Welding Control Unit TE-450
Contents
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3. PLEASE RELEASE SECURITY It occurs when carrying out the self calibration welding in NO WELD It takes place when the control unit does not measure current during the self calibration welding Either the self calibration welding has not been carried out or some errors have occurred when measuring the current Errors in the current measurement during the self calibration procedure During the self calibration procedure the control unit has measured a current too high to be correctly measured The current value set in CURRENT 1 parameter is higher than the welder maximum current The current value set in one of the limits parameters 17 18 is higher than the welder maximum current value The value set in CURR MIN 17 is higher than the value set in CURR MAX 18 The value set in ANGLE MIN 17 is higher than the value set in ANGLE MAX 18 CHK signal indicates that the safety device placed on the handle is activated This can be due to either damage or tampering 29 34 Activate WELD function and repeat the self calibration welding Check the continuity of the secondary circuit Check the electric connection of the current transducer Repeat the self calibration procedure Repeat the self calibration procedure If the same error repeats check the electric conn ection of the current transducer Repeat the self calibration procedure If the problem repeats address to the after
4. 12 00 00 01 40 cycles 0 0 7 01 les 16 02 COMPLEX CYCLE WITH PRE WELD SLOPE UP PULSES AUTOMATIC STROKE AUTOMATIC CYCLE NUMBER PARAMETER VALUE A WORKING MODE Pw B CONTROLMODE 7 1 SQUEEZE1 30cycles 2 SQUEEZE 20 3 PRE WELD O8cycles 4 PREPowR 2 s meys 1 6 SLOPE UP 04 CURRENT 6o oas 416 N IMPULSE 02 als 07 10 07 15 16 02 POST POWER HOLD TIME 09 cycles OFF TIME 40 cycles 13 34 WELDING CURRENT AND CONDUCTION ANGLE MEASURE The following data are displayed after each 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 Prot 12455 104 08 0 12 3 kA 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 conduc
5. 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 and INCREMENT 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 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 26 34 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 s
6. 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 and for about a second The display will show the following message CLEAR COUNTER SPOTS KEY 1251 Press push button E 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 stepper function set the following parameters on the set up menu PARAMETER DESCRIPTION VALUE STEPS INCREM Number of segments for stepper function SPOTS 1 Fist segment spots number 2840 NCREMENT 1 First 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 21 34 DOUBLE STROKE FUNCTION The double stroke fu
7. 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 b SEGMENT 4 181 178 SEGMENT 3 SEGMENT 2 SEGMENT 1 CURRENT kA T T T T 0 1000 2000 3000 4000 NUMBER OF WELDING SPOTS 20 34 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 function 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
8. sale service The control unit built in ammeter capacity is 36 Check that the welding current is within this limit Address to the after sale service Set CURRENT 1 parameter to a value lower than the welder maximum value Set the current limits to a value lower than the welder maximum current Set the current minimum limit to a value lower than the maximum limit Set the current conduction angle minimum limit to a value lower than the maximum limit The welder protection thermostat Check that the correct water THERMOSTAT has been activated quantity is flowing inside the ACTIVATED welder and or check the thermostat correct functioning Synchronism error due to either Press any key to clear the error If a temporary lack of the referring this error repeats frequently check SUPPLY SYNC signal on the supply line or to the correct functioning of the ERROR noise on the supply line devices switching the supply line and check possible noise on the supply The control outputs protection Check the control unit electric device against short circuit has connections Check the solenoid been activated valve coil OUTPUT VALVE FAIL OVER TEMP 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 d
9. than 2 0 kA see paragraph COMPENSATION OF THE SECONDARY CURRENT By setting 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 8 shown When the lamp is on the control unit is set to WELD it carries out sid the standard welding cycles When the lamp is off the control unit is set to NO WELD EJ NO WELD it carries out complete test cycles without welding current NON SALDA even though all the time parameters are preserved When the control unit is set on a waiting condition the display shows the following data Prol 12455 104
10. 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 15kA CURRENT INCREMENT DURING PRODUCTION FINAL CURRENT 19 kA 20 INCREMENT PERCENT 26 18 SPOTS NUMBERS 2000 16 WELDING CURRENT kA 0 500 1000 1500 2000 NUMBER OF WELDING SPOTS 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 18 34 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 C
