Tecna_TE-450 manual
Contents
1. _ x 100 x 100 19 initial current 15 final current initial current 19 5 17 8 Variation segment 2 x 100 x 100 10 initial current 17 8 final current initial current 20 2 19 5 Variation segment 3 x 100 x 100 4 initial current 19 5 final current initial current 20 8 20 2 Variation segment 4 x 100 x 100 3 initial current 20 2 Set the following parameters in the set up menu 700 The welding program must be set in order to carry out the first welding spot that is with an adjustment enabling to obtain the necessary current with the starting electrodes diameter 15 kA It is then possible to start the welding process the current varies according to the programmed increment line The following diagram shows the current variations 22 SEGMENT 4 SEGMENT3 CURRENT SEGMENT 1 el 0 1000 2000 3000 4000 NUMBER OF WELDINGS 19 33 COMPENSATION OF THE SECONDARY CURRENT The compensation function of secondary current is used to facilitate the welding process of oxidized sheets and rods The pieces oxidation blocks the current flow during the first welding phase thus limiting in a different way depending from the welding process the real time of current flow The compensation f2. ACTIVATED It is to mean that the thermostat got open It is not possible to carry out welding processes until the thermostat closes again automatically Check that water circulates in the required quantity and temperature Also check the working rate it must not be too high according to the machine features KEY SELECTOR FUNCTION OPTIONAL On request TE450 can be supplied equipped with a two position key selector This allows to disable the programming of the control unit so to prevent the user from modifying the welding programs 23 33 SELF CALIBRATION PROCEDURE This procedure enables the control unit to survey the welder characteristics as well as to obtain the current best adjustment The values measured with this procedure are used for the correct working of the welding current adjustment We recommend to repeat this procedure if the welder arms are replaced with others having different dimensions especially when working in constant current mode This enables you to get the best adjustment precision Before carrying out this procedure both control unit and welder must be set in standard working conditions In this phase it is carried out a very short weld with high welding currents therefore the electrodes must have a proper diameter and the welder must be set with an adequate electrode force A minimum 4 bar pressure value is recommended The self calibration welding must be carried out in short circuit The following
3. OFF value when the self calibration procedure is over provided it has been correctly carried out For additional information see the relevant paragraph 26 33 ERRORS MESSAGES STOP MAX SPOTS The welds counter has reached the Clear the counter See paragraph maximum set value WELDING COUNTER FUNCTION Out of limits spots The last Press any push button to clear the STOP LIMIT i i See the paragraph LOW CURRENT with a current value lower than the WELDING CURRENT AND min set limit CONDUCTION ANGLE LIMITS Out of limits spots The last Press any push button to clear the STOP LIMIT welding spot has been carried out error See the paragraph WELDING HIGH CURRENT with a current value higher than the CURRENT AND CONDUCTION max set limit ANGLE LIMITS Out of limits spots last Press any push button to clear the STOP LIMIT i i See the paragraph LOW ANGLE with a conduction angle valuel WELDING CURRENT AND lower than the min set limit CONDUCTION ANGLE LIMITS Out of limits spots The last Press any push button to clear the STOP LIMIT i i See the paragraph HIGH ANGLE with a conduction angle value WELDING CURRENT AND higher than the max set limit CONDUCTION ANGLE LIMITS ALARM Error in the current measurement The control unit cannot correctly during the welding process measure the welding current OCURRE Bae Address to the after sale service During the welding process the The control unit built in amm
4. PROGRAMMED INCREMENT CURVE CURRENT NUMBER OF WELDINGS The increment curve is programmed by determining a specific number of linear segments For each segment it is necessary to determine both the number of the welding spots and the desired increment The parameter STEPS INCREM determines the number of segments to be included in the increment curve Insert the number of welding spots forming the segment in SPOTS n insert the correspondent increment expressed in percent in INCREMENT n For the programming procedure refer to the relevant paragraph on the set up menu Example Welding tests have determined that the electrode life corresponds to 4000 welding spots and that the following current values are necessary at different moments of the electrodes life WELDING SPOTS NECESSARY CURRENT 0 initial electrode diameter 15 kA 700 17 8 kA 1800 19 5 kA 3000 20 2 kA 4000 final electrode diameter 20 7 kA 18 33 For each segment it is then possible to calculate both the duration expressed in welding spots and the percent increment Please notice that the percent increment must always be calculated referring to the beginning of the considered segment Segment 1 duration 700 0 700 weldings Segment 2 duration 1800 700 1100 weldings Segment 3 duration 3000 1800 1200 weldings Segment 4 duration 4000 3000 1000 weldings final current initial current 17 8 15 Variation segment 1
5. about a second By doing so the special functions are shown in sequence use push buttons A and F to select them Special functions PARAMETER TEPS INCREM DESCRIPTION POTS 1 NCREMENT 1 POTS2 NCREMENT 2 POTS 3 INCREMENT 3 POTS 4 INCREMENT 4 POTS 5 NCREMENT 5 POTS 6 INCREMENT 6 POTS 7 NCREMENT 7 IRST DELAY LOCK SPOTS LANGUAGE CALIBRATION ifth segment spots number Sixth segment percent increment S eventh segment spots number Seventh segment percent increment First delay Out of limits spots number before unit block Language of displayed messages Self calibration for constant current function 0 9000 0 50 0 5000 1 50 0 5000 1 50 0 5000 1 50 0 5000 1 50 0 5000 1 50 0 5000 1 50 1 99 0 15 ITA ENG OFF ON The following paragraphs present the functions which can be set in the set up menu STEPPER FUNCTION PARAMETERS The first parameter which can be set in the set up menu is STEPS INCREM it enables to set the number of segments forming the electrodes wear compensation curve You can set from 1 to 7 segments For each segment parameters SPOTS n and INCREMENT n enable to set both welds number and current percent increment value The display shows only the parameters concerning the segments which have been set by means of parameter STEPS INCREM DELAY FUNCTION OF FIRST PHASE SHIFT Parameter FIRST DELAY states the delay of first phase shift This function enables to obtain the
