SLOPE UP 00 25 cycles WELD 00 5 99 5 cycles CURRENT 00 5 90 0 kA IMPULSE N 01 50 COLD 2 00 50 cycles SLOPE DOWN 00 25 cycles COLD 3 00 50 cycles POST WELD 00 0 99 5 cycles POST POWER 05 99 HOLD TIM...

Page 66: ...5 90 0 kA ANGLE MIN 005 180 ANGLE MAX 005 180 NOTES FOR THE BUTT WELDING WORKING MODE ONLY When the BUTT WELD MODE is set to ON the seam welding SEAM WELD MODE and high speed welding SER SPOT MODE functions are disabled Should one activate them this will make a programming error be displayed ...

Page 67: ...RKING MODE ONLY When the HIGH SPEED parameter is set to ON the TE550 manages always and only the EV1 solenoid valve output In the FEATURES MENU the parameter LOW FORCE SQ is fixed to ON while FORGE is fixed to OFF When the SER SPOT MODE is set to ON the seam welding SEAM WELD MODE and butt welding BUTT WELD MODE functions are disabled Should one activate them this will make a programming error be ...

Page 68: ... another the signals used to synchronize control units and carry out electrical cascade welds are as follows START CYCLE input AUX input END CYCLE output All the TE550 control units receive the cycle start signal simultaneously Connect the END CYCLE signal to the AUX input of the next control unit It is advisable to program parameter CASCADE MODE of the last control unit to OFF in order to use the...

Page 69: ... IMPULSE N 03 FORGE DELAY EV3 12 SLOPE DOWN 04 PRE WELD 13 COLD 3 05 PRE POWER 14 POST WELD 06 COLD 1 15 POST POWER 07 SLOPE UP 16 HOLD TIME 08 WELD 17 OFF TIME 09 POWER CURRENT Parameters marked by symbol may either be enabled or disabled depending on which welder is used and the job it must perform For safety reasons the microprocessor does not start the weld cycle if the cycle start signal is a...

Page 70: ...M DATA CONTROL MODE CUR SQUEEZE 1 25 0 SQUEEZE 10 0 These parameters allow the user to keep the consistency of the welding current under control to help achieve constant quality results The control unit may work in one of the two following control modes Welding current limits This mode is activated by setting parameter CONTROL MODE to CUR In this case two new parameters are displayed CURR MIN lowe...

Page 71: ...sages is displayed ERR 0108 STOP LIMIT LOW ANGLE ERR 0109 STOP LIMIT HIGH ANGLE Limits of welding current and conduction angle This mode is activated by setting the parameter CONTROL MODE to ALL In this way the following four new parameters will be displayed CURR MIN Minimum current limit CURR MAX Maximum current limit ANGLE MIN Minimum conduction angle limit ANGLE MAX Maximum conduction angle lim...

Page 72: ...ounter The max number of welds to be carried out is adjusted through the same procedure described for the incremental function For example if the user wishes the control unit to carry out 2840 welds and then stop the following parameters are set in the STEPPER MENU STEPPER MENU TOTAL STEPS 0 SPOTS 1 2840 INCREMENT 1 00 PARAMETER PARAMETER DESCRIPTION VALUE TOTAL STEPS Number of segments for increm...

Page 73: ...WORKING MODE IK the output is activated by the current or degrees limits conforming to the setting of parameter CONTROL MODE and by the omission of the current signal In CONTROL MODE NO deactivated the error output is activated only by the omission of the current signal In WORKING MODE ENE the output is activated by the current or degrees limits by the minimum or maximum weld time by the omission ...

Page 74: ...tion limit Error due to no current signal Minimum conduction limit Maximum conduction limit Min time Max time VE out of scale Error due to no electrodes voltage ALL Minimum current limit Maximum current limit Minimum conduction limit Maximum conduction limit Minimum current limit Maximum current limit Minimum conduction limit Maximum conduction limit Error due to no current signal Minimum conducti...

Page 75: ...for 40 ms if the cycle start signal has already been deactivated 3 active for the entire OFF TIME if programmed to other than zero 4 active until any message or signal is deleted from the display 10 3 LOCK The LOCK signal indicates current activation during the weld cycle The output which is an opto electronic contact closes at the beginning of the weld time It may also be the pre weld or the rise...

Page 76: ... 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 61 62 63 64 65 66 123 124 125 126 127 input active The recallable programs are 127 when using RIC6 and RIC7 inputs as additional recall inputs They are 31 in case RIC6 and RIC7 are not used The use of RIC6 and RIC7 inputs can be activated in the SET UP Menu see relevant paragraph In order to recall the weldin...

Page 77: ...p On turning on the machine with input D STROKE active the output is disabled In this case during the first weld the control unit first activates solenoid valve EV4 before the work cycle this solenoid valve moves the electrode from position A to position B It then carries out the programmed weld cycle after a fixed time of 0 6 seconds At the end of the weld solenoid valve EV4 do fi Later on by kee...

Page 78: ...CEPTION RD PIN 4 TRANSMISSION REQUEST RTS PIN 5 READY TO SEND CTS PIN 6 DATA READY DSR PIN 7 MASS SIGNAL GROUND PIN 20 TERMINAL READY DTR The control unit does not perform any type of handshaking at the serial port The printer s serial port must be configured with the following values SPEED 9600 BAUD WORD LENGTH 7 BIT PARITY EVEN STOP BIT 1 The control unit runs the transmission at the beginning o...

