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TE700 Instruction

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THICK SENSOR

This parameter enables the THICKNESS SENSE menu for parameterizing eventual position
sensors connected to the control unit. Also, by means of a stepper law, it enables the
possibility of compensating the electrode’s wear according to the initial quote.

STEPPER TIME

This parameter allows enabling the welding time stepper law inside the stepper menu. This
law is enabled either independently or associated with a current stepper value.

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Summary of Contents for TE700

Page 1: ...UCTION MANUAL TE700 FROM SOFTWARE RELEASE N 1 13 TECNA S p A via Grieco 25 27 40024 Castel S Pietro Terme Bologna ITALY Tel 390516954411 Fax 390516954490 http www tecna net DOCUMENT NUMBER MAN 4147 DISTRIBUTOR EDITION APRIL 2010 ...

Page 2: ...Instruction Manual ITEM TE700 TECNA S p A 2 128 This page is intentionally left blank ...

Page 3: ... Pag 31 2 5 CONSTANT POWER OPERATING MODE Pag 34 2 6 CONSTANT ENERGY OPERATING MODE Pag 37 2 7 DYINAMIC COMPENSATION OPERATING MODE Pag 41 2 8 WORKING PROGRAM PARAMETERS DESCRIPTION Pag 44 2 9 SETUP MENU Pag 54 2 10 STEPPER MENU Pag 57 2 11 ADJUSTMENT STEPPER FUNCTION Pag 61 2 12 FEATURES TE700 Pag 66 2 13 FEATURES INVERTER Pag 70 2 14 PROGRAMS COPY Pag 75 2 15 CHECK INPUT DIAGNOSTIC TE700 Pag 77 ...

Page 4: ... PROGRAM THROUGH EXTERNAL RECALLS Pag 109 CHAPTER 10 DOUBLE STROKE FUNCTION Pag 113 CHAPTER 11 OPTIONS Pag 114 11 1 RS 232 SERIAL INTERFACE Pag 114 11 2 INTERFACE FOR PROPORTIONAL VALVE Pag 116 CHAPTER 12 DESCRIPTION OF THE SIGNALS ON THE TERMINAL BOARD Pag 117 CHAPTER 13 LIST OF TE700 MESSAGES Pag 120 13 1 SYSTEM ERRORS TE700 Pag 120 13 2 SYSTEM ERRORS INVERTER Pag 121 13 3 WORK ERRORS Pag 124 CH...

Page 5: ... contained in this document is subject to modification without prior 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 TECNA s written permission TECNA is a registered brand 5 128 ...

Page 6: ... with constant current FIX constant power constant voltage constant energy adjustment and in dynamic mode The number of the inputs and outputs may be increased to better adapt the welding control unit to automatic machines The control unit can manage up to max 4 different welding transformers It is possible to store up to 300 different welding programs 255 of which are recalled directly from an ex...

Page 7: ...ntation at the end of the weld 6 WORKING MODEs conventional constant current constant power constant voltage FIX constant energy DYNAMIC mode Limit indicators for Current voltage at the electrodes energy power inverter use percentage initial and final resistance of the material to be welded thickness and indentation limit of the material optional Double stroke function Stepper function to compensa...

Page 8: ...that the devices connected to the VAUX cannot injure people or damage 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 p...

Page 9: ... 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 generating the command signal for the inverter welding unit 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...

Page 10: ...th in WELD and NO WELD mode 01 is the identifier of the number of the tool used to carry out the weld The number ranges from 1 to 4 Displayed in WELD and NO WELD mode SPOT 56002 This is the counter that counts the carried out welds the number may range from 00000 to 65000 Each equipment is fitted with its own standalone spot counter that increases only when welds are carried out through a program ...

Page 11: ... value will depend on the type of welding unit the geometry of the machine and the features of the material to be welded Approaching 100 entails a loss of the control unit s current adjustment capacities The value is updated in WELD mode 000 0 is displayed in NO WELD mode Use keys and inside this screen to view data relevant to the previously carried out 20 weld spots The control unit only stores ...

Page 12: ... The displayed value always refers to the main adjustment that is to say to that of the WELD parameter If welding is by pulses the current value is always the value of the last pulse carried out SPOT 02345 It stands for the welded spots counter it may be a number between 00000 and 65000 It is updated in WELD mode only and it may be cleared by means of the CLEAR key r 000 0 It indicates the use per...

Page 13: ...allow viewing the electrodes voltage value The displayed value always refers to the energy supplied inside the weld s main block and in the case of the pulse WORKING MODE it always refers to the last pulse Use keys and inside this screen to view data relevant to the previously carried out 20 weld spots The control unit only stores data relevant to spots carried out in WELD mode The execution of a ...

Page 14: ...ol unit Use keys and inside this screen to view data relevant to the previously carried out 20 weld spots The control unit only stores data relevant to spots carried out in WELD mode The execution of a weld in WELD mode and in NO WELD mode leads to the display of data relevant to the last spot carried out in WELD mode Stepper analysis screen This screen may be accessed only if the stepper function...

Page 15: ...0 weld spots The control unit only stores data relevant to spots carried out in WELD mode The execution of a weld either in WELD mode or in NO WELD mode entails the display of the data relevant to the last spot carried out in WELD mode Electrodes dressing analysis screen This screen may be accessed only if the dressing function optional is activated on the control unit PRG 005 FE ZN 10 01 SOT 0000...

Page 16: ...lected weld program These are 8 characters that are defined at will by the operator to better identify the weld program It is displayed both in WELD and NO WELD mode 01 is the identifier of the number of the transformer used to carry out the weld or the number of the tool used The number ranges from 1 to 4 It is displayed both in WELD and NO WELD mode IDENT 00 000MM It indicates the measurement of...

