TECNA TE700 Instruction Manual

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WELDING CONTROL UNIT

INSTRUCTION MANUAL

TE700

FROM SOFTWARE RELEASE N° 1.13

TECNA

via Grieco 25/27 - 40024 Castel S. Pietro Terme – Bologna ITALY Tel. +390516954411 – Fax +390516954490 – http://www.tecna.net

DOCUMENT NUMBER:

EDITION: APRIL 2010

S.p.A.

MAN 4147

DISTRIBUTOR:

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TECNA S.p.A. ITEM TE700 Instruction Manual

TABLE OF CONTENTS

CHAPTER 1 - TE700 WELDING CONTROL UNIT DESCRIPTION Pag. 6

1.1 - MAIN TECHNICAL FEATURES Pag. 7

1.2 - PANEL CONTROLS Pag. 8

1.3 - PANEL LEDs Pag. 9

1.4 - DESCRIPTION OF DISPLAYED INFORMATION Pag. 10

1.5 - CONTROL UNIT SWITCH-ON Pag. 18

CHAPTER 2 - CONTROL UNIT PROGRAMMING Pag. 20

2.1 - PROGRAM DATA Pag. 21

2.2 - CONSTANT CURRENT OPERATING MODE Pag. 23

2.3 - FIX OPERATING MODE Pag. 27

2.4 - CONSTANT SECONDARY VOLTAGE OPERATING MODE Pag. 31

2.5 - CONSTANT POWER OPERATING MODE Pag. 34

2.6 - CONSTANT ENERGY OPERATING MODE Pag. 37

2.7 - DYINAMIC COMPENSATION OPERATING MODE Pag. 41

2.8 - WORKING PROGRAM PARAMETERS DESCRIPTION Pag. 44

2.9 - SETUP MENU Pag. 54

2.10 - STEPPER MENU Pag. 57

2.11 - ADJUSTMENT STEPPER FUNCTION Pag. 61

2.12 - FEATURES TE700 Pag. 66

2.13 - FEATURES INVERTER Pag. 70

2.14 - PROGRAMS COPY Pag. 75

2.15 - CHECK INPUT – DIAGNOSTIC TE700 Pag. 77

2.16 - CHECK INPUT – DIAGNOSTIC INVERTER Pag. 78

2.17 - PROG. SEQUENCE Pag. 79

2.18 - THICKNESS SENSE Pag. 82

2.19 - TIP-DRESSING Pag. 86

CHAPTER 3 - SEAM WELD OPERATING MODE Pag. 91

CHAPTER 4 - CASCADE OPERATING MODE Pag. 97

CHAPTER 5 - THE WORK CYCLE Pag. 98

CHAPTER 6 - STOP BAD SPOTS Pag. 99

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CHAPTER 7 - WELDS COUNTER FUNCTION Pag. 105

CHAPTER 8 - ESCRIPTION OF THE INTERFACE OUTPUTS Pag. 107

8.1 - WELD ERROR (WRONG) Pag. 107

8.2 - END CYCLE Pag. 108

8.3 - LOCK Pag. 108

CHAPTER 9 - SELECTING THE WORK PROGRAM THROUGH EXTERNAL

RECALLS

CHAPTER 10 - DOUBLE STROKE FUNCTION Pag. 113

CHAPTER 11 – OPTIONS Pag. 114

11.1 - RS-232 SERIAL INTERFACE Pag. 114

11.2 - INTERFACE FOR PROPORTIONAL VALVE Pag. 116

CHAPTER 12 - DESCRIPTION OF THE SIGNALS ON THE TERMINAL

BOARD

CHAPTER 13 - LIST OF TE700 MESSAGES Pag. 120

13.1 - SYSTEM ERRORS – TE700 Pag. 120

13.2 - SYSTEM ERRORS - INVERTER Pag. 121

13.3 - WORK ERRORS

Pag. 124

Pag. 109

Pag. 117

CHAPTER 14 – TECHNICAL SPECIFICATIONS Pag. 126

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The information contained in this document is subject to modification without prior notice. No part of this document can be either reproduced or transferred in whatever format neither by electronic nor mechanic means for whatever purpose, without TECNA’s written permission. TECNA is a registered brand.

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CHAPTER 1 – TE700 WELDING CONTROL UNIT DESCRIPTION

The TE700 is a microprocessor-based welding control unit for resistance welders equipped with inverter technology. The task of the welding control unit is to manage the components of the welder, specifically the IGBT power unit that adjusts the welding current. The TE700 is a particularly versatile control unit since it can be adapted to different types of welders. In addition to the spot and projection welders, it may also be installed on seam welders and work with constant current, FIX, constant power, constant voltage, constant energy adjustment and in dynamic mode. The number of the inputs and outputs may be increased to better adapt the welding control unit to automatic machines. The control unit can manage up to max 4 different welding transformers. It is possible to store up to 300 different welding programs, 255 of which are recalled directly from an external device. An alphanumeric identifier may be associated with each program to simplify its identification. Each program comprises several 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.

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1.1 – MAIN TECHNICAL FEATURES

 Simplified programming via 6 keys and a backlit alphanumeric LCD.  Inverter command with medium frequency IGBT, with possibility of choosing the operating

frequency of the inverter between 1000 Hz and 4000 Hz.

 Storage of up to 300 welding programs; 255 may be called from external devices.  Possibility of associating an 8-character alphanumeric identifier with each weld program.

 Possibility of managing as many as 4 different welding transformers or one transformer and 4

different types of electrodes.

 Overheating protection for the welding transformers.  Up to 32 programmable parameters for each program.  Slope up, Slope down, pulses, pre-weld, post-weld functions and adjustment of the welding times

with units of 1 mS.

 Display of the RMS of the welding current, energy, power, RMS of voltage to the electrodes, of the

initial and final resistance, of the machine's thermal use percentage, of the machine's use percentage and, as an option, of the initial thickness of the welded material and the indentation at the end of the weld.

 6 WORKING MODEs: conventional, constant current, constant power, constant voltage, FIX,

constant energy, DYNAMIC mode.

 Limit indicators for: Current, voltage at the electrodes, energy, power, inverter use percentage,

initial and final resistance of the material to be welded; thickness and indentation limit of the material (optional).

 Double stroke function.  Stepper function to compensate the wear and tear of the electrodes with programmable curves and

possibility of intervening independently on the time and the welding current through differentiated stepper laws. Possibility of using 4 different stepper options associated with 4 different spot counters associated with each weld program.

 Single and automatic cycle. WELD and NO-WELD function.  Control of 5 solenoid valves 24 VDC max. 5 W with self-protected output.  Self-adjustment to the mains frequency 50/60 Hz.  Serial communication with insulated RS232 as an option.  Output for proportional solenoid valve.  Key for selecting foot control or two-hand control.  Selectable languages: Italian, English, French, German, Spanish, Hungarian, Swedish or

Portuguese.

 Possibility of upgrading control unit Firmware via appropriate software.  Electrode tip dressing for up to max of 4 different spot counters (optional).

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1.2 – PANEL CONTROLS

Left-hand direction key used for exiting from the programming menus.

Right-hand direction key used for entering the programming menus.

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.

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 outputs of the control unit. Must be activated each time the control unit is powered on. When this key is pressed, the devices connected to the VAUX are powered and the charge of the inverter capacitors is activated. Before

pressing this key check that the devices connected to the VAUX cannot injure people or damage equipment.

Key for selecting the start cycle device: PEDAL or TWO-HANDS 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 the two-hand push buttons (TWOHANDS 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.

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 keeping all the time parameters unchanged.

CLEAR Key. It is used to clear the error conditions and to set to zero the weld counter.

PROG-RUN Key selector. In PROG position it enables the keyboard and allows the running of all the foreseen programming operations. In RUN start position it enables the spot welder commands and allows the running of the work program only.

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1.3 – PANEL LEDs

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

The turning on of this LED indicates that start cycle 1 command is activated.

The turning on of this LED indicates that start cycle 2 command is activated.

The turning on of this LED indicates that the pressure-only stopping command by means of the AUX1 and AUX2 inlets is activated.

The turning on of this LED indicates that the control unit is generating the command signal for the inverter welding unit.

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

It indicates that the solenoid valve, which controls the back pressure, is activated.

It indicates that the solenoid valve, which enables the forging, is activated.

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

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1.4 – DESCRIPTION OF DISPLAYED INFORMATION

Main work screen

The main screens display some information after every run weld cycle, both for cycles carried out in weld mode, with the control unit set to WELD mode, and for cycles carried out in NO WELD mode. The values displayed in the following description are for reference only.

PRG 005-FE ZN 10-01 WELD 0010mS E 00100J IRMS 020.26 kA SPOT 56002 r 055.4%

In WORK configuration, the displayed descriptions are always in English regardless of the language selected in the SETUP MENU.

PRG 005-FE ZN 10-01 005 indicates the program used to carry out the last weld; the number may range from 001 to

300. It is displayed both in WELD and NO WELD mode.

FE ZN 10 is the alphanumeric identifier associated with the selected weld program. These are

8 characters that are defined at will by the operator to better identify the weld program. It is displayed both in WELD and NO WELD mode.

01 is the identifier of the number of the tool used to carry out the weld. The number ranges

from 1 to 4. Displayed in WELD and NO WELD mode.

SPOT 56002

This is the counter that counts the carried out welds; the number may range from 00000 to

65000. Each equipment is fitted with its own standalone spot counter that increases only when welds are carried out through a program in which the equivalent tool number is set. It is updated in WELD mode only and reset through the CLEAR key. The following screen is displayed on pressing the CLEAR key:

CLEAR COUNTER UP / DN TO SELECT: RESET COUNTER T1? <+> = OK <-> = CANCEL

Use keys and to select which of the four spot counters is to be reset or if all 4 are to be reset at the same time. The number of the spot counters that are to be used depends on the number of tools enabled inside the FEATURES INVERTER menu. Press key to reset the selected counters or key to cancel the counter's deletion procedure.

WELD 0010mS

It indicates the weld time with which the last weld was carried out. The value ranges from 0001 to 9999. The same value is displayed both in WELD mode and in NO WELD mode.

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IRMS 020.26kA

It indicates the value of the current with which the last weld was carried out. In WELD mode the value may range from 000.00 kA to 200.00 kA. In NO WELD mode the value is 000.00 kA. It represents the average of the RMS values measured for each weld time millisecond. The displayed value always refers to the main adjustment that is to say to that of the WELD parameter. In the case of pulse welds, the displayed current value is the average of the RMS values of the current supplied during the single pulses.

E 00100J

It indicates the value of the energy supplied during the welding operation. The displayed value always refers to the energy supplied inside the weld's main block. In the case of the pulse adjustment, the displayed value always refers to the last run pulse. The value is updated if the control unit is in WELD mode, if the control unit is in NO WELD mode, 00000J is displayed. The display of -----J indicates that the configuration of the set machine does not permit measuring the energy.

r 055.4%

It indicates the use percentage of the welding unit (transformer + inverter). The displayed number is directly proportional to the welding unit capacity of supplying current. Approaching 100% means approaching the max current the machine can supply. This value will depend on the type of welding unit, the geometry of the machine and the features of the material to be welded. Approaching 100% entails a loss of the control unit's current adjustment capacities. The value is updated in WELD mode. 000.0% is displayed in NO WELD mode.

Use keys and inside this screen to view data relevant to the previously carried out 20 weld spots. The control unit only stores data relevant to spots carried out in WELD mode. The execution of a weld in WELD mode and in NO WELD mode leads to the display of data relevant to the last spot carried out in WELD mode. Other screens containing information about the weld cycle carried out can be viewed by pressing key in the main work screen.

Sequence screen

The sequence screen may be accessed only in case the sequence function has been enabled inside the control unit.

PRG 005-FE ZN 10-01 ST 001-020 NXTPR 024 WELD 2048 RMS 010.00 SPOT 02345 r 000.0

PRG 005-FE ZN 10-01 005 Indicates the program used to carry out the last weld. The number ranges from 001 to

300. It is displayed both in WELD and NO WELD mode.

FE ZN 10 is the alphanumeric identifier associated with the selected weld program. These are

8 characters that are defined at will by the operator to better identify the weld program. It is displayed both in WELD and NO WELD mode.

01 is the identifier of the number of the transformer used to carry out the weld or the number

of the tool used. The number ranges from 1 to 4. It is displayed both in WELD and NO WELD mode.

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ST 001-020

001 Indicates the current spot inside the set welding sequence. 020 Indicates the total number of weld spots that make the sequence up.

The indication of the number of the spot inside the sequence increases both in WELD mode and in NO WELD mode. Use keys and to increase or decrease the present position inside the sequence so that certain steps may be repeated or skipped.

NXTPR 024

It indicates the program with which the next spot will be carried out. The value is updated both in WELD mode and in NO WELD mode.

WELD 2048

It indicates the weld time with which the last weld was carried out. The value ranges from 0001 to 9999. The same value is displayed both in WELD mode and in NO WELD mode.

RMS 010.00

It indicates the value of the current with which the last weld was carried out. In WELD mode the value may range from 000.00 kA to 200.00 kA. In NO WELD mode the value is 000.00 kA. It represents the average of the RMS values measured for every welding time millisecond. The displayed value always refers to the main adjustment, that is to say to that of the WELD parameter. If welding is by pulses, the current value is always the value of the last pulse carried out.

SPOT 02345

It stands for the welded spots counter; it may be a number between 00000 and 65000. It is updated in WELD mode only and it may be cleared by means of the CLEAR key.

r 000.0%

Weld analysis screen – 1

This screen may always be accessed regardless of the control unit's configuration.

PRG 005-FE ZN 10-01 POWER 000.0KW VE 05.00V Th 083.0% Rend 1285.0uOhm

PRG 005-FE ZN 10-01 005 Indicates the program used to carry out the last weld. The number ranges from 001 to

300. It is displayed both in WELD and NO WELD mode.

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FE ZN 10 is the alphanumeric identifier associated with the selected weld program. These are

8 characters that are defined at will by the operator to better identify the weld program. It is displayed both in WELD and NO WELD mode.

01 is the identifier of the number of the transformer used to carry out the weld or the number

of the tool used. The number ranges from 1 to 4. It is displayed both in WELD and NO WELD mode.

POWER 000.0KW

It indicates the average value of the power supplied during the weld's main block. The value is updated when the control unit is in WELD mode whilst 000.0KW is displayed when the unit is in NO WELD mode. The display of ---.-KW means that the present configuration of the control unit does not allow viewing the supplied power value. The displayed value always refers to the energy supplied inside the weld's main block and in the case of the pulse WORKING MODE it always refers to the last pulse.

VE 05.00V

It indicates the average value of the RMS voltage at the electrodes carried out every millisecond. The value is updated when the control unit is in WELD mode whilst 00.00V is displayed when the control unit is in NO WELD mode. The display of --.—V means that the present configuration of the control unit does not allow viewing the electrodes voltage value. The displayed value always refers to the energy supplied inside the weld's main block and in the case of the pulse WORKING MODE it always refers to the last pulse.

Weld analysis screen – 2

This screen may be accessed when the programming of at least one of the following parameters has been activated inside the control unit: pre-weld, weld 2 or post weld.

PRG 005-FE ZN 10-01 PRE 0000mS 000.00KA POST 0000mS 000.00KA W2 0000mS 000.00KA

PRG 005-FE ZN 10-01 005 Indicates the program used to carry out the last weld. The number ranges from 001 to

300. It is displayed both in WELD and NO WELD mode.

FE ZN 10 is the alphanumeric identifier associated with the selected weld program. These are

8 characters that are defined at will by the operator to better identify the weld program. It is displayed both in WELD and NO WELD mode.

01 is the identifier of the number of the transformer used to carry out the weld or the number

of the tool used. The number ranges from 1 to 4. It is displayed both in WELD and NO WELD mode.

PRE 0000mS 000.00KA

It indicates the duration in mS and the RMS welding current average during the pre-weld block.

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The time value is displayed both in WELD mode and in NO WELD mode. The value of the current is displayed only in WELD mode whilst 000.00KA is displayed in NO WELD mode. If PRE ----mS ---.—KA is displayed, this means that the programming of the pre-weld parameter is disabled inside the control unit.

POST 0000mS 000.00KA

It indicates the duration in mS and the RMS welding current average during the post-weld block. The time value is displayed both in WELD mode and in NO WELD mode. The value of the current is displayed only in WELD mode whilst 000.00KA is displayed in NO WELD mode. If POST ----mS ---.—KA is displayed, this means that the programming of the post-weld parameter is disabled inside the control unit.

W2 0000mS 000.00KA

It indicates the duration in mS and the RMS welding current average during the weld 2 block. The time value is displayed both in WELD mode and in NO WELD mode. The value of the current is displayed only in WELD mode whilst 000.00KA is displayed in NO WELD mode. If W2 ----mS ---.—KA is displayed, this means that the programming of the weld 2 parameter is disabled inside the control unit.

Stepper analysis screen

This screen may be accessed only if the stepper function is activated on the control unit.

PRG 005-FE ZN 10-01 STEP 1-7 SPOT 02400 INC1 001.0 % OF 060% INC2 023.1 % OF 030%

PRG 005-FE ZN 10-01 005 Indicates the program used to carry out the last weld. The number ranges from 001 to

300. It is displayed both in WELD and NO WELD mode.

FE ZN 10 is the alphanumeric identifier associated with the selected weld program. These are

8 characters that are defined at will by the operator to better identify the weld program. It is displayed both in WELD and NO WELD mode.

01 is the identifier of the number of the transformer used to carry out the weld or the number

of the tool used. The number ranges from 1 to 4. It is displayed both in WELD and NO WELD mode.