Page 79: ... 001 10 0 06 00 062 00000 00013 CUR MIN 00 000 0 000 00 0 001 10 0 06 00 062 00000 00014 CUR MAX 00 000 0 000 00 0 001 10 0 06 00 062 00000 00015 CUR MAX 00 000 0 000 00 0 Data print example during the weld in CONTROL MODE DEG PROG CYCLES CURRENT DEGREE ENERGY SPOTS LIMIT THICK IDENT PRES 001 10 0 06 00 062 00000 00009 DEG OK 00 000 0 000 00 0 001 10 0 06 00 062 00000 00010 DEG OK 00 000 0 000 00 ...

Page 80: ...rder to manage data and communication among control units connected in the network a personal computer software is available called TECNANet which allows the user to check the network s structure i e how many and which control units are connected remotely program each control unit and acquire save production data The interface is isolated up to 1500V without the need for any external power supply ...

Page 81: ...tage range of the proportional valve directly via the welding control unit The FEATURES MENU contains parameter PRESSURE RATIO with which to choose the most suitable bar Volt ratio according to the solenoid valve to be used Example PRESSURE Parameter bar PRESSURE RATIO Parameter bar Volt Output Volt 5 0 1 0 5 5 0 2 0 2 5 5 0 0 5 10 CONNECTIONS DIAGRAM PROPORTIONAL VALVE N B _ The card is fitted wi...

Page 82: ...y setting the parameter INPUT VE PRE to PRE in the PROGRAM DATA menu the PROGRAM DATA menu will display the two limits relevant to the pressure value measured by the sensor PARAMETER VALUE RANGE PROGRAM N 001 250 WORKING MODE FIX IK CONTROL MODE NO QUALITY T OFF SQUEEZE 1 00 5 99 5 cycles SLOPE UP 00 25 cycles WELD 00 5 99 5 cycles POWER CURRENT 05 99 00 5 90 0 KA IMPULSE N 01 09 COLD 2 00 50 cycl...

Page 83: ... measured pressure value PRESSURE and the limits set in the program PRESS MIN and PRESS MAX PRG 005 SPOT 01234 PRESSURE 03 8 bar PRESS MIN 01 5 bar PRESS MAX 02 5 bar During this phase should the start cycle signal be removed the control unit stops showing an error when measuring the pressure ERR 0129 PRESSURE SENSOR MEASURE ERROR And activates the output signal WRONG The error will be cleared and...

Page 84: ... WELD mode this input calls the second weld current POWER 3 or CURRENT 3 parameters 13 14 15 16 RIC4 RIC3 RIC2 RIC1 These inputs are used for directly calling welding programs from the outside In order to call the programs correctly these inputs must be enabled before the cycle start signal Inputs are active when closed towards the common COM1 17 COM1 Common for inputs with 24VDC reference 18 AUX2...

Page 85: ...sly or in sequence within a max time of 0 5 seconds 36 COM1 Common for inputs with 24VDC reference 37 VAUX This is a 24VDC output and indicates that the control unit is powered on and ready to receive a cycle start command This output may be used to connect a valve intended for the welder s supplementary services Command suitable for coil control at 24VDC Max 5W 38 EV1 Connect to the solenoid valv...

Page 86: ... 50097 PRE inputs for measuring the optional external pressure sensor It works only with the optional board 50189 To these inputs it must be applied a signal 4 20mA having a range 0 10bar 60 61 DRESSING ALARM This output warns that the dressing pre alarm weld spots number has been attained 62 63 ELECTRODES END LIFE ALARM This output warns that the electrodes end life pre alarm weld spots number ha...

Page 87: ...ulty This is why the outputs cannot be enabled Contact service center BOTH INSIDE RELAYS ARE FAULTY 5 Errors occurred in both electronic components that activate the outputs This is why the outputs cannot be enabled Contact service center CRC INSIDE MEMORY CRC INSIDE MEMORY 6 An integrity error occurred in the data stored in the control unit s EPROM This ensued from the checksum calculation on the...

Page 88: ...T LOW ANGLE 108 A certain number of welds were run out of the set limits The last weld was carried out with a conduction angle value lower than the minimum set limit Clear the error as outlined STOP LIMIT HIGH ANGLE 109 A certain number of welds were run out of the set limits The last weld was carried out with a conduction angle value higher than the maximum set limit Clear the error as outlined R...

Page 89: ...ENSOR ZERO PROCEDURE 119 The QUALITY T function was activated during a weld programme but the coordinate zeroing procedure was not carried out Set the QUALITY T parameter to ZERO and carry out a weld without material between electrodes to define the ZERO coordinate Then restore the original value of the QUALITY T parameter POSITION SENSOR QUOTE FAIL 120 Error during the calculation of the position...

Page 90: ...LIMIT 127 Sheet indentation between electrodes is greater than that set in the IDENT MAX limit Reset the error and check the material between the electrodes POSITION SENSOR NOT FOUND 128 You are using a weld programme that requires the presence of the position sensors but they are not present Check the weld programme used if the QUALITY T function is ON deactivate it PRESSURE SENSOR MEASURE ERROR ...

Page 91: ...he value of which is higher than the AMMETER CAP parameter Modify the parameter that triggered the error OFFSET DRESSING HIGHER THAN STEPPER 207 The DRESSING OFFSET parameter is higher than the required DRESSING STEPS increment value Modify the parameter that triggered the error CURRENT MAX LIMIT HIGHER THAN RANGE 208 The required work program contains the CURR MAX parameter the value of which is ...

Page 92: ...CHNICAL SPECIFICATIONS POWER SUPPLY 24Vac 10 FREQUENCY 50 60Hz 1 CONSUMPTION 0 3A WITHOUT LOAD 2A WITH COMPLETE LOADS MAX ALTITUDE 1000m RELATIVE HUMIDITY from 40 to 80 WORK TEMPERATURE 0 C to 50 C 32 F to 122 F WEIGHT 530g 1 1685 lb PROTECTION RATING IP40 ...

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