11. 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 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 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 w
12. ALIBRATION 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 instructions are to be carried out in the given order 1 Enter the set up menu by pushing at once push buttons 5 for at least a second 2 Select CALIBRATION parameter by means of push buttons M set it to ON by means of push buttons El SETUP MENU CALIBRATION ON 3 Wait for 8 seconds so to end the programming phase The display shows the standard working data Prol 12455 104 Orn Oe 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 Th
13. BER PARAMETER VALUE A WORKINGMODE PW CONTROLMODE 2 SQUEEZE 20 2 6 SLOPEUP OD cycles 8 CURRENT1 40 08 9 N IMPULSE a Ay 02 207 18 15 09 CYCLE WITH PULSES AND SLOPE UP LONG STROKE AUTOMATIC CYCLE NUMBER PARAMETER A PW CONTROLMODE 2 SQUEEZE 30 6 5 0 8 CURRENT 406 1 5 0 Ay 10 COLD2 B cycles 15 THOLDTIME 09 cycles 16 35 cycles CYCLE WITH PRE WELD SLOPE UP AUTOMATIC STROKE AUTOMATIC CYCLE NUMBER PARAMETER VALUE A WORKINGMODE PW CONTROLMODE 1 SQUEEZE1 20 2 SQUEEZE 0 4 206 5 10 6 04 8_ CURRENT1 606 9 N IMPULSE 1 15 16 09 4 lilo 16 02 01 102 03 05 06 07 15 16 02 12 34 CYCLE WITH PRE WELD AUTOMATIC STROKE AUTOMATIC CYCLES NO COLD TIME BETWEEN PRE WELD AND WELD NUMBER PARAMETER VALUE WORKING MODE PW AUTOMATIC rSQUEEZET 20 cycles SQUEEZE 30 eycles 8 3 08 cycles 20 OLD 1 00 cycles 00 cycles 12 60 10 00 cycles
14. 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 11 34 EXAMPLES OF WELDING PROGRAMS 4 TIMES SIMPLE CYCLE SHORT STROKE SINGLE CYCLE NUM
15. 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 This page is left blank intentionally 2 34 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 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 HANDLE WIRING DIAGRAM TE450 WIRING DIAGRAM 3 34 WELDING CONTROL UNIT TE 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 eff
16. LVE 1 It indicates that the solenoid valve executing the main cycle is ELETTROVALVOLA 1 activated SOLENOID VALVE 2 It indicates that the solenoid valve driving the double stroke is ELETTROVALVOLA 2 activated SIGNALS DESCRIPTION ON CONNECTORS CONNECTOR 51 12 PINS It is the control unit supply which must be 24 Vac The supply 5 7 VAC transformer must be of at least 13 VA and must supply only the control unit in order to avoid possible interferences 12 Earthing Connect to earth the output common line 2 Output for the trigger signal for the SCR The output is an impulses TRG train with a 5 Khz frequency 16 20 duty cycle 30 V amplitude on a COM 2 loading of 35 Q It is necessary to use the TECNA firing module for the SCR control ROG The current transducer rogowski ring must be connected to this COM 2 analog input The used transducer must have a 150 mV kA sensitivity with a load of 1 EV1 Connect to the solenoid valve acting the cycle Suitable for the control COM 2 of 24 Vac max 7 2 W coil TERM This input has been designed for connecting a normally closed COM 1 thermostat EV2 Connect to the solenoid valve driving the double stroke Suitable for COM 2 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 31 34 CONNECTOR XS2 6 PINS HANDLE Connect to the st
17. URRENT VARIATIONS REAL CURRENT VARIATIONS 1 WITH LINEAR STEPPER CURRENT NUMBER OF WELDING SPOTS 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 kK REAL CURRENT VARIATIONS WITH PROGRAMMED 4 INCREMENT CURVE NUMBER OF WELDING SPOTS 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 insert the correspondent increment expressed in percent in INCREMENT For the programming procedure refer to the relevant paragraph on the set up menu Example Welding tests have determined that the electrode life corresponds t
18. amage 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 Vdc 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 If the control unit does not switch on this protection fuse could have been activated 30 34 LAMPS ON THE CONTROL UNIT START If on it indicates that 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 RICHIAMO PRG 2 no 2 ADJUSTMENT 2 is activated If on this led indicates that the pressure only control device is activated This input is normally activated by the PRESSURE ONLY push button placed on the handle CURRENT Ay If on this led indicates that the control unit is generating the SCR CORRENTE trigger impulses SOLENOID VA
19. arameter 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 paragraph When the control is set to degree control mode
20. art of cycle device microswitch The input is active closed on the common COM 1 This input allows an external device to block the welding cycle during the 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 this operation the safety function against the accidental triggering is disabled 52 PROTECTION FUSE 51 N TE 450 2102 0000000000 0 32 34 NOILISOd NO 35012 NOILISOd 340 LYS HOLIMS 0123135 0 4