Page 17: ...he value of the spot counter when the signalled error occurred LOG 05 It indicates the position of the error inside the LOG The value may range from 1 to 20 The highest number refers to the last error that occurred whilst the lowest number indicates the oldest error DRESSING 165 CAPS NEED DRESSING Concise description of the displayed error For further information consult this manual Use keys and i...

Page 18: ...ck is finished INVERTER COM CAN BUS NOT READY WAIT The following message is displayed once the working efficiency of the communication channel has been checked INVERTER COM CAN BUS READY Next the mains frequency recognized by the control unit is displayed MAINS FREQUENCY 50 Hz Both the type of control unit and the relevant software version are displayed TE700 REV 1 09 WELD CONTROL UNIT In order to...

Page 19: ...ge to people or equipment The following message is displayed until the inverter is ready to weld INVERTER CAPACITOR CHARGING PLEASE WAIT Before starting any welding operations first program the welding data and set some general operating parameters of the welder For safety reasons the microprocessor does not start the welding cycle if the cycle start signal is actuated when the welder is turned on...

Page 20: ... the control unit being used as some 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 TE700 _ FEATURES INVERTER _ PROGRAM COPY _ DIAGNOSTIC TE700 _ DIAGNOSTIC INV _ PROG SEQUENCE _ THICKNESS SENSE It may be activated _ TIP DRESSING It may be activated TE700 VER ...

Page 21: ...ified Each time key is pressed the next character in the string is selected beginning from position 1 up to position number 8 On reaching the eighth character when key is pressed the operator may modify the first character again PROGRAM DATA T1 PROGRAM N 001 PRG NAME U SI1500P TOOLS N 1 The affected character is indicated on the control unit display by the symbol located on the right hand side of ...

Page 22: ... ignoring the weld spots carried out with other electrodes PROGRAM DATA T2 PROGRAM N 001 PRG NAME USI1500P TOOLS N 2 The modification of the WELD TOOL number is indicated next to the PROGRAM DATA text by means of the symbols T1 T2 T3 T4 so that on scrolling the weld program parameters the operator may always see which tool identifier is associated with the weld program being used PROGRAM DATA T1 P...

Page 23: ...restricted automatically to the max current than can be supplied by the welding transformer set in the FEATURES INVERTER menu In addition to simplifying the programming operations this WORKING MODE also permits to keep the desired welding current even if some factors change such as mains voltage welding circuit dimensions and impedance conditions of the welding tools or surface condition of the ma...

Page 24: ...1000 mS WELD 0001 2000 mS CURRENT 000 30 200 00 KA COLD 2 0000 1000 mS IMPULSE N 1 9 WELD 2 0000 1000 mS CURRENT 2 000 30 200 00 KA SLOPE DOWN 0000 1000 mS COLD 3 0000 1000 mS POST WELD 0000 1000 mS POST CURR 000 30 200 00 KA HOLD TIME 00 5 99 0 cycles OFF TIME 00 0 99 0 cycles CONTROL MODE CUR LIM I MIN 000 30 200 00 KA LIM I MAX 000 30 200 00 KA CONTROL MODE RO LIM RO MIN 005 0 100 0 LIM RO MAX ...

Page 25: ...welding process will not be carried out On setting the WELD 2 parameter to zero WELD 2 will not be carried out On setting LIM I MIN and LIM I MAX to the same value the limits are deactivated On setting LIM RO MIN and LIM RO MAX to the same value the limits are deactivated On setting LIM V MIN and LIM V MAX to the same value the limits are deactivated On setting LIM P MIN and LIM P MAX to the same ...

Page 26: ...ximum limit If a more accurate spot quality control is required activate the QUALITY T parameters to check the initial thickness of the sheets and the electrode penetration at the end of the welding cycle and the QUALITY R parameter to obtain a measurement of the initial and final values of the resistance The presence of the QUALITY T and QUALITY R parameters depends on the control unit s configur...

Page 27: ...t might affect the current supply are changes in the resistance of the material to be welded wearing out of the electrodes and changes in the geometry of the secondary circuit or mains voltage fluctuations The FIX WORKING MODE may be advisable for short term welding with great resistance changes or when using the welder as a metal heating device The slicing of the inverter RO is kept constant The ...

Page 28: ...000 1000 mS WELD 0001 2000 mS RO 005 0 100 0 COLD 2 0000 1000 mS IMPULSE N 1 9 WELD 2 0000 1000 mS RO 2 005 0 100 0 SLOPE DOWN 0000 1000 mS COLD 3 0000 1000 mS POST WELD 0000 1000 mS POST RO 005 0 100 0 HOLD TIME 00 5 99 0 cycles OFF TIME 00 0 99 0 cycles CONTROL MODE CUR LIM I MIN 000 30 200 00 KA LIM I MAX 000 30 200 00 KA CONTROL MODE RO LIM RO MIN 005 0 100 0 LIM RO MAX 005 0 100 0 CONTROL MOD...

Page 29: ...ing process will not be carried out On setting WELD 2 parameter to zero WELD 2 will not be carried out On setting LIM I MIN and LIM I MAX to the same value the limits are deactivated On setting LIM RO MIN and LIM RO MAX to the same value the limits are deactivated On setting LIM V MIN and LIM V MAX to the same value the limits are deactivated On setting LIM P MIN and LIM P MAX to the same value th...

Page 30: ...g as the welding current is less than the maximum current of the welding transformer If the welding current tends to exceed the value set as welding transformer max current the welder intervenes automatically by reducing the set current slicing value in real time to maintain current within the set limits ...