STEP 1-7

It indicates the control unit's present STEP and the total number of STEPS activated on the stepper’s parameterization. The datum increases only when the control unit is in WELD mode and does not increase when the unit is in NO WELD mode.

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SPOT 02400

It indicates the number of the present spot. The counter increases when the control unit is in WELD mode and does not increase when the unit is in NO WELD mode.

INC1 001.0 % 0F 060%

It indicates the present percentage increase of the quantity associated with stepper law 1 and the final increment of the same quantity at the end of the present STEP. If INC 1 000.0 % OF 000 % is displayed, this means that no quantity is present associated with stepper law 1 or that a percentage increase of 0% has been associated with this quantity. The value is not updated when the control unit is in NO WELD mode.

INC2 023.1 % OF 030 % It indicates the present percentage increase of the quantity associated with stepper law 2 and the final increment of the same quantity at the end of the present STEP. If INC 2 000.0% OF 000 % is displayed, this means that no quantity is present associated with stepper law 2 or that a percentage increase of 0% has been associated with this quantity. The value is not updated when the control unit is in NO WELD mode.

Use keys and inside this screen to view data relevant to the previously carried out 20 weld spots. The control unit only stores data relevant to spots carried out in WELD mode. The execution of a weld either in WELD mode or in NO WELD mode entails the display of the data relevant to the last spot carried out in WELD mode.

Electrodes dressing analysis screen

This screen may be accessed only if the dressing function (optional) is activated on the control unit.

PRG 005-FE ZN 10-01 SOT 00001 INC DRESS 01% DRESSING -00500

PRG 005-FE ZN 10-01 005 Indicates the program used to carry out the last weld. The number ranges from 001 to

300. It is displayed both in WELD and NO WELD mode.

FE ZN 10 is the alphanumeric identifier associated with the selected weld program. These are

8 characters that are defined at will by the operator to better identify the weld program. It is displayed both in WELD and NO WELD mode.

01 is the identifier of the number of the transformer used to carry out the weld or the number

of the tool used. The number ranges from 1 to 4. It is displayed both in WELD and NO WELD mode.

SPOT 00001

It indicates the number of the present spot. The counter increases when the control unit is in WELD mode and does not increase when the unit is in NO WELD mode.

INC DRESS 01%

It indicates the percentage increase of the weld parameter inside the present electrodes dressing STEP. The value does not increase when the unit is in NO WELD mode.

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DRESSING – 00500

It indicates the remaining number of weld spots before the need to carry out the electrodes' dressing or changing operations. The counter does not decrease when the control unit is in NO WELD mode.

Use keys and inside this screen to view data relevant to the previously carried out 20 weld spots. The control unit only stores data relevant to spots carried out in WELD mode. The execution of a weld either in WELD mode or in NO WELD mode entails the display of the data relevant to the last spot carried out in WELD mode.

Quality analysis screen

This screen may be accessed only when the quality control function is enabled in the control unit by measuring the resistance of the material to be spot welded or by measuring the thickness of the material in between the electrodes.

PRG 005-FE ZN 10-01 IDENT. 00.000mm THICK. 00.000mm R START 0000.0uOhm

PRG 005-FE ZN 10-01 005 Indicates the program used to carry out the last weld. The number ranges from 001 to

300. It is displayed both in WELD and NO WELD mode.

FE ZN 10 is the alphanumeric identifier associated with the selected weld program. These are

8 characters that are defined at will by the operator to better identify the weld program. It is displayed both in WELD and NO WELD mode.

01 is the identifier of the number of the transformer used to carry out the weld or the number

of the tool used. The number ranges from 1 to 4. It is displayed both in WELD and NO WELD mode.

IDENT. 00.000MM

It indicates the measurement of the electrode penetration into the material at the end of the welding procedure. If this function is disabled, 00.000mm is displayed. The value is updated both in WELD mode and in NO WELD mode.

THICK. 00.000mm

It indicates the initial thickness of the material to be welded. The measurement is carried out before the current passage. If this function is not enabled, 00.000mm is displayed. The value is updated both in WELD mode and in NO WELD mode.

R START 0000.0uOhm

It indicates the initial value of the resistance of the material to be spot welded. The value is updated only when the control unit is in WELD mode.

Use keys

and inside this screen to view data relevant to the previously carried out 20 weld spots. The control unit only stores data relevant to spots carried out in WELD mode. The execution of a weld either in WELD mode or in NO WELD mode entails the display of the data relevant to the last spot carried out in WELD mode.

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Errors log screen

The errors log screen is always accessible and contains information about the last 20 errors signalled by the control unit.

ERR: 162 INVERTER SPOT: 00001 LOG: 05 DRESSING [165] CAPS NEED DRESSING

ERR: 162

This is the code of the error displayed.

INVERTER

It indicates if the error originated from the INVERTER or the TE700 control unit.

SPOT: 00001

It indicates the value of the spot counter when the signalled error occurred.

LOG: 05

It indicates the position of the error inside the LOG. The value may range from 1 to 20. The highest number refers to the last error that occurred whilst the lowest number indicates the oldest error.

DRESSING [165] / CAPS NEED DRESSING

Concise description of the displayed error. For further information consult this manual.

Use keys and inside this screen to scroll through the list of errors saved inside the control unit. Press the + key to scroll through the list of most recent errors or the – key to scroll through the list of the earliest errors.

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1.5 – CONTROL UNIT SWITCH-ON

As soon as the control unit is switched on, the display notifies the operator that the communication interface is initializing.

CAN INTERFACE

INIT

After the initialization of the communication interface, the control unit checks for the integrity of the communication channel with the inverter. The following wait message is displayed until the check is finished:

INVERTER COM CAN-BUS NOT READY WAIT..

The following message is displayed once the working efficiency of the communication channel has been checked.

INVERTER COM CAN-BUS READY

Next, the mains frequency recognized by the control unit is displayed.

MAINS FREQUENCY

50 Hz

Both the type of control unit and the relevant software version are displayed.

TE700 REV. 1.09

WELD CONTROL UNIT

In order to complete the control unit switch-on sequence, the operator is asked to press the RESTART button or to generate the RESTART sequence through external program recalls. The displayed message is as follows.

PRESS RESTART

BUTTON [//]

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This RESTART button enables the control unit's commands and outputs. It must be pressed every time the control unit is powered.

As soon as the RESTART command is issued, all the devices connected to the VAUX output are supplied and the charging procedure for the capacitors bank is started on the inverter.

Before activating the RESTART command, it is important to check that it will not cause damage to people or equipment.

The following message is displayed until the inverter is ready to weld.

INVERTER CAPACITOR CHARGING PLEASE WAIT

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

For safety reasons, the microprocessor does not start the welding cycle if the cycle start signal is actuated when the welder is turned on. Simply release the control and actuate it again. Micro-cutoffs or excessive voltage drops do not alter the control unit's working efficiency but stop it. To restore working efficiency, turn off the machine and then turn it on again.

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CHAPTER 2 – CONTROL UNIT PROGRAMMING

By placing the key in PROGRAM DATA position the following screen is displayed:

-TE700 VER. 1.09 ->PROGRAM DATA SETUP MENU STEPPER MENU

The first row reports the control unit type and the software version. Then the display lists all the menus allowing accessing the various control unit functions.

The following list includes all the menus available in the control unit. However, it is possible that not all of these menus are displayed by the control unit being used as some of them depends either on the options actually inserted in the control unit or on the welder type the control unit is installed onto.

_ PROGRAM DATA _ SETUP MENU _ STEPPER MENU _ FEATURES TE700 _ FEATURES INVERTER _ PROGRAM COPY _ DIAGNOSTIC TE700 _ DIAGNOSTIC INV.

_ PROG. SEQUENCE _ THICKNESS SENSE (It may be activated) _ TIP-DRESSING (It may be activated)

-TE700 VER. 1.09 - PROGRAM DATA >SETUP MENU STEPPER MENU

Use keys of the menus. Use keys

and to move up and down the > arrow cursor displayed on the left-hand side

and to enter and exit from the menu selected by the cursor.

Use keys and to modify the parameter indicated by the cursor.

PROGRAM DATA T1 PROGRAM N. 001 >PRG. NAME TOOLS N° 1

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TECNA S.p.A. ITEM TE700 Instruction Manual

2.1 – PROGRAM DATA

-TE700 VER. 1.09->PROGRAM DATA SETUP MENU STEPPER MENU

The PROGRAM DATA menu contains all the weld cycle parameters, the times and the currents which to carry out the welds with.

PROGRAM DATA T1 >PROGRAM N. 001 PRG. NAME TOOLS N° 1

The first choice to make is the number of the program to be used. Choose among the 300 storable programs using the and keys.

After having selected the program number which to work with, use key to enter an alphanumeric identifier associated with the number of the program so that it is easier to recognize it during the recall or the display.

PROGRAM DATA T1 PROGRAM N. 001 >PRG. NAME USI1500P TOOLS N° 1

Press key to select which character is to be entered or modified. Each time key is pressed, the next character in the string is selected beginning from position 1 up to position number 8. On reaching the eighth character, when key is pressed the operator may modify the first character again.

PROGRAM DATA T1 PROGRAM N. 001 >PRG. NAME U<SI1500P TOOLS N° 1

The affected character is indicated on the control unit display by the symbol "<" located on the right-hand side of the character itself. In order to change the character, use keys and and key [///]. The usable characters are the decimal numbers from 0 to 9, the space key and the capital characters of the international alphabet from A to Z.

After having changed the name of the program to work with, use key to select the weld tool number.

PROGRAM DATA T1 PROGRAM N. 001 PRG. NAME USI1500P >TOOLS N° 1

The values of the parameter may range from 1 up to 4 at the most. The max value is set inside the FEATURES INVERTER menu and is included between 1 and 4 (N.WELDING

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TRAFO). If 1 was set as max value, the value of the parameter cannot be changed by the operator.

The WELD TOOL parameter permits identifying up to max 4 different types of electrodes used during the welding operations. The electrodes may be interchanged on the same welding head and, as such, share the same welding transformer or they can be installed on different welding heads having different welding transformers connected to the same welding unit. An independent spot counter is associated with each WELD TOOL, which increases only when the control unit welds with a program in which the corresponding WELD TOOL is selected. This allows the control unit to manage 4 different current increments or electrodes dressing procedures, in which the current increment or electrode wear is calculated considering only the weld spots carried out by that specific electrode ignoring the weld spots carried out with other electrodes.

PROGRAM DATA T2 PROGRAM N. 001 PRG. NAME USI1500P >TOOLS N° 2

The modification of the WELD TOOL number is indicated next to the PROGRAM DATA text by means of the symbols T1, T2, T3, T4 so that, on scrolling the weld program parameters, the operator may always see which tool identifier is associated with the weld program being used.

PROGRAM DATA T1 PRG. NAME USI1500P TOOLS N° 1 >WORKING MODE IK

Then the next parameters are searched for, using keys and to set the required value, one at a time, using keys

and .

As such all the parameters will be set to the desired value for carrying out the welding process. Please, beware that the data is saved only and exclusively if the program is exited or if the key is turned in RUN position.

Below the six WORKING MODEs are described and the six programming screens are displayed according to the parameter selected in the WORKING MODE. The screens contain all the programmable parameters. The number of available WORKING MODEs may change depending on the configuration of the spot welder on which the control unit is installed.

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2.2 - CONSTANT CURRENT OPERATING MODE (IK)

When the weld control unit works in constant current mode, the current value which to carry out the welding with may be set directly. During the welding procedure, the control unit measures the real effective value (RMS) of the welding current every mS and maintains the set current according to a mathematical correction algorithm. The max welding current value that may be set is restricted automatically to the max current than can be supplied by the welding transformer set in the FEATURES INVERTER menu.

In addition to simplifying the programming operations, this WORKING MODE also permits to keep the desired welding current even if some factors change such as: mains voltage, welding circuit dimensions and impedance, conditions of the welding tools or surface condition of the materials being processed.

The above image shows the welding current maintained by the constant adjustment mathematical algorithm. Notice that the current slicing (RO) of the inverter changes during the welding operation to keep the welding current constant.

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TABLE WITH CONSTANT CURRENT OPERATING MODE PARAMETERS

PARAMETER RANGE VALUE

PROGRAM N. 001 – 300 WORKING MODE IK CONTROL MODE * NO QUALITY – T* OFF QUALITY – R * OFF SQUEEZE 1 0.5 – 99.0 cycles SQUEEZE 00.0 – 99.0 cycles PRESSURE 00.5 – 10.0 bar FORGE DELAY 00 – 99 cycles FORG.PRESS. 00.5 – 10.0 bar PRE-WELD 0000 – 1000 mS PRE-CURR. 000.30 – 200.00 KA COLD 1 0000 – 1000 mS SLOPE UP 0000 – 1000 mS WELD 0001 – 2000 mS CURRENT 000.30 – 200.00 KA COLD 2 0000 – 1000 mS IMPULSE N. 1 – 9 WELD 2 0000 – 1000 mS CURRENT 2 000.30 – 200.00 KA SLOPE DOWN 0000 – 1000 mS COLD 3 0000 – 1000 mS POST-WELD 0000 – 1000 mS POST-CURR. 000.30 – 200.00 KA HOLD TIME 00.5 – 99.0 cycles OFF TIME 00.0 – 99.0 cycles

CONTROL MODE * CUR LIM I MIN 000.30 – 200.00 KA LIM I MAX 000.30 – 200.00 KA

CONTROL MODE * RO LIM RO MIN 005.0 – 100.0% LIM RO MAX 005.0 – 100.0%

CONTROL MODE * VE LIM V MIN 00.20 – 20.00 V LIM V MAX 00.20 – 20.00 V

CONTROL MODE * PW LIM P MIN 000.20 - 600.00 KW LIM P MAX 000.20 – 600.00 KW

CONTROL MODE * ENE LIM E MIN 00000 – 60000 J LIM E MAX 00000 – 60000 J

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QUALITY –T * THICK THICK. MIN 00.00 – 60.00 mm THICK MAX 00.00 – 60.00 mm

QUALITY –T * IDENT IDENT. MIN 0.000 – 6.000 mm IDENT. MAX 0.000 – 6.000 mm

QUALITY –T * TH+ID THICK. MIN 00.00 – 60.00 mm THICK MAX 00.00 – 60.00 mm IDENT. MIN 0.000 – 6.000 mm IDENT. MAX 0.000 – 6.000 mm

QUALITY –T * ZERO

QUALITY –R * PRE RMIN PRE 0 – 60000uOhm RMAX PRE 0 – 60000uOhm

QUALITY –R * POST RMIN POST 0 – 60000uOhm RMAX POST 0 – 60000uOhm

QUALITY –R * PRE+POST RMIN PRE 0 – 60000uOhm RMAX PRE 0 – 60000uOhm RMIN POST 0 – 60000uOhm RMAX POST 0 – 60000uOhm

QUALITY –R * ZERO

There are some special conditions:

 On setting the OFF TIME to zero, the control unit will work in single cycle.  On setting the PRE-WELD parameter to zero, the pre-welding process will not be carried

out.

 On setting the POST-WELD parameter to zero, the post-welding process will not be

carried out.

 On setting the WELD 2 parameter to zero, WELD 2 will not be carried out.  On setting LIM I MIN and LIM I MAX to the same value, the limits are deactivated.  On setting LIM RO MIN and LIM RO MAX to the same value, the limits are deactivated.  On setting LIM V MIN and LIM V MAX to the same value, the limits are deactivated.  On setting LIM P MIN and LIM P MAX to the same value, the limits are deactivated.  On setting LIM E MIN and LIM E MAX to the same value, the limits are deactivated.  On setting THICK. MIN and THICK. MAX to the same value, the limits are deactivated.  On setting IDENT. MIN and IDENT. MAX to the same value, the limits are deactivated.  On setting RMIN PRE and RMAX PRE to the same value, the limits are deactivated.  On setting RMIN POST and RMAX POST to the same value, the limits are deactivated.

It is advisable to activate the CONTROL UNIT in RO MODE and to check the limit use conditions before proceeding with production. For instance, if use is meant to be with 2

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sheets, the limit conditions are either with 1 or 3 sheets. The constant welding current is adjusted by the TE700 control unit (if the value of the r parameter for using the welding unit is less than 100.0%). The operator must then check the values of the r indicator when welding with 1 sheet and set this value as minimum limit and if welding with 3 sheets, set this value as maximum limit. If a more accurate spot quality control is required, activate the QUALITY-T parameters to check the initial thickness of the sheets and the electrode penetration at the end of the welding cycle, and the QUALITY-R parameter to obtain a measurement of the initial and final values of the resistance. The presence of the QUALITY-T and QUALITY-R parameters depends on the control unit's configuration and which spot welder is used.

However, it is not possible to undoubtedly assure that the piece has been effectively welded, as all the conditions and parameters involved in the welding process execution should be checked.

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2.3 – FIX OPERATING MODE (FIX)

In FIX working mode the inverter welding unit does not make any adjustments to the current supplied during welding. The operator must set the power slicing percentage supplied by the inverter, which ranges from 5% to 100%. The power supplied during the welding operation increases for higher slicing values. In this case the current actually supplied by the inverter involves various factors and is no longer constant. The factors that might affect the current supply are: changes in the resistance of the material to be welded, wearing out of the electrodes and changes in the geometry of the secondary circuit or mains voltage fluctuations.

The FIX WORKING MODE may be advisable for short-term welding with great resistance changes or when using the welder as a metal-heating device.

