TECNA TE 500 User Manual

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TABLE OF CONTENTS

TOPICS PAGE

TE500 WELDING CONTROL UNIT 5
MAIN FEATURES 5
CONTROL UNIT SWITCH-ON 6
CONTROL UNIT PROGRAMMING 7
DESCRIPTION OF THE PARAMETERS 9
CONFIGURATION MENU 13
STEPPER MENU 15
CURRENT STEPPER OPERATING MODE 16
INSTALLATION MENU 21
PROGRAM COPY MENU 23
PROGRAM SEQUENCE MENU 24
PROGRAM SEQUENCE EXAMPLE 26
CHECK INPUT MENU 28
PANEL LEDs 29
COMMANDS ON THE PANEL 30
SELF-CALIBRATION PROCEDURE 31
SELECTION OF THE WORK PROGRAM 32
WORK MODES 33
CONSTANT CURRENT OPERATING MODE 34
DESCRIPTION OF THE WORK CYCLE 35
MEASUREMENT OF THE WELDING CURRENT AND THE CONDUCTION ANGLE 36
WELDING ANALYSIS 37
WELDING CURRENT AND CONDUCTION ANGLE LIMITS 38
COMPENSATION OF THE SECONDARY CURRENT 39
WELDING SPOTS COUNTER FUNCTION 39
SERIAL INTERFACE RS-232 ITEM 50214 (Option) 40
SERIAL INTERFACE RS-485 ITEM 50209 (Option) 42
INTERFACE FOR PROPORTIONAL VALVE ITEM 50220 (Option) 43
INTERFACING WITH AUTOMATIC SYSTEMS 44
DOUBLE STROKE FUNCTION 45
DESCRIPTION OF SIGNALS ON TERMINAL BOARD 46
MESSAGES LIST 48
FIRST INSERTION DELAY ADJUSTMENT 51

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WELDING CONTROL UNIT TE 500

The TE 500 is a microprocessor-based welding control unit for resistance welders. The task of the
welding control unit is to manage the welder components, in particular the controlled diodes that carry
out the welding current control.
It is possible to store up to 63 different welding programs, 31 of which are recalled directly from an
external device. Each program comprises 18 programmable parameters that describe the work cycle.
In addition to the plain 4-stage welding cycle, the control unit allows the running of welding processes
with pre-welding current, post-welding current, slope and pulses.

2

1

2

3

4

MADE IN ITALY

MAIN TECHNICAL DATA

• Simplified programming via 6 keys and a backlit alphanumeric LCD.

• Synchronous control with controlled diodes, phase control current adjustment.

• Storage of 63 welding programs, 31 recallable from the outside.

• 26 programmable parameters for each program.

• Slope, pulses, pre-weld, post-weld functions and adjustment of the welding times in half-periods.

• Display of the RMS welding current measurement in kA and relative angle of conduction.

• Dual operating mode: standard and constant current.

• Welding current or angle of conduction limits.

• Double stroke function.

• Stepper function to compensate the electrodes wear with programmable curve.

• Counter for the performed welding spots.

• Compensation function of the secondary current for welding oxidized sheets and rods.

• Single and automatic cycle. WELD and NO-WELD function.

• Adjustment of first insertion delay.

• Control of 4 solenoid valves 24 Vdc max. 5 W with self-protected output.

• Auto-regulation at mains frequency 50/60 Hz.

• Serial data transmission by means of opto-isolated RS232 or RS485 ports.

• Output for optional proportional solenoid valve.

• Key for selecting foot control or two-hand control.

• Selectable languages: Italian, English, French, German and Spanish.

• Possibility of upgrading control unit Firmware via appropriate software.

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CONTROL UNIT SWITCH-ON

As soon as the welding control unit is turned on, the display shows the primary mains frequency and the
software version of the program.

SUPPLY FREQUENCY

50 Hz.

TECNA TE500 2.31

WELD CONTROL UNIT

After a few seconds, the TE500 is set to a waiting condition until the Restart key is pressed.
This key enables the control unit’s commands and outputs.

009

PUSH KEY[//]

RESTART TO CONTINUE

It must be pressed every time the control unit is powered. When the key is pressed all the devices
connected to the VAUX are powered, such as for example, any double stroke valves.

k

Before starting any welding operations, first program the welding data and set some general operating
parameters of the welder.

Before pressing the key it is important to check that it will not cause
injury/damage to people or equipment.

6 / 52

CONTROL UNIT PROGRAMMING

To begin the programming operations, turn the key in the PROG position and be aware of some of the
fundamental features of the control unit.

TE500 VER. 2.31
> PROGRAM DATA
SETUP MENU

STEPPER MENU

The programming parameters of the control unit are divided into different menus as shown in the
drawing above:

_ PROGRAMMING
_ CONFIGURATION
_ STEPPER
_ INSTALLATION
_ PROGRAM COPYING
_ INPUT CHECK
_ PROGRAM SEQUENCES

Arrow ">" on the left-hand side of the display indicates the cursor’s position.
Use keys d and f to move the cursor up and down whereas keys h and g are used for entering and
exiting from the menu selected by the cursor.
Use keys a and s to set the value of the parameter indicated by the cursor.

PROGRAMMING MENU

The "Programming" menu contains all the parameters associated with the welding cycle, the times and
the currents by means of which to carry out the welding process.

PROGRAM DATA
> PROGRAM NUMBER 01
WORK MODE IK
CONTROL MODE CUR

The first choice to make is the number of the program to be used. Choose among the 63 storable
programs using the a and s keys.
Then proceed with the next parameters moving with the d and f keys, adjusting the desired value
always using the a and s keys.

As such all the parameters will be set to the desired value for carrying out the welding process. Keep in
mind that there is no need to confirm the set data item that is stored automatically after the adjustment.
Parameters can have several values, according to the type of parameter. The minimum and maximum
limits of each parameter are shown in the following table.

7 / 52

WORK PROGRAM PARAMETERS TABLE

WORK MODE WORK MODE IK - PW%-FIX
CONTROL MODE CONTROL MODE NO - CURR - DEG

PARAMETER DESCRIPTION VALUE RANGE

1 SQUEEZE 1 1s1 SQUEEZE TIME 01 - 99 cycles
2 SQUEEZE SQUEEZE TIME 00 - 99 cycles
3 PRESSURE WELDING PRESSURE 00 - 99 cycles
4 FORGE DELAY FORGING TIME 00 - 99 cycles
5 PRE-WELD PRE-WELD TIME 00.0 - 99.5 cycles
6 PRE-POWER PRE-WELD CURRENT 05 - 99%
7 COLD I COLD 1 TIME 00 - 50 cycles
8 SLOPE UP SLOPE UP TIME 00 - 25 cycles
9 WELD 1 WELDING TIME 00.5 - 99.5 cycles

POWER 1

10

CURRENT 1
11 COLD 2 COLD 2 TIME 01 - 50 cycles
12 N. IMPULSE NUMBER OF IMPULSES 00 - 09
13 SLOPE DOWN SLOPE DOWN TIME 00 - 25 cycles
14 COLD 3 COLD 3 TIME 00 - 50 cycles
15 POST-WELD POST-WELD TIME 00.0 - 99.5 cycles
16 POST-POWER POST-WELD CURRENT 05 - 99%
17 HOLD TIME HOLD TIME 01 - 99 cycles
18 OFF TIME DWELL TIME 00 - 99 cycles

WELDING CURRENT

5 - 99%

1.0 - 90.0 kA

If CONTROL MODE is activated it will be possible to have additional parameters, namely:

19 CURR MIN MIN LIMIT IN CURRENT 1.0 - 90.0 kA
20 CURR MAX. MAX. LIMIT IN CURRENT 1.0 - 90.0 kA

if the CONTROL MODE parameter is set to CURR, otherwise

21 ANGLE MIN MIN LIMIT IN DEGREES 001° - 180°
22 ANGLE MAX. MAX. LIMIT IN DEGREES 001° - 180°

if the parameter is set to DEG.
There are few special conditions:

• If OFF TIME is set to (0), the welding control unit will work in single cycle.

• If OFF TIME is set to (99), the welding control unit will carry out the min. current compensation with a

value lower than 2.0 kA (see paragraph "COMPENSATION OF THE SECONDARY CURRENT")

• By setting the PRE-WELD parameter to zero, the pre-weld is not carried out.

• By setting the POST-WELD parameter to zero, the post-weld is not carried out.

8 / 52

DESCRIPTION OF THE PARAMETERS

All the following parameters that indicate times are expressed in periods, also called mains cycles. The
mains frequency defines the duration of a period.

Mains frequency of 50 Hz 1 period = 20 ms
Mains frequency of 60 Hz 1 period = 16.6 ms

WORK MODE

The WORK MODE parameter defines the mode for adjusting the welding current of the program: either
power percent (PW%), constant current (IK) or fixed (FIX). Welding time WELD 1 is carried out
according to the adjustment mode set in this parameter. PRE-WELD and POST-WELD times are
always run with the power percent or fixed adjustment.

CONTROL MODE

The CONTROL MODE parameter permits to select the control mode of the desired welding current.

NO No control is performed on the supplied welding current.
CUR TE500 permits to set the welding current min. and max. limits.
DEG TE500 permits to set the min. and max. limits of the welding current conduction angle.

For further information, please read the relevant paragraph.