Page 31: ...pt constant as long as it is lower than the CURR MAX parameter If the welding current tends to exceed the value set in CURR MAX the inverter unit will automatically decrease the value of the secondary voltage in real time to maintain the welding current within the set limits The CURR MAX value may be set as high as the max value of the transformer welding current Its task is to prevent damage to t...

Page 32: ... 1000 mS WELD 0001 2000 mS VE 00 20 20 00 V CURR MAX 001 00 200 00 KA COLD 2 0000 1000 mS IMPULSE N 1 9 WELD 2 0000 1000 mS VE 2 00 20 20 00 V SLOPE DOWN 0000 1000 mS COLD 3 0000 1000 mS POST WELD 0000 1000 mS POST VE 00 20 20 00 V HOLD TIME 00 5 99 0 cycles OFF TIME 00 0 99 0 cycles CONTROL MODE CUR LIM I MIN 000 30 200 00 KA LIM I MAX 000 30 200 00 KA CONTROL MODE RO LIM RO MIN 005 0 100 0 LIM R...

Page 33: ...ng process will not be carried out On setting the POST WELD parameter to zero the post welding process will not be carried out On setting WELD 2 parameter to zero WELD 2 will not be carried out On setting LIM I MIN and LIM I MAX to the same value the limits are deactivated On setting LIM RO MIN and LIM RO MAX to the same value the limits are deactivated On setting LIM V MIN and LIM V MAX to the sa...

Page 34: ...lied current The supplied welding current may never exceed the max value set for the used welding transformer Using constant power may be seen as a constant energy welding at a known time In fact when working with constant power during the welding operation a constant energy value is always supplied at a fixed time The use of the constant power working mode may be useful to compensate the wear of ...

Page 35: ...000 20 600 00 KW CURR MAX 001 00 200 00 KA COLD 2 0000 1000 mS IMPULSE N 1 9 WELD 2 0000 1000 mS POWER 2 000 20 600 00 KW SLOPE DOWN 0000 1000 mS COLD 3 0000 1000 mS POST WELD 0000 1000 mS POST POWER 000 20 600 00 KW HOLD TIME 00 5 99 0 cycles OFF TIME 00 0 99 0 cycles CONTROL MODE CUR LIM I MIN 000 30 200 00 KA LIM I MAX 000 30 200 00 KA CONTROL MODE RO LIM RO MIN 005 0 100 0 LIM RO MAX 005 0 100...

Page 36: ...e carried out On setting the POST WELD parameter to zero the post welding process will not be carried out On setting WELD 2 parameter to zero WELD 2 will not be carried out On setting LIM I MIN and LIM I MAX to the same value the limits are deactivated On setting LIM RO MIN and LIM RO MAX to the same value the limits are deactivated On setting LIM V MIN and LIM V MAX to the same value the limits a...

Page 37: ...g 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 working mode we recommend following the procedure below step by step 1 adjust the welding pressure the welding current and the diameter of the electrodes according to the traditional tables for t...

Page 38: ...200 00 KA ENERGY 0 60000 J WELD MIN 0001 999 mS WELD MAX 0002 1000 mS COLD 2 0000 1000 mS IMPULSE N 1 9 WELD 2 0000 1000 mS CURRENT 2 000 30 200 00 KA SLOPE DOWN 0000 1000 mS COLD 3 0000 1000 mS POST WELD 0000 1000 mS POST CURR 000 30 200 00 KA HOLD TIME 00 5 99 0 cycles OFF TIME 00 0 99 0 cycles CONTROL MODE CUR LIM I MIN 000 30 200 00 KA LIM I MAX 000 30 200 00 KA CONTROL MODE RO LIM RO MIN 005 ...

Page 39: ...ss will not be carried out On setting the POST WELD parameter to zero the post welding process will not be carried out On setting WELD 2 parameter to zero WELD 2 will not be carried out On setting LIM I MIN and LIM I MAX to the same value the limits are deactivated On setting LIM RO MIN and LIM RO MAX to the same value the limits are deactivated On setting LIM V MIN and LIM V MAX to the same value...

Page 40: ...either with 1 or 3 sheets The constant energy is adjusted by the TE700 control unit The operator must then check the current slicing percentage of the inverter with 1 sheet and set this value as minimum limit The value with 3 sheets should 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 involve...

Page 41: ...ameters must NOT be set to IK WORKING MODE otherwise it will not be possible to activate the DYNAMIC MODE Check that the electrodes used are in perfect working order Spot weld a sample of material not subjected to anomalous conditions that is to say with paired sheets clean and without any shunt spots in the whereabouts If the quality of the welding is satisfactory switch the control unit WORKING ...

Page 42: ...PE UP 0000 1000 mS WELD 0001 2000 mS CURRENT 000 30 200 00 KA POWER 2 000 20 600 00 KW CURR MAX 001 00 200 00 KA SLOPE DOWN 0000 1000 mS COLD 3 0000 1000 mS POST WELD 0000 1000 mS POST POWER 000 20 600 00 KW HOLD TIME 00 5 99 0 cycles OFF TIME 00 0 99 0 cycles CONTROL MODE CUR LIM I MIN 000 30 200 00 KA LIM I MAX 000 30 200 00 KA CONTROL MODE RO LIM RO MIN 005 0 100 0 LIM RO MAX 005 0 100 0 CONTRO...

Page 43: ...weld will not be carried out On setting the POST WELD parameter to zero the post welding process will not be carried out On setting WELD 2 parameter to zero WELD 2 will not be carried out On setting LIM I MIN and LIM I MAX to the same value the limits are deactivated On setting LIM RO MIN and LIM RO MAX to the same value the limits are deactivated On setting LIM V MIN and LIM V MAX to the same val...