6. adjustable curve e Welds counter Compensation of the secondary current to weld oxidized sheets and rods Single and automatic cycle WELD NO WELD function Delay of first phase shift adjustment to get the best balance of the machine absorption from mains Control of 2 solenoid valves 24 Vac 7 2 W Max with protected output against short circuit electrode closing valve and double stroke valve Self adjustment to the mains frequency 50 60 Hz 3 33 PROGRAMMING THE CONTROL UNIT As soon as the welding control unit is turned on the display shows the supply frequency and the version of the program SUPPLY FREQUENCY 50 Hz 450 REL 1 50 WELD CONTROL After a few seconds the TE450 is set in a waiting condition enabling to carry out the welding process 01 12455 104 08 0 lt 12 3kA Before starting the programming phase it is important to learn some fundamental features of TE450 TE450 stores up 63 different welding programs If the type of handle connected to the control units enables it when working it is possible to quickly select two different programs respectively called ADJUSTMENT 1 and ADJUSTMENT 2 When working the two adjustments are commonly carried out by means of a selector For instance when using the handle type 70838 the selection is carried out by means of selector no 4 For each of the two adjustments the welding program to be used is selected when programming If the h
7. best machine line current balance Once selected before changing this parameter it is necessary to push push button WELD NO WELD Afterwards the value can be set form 1 to 99 by means of push buttons and This adjustment is carried out by the welder manufacturer the user does not need to modify this value 25 33 OUT OF LIMITS SPOTS BLOCKING FUNCTION Parameter BLOCK SPOTS enables to program the control unit so to have it blocked in case of out of limits welding spots The set value indicates the number of consecutive out of limits welding spots after which the machine stops The limit error occurs when a welding spot is carried out with values either higher or lower then the limits set in parameters 17 CURR MIN ANGLE MIN and 18 CURR MAX ANGLE MAX To set the value use push buttons and the value can be set from 0 to 15 If the value is set to zero this function is deactivated in this case the machine does not stop even in case of out of limits welding spots LANGUAGE OF MESSAGES Parameter LANGUAGE enables the user to set the language of the messages displayed by the control unit The programming parameters are always indicated in English SELF CALIBRATION WELDING Parameter CALIBRATION enables to activate the self calibration procedure carried out by the control unit on the machine Push buttons and enables to select if either activate ON or deactivate OFF this function This function is automatically deactivated
8. between 0 and 15 By setting it to O this function is deactivated so that the welding process is not blocked in case of out of limits welding spots Please notice that in order to be effectively considered and counted the out of limits welding spots must follow each other When the set error condition takes place the control unit locks and the displays show an error message The error message refers to the last welding spot When working with the current control mode CONTROL MODE CUR if the last welding spot current is either lower or higher than the limits set in the above stated parameters the display will show one of the following messages STOP LIMIT STOP LIMIT LOW CURRENT HIGH CURRENT When working with conduction angle control mode CONTROL MODE DEO if the last welding spot conduction angle is either lower or higher than the limits set in the above stated parameters the display will show one of the following messages STOP LIMIT STOP LIMIT LOW ANGLE HIGH ANGLE Push any key to clear the error 14 33 CONSTANT CURRENT OPERATING MODE TE450 enables to adjust the welding current in two different operating modes the standard percent adjustment and the constant current adjustment When the control unit works in constant current it is possible to directly set the welding current value During the welding process for each half period the control unit measures the welding current true RMS value and by using a
9. correcting mathematical algorithm keeps the set current Besides simplifying the programming this operating mode enables also to keep the desired welding current even if some factors change mains voltage welding circuit impedance and dimensions status of the welding tools superficial status of the materials in process CONSTANT CURRENT OPERATING MODE SURVEY Welding current I variations according to the mains Welding current I variations according to the mains voltage V variation under standard operating mode voltage V variation under constant current operating mode The selection of the current adjustment mode is independent for each welding program and is set by means of A WORKING MODE parameter By setting the PW value the welding current adjustment is carried out in percent values Please notice that the set value stands for the real percent value of the welder maximum current By setting the IK value the program in progress carries out the adjustment mode in constant current TE450 monitors the welder characteristics by means of the self calibration procedure The values measured during this operation are used for the correct functioning of the working mode in constant current In order to get a better adjustment precision we recommend to repeat this procedure in case the arms are replaced with other having different dimensions This procedure is described in the relevant paragraph When operating in constan
10. 1000 1500 2000 NUMBER OF WELDINGS When all the 2000 welding spot s have been carried out the TE450 stops the working progress The following message is displayed STOP MAX SPOTS By now the operator can replace the electrodes or restore their original diameter and clear the counter TE450 resets the working initial parameters and starts a new stepper phase 17 33 COMPLETE USE NON LINEAR INCREMENT CURVE The previous working mode uses a linear increment of the welding current for the whole electrodes life Nevertheless the increment of the contact section of the electrode on the sheet is not linear but shows a progress similar to the one represented on the following diagram IDEAL CURRENT VARIATIONS N REAL CURRENT VARIATIONS WITH LINEAR STEPPER CURRENT NUMBER OF WELDINGS The use of the linear increment is an approximation enabling to carry out good results in most applications Nevertheless when it is necessary to get the maximum stability of the working 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 CURRENT VARIATIONS REAL CURRENT VARIATIONS WITH
11. LE WITH PRE WELD AUTOMATIC STROKE AUTOMATIC CYCLES NO COLD TIME BETWEEN PRE WELD AND WELD NUMBER PARAMETER VALUE A WORKNGMODE PW B 4 CONTROLMODE NO C STROKE AUTOMATIC 1 SQUEEZE1 X 20cycles 2 SQUEEZE 30 fk 2 3 _ PREWED 08Wcycles__ 4 _ PREPOWER 20 5 X COLD _____ _ cycles 6 X SLOPEUP O0oydes Bi WELD1 12 WELD 1 CURRENT 1 11 ____ SLOPEDOWN 00 12 COLD3 00 18 POST WELD O0cydes _ 14 POSLFPOWER o 15 HOLDTIME O9 cycles 16 OFFTIME 40 01 N 16 02 COMPLEX CYCLE WITH PRE WELD SLOPE UP PULSES AUTOMATIC STROKE AUTOMATIC CYCLE F NUMBER PARAMETER VALUE A WORKING MODE PW B CONTROLMODE NO 1 sQUEEZEi 3 SQUEEZE 20 eycles B 3 PRE WELD_ 08 cycles a PREPOWER 20 s cor 6 SLOPE UP 04 cycles 8 CURRENTi eo L NiMPULSE 0 y 10 leona cycles 18 HOLD TIME 08 cycles 16 OFF TIME 40 eycles ala los 07 um 16 02 12 33 WELDING CURRENT AND CONDUCTION ANGLE MEASURE The following data are displayed after e