SQUEEZE 1

The 1st SQUEEZE time or first squeeze determines the time needed by the electrode to move down.
If a pneumatic circuit is present with low-pressure squeeze, such time is that which determines the
duration of the squeeze at low pressure, i.e. the interval of time that elapses from the beginning of the
head descent to the application of the welding force. The set value must be long enough to allow the
electrodes to reach the workpiece to be welded.
In a standard pneumatic circuit, such time is the interval from the beginning of the head descent to the
beginning of the welding. The set value must be long enough to allow the electrodes to achieve the
proper clamping force, before the welding begins.
During the first squeeze time, it is possible to end the cycle if the start cycle signal is deactivated.

SQUEEZE Optional

The SQUEEZE time is a wait time like that of the 1st SQUEEZE. It is necessary for welding machines
with low-pressure squeeze functions. In this case, such time determines the interval from the
application of the welding force onto the electrodes (energizing of the SV2 valve) to the beginning of the
welding. It should be long enough to allow the electrodes to achieve the proper clamping force before
the welding begins. An inadequate adjustment of such time produces sparks among the electrodes and
the sheet when the welding begins, causing quality inconsistencies. If the welding machine does not
contemplate low-pressure squeeze, deactivate this parameter (see Installation Menu). Otherwise it will
be added to the 1
sequence is interrupted.

st

squeeze time. If the start cycle signal is deactivated, during the squeeze time, the

9 / 52

PRESSURE Optional

This parameter, expressed in bar, expresses the welding pressure value. The set value must be such
that it guarantees a proper clamping force during the welding cycle. An inadequate adjustment of such
value produces sparks between electrodes and sheet when the welding begins.

FORGE DELAY Optional

The FORGE DELAY parameter is used exclusively with pneumatic circuits that contemplate the forging
function. Such function permits to increase the electrode force during the welding cycle.
The parameter describes the time that elapses from the beginning of the welding process to the
application of the forging force onto the electrodes by means of solenoid valve SV3. If the value is set
to zero the forging function is disabled, valve SV3 will be activated at the beginning of the squeezing
phase.

PRE-WELD

The PRE-WELD parameter indicates the duration of a current flow that can be carried out before the
welding process so as to pre-heat the workpiece to be welded. This parameter is expressed by three
digits since it can be set with 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 equivalent to that indicated in the PRE­POWER parameter (PRE-WELD CURRENT).

PRE-POWER (PRE-WELD CURRENT)

The value expressed in this parameter indicates the power used for carrying out the pre-weld.

COLD 1

The COLD 1 parameter indicates the time that elapses from the pre-weld (PRE-WELD) to the weld
(WELD 1).
If the pre-weld is deactivated (that is, when PRE-WELD time = 0), this cooling time is not carried out.

SLOPE UP

The SLOPE UP parameter describes the time for attaining the programmed welding current value. The
starting value of this slope always corresponds to the minimum current, whereas the final value
corresponds to the current value set at parameter CURRENT 1 (WELDING CURRENT). The slope
inclination is automatically calculated by the microprocessor according to the set values. The SLOPE
UP time is added to the welding time (WELD 1).

WELD 1 (WELDING TIME)

The WELD 1 parameter indicates the welding current flow duration. It is carried out with the same
power value set at parameter CURRENT 1 (WELDING CURRENT). When the pulse operating mode is
activated, this parameter indicates the duration of each pulse. This parameter is expressed by three
digits since it can be adjusted with half-period precision.

10 / 52

CURRENT 1 (WELDING CURRENT)

The value indicated in CURRENT 1 shows the current adjustment used for carrying out the welding
process.
Depending on the adjustment mode selected by means of the WORK MODE parameter, this value
indicates either the current percent adjustment (PW%, power percent adjustment), or the required
welding current value expressed in kA (IK, constant current adjustment).

N. IMPULSE (NUMBER OF IMPULSES)

The N. IMPULSE parameter indicates the number of impulses used for carrying out the welding
process. The duration of each impulse corresponds to the time set in parameter WELD 1 (WELDING
TIME).

COLD 2 (COLD 2 TIME)

The COLD 2 parameter is used in the pulse operating mode; it indicates the time that elapses from a
welding impulse to the next one.

SLOPE DOWN

The SLOPE DOWN parameter is a welding time that is added at the end of the welding process: it
enables to decrease the welding current from the value set at CURRENT 1 down to the minimum value.
The slope inclination is automatically calculated by the microprocessor according to the set values. The
SLOPE DOWN time is always added to the welding time.

COLD 3 (COLD 3 TIME)

The COLD 3 parameter indicates the time that elapses from the welding process (WELD 1) to the post­weld (POST-WELD).

POST-WELD

The POST-WELD parameter indicates the duration of a current flow that can be carried out after the
welding time in order to enable a more gradual cooling of the welded workpiece. This parameter is
expressed by three digits since it can be adjusted with half-period precision. If this parameter is set to 0
the post-weld is not carried out. The post-weld is carried out with the current adjustment set in the
POST-POWER parameter.

POST-POWER

The value expressed in this parameter indicates the post-welding power.

HOLD TIME

The HOLD parameter indicates the time that elapses from the end of the welding process to the
opening of the electrodes. It allows a quicker cooling of the welding spot and prevents the spot from
being stimulated before being properly cooled.

OFF TIME (DWELL TIME)

The OFF TIME parameter indicates a welder wait time, namely the one that elapses from one welder
cycle to the next one when the welder is working in automatic cycle. When this value is set to zero, the
welder always works in single cycle; if it is set to another value, the welder will work in the automatic
cycle.
When the welder works in single cycle, the control unit carries out a single welding cycle each time it
receives a start cycle signal. When the welder 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).

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CURR MIN / ANGLE MIN (MINIMUM CURRENT LIMIT OR CONDUCTION ANGLE)

The meaning of this parameter depends on the control mode selected in the CONTROL MODE
parameter.

When the control unit is set to current control mode (CONTROL MODE=CUR), this parameter fixes a
minimum current value. For each weld, the TE500 monitors that the welding current supplied by the
welder is higher than the value set at this parameter; if it is lower, an error message will be displayed
(see the relevant paragraph).

When the control unit is set to degree control mode (CONTROL MODE=DEG), this parameter fixes a
minimum conduction angle value. For each weld, the TE500 monitors that the maximum welding
current conduction angle supplied by the welder is higher than the value set at this parameter; if it is
lower, an error message will be displayed (see the relevant paragraph).

If the CONTROL MODE parameter is set to NO (no control on the welding current), the parameter is not
displayed during the programming phase.

CURR MAX. / ANGLE MAX. (MAXIMUM CURRENT LIMIT OR CONDUCTION ANGLE)

This parameter expresses different data according to the control mode selected at the CONTROL
MODE parameter:

When the control unit is set to current control mode (CONTROL MODE=CUR), this parameter fixes a
maximum current value. For each weld, the TE500 monitors that the welding current supplied by the
welder is lower than the value set in this parameter; if it is higher, an error message will be displayed
(see the relevant paragraph).

When the control unit is set to degree control mode (CONTROL MODE=DEG), this parameter fixes a
maximum conduction angle value. For each weld, the TE500 monitors that the maximum welding
current conduction angle supplied by the welder is lower than the value set in this parameter; if it is
higher, an error message will be displayed (see the relevant angle).

If the CONTROL MODE parameter is set to NO (no control on the welding current), the parameter is not
displayed during the programming phase.é

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CONFIGURATION MENU

The "Configuration" menu contains those parameters that are used for enabling or disabling a function
of the control unit.

CONFIGURATION MENU PARAMETERS TABLE

START1 PRG Start cycle 1 program 00 - 63
START2 PRG Start cycle 2 program 01 - 63
PRINTER SPOT Welding spots print ALL - GOOD - BAD
STOP BAD SPOT Number of spots for out-of-limit stop 0 - 9
PROG SEQUENCE Program sequence activation ON - OFF
AMMETER CAP. Ammeter capacity 40 - 90 kA
CALIBRATION Self-calibration procedure ON - OFF
LANGUAGE Language for describing parameters ITA-ENG-SPA-DEU-FRE

---CONFIGURATION--­> START CYCLE1 10
START CYCLE2 06

SPOTS PRINT OFF

PARAMETER DESCRIPTION VALUE RANGE

START CYCLE 1

This parameter indicates the program number to be run when the cycle is activated from the start cycle
1 command. The value of the program also includes 0 which, if set, allows the control unit to work with
the program that is active in the setting.

START CYCLE 2

This parameter indicates the program number to be run when the cycle is activated from the start cycle
2 command.

SPOTS PRINT

With this parameter, if the serial port is setup for print (see "Installation" paragraph), the user can
choose which welding spots to be printed. It is possible to print all spots or only the spots whose
current value remains within the set limits or those with out-of-limits values.

OUT-OF-LIMITS SPOTS STOPPING FUNCTION

Parameter STOP SPOTS permits to program the control unit so that it stops when out-of-limits welding
spots are performed. 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 than the limits set in parameters CURR MIN and CURR MAX. To set the value
use keys a and s ; the value can be set from 0 to 9.
If the value is set to zero, this function is deactivated; in this case, the welder does not stop even in
case of "out-of-limits" welding spots.

PROGRAM SEQUENCE

The sequence type operation is activated with this parameter. If this parameter is set to ON, the menu
for setting the program sequences will appear in the list of the main menus.