Page 44: ...ed out when the secondary voltage is present during the WELDING block If working in pulse mode the comparison is carried out on the last run impulse PW The operator may set the minimum and maximum limits of the average supplied power value The comparison is carried out with the average power value supplied during the WELDING block If working in pulse mode the comparison is carried out on the last ...

Page 45: ...rial OFF The resistance of the material in between the electrodes is not measured PRE The initial resistance of the material to be welded is measured The operator may set the minimum and maximum limits on the measured value POST The final resistance of the material to be welded is measured The operator may set the minimum and maximum limits on the measured value PRE POST Both the initial and the f...

Page 46: ...rameter expresses the delay time that elapses from the beginning of the welding process and the application of the forging force It is used exclusively with pneumatic circuits that contemplate the forging function Such function activates EV3 which permits to increase the electrodes force during the welding cycle If the value is set to zero the FORGE function is disabled valve EV3 is activated eith...

Page 47: ...is other than 0 then the initial value will no longer be the minimum value of the adjustment parameter but the adjustment quantity value used in the PRE WELD Whilst the final value is equivalent to the current value programmed in the WELD parameter the inclination of the SLOPE UP is calculated automatically by the microprocessor according to programmed values The SLOPE UP time is summed up to the ...

Page 48: ...he WELD is carried out with This parameter is displayed only in the PWK or DYN WORKING MODE ENERGY This parameter indicates the energy value expressed in joules which must be developed during welding This rating must be reached in a number of cycles between the minimum time and the maximum time This parameter is only displayed when ENE Constant Energy WORKING MODE is selected IMPULSE N The number ...

Page 49: ...r of the WELD or WELD 2 if present down to the minimum value foreseen by the adjustment parameter if the COLD 3 TIME is other than zero whilst if the COLD 3 TIME is zero and POST WELD is other than zero the minimum value will be the value set for the adjustment parameter in POST WELD The downward inclination is calculated automatically by the microprocessor according to the programmed values The S...

Page 50: ...en 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 LIM I MIN This parameter fixes a minimum current limit value For each weld the control unit monitors that the welding current supplied by the w...

Page 51: ...S TE700 menus LIM V MAX This parameter defines a maximum secondary voltage limit value Each time a weld is carried out the control unit checks that the secondary voltage during the welding operation is less than the value set in this parameter Otherwise an error condition occurs see the specific paragraph Activate this parameter by setting the CONTROL MODE to VE otherwise the parameter is not disp...

Page 52: ...must be greater than the set minimum limit Otherwise an error condition occurs see the specific paragraph Activate this parameter by setting QUALITY T to THICK or TH ID otherwise the parameter is not displayed during the programming phase The display of this parameter depends on the configuration of the machine set in the FEATURES INVERTER and FEATURES TE700 menus THICK MAX This parameter defines ...

Page 53: ...the initial resistance value must be less than the maximum set value Otherwise an error condition occurs see the specific paragraph Activate this parameter by setting QUALITY R to PRE or PRE POST otherwise the parameter is not displayed during the programming phase The display of this parameter depends on the configuration of the machine set in the FEATURES INVERTER and FEATURES TE700 menus R MIN ...

Page 54: ...s relevant to the PRE WELD ON OFF POST WELD It activates the parameters relevant to the POST WELD ON OFF WELD 2 Activates the WELD 2 parameters ON OFF PROG SEQUENCE Activates the sequence of programs ON OFF DYNAMIC TIME Max welding time adjustment in DYNAMIC mode 2X 9X DYNAMIC COMP Dynamic correction algorithm intervention adjustment 30 200 WELD QUALITY Activation of the quality control limits in ...

Page 55: ... T3 The STOP BAD SPOT T3 parameter allows the operator to program the control unit so that it stops when welds are carried out with weld programs associated with tool number 3 with values of the controlled parameter beyond the set limits The programmed value indicates the number of consecutive out of limits welds that cause the machine to stop The limits error occurs when a welding is carried out ...

Page 56: ...gnals the error see the specific chapter DYNAMIC COMP This parameter allows the operator to set with DYN WORKING MODE active how effective the action of the weld correction algorithm should be When using the machine under routine conditions this parameter should be set to 30 Increase the value of the parameter if the corrective action is not satisfactory WELD QUALITY This parameter allows the oper...

Page 57: ...vate the electrodes dressing function for the selected tool Press key to deactivate the electrodes dressing function for the selected tool without losing the parameterization entered for the electrodes dressing and activate the stepper function on the same tool Two different stepper laws having segments of the same duration as far as number of steps but different stepper percentages for each segme...

Page 58: ... 50 INCREMENT 6 L2 INCREMENT percentage law 2 0 50 SPOTS 7 Spots step 7 0 5000 INCREMENT 7 L1 INCREMENT percentage law 1 0 50 INCREMENT 7 L2 INCREMENT percentage law 2 0 50 TOOLS N This parameter allows the operator to choose on which INCREMENT module a corresponding INCREMENT module will be available for each tool made available in the INVERTER FEATURES menu On changing the value of the parameter...

Page 59: ...s N TOTAL STEPS This parameter indicates by how many segments the current stepper curve is to be made up of In order to deactivate the stepper module function STEPPER WELD and STEPPER TIME and STEPPER THICK must all be OFF SPOTS 1 This parameter indicates the number of spots which the associated segment is composed of When STEPPER 1 L1 0 and SPOTS 1 0 the value set in parameter SPOTS 1 equals the ...

Page 60: ...e percentage increase relevant to the fifth segment of stepper law 1 INCREMENT 5 L2 This increment indicates the percentage increase relevant to the fifth segment of stepper law 2 SPOTS 6 This parameter indicates the number of spots which the associated segment is composed of INCREMENT 6 L1 This increment indicates the percentage increase relevant to the sixth segment of stepper law 1 INCREMENT 6 ...