The slicing of the inverter (RO) is kept constant. The slicing is understood to be the relationship between the switch-on time of the IGBT power devices and their OFF time. The current supplied to the secondary circuit is no longer constant but depends on the resistance of the secondary circuit and on the resistance of the material to be welded.

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TABLE WITH FIX OPERATING MODE PARAMETERS

PARAMETER RANGE VALUE

PROGRAM N. 001 – 300 WORKING MODE FIX CONTROL MODE * NO QUALITY – T* OFF QUALITY – R * OFF SQUEEZE 1 0.5 – 99.0 cycles SQUEEZE 00.0 – 99.0 cycles PRESSURE 00.5 – 10.0 bar FORGE DELAY 00 – 99 cycles FORG.PRESS. 00.5 – 10.0 bar PRE-WELD 0000 – 1000 mS PRE-RO 005.0 – 100.0 % COLD 1 0000 – 1000 mS SLOPE UP 0000 – 1000 mS WELD 0001 – 2000 mS RO 005.0 – 100.0 % COLD 2 0000 – 1000 mS IMPULSE N. 1 – 9 WELD 2 0000 – 1000 mS RO 2 005.0 – 100.0 % SLOPE DOWN 0000 – 1000 mS COLD 3 0000 – 1000 mS POST-WELD 0000 – 1000 mS POST-RO 005.0 – 100.0 % HOLD TIME 00.5 – 99.0 cycles OFF TIME 00.0 – 99.0 cycles

CONTROL MODE * CUR LIM I MIN 000.30 – 200.00 KA LIM I MAX 000.30 – 200.00 KA

CONTROL MODE * RO LIM RO MIN 005.0 – 100.0% LIM RO MAX 005.0 – 100.0%

CONTROL MODE * VE LIM V MIN 00.20 – 20.00 V LIM V MAX 00.20 – 20.00 V

CONTROL MODE * PW LIM P MIN 000.20 - 600.00 KW LIM P MAX 000.20 – 600.00 KW

CONTROL MODE * ENE LIM E MIN 00000 – 60000 J LIM E MAX 00000 – 60000 J

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QUALITY –T * THICK THICK. MIN 00.00 – 60.00 mm THICK MAX 00.00 – 60.00 mm

QUALITY –T * IDENT IDENT. MIN 0.000 – 6.000 mm IDENT. MAX 0.000 – 6.000 mm

QUALITY –T * TH+ID THICK. MIN 00.00 – 60.00 mm THICK MAX 00.00 – 60.00 mm IDENT. MIN 0.000 – 6.000 mm IDENT. MAX 0.000 – 6.000 mm

QUALITY –T * ZERO

QUALITY –R * PRE RMIN PRE 0 – 60000uOhm RMAX PRE 0 – 60000uOhm

QUALITY –R * POST RMIN POST 0 – 60000uOhm RMAX POST 0 – 60000uOhm

QUALITY –R * PRE+POST RMIN PRE 0 – 60000uOhm RMAX PRE 0 – 60000uOhm RMIN POST 0 – 60000uOhm RMAX POST 0 – 60000uOhm

QUALITY –R * ZERO

There are some special conditions:

 On setting the OFF TIME to zero, the control unit will work in single cycle.  On setting the PRE-WELD parameter to zero, the pre-welding process will not be carried

out.

 On setting the POST-WELD parameter to zero, the post-welding process will not be

carried out.

 On setting WELD 2 parameter to zero, WELD 2 will not be carried out.  On setting LIM I MIN and LIM I MAX to the same value, the limits are deactivated.  On setting LIM RO MIN and LIM RO MAX to the same value, the limits are deactivated.  On setting LIM V MIN and LIM V MAX to the same value, the limits are deactivated.  On setting LIM P MIN and LIM P MAX to the same value, the limits are deactivated.  On setting LIM E MIN and LIM E MAX to the same value, the limits are deactivated.  On setting THICK. MIN and THICK. MAX to the same value, the limits are deactivated.  On setting IDENT. MIN and IDENT. MAX to the same value, the limits are deactivated.  On setting RMIN PRE and RMAX PRE to the same value, the limits are deactivated.  On setting RMIN POST and RMAX POST to the same value, the limits are deactivated

In the FIX WORKING MODE, and current slicing being the same, the current supplied by the inverter depends exclusively on the resistance of the secondary area and on the resistance of

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the material to be welded. This condition applies as long as the welding current is less than the maximum current of the welding transformer. If the welding current tends to exceed the value set as welding transformer max current, the welder intervenes automatically by reducing the set current slicing value in real time to maintain current within the set limits.

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2.4 - CONSTANT SECONDARY VOLTAGE OPERATING MODE (VEK)

When working with constant secondary voltage, the welder calculates the real effective value (RMS) of the voltage at the electrodes every mS and keeps the set voltage value constant according to a mathematical algorithm. The value of the current supplied by the inverter is consequently inversely proportional to the resistance of the secondary circuit and to the resistance of the material to be welded. The value of the supplied current will be independent from power line fluctuations. The secondary voltage is kept constant as long as it is lower than the CURR. MAX parameter. If the welding current tends to exceed the value set in CURR. MAX., the inverter unit will automatically decrease the value of the secondary voltage in real time to maintain the welding current within the set limits. The CURR. MAX. value may be set as high as the max value of the transformer welding current. Its task is to prevent damage to the welding tools in the case of harsh changes in the resistance of the material to be welded.

The constant secondary voltage working mode may be used for welds with tungsten electrodes or to compensate the wear of the electrodes during the welding operation.

The VE value remains constant during the welding operation, but the current value changes according to the impedance of the secondary circuit.

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TABLE WITH CONSTANT SECONDARY VOLTAGE OPERATING MODE PARAMETERS

PARAMETER RANGE VALUE

PROGRAM N. 001 – 300 WORKING MODE VEK CONTROL MODE * NO QUALITY – T* OFF QUALITY – R * OFF SQUEEZE 1 0.5 – 99.0 cycles SQUEEZE 00.0 – 99.0 cycles PRESSURE 00.5 – 10.0 bar FORGE DELAY 00 – 99 cycles FORG.PRESS. 00.5 – 10.0 bar PRE-WELD 0000 – 1000 mS PRE-VE 00.20 – 20.00 V COLD 1 0000 – 1000 mS SLOPE UP 0000 – 1000 mS WELD 0001 – 2000 mS VE 00.20 – 20.00 V CURR. MAX. 001.00 – 200.00 KA COLD 2 0000 – 1000 mS IMPULSE N. 1 – 9 WELD 2 0000 – 1000 mS VE 2 00.20 – 20.00 V SLOPE DOWN 0000 – 1000 mS COLD 3 0000 – 1000 mS POST-WELD 0000 – 1000 mS POST-VE 00.20 – 20.00 V HOLD TIME 00.5 – 99.0 cycles OFF TIME 00.0 – 99.0 cycles

CONTROL MODE * CUR LIM I MIN 000.30 – 200.00 KA LIM I MAX 000.30 – 200.00 KA

CONTROL MODE * RO LIM RO MIN 005.0 – 100.0% LIM RO MAX 005.0 – 100.0%

CONTROL MODE * VE LIM V MIN 00.20 – 20.00 V LIM V MAX 00.20 – 20.00 V

CONTROL MODE * PW LIM P MIN 000.20 - 600.00 KW LIM P MAX 000.20 – 600.00 KW

CONTROL MODE * ENE LIM E MIN 00000 – 60000 J LIM E MAX 00000 – 60000 J

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QUALITY –T * THICK THICK. MIN 00.00 – 60.00 mm THICK MAX 00.00 – 60.00 mm

QUALITY –T * IDENT IDENT. MIN 0.000 – 6.000 mm IDENT. MAX 0.000 – 6.000 mm

QUALITY –T * TH+ID THICK. MIN 00.00 – 60.00 mm THICK MAX 00.00 – 60.00 mm IDENT. MIN 0.000 – 6.000 mm IDENT. MAX 0.000 – 6.000 mm

QUALITY –T * ZERO

QUALITY –R * PRE RMIN PRE 0 – 60000uOhm RMAX PRE 0 – 60000uOhm

QUALITY –R * POST RMIN POST 0 – 60000uOhm RMAX POST 0 – 60000uOhm

QUALITY –R * PRE+POST RMIN PRE 0 – 60000uOhm RMAX PRE 0 – 60000uOhm RMIN POST 0 – 60000uOhm RMAX POST 0 – 60000uOhm

QUALITY –R * ZERO

There are some special conditions:

 On setting the OFF TIME to zero, the control unit will work in single cycle.  On setting the PRE-WELD parameter to zero, the pre-welding process will not be carried

out.

 On setting the POST-WELD parameter to zero, the post-welding process will not be

carried out.

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2.5 – CONSTANT POWER OPERATING MODE (PWK)

When working in constant power mode, the inverter calculates the real effective value (RMS) of the secondary voltage and the secondary current every mS and maintains the product constant through a mathematical algorithm during mains voltage changes. Consequently if the secondary resistance decreases, the welding current will increase and vice versa when the secondary resistance increases the welding current will decrease. The adjustment in constant power works correctly until the welding current reaches the current value set in the CURR. MAX. parameter. On attaining said limit, the inverter automatically reduces the supplied power in real time to limit the value of the supplied current. The supplied welding current may never exceed the max value set for the used welding transformer. Using constant power may be seen as a constant energy welding at a known time. In fact, when working with constant power during the welding operation, a constant energy value is always supplied at a fixed time.

The use of the constant power working mode may be useful to compensate the wear of the electrodes or to weld materials that are subjected to significant resistance changes during the welding process such as, for instance, rod welding or highly-resistive metal welding. In these cases the current decreases during the initial welding phase in which the resistance of the material is typically higher. As such, the squirting of molten material is avoided, phenomena that reduce the quality of the weld.

You can see the inconstancy of the current and secondary voltage to maintain constant the product of the two quantities and, as such, the supplied power.

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TABLE WITH CONSTANT POWER OPERATING MODE PARAMETERS

PARAMETER RANGE VALUE

PROGRAM N. 001 – 300 WORKING MODE PWK CONTROL MODE * NO QUALITY – T* OFF QUALITY – R * OFF SQUEEZE 1 0.5 – 99.0 cycles SQUEEZE 00.0 – 99.0 cycles PRESSURE 00.5 – 10.0 bar FORGE DELAY 00 – 99 cycles FORG.PRESS. 00.5 – 10.0 bar PRE-WELD 0000 – 1000 mS PRE-POWER 000.20 – 600.00 KW COLD 1 0000 – 1000 mS SLOPE UP 0000 – 1000 mS WELD 0001 – 2000 mS POWER 000.20 – 600.00 KW CURR. MAX. 001.00 – 200.00 KA COLD 2 0000 – 1000 mS IMPULSE N. 1 – 9 WELD 2 0000 – 1000 mS POWER 2 000.20 – 600.00 KW SLOPE DOWN 0000 – 1000 mS COLD 3 0000 – 1000 mS POST-WELD 0000 – 1000 mS POST-POWER 000.20 – 600.00 KW HOLD TIME 00.5 – 99.0 cycles OFF TIME 00.0 – 99.0 cycles

CONTROL MODE * CUR LIM I MIN 000.30 – 200.00 KA LIM I MAX 000.30 – 200.00 KA

CONTROL MODE * RO LIM RO MIN 005.0 – 100.0% LIM RO MAX 005.0 – 100.0%

CONTROL MODE * VE LIM V MIN 00.20 – 20.00 V LIM V MAX 00.20 – 20.00 V

CONTROL MODE * PW LIM P MIN 000.20 - 600.00 KW LIM P MAX 000.20 – 600.00 KW

CONTROL MODE * ENE LIM E MIN 00000 – 60000 J LIM E MAX 00000 – 60000 J QUALITY –T * THICK THICK. MIN 00.00 – 60.00 mm

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THICK MAX 00.00 – 60.00 mm

QUALITY –T * IDENT IDENT. MIN 0.000 – 6.000 mm IDENT. MAX 0.000 – 6.000 mm

QUALITY –T * TH+ID THICK. MIN 00.00 – 60.00 mm THICK MAX 00.00 – 60.00 mm IDENT. MIN 0.000 – 6.000 mm IDENT. MAX 0.000 – 6.000 mm

QUALITY –T * ZERO

QUALITY –R * PRE RMIN PRE 0 – 60000uOhm RMAX PRE 0 – 60000uOhm

QUALITY –R * POST RMIN POST 0 – 60000uOhm RMAX POST 0 – 60000uOhm

QUALITY –R * PRE+POST RMIN PRE 0 – 60000uOhm RMAX PRE 0 – 60000uOhm RMIN POST 0 – 60000uOhm RMAX POST 0 – 60000uOhm

QUALITY –R * ZERO

There are some special conditions:

 On setting the OFF TIME to zero, the control unit will work in single cycle.  On setting the PRE-WELD parameter to zero, the pre-welding process will not be carried

out.

 On setting the POST-WELD parameter to zero, the post-welding process will not be

carried out.

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2.6 – CONSTANT ENERGY OPERATING MODE (ENE)

With a constant energy control unit, all the settings are made as for conventional control units except for the ENERGY parameter and the welding time parameter, where a set rating is not required but minimum and maximum ratings are set. The inverter constantly adjusts the welding current to match it with the set value. During the welding operations, the inverter detects the real effective value (RMS) of the welding current, the non-inductive component of the voltage at the electrodes in volts and the welding duration in mS. The product of I x V x time gives the thermal energy produced during welding, expressed in joules (W x sec).

Since the energy subtracted by conduction and that dissipated between the external sheets and the electrodes, reduce the precision of the energy measured, it is advisable to weld with short timings and high electrode force. Therefore it is important, for good execution of the spot quality control, that the welding machine it is applied to has adequate specifications relating to power, electrode force and welding current for the execution of high A and B class spots.

To ensure correct use of the control unit in this working mode, we recommend following the procedure below step by step:

1. adjust the welding pressure, the welding current and the diameter of the electrodes according to the traditional tables for the execution of the required welding.

2. disable the stepper function or the dressing function if activated.

3. set AUTORETAIN ON

4. set the control unit to work in constant current mode.

5. carry one spot weld out and verify that it is satisfactory.

6. read the total developed energy value on the control unit.

7. set the control unit to work in constant energy mode.

8. set the energy value read in the ENERGY parameter of the work program.

9. adjust the minimum time (T. MIN. WELD.) equal to the number of mS required to carry out the spot with the new electrodes.

10. adjust the maximum time (T. MAX. WELD.) equal to a number of mS that will not damage the piece to be welded.

ENERGY TREND READINGS DURING WELDING

1400

1200

1000

800

600

400

200

02468101214

TABLE WITH CONSTANT ENERGY OPERATIONG MODE PARAMETERS

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PARAMETER RANGE VALUE

PROGRAM N. 001 – 300 WORKING MODE ENE CONTROL MODE * NO QUALITY – T* OFF QUALITY – R * OFF SQUEEZE 1 0.5 – 99.0 cycles SQUEEZE 00.0 – 99.0 cycles PRESSURE 00.5 – 10.0 bar FORGE DELAY 00 – 99 cycles FORG.PRESS. 00.5 – 10.0 bar PRE-WELD 0000 – 1000 mS PRE-CURR. 000.30 – 200.00 KA COLD 1 0000 – 1000 mS SLOPE UP 0000 – 1000 mS CURRENT 000.30 – 200.00 KA ENERGY 0 – 60000 J WELD. MIN. 0001 – 999 mS WELD. MAX. 0002 – 1000 mS COLD 2 0000 – 1000 mS IMPULSE N. 1 – 9 WELD 2 0000 – 1000 mS CURRENT 2 000.30 – 200.00 KA SLOPE DOWN 0000 – 1000 mS COLD 3 0000 – 1000 mS POST-WELD. 0000 – 1000 mS POST-CURR. 000.30 – 200.00 KA HOLD TIME 00.5 – 99.0 cycles OFF TIME 00.0 – 99.0 cycles

CONTROL MODE * CUR LIM I MIN 000.30 – 200.00 KA LIM I MAX 000.30 – 200.00 KA

CONTROL MODE * RO LIM RO MIN 005.0 – 100.0% LIM RO MAX 005.0 – 100.0%

CONTROL MODE * VE LIM V MIN 00.20 – 20.00 V LIM V MAX 00.20 – 20.00 V

CONTROL MODE * PW LIM P MIN 000.20 - 600.00 KW LIM P MAX 000.20 – 600.00 KW

QUALITY –T * THICK

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THICK. MIN 00.00 – 60.00 mm THICK MAX 00.00 – 60.00 MM

QUALITY –T * IDENT IDENT. MIN 0.000 – 6.000 mm IDENT. MAX 0.000 – 6.000 mm

QUALITY –T * TH+ID THICK. MIN 00.00 – 60.00 mm THICK MAX 00.00 – 60.00 MM IDENT. MIN 0.000 – 6.000 mm IDENT. MAX 0.000 – 6.000 mm

QUALITY –T * ZERO

QUALITY –R * PRE RMIN PRE 0 – 60000uOhm RMAX PRE 0 – 60000uOhm

QUALITY –R * POST RMIN POST 0 – 60000uOhm RMAX POST 0 – 60000uOhm

QUALITY –R * PRE+POST RMIN PRE 0 – 60000uOhm RMAX PRE 0 – 60000uOhm RMIN POST 0 – 60000uOhm RMAX POST 0 – 60000uOhm

QUALITY –R * ZERO

There are some special conditions:

 On setting the OFF TIME to zero, the control unit will work in single cycle.  On setting the PRE-WELD parameter to zero, the pre-welding process will not be carried

out.

 On setting the POST-WELD parameter to zero, the post-welding process will not be

carried out.

