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TECNA TE470 Instruction Manual

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WELDING CONTROL UNIT
INSTRUCTION MANUAL
TE470/TE480
FROM SOFTWARE RELEASE N° 2.21
ia Meucci, 27 - 40024 Castel S. Pietro Terme – Bologna ITALY
S.p.A.
V
Pho. +39.051.6954400 – Fax +39.051.6954490 – http://www.tecna.net
DOCUMENT
DISTRIBUTOR:
MAN 4162
NUMBER:
EDITION:
JULY 2011

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  • Page 1 WELDING CONTROL UNIT INSTRUCTION MANUAL TE470/TE480 FROM SOFTWARE RELEASE N° 2.21 ia Meucci, 27 - 40024 Castel S. Pietro Terme – Bologna ITALY S.p.A. Pho. +39.051.6954400 – Fax +39.051.6954490 – http://www.tecna.net DOCUMENT DISTRIBUTOR: MAN 4162 NUMBER: EDITION: JULY 2011...
  • Page 2 S.p.A. TE470/TE480 Instruction Manual This page intentionally left blank. The information contained in this document is subject to modification without notice. No part of this document can be either reproduced or transferred in whatever format neither by electronic nor by mechanic means for whatever purpose, without ’s written permission.

  • Page 3: Table Of Contents

    S.p.A. Instruction Manual TE470/TE480 TABLE OF CONTENTS CHAPTER 1 – THE TE470/TE480 WELD CONTROL UNIT ........... 5     1.1 – MAIN FEATURES..........................6   1.2 – COMMANDS ON THE PANEL......................7   1.3 – PANEL LEDs ............................7   1.4 – DESCRIPTION OF THE DISPLAYED INFORMATION ...............8  ...
  • Page 4 S.p.A. TE470/TE480 Instruction Manual   8.3 – FUNCTION OF THE THERMOSTAT OR FLOWSWITCH INPUT (OPTIONAL) ......39   8.4 - CYCLE END OUTPUT........................39 CHAPTER 9 – DOUBLE STROKE FUNCTION..............40   CHAPTER 10 – OPTIONS ..................... 42    ...

  • Page 5: Chapter 1 - The Te470/Te480 Weld Control Unit

    Each program consists of programmable parameters that describe the work cycle. In addition to the simple 4- stroke cycle, the control unit enables the execution of welds with pre-weld, post-weld, slope and pulse current. The TE470 can operate in conventional mode and constant current while the TE480 can work also in constant energy mode.

  • Page 6: Main Features

    S.p.A. TE470/TE480 Instruction Manual 1.1 – MAIN FEATURES Simplified programming by means of 5 push-buttons and LCD alphanumeric display.  Synchronous controlled diodes command, adjustment of the phase control current.  Possibility of connecting 2 handles.  Storage of 63 weld programmes, 2 called through the switch on the handle (or 4 through the commutator).

  • Page 7: Commands On The Panel

    S.p.A. Instruction Manual TE470/TE480 1.2 – COMMANDS ON THE PANEL Upward direction key used for moving the cursor inside the upper parameter. Downward direction key used for moving the cursor inside the lower parameter. This key is used for increasing the value of a numeric parameter or for changing the status of a parameter.

  • Page 8: Description Of The Displayed Information

    WELD mode, and for the cycles run in NO WELD mode. The values displayed in the following description are for reference only. This is what is displayed by the screen of the TE470 control unit: Pr01 12455 104°...
  • Page 9 S.p.A. Instruction Manual TE470/TE480 This is what the screen of the TE480 control unit (Constant Energy) displays: Where, to the above described information, is added: 6. 02500J Indicates the value of the total energy with which the last weld was performed. In WELD mode the value ranges from 00000 J to 99999 J.

  • Page 10: Control Unit Switch-On

    SUPPLY FREQUENCY TE470 REV. 2.21 WELD CONTROL After a few seconds, the TE470/TE480 is set in a waiting condition to carry out the welding process. Pr01 12455 104° 08.0 ~ 12.35 kA Before starting the programming phase, it is important to learn some fundamental features of the control unit.

  • Page 11: Chapter 2 - Control Unit Programming

    S.p.A. Instruction Manual TE470/TE480 CHAPTER 2 - CONTROL UNIT PROGRAMMING 2.1 – WELDING CYCLE PARAMETERS PROGRAMMING MENU Press buttons simultaneously for at least one second to program the welding cycle parameters. Once inside the menu, the control unit automatically exits from the programming procedure after 8 seconds of inactivity and allows the process to be run.

