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Instruction Manual

TE470/TE480

S.p.A.

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TABLE OF CONTENTS

CHAPTER 1 – THE TE470/TE480 WELD CONTROL UNIT ................................................... 5

1.1 – MAIN FEATURES.................................................................................................................................6

1.2 – COMMANDS ON THE PANEL.............................................................................................................7

1.3 – PANEL LEDs ........................................................................................................................................7

1.4 – DESCRIPTION OF THE DISPLAYED INFORMATION .......................................................................8

1.5 – CONTROL UNIT SWITCH-ON ...........................................................................................................10

CHAPTER 2 - CONTROL UNIT PROGRAMMING................................................................ 11

2.1 – WELDING CYCLE PARAMETERS PROGRAMMING MENU...........................................................11

2.2 – PERCENTAGE ADJUSTMENT OPERATING MODE .......................................................................12

2.3 – CONSTANT CURRENT OPERATING MODE ...................................................................................14

2.4 - CONSTANT ENERGY WORKING MODE (ONLY IN TE480) ............................................................16

2.5 – DESCRIPTION OF THE PARAMETERS ...........................................................................................18

2.6 - SETUP MENU......................................................................................................................................22

2.7 – CURRENT STEPPER FUNCTION .....................................................................................................25

2.8 – ADJUSTING THE FIRST INSERT DELAY ........................................................................................30

CHAPTER 3 – THE WORK CYCLE ...................................................................................... 31

3.1 – EXAMPLES OF WORK PROGRAMS................................................................................................32

CHAPTER 4 - WELDING CURRENT AND CONDUCTION ANGLE MEASURE .................. 34

CHAPTER 5 - STOP DUE TO SPOTS OUT OF LIMIT.......................................................... 35

5.1 - WELDING CURRENT LIMITS.............................................................................................................35

5.2 – CONDUCTION ANGLE LIMITS .........................................................................................................35

CHAPTER 6 – WELDS COUNTER FUNCTION .................................................................... 36

CHAPTER 7 - HANDLES DESCRIPTION ............................................................................. 37

CHAPTER 8 – INPUTS AND OUTPUTS OPERATION ......................................................... 38

8.1 – FUNCTION OF THE "PRESSURE ONLY" COMMAND ("AUX" INPUT) .........................................38

8.2 - "SAFETY" CONTROL FUNCTION ("CHK" INPUT) .........................................................................38

Содержание TE470

Страница 1: ...UCTION MANUAL TE470 TE480 FROM SOFTWARE RELEASE N 2 21 S p A Via Meucci 27 40024 Castel S Pietro Terme Bologna ITALY Pho 39 051 6954400 Fax 39 051 6954490 http www tecna net DOCUMENT NUMBER MAN 4162 DISTRIBUTOR EDITION JULY 2011 ...

Страница 2: ...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 2 52 ...

Страница 3: ...DE 14 2 4 CONSTANT ENERGY WORKING MODE ONLY IN TE480 16 2 5 DESCRIPTION OF THE PARAMETERS 18 2 6 SETUP MENU 22 2 7 CURRENT STEPPER FUNCTION 25 2 8 ADJUSTING THE FIRST INSERT DELAY 30 CHAPTER 3 THE WORK CYCLE 31 3 1 EXAMPLES OF WORK PROGRAMS 32 CHAPTER 4 WELDING CURRENT AND CONDUCTION ANGLE MEASURE 34 CHAPTER 5 STOP DUE TO SPOTS OUT OF LIMIT 35 5 1 WELDING CURRENT LIMITS 35 5 2 CONDUCTION ANGLE LIM...

Страница 4: ...TIONAL 39 8 4 CYCLE END OUTPUT 39 CHAPTER 9 DOUBLE STROKE FUNCTION 40 CHAPTER 10 OPTIONS 42 10 1 RS 485 SERIAL INTERFACE 42 10 2 INTERFACE FOR PROPORTIONAL VALVE 43 CHAPTER 11 DESCRIPTION OF THE SIGNALS ON THE TERMINAL STRIP 44 CHAPTER 12 LIST OF MESSAGES 47 CHAPTER 13 TECHNICAL SPECIFICATIONS 49 ...