Page 61: ...the stepper curve trend by changing the parameters determining its trend In order to begin a new stepper curve reset the spot counter relevant to the stepper module to be cleared that is to say the one relevant to the tool in which the electrodes starting diameter was restored SIMPLIFIED USE OF THE STEPPER FUNCTION LINEAR STEPPER The present example is carried out considering the control unit set ...

Page 62: ...al number of stepper steps 1 SPOTS 1 Number of spots of first segment 2000 INCREMENT 1 L1 Percentage increase of the first segment relevant to law L1 26 INCREMENT 1 L2 Percentage increase of the first segment relevant to law L2 00 The welding program must be set in order to carry out the first welding spot which is with an adjustment enabling to obtain the necessary current with the starting elect...

Page 63: ...the one shown in the graph below IDEAL PATTERN 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 operator wishes to achieve utmost constancy during work conditions a non linear increment curve can be set that is described by defining a...

Page 64: ...t always be calculated referring to the beginning of the considered segment spots 700 0 700 1 segment of Duration spots 1100 700 1800 2 segment of Duration spots 1200 1800 3000 3 segment of Duration spots 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 segme...

Page 65: ...vant to law L2 00 The welding program must be set in order to carry out the first welding spot which is with an adjustment enabling to obtain the necessary current with the starting electrodes diameter 15 kA Now the welding process can begin Current will change according to the programmed increment rule The graph below shows its pattern CURRENT kA NUMBER OF WELDING SPOTS SEGMENT 1 SEGMENT 2 SEGMEN...

Page 66: ...URES TE700 SERIAL COM OFF NET ADDRESS 01 OUT LOCK END END Keep in mind that only skilled personnel are permitted to edit the following parameters to prevent damage to people or equipment PARAMETER PARAMETER DESCRIPTION RANGE VALUE SERIAL COM Serial communication 232 485 OFF NET ADDRESS Network address 01 31 OUT LOCK END Output function END LOCK LOW FORCE SQ Low force squeeze ON OFF FORGE Forging O...

Page 67: ...umatic circuit welders that are equipped with this function Its enabling adds the FORGE DELAY parameter to the work program PROP VALVE This parameter is used for enabling the use of a proportional valve for pneumatic circuit welders that are equipped with this function Its enabling adds the PRESSURE parameter to the work program If the FORGE parameter is enabled too then the FORG PRESS parameter i...

Page 68: ... the seam weld mode automatically deactivates the autoretain Further information is supplied in the SEAM WELD MODE paragraph CASCADE MODE This parameter allows reversing the output signal of the end cycle END that is to say from normally open contact to normally closed contact to allow putting more control units in cascade Check the proper paragraph for further information WELD NO WELD When the op...

Page 69: ...n sensors connected to the control unit Also by means of a stepper law it enables the possibility of compensating the electrode s wear according to the initial quote STEPPER TIME This parameter allows enabling the welding time stepper law inside the stepper menu This law is enabled either independently or associated with a current stepper value ...

Page 70: ...z Keep in mind that only skilled personnel are permitted to edit the following parameters to prevent damage to people or equipment PARAMETER PARAMETER DESCRIPTION RANGE VALUE INVERTER SIZE Max current supplied by the inverter 50 A 4000 A TA TURNS Number of sensor turns primary current 500 2000 FREQUENCY Inverter operating frequency 1000 2000 3000 4000 Hz CURRENT LOOP Current adjustment loop ROG TA...

Page 71: ... be damaged If an operating frequency higher than 1000 Hz is selected it will not be possible to activate the thermal limit switches relevant to the welding transformer and or the diodes If the thermal limit switches relevant to the welding transformer and or the diodes were previously activated when a work frequency higher than 1000Hz is selected the following message is displayed THERMAL LIMIT S...

Page 72: ... thermal current of the welding transformer If the value is equal to zero or the value of the TH TR TIME parameter equals zero the limit switch at the thermal current of the welding transformer is deactivated This function may be activated only when the inverter unit has been set with an operating frequency of 1000 Hz If the operating frequency is greater than 1000 Hz the following message is disp...

Page 73: ...ame turns and max current value in the following parameters for all the welding transformers If the operator intends using different welding transformers each transformer should be characterized by its turns ratio and by the max secondary current that can be supplied If the operator uses different welding transformers the Rogowsky integrity test must not be enabled If the operator uses more than o...

Page 74: ... the number of turns of welding transformer 3 IMAX TR 3 It sets the max current that may be supplied by welding transformer 3 TURNS TR 4 It sets the number of turns of welding transformer 4 IMAX TR 4 It sets the max current that may be supplied by welding transformer 4 ...

Page 75: ...to be saved in simply press the key and a request will appear asking either to continue and copy or cancel the operation COPY PROGRAM OK CANCEL In order to copy simply press key and the following screen is displayed The bar shows the copying progress state PROGRAM COPY WAIT When the copying procedure is finished the main programming screen is displayed TE700 VER 1 09 FEATURES TE700 FEATURES INVERT...

Page 76: ...The value of this parameter may range from 001 to 250 COPY FROM PRG This program indicates the first program which the source program is copied into The value of this parameter may range from 001 to 250 TO PROGRAM This program indicates the last program which to copy the source program into The value of this parameter may range from 001 to 250 ...

Page 77: ...f the thermostat 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 INVERTER READY It indicates the status of the READY signal from the inverter unit ON OFF SAFETY START...