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AMMETER CAPACITY

This parameter indicates the ammeter capacity of the control unit. Keep in mind that the capacity refers
to simple harmonic currents and as such overflow conditions might occur even with effective current
values lower than the nominal value of the carrying capacity and this depends on the sensitiveness of
the connected transducer.

CALIBRATION

Set this parameter to ON for starting the self-calibration procedure. For further information refer to the
relevant paragraph.

LANGUAGE

With this parameter the user programs the language in which the control unit should display both the
parameters to be set and the error messages.

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STEPPER MENU

The "Stepper" menu contains parameters associated with the current stepper operations.

--- STEPPER --­> NUM. INCREMENTS 01
SPOTS 1 4000

INCREMENT 1 12%

STEPPER MENU PARAMETERS TABLE

PARAMETER DESCRIPTION VALUE RANGE

TOTAL STEPS Number of incremental steps 01 - 07
SPOTS 1 Spots step 1 0 - 10000
INCREMENT-1 % Percent increment step 1 0 - 50
SPOTS 2 Spots step 2 0 - 5000
INCREMENT 2 % Percent increment step 2 0 - 50
SPOTS 3 Spots step 3 0 - 5000
INCREMENT 3 % Percent increment step 3 0 - 50
SPOTS 4 Spots step 4 0 - 5000
INCREMENT 4 % Percent increment step 4 0 - 50
SPOTS 5 Spots step 5 0 - 5000
INCREMENT 5 % Percent increment step 5 0 - 50
SPOTS 6 Spots step 6 0 - 5000
INCREMENT 6 % Percent increment step 6 0 - 50
SPOTS 7 Spots step 7 0 - 5000
INCREMENT 7 % Percent increment step 7 0 - 50

NUM. OF INCREMENTS

This parameter indicates how many segments are to be created for implementing the stepper curve.
Only the parameters that describe the desired function will be displayed in relation to the set value.

SPOTS 1,2,3,...

Each of these parameters indicates the number of spots of which the associated segment is composed.

INCREMENT 1,2,3,...

These parameters indicate the current stepper percent to be attained upon the completing of the spots
set in the associated segment.

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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 workpiece to be welded increases and, as a consequence, the welding current
density (Ampere/mm
electrode life, it will be noticed that the quality of the last spots is poorer than the first ones. The stepper
function is used for overcoming this problem. It gradually increases the current adjustment during the
welding process when the diameter of the electrodes increases: this enables to maintain a constant
current density.

This function is suitable especially when using the control unit in constant current mode.

Nevertheless, it also works when the control unit operates in percent adjustment mode, but it is
not active in FIX mode.

An increment curve is programmed to describe the pattern of the current during the electrodes' life.
This curve is described by one or more segments for each of which the number of welding spots and
the associated current increment in percent are programmed.

After it has been set, the current increment is applied to all the welding programs used.
The current or conduction angle limits, if used, increment by the same percent. The same holds true for

the pre-weld and post-weld current adjustments.

2

) decreases. If the current is maintained at a fixed value throughout the whole

If the set welding (or power) current values are changed during the process, the control unit takes them
into consideration and re-calculates the welding conditions.

If modifications are made to the programmed stepper curve, the control unit clears the counter and
therefore the starting diameter of the electrodes must be reset.

SIMPLIFIED USE OF THE STEPPER FUNCTION (LINEAR INCREMENT)
The stepper function can be used in a simplified manner by programming a simple percent increment

for a specific number of welding spots that are to be carried out with the same electrodes.
The user must know the service life of the electrodes in order to adjust these parameters. To do this
run some welding tests with new electrodes before they are replaced. Under these two conditions the
currents, required for carrying out the welding spots of the required quality, are assessed. The change
in percent is calculated and then it is set in the control unit.

The parameters that allow the carrying out of the stepper function are entered in the "Stepper" menu.
The instructions for programming these parameters are outlined in the relevant paragraph.

For the "simplified" use of the stepper function, always set parameter STEPS INCREM to 1 (since the
segment to be programmed is only one). Enter the number of welding spots to be carried out in
parameter SPOTS 1, i.e. the foreseen life span of the electrodes. Enter the percent increment to be
achieved in parameter INCREMENT 1.

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−=×−

A

Example:

After having run the welding tests, the result was that the usable life of the electrodes = 2000 welding
spots. Another fact that ensued was that the required current for new electrodes = 15 kA, whereas after
2000 welding spots the diameter increase of the electrodes requires a current of 19 kA.

Therefore calculate the change in percent as follows:

Change

rentinitialcurendcurrent

=

100% =×

rentinitialcur

15

1519

%26100

Consequently the following parameters are set in the "Stepper" menu:

PARAMETER DESCRIPTION VALUE

STEPS INCREM Number of segments for stepper function 1
SPOTS 1 First segment spots number 2000
INCREMENT1 First segment increment percent 26%

The welding program should be adjusted for carrying out the first welding spot followed by the
adjustment that permits to obtain the required current with the starting electrode diameter: 15 kA.

Now the welding process can begin. Current will vary conforming to the set increment rule. The graph
below shows its pattern.

INITIAL CURRENT = 15 kA
END CURRENT = 19 kA
INCREMENT PERCENT = 26 %
NUMBER OF WELDING SPOTS = 2000

CURRENT INCREMENT DURING PRODUCTION

20

18

16

14

12

10

8

6

4

WELDING CURRENT (k

2

0

0 500 1000 1500 2000

NUM BER OF WELDI NG SPOTS

Upon having completed all 2000 welding spots the TE500 stops the production cycle and displays the
following message:

22

------STOP-----­MAX. N. of SPOTS

At this point the operator replaces the electrodes (or resets their original diameter) and clears
the spots counter to clear stepper calculations. The TE500 resets the initial work parameters
and begins a new increment phase.

17 / 52

COMPLETE USE (NON-LINEAR INCREMENT CURVE)

In the aforesaid work method, a linear welding current increment is used during the whole life span of
the electrodes. In actual fact the increase of the contact section of the electrode on the sheet is not
linear but has a pattern that is similar to the one shown in the graph below.

IDEL PATTERN

CURRENT

REAL PATTERN

WITH LINEAR INCREMENT

NUMBER OF WELDING SPOTS

As such the use of the linear increment is an approximation which nonetheless permits to achieve good
results in most applications. However when the user wishes to achieve utmost constancy during work
conditions, a non-linear increment curve can be set that is described by defining a certain number of
segments.
This type of adjustment requires an adequate knowledge on how electrodes wear and on the
parameters required during their life. Consequently many welding spot tests are necessary for
assessing the work conditions in different moments of the electrodes' life.

IDEAL PATTERN

CURRENT

The increment curve is set by assessing a certain number of linear segments. The number of welding
spots and the desired increment are assessed for each segment.
The STEPS INCREM parameter determines the number of segments to be inserted in the increment
curve. Enter the number of welding spots that make up the segment in the “SPOTS n” parameters.
Enter the corresponding percent increment to be achieved in the “INCREMENT n” parameter.
The programming procedure is outlined in the "Stepper" menu paragraph.

REAL PATTERN

WITH SET INCREMENT

CURVE

NUMBER OF WELDING S P OT S

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−=×−

−=×−

−=×−

−=×−

Example:

After a number of welding tests, the ensuing life of the electrodes resulted to be 4000 welding spots and
the following current values are required during the different moments of the electrodes' life.

SPOTS PERFORMED REQUIRED 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

Therefore calculate the duration (in number of welding spots) and the percent increment of each
segment.
Keep in mind that the percent increment must always be calculated in relation to the beginning of the
segment being examined.

spots 700=0-700=1segment ofDuration

spots 1100=700-1800=2segment ofDuration

spots 1200=1800-3000=3segment ofDuration

spots 1000=3000-4000=4segment ofDuration

15

158.17
%19100

rentinitialcurendcurrent

segmentChange

=

1001 % =×

rentinitialcur

rentinitialcurendcurrent

segmentChange

=

1002 % =×

rentinitialcur

rentinitialcurendcurrent

segmentChange

=

1003 % =×

rentinitialcur

rentinitialcurenecurrent

segmentChange

=

1004 % =×

rentinitialcur

The following parameters are consequently set in the "Stepper" menu:

PARAMETER DESCRIPTION VALUE

TOTAL STEPS Number of segments per stepper function 4
SPOTS 1 Number of spots of the first segment 700
INCREMENT1 Increment percent of first segment 19%
SPOTS 2 Number of spots of the second segment 1100
INCREMENT2 Increment percent of second segment 10%
SPOTS 3 Number of spots of the third segment 1200
INCREMENT3 Increment percent of third segment 4%
SPOTS 4 Number of spots of the fourth segment 1000
INCREMENT4 Increment percent of fourth segment 3%

8.175.19

8.17

5.192.20

5.19

2.208.20

2.20

%10100

%4100

%3100

19 / 52

)

The welding program should be adjusted for carrying out the first welding spot followed by the
adjustment that allows the achieving of the required current with the starting diameter of the electrodes:
15 kA.

Now the welding process can begin. Current will change according to the programmed increment rule.
The graph below shows its pattern.

22

20.2 kA

20.7 kA

SEGMENT 4

SEGMENT 3

1800

3000

40003000200010000

21
20
19

17.8 kA

18
17

16

CURRENT (kA

15
14
13

19.5 kA

SEGMENT 2

SEGMENT 1

700

NUMBER OF WELDING SPOTS

20 / 52

INSTALLATION MENU

The installation menu contains the parameters that determine the complexity and typology of the welder
at which the control unit is working. Therefore, due to their importance, the access to this menu is
protected by a code.