 On setting WELD 2 parameter to zero, WELD 2 will not be carried out.  On setting LIM I MIN and LIM I MAX to the same value, the limits are deactivated.  On setting LIM RO MIN and LIM RO MAX to the same value, the limits are deactivated.  On setting LIM V MIN and LIM V MAX to the same value, the limits are deactivated.  On setting LIM P MIN and LIM P MAX to the same value, the limits are deactivated.  On setting LIM E MIN and LIM E MAX to the same value, the limits are deactivated.  On setting THICK. MIN and THICK. MAX to the same value, the limits are deactivated.  On setting IDENT. MIN and IDENT. MAX to the same value, the limits are deactivated.  On setting RMIN PRE and RMAX PRE to the same value, the limits are deactivated  On setting RMIN POST and RMAX POST to the same value, the limits are deactivated

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It is advisable to activate the CONTROL UNIT in RO MODE and to check the limit use conditions before proceeding with production. For instance, if use is meant to be with 2 sheets, the limit conditions are either with 1 or 3 sheets. The constant energy is adjusted by the TE700 control unit. The operator must then check the current slicing percentage of the inverter with 1 sheet and set this value as minimum limit. The value with 3 sheets should be set as maximum limit.

However, it is not possible to undoubtedly assure that the piece has been effectively welded, as all the conditions and parameters involved in the welding process execution should be checked.

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TECNA S.p.A. ITEM TE700 Instruction Manual

2.7 - OPERATING IN DYNAMIC MODE (DYN)

The DYNAMIC MODE is an adaptive type inverter working mode. This unit is capable of detecting faulty conditions, during the welding operation, such as the imperfect contact of the sheets to be welded, presence of impurities between the pieces to be welded, presence of shunts near the electrodes or wear of the electrodes. After having identified one or more faulty conditions, the control unit can dynamically modify the welding process to correct said conditions. The welding process is corrected by extending the welding time up to a max limit defined by the operator. In DYNAMIC MODE the control unit adjusts the welding current for the purpose of obtaining a correct weld and avoiding, at the same time, the squirting of molten material that could lead to welds of lower classes.

Proceed as follows to use the DYNAMIC MODE:

 Set the control unit to IK WORKING MODE.  Adjust the welding pressure, the welding current and the diameter of the

electrodes, conforming to the standard tables, to carry out the required weld.

 In order to activate the DYNAMIC MODE at the end of the welding procedure, the

PULSE and CURRENT 2 parameters must NOT be set to IK WORKING MODE otherwise it will not be possible to activate the DYNAMIC MODE.

 Check that the electrodes used are in perfect working order.  Spot-weld a sample of material not subjected to anomalous conditions that is to

say with paired sheets, clean and without any shunt spots in the whereabouts.

 If the quality of the welding is satisfactory, switch the control unit WORKING

MODE to DYN. The DYN mode may be activated only if the affected weld program is the same with which the last weld was carried out and if the last weld was carried out in IK WORKING MODE.

The control unit asks the operator whether or not to activate the DYNAMIC MODE. If the – key is pressed, the working mode goes back to IK mode whilst if the + key is pressed, the new WORKING MODE will be DYN.

ACTIVATE DYNAMIC ? <+> OK <-> CANCEL

After having activated the dynamic mode, the welding parameters inside the program set to dynamic mode should not be changed by the operator since they are compiled automatically by the control unit. Should the operator change any of them, this would invalidate the correcting capacity of the dynamic mode and therefore would entail a new calibration cycle to work efficiently.

However, it is not possible to undoubtedly assure that the piece has been effectively welded, as all the conditions and parameters involved in the welding process execution should be checked.

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TABLE WITH DYNAMIC OPERATING MODE PARAMETERS

PARAMETER RANGE VALUE

PROGRAM N. 001 – 300 WORKING MODE DYN CONTROL MODE * NO QUALITY – T* OFF QUALITY – R * OFF SQUEEZE 1 0.5 – 99.0 cycles SQUEEZE 00.0 – 99.0 cycles PRESSURE 00.5 – 10.0 bar FORGE DELAY 00 – 99 cycles FORG.PRESS. 00.5 – 10.0 bar PRE-WELD 0000 – 1000 mS PRE-POWER 000.20 – 600.00 KW COLD 1 0000 – 1000 mS SLOPE UP 0000 – 1000 mS WELD 0001 – 2000 mS CURRENT 000.30 – 200.00 KA POWER 2 000.20 – 600.00 KW CURR. MAX. 001.00 – 200.00 KA SLOPE DOWN 0000 – 1000 mS COLD 3 0000 – 1000 mS POST-WELD 0000 – 1000 mS POST-POWER 000.20 – 600.00 KW HOLD TIME 00.5 – 99.0 cycles OFF TIME 00.0 – 99.0 cycles

CONTROL MODE * CUR LIM I MIN 000.30 – 200.00 KA LIM I MAX 000.30 – 200.00 KA

CONTROL MODE * RO LIM RO MIN 005.0 – 100.0% LIM RO MAX 005.0 – 100.0%

CONTROL MODE * VE LIM V MIN 00.20 – 20.00 V LIM V MAX 00.20 – 20.00 V

CONTROL MODE * PW LIM P MIN 000.20 - 600.00 KW LIM P MAX 000.20 – 600.00 KW

CONTROL MODE * ENE LIM E MIN 00000 – 60000 J LIM E MAX 00000 – 60000 J

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QUALITY –T * THICK THICK. MIN 00.00 – 60.00 mm THICK MAX 00.00 – 60.00 mm

QUALITY –T * IDENT IDENT. MIN 0.000 – 6.000 mm IDENT. MAX 0.000 – 6.000 mm

QUALITY –T * TH+ID THICK. MIN 00.00 – 60.00 mm THICK MAX 00.00 – 60.00 mm IDENT. MIN 0.000 – 6.000 mm IDENT. MAX 0.000 – 6.000 mm

QUALITY –T * ZERO

QUALITY –R * PRE RMIN PRE 0 – 60000uOhm RMAX PRE 0 – 60000uOhm

QUALITY –R * POST RMIN POST 0 – 60000uOhm RMAX POST 0 – 60000uOhm

QUALITY –R * PRE+POST RMIN PRE 0 – 60000uOhm RMAX PRE 0 – 60000uOhm RMIN POST 0 – 60000uOhm RMAX POST 0 – 60000uOhm

QUALITY –R * ZERO

There are some special conditions:

 On setting the OFF TIME to zero, the control unit will work in single cycle.  On setting the PRE-WELD parameter to zero, the pre-weld. will not be carried out.  On setting the POST-WELD. parameter to zero, the post-welding process will not be

carried out.

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2.8 – WORK PROGRAM PARAMETERS DESCRIPTION

All the following parameters that indicate non-weld times are expressed in periods, also called mains cycles. The mains frequency determines the duration of a period:

Mains frequency 50 Hz - 1 period = 20 ms

Mains frequency 60 Hz - 1 period = 16.6 ms

WORKING MODE

The WORKING MODE parameter defines the program's welding current type of adjustments: by current slicing percentage (FIX), by constant current (IK), by constant energy (ENE), by constant power (PWK), by constant secondary voltage (VEK) and by DYNAMIC MODE (DYN). The foregoing modes affect the adjustments of the welding current, the secondary voltage and the current slicing percentage of the inverter. The different adjustment modes affect the welding blocks relevant to the welding, welding 2, pre welding and post welding. The possibility of selecting a specific work mode depends on the configuration of the TE700 + INVERTER units and on the configuration of the spot welder on which they are installed.

CONTROL MODE

This parameter allows the operator to select the control mode of the required weld parameter:

 NO No control is carried out on the parameters of the run weld.  CUR The welding current min. and max. limits may be set.  RO The operator may set the minimum and maximum limits of the inverter current slicing

percentage when the weld is executed.

 VE The operator may set the minimum and maximum limits of the average secondary

voltage RMS. The comparison is carried out when the secondary voltage is present during the WELDING block. If working in pulse mode, the comparison is carried out on the last run impulse.

 PW The operator may set the minimum and maximum limits of the average supplied

power value. The comparison is carried out with the average power value supplied during the WELDING block. If working in pulse mode, the comparison is carried out on the last run pulse.

 ENE The operator may set the minimum and maximum limits of the supplied energy value.

The comparison is carried out with the value of the energy supplied by the inverter during the WELDING block. If working in pulse mode, the comparison is carried out on the last

run pulse. The possibility of using a specific control mode depends on the configuration of the TE700 + INVERTER units and on the configuration of the spot welder which they are installed on. Moreover, the available control modes depend on the currently selected WORKING MODE.

QUALITY-T

This parameter allows the operator to select if and which controls are to be carried out on the mechanical qualities of the welded material. The controls are carried out before the passage of the welding current in order to measure the initial thickness of the material to be welded and after the passage of the welding current to measure the electrode penetrations inside the material to be welded.

 OFF No control is carried out on the mechanical dimensions of the material present

between the electrodes.

 THICK The thickness of the material to be welded is measured, before the passage of

the welding current, at the end of the SQUEEZE 1 and SQUEEZE times (if present). The minimum and maximum limits may be set in the measurement carried out.

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 IDENT At the end of the passage of the welding current and before the execution of

the HOLD TIME, the electrodes penetration into the material (that took place during the welding operation), is measured. In order to identify the correct penetration values according to the type of material to be welded, consult the specific welding tables. The minimum and maximum limits may be set in the measurement carried out.

 TH+ID Both measurements are carried out before and after the welding and the

minimum and maximum limits may be set in both.

 ZERO In this mode the welder switches automatically to NO WELD mode. As such, the

operator may carry out a welding cycle without any material in between the electrodes. During this cycle the control unit calculates the zero coordinate used as a reference for the thickness and penetration measurements. The zero procedure is required every time the machine is turned on, when the welder's secondary geometry changes or when maintenance is performed to the electrodes.

This control mode may be activated only if the specific position sensor is properly installed on the spot welder and is activated through the SETUP MENU.

QUALITY-R

This parameter allows the operator to select if and which controls are to be carried out on the electrical qualities of the welded material. The activation of the parameter introduces an initial weld (into the main welding cycle), with reduced current and time as compared to that set in the WELDING block, capable of measuring the initial resistance of the material placed in between the electrodes without altering it from a mechanical point of view. Moreover, a final weld is introduced having the same time and current values as the initial one so as to measure the final resistance of the welded material.

 OFF The resistance of the material in between the electrodes is not measured.  PRE The initial resistance of the material to be welded is measured. The operator may

set the minimum and maximum limits on the measured value.

 POST The final resistance of the material to be welded is measured. The operator may

set the minimum and maximum limits on the measured value.

 PRE+POST Both the initial and the final resistances are measured and the operator

may set the minimum and maximum limits on both measured values.

 ZERO When this mode is selected on the welder, the unit carries out a welding cycle

with reduced current and time as compared to that set in the WELDING block. The procedure is intended to compensate the resistance of the arms so as to read the actual resistance of the material in between the electrodes. The zero procedure must be carried out each time the machine is turned on, when the welder's secondary geometry changes or when maintenance is performed to the electrodes.

The activation of this control mode depends on the configuration mode of the control unit and is activated through the SETUP MENU.

SQUEEZE 1

The SQUEEZE 1 time determines the time needed by the electrode to move down. If a simple pneumatic circuit is present, such time represents the interval of time that elapses from the beginning of the head descent to the welding process beginning. The set value must be long enough to allow the electrodes to achieve the proper clamping force, before the welding process begins. In a pneumatic circuit with low-pressure squeeze, the SQUEEZE 1 time is combined with the SQUEEZE time where the SQUEEZE 1 time is the one determining the duration of the low force squeeze, that is to say the interval of time that elapses from the beginning of the head descent to the application of the welding pressure. The set value must be long enough to allow the electrodes to reach the work piece to be welded. During the SQUEEZE 1 time, it is possible to end the cycle by disabling the start cycle signal.

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SQUEEZE

Even the SQUEEZE time is a wait time similar to that of SQUEEZE 1. It is required in the case of welders that contemplate low-force squeeze function. In this case, said time determines the interval between the application of the welding force to the electrodes (valve EV2 energizes) and the beginning of the welding. It must be long enough to allow the electrodes to reach the correct clamping force before the welding starts. An insufficient adjustment of this time triggers sparks between the electrodes and the sheet when the

welding begins and could cause quality inconsistency. The SQUEEZE time is activated via

parameter LOW FORCE SQUEEZE inserted in the FEATURES TE700 menu. It is advisable to activate this parameter only in the presence of a pneumatic circuit fitted with low-force squeeze. The SQUEEZE time is summed up to the SQUEEZE time 1. The cycle may be

interrupted during the SQUEEZE time by deactivating the cycle start signal.

PRESSURE

This parameter, expressed in bar, represents the welding pressure value. It is used only if the proportional valve is installed in the pneumatic system. The set value must guarantee a suitable clamping force during the welding operation. An insufficient adjustment of this value produces sparks between the electrodes and the sheet when the welding begins. This parameter is activated through the PROP. VALVE function present in the FEATURES TE700 menu.

FORGE

The FORGE parameter expresses the delay time that elapses from the beginning of the welding process and the application of the forging force. It is used exclusively with pneumatic circuits that contemplate the forging function. Such function activates EV3 which permits to increase the electrodes force during the welding cycle. If the value is set to zero, the FORGE function is disabled, valve EV3 is activated either simultaneously with SQUEEZE time 1 or with the SQUEEZE, if the relevant function was activated. This parameter is activated through the specific function in the FEATURES TE700 menu.

PRES-FORG.

This parameter, expressed in bar, represents the forge pressure value. It is used only if the proportional valve is installed in the pneumatic system. The set value must guarantee a suitable clamping force during the forging. An insufficient adjustment of this value produces sparks between the electrodes and the sheet during the welding operation. This parameter is activated after the activation of the FORGE and PROP. VALVE parameters in the TE700 FEATURES menu.

PRE-WELD.

The pre-weld. time parameter (PRE-WELD) describes the duration of a current passage that can be carried out before the weld itself. This parameter is expressed by four digits since it can be adjusted with a 1-mS precision. If the parameter is set to 0, the pre-weld. will not be carried out. This parameter may be activated through the relevant function in the SETUP MENU.

PRE-CURR.

The value expressed in this parameter indicates the current which the PRE-WELD is carried out with. This parameter is activated through the specific function in the SETUP MENU. This parameter is displayed only in IK or ENE WORKING MODE.

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PRE-RO

The value expressed in this parameter indicates the current slicing percentage which the PRE-WELD is carried out with. This parameter is activated through the specific function in the SETUP MENU. This parameter is displayed only in FIX WORKING MODE.

PRE-VE

The value expressed in this parameter indicates the value of the secondary voltage which the PRE-WELD is carried out with. This parameter is activated through the specific function in the SETUP MENU. This parameter is displayed only in VEK WORKING MODE.

PRE-POWER

The value expressed in this parameter indicates the value of the secondary power which the PRE-WELD is carried out with. This parameter is activated through the specific function in the SETUP MENU. This parameter is displayed only in PWK or DYN WORKING MODE.

COLD 1

The COLD 1 parameter indicates the time that elapses from the pre-weld. to the weld. If the pre-weld. is deactivated (that is, when PRE-WELD time = 0), this cold time is not carried out. This parameter may be activated through the relevant function in the SETUP MENU.

SLOPE UP

The current slope up parameter (SLOPE UP) describes the time within which the programmed value of the weld adjustment parameter is attained. The initial value of this parameter is equivalent to the minimum value that the adjustment parameter may have if COLD T. 1 differs from 0. If COLD T. 1 equals 0 and PRE-WELD is other than 0, then the initial value will no longer be the minimum value of the adjustment parameter but the adjustment quantity value used in the PRE-WELD.. Whilst the final value is equivalent to the current value programmed in the WELD parameter, the inclination of the SLOPE UP is calculated automatically by the microprocessor according to programmed values. The SLOPE UP time is summed up to the welding time.

WELD

The WELD time parameter represents the duration of the passage of the welding current. It will be carried out according to the work mode selected for the control unit. When the impulse work mode is activated, this parameter indicates the duration of every single pulse. This parameter is expressed by four digits since it can be adjusted with a 1 mS precision.

WELD. MIN.

The minimum weld. time parameter (WELD. MIN.) is expressed in mS and represents the minimum welding duration. This is carried out with a current value equal to the one indicated in the CURRENT parameter. The welding operation stops if on the elapsing of said time the measured energy value is higher than or equal to the corresponding programmed value. This parameter is displayed only on selecting the ENE WORKING MODE.

WELD. MAX.

The maximum weld. time parameter (WELD. MAX.) is expressed in mS and represents the maximum welding duration. This is carried out with a power value equal to the one indicated in the POWER parameter. In any case, the welding operation stops if on the elapsing of said time the measured energy value is lower than the corresponding programmed value. This parameter is displayed only on selecting the ENE WORKING MODE.

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CURR. MAX

The parameter indicates the maximum current that can circulate on the secondary circuit when the unit's adjustment mode is not by constant current. The task of this parameter is to protect the integrity of the tool used against excessive increases in the welding current. The set value must be greater than the value of the welding current that usually circulates in the machine's secondary circuit with a typical welding performed with a certain spot welder in its work cycle. This parameter is displayed only on selecting the VEK, PWK or DYN WORKING MODE.

CURRENT

The value expressed in this parameter indicates the current which the WELD is carried out with. This parameter is displayed only in the IK or ENE WORKING MODE.

The value expressed in this parameter indicates the current slicing percentage which the WELD is carried out with. This parameter is displayed only in the FIX WORKING MODE.