Страница 5: ...dle The handle is not an integral part of the control unit since different types of handles are used to adapt the machine to different work needs As many as 63 different weld programmes can be stored Depending on the type of handle connected to the control unit from 2 to 4 programmes can be called from the outside Each program consists of programmable parameters that describe the work cycle In add...

Страница 6: ...ting modes conventional constant current and constant energy only TE480 Either welding current or conductor angle limits Automatic double stroke function to be employed only when the welder has been designed for this function Stepper function to balance the electrodes wear out with adjustable curve Welds counter Single and automatic cycle WELD NO WELD function Delay of first phase shift adjustment...

Страница 7: ... above When the lamp is on the control unit is set to WELD and carries out the standard welding cycles When the lamp is off the control unit is set to NO WELD complete test cycles will be carried out without welding while maintaining all the time parameters 1 3 PANEL LEDs START INIZIO CICLO If on this LED indicates that the cycle start command from the button of handle 1 connected to XS10 is activ...

Страница 8: ...e conduction angle represents the current flowing time along the half cycle The displayed value represents the average of the measured values for each half cycle of the welding time The showed value always refers to the main adjustment basically to the WELD parameter one In no instance is the conduction angle of the current measured during the slope time In the case of pulse weldings the angle val...

Страница 9: ...trol unit Constant Energy displays Where to the above described information is added 6 02500J Indicates the value of the total energy with which the last weld was performed In WELD mode the value ranges from 00000 J to 99999 J In NO WELD mode the displayed value is 00000 J 9 52 ...

Страница 10: ...uickly select up to four different programs called ADJUSTMENT 1 ADJUSTMENT 2 ADJUSTMENT 3 and ADJUSTMENT 4 respectively While working the adjustments are selected by means of a switch or a commutator on the handle For example the choice is made through selector 4 using the following handle During the programming stage the user selects for each adjustment the weld program to be used The control uni...

Страница 11: ... associated inside the SETUP menu It can have the following values ADJ1 ADJUSTMENT 1 ADJ2 ADJUSTMENT 2 ADJ3 ADJUSTMENT 3 ADJ4 ADJUSTMENT 4 or ADJ when the selected program number is not associated with an ADJ also see description inside the SETUP menu 2 PRG01 Indicates the selected program number e g PRG01 program number 1 and its value is between 01 and 63 3 PRM07 Identifies the selected paramete...

Страница 12: ...econdary coil feedback during the welding process for this reason it is suitable for being used especially when one operates in difficult working conditions beyond the welding tables as for instance when using a very short welding time where it would be critical to use one of the more complex working modes foreseen in this control unit TABLE PERCENTAGE OPERATING MODE PARAMETERS ADJ1 PRG01 PRM A WO...

Страница 13: ...etting the PRE WELD parameter 3 to zero the pre weld is not carried out By setting the POST WELD parameter 13 to zero the post weld is not carried out We recommend activating the CONTROL MODE in CUR and checking the use limit conditions before starting the production if use is with 2 sheets for example limit conditions are with 1 or 3 sheets The weld current is adjusted by control unit TE470 TE480...

Страница 14: ...rding to a mathematical correction algorithm In addition to simplifying the programming operations this operating mode also permits to keep the desired welding current even if some factors change such as mains voltage welding circuit dimensions and impedance conditions of the welding tools or surface condition of the materials being processed CONSTANT CURRENT OPERATING MODE SURVEY Welding current ...

Страница 15: ...IME Interval time 00 99 cycles B CONTROL MODE Control unit mode NO 17 PRESSURE Pressure value 0 5 10 0 bar B CONTROL MODE Control unit mode CURR 17 CURR MIN Min current limit 1 0 36 0 kA 18 CURR MAX Max current limit 1 0 36 0 kA 19 PRESSURE Pressure value 0 5 10 0 bar B CONTROL MODE Control unit mode DEG 17 ANGLE MIN Min limit in degrees 005 180 18 ANGLE MAX Max limit in degrees 005 180 19 PRESSUR...

Страница 16: ...f 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 of the electrod...