035

ENTER ACCESS CODE

* * * *

If the user is not authorized and consequently does not know the access code, the following message is
displayed:

036

ACCESS CODE ERROR

ACCESS DENIED !!

The parameters can be edited only after having typed in the access code.

k

Keep in mind that only skilled personnel are permitted to edit the
following parameters to prevent damage to people or equipment.

PARAMETER DESCRIPTION VALUE RANGE

FIRST INSERT. 1
SERIAL COM. Serial communication PRT/232 - NET/485 - NONE
NETWORK ADDRESS Network address 01 - 32
COIL RATIO Rogowski ratio X1 - X5 - X10
LOCK/END OUT Output function END - LOCK
FUNCTION REC. Recall function 5 RIC5 - ODD - EVEN
LOW FORCE SQ. Low force squeeze ON - OFF
FORGE Forging ON - OFF
PROPORT. VALVE Proportional valve ON - OFF
PRESSURE RATIO Pressure transducer for proportional 0.1 - 2.0

st

Insertion delay 01 - 99

FIRST INSERTION DELAY FUNCTION

The FIRST INSERTION parameter shows the first insertion delay. This function permits to optimize the
balance of the mains consumption of the welder. After having selected this parameter, the value can be
adjusted from 1 to 99 with keys a and s . For more information refer to the specific chapter.

SERIAL COMM.

The user may choose whether to activate the serial data transmission port and how it is to be used,
connect a printer (PRT/232) or connect the control unit to a data supervision network (NET/485), or not
use this option (NONE).

NETWORK ADDRESS

This parameter indicates the identifying address of the control unit when connected in the network,
activating the aforesaid option.

21 / 52

COIL RATIO

This parameter shows the sensitivity of the current transducer installed on the welder.

OPTIONS SIGNAL RATIO AMMETER CAPACITY

X1 150 mV / kA 40 - 90 kA
X5 750 mV / kA 8 - 18 kA

X10 1.5 V / kA 4 - 9 kA

LOCK/END OUT

This parameter indicates, interlock (LOCK) or cycle end (END), the activation time of the corresponding
output.

RECALL 5 FUNCTION

This parameter indicates the function associated to the Recall 5 input.
_ Input for the direct recalling of the work program up to 31 (REC 5).
_ EVEN parity test input for the other recalls.
_ ODD parity test input for the other recalls.

LOW FORCE SQUEEZE

This parameter is activated for welders that envisage the low-pressure squeeze function. Its enabling
adds the Squeeze parameter to the welding program.

FORGE FUNCTION

This parameter is used for enabling the forging for pneumatic circuit welders that envisage this function.
Its enabling adds the Forge Delay parameter to the work program.

PROPORTIONAL VALVE

This parameter is used for welders that envisage the use of a proportional valve and the parameter that
is activated in the program is the Pressure parameter.

PRESSURE TRANSDUCER

With this parameter it is possible to select, if the above parameter is activated, the most suitable BAR/
VOLT ratio for the type of solenoid valve the user intends using.

22 / 52

PROGRAM COPY MENU

The "Program copy" menu is used for copying the values of the parameters of a program to other
programs without having to set one parameter at a time.

-- PROGRAMS COPY -­> SOURCE PROGRAM 03
FROM PROGRAM 06

TO PROGRAM 10

PROGRAM COPY MENU PARAMETERS TABLE

PARAMETER DESCRIPTION VALUE RANGE

SOURCE PROGRAM Source program 01 - 63
FROM PROGRAM Program start copy/target 01 - 63
TO PROGRAM Copy end program 00 - 63

SOURCE PROGRAM

This program indicates the number of the program to be copied to other programs. The value of this
parameter may vary from 01 to 63.

COPY FROM PROGRAM

This program indicates the first program into which the source program is copied in the case of a multi­program copying operation. If it concerns an individual copying, it represents the target program to
which the source program is to be copied. The value of this parameter may vary from 01 to 63.

TO PROGRAM

This program indicates the last program into which to copy the source program. The value of this
parameter may vary from 00 to 63. Programmed value 00 indicates that the source program will be
copied to the target program only.

To copy programs access the copy menu from the main menu using key g , set the desired values in
the aforesaid parameters and then press key h .

Now the confirmation message of the copying action is displayed:

Press key a to copy, conforming to the parameters displayed in the video page shown above. The
operation is completed when the last line of the display is filled and the control unit shows the main
programming video page. If any other key is pressed or if you wait a few seconds, the operation will not
be carried out and the main programming video page is returned to.

COPY PROGRAM <03>
FROM <06> TO <10> ?
PRESS KEY[+]=OK

❙ ❙ ❙ ❙ ❙ ❙ ❙ ❙ ❙ ❙

23 / 52

❙

PROGRAM SEQUENCE MENU

This menu includes the parameters required for activating the program sequence operations. In this
work mode the weld control unit commands the welder to perform a series of spots, deciding
automatically the work program for each spot and the spots order without having to make an external
selection of the program.

This menu is not always active in the main programming menu. It is activated by setting the parameter
of the Setup to ON.

PROG SEQUENCE

Program sequence activation

ON

When this menu is activated it can be accessed with key g and the parameters shown in the figure can
be set.

- PROGRAM SEQUENCES­> NUM. STEPS 02
PROG. STEP 1 03

WELD STEP 1 07

PROGRAM SEQUENCE MENU PARAMETERS TABLE

PARAMETER DESCRIPTION VALUE RANGE

NUMBER SEQUENCES Number of sequences 01 - 05
STEP 1 PRG. Program of step 1 01 - 63
STEP 1 WELDS Number of welds with step 2 00 - 20
STEP 2 PRG. Program of step 2 01 - 63
STEP 2 WELDS Number of welds with step 1 00 - 20
STEP 3 PRG. Program of step 3 01 - 63
STEP 3 WELDS Number of welds with step 3 00 - 20
STEP 4 PRG. Program of step 4 01 - 63
STEP 4 WELDS Number of welds with step 4 00 - 20
STEP 5 PRG. Program of step 5 01 - 63
STEP 5 WELDS Number of welds with step 5 00 - 20

N. STEPS

The value of this parameter indicates the number of steps, i.e. the number of spot sequences with
different work programs.

STEP PROG. 1,2,3,...

This program indicates the program number that the welder must carry out and is matched to the
associated step number.

WELDS STEP 1,2,3,...

The value of this parameter indicates the number of welds to be carried out with the program matched
to the same step.

After having activated this mode and having set the parameters of the "Program sequences" menu as
described above, the welding spots can be started. With the key in RUN position, the display shows the
sequence data as shown in the figure below.

24 / 52

WELD 008 OF 013
STEP 03 OF 04
PROG. 03 RMS 10.45
NEXT WELD 009

Information on the display indicates the following:
$ Line 1. The succeeding number of the last weld performed and the total number of welds of which
this sequence is composed.
$ Line 2. The number of the step with which the last weld was performed and the total number of
steps.

$ Line 3. The program number and the RMS current value of the last weld.
$ Line 4. The progressive number of the next weld.

25 / 52

PROGRAM SEQUENCE MENU

Let's take for example the sequence operation after having set the following values in the parameters.

PARAMETER VALUE

NUMBER SEQUENCE 04
STEP 1 PRG. 03
STEP 1 WELDS 04
STEP 2 PRG. 07
STEP 2 WELDS 02
STEP 3 PRG. 11
STEP 3 WELDS 06
STEP 4 PRG. 04
STEP 4 WELDS 01

For each start cycle signal a spot is carried out with the weld program associated with the current step.
In this specific case, as shown in the chart below, the following welds are performed in sequence:

$ 4 welds with program 03
$ 2 welds with program 07
$ 6 welds with program 11
$ 1 weld with program 04

WELD 1 2 3 4 5 6 7 8 9 10 11 12 13
STEP 1 1 1 1 2 2 3 3 3 3 3 3 4

PROG 03 03 03 03 07 07 11 11 11 11 11 11 04

Usually this type of operation is applied to one manual welder where the operator always performs weld
spots in the same order but with different work parameters. By means of this system the operator does
not need to change the program manually which would cause his/her attention to be distracted from the
workpiece to be welded or does not have to change pedal or other start cycle device.
However the operator must pay utmost attention during the process not to perform fewer spots than
those programmed, overlapping spots or not in the same order.

26 / 52

In any case if a sequence process error is made, it is possible to repeat the last weld or another weld,
or continue by avoiding some spots. Always with the key in RUN position, use keys a to increase the
welds counter to the next spot or to the desired spot. Use key s to go back one or more positions of
the spots to be carried out.

Display data Display data after key

WELD 006 OF 013
STEP 02 OF 04
PROG. 07 RMS 06.15

NEXT WELD 007

WELD 013 OF 013
STEP 04 OF 04
PROG. 04 RMS 04.31

NEXT WELD 001

WELD 007 OF 013
STEP 03 OF 04
PROG. 11 RMS 06.15

NEXT WELD 008

WELD 012 OF 013
STEP 03 OF 04
PROG. 11 RMS 04.31

NEXT WELD 013

27 / 52

CHECK INPUT MENU

This menu displays the status of the welding control unit inputs. It is activated with the key in PROG
position and is used for checking the efficiency and proper operation of the external devices, connected
to the control unit, required for using the welder.