The value expressed in this parameter indicates the value of the secondary voltage which the WELD is carried out with. This parameter is displayed only in the VEK WORKING MODE.

POWER

The value expressed in this parameter indicates the value of the secondary power which the WELD is carried out with. This parameter is displayed only in the PWK or DYN WORKING MODE

ENERGY

This parameter indicates the energy value, expressed in joules, which must be developed during welding. This rating must be reached in a number of cycles between the minimum time and the maximum time. This parameter is only displayed when ENE (Constant Energy WORKING MODE) is selected.

IMPULSE N.

The number of impulses parameter (IMPULSE N.) indicates the number of impulses which the weld is carried out with. The duration time of every single impulse is the one set in the weld. time parameter (WELD). This parameter is not visible if it is selected as DYN WORKING MODE.

COLD 2

The COLD 2 parameter is used in the pulse working mode; it indicates the time that elapses from a welding impulse to the next one. When the number of the impulses is programmed to zero, cold 2 time is carried out only if a WELD 2 is programmed afterwards, otherwise it is not carried out. This parameter is not visible if it is selected as DYN WORKING MODE.

WELD 2

The WELD 2 time parameter represents the duration of the passage of the welding current. This is carried out conforming to the working mode selected for the control unit. This parameter is expressed by four digits since it can be adjusted with a 1 mS precision. This parameter is not visible if it is selected as DYN WORKING MODE. This parameter is activated through the specific function in the SETUP MENU.

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CURRENT 2

The value expressed in this parameter indicates the current which the WELD is carried out with. This parameter is displayed only in the IK or ENE WORKING MODE. This parameter is activated through the specific function in the SETUP MENU.

RO 2

The value expressed in this parameter indicates the current slicing percentage which the WELD is carried out with. This parameter is displayed only in the FIX WORKING MODE. This parameter is activated through the specific function in the SETUP MENU.

VE 2

The value expressed in this parameter indicates the value of the secondary voltage which the WELD is carried out with. This parameter is displayed only in the VEK WORKING MODE. This parameter is activated through the specific function in the SETUP MENU.

POWER 2

The value expressed in this parameter indicates the value of the secondary power which the WELD is carried out with. This parameter is displayed only with WORKING MODE in PWK. This parameter is activated through the specific function in the SETUP MENU.

SLOPE DOWN

The current slope down parameter (SLOPE DOWN) is a weld. time that is added at the end of the welding procedure during which the welding current decreases from the value set in the adjustment parameter of the WELD or WELD 2 (if present) down to the minimum value foreseen by the adjustment parameter if the COLD 3 TIME is other than zero whilst if the COLD 3 TIME is zero and POST-WELD is other than zero, the minimum value will be the value set for the adjustment parameter in POST WELD. The downward inclination is calculated automatically by the microprocessor according to the programmed values. The SLOPE DOWN time is always summed up to the welding time. This parameter may be activated through the relevant function in the SETUP MENU.

COLD 3

The COLD 3 parameter indicates the time that elapses between the WELD time and the POST-WELD time. This parameter is activated through the specific function in the SETUP MENU.

POST-WELD

The post-weld. time parameter (POST-WELD) describes the duration of a current passage that may be carried out after the weld. time. This parameter is expressed by four digits since it can be adjusted with a 1-mS precision. If the parameter is set to 0, the post-weld. will not be carried out. The post-weld. will be carried out in the adjustment mode set in the working mode with value equal to that set in the control parameter. This parameter is activated through the specific function in the SETUP MENU.

POST-CURR.

The value expressed in this parameter indicates the current which the POST WELD is carried out with. This parameter is displayed only in the IK or ENE WORKING MODE. This parameter is activated through the specific function in the SETUP MENU.

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POST-RO

The value expressed in this parameter indicates the current slicing percentage which the POST-WELD is carried out with. This parameter is displayed only in the FIX WORKING MODE. This parameter is activated through the specific function in the SETUP MENU.

POST-VE

The value expressed in this parameter indicates the value of the secondary voltage which the POST-WELD is carried out with. This parameter is displayed only in the VEK WORKING MODE. This parameter is activated through the specific function in the SETUP MENU.

POST-POWER

The value expressed in this parameter indicates the value of the secondary power which the POST-WELD is carried out with. This parameter is displayed only with WORKING MODE in PWK and DYN. This parameter is activated through the specific function in the SETUP MENU

HOLD TIME

The HOLD TIME 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

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 0, 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.

LIM I MI N

This parameter fixes a minimum current limit value. For each weld, the control unit 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). Activate this parameter by setting the CONTROL MODE to CUR., otherwise the parameter is not displayed during the programming phase. The display of this parameter depends on the configuration of the machine set in the FEATURES INVERTER and FEATURES TE700 menus.

LIM I MAX

This parameter fixes a maximum current limit value. For each weld, the control unit monitors that the welding current supplied by the welder is lower than the value set at this parameter; if it is higher, an error message will be displayed (see the relevant paragraph). Activate this parameter by setting the CONTROL MODE to CUR., otherwise the parameter is not displayed during the programming phase. The display of this parameter depends on the configuration of the machine set in the FEATURES INVERTER and FEATURES TE700 menus.

LIM RO MIN

This parameter defines a minimum current slicing limit value. Each time a weld is carried out the control unit checks that the average current slicing held during the welding operation is greater than the value set in this parameter. Otherwise an error condition occurs (see the specific paragraph).

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Activate this parameter by setting the CONTROL MODE to RO, otherwise the parameter is not displayed during the programming phase. The display of this parameter depends on the configuration of the machine set in the FEATURES INVERTER and FEATURES TE700 menus.

LIM RO MAX

This parameter defines a maximum current slicing limit value. Each time a weld is carried out the control unit checks that the average current slicing held during the welding operation is less than the value set in this parameter. Otherwise an error condition occurs (see the specific paragraph). Activate this parameter by setting the CONTROL MODE to RO, otherwise the parameter is not displayed during the programming phase. The display of this parameter depends on the configuration of the machine set in the FEATURES INVERTER and FEATURES TE700 menus.

LIM V MIN

This parameter defines a minimum secondary voltage limit value. Each time a weld is carried out the control unit checks that the secondary voltage during the welding operation is greater than the value set in this parameter. Otherwise an error condition occurs (see the specific paragraph). Activate this parameter by setting the CONTROL MODE to VE, otherwise the parameter is not displayed during the programming phase. The display of this parameter depends on the configuration of the machine set in the FEATURES INVERTER and FEATURES TE700 menus.

LIM V MAX

This parameter defines a maximum secondary voltage limit value. Each time a weld is carried out the control unit checks that the secondary voltage during the welding operation is less than the value set in this parameter. Otherwise an error condition occurs (see the specific paragraph). Activate this parameter by setting the CONTROL MODE to VE, otherwise the parameter is not displayed during the programming phase. The display of this parameter depends on the configuration of the machine set in the FEATURES INVERTER and FEATURES TE700 menus.

LIM P MIN

This parameter defines a minimum power limit value. Each time a weld is carried out the control unit checks that the power supplied by the welder is greater than the value set in this parameter. Otherwise an error condition occurs (see the specific paragraph). Activate this parameter by setting the CONTROL MODE to PW, otherwise the parameter is not displayed during the programming phase. The display of this parameter depends on the configuration of the machine set in the FEATURES INVERTER and FEATURES TE700 menus.

LIM P MAX

This parameter defines a maximum power limit value. Each time a weld is carried out the control unit checks that the power supplied by the welder is less than the value set in this parameter. Otherwise an error condition occurs (see the specific paragraph). Activate this parameter by setting the CONTROL MODE to PW, otherwise the parameter is not displayed during the programming phase. The display of this parameter depends on the configuration of the machine set in the FEATURES INVERTER and FEATURES TE700 menus.

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LIM E MIN

This parameter defines a minimum energy limit value. Each time a weld is carried out the control unit checks that the energy supplied by the welder is greater than the value set in this parameter. Otherwise an error condition occurs (see the specific paragraph). Activate this parameter by setting the CONTROL MODE to ENE, otherwise the parameter is not displayed during the programming phase. The display of this parameter depends on the configuration of the machine set in the FEATURES INVERTER and FEATURES TE700 menus.

LIM E MAX

This parameter defines a maximum energy limit value. Each time a weld is carried out the control unit checks that the energy supplied by the welder is less than the value set in this parameter. Otherwise an error condition occurs (see the specific paragraph). Activate this parameter by setting the CONTROL MODE to ENE, otherwise the parameter is not displayed during the programming phase. The display of this parameter depends on the configuration of the machine set in the FEATURES INVERTER and FEATURES TE700 menus.

THICK MIN

This parameter defines a lower limit as concerns the minimum thickness of the material in between the electrodes. Before the welding begins, the measurement of the thickness of the material in between the electrodes must be greater than the set minimum limit. Otherwise an error condition occurs (see the specific paragraph). Activate this parameter by setting QUALITY-T. to THICK or TH+ID, otherwise the parameter is not displayed during the programming phase. The display of this parameter depends on the configuration of the machine set in the FEATURES INVERTER and FEATURES TE700 menus.

THICK MAX

This parameter defines an upper limit as concerns the maximum thickness of the material in between the electrodes. Before the welding begins, the measurement of the thickness of the material in between the electrodes must be less than the set maximum limit. Otherwise an error condition occurs (see the specific paragraph). Activate this parameter by setting QUALITY-T. to THICK or TH+ID, otherwise the parameter is not displayed during the programming phase. The display of this parameter depends on the configuration of the machine set in the FEATURES INVERTER and FEATURES TE700 menus.

IDENT MIN

This parameter defines a lower limit as concerns the minimum electrodes penetration at the end of the welding procedure. At the end of the welding operation the measurement of the penetration value must be greater than the set limit. Otherwise an error condition occurs (see the specific paragraph). Activate this parameter by setting QUALITY-T. to IDENT or TH+ID, otherwise the parameter is not displayed during the programming phase. The display of this parameter depends on the configuration of the machine set in the FEATURES INVERTER and FEATURES TE700 menus.

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IDENT MAX

This parameter defines an upper limit as concerns the maximum electrodes penetration at the end of the welding procedure. At the end of the welding operation the measurement of the penetration value must be less than the set limit. Otherwise an error condition occurs (see the specific paragraph). Activate this parameter by setting QUALITY-T. to IDENT or TH+ID, otherwise the parameter is not displayed during the programming phase. The display of this parameter depends on the configuration of the machine set in the FEATURES INVERTER and FEATURES TE700 menus.

R MIN PRE

This parameter defines a lower limit as concerns the value of the material's initial resistance. Before starting the welding, the initial resistance value must be greater than the minimum set value. Otherwise an error condition occurs (see the specific paragraph). Activate this parameter by setting QUALITY-R. to PRE or PRE+POST, otherwise the parameter is not displayed during the programming phase. The display of this parameter depends on the configuration of the machine set in the FEATURES INVERTER and FEATURES TE700 menus.

R MAX PRE

This parameter defines an upper limit as concerns the value of the material's initial resistance. Before starting the welding, the initial resistance value must be less than the maximum set value. Otherwise an error condition occurs (see the specific paragraph). Activate this parameter by setting QUALITY-R. to PRE or PRE+POST, otherwise the parameter is not displayed during the programming phase. The display of this parameter depends on the configuration of the machine set in the FEATURES INVERTER and FEATURES TE700 menus.

R MIN POST

This parameter defines a lower limit as concerns the value of the material's final resistance. At the end of the welding, the value of the material's final resistance must be greater than the minimum set limit. Otherwise an error condition occurs (see the specific paragraph). Activate this parameter by setting QUALITY-R. to POST or PRE+POST, otherwise the parameter is not displayed during the programming phase. The display of this parameter depends on the configuration of the machine set in the FEATURES INVERTER and FEATURES TE700 menus.

R MAX POST

This parameter defines the maximum limit as concerns the value of the material's final resistance. At the end of the welding, the value of the material's final resistance must be greater than the maximum set limit. Otherwise an error condition occurs (see specific paragraph). Activate this parameter by setting QUALITY-T. to THICK or TH+ID, otherwise the parameter is not displayed during the programming phase. The display of this parameter depends on the configuration of the machine set in the FEATURES INVERTER and FEATURES TE700 menus.

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2.9 - SETUP MENU

-TE700 VER. 1.13- PROGRAM DATA >SETUP MENU STEPPER MENU

In this menu, the operator may find those parameters that allow simplifying the programming and better adjusting the control unit to the operator’s requirements.

SETUP MENU >START 1 PRG 010 CYCLE START 2 006 PRINTER SPOTS NONE

SETUP MENU PARAMETERS TABLE

PARAMETER PARAMETER DESCRIPTION VALUE

START 1 PRG Start cycle 1 program 000 – 300 START 2 PRG Start cycle 2 program 001 – 300 PRINTER SPOTS Welding spots print ALL – NONE – BAD STOP BAD SPOT T1 Number of spots to stop out of limit for tool 1 0 – 15 STOP BAD SPOT T2 Number of spots to stop out of limit for tool 2 0 – 15 STOP BAD SPOT T3 Number of spots to stop out of limit for tool 3 0 – 15 STOP BAD SPOT T4 Number of spots to stop out of limit for tool 4 0 – 15 LANGUAGE Language for describing parameters ITA – ENG – SPA – DEU -

FRA - UNG – POR - SWE

PRE-WELD It activates the parameters relevant to the PRE-

WELD.

POST-WELD It activates the parameters relevant to the POST-

WELD. WELD 2 Activates the WELD 2 parameters ON – OFF PROG. SEQUENCE Activates the sequence of programs ON - OFF DYNAMIC TIME Max welding time adjustment in DYNAMIC mode 2X – 9X DYNAMIC COMP Dynamic correction algorithm intervention

adjustment WELD QUALITY Activation of the quality control limits in the weld

program during the welding operation.

OFF – R ONLY – T ONLY –

ON - OFF

30 % - 200 %

R+T

START 1 PRG

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 selected in the programming frame.

START 2 PRG

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

PRINTER SPOTS

With this parameter, if the serial port is setup for print (see FEATURES TE700), the operator can choose which welding spots to be printed. It is possible to disable the print, print all spots or only the spots whose current value remains out of the set limits values.

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STOP BAD SPOT T1

The STOP BAD SPOT T1 parameter allows the operator to program the control unit so that it

stops when welds are carried out with weld programs associated with tool number 1 with values of the controlled parameter beyond the set limits. The programmed value indicates the number of consecutive "out of limits" welds that cause the machine to stop. The limits error occurs when a welding is carried out with values that are greater than or less than the set limits. Adjust the value with keys and from 0 to 15. When the value is set to zero the function is disabled therefore the condition in which the preset limits are exceeded does not stop the welder. For further information, please, check the relevant paragraph.

STOP BAD SPOT T2

The STOP BAD SPOT T2 parameter allows the operator to program the control unit so that it

stops when welds are carried out with weld programs associated with tool number 2 with values of the controlled parameter beyond the set limits. The programmed value indicates the number of consecutive "out of limits" welds that cause the machine to stop. The limits error occurs when a welding is carried out with values that are greater than or less than the set limits. Adjust the value with keys and from 0 to 15. When the value is set to zero the function is disabled therefore the condition in which the preset limits are exceeded does not stop the welder. For further information, please, check the relevant paragraph.

STOP BAD SPOT T3

The STOP BAD SPOT T3 parameter allows the operator to program the control unit so that it

stops when welds are carried out with weld programs associated with tool number 3 with values of the controlled parameter beyond the set limits. The programmed value indicates the number of consecutive "out of limits" welds that cause the machine to stop. The limits error occurs when a welding is carried out with values that are greater than or less than the set limits. Adjust the value with keys and from 0 to 15. When the value is set to zero the function is disabled therefore the condition in which the preset limits are exceeded does not stop the welder. For further information, please, check the relevant paragraph.

STOP BAD SPOT T4

The STOP BAD SPOT T4 parameter allows the operator to program the control unit so that it

stops when welds are carried out with weld programs associated with tool number 4 with values of the controlled parameter beyond the set limits. The programmed value indicates the number of consecutive "out of limits" welds that cause the machine to stop. The limits error occurs when a welding is carried out with values that are greater than or less than the set limits. Adjust the value with keys and from 0 to 15. When the value is set to zero the function is disabled therefore the condition in which the preset limits are exceeded does not stop the welder. For further information, please, check the relevant paragraph.

LANGUAGE

With this parameter the operator programs the language in which the control unit should display both the parameters to be set and the error messages. One may select the following languages: ITALIAN – ENGLISH – SPANISH – GERMAN – FRENCH – HUNGARIAN – PORTUGUESE – SWEDISH.

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PRE-WELD

When set to ON it activates the pre-weld parameters in all the programs.

POST-WELD

When set to ON it activates the parameters relevant to the post welding, the cold 3 time and the slope down in all the programs.

WELD 2

When set to ON it activates the welding 2 parameters in all the programs. If the WORKING MODE of a program is set to DYNAMIC, the WELD 2 parameters in that program will not be activated.

DYNAMIC TIME

This parameter allows the operator to set the time window inside which the DYN WORKING MODE can intervene to correct any welding defects. The intervention time may be adjusted from twice the time required to carry out the sample weld up to 9 times the time used to carry out the sample weld. If the DYNAMIC control unit is not capable of correcting the error within the max foreseen time, the control unit stops and signals the error (see the specific chapter).

DYNAMIC COMP

This parameter allows the operator to set, with DYN WORKING MODE active, how effective the action of the weld correction algorithm should be. When using the machine under routine conditions this parameter should be set to 30%. Increase the value of the parameter if the corrective action is not satisfactory.