Страница 17: ... Pressure value 0 5 10 0 bar B CONTROL MODE Control unit mode DEG 17 ANGLE MIN Min limit in degrees 005 180 18 ANGLE MAX Max limit in degrees 005 180 19 PRESSURE Pressure value 0 5 10 0 bar There are some peculiar conditions If the OFF TIME is set to 0 the control unit will work in single cycle By setting the POST WELD parameter to zero the post welding process will not be carried out By setting t...

Страница 18: ...le are designed for the control of the double stroke from the control unit PRM01 SQUEEZE 1 The SQUEEZE 1 time first squeeze is used during the double automatic stroke work mode STROKE parameter set to AUTOMATIC It determines the electrode s shifting time from the long stroke position to the short one The set value must be long enough to enable the mobile electrode to reach the short stroke positio...

Страница 19: ...ant Energy the POWER parameter appears Its value indicates the power percentage adjustment with which the weld is carried out When the WORKING MODE parameter is adjusted IK Constant Current the CURRENT parameter appears Its value indicates the current adjustment with which the weld is carried out PRM09 IMPULSE N The IMPULSE N parameter indicates the number of impulses used to carry out the welding...

Страница 20: ...ent in the SETUP MENU is set to ON proportional valve ON If the CONTROL MODE parameter is set to NO and the PR VALVE parameter is set to OFF proportional valve OFF the PRM17 parameter is not displayed during the programming PRM18 CURR MAX ANGLE MAX The meaning of this parameter depends on the control mode selected in parameter CONTROL MODE When the control unit is set to current control mode CONTR...

Страница 21: ...of this period of time is below the programmed rating This parameter is only displayed when the WORK MODE is selected in ENE Constant Energy operating mode PRM22 ENERGY only in TE480 This parameter indicates the energy value expressed in joule which must be developed during welding This value must be reached within a number of cycles included between the minimum time WELD MIN and the maximum time ...

Страница 22: ... Number of spots of the third segment 0 5000 INCREMENT 3 Increase percentage of the third segment 1 60 SPOTS 4 Number of spots of the fourth segment 0 5000 INCREMENT 4 Increase percentage of the fourth segment 1 60 SPOTS 5 Number of spots of the fifth segment 0 5000 INCREMENT 5 Increase percentage of the fifth segment 1 60 SPOTS 6 Number of spots of the sixth segment 0 5000 INCREMENT 6 Increase pe...

Страница 23: ...he first insertion delay This function permits optimizing the balance of machine line absorption After having selected this parameter in order to change it you must first press the WELD NO WELD button Then the value can be adjusted from 1 to 99 using buttons and Since this adjustment is performed by the welder manufacturer the user need not change this value For more information refer to the speci...

Страница 24: ...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 PRESS RATIO This parameter permits choosing the bar volt ratio that is most suitable for the type of proportional solenoid valve you intend using and works only if the PR VALVE parameter is active Further pieces of informa...

Страница 25: ... same percentage as are the settings for the pre welding current and 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 STEP...

Страница 26: ...ent with the electrodes starting diameter 15 kA It does not matter if the TE470 TE480 is programmed to be adjusted in percentage or constant current since the stepper function works in both modes It is then possible to start the welding process The welding current increases according to the set stepper function The following diagram shows the current variations INITIAL CURRENT 15 kA FINAL CURRENT ...

Страница 27: ...condition it is possible to set a non linear increment curve by defining a specific number of segments This type of adjustment requires a precise knowledge of the electrodes wear out as well as of the parameters to be used during the electrode life Therefore it is necessary to carry out many welding tests in order to determine the working condition in different moments of the electrodes life IDEAL...

Страница 28: ...itialcur 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 parameters are set in the SETUP MENU PARAMETER PARAMETER DESCRIPTION VALUE TOTAL STEPS Number o...

Страница 29: ...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 On having completed the 4000 welding spots the control unit stops the production cycle and displays the following message MAX SPOTS NUMBER At this point the operator replaces the electrodes or resets their original diameter and clears the spots counter by means of the proper key to clear stepper calculations Th...