-- CHECK INPUT -­> START N.O. OFF
START N.O. ON
START2 N.O. OFF

All the inputs available at the connectors of the control unit are included in the list that is scrolled with
keys d and f
not active with wording OFF.

. The status of the inputs is shown as active (Input closed with COM1) with wording ON;

28 / 52

PANEL LEDs

1
2

3
4

The turning on of this LED indicates that the welder control unit is powered.

If this LED is switched on it indicates that start cycle 1 command is activated.

If this LED is switched on it indicates that start cycle 2 command is activated.

2

The turning on of this LED indicates that the pressure-only stopping command is
activated.

The turning on of this LED indicates that the control unit is producing the command
impulses for the SCR.

It indicates that the solenoid valve 1, which carries out the main cycle, is activated.

It indicates that the solenoid valve, which controls back pressure, is activated.
It indicates that the solenoid valve, which carries out the pressure or forging cycle, is

activated.
It indicates that the solenoid valve, which controls the double stroke, is activated.

29 / 52

COMMANDS ON THE PANEL

Left direction key used for exiting from the programming menu.

Right direction key used for accessing the programming menu.

Up direction key used for moving the cursor into the upper parameter.

Down direction key used for moving the cursor into the lower

parameter.

This key is used for increasing the value of a numeric parameter, or for

changing the status of a parameter.

This key is used for decreasing the value of a numeric parameter, or for

changing the status of a parameter.

RESTART key. It enables the commands and the control unit's outputs.

It must be pressed every time the control unit is powered. When this key
is pressed, all the devices connected to VAUX are powered such as for
example any double stroke valves. Before pressing the key it is
important to check that it will not cause injury/damage to people or
equipment.

Key for selecting the start cycle device: PEDAL or TWO-HAND

CONTROL. When the nearby LED is switched off, the start cycle
command is carried out by the PEDAL whereas if the LED is switched
on, the command is carried out by two-hand push buttons (TWO-HANDS
CONTROL). In order to work properly, the two push buttons must be
pressed at the same time or in sequence within a maximum time of 0.5
seconds conforming to the accident prevention regulations.

WELD-NO WELD Key. In WELD position (LED switched on) the control

unit runs the programmed welding cycle. In NO-WELD position (LED
switched off), the control unit runs the programmed cycle without welding
current circulation yet keeping all the time parameters unchanged.

CLEAR Key. It is used to clear the error conditions and for zeroing the

welds counter and during programming activities for zeroing the
parameters.

PROG-RUN Key selector. In PROG position (key turned to the 4-button

position) it enables the keyboard and allows the running of all the
foreseen programming operations. In RUN position it enables the spot
welder commands and allows the running of the work program only.

30 / 52

SELF-CALIBRATION PROCEDURE

This procedure allows the control unit to read the welder's characteristics and also to optimize the
current 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
permits to obtain the best adjustment precision.

Before carrying out this procedure, both the control unit and the welder must be set

k

The following operations are to be carried out in the following order:

1. Enter the setup menu, by turning the key to PROG position and selecting the SETUP item

2. Select the CALIBRATION parameter by means of keys d and f
and s .

3. Turn the key to RUN position to end the programming phase. At this point the display shows the
standard work data associated with the last spot performed.

4. Ensure that the WELD/NO WELD function is set to WELD (LED must be on).

5. Activate the start cycle device. The control unit displays the following message and carries out one
welding spot, which lasts for a few periods, with different current adjustments.

to standard work conditions. In this phase, a very short weld is carried out with high
welding currents; therefore the electrodes must have a proper diameter, and the
welder must be adjusted to an adequate electrode force.

A pressure of at least 4 bar is recommended. The self-calibration welding
procedure must be carried out in short-circuit.

; set it to ON by means of keys a

CALIBRATION

IN PROGRESS

When this procedure is completed, the control unit displays the maximum current value supplied and
the machine's cosn value.

CALIBRATION OK

Fi=34° 17kA

If error messages are displayed instead of the aforesaid message, proceed as follows:

$ Clear the error by pressing any key.
$ Eliminate the cause that triggered the error (see specific paragraph).

Activate the start cycle device again for repeating the self-calibration welding
procedure.

k

31 / 52

SELECTION OF THE WORK PROGRAM

The table below shows which inputs are to be activated to recall the work program directly. The
selection is made by means of five inputs, appropriately activated according to the combinations shown
below.

PROG. N. REC1 REC2 REC3 REC4 REC5

1 • •
2 • •
3 • • •
4 • •
5 • • •
6 • • •
7 • • • •
8 • •

9 • • •
10 • • •
11 • • • •
12 • • •
13 • • • •
14 • • • •
15 • • • •
16 •
17 • •
18 • •
19 • • •
20 • •
21 • • •
22 • • •
23 • • • •
24 • •
25 • • •
26 • • •
27 • • • •
28 • • •
29 • • • •
30 • • • •
31 • • • • •

REC5

EVEN

•

REC5

ODD

• = input active

The programs that can be selected are 31, when using input REC5 as additional recall input, or 15 if
using input REC5 as parity check. The use of input REC5 as parity check is activated in the
"Installation" Menu (see specific paragraph) in which the type of parity is also selected: Even or Odd.
The parity check consists in checking that the number of activated inputs, for recalling a program, is
even or odd.

Example:
Recall of Prog. N. 06 with even parity check.
To recall program 6 you must activate two inputs, REC2 and REC3, but since parity is odd you must
also activate input REC5 to obtain an odd number of active inputs.

To properly recall the welding programs, either activate the direct recall inputs before the start
cycle signal or simultaneously.

32 / 52

WORK MODES

The TE500 weld control unit permits to perform welds with different welding current supply and check
methods. The table below shows the different modes, the operations required for activating them and
the compatible functions.

Self-calibration procedure

Rogowski ring sensor
Stepper function NO YES YES

Program sequence function YES YES YES
CUR control mode YES YES YES
DEG control mode YES YES YES
Current compensation YES YES NO
Welding analysis YES YES YES
Proportional valve YES YES YES

Rogowski ratio All

FIX PW% IK

x

x x

Only the one with

which the Self-

z z

calibration is

performed

calibration is performed

z

Only the one with

which the Self-

Automatic mains
compensation

First insertion delay

Ammeter capacity All

NO NO YES

z z z

x = not compulsory

z = compulsory

Only the one

recommended in Self-

calibration

Only the one

recommended in Self-

calibration

33 / 52

CONSTANT CURRENT OPERATING MODE

TE500 allows the user 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 set the welding current value directly. During the welding process the control
unit measures, for each half-period, the true welding current RMS value and, based on a correcting
mathematical algorithm, keeps the set current.
In addition to simplifying the programming operations, this operating mode also permits to keep the
desired welding current even if some factors change such as: mains voltage, welding circuit dimensions
and impedance, condition of the welding tools, surface conditions of the materials being processed.

CONSTANT CURRENT BEHAVIOR READINGS

Welding current changes (I) according to the mains
voltage (V) variation under standard operating mode

Welding current changes (I) according to the mains
voltage (V) variation under constant current operating mode

The selection of the current adjustment mode is independent for each welding program and is set by
means of the 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.
TE500 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

34 / 52

DESCRIPTION OF THE WORK CYCLE

The TE500 work cycle is set by the user by adjusting the programming parameters. These parameters
indicate the operating times and the current adjustments characterizing the work cycle when carried out
consecutively.
The following chart shows the sequence in which the programmed functions are carried out.

The aforesaid numbers refer to the programming parameters described in the "Programming" Menu
paragraph.

For safety reasons, the microprocessor does not start the welding cycle if the

k

start cycle device is activated when switching on the welder; release it and
restart it.
Any microinterruptions or excessive voltage drops will stop the control unit
and do not alter the operation; to reset the operation, turn the machine off and
then turn it on again.

35 / 52

READING OF THE WELDING CURRENT AND THE CONDUCTION ANGLE

After every welding operation, the display shows the following information:

$ The welding program used.
$ The number of the welding spots carried out as of the last counter reset.
$ The current conduction angle of the last welding spot.
$ The set welding time.
$ The value of the current of the last welding spot.

PROG. 01 SPOT 12340
WELD CYCLE 01.0
CURRENT RMS 43.26
CONDUCTION DEG 142°

The value of the current, which the control unit measures and which is displayed, stands for the
average of the RMS values measured for every welding time half-period. The displayed value always
refers to the main adjustment i.e. to that of the WELD 1 parameter. For pulse welding spots the value
of the current will always be the average value of all the impulses.

The control unit also measures the welding current conduction angle. The conduction angle stands for
the time in which the current was carried during the half-period. The displayed value stands for the
average of the values measured for each welding time half-period.

The displayed value always refers to the main adjustment i.e. to that of the WELD 1 parameter. The
conduction angle of the current that circulated during the slope times is never measured. For pulse
welding spots the value of the angle is related to the last impulse the maximum value of which can be
180 degrees.

Example of currents with different conduction angles:

If a test welding stop is performed in "NO WELD" mode, the current and conduction angle values
displayed will be zero.

36 / 52

WELDING ANALYSIS

The welding pattern can be analyzed exhaustively by means of the welding check. It is possible to view
in detail the current values and the conduction degrees, read at each half-cycle of the main WELD1, the
values of any pre-welds and post-welds, and (if activated) the progress status of the stepper function.