WELD QUALITY

This parameter allows the operator to activate additional weld quality controls inside the weld program. The operator may choose to activate either the measurement of the initial and/or final resistance quality or only the measurement of the initial thickness and/or penetration, or activate both the measurement of the material's electrical resistance and the measurement of its mechanical characteristics. The activation of items T ONLY and R+T is subordinated to the correct installation of the linear position transducer on the machine. The activation of items R ONLY and R+T is subordinated to the presence of the cables that measure the electrodes' voltage on the spot welder otherwise said items may not be selected.

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2.10 - STEPPER MENU

-TE700 VER. 1.09->PROGRAM DATA SETUP MENU STEPPER MENU

This menu contains parameters associated with the current stepper operations.

STEPPER MENU T1 >TOOLS N° 1 STEPPER WELD OFF STEPPER TIME OFF

The unit can manage up to max 4 different stepper modules, one for each welding tool managed by the control unit. This allows the operator to personalize a stepper curve, for each type of tool used, which takes into consideration only the spots carried out by the specific tool selected and the different wear speeds of the individual tools. For each tool the operator can choose, in a self-contained and mutually exclusive manner, whether to activate the stepper function or the electrodes dressing function. If the electrodes dressing function has already been activated for the selected tool, when the operator attempts to activate the stepper function the following screen will be displayed to warn the operator about the conflicting condition.

SW OFF DRESSING ? <+> OK <-> CANCEL

Press key – to deactivate the stepper function and activate the electrodes dressing function for the selected tool. Press key + to deactivate the electrodes dressing function for the selected tool (without losing the parameterization entered for the electrodes dressing) and activate the stepper function on the same tool. Two different stepper laws, having segments of the same duration as far as number of steps but different stepper percentages for each segment, may be defined for each stepper module. The use of two different stepper laws inside the same stepper module permits to correct parameter changes that occur at different speeds during the welding operation.

For example, the operator may correct the wear of the electrode by increasing the welding current and, at the same time, also correct the reduction of the dimensions of the electrode within the QUALITY-T control on the initial thickness of the material to be welded. Or, with one law it is possible to intervene on the increase of the welding current proportionally with the consumption of the electrode and increase the weld. time with a second law. As such, the total welding current increase can be restricted in case the tool or the spot welder is not capable of withstanding the current increase that would be necessary without intervening on the weld. time.

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STEPPER MENU PARAMETERS TABLE

PARAMETER PARAMETER DESCRIPTION RANGE VALUE

TOOLS N° Number of the tool which the

parameterization refers to

STEPPER WELD Stepper of the main adjustment

parameter STEPPER TIME Weld time increase OFF – ON L1 – ON L2 STEPPER THICK. Decrease of the electrodes size OFF – ON L1 – ON L2 N.TOTAL STEPS Total number of steps 1 – 7 SPOTS 1 Spots step 1 0 – 10000 INCREMENT 1-L1 INCREMENT percentage law 1 0 – 50 % INCREMENT 1-L2 INCREMENT percentage law 2 0 – 50 % SPOTS 2 Spots step 2 0 – 5000 INCREMENT 2-L1 INCREMENT percentage law 1 0 – 50 % INCREMENT 2-L2 INCREMENT percentage law 2 0 – 50 % SPOTS 3 Spots step 3 0 – 5000 INCREMENT 3-L1 INCREMENT percentage law 1 0 – 50 % INCREMENT 3-L2 INCREMENT percentage law 2 0 – 50 % SPOTS 4 Spots step 4 0 – 5000 INCREMENT 4-L1 INCREMENT percentage law 1 0 – 50 % INCREMENT 4-L2 INCREMENT percentage law 2 0 – 50 % SPOTS 5 Spots step 5 0 – 5000 INCREMENT 5-L1 INCREMENT percentage law 1 0 – 50 % INCREMENT 5-L2 INCREMENT percentage law 2 0 – 50 % SPOTS 6 Spots step 6 0 – 5000 INCREMENT 6-L1 INCREMENT percentage law 1 0 – 50 % INCREMENT 6-L2 INCREMENT percentage law 2 0 – 50 % SPOTS 7 Spots step 7 0 – 5000 INCREMENT 7-L1 INCREMENT percentage law 1 0 – 50 % INCREMENT 7-L2 INCREMENT percentage law 2 0 – 50 %

OFF – ON L1 – ON L2

1 – 4

TOOLS N°

This parameter allows the operator to choose on which INCREMENT module a corresponding INCREMENT module will be available for each tool made available in the INVERTER FEATURES menu. On changing the value of the parameter, all the next parameters will be updated with the newly selected INCREMENT module.

STEPPER WELD

This parameter allows the operator to activate or deactivate the stepper of the welding adjustment parameter. The stepper will act on the adjustment parameter selected in the working mode of the called weld program. For example in the case of IK, the stepper will affect the welding current, in the case of PWK the stepper will affect the power supplied during the welding operation. The stepper of the main adjustment parameter may be left deactivated or arbitrarily associated with one of the two available stepper laws.

STEPPER TIME

This parameter allows the operator to activate or deactivate the stepper of the parameter time referred to the duration of each hot phase of the welding process, pre-weld time, slope-up time, weld time, weld. 2 time, slope-down time and post-weld time. The cold weld times and

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the movement times are not increased. The time increase may be left deactivated or arbitrarily associated with one of the two available stepper laws.

STEPPER THICK.

This parameter may be modified only if the sensors that check for the position of the electrodes have been correctly installed in the spot welder. If affirmative, the parameter may be changed and consequently it will be possible to define a law that corrects the thickness reduction of the electrodes caused by wear and tear. The correction permits to maintain the exact measurement of the initial thickness of the sheets to be welded. Otherwise if the electrodes are very worn out and the operator does not wish to resort to a stepper law, the zero procedure may be carried out more often than the rate at which the change in size of the electrodes is corrected.

The parameter may be left deactivated or arbitrarily associated with one of the two available stepper laws.

N.TOTAL STEPS

This parameter indicates by how many segments the current stepper curve is to be made up of. In order to deactivate the stepper module function, STEPPER WELD. and STEPPER TIME and STEPPER THICK must all be OFF.

SPOTS 1

This parameter indicates the number of spots which the associated segment is composed of. When STEPPER 1-L1 = 0 and SPOTS 1 ≠ 0, the value set in parameter SPOTS 1 equals the max number of weld spots.

INCREMENT 1-L1

This increment indicates the percentage increase relevant to the first segment of stepper law 1.

INCREMENT 1-L2

This increment indicates the percentage increase relevant to the first segment of stepper law 2.

SPOTS 2

This parameter indicates the number of spots which the associated segment is composed of.

INCREMENT 2-L1

This increment indicates the percentage increase relevant to the second segment of stepper law 1.

INCREMENT 2-L2

This increment indicates the percentage increase relevant to the second segment of stepper law 2.

SPOTS 3

This parameter indicates the number of spots which the associated segment is composed of.

INCREMENT 3-L1

This increment indicates the percentage increase relevant to the third segment of stepper law

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INCREMENT 3-L2

This increment indicates the percentage increase relevant to the third segment of stepper law

SPOTS 4

This parameter indicates the number of spots which the associated segment is composed of.

INCREMENT 4-L1

This increment indicates the percentage increase relevant to the fourth segment of stepper law 1.

INCREMENT 4-L2

This increment indicates the percentage increase relevant to the fourth segment of stepper law 2.

SPOTS 5

This parameter indicates the number of spots which the associated segment is composed of.

INCREMENT 5-L1

This increment indicates the percentage increase relevant to the fifth segment of stepper law

INCREMENT 5-L2

This increment indicates the percentage increase relevant to the fifth segment of stepper law

SPOTS 6

This parameter indicates the number of spots which the associated segment is composed of.

INCREMENT 6-L1

This increment indicates the percentage increase relevant to the sixth segment of stepper law

INCREMENT 6-L2

This increment indicates the percentage increase relevant to the sixth segment of stepper law

SPOTS 7

This parameter indicates the number of spots which the associated segment is composed of.

INCREMENT 7-L1

This increment indicates the percentage increase relevant to the seventh segment of stepper law 1.

INCREMENT 7-L2

This increment indicates the percentage increase relevant to the seventh segment of stepper law 2.

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2.11 - ADJUSTMENT STEPPER FUNCTION

The adjustment stepper function permits correcting the wear of the electrodes that affects the quality of the welds. When the diameter of the electrodes increases, so does the contact section between electrode and piece to be welded and consequently the welding current density decreases (Amperes/mm2). If the same adjustment is maintained for the entire electrodes' life, the quality of the last spots carried out is poorer as compared to the first ones. In order to correct this event, the adjustment stepper function was introduced, also called "stepper". The operating principle is to gradually increase the adjustment as the diameter of the electrodes increases so that constant current density is maintained.

In order to describe the trend of the adjustment during the electrodes' lifespan, a stepper curve is programmed. This curve is made up of one or more segments for each of which the operator programs the number of welds and the relevant increment of the adjustment parameter in percentage.

Once programmed, the increment of the adjustment parameter is applied to all the weld programs that use the same tool number of the programmed stepper module.

Limits, if used, increase by the same percentage, as well as the pre-weld., post-weld. and welding 2 adjustments and the energy value to be attained.

During the welding process, it is possible to correct the stepper curve trend by changing the parameters determining its trend.

In order to begin a new stepper curve, reset the spot counter relevant to the stepper module to be cleared, that is to say the one relevant to the tool in which the electrodes' starting diameter was restored.

SIMPLIFIED USE OF THE STEPPER FUNCTION (LINEAR STEPPER)

The present example is carried out considering the control unit set to IK WORKING MODE. Only tool 1 will be used and the only active stepper will be the one relevant to the parameter adjustment associated with stepper law number 1. 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 operator 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.

In the "simplified" stepper function use, always set N.TOTAL STEPS parameter to 1 (since there is only one segment to be programmed). Enter the number of welds to be carried out in parameter SPOTS 1. In practice, the foreseen service life of the electrodes. Enter the required percentage increase in parameter INCREMENT 1-L1.

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

Example:

The welding tests proved that: the electrode life corresponds to 2000 welding spots; that with new electrodes the required current is 15 kA; that after 2000 spots the electrodes diameter increment requires a 19 kA current.

The percent variation is calculated as follows:

1519

%26100

Change





rentinitialcurendcurrent

100% 



rentinitialcur

Consequently the following parameters are set in the "STEPPER MENU":

PARAMETER PARAMETER DESCRIPTION VALUE

TOOLS N° Identifier of the tool which the stepper module works on 1 STEPPER WELD Parameter adjustment increase, current in the example ON L1 STEPPER TIME Weld time increase OFF STEPPER THICK. Electrodes thickness decrease OFF TOTAL STEPS Total number of stepper steps 1 SPOTS 1 Number of spots of first segment 2000 INCREMENT 1-L1 Percentage increase of the first segment relevant to law L1 26 % INCREMENT 1-L2 Percentage increase of the first segment relevant to law L2 00 %

The welding program must be set in order to carry out the first welding spot, which is with an adjustment enabling to obtain the necessary current with the starting electrodes 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

FINAL CURRENT = 19 kA

INCREMENT PERCENT = 26 %

WELDING SPOTS NUMBERS = 2000

CURRENT INCREASE DURING THE PRODUCTION

WELDING CURRENT (kA)

0 500 1000 1500 2000

NUMBER OF WELDING SPOTS

On having completed the 2000 welding spots, the control unit stops the production cycle and displays the following message:

STEPPER [164] END WARNING ON TOOLS T1 PUSH [///] TO RESET

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Now the operator replaces the electrodes (or restores their original diameter) and clears the spots counter relevant to the tool whose electrodes were replaced to clear the stepper calculations.

The TE700 resets the initial work parameters and begins a new stepper phase.

COMPLETE USE OF THE STEPPER 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. 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.

IDEAL 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 operator 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

REAL PATTERN

CURRENT

WITH SET INCREMENT

CURVE

NUMBER OF WELDING S POT S

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.

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

The N.TOTAL STEPS parameter determines the number of segments to be entered in the stepper curve. Enter the number of welds that make up the segment in parameters SPOTS 1,2… and enter the relevant percentage increase to be carried out in parameter INCREMENT 1-L1,2-L1…. The programming procedure is outlined in the STEPPER MENU paragraph.

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

WELDING SPOTS EXECUTED NECESSARY CURRENT

0 (initial electrode diameter) 15 kA

700 17.8 kA 1800 19.5 kA 3000 20.2 kA

4000 (final electrode diameter) 20.7 kA

Therefore calculate the duration (in number of welding spots) and the percent increment of each segment. Please, notice that the percent increment must always be calculated referring to the beginning of the considered segment.

spots 700=0-700=1segment ofDuration

spots 1100=700-1800=2segment ofDuration

spots 1200=1800-3000=3segment ofDuration

spots 1000=3000-4000=4segment ofDuration

158.17

8.17

5.19

220

rentinitialcurendcurrent

segmentChange



1001 % 

rentinitialcur

rentinitialcurendcurrent

segmentChange



1002 % 

rentinitialcur

rentinitialcurendcurrent

segmentChange



1003 % 

rentinitialcur

4 segment % Change 3100



rentinitialcurendcurrent

100 

rentinitialcu

The following parameters are consequently set in the STEPPER MENU:

PARAMETER PARAMETER DESCRIPTION VALUE

TOOLS N° Identifier of the tool on which the stepper module works 1 STEPPER WELD Parameter adjustment increase, current in the example ON L1 STEPPER TIME Weld time increase OFF STEPPER THICK. Electrodes thickness decrease OFF N.TOTAL STEPS Total number of stepper steps 4 SPOTS 1 Number of spots of first segment 700 INCREMENT 1-L1 Percentage increase of the first segment relevant to law L1 19 %

%19100

8.175.19 %10100

5.192.20 %4100

220820

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)

PARAMETER PARAMETER DESCRIPTION VALUE

INCREMENT 1-L2 Percentage increase of the first segment relevant to law L2 00 % SPOTS 2 Number of spots of second segment 1100 INCREMENT 2-L1 Percentage increase of the second segment relevant to law

INCREMENT 2-L2 Percentage increase of the second segment relevant to law

L2 SPOTS 3 Number of spots of third segment 1200 INCREMENT 3-L1 Percentage increase of the third segment relevant to law L1 4 % INCREMENT 3-L2 Percentage increase of the third segment relevant to law L2 00 % SPOTS 4 Number of spots of fourth segment 1000 INCREMENT 4-L1 Percentage increase of the fourth segment relevant to law L1 3 % INCREMENT 4-L2 Percentage increase of the fourth segment relevant to law L2 00 %

The welding program must be set in order to carry out the first welding spot, which is with an adjustment enabling to obtain the necessary current with the starting electrodes diameter: 15 kA.

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

10 %

00 %

17.8 kA

CURRENT (kA

19.5 kA

SEGMENT 1

700

20.2 kA

SEGMENT 2

20.7 kA

SEGMENT 3

1800

NUMBER OF WELDING SPOTS

SEGMENT 4

3000

40003000200010000

On having completed the 4000 welding spots, the control unit stops the production cycle and displays the following message:

STEPPER [164] END WARNING ON TOOLS T1 PUSH [///] TO RESET

Now the operator replaces the electrodes (or restores their original diameter) and clears the spots counter relevant to the tool the electrodes of which were replaced to clear the stepper calculations.

The TE700 resets the initial work parameters and begins a new stepper phase.

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2.12 - FEATURES TE700

-TE700 VER. 1.13- SETUP MENU STEPPER MENU >FEATURES TE700

The TE700 installation menu contains the parameters that describe the complexity and the typology of the welder on which the control unit works. Access to said menu is protected by an access code due the importance of these parameters.

ENTER ACCESS CODE

FEATURES MENU

- - - - -

If the operator is not authorized to enter this menu and does not know the access code, the following message is displayed:

WRONG CODE

TRY AGAIN !

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

FEATURES TE700 >SERIAL COM. OFF NET ADDRESS 01 OUT LOCK/END END

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

PARAMETER PARAMETER DESCRIPTION RANGE VALUE

SERIAL COM. Serial communication 232 – 485 – OFF NET ADDRESS Network address 01 – 31 OUT LOCK/END Output function END – LOCK LOW FORCE SQ. Low force squeeze ON - OFF FORGE Forging ON – OFF PROP. VALVE Proportional valve ON - OFF PRESSURE RATIO Proportional ratio 0.1 – 2.0 AUTORETAIN Start Autoretain ON – OFF START 1-2 NC Operation of NC inputs OFF – RIC 7-8 – ON BIC 1-2 NC Operation of NC inputs OFF – RIC 5-6 – ON SEAM WELD MODE Spots / seams ON – OFF CASCADE MODE Electric cascade function ON – OFF WELD – NO WELD Operation of weld - no weld external

input

DSP UPG PRESS Command to update inverter SW <+>

INT – EXT – BOTH

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THICK SENSOR Enabling of the parameters relevant to

the thick sensor (position sensor)

STEPPER TIME Enabling of the stepper functionality on

the welding time

SERIAL COM.

The operator may choose whether to activate the serial data transmission port and how it is to be used, connect a printer (232) or connect the control unit to a data supervision network (485), or not to use this option (OFF).

NET ADDRESS

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

OUT LOCK/END

This parameter is used to indicate the time for activation of the corresponding output, interlock (LOCK) or end of cycle (END).

LOW FORCE SQ.

This parameter is used for enabling the low-pressure squeeze function for pneumatic circuit welders that are equipped with this function. Its enabling adds the SQUEEZE parameter to the welding program.