21. at 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 wnen 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 9 34 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 indicates either the current percent PW power per cent adjustment
22. e 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 Clear the 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 25 34 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 El for about a second By doing so the special functions are shown in sequence use push buttons and to select them Special functions TEPS INGREM POTS 8000 POTS 2 0 5000 INCREMENT 2 1 50 POTS 5000 POTS 4 5000 POTS 5 0 5000 INCREMENT 5 1 50 POTS 6 0 5000 INCREMENT 6 ixth segment percent increment 1 50 POTS 5000 INCREMENT 7 1 50 FIRST DELAY 190 BLOCK SPOTS Out of limits spots number before unit block 0 15 LANGUAGE TAENG CALIBRATION OFF ON The following paragraphs present the functions which can be set in the set up menu
23. elding spot has been carried out with a conduction angle value higher than the max set limit Error in the current measure ment during the welding process During the welding process the control unit has surveyed a current too high to be correctly measured No secondary current circulation during the last welding cycle 28 34 Clear the counter See paragraph WELDING COUNTER FUNCTION Press any push button to clear the error See the paragraph WELDING CURRENT AND CONDUCTION ANGLE LIMITS Press any push button to clear the error See the paragraph WELDING CURRENT AND CONDUCTION ANGLE LIMITS Press any push button to clear the error See the paragraph WELDING CURRENT AND CONDUCTION ANGLE LIMITS Press any push button to clear the error See the paragraph WELDING CURRENT AND CONDUCTION ANGLE LIMITS The control unit cannot correctly measure the welding current Address to the after sale service The control unit built in ammeter capacity is 36 kA Check that the supplied current is within this limit Address to the after sale service Check the continuity of the secondary circuit Check the electric connection of the current transducer CALIBRATION NO WELD ERROR CALIBRATION NO CURRENT ERROR CALIBRATION SAMPLING ERROR CALIBRATION CURRENT ERROR CALIBRATION CURRENT OVERFLOW CURRENT 1 HIGHER CURMAX CURRENT LIMIT HIGHER CURMAX CURMIN HIGHER CURMAX DEG MIN HIGHER DEG MAX
24. er 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 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 24 34 SELF C
25. et 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 El enables to select if either activate ON or deactivate OFF this function This function is automatically deactivated OFF value when the self calibration procedure is over provided it has been correctly carried out For additional information see the relevant paragraph 27 34 ERRORS MESSAGES STOP MAX SPOTS STOP LIMIT LOW CURRENT STOP LIMIT HIGH CURRENT STOP LIMIT LOW ANGLE STOP LIMIT HIGH ANGLE ALARM CURRENT ERROR WELD FAULTY OVERFLOW CURRENT NO SECONDARY CURRENT SIGNAL The welds counter has reached the maximum set value Out of limits spots The last welding spot has been carried out with a current value lower than the min set limit Out of limits spots The last welding spot has been carried out with a current value higher than the max set limit Out of limits spots The last welding spot has been carried out with a conduction angle value lower than the min set limit Out of limits spots The last w
26. hen the welder has been designed for this function e Stepper function to balance the electrodes wear out with adjustable curve e Welds counter Compensation of the secondary current to weld oxidized sheets and rods e 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 e Control of 2 solenoid valves 24 Vdc 7 2 W with protected output against short circuit electrode closing valve and double stroke valve Self adjustment to the mains frequency 50 60 Hz 4 34 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 TE 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 Prol 12455 104 08 0 12 3 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
27. icacy of the safety devices eventually installed on the handle of the machine The handle is not a standard 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 Synchronous thyristors drive with phase shift control for welding current adjustment 63 welding programs to be stored up 2 programs be recalled from the handle 18 programmable parameters for each program e Slope and pulse functions pre weld post weld functions e Welding times adjustment in half periods e Display of both welding current and connected conduction angle Double working mode standard and constant current e Either welding current or conductor angle limits Automatic double stroke function to be employed only w
28. ith conduction angle control mode CONTROL MODE DEG 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 15 34 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 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 1 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