To access these functions turn the key to RUN position, perform a weld and press key : to display the
first data video page. Then you may continue in the succeeding video pages as shown below.

Welding example with these parameters:

$ Pre-Weld Time 4 cycles
$ WELD1 Time 8 cycles
$ Post-Weld Time 0 cycles
$ Incremental step 1 (10000 spots / 18%)

PROG. 03 SPOTS 05148
WELD TIME 08.0
CURRENT 09.52 kA RMS

CONDUCTION DEG 110°



PROG. 03 SPOTS 05148
WELD CYCLE N. 02
POS+ 09.32 kA 106°
NEG- 09.40 kA 110°





PROG. 03 SPOTS 05148
PREW 068°|POSTW 000°

04.0 ~ | 00.0 ~

05.90 kA | 00.00 kA



PROG. 03 SPOTS 05148
WELD CYCLE N. 01
POS+ 08.92 kA 098°
NEG- 09.10 kA 103°



SPOTS MAX 10000
SPOTS 05148
INCREMENT 09% OF 18%

STEP NUMBER 1 OF 1









PROG. 03 SPOTS 05148
WELD CYCLE N. 08
POS+ 09.60 kA 110°
NEG- 09.56 kA 110°



37 / 52

WELDING CURRENT AND CONDUCTION ANGLE LIMITS

TE500 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 CONTROL MODE to CUR.
Two new parameters will be displayed:

CURR MIN minimum current limit
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 CONTROL MODE on DEG.
Two new parameters will be displayed:

ANGLE MIN minimum conduction angle limit
ANGLE MAX maximum conduction angle limit

These two parameters enable to set the welding current conduction angle limit-values.
When working, if the measured value of the welding current, or its conduction angle, is beyond the set

limits, the welding spot is considered as "out-of-limits".
If consecutive "out-of-limits" welding spots occur, 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 between 0 and 15. By setting it to 0, this function
is deactivated, so that the welding process is not blocked in case of "out-of-limits" welding spots.

Bear in mind that in 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

MINIMUM CURRENT

STOP LIMIT

MAXIMUM CURRENT

When working with 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

MIN. CONDUCTION

STOP LIMIT

MAX. CONDUCTION

38 / 52

COMPENSATION OF THE SECONDARY CURRENT

The secondary current compensation function is used for facilitating the welding process of oxidized
sheets and rods. The oxidation of the workpieces blocks the current flow during the first welding phase,
thus limiting, in a different way depending on the type of welding process, the real current flow time.
The compensation function controls the welding current, until the current exceeds a pre-set threshold
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 a constant real current flow time. Keep in mind that this
function should be used only in the event of welding conditions that cannot be overcome otherwise,
since it is not a system that assures welding quality.

This function is activated by setting the OFF TIME parameter value to 99; when this function is active,
the control unit works in single cycle. In constant current operating mode, this function is deactivated.

WELDING SPOTS COUNTER FUNCTION

The control unit contains a weld counter with the possibility of programming the maximum number of
welding spots. During the welding process, the control unit displays the value currently attained by the
counter. The counter is updated after each welding spot, with the only exception of welding tests
carried out in NO WELD.
To clear the counter press, in RUN mode, the CLEAR key. The display will show the following
message:

CLEAR COUNTER

SPOTS? [-]=YES

Press the MINUS (-) key to clear the counter otherwise wait 8 seconds to end the procedure without
clearing the counter.
The maximum welds number is set by following the same procedure described for the stepper function.
For example, if you want to carry out 2840 welding spots without using the stepper function, set the
following parameters in the setup menu:

PARAMETER DESCRIPTION VALUE

STEPS INCREM Number of segments for stepper function 1
SPOTS 1 Fist segment spots number 2840
INCREMENT 1 First segment increment percent 0%

When setting these parameters, the counter is automatically cleared.
When the counter attains the set number of welds, the control unit displays the following message:

-----STOP-----

N. MAX SPOTS

Welder operations are interrupted until the counter is cleared. If SPOTS 1 parameter is set to zero, the
stop function is deactivated.

39 / 52

SERIAL INTERFACE RS-232 ITEM 50214 (Option)

Use expansion card ITEM 50214 to connect the TE500 with a printer or a PC fitted with RS232 serial
interface to document production data.

The card interfaces with the control unit by means of a 6-pin connector and with the printer (or
computer) by means of a standard female 9-pole connector. The 9-pole connector is wired as follows:

PIN 1 CD (ALWAYS ON)
PIN 2
PIN 3
PIN 4 DTR (ALWAYS ON)
PIN 5 MASS (GROUND SIGNAL)
PIN 6 DSR (ALWAYS ON)
PIN 7 RTS
PIN 8 CTS
PIN 9 NOT CONNECTED

On request, cable Art. 70377 is available for the connection with standard serial printers that as a rule
are equipped with a female 25-pole connector as follows:

TRANSMISSION (TD)
RECEPTION (RD)

PIN1 GROUND (GROUND FRAME)
PIN2 TRANSMISSION (TD)
PIN3 RECEPTION (RD)
PIN 4 TRANSMISSION REQUEST (RTS)
PIN 5 READY AT START (CTS)
PIN 6 DATA READY (DSR)
PIN 7 MASS (GROUND SIGNAL)
PIN 20 TERMINAL READY (DTR)

The control unit does not execute any type of handshaking at the serial port. The serial port of the
printer must be configured with the following values:

SPEED 9600 BAUD
WORD LENGTH 7 BIT
PARITY EVEN
STOP BIT 1

The control unit runs the data transmission at the beginning of the OFF time. Keep in mind that the
time used for printing data is approximately 20 ms and such time will be added to the set OFF time.
A specific parameter in the special functions menu permits to choose whether or not to activate the
print. The following items are printed for each weld:

$ Welding program number
$ Number of cycles with which the weld was carried out
$ Welding current
$ Welding current conduction angle
$ Progressive spot number
$ Out-of-limit spot signal

When the control unit is powered, every time a programming value is edited and when the key selector
is switched from PROGRAM to RUN the control unit prints the header and the values of the parameters
of the selected program.

40 / 52

Data printout example during the weld:

PROG

01
01
01
01

CYCLES

10,0
10,0
10,0
10,0

CURRENT

06.0

06.0

06.0

06.0

DEGREE

061
061
061
061

SPOTS
00001
00002
00003
00004

LIMIT

Data printout example during the weld in CUR Control Mode:

PROG

01
01
01
01
01
01
01

CYCLES

10,0
10,0
10,0
10,0
10,0
10,0
10,0

CURRENT

06.0

06.0

06.0

06.0

06.0

06.0

06.0

DEGREE

062
062
062
062
062
062
062

SPOTS
00009
00010
00012
00013
00014
00015
00016

LIMIT
CUR OK
CUR OK
CUR MIN
CUR MIN
CUR MAX
CUR MAX
CUR MAX

Data printout example during the weld in DEG Control Mode:

PROG
01
01
01
01
01
01
01
01

CYCLES
10,0
10,0
10,0
10,0
10,0
10,0
10,0
10,0

CURRENT

06.0

06.0

06.0

06.0

06.0

06.0

06.0

06.0

DEGREE
062
062
062
062
062
062
062
062

SPOTS
00018
00019
00020
00021
00022
00023
00024
00025

LIMIT
DEG MIN
DEG MIN
DEG MIN
DEG OK
DEG OK
DEG MAX
DEG MAX
DEG MAX

Printout example of work program parameter values:

CONTROL UNIT
PROGRAM NUMBER
WORKING MODE
CONTROL MODE
SQUEEZE 1
SQUEEZE
FORGE DELAY
PRE-WELD
PRE-POWER
COLD 1
SLOPE UP
WELD
CURRENT
COLD 2
IMPULSE N.
SLOPE DOWN
COLD 3
POST-WELD
POST-POWER
HOLD TIME
OFF TIME
ANGLE MIN
ANGLE MAX

TE500
01
IK
DEG
20 ~
20 ~
10 ~

00.0~
05 %
00 ~
00 ~

10.0 ~

06.0 kA
00 ~
1
00 ~
00 ~

00.0 ~
05 %
20 ~
20 ~
053°
087°

41 / 52

SERIAL INTERFACE RS-485 ITEM 50209 (Option)

The RS-485 serial expansion card permits the control unit to be networked with other welding control
units and with a central PC for programming the control unit or for documenting production data. The
card interfaces with the control unit by means of a 6-pin connector and with the external network by
means of a standard male 9-pin connector with the following signals:

CONNECTIONS OF CONNECTOR DB9

1 Ground
2 Y
3 A
4 R1A
5 R2A
6 Z
7 B
8 R1B
9 R2B

The card can be connected only when the control unit is not powered. It is also advisable to first
connect the 6-pin wire, which connects the weld control unit, and then make the RS485 connection. At
this point the control unit can be powered and the NET/485 function can be activated in the
"Installation" menu.

In the network communication an identifying address must be assigned to the weld control unit (slave)
so that it can be recognized by a Master, for instance a Personal Computer. This parameter, called
NETWORK ADDRESS is set in the "Installation" menu.

A PC software program, called tecnaNet, is available for handling data and communication among the
networked control units for checking the network's structure, i.e. how many and which control units are
connected, for carrying out (for each control unit) all the programming functions remotely, and for
acquiring and storing production data.

