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TABLE OF CONTENTS

TOPICS

PAGE

TE500 WELDING CONTROL UNIT

MAIN FEATURES

CONTROL UNIT SWITCH-ON

CONTROL UNIT PROGRAMMING

DESCRIPTION OF THE PARAMETERS

CONFIGURATION MENU

STEPPER MENU

CURRENT STEPPER OPERATING MODE

INSTALLATION MENU

PROGRAM COPY MENU

PROGRAM SEQUENCE MENU

PROGRAM SEQUENCE EXAMPLE

CHECK INPUT MENU

PANEL LEDs

COMMANDS ON THE PANEL

SELF-CALIBRATION PROCEDURE

SELECTION OF THE WORK PROGRAM

WORK MODES

CONSTANT CURRENT OPERATING MODE

DESCRIPTION OF THE WORK CYCLE

MEASUREMENT OF THE WELDING CURRENT AND THE CONDUCTION ANGLE

WELDING ANALYSIS

WELDING CURRENT AND CONDUCTION ANGLE LIMITS

COMPENSATION OF THE SECONDARY CURRENT

WELDING SPOTS COUNTER FUNCTION

SERIAL INTERFACE RS-232 ITEM 50214 (Option)

SERIAL INTERFACE RS-485 ITEM 50209 (Option)

INTERFACE FOR PROPORTIONAL VALVE ITEM 50220 (Option)

INTERFACING WITH AUTOMATIC SYSTEMS

DOUBLE STROKE FUNCTION

DESCRIPTION OF SIGNALS ON TERMINAL BOARD

MESSAGES LIST

FIRST INSERTION DELAY ADJUSTMENT

Содержание TE 500

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Страница 3: ...ELECTION OF THE WORK PROGRAM 32 WORK MODES 33 CONSTANT CURRENT OPERATING MODE 34 DESCRIPTION OF THE WORK CYCLE 35 MEASUREMENT OF THE WELDING CURRENT AND THE CONDUCTION ANGLE 36 WELDING ANALYSIS 37 WELDING CURRENT AND CONDUCTION ANGLE LIMITS 38 COMPENSATION OF THE SECONDARY CURRENT 39 WELDING SPOTS COUNTER FUNCTION 39 SERIAL INTERFACE RS 232 ITEM 50214 Option 40 SERIAL INTERFACE RS 485 ITEM 50209 O...

Страница 4: ...4 52 This page is intentionally left blank ...

Страница 5: ...the outside 26 programmable parameters for each program Slope pulses pre weld post weld functions and adjustment of the welding times in half periods Display of the RMS welding current measurement in kA and relative angle of conduction Dual operating mode standard and constant current Welding current or angle of conduction limits Double stroke function Stepper function to compensate the electrodes...

Страница 6: ...software version of the program After a few seconds the TE500 is set to a waiting condition until the Restart key is pressed This key enables the control unit s commands and outputs Before starting any welding operations first program the welding data and set some general operating parameters of the welder Before pressing the key it is important to check that it will not cause injury damage to peo...

Страница 7: ...contains all the parameters associated with the welding cycle the times and the currents by means of which to carry out the welding process CONTROL UNIT PROGRAMMING TE500 VER 2 31 PROGRAM DATA SETUP MENU STEPPER MENU The first choice to make is the number of the program to be used Choose among the 63 storable programs using the a and s keys Then proceed with the next parameters moving with the d a...

Страница 8: ... PRE WELD TIME 00 0 99 5 cycles 6 PRE POWER PRE WELD CURRENT 05 99 7 COLD I COLD 1 TIME 00 50 cycles 8 SLOPE UP SLOPE UP TIME 00 25 cycles 9 WELD 1 WELDING TIME 00 5 99 5 cycles 10 POWER 1 CURRENT 1 WELDING CURRENT 5 99 1 0 90 0 kA 11 COLD 2 COLD 2 TIME 01 50 cycles 12 N IMPULSE NUMBER OF IMPULSES 00 09 13 SLOPE DOWN SLOPE DOWN TIME 00 25 cycles 14 COLD 3 COLD 3 TIME 00 50 cycles 15 POST WELD POST...

Страница 9: ... 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 pro...

Страница 10: ...r 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 ...

Страница 11: ...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...