Страница 30: ...just parameter FIRST INSERT in the SETUP MENU so that positive and negative line absorptions are balanced Use an ammeter to measure the maximum positive and negative peak values The adjustment is correct when the positive peak value is similar to the negative one Use an appropriate current gauge having a CAT III 600V class of insulation and work by wearing specific insulated gloves when making int...

Страница 31: ...09 IMPULSE N 02 SQUEEZE EV1 10 COLD 2 03 PRE WELD 11 SLOPE DOWN 04 POWER 1 12 COLD 3 05 COLD 1 13 POST WELD 06 SLOPE UP 14 POWER 2 07 WELD 15 HOLD TIME 08 POWER CURRENT 16 OFF TIME Parameters marked by symbol can be enabled or disabled according to the programmed WORKING MODE or STROKE For safety reasons the microprocessor does not start the welding cycle if the start cycle device is activated whe...

Страница 32: ...les 12 COLD 3 00 cycles 13 POST WELD 00 cycles 14 POWER 2 05 15 HOLD TIME 09 cycles 16 OFF TIME 00 cycles 02 07 15 1 2 08 CYCLE WITH PULSES AND SLOPE UP LONG STROKE AUTOMATIC CYCLE NUMBER PARAMETER VALUE TO WORKING MODE PW B CONTROL MODE NO C STROKE LONG 2 SQUEEZE 30 cycles 3 PRE WELD 00 cycles 4 POWER 1 05 5 COLD 1 00 cycles 6 SLOPE UP 06 cycles 7 WELD 04 cycles 8 POWER 40 9 IMPULSE N 03 10 COLD ...

Страница 33: ...ROL MODE NO C STROKE AUTOMATIC 1 SQUEEZE 1 20 cycles 2 SQUEEZE 30 cycles 3 PRE WELD 08 cycles 4 POWER 1 20 5 COLD 1 00 cycles 6 SLOPE UP 00 cycles 7 WELD 12 cycles 8 POWER 60 9 IMPULSE N 01 10 COLD 2 00 cycles 11 SLOPE DOWN 00 cycles 12 COLD 3 00 cycles 13 POST WELD 00 cycles 14 POWER 2 05 15 HOLD TIME 09 cycles 16 OFF TIME 40 cycles 01 02 03 07 15 16 1 04 2 08 02 COMPLEX CYCLE WITH PRE WELD SLOPE...

Страница 34: ...rrent and the current that flowed during the slope times are never measured The control unit also measures the welding current conduction angle The conduction angle represents the current flow time during the half period The displayed value represents the average of the values measured for each weld time half period The displayed value always refers to the main adjustment i e to that of the WELD p...

Страница 35: ...d CURR MIN lower current limit CURR MAX higher current limit These two parameters enable to set the welding current limit values ADJ1 PRG01 PRM17 CURR MIN 10 5 ADJ1 PRG01 PRM18 CURR MAX 12 5 When the programmed condition occurs the control unit stops and an error message is displayed The displayed message refers to the error condition of the last run weld In current control mode CONTROL MODE CUR i...

Страница 36: ... COUNTER SPOTS YES On pressing key the counter resets and after 8 seconds the procedure ends without resetting the counter The maximum welds number is set by following the same procedure stated for the stepper function For example if the control unit is set to carry out 2840 welds and then stops set the following parameters in the setup menu PARAMETER VALUE TOTAL STEPS 1 SPOTS 1 2840 INCREMENT 1 0...

Страница 37: ...rameter to 1 when only one handle is connected to input XS10 In this configuration the programs selected in ADJUSTMENT 1 and 2 will be called Set the HANDLE parameter to 2 when 2 handles are connected one to input XS10 and the other to input XS11 In this configuration even the programs selected in ADJUSTMENT 3 and 4 will be called through the handle connected to XS11 Handle with 4 position selecto...

Страница 38: ...se they have been opened by means of the OPEN control or because the welder has just been switched on When starting the welding cycle the TE470 TE480 brings the electrodes to short stroke position thus activating solenoid valve EV2 in 0 6 seconds If the PRESSURE ONLY control is activated the welding cycle stops in this position By keeping this condition for one second and then deactivating the cyc...