12. LORS TECNA 1090 LOUSONS ROAD UNION NEW JERSEY 07083 USA Tel 908 964 9100 Fax 908 964 4492 email sales lors com WELDING CONTROL UNIT TE 450 USER MANUAL RELEASE SOFTWARE No 1 50 DOCUMENT NUMBER MAN 4097 EDITION MARCH 1998 TABLE OF CONTENTS SUBJECTS WELDING CONTROL UNIT TE450 PROGRAMMING THE CONTROL UNIT DESCRIPTION OF THE WORKING CYCLE DESCRIPTION OF THE PARAMETERS EXAMPLES OF WELDING PROGRAMS WELDING CURRENT AND CONDUCTION ANGLE MEASURE WELDING CURRENT AND CONDUCTION ANGLE LIMITS CONSTANT CURRENT OPERATING MODE STEPPER FUNCTION OPERATION COMPENSATION OF THE SECONDARY CURRENT WELDING COUNTER FUNCTION DOUBLE STROKE FUNCTION USE OF THE PRESSURE ONLY CONTROL CHK INPUT FUNCTION THERMOSTAT INPUT FUNCTION KEY SELECTOR FUNCTION OPTIONAL SELF CALIBRATION PROCEDURE SET UP MENU DESCRIPTION ERRORS MESSAGES ORDINARY AND EXTRAORDINARY MAINTENANCE LAMPS ON THE CONTROL UNIT SIGNAL DESCRIPTION ON CONNECTORS 2 33 WELDING CONTROL UNIT 450 TE450 is a microprocessor welding control unit for suspended resistance welding guns The welding control unit is used to control the welder parts and in particular the thyristors adjusting the welding current This control unit includes specific functions to be used when working with suspended welding guns such as double stroke control control of the efficacy of the safety devices eventually installed on the handle of the machine The handle is not a sta
13. MS 4 TIMES SIMPLE CYCLE SHORT STROKE SINGLE CYCLE NUMBER PARAMETER VALUE A WORKNGMODE PW B X CONTROLMOD NO 2 SQUEEZE _ 20 Bx2 ___6 ____ X OD cycles 8 ___ CURRENT 40 08 9 N IMPULSE n Ay por us 15 HOLDTIME 09 CYCLE WITH PULSES AND SLOPE UP LONG STROKE AUTOMATIC CYCLE NUMBER PARAMETER VALUE A WORKING MODE Pw B CONTROLMODE NO c LONG 1 01 cycles 30cycles SQUEEZE 2 3 PRE WELD 00 cycles Bx 4 PRE POWER 0196 5 COLD 1 00 cycles 1 SLOPE UP 06 cycles Bi WELD 1 O4cycles Le 1 A 9 N IMPULSE B O 4 COLD2 03 cycles 11 SLOPE DOWN 00 cycles 12 COLD 3 00 cycles 13 POST WELD 00 cycles 14 POST POWER 0196 15 HOLDTIME 09 16 OFFTIME 35 CYCLE WITH PRE WELD SLOPE UP AUTOMATIC STROKE AUTOMATIC CYCLE NUMBER PARAMETER VALUE A WORKING MODE Pw B CONTROLMOE NO 1 SQUEEZE1 ___ 20cycles 2 SQUEEZE ___ 30 3 PREWELD X 08 4 PREPOWER 205 5 X COLDD 5 10 6 X SLOPEUP X O4cyces 8 CURRENT 60 9 N IMPULSE 01102 03 05 06 07 15 16 02 15 HOLD TIME 9 O9 cycls 16 __ 40 a aalan mnm 16 02 11 33 CYC
14. NLY CONTROL The PRESSURE ONLY control is usually used to check that the electrodes are correctly positioned before carrying out the welding process By activating the PRESSURE ONLY control usually by pressing a push button placed on the welder handle while the electrodes are closing the welder clamps the pieces to weld and waits the operator after having checked the correct positioning of the electrodes enables the cycle to continue by deactivating the control PRESSURE ONLY releasing the push button If the electrodes are not correctly positioned the operator can cancel the operation by releasing the start of cycle device For welders with double stroke control only If the control unit has been set to short stroke mode C STROKE SHORT the control PRESSURE ONLY device can be used to shift the electrodes from long stroke position to short stroke position without closing the electrodes on the workpiece This operation is sometimes necessary for particular welding conditions i e works on thin thickness or requiring high precision The electrodes can be placed in a long stroke position either because they have been opened by means of the OPEN control or because the welder has just been switched on When starting the welding cycle TE450 brings the electrodes to short stroke position thus activating the solenoid valve EV2 in 0 6 seconds If the control PRESSURE ONLY is activated the welding cycle stops in this position By ke
15. OKE By setting the C STROKE parameter value to SHORT the operator adjusts the control unit for the short stroke Under this mode the solenoid valve EV2 is kept activated and the mobile electrode under the rest condition will be on B position If the operator needs to open the electrodes while working he will press the double stroke opening push button it by means of the OPEN input disconnects the solenoid valve EV2 After having pressed the double stroke opening push button or when switching the welder on the electrode is placed on A position the control unit will move it to B position when the first weld is carried out During the first weld TE450 activates the solenoid valve EV2 which shifts the electrode from A to B position then it awaits for a 0 6 second fixed time and finally it carries out the programmed welding cycle When the weld has been carried out the solenoid valve EV2 is not deactivated and the electrode is kept on B position The following welds will be carried out starting from this position It is possible to shift the electrodes from the long stroke position to the short one by means of the control PRESSURE ONLY see paragraph USE OF PRESSURE ONLY CONTROL Notice that each time the programming of the control unit starts the double stroke solenoid valve EV2 is deactivated LONG STROKE By setting the C STROKE parameter value to LONG the operator adjusts the control unit for the long str
16. OW measured a current too high to be welding current is within this limit correctly measured Address to the after sale service CURRENT 1 The current value set in CURRENT Set CURRENT 1 parameter to a HIGHER CURMAX 1 parameter is higher than the value lower than the welder welder maximum current maximum value The current value set in one of the Set the current limits to a value CURRENT LIMIT ea 17 18 is a lower e the welder maximum HIGHER CURMAX an the welder maximum current current CURMIN HIGHER The value set in CURR MIN 17 is Set the current minimum limit to a higher than the value set in CURR value lower than the maximum limit vee MAX 18 DEG MIN HIGHER The value set in ANGLE MIN 17 Set the current conduction angle DEG MAX is higher than the value set in minimum limit to a value lower than ANGLE MAX 18 the maximum limit CHK signal indicates that the Check PLEASE RELEASE safety device placed on the handle SECURITY is activated This can be due to either damage or tampering 28 33 The welder protection thermostat Check that the correct water quantity THERMOSTAT has been activated is flowing inside the welder and or ACTIVATED check the thermostat correct functioning Synchronism error due to either a Press any key to clear the error If SUPPLY SYNC temporary lack of the referring this error repeats frequently check signal on the supply line or correct functioning of the devi