Страница 12: ...o 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 th...

Страница 13: ...ter 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 s...

Страница 14: ...rrent 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...

Страница 15: ... 0 50 SPOTS 6 Spots step 6 0 5000 INCREMENT 6 Percent increment step 6 0 50 SPOTS 7 Spots step 7 0 5000 INCREMENT 7 Percent increment step 7 0 50 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 ...

Страница 16: ...ent 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 S...

Страница 17: ...gram 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 INITIAL CURRENT 15 kA END CURRENT 19 kA INCREMENT PERCENT 26 NUMBER OF WELDING SPOTS 2000 CURRENT I...

Страница 18: ...quate 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 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 parame...

Страница 19: ...nt 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 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 ren...

Страница 20: ...rent 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 CURRENT kA NUMBER OF WELDING SPOTS SEGMENT 1 SEGMENT 2 SEGMENT 3 SEGMENT 4 4000 3000 2000 1000 0 15 14 13 16 17 18 19 20 21 22 17 8 kA 19 5 kA 20 2 kA 20 7 kA 700 1800 3000 ...

Страница 21: ...on of the welder After having selected this parameter the value can be adjusted from 1 to 99 with keys a and s 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...

Страница 22: ...RGE 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 ...

Страница 23: ...d 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 will be copied to the target program only To copy programs access the copy menu from the main menu using key g set the desired values in the aforesaid pa...

Страница 24: ...r of welds with step 2 00 20 STEP 2 PRG Program of step 2 01 63 STEP 2 WELDS Number of welds with step 1 00 20 STEP 3 PRG Program of step 3 01 63 STEP 3 WELDS Number of welds with step 3 00 20 STEP 4 PRG Program of step 4 01 63 STEP 4 WELDS Number of welds with step 4 00 20 STEP 5 PRG Program of step 5 01 63 STEP 5 WELDS Number of welds with step 5 00 20 This menu includes the parameters required ...

Страница 25: ... number of welds of which this sequence is composed Line 2 The number of the step with which the last weld was performed and the total number of steps Line 3 The program number and the RMS current value of the last weld Line 4 The progressive number of the next weld WELD 008 OF 013 STEP 03 OF 04 PROG 03 RMS 10 45 NEXT WELD 009 ...

Страница 26: ...t the following values in the parameters PROGRAM SEQUENCE MENU 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 ...

Страница 27: ...elds counter to the next spot or to the desired spot Use key s to go back one or more positions of the spots to be carried out WELD 006 OF 013 STEP 02 OF 04 PROG 07 RMS 06 15 NEXT WELD 007 WELD 013 OF 013 STEP 04 OF 04 PROG 04 RMS 04 31 NEXT WELD 001 WELD 007 OF 013 STEP 03 OF 04 PROG 11 RMS 06 15 NEXT WELD 008 WELD 012 OF 013 STEP 03 OF 04 PROG 11 RMS 04 31 NEXT WELD 013 Display data Display data...

Страница 28: ...sed with COM1 with wording ON not active with wording OFF 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 START N O OFF START N O ON START2 N O OFF ...

Страница 29: ...essure only stopping command 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 1 which carries out the main cycle is activated It indicates that the solenoid valve which controls back pressure is activated It indicates that the solenoid valve which carries out the pressure or forging cycle is a...

Страница 30: ...WO 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 WE...

Страница 31: ...procedure is completed the control unit displays the maximum current value supplied and the machine s cosn value If error messages are displayed instead of the aforesaid message proceed as follows Clear the error by pressing any key Eliminate the cause that triggered the error see specific paragraph Activate the start cycle device again for repeating the self calibration welding procedure The foll...

Страница 32: ...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 m...

Страница 33: ...m sequence function YES YES YES CUR control mode YES YES YES DEG control mode YES YES YES Current compensation YES YES NO Welding analysis YES YES YES Proportional valve YES YES YES Rogowski ratio All Only the one with which the Self calibration is performed Only the one with which the Self calibration is performed Automatic mains compensation NO NO YES First insertion delay z z z Ammeter capacity...

Страница 34: ...n the control unit does not carry out the adjustment it blocks the welding process and displays the following error message Welding current changes I according to the mains voltage V variation under standard operating mode Welding current changes I according to the mains voltage V variation under constant current operating mode NO SECONDARY CURRENT SIGNAL TE500 allows the user to adjust the weldin...