29. ke 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 carried out Pre weld is carried out with a current adjustment equal to th
30. nction 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 MOBILE ELECTRODE POSITION WITH DISCONNECTED DOUBLE STROKE LONG STROKE B MOBILE ELECTRODE POSITION WITH OPERATING DOUBLE STROKE SHORT STROKE SHORT STROKE 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 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 contr
31. no 4 For each of the two adjustments the welding program to be used is selected when programming If the handle 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 start the programming push simultaneously the push buttons and M 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 5 34 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 and El 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 butto
32. ns 4 and F The parameters are marked either with a letter from A to C or a number from 1 to 18 The display shows the following data 1 2 3 t ADJ1 1 PRMO7 WELD 1 08 0 4 5 1 Selected adjustment ADJ1 ADJUSTMENT 1 ADJ2 ADJUSTMENT 2 2 Number of the selected program PRGO1 program number 1 3 Identification mark of the selected parameter 4 Name of the parameter 5 Value of the parameter The value of the welding parameters be adjusted by means of the push buttons and 5 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 RANGE VALUE WORKING MODE IK PW CONTROL MODE NO CURR DEG SQUEEZE 1 01 99 cycles SQUEEZE 01 99 cycles PRE WELD 00 0 99 5 cycles STROKE SHORT LONG AUTOMATIC PRE POWER 01 99 COLD 1 00 50 cycles SLOPE UP 00 25 cycles WELD 1 00 5 99 5 cycles POWER 1 10 99 CURRENT 1 2 0 36 0 kA CURR MIN 2 0 36 0 kA ANGLE MIN 001 180 CURR MAX 2 0 36 0 kA ANGLE MAX 001 180 6 34 N IMPULSE 00 09 There are some peculiar conditions e If OFF TIME 16 is set to zero the welding control unit will work in single cycle e If OFF TIME 16 is set to 99 the welding control unit will carry out the min current compensation with a value lower
33. o 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 17 8 1800 19 5 3000 20 2 4000 final electrode diameter 20 7 19 34 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 _ 100 100 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 100 100 4 initial current 19 5 final current initial current 20 8 20 2 Variation segment 4 _ x 100 100 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
34. 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 current 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
35. ol unit will move it to 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 stroke 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 22 34 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 OF F 0 It enables to carry out sequences of welding cycles with the short stroke but starting fr
36. om a long stroke working condition that which for instance is useful for positioning the welding gun on the piece to Shy 1 2 Ii On START the control unit activates the solenoid valve EV2 which shifts the electrode from A to 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 WELD WELD REST USE OF THE PRESSURE ONLY 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 ope
37. or the required current value expressed in kA IK constant current adjustment 9 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 10 34 14 POST POWER The value expressed in this parameter indicates the post welding power 15 HOLD TIME The p
38. rator 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 keeping 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 23 34 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 bett
39. s 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 450 enables to set the welding current min and max limits DEG 450 enables to set the and max limits of the welding current conduction angle For further information please read the relevant paragraph 8 34 C STROKE DOUBLE STROKE TE450 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 The SQUEEZE 1 time is used when working with the automatic double stro
40. 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 constant 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 16 34 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 decreases If the current is maintained at a fixed value throughout the whole electrode life it will be noticed that the last spots are
41. tion 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 angle displayed values are of course equal to zero 14 34 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 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 MODE on DEG Two new parameters
42. 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 the 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 17 34 The percent variation is calculated as follows final current initial current 19 15 Variation 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 5 SPOTS 1 Number of spots
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