17. ach weld 1 Number of the program 2 Number of welds carried out after the last counter reset 3 Last weld current conduction angle 4 Set welding time 5 Last weld welding current 1 2 3 i Pr01 12455 104 08 0 12 3 The current value measured and displayed stands for the average of the RMS values measured for each half period of the welding time The displayed value always refers to the main adjustment that is to the adjustment set on parameter 7 WELD 1 When working in pulse mode the current value always refers to the last pulse Pre weld current PRE WELD post weld current POST WELD and slope times current are never measured The control unit measures also the welding current conduction angle The conduction angle indicates the welding circulation time in the half period The displayed value stands for the average of the values measured for each half period of the welding time The displayed value always refers to the main adjustment that is the adjustment set on parameter 7 WELD 1 Pre weld current conduction angle PRE WELD post weld current conduction angle POST WELD and slope times current conduction angle are never measured The conduction angle can reach a maximum value corresponding to 180 degrees Examples of currents having different conduction angles Conduction angle 180 Conduction angle 72 If a welding test is carried out in NO WELD both welding current and conduction
18. andle is not equipped with the selector enabling to select the two adjustments the welding control unit always works in ADJUSTMENT 1 The control unit shows all data and messages on a LCD display The user can select the language of both warning and error messages The programming parameters are always displayed in English The programming is carried out by setting the parameters describing the welding cycle select each parameter and set the required values one by one To better understand the meaning of each parameter read the relevant paragraph To start the programming push simultaneously the push buttons A and Y for at least a second it is then possible to carry out the programming operations After 8 seconds of inactivity the control unit will automatically end the programming operation and enable the working process 4 33 The first selection concerns the number of the program to be used for the adjustment in process The adjustment selection ADJUSTMENT 1 or ADJUSTMENT 2 is carried out by means of the proper selector which is commonly a two position selector placed on the handle The program is selected by means of the push buttons e ADJUSTMENT 1 PROGRAM NUM 34 After having selected the number of the program it is possible to select the parameters forming the program by means of the push buttons A e V The parameters are marked either with a letter from A to C or a number from 1 to 18 The dis
19. angle displayed values are of course equal to zero 13 33 WELDING CURRENT AND CONDUCTION ANGLE LIMITS TE450 enables to set some control limits on the welding current The purpose is that of monitoring the stability of the welding current so to improve a constant welding quality The control unit enables to select two different control modes Welding current limits To activate this control mode set parameter B CONTROL MODE on CUR Two new parameters will be displayed 17 CURR MIN minimum current limit 18 CURR MAX maximum current limit These two parameters enable to set the welding current limit values Conduction angle limits To activate this control mode set parameter B CONTROL MODE on DEG Two new parameters will be displayed 17 ANGLE MIN minimum conduction angle limit 18 ANGLE MAX maximum conduction angle limit These two parameters enable to set the welding current conduction angle limit values When working if either the welding current or the welding current conduction angle measured values are out of the set limits the welding spot is considered as out of limits In case of a consecutive out of limits welding spots it is possible to stop the welder The number of the consecutive out of limits welding spots after which the control unit blocks can be adjusted by means of the BLOCK SPOTS parameter placed in the set up menu see the relevant paragraph for the programming operations This value can be included
20. aragraph When the control is set to degree control mode CONTROL MODE DEG this parameter fixes a minimum conduction angle value For each weld the TE450 monitors that the welding current conduction angle is higher than the limit set on this parameter if it is lower an error message will be displayed see the relevant paragraph If the B CONTROL MODE parameter is set to NO no control on the welding current the parameter is not displayed during the programming phase 18 CURR MAX ANGLE MAX MAXIMUM CURRENT LIMIT OR CONDUCTION ANGLE This parameter expresses different data according to the control mode selected on parameter B CONTROL MODE When the control is set to current control mode CONTROL MODE CUR this parameter fixes a maximum current value For each weld the TE450 monitors that the welding current is lower than the limit set on this parameter if it is higher an error message will be displayed see the relevant paragraph When the control is set to degree control mode CONTROL MODE DEG this parameter fixes a maximum conduction angle value For each weld the TE450 monitors that the welding current conduction angle is lower than the limit set on this parameter if it is higher an error message will be displayed see the relevant angle If the B CONTROL MODE parameter is set to NO no control on the welding current the parameter is not displayed during the programming phase 10 33 EXAMPLES OF WELDING PROGRA
21. ces noise on the supply line switching the supply line and check possible noise on the supply ERROR OUTPUT VALVE n control Eus Check Tu evice against short circuit ec e solenoi Ee ONE TENE been activated valve coil ORDINARY AND EXTRA ORDINARY 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 and gases which could damage the plastic components of the control unit The built in ammeter does not require any calibration Nevertheless we recommend to check the correct functioning of the ammeter this operation can be carried out by comparing the TE450 measure with that carried out by another measurement instrument The built in ammeter measures the true RMS current value see the paragraph WELDING CURRENT AND CONDUCTION ANGLE MEASURE The instrument used for the comparison must provide the same type of measurement The electronic board is protected against overloads by a 3 5 kA delayed fuse placed on the 24 Vac supply The fuse is placed on the board closed to the XS1 connector and is marked F2 The used model is PICOSFUSE 47303 5 manufactured by LITTELFUSE f the control unit does not switch on this protection fuse could have been activated 29 33 LAMPS ON THE CONTROL UNIT START L1 lt gt If on it indicates that