  • Page 12: Percentage Adjustment Operating Mode

    S.p.A. TE470/TE480 Instruction Manual 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. 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.
  • Page 13 2 sheets for example, limit conditions are with 1 or 3 sheets. The weld current is adjusted by control unit TE470/TE480. However, it is necessary to check the welding current value with one sheet so to be set as minimum limit and to check it with 3 sheets so to be set as maximum limit.

  • Page 14: Constant Current Operating Mode

    S.p.A. TE470/TE480 Instruction Manual 2.3 – CONSTANT CURRENT OPERATING MODE When the weld control unit works in constant current operating mode (parameter WORKING MODE selected in IK), the current value with which to perform the weld is set directly. During the weld, the control unit measures the weld current's real effective value (RMS) in every half-period and maintains the set current according to a mathematical correction algorithm.
  • Page 15 S.p.A. Instruction Manual TE470/TE480 TABLE CONSTANT CURRENT OPERATING MODE PARAMETERS ADJ1 PRG01 PRM A WORK MODE IK NUMBER PARAMETER DESCRIPTION VALUE RANGE WORKING MODE Working mode CONTROL MODE * Control unit mode NO - CURR - DEG STROKE Double stroke mode...

  • Page 16: Constant Energy Working Mode (Only In Te480)

    S.p.A. TE470/TE480 Instruction Manual 2.4 - CONSTANT ENERGY WORKING MODE (ONLY IN TE480) WORKING MODE parameter selected in ENE, the working frame is the following one: 01 08.0~ 08.00kA 02500J 104°12345 Adjustments are performed in the constant energy control unit (TE480) as in a conventional control unit except for the ENERGY parameter and the weld time parameter for which a precise value is not set, just the minimum and maximum value.
  • Page 17 S.p.A. Instruction Manual TE470/TE480 TABLE CONSTANT ENERGY OPERATING MODE PARAMETERS ADJ1 PRG01 PRM A WORKING MODE ENE NUMBER PARAMETER DESCRIPTION VALUE RANGE WORKING MODE Working mode CONTROL MODE * Control unit mode NO - CURR - DEG STROKE Double stroke mode...

  • Page 18: Description Of The Parameters

    There is no control on the supplied welding current. The TE470/TE480 enables to set the welding current min. and max. limits. The TE470/TE480 enables to set the min. and max. limits of the welding current conduction angle. For further information, please read the relevant paragraph.
  • Page 19 S.p.A. Instruction Manual TE470/TE480 PRM04 – POWER 1 The value expressed in the POWER 1 parameter indicates the power used to carry out the pre-weld. PRM05 – COLD 1 The COLD 1 time parameter indicates the time that elapses between the PRE-WELD and the WELD.
  • Page 20 In current control mode (CONTROL MODE = CUR), the CURR. MIN parameter fixes a minimum current limit value. For each weld performed, the TE470/TE480 checks that the current supplied by the welder is greater than the value set in this parameter. Otherwise an error occurs (see specific paragraph).
  • Page 21 S.p.A. Instruction Manual TE470/TE480 PRM21 – WELD MAX (only in TE480) The maximum weld time parameter (WELD MAX) is expressed in cycles and represents the welding duration maximum time. It is carried out with the same power value set at parameter POWER. Welding will stop also if the energy measured at the end of this period of time is below the programmed rating.

  • Page 22: Setup Menu

    S.p.A. TE470/TE480 Instruction Manual 2.6 - SETUP MENU This menu contains the parameters of certain special and configuration functions of the machine on which the control unit works. Keep in mind that only skilled personnel are permitted to edit the following parameters to prevent damage to people or equipment.
  • Page 23 For further information, please, check the relevant paragraph. HANDLE With this parameter, the user determines the number or type of handles connected on the TE470/TE480. There are 3 different choices: a handle was connected to connector XS10 with the switch for the external calling of 2 programmes.
  • Page 24 S.p.A. TE470/TE480 Instruction Manual LANGUAGE With this parameter the user programs the language in which the control unit should display both the parameters to be set and the error messages. The languages that may be selected are: ITALIAN – ENGLISH – SPANISH – GERMAN – FRENCH –...