FORGE

This parameter is used for enabling the forging for pneumatic circuit welders that are equipped with this function. Its enabling adds the FORGE DELAY parameter to the work program.

PROP. VALVE

This parameter is used for enabling the use of a proportional valve for pneumatic circuit welders that are equipped with this function. Its enabling adds the PRESSURE parameter to the work program. If the FORGE parameter is enabled too, then the FORG.PRESS. parameter is added to the work program.

PRESSURE RATIO

This parameter can be used to select the optimum bar/Volt ratio for the type of proportional solenoid valve that is to be employed. It works only if the PROP. VALVE parameter is enabled. Further pieces of information are described in the paragraph INTERFACE FOR PROPORTIONAL VALVE.

AUTORETAIN

This parameter allows disabling the AUTORETAIN cycle start signal. On setting the parameter on the OFF value, the working cycle is stopped the moment the cycle start signal is disabled and does not complete the welding time. This occurs even if the welding current is in its flowing phase. The welding time is always completed whenever the value is set to ON. This function is specifically to be used when the machine works with mechanical devices instead of pneumatic ones.

ON – OFF

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If the control unit is in seam weld mode with autoretain deactivated, its activation implies the automatic deactivation of the seam weld mode and automatic commutation of the unit to SPOT mode.

START 1-2 NC

When this parameter is set to ON it enables the normally closed inputs of the cycle start signals. This allows the starting of the welding cycle only in the presence of the double exchange contact, normally open that closes and normally closed that opens. When set to OFF, the control unit ignores the status of the two signals and the starting of the welding only depends on the status of the NO inputs. If set to RIC 7-8, the two NO inputs become program recalls from a functional point of view so as to extend the number of recallable programs directly through the inputs.

BIC 1-2 NC

When this parameter is set to ON it enables the normally closed inputs of the cycle start signals. This allows the starting of the welding cycle only in the presence of the double exchange contact, normally open that closes and normally closed that opens. When set to OFF, the control unit ignores the status of the two signals and the starting of the welding only depends on the status of the NO inputs. If set to RIC 5-6, the two NO inputs become program recalls so as to extend the number of recallable programs directly through the inputs.

SEAM WELD MODE

This parameter is used to enable the function that adapts the control unit to seam welder specifications. The activation of the seam weld mode automatically deactivates the autoretain. Further information is supplied in the SEAM WELD MODE paragraph.

CASCADE MODE

This parameter allows reversing the output signal of the end cycle (END), that is to say from normally open contact to normally closed contact, to allow putting more control units in cascade. Check the proper paragraph for further information.

WELD – NO WELD

When the optional board code 50200 is installed, this parameter allows the operator to select the priority of the weld-no-weld control. When the parameter is set to INT, the running of the external WELD-NO WELD line is deactivated whilst the button on the TE700 control unit remains enabled. When the parameter is set to EXT, the running of the external WELD-NO WELD line on board code 50200 is active whilst the button on the front panel of the TE700 control unit is disabled. When the parameter is set to BOTH, both WELD-NO WELD controls are enabled: the one on the TE700 front panel and the external control line on the board code 50200. The two controls are in series therefore to switch the unit to NO WELD mode, simply set only one of the two controls to NO WELD mode whilst in order to switch the unit to WELD mode both controls must be switched to WELD mode.

DSP UPG PRESS

If key <+> is pressed when this parameter is selected, the operator can remotely activate the software upgrade procedure inside the inverter unit. The spot welder must not be off during the upgrade procedure. Any other operation during the upgrade procedure is prohibited and welds may not be carried out. In order to resume the running of the spot welder after the upgrade procedure, it must be turned off and then back on again once the procedure is finished.

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THICK SENSOR

This parameter enables the THICKNESS SENSE menu for parameterizing eventual position sensors connected to the control unit. Also, by means of a stepper law, it enables the possibility of compensating the electrode’s wear according to the initial quote.

STEPPER TIME

This parameter allows enabling the welding time stepper law inside the stepper menu. This law is enabled either independently or associated with a current stepper value.

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2.13 - FEATURES INVERTER

-TE700 VER. 1.13- STEPPER MENU FEATURES TE700 >FEATURES INVERTER

The inverter installation menu contains the parameters that describe the complexity and the typology of the welder on which the control unit works. Access to said menu is protected by an access code due the importance of these parameters.

ENTER ACCESS CODE

FEATURES MENU

- - - - -

If the operator is not authorized to enter this menu and does not know the access code, the following message is displayed:

WRONG CODE

TRY AGAIN !

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

FEATURES INVERTER >INVERTER SIZE 0250A TA TURNS 500 FREQUENCY 1000Hz

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

PARAMETER PARAMETER DESCRIPTION RANGE VALUE

INVERTER SIZE Max current supplied by the inverter 50 A – 4000 A TA TURNS Number of sensor turns primary current 500 – 2000 FREQUENCY Inverter operating frequency 1000–2000–3000–4000 Hz CURRENT LOOP Current adjustment loop ROG – TA EXT.REF.INPUT Analogue input for current profile OFF – ON VE INPUT Electrodes voltage gauge OFF – ON TH TR. PRIM. Transformer primary thermal current 0 – 60000 A TH TR TIME Transformer thermal time constant 0.0 – 6000.0 S TH TR DIODE Type of diodes installed in the welding

transformer

ROGOWSKY TEST Check for Rogowsky coil integrity OFF – ON N° WELDING TRAFO Number of welding transformers or tools

used.

TURNS TR.1 Transformer 1 turns ratio 1 – 200

OFF – 2*56DN – 4*56DN –

8*56DN – 2*65DN – 4*65DN

– 8*65DN

1 – 4

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I MAX TR.1 Max supplied current 2.00 – 200.00 KA TURNS TR.2 Transformer 2 turns ratio 1 – 200 I MAX TR.2 Max supplied current 2.00 – 200.00 KA TURNS TR.3 Transformer 3 turns ratio 1 – 200 I MAX TR.3 Max supplied current 2.00 – 200.00 KA TURNS TR.4 Transformer 4 turns ratio 1 – 200 I MAX TR.4 Max supplied current 2.00 – 200.00 KA

It is important to keep in mind that after having modified the following parameters the memory of the TE700 control unit must always be reset.

INVERTER SIZE

Indicates the max current that the inverter can supply at output. If a wrong value is set, this could damage the inverter and/or the welding transformer.

TA TURNS

Indicates the turns ratio of the current transducer installed inside the inverter. If a wrong value is set, this could lead to a wrong adjustment of the welding current.

FREQUENCY

This parameter sets the frequency at which the power semiconductors are switched. This control unit can work at 1000 Hz, 2000 Hz, 3000 Hz and 4000 Hz. The selected operating frequency must be adapted to the welding transformer used otherwise it might be damaged. If an operating frequency higher than 1000 Hz is selected, it will not be possible to activate the thermal limit switches relevant to the welding transformer and/or the diodes. If the thermal limit switches relevant to the welding transformer and/or the diodes were previously activated,

when a work frequency higher than 1000Hz is selected, the following message is displayed:

THERMAL LIMIT SW OFF

<+> OK <-> CANCEL

If key <-> is pressed, the previously set thermal limit switches will remain energized and the operating frequency of the inverter remains at 1000 Hz. If key <+> is pressed, the thermal limit switches relevant to diodes and welding transformer will be disabled automatically and the operator will be able to use an inverter operating frequency higher than 1000 HZ.

CURRENT LOOP

This parameter allows the operator to choose which current transducer should be used in the adjustment loop. If set to ROG, the Rogowsky coil installed on the secondary circuit of the machine is used to adjust the current. If set to TA, a current sensor inside the inverter and installed on the primary of the welding transformer is used for the adjustment. The best performance of the current adjustment loop is achieved by selecting ROG and installing the Rogowsky coil on the secondary circuit of the spot welder.

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The adjustment, made through TA, is to be used when a Rogowsky coil cannot be installed on the secondary circuit of the spot welder or if set to seam weld mode. If the seam weld mode is selected when Rogowsky has been selected as current sensor, a continuous weld cannot be carried out but the minimum COLD 2 TIME will be 8 mS. If TA has been selected as current sensor, the COLD 2 TIME may be set to 0mS and a continuous weld may be carried out without any interruptions.

EXT.REF.INPUT

This parameter allows the operator to enable an analogue input in the inverter unit with dynamics 0 – 10V by means of which a current profile may be supplied to the welder to be followed through a variable voltage applied at the appropriate input.

VE INPUT

This parameter allows the gauging of the voltage at the electrodes but, before doing so, be sure that the wires that carry out the measurement are properly installed.

TH TR. PRIM

This parameter allows the setting of the primary thermal current of the welding transformer. If the value is equal to zero or the value of the TH TR. TIME parameter equals zero, the limit switch at the thermal current of the welding transformer is deactivated. This function may be activated only when the inverter unit has been set with an operating frequency of 1000 Hz. If the operating frequency is greater than 1000 Hz the following message is displayed:

FAIL INIT THERMAL

LIM

CHECK PARAM. CONFIG.

This parameter may be modified only after having set an operating frequency of 1000 Hz. The function cannot be activated if an operating frequency greater than 1000Hz is set.

TH TR. TIME

This parameter allows the setting of the thermal time constant of the welding transformer. If the value is equal to zero or the value of the TH TR. PRIM parameter equals zero, the limit switch at the thermal current of the welding transformer is deactivated. This function may be activated only when the inverter unit has been set to an operating frequency of 1000 Hz. If the operating frequency is greater than 1000 Hz the following message is displayed:

FAIL INIT THERMAL

LIM

CHECK PARAM. CONFIG.

The parameter may be modified only after having set an operating frequency of 1000 Hz.

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TH TR. DIODE

This parameter allows the setting of the type of rectifiers installed on the secondary circuit of the welding transformer. This function may be activated only if the operating frequency of the inverter equals 1000 Hz. If operating frequencies are greater, the parameter cannot be modified and the following message is displayed:

FAIL INIT THERMAL

LIM

CHECK PARAM. CONFIG.

ROGOWSKY TEST

It enables the check for the integrity both of the Rogowsky coil and the cable that connects it to the inverter unit. If the function is activated, the inverter periodically checks that the circuit of the current sensor is neither open nor short circuited. If a fault occurs, welding is inhibited and the condition is signalled on the TE700 display. The activation of the Rogowsky test function leads to a decrease in the max number of spots that the inverter may carry out in one minute.

N° WELDING TRAFO

This parameter sets the number of welding transformers used with the inverter or alternatively the number of the different welding tools used. If the operator intends using different tools for the welding operations but only one welding transformer, set the required number of tools and set the same turns and max current value, in the following parameters, for all the welding transformers. If the operator intends using different welding transformers, each transformer should be characterized by its turns ratio and by the max secondary current that can be supplied. If the operator uses different welding transformers the Rogowsky integrity test must not be enabled. If the operator uses more than one transformer or welding tool, the thermal limit switches cannot be activated at the primary thermal current and at the diodes thermal switch. If the operator wishes to use different tools for alternating welds on a single welding transformer, he/she must set the parameter equal to the number of welding tools used and in any case the max number is four. Moreover, the operator must set the turns ratio of the welding transformers to an identical value for all the transformers and equivalent to the turns ratio of the transformer installed on the spot welder. Even the max supplied current values from each transformer must all be set to the same value of the max current that is supplied by the transformer installed on the spot welder.

TURNS TR.1

It sets the number of turns of welding transformer 1.

IMAX TR.1

It sets the max current that may be supplied by welding transformer 1.

TURNS TR.2

It sets the number of turns of welding transformer 2.

IMAX TR.2

It sets the max current that may be supplied by welding transformer 2.

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TURNS TR.3

It sets the number of turns of welding transformer 3.

IMAX TR.3

It sets the max current that may be supplied by welding transformer 3.

TURNS TR.4

It sets the number of turns of welding transformer 4.

IMAX TR.4

It sets the max current that may be supplied by welding transformer 4.

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2.14 - PROGRAMS COPY

-TE700 VER. 1.13- FEATURES TE700 FEATURES INVERTER >PROGRAM COPY

This 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 (to make programming quicker).

PROGRAM COPY >SOURCE PROGRAM. 003 COPY FROM PRG. 006 TO PROGRAM 010

After having selected the source program and the programs which it is to be saved in, simply press the ¼ key and a request will appear asking either to continue and copy or cancel the operation.

COPY PROGRAM?

<+> OK <-> CANCEL

In order to copy, simply press key <+> and the following screen is displayed. The bar shows the copying progress state.

PROGRAM COPY WAIT…

▌▌▌▌▌▌▌▌▌

When the copying procedure is finished, the main programming screen is displayed.

-TE700 VER. 1.09- FEATURES TE700 FEATURES INVERTER >PROGRAM COPY

PROGRAM COPY MENU PARAMETERS TABLE

PARAMETER PARAMETER DESCRIPTION RANGE VALUE

SOURCE PROGRAM Source program 001 – 300 COPY FROM PRG Start copy/target program 001 – 300 TO PROGRAM Copy end program 001 – 300

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SOURCE PROGRAM

This program indicates the number of the program to be copied to other programs. The value of this parameter may range from 001 to 250.

COPY FROM PRG

This program indicates the first program which the source program is copied into. The value of this parameter may range from 001 to 250.

TO PROGRAM

This program indicates the last program which to copy the source program into. The value of this parameter may range from 001 to 250.

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2.15 – CHECK INPUT – DIAGNOSTIC TE700

-TE700 VER. 1.13- FEATURES INVERTER PROGRAM COPY >DIAGNOSTIC TE700

This menu displays the status of the inputs of the TE700 weld control unit. It is used to check the working efficiency of the external devices, connected to the TE700 control unit, required for using the welder.

DIAGNOSTIC TE700 >START 1 PRG OFF START1 NC-RIC7 OFF AUX OFF

The following inputs are mentioned in the list which may be scrolled by means of the and

keys.

PARAMETER PARAMETER DESCRIPTION VALUE

START 1 PRG It indicates the status of the cycle start signal ON – OFF START1 NC-RIC7 It indicates the status of cycle start NC signal or RIC7 ON – OFF AUX It indicates the status of the auxiliary signal ON – OFF AUX 3 It indicates the status of the auxiliary 3 signal ON – OFF DOUBLE STROKE It indicates the status of the double stroke signal ON – OFF START 2 PRG It indicates the status of the cycle 2 start signal ON – OFF START2 NC-RIC8 It indicates the status of cycle start NC signal or RIC8 ON – OFF TERM/FLUX It indicates the status of the thermostat signal ON – OFF PRG.RECALL 1 It indicates the status of the recall 1 signal ON – OFF PRG.RECALL 2 It indicates the status of the recall 2 signal ON – OFF PRG.RECALL 3 It indicates the status of the recall 3 signal ON – OFF PRG.RECALL 4 It indicates the status of the recall 4 signal ON – OFF INVERTER READY It indicates the status of the READY signal from the inverter unit ON – OFF SAFETY START 1 It indicates the status of the signal of safety start 1 ON – OFF BIC1 NC-RIC5 It indicates the status of the NC signal of two-hand control button 1 or

RIC5 SAFETY START 2 It indicates the status of the signal of safety start 2 ON – OFF BIC2 NC-RIC6 It indicates the status of the NC signal of two-hand control button 2 or

RIC6

ON – OFF

(When Code 50200 option is present)

RESET DRESS It indicates the status of the accomplished electrodes dressing signal ON – OFF WELD / NO WELD It indicates the status of the external weld / no weld signal ON – OFF RESET ERROR It indicates the status of the errors clear signal ON – OFF RESET ELECTRODE It indicates the status of the accomplished electrodes change signal ON – OFF

The input status is represented as enabled (closed input with COM1) by means of the wording ON, while it is represented as disabled by means of the wording OFF.

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2.16 – CHECK INPUT – DIAGNOSTIC INVERTER

-TE700 VER. 1.09- PROGRAM COPY DIAGNOSTIC TE700 >DIAGNOSTIC INV.

This menu displays the status of the inputs and outputs of the inverter unit connected to the TE700. It is used to check the working efficiency of the inverter unit.

DIAGNOSTIC INV. >VERSION INV. 2.02 RIC 1 OFF RIC 2 OFF

The following inputs are mentioned in the list which may be scrolled by means of the

and

keys.

PARAMETER PARAMETER DESCRIPTION VALUE

VERSION INV. It indicates the software version installed in the inverter. X.XX RIC 1 It indicates the status of the signal relative to RIC 1 inside the inverter. ON – OFF RIC 2 It indicates the status of the signal relative to RIC 2 inside the inverter. ON – OFF RIC 3 It indicates the status of the signal relative to RIC 3 inside the inverter. ON – OFF RIC 4 It indicates the status of the signal relative to RIC 4 inside the inverter. ON – OFF TERM It indicates the status of the signal relative to thermostat wired on the

inverter.

DRIVER It indicates a power semiconductor driver fault. NO ERR –

EMERGENCY It indicates the status of the signal relevant to the emergency chain on

the inverter. WELD NO WELD It indicates the status of the weld-no weld signal inside the inverter. ON – OFF TRIGGER It indicates the status of the welding start signal inside the inverter. ON – OFF RIC 5 / WELD 2 It indicates the status of signal RIC 5 or SEAM WELD. 2 inside the

inverter. OUT EV WATER It indicates the status of the inverter output that controls the EV for the

cooling circuit water. OUT READY It indicates the status of inverter output for the READY signal

transmitted to the TE700 control unit. OUT LOCK It indicates the status of the LOCK output of the inverter. ON – OFF OUT WRONG It indicates the status of the WRONG output of the inverter. ON – OFF VER. DRIVER It indicates the software version installed inside the board that checks

for the capacitors' charged condition. CAPACITOR VOLT It indicates the voltage present on the bank of capacitors inside the

inverter.