Page 78: ... OFF TRIGGER It indicates the status of the welding start signal inside the inverter ON OFF RIC 5 WELD 2 It indicates the status of signal RIC 5 or SEAM WELD 2 inside the inverter ON OFF OUT EV WATER It indicates the status of the inverter output that controls the EV for the cooling circuit water ON OFF OUT READY It indicates the status of inverter output for the READY signal transmitted to the TE...

Page 79: ... 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 number of the program that the welder ...

Page 80: ...ving set the parameters of the PROGRAM SEQUENCES menu as outlined above Switch the key to WORK position on the display to view the data of the sequences as shown in the figure below WELD N 008 TOTAL 013 PROG N 003 RMS 10 45 TIME 10 0 SPOT 00050 NEXT 009 NEXTPRG 002 WELD N 008 TOTAL 013 It indicates the progressive number of the last carried out welding spot and the welding spots total number the s...

Page 81: ...be welded from changing the foot pedal or other cycle start 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 However should any error occur in the sequence work mode it is possible to repeat either the last or another welding spot or to go ahead avoiding certain spots By always turni...

Page 82: ...operator must then solve the failed initialization problem enter the THICKNESS SENSE menu and re enable the position sensors manually If multiple position sensors connected to different welding transformers are used it is essential that when the TE700 control unit is turned on all the sensors should be connected to the communication bus so as to be initialized correctly PARAMETER PARAMETER DESCRIP...

Page 83: ...ools are enabled with 3 associated position sensors and the operator carries out a weld with a program in which tool number 2 was selected linear sensor number 2 will be used to measure the coordinates SENSOR1 S N_P1 This parameter contains the first part of the serial number of linear sensor 1 The serial number can be read on the sensor body SENSOR1 S N_P2 This parameter contains the second part ...

Page 84: ...easure the coordinate with which to obtain the electrode penetration value during the welding operation SENSOR4 S N_P1 This parameter contains the first part of the serial number of linear sensor 4 The serial number can be read on the sensor body SENSOR4 S N_P2 This parameter contains the second part of the serial number of linear sensor 4 The serial number can be read on the sensor body SENSOR4 I...

Page 85: ...ter to ZERO in the program used for welding Carry out a spot in short circuit to zero the coordinate electrodes without material in between 5 Set in the PROGRAM DATA menu the QUALITY T parameter to IDENT in the program used for welding 6 Carry out a spot in short circuit observe the penetration measurement supplied on the TE700 control unit display at the end of the welding procedure If the value ...

Page 86: ...nce of an automation that provides an interface between the weld control unit and the dresser After it has been set the current increment is applied to all the welding programs used 4 different electrode dressing parameterizations are available and each parameterization is associated with one of the four different welding tools available In this way it is possible to manage the use and dressing of...

Page 87: ...ate the dressing function on the tool specified in the TOOLS N parameter Should the stepper function be active in the selected TOOL a warning is displayed requesting the operator to deactivate the stepper function DRESSING NUMBER This parameter indicates the number of tip dressing to be carried out on the electrodes before these ones become useless If this parameter is set to zero the tip dressing...

Page 88: ...ALARM output is enabled requesting the replacement of the welding electrodes If at the end of the pre alarm welding spots the control unit has not received the signal that indicates that the electrodes were replaced it stops and displays the following message DRESSING 166 END CAPS LIFE WARNING ON TOOLS TI PUSH O RESET In order to restore control unit working efficiency first of all clear the scree...

Page 89: ...e WORKING MODE IK with an initial current value set to 10KA PARAMETER 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 You may notice that the initial current of the first dressing begins at 10KA whilst a percentage is added to th...

Page 90: ...sings 1 3 and 4 In the example above the very last spot of the dressing was reached during DRESSING no 2 without resetting the DRESSING ALARM In this case the control unit stops and displays the relevant warning message ERROR 116 In this case the operator must first delete the screen from the control unit either through the ERROR RESET input or the CLEAR key and then reset the DRESSING ALARM outpu...

Page 91: ...sed for the forging On enabling the programming of the WELD 2 parameter the operator may set not only the CURRENT parameter but also the CURRENT 2 parameter During the welding operation it is possible to commutate between one set current value and the other using the WELD 2 input present on the INVERTER unit If the COLD T 2 parameter is other than zero each time the two foregoing current values co...

Page 92: ... 5 10 0 bar MOTOR DELAY 05 99 cycles PRE WELD 0000 1000 mS PRE CURR 000 30 200 00 KA COLD 1 0000 1000 mS SLOPE UP 0000 1000 mS WELD 0001 2000 mS CURRENT 000 30 200 00 KA COLD 2 0000 1000 mS CURRENT 2 000 30 200 00 KA HOLD TIME 00 5 99 0 cycles CONTROL MODE CUR LIM I MIN 000 30 200 00 KA LIM I MAX 000 30 200 00 KA CONTROL MODE RO LIM RO MIN 005 0 100 0 LIM RO MAX 005 0 100 0 CONTROL MODE VE LIM V M...

Page 93: ...SSURE 00 5 10 0 bar MOTOR DELAY 05 99 cycles PRE WELD 0000 1000 mS PRE RO 005 0 100 0 COLD 1 0000 1000 mS SLOPE UP 0000 1000 mS WELD 0001 2000 mS RO 005 0 100 0 COLD 2 0000 1000 mS RO 2 005 0 100 0 HOLD TIME 00 5 99 0 cycles CONTROL MODE CUR LIM I MIN 000 30 200 00 KA LIM I MAX 000 30 200 00 KA CONTROL MODE RO LIM RO MIN 005 0 100 0 LIM RO MAX 005 0 100 0 CONTROL MODE VE LIM V MIN 00 20 20 00 V LI...