22. d out Pre weld is carried out with a current adjustment equal to that stated on parameter 4 PRE POWER PRE WELD CURRENT 4 PRE POWER PRE WELD CURRENT The value expressed in this parameter indicates the power used to carry out the pre weld 5 COLD 1 The COLD 1 parameter indicates the time elapsing between the pre weld 3 PRE WELD and the weld 7 WELD 1 If the pre weld is deactivated that is when PRE WELD 0 this cooling time is not carried out 6 SLOPE UP The SLOPE parameter describes the time used to reach the programmed welding power value The starting value of this slope always corresponds to the minimum power while the final value corresponds to the value of power set to parameter 8 CURRENT welding current The slope speed is automatically calculated by the microprocessor according to the set values SLOPE time is added to the welding time 8 33 7 WELD 1 The WELD 1 parameter indicates the current flow duration It is carried out with the same power value set on parameter 8 CURRENT When the pulse operating mode is activated this parameter indicates the duration of each pulse This parameter is expressed in three digits as it can be adjusted with the half period precision 8 CURRENT 1 The value indicated in CURRENT 1 shows the current adjustment used to carry out the welding process Depending on the working mode operation which has been selected by means of parameter A WORKING MODE this value indica
23. e SQUEEZE 1 time is used when working with the automatic double stroke It determines the time employed by the electrode to shift from the long stroke to the short stroke position The set value must be long enough to enable the mobile electrode to reach the short stroke position During the SQUEEZE 1 time it is possible to end the cycle if the start of cycle signal is deactivated This parameter can be set only if both the machine and the handle are designed for the control of the double stroke from the control unit 2 SQUEEZE The SQUEEZE time determines the electrodes closing time that is to say the time interval elapsing between the beginning of the electrodes closing and the starting of the welding process The set value must be long enough to have the electrodes reach both the piece to weld and the proper clamping force before the starting of the welding process A too low adjustment of this time causes sparkles between electrodes and sheet when the welding process starts it can also cause an unsteadiness of the welding quality If the start cycle signal is deactivated during the squeeze time the sequence is broken up 3 PRE WELD The PRE WELD parameter indicates the length of a current passage which can be carried out before the welding process so to pre heat the piece to be welded This parameter is indicated by three digits as it can be set with a half period precision If this parameter is set to 0 the pre weld will not be carrie
24. eping this condition for one second and then deactivating the start of cycle control the electrodes stay in the short stroke position If the PRESSURE ONLY control is released the cycle continues and the welding is accomplished 22 33 CHK INPUT FUNCTION On the handle of the suspended welding gun there can be installed a safety micro switch carrying out a special function it enables to start the cycle only if the operator has previously grasped the handle As a rule this micro switch is placed in series to the start of cycle one In order to get a better safety the control unit by means of the CHK input checks that this input is activated when the welding process starts If the signal is not activated the TE450 does not accept the start of cycle signal Moreover the control unit checks that this micro switch is neither broken it keeps closed nor tampered This test is carried out e when switching the control unit on e when shifting from RUN to PROGRAM Under these conditions the control unit displays the following error message and it does not enable the welding process PLEASE RELEASE SECURITY The error does not block the machine functioning the error will be automatically cleared when its cause is removed THERMOSTAT INPUT FUNCTION This input is connected to a normally closed thermostat which is placed on the welder When starting the welding cycle if the following error message is displayed THERMOSTAT
25. epper function set the following parameters on the set up menu DESCRIPTION SPOTS 1 Fist segment spots number Z o Z o INCREMENT 1 ___ segment increment percent When adjusting these parameters the counter is automatically cleared When the counter reaches the set welds number the control unit displays the following message STOP MAX SPOTS The welder functioning is suspended until the counter is cleared If SPOTS 1 parameter is set to zero the block function is deactivated 20 33 DOUBLE STROKE FUNCTION The double stroke function is enabled only when the control unit is equipped with a handle enabling this function This function is deactivated on all machines which are not designed for the double stroke control as a consequence it is not possible to set SQUEEZE 1 parameter The solenoid valve EV2 output drives the double stroke solenoid valve When the machine is switched on it is always deactivated even though the control unit is programmed for working with the short stroke The OPEN input is connected to a push button close to the operator which is used to have the double stroke deactivated electrodes opening The operator by means of the C STROKE parameter selects one among the three possible working modes here after explained A MOBILE ELECTRODE POSITION WITH DISCONNECTED DOUBLE STROKE LONG STROKE B MOBILE ELECTRODE POSITION WITH OPERATING DOUBLE STROKE SHORT STROKE SHORT STR
26. er indicates the post welding power 15 HOLD TIME The parameter HOLD indicates the time elapsing between the end of the welding process and the opening of the electrodes It allows a quicker cooling of the welding spot and prevents that the spot is moved before a proper cooling 16 OFF TIME The OFF parameter indicates a machine waiting time namely that elapsing between one machine cycle and the next one when the welder is working in automatic cycle When this value is set to zero the machine will go on working in single cycle if it is set to another value the machine will work in the automatic cycle When the machine works in single cycle the control unit will carry out a single cycle each time it receives a start cycle signal When the machine works in automatic cycle the welder goes on executing welding cycles until the start cycle signal is released By programming this parameter to 99 the welding current compensation function is activated see the relevant paragraph 17 CURR MIN ANGLE MIN MINIMUM CURRENT LIMIT OR CONDUCTION ANGLE This parameter expresses different data according to the control mode selected on parameter B CONTROL MODE When the control is set to current control mode CONTROL MODE CUR this parameter fixes a minimum current value For each weld the TE450 monitors that the welding current is higher than the limit set on this parameter if it is lower an error message will be displayed see the relevant p