Страница 35: ...s are carried out DESCRIPTION OF THE WORK CYCLE The aforesaid numbers refer to the programming parameters described in the Programming Menu paragraph 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 n...

Страница 36: ...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...

Страница 37: ... you may continue in the succeeding video pages as shown below Welding example with these parameters Pre Weld Time 4 cycles WELD1 Time 8 cycles Post Weld Time 0 cycles Incremental step 1 10000 spots 18 WELDING ANALYSIS 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 PROG 03 SPOTS 05148 WELD CYCLE N 01 POS...

Страница 38: ... 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 or...

Страница 39: ...orks in single cycle In constant current operating mode this function is deactivated COMPENSATION OF THE SECONDARY CURRENT The control unit contains a weld counter with the possibility of programming the maximum number of welding spots During the welding process the control unit displays the value currently attained by the counter The counter is updated after each welding spot with the only except...

Страница 40: ...ilable for the connection with standard serial printers that as a rule are equipped with a female 25 pole connector as follows The control unit does not execute any type of handshaking at the serial port The serial port of the printer must be configured with the following values The control unit runs the data transmission at the beginning of the OFF time Keep in mind that the time used for printin...

Страница 41: ...10 0 10 0 CURRENT 06 0 06 0 06 0 06 0 06 0 06 0 06 0 06 0 DEGREE 062 062 062 062 062 062 062 062 SPOTS 00018 00019 00020 00021 00022 00023 00024 00025 LIMIT DEG MIN DEG MIN DEG MIN DEG OK DEG OK DEG MAX DEG MAX DEG MAX CONTROL UNIT PROGRAM NUMBER WORKING MODE CONTROL MODE SQUEEZE 1 SQUEEZE FORGE DELAY PRE WELD PRE POWER COLD 1 SLOPE UP WELD CURRENT COLD 2 IMPULSE N SLOPE DOWN COLD 3 POST WELD POST...

Страница 42: ...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 externa...

Страница 43: ... 10 5 0 0 5 2 5 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 Example WIRING DIAGRAM N B _ A red D10 LED is present on card 50220 near the relay for ind...

Страница 44: ...activated after the Start and is deactivated at the end of the HOLD TIME Wrong Error signal for limits or power failure Active for HOLD and PAUSE Lock This output signals the beginning and the end of the current circulation during the cycle End cycle This output signals the end of the cycle of one weld for the pause time During the single cycle the signal closes at the end of the Hold time and reo...

Страница 45: ...solenoid valve EV4 is kept activated and the electrode in rest status will be in position B Should the operator need to open the electrodes during the process deactivate the input to trigger the deactivation of solenoid valve EV4 The output of the control unit called SV4 controls the double stroke solenoid valve When the machine is powered it is always disabled even if the D_STROKE input is active...

Страница 46: ...or 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 13 14 15 16 COM1 START2_NO Connect to the microswitches of the start cycle pedal START2 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 17 1...

Страница 47: ...arts when BIC1_NO and BIC2_NO are closed simultaneously or closed in sequence within a maximum time of 0 5 secs 35 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 37 SV1 COM2 Connect to the solenoi...

Страница 48: ...vation of the VAUX does not cause damage to equipment and or people then press the key ERROR MAINS SYNCHRONISM 10 A synchronism error has occurred due to the temporary lack of the reference signal of the power supply line or due to line interferences Clear the error by pressing any key If the error occurs frequently check the working efficiency of the devices that cut the power supply line and che...

Страница 49: ... current measurement procedure The control unit cannot measure the welding current properly Contact the customer service ALARM CURRENT OVERFLOW 21 A weld with a too high current signal has occurred Changethe programming parameters of the welding program or change the ammeter capacity if possible STOP MAX SPOTS N 22 The welds counter has attained the maximum set value Clear the counter see chapter ...

Страница 50: ...ammeter capacity or change the program parameter to select a different work mode NO EMERGENCY SIGNAL 33 The emergency signal required for operating the control unit is missing Ensure that the emergency contact is closed ZERO SPOTS COUNTER KEY YES 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 pr...

Страница 51: ...tive 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...

Страница 52: ...52 52 NOTES ...

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