TECHNICAL RECOMMENDATIONS

The interface is isolated up to 1500V, without the need for any external power supply, and works
connected to standard RS485 signals in half duplex or full duplex mode. The male 9-pin connector has
two screws with thread 4-40 UNC with threaded head. These screws are to be used for wall mounting
purposes (max. 3mm) and for locking the mobile connector. The 50209 item is fit with a black
protective cover for protecting it against dust and electrostatic charges. It is advisable to always keep it
on the connector when the interface is not used.

Some terminating resistances are present on the cards which should be connected only at the first and
last network connector. Furthermore it is essential that the ground be connected among all the devices
connected to the network.

The connection cable between the devices must not be longer than 1200m. It must be shielded and
have metallic or metallized connection connectors such as Belden 8777 cable at 24 AWG.

42 / 52

INTERFACE FOR PROPORTIONAL VALVE ITEM 50220 (Option)

Interface card ITEM 50220 permits the control unit to control a proportional valve and to set, as program
parameter, the welding pressure in bars. This interface requires an external power supply. The 12-pin
terminal strip permits the connection of the proportional valve, the control unit and the interface power
supply.

TERMINAL STRIP CONNECTIONS

64 SV+ from the control unit (PIN 46)
65 SV- from the control unit (PIN 45)
66 24Vac
67 24Vac
68 Ground
69 OUT-I
70 0-10Vdc to the proportional SV
71 +24Vdc to the proportional SV
72 Ground to the proportional SV
73 ALARM-IN
74 ALARM1 (PIN 33- AUX3)
75 ALARM2 (PIN 34- COM1)

It is possible to program the control voltage range of the proportional valve directly from the weld control
unit. The PRESSURE TRANSDUCER parameter is in the "Installation" menu by means of which it is
possible to select the bar/Volt ratio most suitable for the type of solenoid valve to be used.

Example:

Pressure Parameter bar Pressure Transducer Parameter bar/Volt Output Volt

5.0 1.0 5

5.0 2.0 10

5.0 0.5 2.5

WIRING DIAGRAM

TE500

Pin46

Pin45

Ev+

Ev-

64 70

ITEM 50220

65 71
66 67 68 72

0-10 V

+24 Vdc

Ground

PROPORTIONAL

VALVE

N.B.

_ A red D10 LED is present on card 50220 (near the relay) for indicating when +24VDC (Pin 71) is
present and which goes to the proportional valve. If the LED is OFF check for the correct 24VAC wiring
(Pin66 and Pin67) and ground wiring (Pin68);
_ Card 50220 also contains a small trimmer for regulating the voltage output full scale (Pin70). This
regulation is performed when the required tests are run and therefore MUST NOT be shifted from its
default position so that the value at output will always be exact.

24 Vac

Ground

24 Vac

43 / 52

INTERFACING WITH AUTOMATIC SYSTEMS

The TE500 weld control unit can be used in an automated welding system by exploiting a few signal
inputs and outputs, the activation of which identifies a precise welding process moment.

Inputs

$ Start. Start cycle command. To perform the weld it must be kept active at least until the LOCK
contact is activated.

$ Aux. This input locks the cycle in pressure only. If activated, it locks the welder with electrodes in
closed status during one of the squeeze times.

Outputs

$ SV1. Main solenoid valve output. It is activated after the Start and is deactivated at the end of the
HOLD TIME.

$ Wrong. Error signal for limits or power failure. Active for HOLD and PAUSE.
$ Lock. This output signals the beginning and the end of the current circulation during the cycle.
$ End cycle. This output signals the end of the cycle of one weld, for the pause time. During the

single cycle the signal closes at the end of the Hold time and reopens on issuing the cycle-start signal.
If the cycle-start signal had already been deactivated, the contact remains closed for 2 cycles (40ms).
If the control unit is used in automatic cycle mode (OFF pause time other than 0) the cycle will stay
closed for the entire OFF time.

44 / 52

DOUBLE STROKE FUNCTION

The output of the control unit called SV4 controls the double stroke solenoid valve.
When the machine is powered, it is always disabled even if the D_STROKE input is
active and the electrode is in position "A". The control unit sets it to position "B" when

During this first weld the TE500 activates solenoid valve EV4 (that shifts the electrode from position "A"
to position "B"), waits a fixed time of 0.6 seconds and performs the programmed weld cycle. At the end
of the weld, solenoid valve EV4 is not deactivated and the electrode remains in position "B". The
succeeding welds will be performed starting from this position. When input D_STROKE is activated,
solenoid valve EV4 is kept activated and the electrode, in rest status, will be in position "B". Should the
operator need to open the electrodes during the process, deactivate the input to trigger the deactivation
of solenoid valve EV4.

the first weld is performed as shown in the figure below.

WORK STROKE (SHORT)

AB

TOT AL STROKE (LONG)

45 / 52

DESCRIPTION OF SIGNALS ON TERMINAL BOARD

NAME MEANING CONNECTOR

VAC

GND
LOCK- / END-

LOCK+ / END+

WRONG­WRONG+

COM2
TRIGGER

COM1
RIC5/PARITY

RIC4
RIC3
RIC2
RIC1

This is the control unit's power supply, which must be 24 Vac. The
power supply transformer should be at least 50 VA and must supply the
control unit only, in order to avoid possible sources of interference.

Ground connection.
This output is a polarized opto-electronic switch Max. 30 V/ 10 mA, and

is used for signaling when a cycle ends if END CYCLE is selected;
when LOCK in selected, the control unit gives an output signal from the
beginning of the welding process to the hold.

This output is a polarized opto-electronic switch Max. 30 V/ 10 mA, that
closes if the set current limits are not respected. The contact remains
closed for the HOLD and OFF time. A max. voltage of 24Vdc and a
maximum current of 0.1A can be applied to this contact.

Output of the trigger signal for the SCRs. Output is an impulse train
with a 5 KHz frequency, duty cycle of 16-20%, 30V amplitude on a load
of 35 S2. It is necessary to use the TECNA firing modules.

This input, closed on COM1, can have two functions depending on the
choice made in the setup menu. The first function is external recall, the
second function is to control the parity during the recall.

These inputs are used to directly recall the welding program from an
external device. For a correct recall of the programs, these inputs
should be enabled before the start cycle signal. The inputs are active
when closed on the shared COM1.

1
3

2
4

5

6
7

9

10

11
12

13
14
15
16

COM1
START2_NO

AUX2

START_NC
COM1

START-NO

AUX

START_NC
BIC1_NO

Connect to the microswitches of the start cycle pedal. START2
determines the beginning of the work cycle of the second program
chosen during the programming operations. This input is active when
closed on the shared COM1.

This input allows an external device to stop the welding cycle during
the squeeze phase. It can be used as an interlocking input or for
connecting safety devices such as for instance flow regulators or
pressure switches. The contact connected to it should be the normally
open type and is activated when closed on COM1.

Not used.
Connect to the microswitches of the start cycle pedal. The START

determines the beginning of the work cycle. This input is active when
closed on the shared COM1.

This input allows an external device to stop the welding cycle during
the squeeze phase. It can be used as an interlocking input or for
connecting safety devices such as for instance flow regulators or
pressure switches. The contact connected to it should be the normally
open type and is activated when closed on COM1.

Not used.
This input can be connected to the hand-operated start cycle push

buttons. The welding cycle starts when BIC1_NO and BIC2_NO are
closed simultaneously or closed in sequence within a maximum time of

0.5 secs. This value has been chosen in accordance to the
international safety rules.

17
19

18

24
21

23

22

24
25

BIC1_NC

Not used.

COM1

26
29

46 / 52

D_STROKE
COM1

BIC2_NC
COM1

TERM
FLUX/TERM
COM1

AUX3
COM1

BIC2_NO

VAUX

SV1
COM2

This input is used for the manual control of the double stroke in welders
fit with this function.

Not used.

This input can be used for connecting a thermostat (pin 30-32). If a flow
regulator is also present, the input must be connected in series with the
thermostat, i.e. the thermostat with pin 30-31 and the flow regulator
with pin 31-32.

This input allows an external device to stop the welding cycle during
the squeeze phase. It can be used as an interlocking input or for
connecting safety devices such as for instance flow regulators or
pressure switches. The contact connected to it should be the normally
open type and is activated when closed on COM1.

Input for the hand-operated start cycle push buttons. The welding cycle
starts when BIC1_NO and BIC2_NO are closed simultaneously or
closed in sequence within a maximum time of 0.5 secs.

24 Vdc output. It indicates that the control unit is powered and ready to
receive a start cycle command. This output can be used to connect a
valve for the opening of the cooling circuit. This is a suitable command
for piloting a 24Vdc coil max. 5 W.

Connect to the solenoid valve that actuates the main cycle. This is a
suitable command for piloting a 24Vdc coil max. 5 W.

27
29

28
29

30
31
32

33
34

35

37

38
39

SV2
COM2

SV3
COM2
SV4

SV PROP­SV PROP+

EMERGENCY
EMERGENCY

ROG
AGND

SHIELD

Connect to solenoid valve 2 (BACK PRESSURE). This is a suitable
command for piloting a 24Vdc coil max. 5 W.

Connect to solenoid valve 3 (FORGING) and 4 (DOUBLE STROKE).
This is a suitable command for piloting a 24Vdc coil max. 5 W.

This is an output that is connected to the piloting card of the
proportional solenoid valve. Option art. 50193.

Emergency input. An emergency button can be connected to these
inputs, the contacts of which should open if faults occur. The
emergency procedure and consequently the opening of these inputs
cut voltage to all the outputs.