27. eriod of time are expressed in periods also called mains cycles The mains frequency defines the duration of a cycle Mains frequency 50 Hz 1 period 20 ms Mains frequency 60 Hz 1 period 16 6 ms A WORKING MODE The WORKING MODE parameter defines the adjustment mode of the program welding current power percent PW or constant current IK Welding time WELD 1 7 is carried out according to the adjustment mode set in this parameter PRE WELD 3 and POST WELD 13 are always carried out with the power percent adjustment B CONTROL MODE The CONTROL MODE parameter enables to select the desired control mode of the welding current NO There is no control on the supplied welding current CUR TE450 enables to set the welding current min and max limits DEG TE450 enables to set the min and max limits of the welding current conduction angle For further information please read the relevant paragraph 7 33 C STROKE DOUBLE STROKE TE 450 enables to control the double stroke also called retraction working on those machines equipped with this function This parameter enables to define the double stroke desired working mode SHORT Short stroke LONG Long stroke AUTOMATIC Automatically set stroke Additional data on this function are given in the relevant paragraph This parameter can be set only if both the machine and the handle are designed for the control of the double stroke from the control unit 1 SQUEEZE 1 Th
28. eter WELD FAULTY control unit has surveyed a current capacity is 36 kA Check that the OVERFLOW CURRENT too high to be correctly measured supplied current is within this limit Address to the after sale service NO SECONDARY No secondary current circulation Check the continuity of the during the last welding cycle secondary circuit Check the electric CURRENT SISNAS connection of the current transducer 27 33 CALIBRATION It ECOL bu d out ae ni ae and repeat NO WELD ERROR WELDS ration welding e welding It takes place when the control the continuity of the CALIBRATION does not measure current during secondary circuit Check the electric the self calibration welding connection of the current transducer REED EREBOR Repeat the self calibration procedure Either the self calibration weldinglIRepeat the self calibration CALIBRATION has not been carried out or some procedure If the same error SAMPLING ERROR errors have occurred when repeats check the electric measuring the current connection of the current transducer CALIBRATION Errors in the current measurementlIRepeat the self calibration CURRENT ERROR during the self calibration procedure If the problem repeats procedure address to the after sale service During the self calibration The control unit built in ammeter CALIBRATION procedure the control unit has capacity is 36 kA Check that the CURRENT OVERFL
29. he double stroke Suitable for the control of 24 Vac max 7 2 W coil REMARK The outputs EV1 EV2 TRG are protected against short circuit thanks to electronic devices with automatic restart 30 33 CONNECTOR XS2 6 PINS HANDLE START Connect to the start of cycle device microswitch The input is active COM 1 closed on the common COM 1 AUX This input allows an external device to block the welding cycle during the COM 1 squeeze phase It is normally used for the ONLY PRESSURE function The contact connected to this input must be of the normally open type This input enables the welding adjustment No 2 ADJUSTMENT 2 direct recall For a correct functioning this input must be enabled before the start of cycle signal The input is working when closed towards common line COM 1 It is connected to the OPEN micro switch placed on the welder handle It enables the double stroke opening This input is working when closed towards common line COM 1 In the handles which are not equipped with this function OPEN signal is always in short circuit with the common COM 1 This indicates to the control that the double stroke function must not be carried out Input used to check the safety function eventually installed on the handle This input is working when closed towards common line COM 1 If this function is not used because the handle is not equipped with this microswitch short circuit this input with the START one pin 4 By thi
30. he welds number electrodes life in the SPOTS 1 parameter Set the required percent increment in the INCREMENT 1 parameter Example The welding tests proved that the electrode life corresponds to 2000 welding spots that with new electrodes the required current is 15 kA that after 2000 spots the electrodes diameter increment requires a 19 kA current 16 33 The percent variation is calculated as follows final current initial current 19 15 Variation 96 100 initial current 15 X 100 26 The following parameters are then set in the set up menu PARAMETER DESCRIPTION VALUE STEPS INCREM Number of segments for stepper function SPOTS 1 Number of spots to be included in the first segment 2000 INCREMENT 1 First segment percent increment The welding program must be set in order to carry out the first welding spot that is with an adjustment enabling to obtain the necessary current with the starting electrodes diameter 15 kA The stepper function works with all current operating modes both percent adjustment and constant current adjustment 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 CURRENT INCREASE DURING THE PRODUCTION FINAL CURRENT 19 kA mA INCREMENT PERCENT 26 lt 18 SPOTS NUMBERS 2000 46 z 14 A 12 5 2 10 o 8 z 6 4 2 0 0 500
31. in current compensation with a value lower than 2 0 kA see paragraph COMPENSATION OF THE SECONDARY CURRENT Bysetting 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 By following this procedure it is possible to set all parameters to the required value in order to carry out the welding Please note that it is not necessary to press any push button to confirm the set data as each data is automatically stored up after the adjustment When the programming operations are accomplished wait until the control unit ends the programming phase this takes automatically place after 8 seconds of inactivity If the start of cycle device is activated before the control unit moves from the programming phase to the working phase it will not be considered Release the control device and start it again Use the WELD NO WELD function to carry out any test cycle without welding current The welding current can be either enabled or disabled by means of the push button here WELD 5 shown When the lamp is on the control unit is set to WELD it carries out the JADA standard welding cycles When the lamp is off the control unit is set to NO NO WELD amp WELD it carries out complete test cycles without welding current even NON SALDA though all the time parameters are preserved When the control unit is set on a waiting condition the display sho