  • Page 25: Current Stepper Function

    S.p.A. Instruction Manual TE470/TE480 2.7 – CURRENT STEPPER FUNCTION The stepper function enables to compensate the wear of the electrodes that affects the quality of the welding spots. When the electrode diameter is enlarged, the contact section area between the electrode and the work piece to be welded increases and, as a consequence, the welding current density (Ampere/mm2) decreases.
  • Page 26 The welding program must be first adjusted to carry out the first weld and then adjusted to obtain the necessary current with the electrodes' starting diameter: 15 kA. It does not matter if the TE470/TE480 is programmed to be adjusted in percentage or constant current since the stepper function works in both modes.
  • Page 27 S.p.A. Instruction Manual TE470/TE480 COMPLETE USE OF THE STEPPER MENU FUNCTION (NON-LINEAR INCREMENT CURVE) It is possible to use the non-linear increment curve function by knowing the real electrodes consumption only. In the aforesaid work method, a linear welding current increment is used during the whole life span of the electrodes.
  • Page 28 S.p.A. TE470/TE480 Instruction Manual Example: Welding tests have determined that the electrode life corresponds to 4000 welding spots, and that the following currents values are necessary at different moments of the electrodes life SPOTS PERFORMED REQUIRED CURRENT 15 kA 0 (initial electrodes diameter) 17.8 kA...
  • Page 29 At this point the operator replaces the electrodes (or resets their original diameter) and clears the spots counter, by means of the proper key, to clear stepper calculations. The TE470/TE480 resets the initial work parameters and begins a new increment phase. 29/52...

  • Page 30: Adjusting The First Insert Delay

    S.p.A. TE470/TE480 Instruction Manual 2.8 – ADJUSTING THE FIRST INSERT DELAY During the installation stage, it is compulsory to adjust the first insert delay to decrease absorption from the feed line and to decrease the power dissipated at the transformer primary circuit (risk of damaging the weld transformer permanently).

  • Page 31: Chapter 3 - The Work Cycle

    TE470/TE480 CHAPTER 3 – THE WORK CYCLE The user defines the work cycle to be carried out by the TE470/TE480 by adjusting the programming parameters. These parameters describe the operating times and the current adjustments that, in sequence, constitute the work cycle.

  • Page 32: Examples Of Work Programs

    S.p.A. TE470/TE480 Instruction Manual 3.1 – EXAMPLES OF WORK PROGRAMS 4 TIMES SIMPLE CYCLE, SHORT STROKE, SINGLE CYCLE NUMBER PARAMETER VALUE WORKING MODE CONTROL MODE STROKE SHORT SQUEEZE 1 10 cycles SQUEEZE 20 cycles PRE-WELD 00 cycles POWER 1 05 %...
  • Page 33 S.p.A. Instruction Manual TE470/TE480 CYCLE WITH PRE-WELD, SLOPE UP, AUTOMATIC STROKE, AUTOMATIC CYCLE NUMBER PARAMETER VALUE WORKING MODE CONTROL MODE STROKE AUTOMATIC SQUEEZE 1 20 cycles SQUEEZE 30 cycles PRE-WELD 08 cycles POWER 1 20 % COLD 1 10 cycles...

  • Page 34: Chapter 4 - Welding Current And Conduction Angle Measure

    S.p.A. TE470/TE480 Instruction Manual CHAPTER 4 - WELDING CURRENT AND CONDUCTION ANGLE MEASURE The following data are displayed after each weld: 1) Welding program used. 2) Number of welds carried out after the last counter reset. 3) Last weld current conduction angle.

  • Page 35: Chapter 5 - Stop Due To Spots Out Of Limit

    STOP SPOTS parameter, also enable the CONTROL MODE parameter in one of the control unit's allowed modes. The TE470/TE480 can work in one of the following control modes. 5.1 - WELDING CURRENT LIMITS Activate this mode by setting parameter PRM B - CONTROL MODE to CUR.

  • Page 36: Chapter 6 - Welds Counter Function

    S.p.A. TE470/TE480 Instruction Manual CHAPTER 6 – WELDS COUNTER FUNCTION A welds counter has been built into the control unit to count the welds carried out, with the possibility of programming the max limit. During the process, the counter's present value is displayed.

  • Page 37: Chapter 7 - Handles Description

    TE470/TE480 CHAPTER 7 - HANDLES DESCRIPTION Below are briefly described the characteristics of the handles that the TE470/TE480 can manage and be fitted with. Set the HANDLE parameter inside the SETUP MENU by indicating the number or type of handle that is connected to the control unit.

  • Page 38: Chapter 8 - Inputs And Outputs Operation

    Instruction Manual CHAPTER 8 – INPUTS AND OUTPUTS OPERATION Below are described the functions relative to the input and output signals on the TE470/TE480 control unit. 8.1 – FUNCTION OF THE "PRESSURE ONLY" COMMAND ("AUX" INPUT) Usually the PRESSURE ONLY command (AUX input) is used to check, before carrying out a weld, that the electrodes are properly positioned.