The current transducer (Rogowski ring) must be connected to this
analog input.

Shield for transducer cable.

40
41

42
43
44

45
46

47
48

49
50

51

NOTE

The component indicated with acronym "F3", located on the connector side of the control unit, is a
delayed fuse, non-resettable, which supports a max. current of 3.5 A. If the ON LED does not light up,
check the status of the aforesaid component.

47 / 52

TE500 MESSAGES LIST Ver. 2.31

MESSAGE Nº CAUSE REMEDY

MAINS FREQUENCY

50 HZ

MAINS FREQUENCY

60 HZ

MAINS FREQUENCY

ERROR

STORING OF

DEFAULT VALUES

PRESS KEY [+]

TO ZERO DATA

DATA ZEROING IN

PROGRESS

SOFTWARE UPGRADE

IN PROGRESS

PRESS REARM KEY
[//] TO PROCEED

The control unit measured a mains
frequency of 50 Hz.

The control unit measured a mains

2

frequency of 60 Hz.

The control unit was not able to

3

measure a steady mains
frequency.

The control unit is entering default

4

values in its program storage.

The control unit's data zeroing

5

procedure has been activated.

The data zeroing procedure of the

6

control unit is in progress.

The upgrade procedure of the

7

control unit is in progress.

The control unit is waiting for the

9

rearm key to be pressed so as to
activate the welding control unit
functions.

Try to turn on the control unit again
and ensure that power supply is 24
VAC with 50/60 Hz frequency.

Press key [+] to continue otherwise
press any other key or wait a few
seconds.

Ensure that the activation of the
VAUX does not cause damage to
equipment and/or people, then
press the key.

ERROR - MAINS

SYNCHRONISM

TECNA TE500

VER. 2.31

WELDING CONTROL

UNIT

CALIBRATION IN

PROGRESS

CALIBRATION

CURRENT ERROR

CALIBRATION

OVERFLOW ERROR

A synchronism error has occurred

10

due to the temporary lack of the
reference signal of the power
supply line or due to line
interferences.

When the control unit is turned on

11

it displays the type of control unit
and the software version.

The control unit is carrying out the

12

self-calibration welding procedure.

Current measuring errors occurred

13

during the self-calibration
procedure.

During the self-calibration

14

procedure the control unit
measured a too-high current which
cannot be measured correctly.

Clear the error by pressing any
key. If the error occurs frequently,
check the working efficiency of the
devices that cut the power supply
line and check for any interference.

Complete the self-calibration
welding procedure.

Repeat the self-calibration
procedure. If the error occurs
again contact the customer
service.

The capacity of the built-in
ammeter is 36kA. Ensure that the
current supplied by the machine is
within this value. Contact the
customer service.

48 / 52

CALIBRATION -

SAMPLING ERROR

CALIBRATION NO

CURRENT ERROR

CALIBRATION

TE500 IN "NO

WELD"

THERMOSTAT

ACTIVATED

SOLENOID VALVES

OVERHEATING

ALARM CURRENT

ERROR

The self-calibration welding was

15

not carried out or current
measurement errors occurred
during the self-calibration
procedure.

This error occurs when the control

16

unit does not measure the current
during the self-calibration welding
procedure.

This error occurs when performing

17

the self-calibration welding
procedure in "NO WELD".

The protection thermostat inside

18

the welder has been activated.

The short circuit safety device of

19

the control unit outputs has
tripped.

During the welding process an

20

error occurred during the current
measurement procedure.

Repeat the self-calibration
procedure. If the error occurs
again, check the electric
connection of the current
transducer.

Check for continuity of the
secondary circuit. Check the
electric wiring of the current
transducer. Repeat the self
calibration procedure.

Activate the "WELD" function and
repeat the self-calibration welding
procedure.

Check that water is flowing inside
the welder in the necessary
quantity and / or check the working
efficiency of the thermostat.

Check the electric wiring of the
control unit. Check the coil of the
solenoid valve.

The control unit cannot measure
the welding current properly.
Contact the customer service.

ALARM CURRENT

OVERFLOW

----STOP----

MAX. SPOTS N.

STOP MINIMUM

CURRENT LIMIT

CURRENT > MAX.

CURRENT

CURRENT LIMITS >

MAX. CURRENT

MIN. CURRENT >

MAX. CURRENT

A weld with a too-high current

21

signal has occurred.

The welds counter has attained the

22

maximum set value.

The control unit counts some faulty

23

spots, the last of which has been
carried out with a current value
lower than the min. set limit.

The set value in CURRENT 1

24

parameter is higher than the max.
current value of the welder.

The set value in one of the current

25

limits (parameters 17-18) is higher
than the max. current value of the
welder.

The set value in MIN. CURR. (17)

26

is higher than the set value in MAX
CURR (18).

Change the programming
parameters of the welding program
or change the ammeter capacity, if
possible.

Clear the counter, see chapter
"FUNCTION OF THE WELDS
COUNTER"

Clear the error by pressing any
key. See chapter "CURRENT AND
CONDUCTION ANGLE LIMITS"

Set the CURRENT 1 parameter to
a lower value than the max.
current value of the welder.

Set the current limits to a lower
value than the max. current value
of the welder.

Set the min. current limit to a lower
value than the max. current limit.

DEG MIN > DEG

MAX.

The set value in ANGLE MIN (17)

27

is higher than the set value in
ANGLE MAX. (18)

49 / 52

Set the minimum conduction angle
value to a lower value than the
maximum limit.

STOP MAXIMUM

CURRENT LIMIT

STOP MINIMUM

CONDUCTION LIMIT

STOP MAXIMUM

CONDUCTION LIMIT

NO CURRENT SIGNAL

CHANGE AMMETER

CAPACITY

The control unit counts some faulty

28

spots, the last of which has been
carried out with a current value
higher than the max. set limit.

The control unit counts some faulty

29

spots, the last of which has been
carried out with a conduction
angle value lower than the
minimum set limit.

The control unit counts some faulty

30

spots, the last of which has been
carried out with a conduction angle
value higher than the max. set
limit.

During the last welding cycle there

31

was no secondary current
circulation in the machine.

The welding process is being

32

performed in constant current or
with a power percentage using an
ammeter capacity different from
the one set in the self learning
procedure.

Clear the error by pressing any
key. See chapter "CURRENT AND
CONDUCTION ANGLE LIMITS"

Clear the error by pressing any
key. See chapter "CURRENT AND
CONDUCTION ANGLE LIMITS"

Clear the error by pressing any
key. See chapter "CURRENT AND
CONDUCTION ANGLE LIMITS"

Check for continuity of the
secondary circuit. Check the
electric wiring of the current
transducer.

Change the ammeter capacity or
change the program parameter to
select a different work mode.

NO EMERGENCY

SIGNAL

ZERO SPOTS

COUNTER? KEY[-]

=YES

ACCESS CODE

CODE ERROR

NO ENTRY

PULSES > MAX.

WELDING TIME

PRESSURE
xx.x Bar

ERROR!!

SAFETY RELAY

The emergency signal, required for

33

operating the control unit, is
missing.

The CLEAR key was pressed to

34

zero the number of spots and the
control unit requests confirmation.

Someone is trying to access the

35

menu restricted to installers.

Someone is attempting to enter the

36

installers-only menu without
knowing the access password.

The total pulse welding time is

37

higher than the maximum value of
125 periods.

The measured and displayed

38

welding pressure is not within the
limits set in the execution program.

The safety relay that supplies the

39

control unit’s outputs is faulty

Ensure that the emergency contact
is closed.

Press the key [-] to clear the spots
counter, otherwise press any other
keys or wait a few seconds.

Enter the access code if known.
Otherwise wait a few seconds.

Decrease the pulse welding time
or the number of impulses.

Check the air feed circuit or
change the pressure limits in the
program.

STEPPER FUNCTION

NOT ACTIVE

The stepper function is not active

40

and therefore any data entered in
the associated menu have not
been accepted.

50 / 52

In order to activate the stepper
function, check the set data and
make sure that there are no
inconsistencies.

FIRST INSERTION DELAY ADJUSTMENT

During the installation phase, the first insertion delay is to be adjusted. This adjustment allows the
optimizing of the welder's line consumption balance. Adjust by setting the control unit to maximum
power (CURRENT 1 = 99%) and carry out "loadless" welding spots, interrupting the secondary circuit
(e.g. by placing non-conducting material in between the electrodes). Adjust the "FIRST DELAY"
parameter (see the "INSTALLATION" paragraph) so that positive and negative line consumptions are
balanced. It is possible to use two different solutions for measuring the primary current:

Use an ammeter capable of measuring positive and negative maximum peak values (such as the
TECNA TE1600). In this manner the adjustment will be correct when the positive peak value will be
similar to the negative one. The value of the current consumed by the welder (when loadless) might be
too low for the instrument's minimum capacity. Solve this problem by running the cable, on which the
measurement is being taken, inside the current sensor several times. In this case the read value will be
multiplied by the same number of cable-run-through operations performed in the sensor.

Use an ammeter that allows the displaying of the wave forms on a digital oscilloscope. In this case
perform the adjustment so that all the half waves of the primary current have the same amplitude. The
graphs below show the wave forms achieved both with an incorrect and a correct adjustment.

Unbalanced consumption Balanced consumption

51 / 52

NOTES

52 / 52