Page 94: ...5 10 0 bar MOTOR DELAY 05 99 cycles PRE WELD 0000 1000 mS PRE VE 00 20 20 00 V COLD 1 0000 1000 mS SLOPE UP 0000 1000 mS WELD 0001 2000 mS VE 00 20 20 00 V CURR MAX 001 00 200 00 KA COLD 2 0000 1000 mS VE 2 00 20 20 00 V HOLD TIME 00 5 99 0 cycles CONTROL MODE CUR LIM I MIN 000 30 200 00 KA LIM I MAX 000 30 200 00 KA CONTROL MODE RO LIM RO MIN 005 0 100 0 LIM RO MAX 005 0 100 0 CONTROL MODE VE LIM...

Page 95: ... DELAY 05 99 cycles PRE WELD 0000 1000 mS PRE POWER 000 20 600 00 KW COLD 1 0000 1000 mS SLOPE UP 0000 1000 mS WELD 0001 2000 mS POWER 000 20 600 00 KW CURR MAX 001 00 200 00 KA COLD 2 0000 1000 mS POWER 2 000 20 600 00 KW HOLD TIME 00 5 99 0 cycles CONTROL MODE CUR LIM I MIN 000 30 200 00 KA LIM I MAX 000 30 200 00 KA CONTROL MODE RO LIM RO MIN 005 0 100 0 LIM RO MAX 005 0 100 0 CONTROL MODE VE L...

Page 96: ...ARAMETER RANGE VALUE PROGRAM N 001 300 WORKING MODE IK CONTROL MODE NO SQUEEZE 1 0 5 99 0 cycles SQUEEZE 00 0 99 0 cycles PRESSURE 00 5 10 0 bar MOTOR DELAY 05 99 cycles PRE WELD 0000 1000 mS PRE CURR 000 30 200 00 KA COLD 1 0000 1000 mS SLOPE UP 0000 1000 mS WELD 0001 2000 mS CURRENT 000 30 200 00 KA COLD 2 0000 1000 mS CURRENT 2 000 30 200 00 KA HOLD TIME 00 5 99 0 cycles ...

Page 97: ...one another the signals used to synchronize control units and carry out electrical cascade welds are as follows START CYCLE input AUX input CYCLE END output All the TE700 control units receive the cycle start signal simultaneously Connect the CYCLE END 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 ...

Page 98: ...EZE EV2 11 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 s...

Page 99: ... enable the CONTROL MODE parameter relevant to the current limits in the PROGRAM DATA menu PROGRAM DATA T1 TOOLS N 1 WORKING MODE IK CONTROL MODE CUR These parameters allow the operator to keep the consistency of the welding current under control to help achieve constant quality results The control unit enables to select two different control modes Welding current limits This mode is activated by ...

Page 100: ...he foregoing parameters one of the following messages is displayed STOP BAD SPOT MAX T1 RO 203 LIMIT LOW PUSH TO RESET STOP BAD SPOT MAX T1 RO 204 LIMIT HIGH PUSH TO RESET Limits on secondary voltage Activate this mode by setting the CONTROL MODE parameter to VE Two new parameters will be displayed LIM V MIN lower limit on the secondary voltage LIM V MAX upper limit on the secondary voltage that p...

Page 101: ...ENE Two new parameters will be displayed LIM E MIN lower limit of the energy supplied during the welding operation LIM E MAX upper limit of the energy supplied during the welding operation that permit setting limit values on the energy supplied during the welding operation PROGRAM DATA T1 TOOLS N 1 WORKING MODE IK CONTROL MODE ENE PROGRAM DATA T1 PAUSE 00 LIM E MIN 01000J LIM E MAX 02000J In contr...

Page 102: ...T1 RESISTANCE 214 LIMIT HIGH PUSH TO RESET The operator may set the following limits simultaneously a limit on the electrical parameters of the weld current voltage RO power energy the limits on the final resistance of the welded material if the spot welder has the electrodes voltage gauge and the limits on the electrode penetration at the end of the welding procedure if the spot welder has the li...

Page 103: ...t the beginning of the welding RMAX PRE upper limit of the resistance at the beginning of the welding that permit setting limit values of the resistance at the beginning of the welding PROGRAM DATA T1 WORKING MODE IK CONTROL MODE NO QUALITY R PRE PROGRAM DATA T1 PAUSE 00 RMIN PRE 00100uOhm RMAX PRE 00200uOhm In initial resistance control mode QUALITY R PRE or PRE POST if the value of the resistanc...

Page 104: ... T THICK or TH ID if the value of the initial thickness is higher or lower than the values set in the foregoing parameters one of the following messages is displayed THICKNESS 175 UNDER LOW LIMIT WARNING ON TOOLS T1 PUSH TO RESET THICKNESS 176 OVER HIGH LIMIT WARNING ON TOOLS T1 PUSH TO RESET ...

Page 105: ...the counter value as it is If a number higher than one was selected for the welding transformers or tools use keys and in the foregoing screen either to choose which counter to reset or reset all the counters of the spots associated with the tools used If more than one tool was used press the CLEAR key to view the request for resetting the counter associated with the last tool used Press key to re...

Page 106: ...STEPPER MENU T1 TOOLS N 1 STEPPER WELD ON L1 STEPPER TIME OFF PARAMETER PARAMETER DESCRIPTION VALUE TOOLS N Number of the tool in which a limit is to be set 1 STEPPER WELD Stepper function activation with increase of 0 ON L1 STEPPER TIME OFF STEPPER THICK OFF N TOTAL STEPS 1 SPOTS 1 Number of spots after which the unit must stop 02840 INCREMENT 1 L1 00 INCREMENT 1 L2 00 Further information about t...