  • Page 39: Function Of The Thermostat Or Flowswitch Input (Optional)

    S.p.A. Instruction Manual TE470/TE480 8.3 – FUNCTION OF THE THERMOSTAT OR FLOWSWITCH INPUT (OPTIONAL) 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...

  • Page 40: Chapter 9 - Double Stroke Function

    "B" when the first weld is carried out. During this first weld, the TE470/TE480 activates solenoid valve EV2 (that brings the electrode from position "A" to position "B"), waits a fixed time of 0.6 seconds and then carries out the programmed weld cycle. At the end of the welding, solenoid valve EV2 does not deactivate and the electrode remains in position "B".
  • Page 41 S.p.A. Instruction Manual TE470/TE480 AUTOMATIC By programming the value of the STROKE parameter to AUTOMATIC, the operator adjusts the control unit for the automatic stroke. This mode is used during the automatic cycle mode (PAUSE parameter other than 0). It allows carrying out consecutive welding cycles with the short stroke but starting from a long stroke work condition, useful, for example, for inserting the welding gripper in the workpiece to be welded.

  • Page 42: Chapter 10 - Options

    S.p.A. TE470/TE480 Instruction Manual CHAPTER 10 – OPTIONS 10.1 - RS-485 SERIAL INTERFACE Should you will need a network connection, please contact for technical support. The RS-485 serial expansion card allows the control unit to be networked to other weld control units and to a central personal computer to program the control unit or to document production data.

  • Page 43: Interface For Proportional Valve

    S.p.A. Instruction Manual TE470/TE480 10.2 – INTERFACE FOR PROPORTIONAL VALVE This interface card, code 50220, permits the control unit to control a proportional valve and set the welding pressure in bars as one of the program's parameters. This interface requires external power supply. The 12-pole terminal strip permits the connection of the proportional valve, the control unit and the interface power supply.

  • Page 44: Chapter 11 - Description Of The Signals On The Terminal Strip

    COM1. This indicates to the control unit that it must not carry COM1 out the double stroke function. If the OPEN input is closed on powering-on the TE470, the double stroke function is DEACTIVATED. Connect it to the microswitch of the device that starts the weld cycle of the first START NC handle.
  • Page 45 The built-in ammeter is calibration-free. In any case, its working efficiency should be checked by comparing the measurement of the TE470/TE480 with that of another instrument. The built-in ammeter measures the current's real effective value (RMS) (see chapter "WELDING CURRENT AND CONDUCTION ANGLE MEASURE"). The instrument used for comparison should be able to perform the same type of measurement.
  • Page 46 S.p.A. TE470/TE480 Instruction Manual NOTES: If the control unit does not turn on, check that the 24Vac power supply is present at Pins 5-7 of connector XS1). If power supply is present, check the state of the control unit fuses. The components marked "F2" and "F3", located on the connectors side, are delayed fuses that cannot be restored and that can withstand a max current of 4 A each ("LITTELFUSE"...

  • Page 47: Chapter 12 - List Of Messages

    The control unit is entering default MEMORY RESET values into its programs memory. When powered-on, the control unit TE470 REV. 2.21 display shows the type of control unit WELD CONTROL and software version. One of the solenoid valve outputs is...
  • Page 48 S.p.A. TE470/TE480 Instruction Manual A certain number of welds were Reset the error by pressing any performed outside the set limits. The button. STOP LIMIT last weld was performed with a HIGH CURRENT current value higher than the max set limit.

  • Page 49: Chapter 13 - Technical Specifications

    S.p.A. Instruction Manual TE470/TE480 CHAPTER 13 – TECHNICAL SPECIFICATIONS POWER SUPPLY: 24VAC +/- 10% FREQUENCY: 50/60Hz +/- 1% CONSUMPTION: 0.25A WITHOUT LOAD/ < 1A WITH COMPLETE LOADS MAX ALTITUDE: 1000m RELATIVE HUMIDITY: from 40% to 80% WORK TEMPERATURE: 0°C to 50°C / 32°F to 122°F WEIGHT: 358g / 0.78925 lb...
  • Page 50 S.p.A. TE470/TE480 Instruction Manual NOTES 50/52...
  • Page 51 S.p.A. Instruction Manual TE470/TE480 NOTES 51/52...
  • Page 52 S.p.A. Via Meucci, 27 - 40024 Castel S. Pietro Terme – Bologna ITALY Pho. +39.051.6954400 Tel. 051.6954410 – Fax +39.051.6954490 E-mail:sales@tecna.net - vendite@tecna.net - http://www.tecna.net...

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