32. instructions are to be carried out in the given order 1 Enter the set up menu by pushing at once push buttons and for at least a second 2 Select CALIBRATION parameter by means of push buttons A and set it to ON by means of push buttons and SETUP MENU CALIBRATION ON 3 Wait for 8 seconds so to end the programming phase The display shows the standard working data Pr01 12455 104 08 0 12 3 4 Check that WELD NO WELD function is set on WELD the led must be on 5 Activate the start of cycle device The control unit displays the following message and carries out a welding spot lasting for a few periods length and with different current adjustments CALIBRATION IN PROGRESS When this procedure is over the control unit displays the maximum current value and the machine cos value this operation ends the self calibration procedure CALIBRATION OK Fi 34 17 If error messages are displayed instead of the above shown message proceed as follows 1 Clearthe error by pushing any key 2 Remove the error cause see paragraph ERRORS MESSAGES 3 Activate the start of cycle device so to repeat the self calibration welding 24 33 SET UP MENU DESCRIPTION For some functions i e the current increment it is necessary to set some parameters which have been grouped in a special section called SET UP menu To enter the SET UP menu press at once push buttons and for
33. ndard component of the welding control unit it is possible to install different handles so to set the machine according to different working performances It is possible to store up to 63 different welding programs it is possible to directly recall 2 programs by means of an external selector commonly installed on the handle Each program is formed by 18 adjustable parameters describing the working cycle Besides the simple 4 times cycle the control unit enables to carry out welding processes with pre weld current post weld current slope and pulses TE450 can work in constant current mode it displays the welding current and check the current according to the set limits MAIN TECHNICAL DATA e Simplified programming by means of 5 push buttons and LCD alphanumeric display e Synchronous thyristors drive with phase shift control for welding current adjustment 63 welding programs to be stored up 2 programs can be recalled from the handle 18 programmable parameters for each program Slope and pulse functions pre weld e post weld functions Welding times adjustment in half periods Display of both welding current in and connected conduction angle Double working mode standard and constant current 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
34. nt increment applies to all welding programs in turn used When used either the welding current or the conduction angle limits are increased with the same percent The same happens for both pre weld and post weld current adjustment If the set welding current or power values are modified during the welding process the control unit detects the new values and adjusts the welding conditions In case of changes on the set stepper curve the control unit clears the counter it is then necessary to restore the starting electrodes diameter SIMPLIFIED USE OF THE STEPPER FUNCTION LINEAR STEPPER It is possible to use this function in a simplified way that is by programming a simple percent increase to be applied to a predetermined number of welding spot which must be carried out with the same electrodes To adjust these parameters it is necessary to know first the electrodes life Welding tests are carried out with new electrodes and before their replacement In both cases the currents which are necessary to carry out the welding process at the required quality are determined Calculate the percent variation and set it up in the control unit The parameters enabling the stepper function are included in the set up menu The relevant paragraph shows how to program these parameters In the simplified use of the stepper function the parameter STEPS INCREM must always be set to 1 this is because there is only one segment to be programmed Set t
35. oke Under this mode the solenoid valve EV2 is kept deactivated and under the rest condition the mobile electrode will be on A position In this case the OPEN input activation has no effect During the welding cycle the SQUEEZE 1 time is not carried out 21 33 AUTOMATIC STROKE By setting the C STROKE parameter to AUTOMATIC the operator adjusts the control unit for the automatic stroke This mode is used together with the automatic cycle functioning parameter OFF 0 It enables to carry out sequences of welding cycles with the short stroke but starting from a long stroke working condition that which for instance is useful for positioning the welding gun on the piece to weld Sop HoH oH 5 GHHAHHAHA wo n _ __ g sc F __ WELD WELD REST On START the control unit activates the solenoid valve EV2 which shifts the electrode from A to B position and before the activation of EV1 it carries out the programmed SQUEEZE 1 time When the first weld of the automatic cycle is carried out the EV2 is not disconnected and the SQUEEZE 1 is ignored for the following welds This goes on until the operator does not release the start of cycle control device thus ending the welds sequence the control unit disconnects both EV1 and EV2 which returns the electrodes to the maximum opening If the double stroke is activated before the starting of the welding process the control will not carry out the SQUEEZE 1 time USE OF THE PRESSURE O
36. play shows the following data 1 2 3 i i i ADJ1 PRGO1 PRMO7 WELD 1 08 0 4 5 Selected adjustment ADJ1 ADJUSTMENT 1 ADJ22ADJUSTMENT 2 Number of the selected program PRG01 program number 1 Identification mark of the selected parameter Name of the parameter Value of the parameter The value of the welding parameters can be adjusted by means of the push buttons and either increasing or decreasing the value shown by the display The parameters can be adjusted to different values according to the type of parameter the limits range for each parameter is given in the following table PARAMETER NUMBER PARAMETER RANGEVALUE A WK PW amp B CONTROLVOE X NOCURRDEG C Smoke SHORTLONG AUTOMATO 1 Ol 99cydes O 2 SQUEEZE Olt 99cydes O a0 998 aes 5 CODD 00 50cyles O eStore UP 0 25odes 7 O 005 995cydes _ CURRENT 1 2 0 36 0 kA Po NMPUS _ 0 0 1 stoREDON O0 25cydes PS oome Oi S9ceydes O CURR MIN 2 0 36 0 kA ANGLE MIN 001 180 18 CURR MAX 2 0 36 0 kA ANGLE MAX 001 180 5 33 There are some peculiar conditions If OFF TIME 16 is set to zero the welding control unit will work in single cycle If OFF TIME 16 is set to 99 the welding control unit will carry out the m
37. s operation the safety function against the accidental triggering is disabled XS2 PROTECTION FUSE XS1 X 450 1000000000002 inuuuunje S163 NOILISOd NO 35019 NOILISOd NO N3dO LYS HOLIMS 8012313S WV903d 8 vas N u012313S WS 3unss3aud 1 eas 3015 33M 319A9 40 LYVLS Za 5 SNId 31VW33 YOLISNNOD LNGOW dNV Nid 9 Cif or NIS gs WALI NO 0Sr31 00831 INVelO VIO 9NIHIM 3 10NVH x 5 S 5 62 25 gt cz o gt 5 us lt or N m c lt X 25 S 74 o 22 ELE FIRING MODULE AP1 POWER MODULE TC1 FU2 1A i a Fu 1A 34031s 318n0G CONTROL UNIT SNISOTO 300819313 TO THE HANDLE 1090 LOUSONS ROAD UNION NJ 07083 WIRING DIAGRAM FOR TE300 TE450