Страница 39: ...ater circulates in the required quantity and temperature Also check the working rate it must not be too high according to the machine features To cancel the message both the safety device and the cycle start device must be released and then a key must be pressed to cancel the error 8 4 CYCLE END OUTPUT The CYCLE END signal indicates the end of the welding cycle This output is an opto electronic co...

Страница 40: ... electrodes he she presses the wide opening button that deactivates solenoid valve EV2 through the OPEN input After having pressed the wide opening button or on turning on the machine the electrode is in position A the control unit moves it to position B when the first weld is carried out During this first weld the TE470 TE480 activates solenoid valve EV2 that brings the electrode from position A ...

Страница 41: ...ol unit activates solenoid valve EV2 that moves the electrode from position A to position B and carries out the programmed first squeeze time SQUEEZE 1 before activating EV1 After having carried out the first weld of the automatic cycle solenoid valve EV2 is not deactivated and the first squeeze time SQUEEZE1 is ignored during the subsequent welds This continues until the operator releases the cyc...

Страница 42: ...n the SETUP MENU In order to manage data and communication between the networked control units there is a PC software called Net designed to check the network structure i e how many and which control units are connected remotely performing the programming in each control unit and acquiring and saving production data The interface is isolated up to 1500V without the need for any external power supp...

Страница 43: ...e proportional valve directly via the weld control unit The SETUP MENU contains the PRESS RATIO parameter by means of which to choose the bar volt ratio most suited to the type of solenoid valve you intend using Example PRESSURE Parameter bar PRESS RATIO Parameter bar volt Output volt 5 0 1 0 5 5 0 2 0 2 5 5 0 0 5 10 CONNECTIONS DIAGRAM N B _ The card is fitted with a red LED indicated by acronym ...

Страница 44: ...s not used because the handle is not equipped with this microswitch short circuit this input with the START one pin 4 This disables the safety function against accidental activation 22 25 RIC2 COM1 This input permits calling weld adjustment number 2 ADJUSTMENT 2 In order to work efficiently this input should be enabled before the cycle start signal This input is activated when it is closed on the ...

Страница 45: ...rd of the proportional valve 32 31 VE VE The electrodes voltage signal should be connected to this analog input through the appropriate isolation transformer ORDINARY AND EXTRAORDINARY MAINTENANCE Frequently check the correct functioning and the status of both control devices and relevant connecting cables Do not wash the control unit with water which could enter it avoid strong solvent thinner an...

Страница 46: ...ply is present at Pins 5 7 of connector XS1 If power supply is present check the state of the control unit fuses The components marked F2 and F3 located on the connectors side are delayed fuses that cannot be restored and that can withstand a max current of 4 A each LITTELFUSE 460004 XS4 XS3 46 52 F3 F2 XS2 XS1 ...

Страница 47: ...fety thermostat or flowswitch inside the welder tripped Check that the water flows in the welder in the required quantity and or check the working efficiency of the thermostat RELEASE SAFETY The CHK signal indicates that the safety on the handle is activated when it should not be This may be due to a malfunction or tampering Check MODIFICATION CODE 0 0 0 Enter the code to be able to access the pro...

Страница 48: ...ached with the minimum weld time Reset the error as indicated and check the program to change some parameters such as ENERGY POWER and MIN WELD and MAX WELD STOP LIMIT MAX ENE TIME The energy that the control unit read during the welding is lower than that set Reset the error as indicated and check the program to change some parameters such as ENERGY POWER and MIN WELD and MAX WELD MINIMUM LIMIT M...

Страница 49: ...CHNICAL SPECIFICATIONS POWER SUPPLY 24VAC 10 FREQUENCY 50 60Hz 1 CONSUMPTION 0 25A WITHOUT LOAD 1A 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 358g 0 78925 lb PROTECTION RATING IP65 ...

Страница 50: ...S p A TE470 TE480 Instruction Manual 50 52 NOTES ...

Страница 51: ...Instruction Manual TE470 TE480 S p A 51 52 NOTES ...

Страница 52: ...S p A Via Meucci 27 40024 Castel S Pietro Terme Bologna ITALY Pho 39 051 6954400 Tel 051 6954410 Fax 39 051 6954490 E mail sales tecna net vendite tecna net http www tecna net ...

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