Page 107: ...ORKING MODE CONTROL MODE IK FIX RO VEK PWK DYN ENE NO Min time Max time CUR Minimum current limit Maximum current limit Min time Max time Minimum current limit Maximum current limit RO Minimum conduction limit Maximum conduction limit Min time Max time Minimum conduction limit Maximum conduction limit VE Minimum secondary voltage limit Maximum secondary voltage limit Min time Max time Minimum seco...

Page 108: ...cycle The output which is an opto electronic contact closes at the end of the hold time and may last according to the following possibilities 1 active until the cycle start signal is present 2 active 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 8 3 ...

Page 109: ...ed in order to call the work program directly The selection is made through five inputs that are duly activated in the combinations outlined below PROG N RIC1 RIC2 RIC3 RIC4 RIC5 RIC6 RIC7 RIC8 1 2 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 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 ...

Page 110: ...3 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 86 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 ...

Page 111: ...141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 ...

Page 112: ... 251 252 253 254 255 input active The operator may choose among 255 programs when using inputs RIC5 RIC6 RIC7 and RIC8 but just 15 if using inputs RIC1 RIC2 RIC3 and RIC4 only Inputs RIC5 RIC6 RIC7 and RIC8 may be activated via the FEATURES TE700 menu as recalls see the specific paragraph To properly recall the welding programs either activate the direct recall inputs before the start cycle signal...

Page 113: ...tion On turning on the machine with input D STROKE active the output is disabled In this case during the first welding the control unit activates solenoid valve EV4 that switches the electrode from position A to position B before the work cycle begins Then the programmed welding cycle is carried out on the elapsing of a fixed time of 0 6 seconds When the cycle is over solenoid valve EV4 p Later on...

Page 114: ...pin configuration PIN1 GROUND FRAME GROUND PIN2 TRANSMISSION TD PIN3 RECEPTION 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 EV...

Page 115: ...int example during the weld in CONTROL MODE CUR WELD CONTROL UNIT TE700 REV 1 13 PROG TOOL WELD CURRENT RO ENERGY SPOTS LIMIT 001 1 0200 002 99 034 6 00741 00004 CUR OK 001 1 0200 002 99 034 7 00741 00005 CUR MIN Current lower than MIN limit 001 1 0200 002 99 034 9 00747 00006 CUR MAX Current higher than MAX limit 001 1 0200 002 99 034 9 00749 00007 CUR OK 001 1 0200 002 99 035 0 00756 00008 CUR O...

Page 116: ... control range of the proportional valve directly via the weld control unit The FEATURES TE700menu contains the PRESSURE RATIO parameter with which to select the most suitable bar Volt ratio for the type of solenoid valve that is to be used Example Pressure Parameter bar PRESSURE RATIO Parameter bar Volt Output Volt 5 0 1 0 5 5 0 2 0 10 5 0 0 5 2 5 CONNECTIONS DIAGRAM N B _ The board is fitted wit...

Page 117: ...fore the cycle start signal Inputs are active when closed towards the common COM1 17 COM1 Common for inputs with 24VDC reference 18 AUX2 This input allows an external device to stop the weld cycle during the squeeze stage It may be used as interlocking input or to connect safety devices such as for instance flow meters or pressure switches The contact connected to it must be the normally open type...

Page 118: ...ommon 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 valve that actuates the main cycle Command suitable for coil cont...

Page 119: ...M This output warns that the dressing pre alarm weld spots number has been attained 62 63 ELECTRODES LIFE FINISHED ALARM This output warns that the electrodes end life pre alarm weld spots number has been attained Before turning on the TE700 control unit with the supplementary expansion board code 50200 check that input RESET ELECTRODES LIFE Pin 52 is NOT active Otherwise the 50200 board is not re...

Page 120: ... This is why the outputs cannot be enabled Contact service center BOTH INTERNAL RELAYS 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 Eeprom This ensued from the checksum calculation on the data...

Page 121: ...re for charging the capacitors bank Check the three phase INV NOT READY MISS END WELD 156 The welding finished signal was not acknowledged Contact service center INV NOT READY PRIMARY CURR MIS 157 The inverter was not capable of measuring the passage of the primary current Contact service center INV NOT READY SEC CURR MISS 158 The inverter was not capable of detecting the current passage on the se...

Page 122: ...ange the electrodes STOP N SPOT MAX 167 The max set number of spots was attained Reset the error as specified and reset the spots counter FAIL ROG COIL SHORTED OR OPEN 168 With the Rogowsky test activated a problem was detected at the secondary current sensor or its wiring Contact service center COM FAIL SPOT DATA LOST 169 Malfunction of the CAN communication between TE700 control unit and inverte...

Page 123: ...ets between the electrodes is more than that set in the limit Reset the error and check the material present between the electrodes DYNAMIC MODE FAIL COMPENSATION 177 The DYNAMIC WORKING MODE was not capable of completing the weld within the max time set by the user Reset the error and check the welding that was just carried out Repeat the learning procedure if needed MISSING R COMPENSATION 178 Th...

Page 124: ...specified RO LIMIT HIGH 204 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 Reset the error as specified SECONDARY VE LIMIT LOW 205 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 Reset the error as specified SECONDARY VE LIMIT HIGH 2...

Page 125: ...nts some faulty spots the last of which has been carried out with a current value lower than the min set limit Reset the error as specified RESISTANCE LIMIT LOW 213 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 Reset the error as specified RESISTANCE LIMIT HIGH 214 The control unit counts some faulty spots the las...

Page 126: ...4 TECHNICAL 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 ...

Page 127: ...TECNA S p A ITEM TE700 Instruction Manual 127 128 NOTES ...

Page 128: ...Instruction Manual ITEM TE700 TECNA S p A 128 128 NOTES ...

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