38. t current mode and if during the welding process for any reasons there is no current circulation the control unit does not carry out the adjustment it blocks the welding process and displays the following error message NO SECONDARY CURRENT SIGNAL 15 33 STEPPER FUNCTION OPERATION The stepper function enables to compensate the electrodes wear affecting the quality of the welding spots When the electrode diameter is enlarged the contact section area between the electrode and the workpiece is equally increased and as a consequence the current density Ampere mm decreases If the current is maintained at a fixed value throughout the whole electrode life it will be noticed that the last spots are of a lower quality in comparison with the first ones The stepper function is used in order to overcome this problem It gradually increases the current adjustment during the welding process in comparison with the electrodes diameter enlargement this enables to maintain a constant current density This function is suitable especially when using the control unit in constant current mode Nevertheless it works also when the control unit works in percent adjustment mode Program a stepper curve to describe the variations of the current along the electrodes life The curve is formed by one or more segments for each segment program the weld numbers and the corresponding current increment in percent Once it has been programmed the curre
39. tes either the current percent PW96 power per cent adjustment or the required current value expressed in kA IK constant current adjustment 9 N IMPULSE The N IMPULSE parameter indicates the number of impulses used to carry out the welding process The duration of each impulse corresponds to the time set on parameter 7 WELD1 welding time 10 COLD 2 COLD 2 parameter is used with the pulse operating mode it indicates the time elapsing between a welding impulse and the following one 11 SLOPE DOWN The SLOPE DOWN parameter is an additional welding time which is added at the end of the welding process it enables to decrease the welding current from the value set on 8 CURRENT 1 to the minimum value The slope speed is automatically calculated by the microprocessor according to the set values 12 COLD 3 The COLD 3 parameter indicates the time elapsing between the welding process 7 WELD 1 and the post weld 13 POST WELD 13 POST WELD The POST WELD parameter indicates the duration of a current passage which can be carried out after the welding time in order to enable a more gradual cooling of the welding spot This parameter is indicated by three digits as it can be adjusted with the 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 on parameter 14 POST POWER 9 33 14 POST POWER The value expressed in this paramet
40. the start of cycle control triggered by the push INIZIO CICLO button placed on the handle is activated PRG 2 RECALL It indicates that the external device recalling the welding adjustment no Richiamo PRG L ADJUSTMENT 2 is activated If on this led indicates that the pressure only control device is o activated This input is normally activated by the PRESSURE ONLY push button placed on the handle CURRENT L If on this led indicates that the control unit is generating the SCR trigger CORRENTE Ay impulses UU 1 X It indicates that the solenoid valve executing the main cycle is activated 5 It indicates that the solenoid valve driving the double stroke is activated SIGNALS DESCRIPTION ON CONNECTORS CONNECTOR 51 12 PINS It is the control unit supply which must be 24 Vac The supply transformer must be of at least 13 VA and must supply only the control unit in order to avoid possible interferences Output for the trigger signal for the SCR The output is an impulses train with a 5 Khz frequency 16 20 duty cycle 30 V amplitude on a loading of 35 It is necessary to use the TECNA firing module for the SCR control The current transducer rogowski ring must be connected to this analog input The used transducer must have a 150 mV kA sensitivity with a load This input has been designed for connecting a normally closed thermostat Connect to the solenoid valve driving t
41. unction controls the welding current until the current does not exceed a pre set limit equal to 2000 A the welding time is automatically extended up to a limit of 99 periods In this way it is possible to carry out welding processes with an always constant real time of current flow Please consider that this function should be used only in case of welding conditions which cannot be otherwise overcome as it is not a system in itself assuring the welding quality This function is activated by setting to 99 the value of 16 OFF TIME parameter when this function is activated the control unit will work in single cycle Under constant current operating mode this function is deactivated WELDING COUNTER FUNCTION The control unit contains a welds counter enabling the programming of the maximum number of welding spots During the welding process the control unit displays the counter reached value The counter is updated after each welding spot with the only exception of welding tests carried out in NO WELD To clear the counter press at once push buttons A and for about a second The display will show the following message CLEAR COUNTER SPOTS KEY Press push button to clear the counter wait for 8 seconds to end the procedure without clearing the counter The maximum welds number is set by following the same procedure stated for the stepper function For example if you want to carry out 2840 welding spots without using the st
42. ws the following data 1 2 3 Pr01 12455 104 08 0 12 3 Selected welding program Number of the welds executed after the last counter reset The conduction angle of the last weld Set welding time Current value of the last weld As soon as the welding cycle is activated the control unit checks the data of the selected program An error message will be displayed if the values of the parameters are not compatible Please refer to the welder user manual for the description of the control device functions 6 33 DESCRIPTION OF THE WORKING CYCLE TE 450 working cycle is set by the user when adjusting the programming parameters These parameters indicate the operating times and the current adjustments characterizing the working cycle when carried out consecutively The following chart shows in which sequence the set functions are carried out 01 nini 16 The numbers here above indicated refer to the programming parameters described in the following paragraph For safety reasons the microprocessor does not trigger the welding cycle if the start device is activated when switching on the welder release it and start it again Any microinterruptions or excessive voltage drops block the control and do not alter the operation to reset the operation turn the machine off and then turn it on again DESCRIPTION OF THE PARAMETERS All the following parameters indicating a p
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