Warning: this measurement is indicative and should not be used

as a reference when operating in the inverter unit.

BOARD TEMP. It indicates the room temperature on the inverter unit. XX.X°C SINK TEMP. It indicates the temperature of the dissipater on which the power

semiconductors are installed. THERMAL LEVEL It indicates the use percentage of the inverter in case the thermal limit

switches tripped relative to the primary of the weld transformer and/or

the diodes of the secondary rectifier. SCR DRV STATUS Alphanumeric code that indicates the operating status of the board

that checks for the capacitors' charged condition. INV. SERIAL Inverter unit serial number. XXXXX

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ON – OFF

ERR

ON – OFF

XX.X

000V

XX.X°C

XXX%

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2.17 - PROG. SEQUENCE

-TE700 VER. 1.13- DIAGNOSTIC TE700 DIAGNOSTIC INV. >PROG. SEQUENCE

This menu includes the parameters required for activating the programs sequences operations. In this working 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.

PROG. SEQUENCE >STEP 1 PRG. 003 STEP 1 WELDS 07 STEP 2 PRG. 012

PROGRAM SEQUENCES MENU PARAMETERS TABLE

PARAMETER PARAMETER DESCRIPTION RANGE VALUE

STEP 1 PRG. Program to be carried out in the step 1 000 – 250 STEP 1 WELDS Number of spots to be carried out with step 1 01 – 25 STEP 2 PRG. Program to be carried out in the step 2 001 – 250 STEP 2 WELDS Number of spots to be carried out with step 2 00 – 25 STEP 3 PRG. Program to be carried out in the step 3 001 – 250 STEP 3 WELDS Number of spots to be carried out with step 3 00 – 25 STEP 4 PRG. Program to be carried out in the step 4 001 – 250 STEP 4 WELDS Number of spots to be carried out with step 4 00 – 25 STEP 5 PRG. Program to be carried out in the step 5 001 – 250 STEP 5 WELDS Number of spots to be carried out with step 5 00 – 25

STEP 1 PRG.

This parameter indicates the number of the program that the welder must carry out, and is coupled with the STEP 1 WELDS parameter. When this parameter is set to zero, the programs sequence is disabled.

STEP 1 WELDS

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

STEP 2 PRG.

This parameter indicates the program number that the welder has to carry out and is always coupled with the STEP 2 WELDS parameter.

STEP 2 WELDS

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

STEP 3 PRG.

This parameter indicates the program number that the welder has to carry out and is always coupled with the STEP 3 WELDS parameter.

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STEP 3 WELDS

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

STEP 4 PRG.

This parameter indicates the program number that the welder has to carry out and is always coupled with the STEP 4 WELDS parameter.

STEP 4 WELDS

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

STEP 5 PRG.

This parameter indicates the program number that the welder has to carry out and is always coupled with the STEP 5 WELDS parameter.

STEP 5 WELDS

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

The weld spots may be carried out after having activated this mode and having set the parameters of the PROGRAM SEQUENCES menu as outlined above. Switch the key to WORK position on the display to view the data of the sequences as shown in the figure below.

WELD N.008 TOTAL 013 PROG N.003 RMS 10.45 TIME 10.0 SPOT 00050 NEXT 009 NEXTPRG 002

WELD N.008 TOTAL 013

It indicates the progressive number of the last carried out welding spot and the welding spots total number the sequence is composed of.

PROG. N.003 RMS 10.45

It indicates the program number and the RMS current value of the last welding spot.

TIME 10.0 SPOT 00050

It indicates the welding time of the last carried out program and the spots counter value.

NEXT 009 NEXTPRG 002

It indicates the progressive number of the next spot and the program to be carried out.

SEQUENCE EXAMPLE

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

PARAMETER VALUE

STEP 1 PRG.

STEP 1 WELDS

STEP 2 PRG.

STEP 2 WELDS

STEP 3 PRG.

STEP 3 WELDS

STEP 4 PRG.

STEP 4 WELDS

03 04 07 02 11 06 04 01

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At each cycle start signal, a welding spot is carried out with the welding program relevant to the actual step. In this specific case, as shown by the below scheme, the following welding spots are carried out 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

STEPS 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

This working mode typology is usually applied to a manual welder, where the operator carries the welding spots out always in the same order but with different working parameters. This working mode prevents the operator from manually changing the program and, therefore, from diverting his attention away from the piece to be welded, from changing the foot-pedal or other cycle start 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.

However, should any error occur in the sequence work mode, it is possible to repeat either the last or another welding spot or to go ahead avoiding certain spots. By always turning the key in RUN position, by means of the key it is possible to increase the welding spots counter to the following spot or to the desired one, while, by means of the to go back of one or more positions along the spots to be carried out.

key it is possible

Display data Display data after key

PRG 007- -01 ST 002-010 NXTPR 008 WELD 0200 RMS 002.99 SPOT 02300 r 034.4

PRG 008- -01 ST 003-010 NXTPR 009 WELD 0200 RMS 002.99 SPOT 02300 r 034.4

PRG 008- -01 ST 002-010 NXTPR 008 WELD 0200 RMS 002.99 SPOT 02300 r 034.4

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2.18 – THICKNESS SENSE

The THICKNESS SENSE menu contains the parameters for configuring the linear position sensors. A max number of 4 different linear position sensors may be connected to the TE700 control unit, one for each welding tool or one for each welding transformer. Access to said menu is protected by an access code due to the importance of these parameters.

ENTER ACCESS CODE

FEATURES MENU

- - - - -

If the operator is not authorized to enter this menu and does not know the access code, the following message is displayed:

WRONG CODE

TRY AGAIN !

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

THICKNESS SENSE >LINEAR SENSOR OFF LINEAR SENSOR N° 1 SENSOR1 S/N_P1:0000

If the position sensors are activated, they initialize every time the control unit is turned on. If an initialization error occurs it is signalled on the control unit and the sensors are disabled automatically. The operator must then solve the failed initialization problem, enter the THICKNESS SENSE menu and re-enable the position sensors manually. If multiple position sensors connected to different welding transformers are used, it is essential that when the TE700 control unit is turned on, all the sensors should be connected to the communication bus so as to be initialized correctly.

PARAMETER PARAMETER DESCRIPTION RANGE VALUE

LINEAR SENSOR Activation – deactivation of linear

sensors LINEAR SENSOR N° Number of installed linear sensors 1 – 4 SENSOR1 S/N_P1: Part 1 sensor 1 serial n. XXXX SENSOR1 S/N_P2: Part 2 sensor 1 serial n. XXXX SENSOR1 ID CAN: ID CAN for sensor 1 100 – 119 DELAY ID. S1 Delay for indentation measurement 0 – 1000 mS SENSOR2 S/N_P1: Part 1 sensor 2 serial n. XXXX SENSOR2 S/N_P2: Part 2 sensor 2 serial n. XXXX SENSOR2 ID CAN: ID CAN for sensor 2 100 – 119 DELAY ID. S2 Delay for indentation measurement 0 – 1000 mS SENSOR3 S/N_P1: Part 1 sensor 3 serial n. XXXX SENSOR3 S/N_P2: Part 2 sensor 3 serial n. XXXX SENSOR3 ID CAN: ID CAN for sensor 3 100 – 119 DELAY ID. S3 Delay for indentation measurement 0 – 1000 mS SENSOR4 S/N_P1: Part 1 sensor 4 serial n. XXXX

ON – OFF

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PARAMETER PARAMETER DESCRIPTION RANGE VALUE

SENSOR4 S/N_P2: Part 2 sensor 4 serial n. XXXX SENSOR4 ID CAN: ID CAN for sensor 4 100 – 119 DELAY ID. S4 Delay for indentation measurement 0 – 1000 mS

LINEAR SENSOR

It activates or deactivates the use of the linear position sensors. If a sensor initialization error occurs, it automatically commutates to OFF and the error condition is signalled on the TE700 display. Sensor identification parameters are not deleted. The enabling of the position sensors makes available the measurements relevant to the initial thickness of the sheets to be welded and to the electrode penetration at the end of the welding procedure and relevant limits.

LINEAR SENSOR N°

It indicates the number of sensors installed on the machine. If multiple sensors are installed, the choice of which one to use to carry out the measurement depends on the number of the welding tool selected for the currently called weld program. For example, if 3 different welding tools are enabled with 3 associated position sensors and the operator carries out a weld with a program in which tool number 2 was selected, linear sensor number 2 will be used to measure the coordinates.

SENSOR1 S/N_P1:

This parameter contains the first part of the serial number of linear sensor 1. The serial number can be read on the sensor body.

SENSOR1 S/N_P2:

This parameter contains the second part of the serial number of linear sensor 1. The serial number can be read on the sensor body.

SENSOR1 ID CAN:

This parameter allows the setting of the sensor identifier in the CAN network. In order to work efficiently, the sensors present inside the CAN network must have univocal identifiers.

DELAY ID. S1

This parameter specifies the delay, in mS, that the system must wait after having finished the welding current passage in order to measure the coordinate with which to obtain the electrode penetration value during the welding operation.

SENSOR2 S/N_P1:

This parameter contains the first part of the serial number of linear sensor 2. The serial number can be read on the sensor body.

SENSOR2 S/N_P2:

This parameter contains the second part of the serial number of linear sensor 2. The serial number can be read on the sensor body.

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SENSOR2 ID CAN:

This parameter allows the setting of the sensor identifier in the CAN network. In order to work efficiently, the sensors present inside the CAN network must have univocal identifiers.

DELAY ID. S2

SENSOR3 S/N_P1:

This parameter contains the first part of the serial number of linear sensor 3. The serial number can be read on the sensor body.

SENSOR3 S/N_P2:

This parameter contains the second part of the serial number of linear sensor 3. The serial number can be read on the sensor body.

SENSOR3 ID CAN:

This parameter allows the setting of the sensor identifier in the CAN network. In order to work efficiently, the sensors present inside the CAN network must have univocal identifiers.

DELAY ID. S3

SENSOR4 S/N_P1:

This parameter contains the first part of the serial number of linear sensor 4. The serial number can be read on the sensor body.

SENSOR4 S/N_P2:

This parameter contains the second part of the serial number of linear sensor 4. The serial number can be read on the sensor body.

SENSOR4 ID CAN:

This parameter allows the setting of the sensor identifier in the CAN network. In order to work efficiently, the sensors present inside the CAN network must have univocal identifiers.

DELAY ID. S4

SETTING THE DELAY PARAMETER ID. SX

During the welding stage which the current passes in, the machine's mechanical structure might vibrate further to the current's electro-dynamic action. The vibration induced by the passage of the current does not stop immediately at the end of the current passage but might require a certain amount of time to stop. Said time depends on the elasticity of the spot welder structure. The execution of a coordinate measurement during this transient might be

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altered by the vibrations induced in the structure. As such, a minimum delay must be set, which depends on each structure, to carry out the coordinate measurements in a static type situation. Proceed as follows to determine the minimum wait time before executing the measurement:

1) Configure the linear position sensor for use.

2) Set the DELAY ID. parameter to zero.

3) Set the WELD QUALITY parameter in the SET UP menu equivalent to TONLY (THICKNESS).

4) Set, in the PROGRAM DATA menu, the QUALITY-T parameter to ZERO in the program used for welding. Carry out a spot in short circuit to zero the coordinate (electrodes without material in between).

5) Set, in the PROGRAM DATA menu, the QUALITY-T parameter to IDENT in the program used for welding.

6) Carry out a spot in short circuit, observe the penetration measurement supplied on the TE700 control unit display at the end of the welding procedure. If the value remains equal to zero even after several weld spots this means that the set delay is correct.

7) If the displayed penetration value does not remain constant on carrying out several welds, return to the THICKNESS SENSE menu and increase the DELAY ID. parameter relevant to the position sensor used.

8) Repeat a few weld spots as specified in point 6.

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2.19 – TIP-DRESSINGS

The tip-dressing function is the combination, in just one function, of the current linear stepper function coupled with the restoring of the electrodes original diameter. The current stepper function allows compensating the electrodes wear which affects the welding quality. When the electrodes diameter increases also the contact section between the electrode and the piece to be welded increases. Consequently, the welding current density (Ampere/mm2) decreases. In order to compensate this phenomenon, the current adjustment is gradually increased according to the electrodes diameter increase so to keep a constant current density. The restoring of the electrodes original diameter is an operation which is usually carried out by means of a tool (dresser) allowing restoring the electrodes diameter, which worn out and increased during the production, to its initial working value. If the same current adjustment is kept all along the electrodes life or if the electrodes diameter is never restored to its optimal value, the last carried out welding spots will have a lower quality than the first ones. As a rule the electrodes dressing function is used in the presence of an automation that provides an interface between the weld control unit and the dresser.

After it has been set, the current increment is applied to all the welding programs used.

4 different electrode dressing parameterizations are available and each parameterization is associated with one of the four different welding tools available. In this way it is possible to manage the use and dressing of 4 different types of electrodes separately, taking into consideration, for the current increase, only the spots carried out by every single electrode.

This menu allows programming the tip-dressing number to be carried out during the electrodes life.

TIP-DRESSING T1 >TOOLS N° 1 DRESSING OFF DRESSING NUMBER 01

This function is displayed only if the (optional) expansion board, code 50200, is installed on the control unit.

Before turning on the TE700 control unit with the supplementary expansion board, code 50200, check that the CLEAR ELECTRODES LIFE (Pin 52) input is not active. Otherwise, the 50200 board is not recognized by the control unit.

The activation of this function inhibits the programming of the STEPPER menu. If the stepper function is active, a message is displayed requesting the operator to confirm the deactivation of the stepper function for the tool whose electrodes dressing activation is required. The deactivation of the stepper function does not entail the loss of the parameterization set for the stepper function.

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The parameters to be programmed for using the tip-dressing function are the following ones:

PARAMETER PARAMETER DESCRIPTION VALUE

TOOLS N° Selection of the tool in which to parameterize the dressing

function

DRESSING Activation of the dressing function ON – OFF

DRESSING NUMBER Number of tip-dressing to be carried out 00 - 20 SPOT DRESSING Number of welding spots per tip-dressing 001 - 999 DRESSING STEPS Stepper percentage per tip-dressing 01 - 50% DRESSING ALARM Notice welding spots number 00 – 40 ELECTROD. ALARM Pre-alarm electrodes 01 – 40 DRESSING OFFSET Tip-dressing current compensation 00 – 30%

1 – 4

Each time a value relevant to the tip-dressing is modified, the spots counter is cleared and the tip-dressing is recalculated from the beginning.

TOOLS N°

This parameter permits selecting on which tool number the electrodes dressing function is to be parameterized.

DRESSING

This parameter allows the operator to activate or deactivate the dressing function on the tool specified in the TOOLS N° parameter. Should the stepper function be active in the selected TOOL, a warning is displayed requesting the operator to deactivate the stepper function.

DRESSING NUMBER

This parameter indicates the number of tip-dressing to be carried out on the electrodes before these ones become useless. If this parameter is set to zero, the tip-dressing is not carried out.

SPOT DRESSING

It indicates the number of welding spots per each tip-dressing. The product of this parameter multiplied by the tip-dressing number (see previous paragraph) indicates the maximum welding spots number the control unit carries out.

DRESSING STEPS

This parameter indicates the current stepper percentage to be achieved at the end of each tip-dressing.

DRESSING ALARM

This parameter indicates the number of warning spots during which the DRESSING ALARM output is enabled, requesting maintenance for the welding electrodes. If, at the end of the pre-alarm welding spots, the control unit has not received the accomplished tip-dressing signal, it stops and displays the following message:

DRESSING [165] CAPS NEED DRESSING WARNING ON TOOLS T1 PUSH [///] TO RESET

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In order to restore control unit working efficiency, first of all clear the screen through the DELETE ERRORS input and then activate the electrodes-dressed signal. If more than one weld tool was activated the operator can choose which tool to use to dress the electrodes as follows: if only the external dressing input is activated, to the control unit this means that the electrode is being dressed on the tool used during the last weld carried out. If the dressing is to be carried out on a tool other than the one used during the last weld carried out, the operator uses the RIC1, RIC2 and RIC3 inputs to decide which of the four tools to use to carry out the dressing as outlined in the following table:

RIC1 RIC2 RIC3 FUNCTION

OFF OFF OFF Dressing of the tool used during the last program used.

ON OFF OFF Dressing of the electrodes of tool 1

OFF ON OFF Dressing of the electrodes of tool 2

ON ON OFF Dressing of the electrodes of tool 3

OFF OFF ON Dressing of the electrodes of tool 4

The required recalls configuration must be set before the activation of the dressing signal and must be kept steady for the whole duration of the dressing signal activation.

ELECTROD ALARM

This parameter indicates the number of pre-warning spots during which the ELECTRODES ALARM output is enabled, requesting the replacement of the welding electrodes. If, at the end of the pre-alarm welding spots, the control unit has not received the signal that indicates that the electrodes were replaced, it stops and displays the following message:

DRESSING [166] END CAPS LIFE WARNING ON TOOLS TI PUSH [///] O RESET

In order to restore control unit working efficiency, first of all clear the screen through the DELETE ERRORS input and then activate the electrodes-replaced signal. If more than one weld tool was activated the operator can choose which tool to use to change the electrodes as follows: if only the external electrodes-replacement input is activated, to the control unit this means that the electrode is being replaced on the tool used during the last weld carried out. If the electrode is to be replaced on a tool other than the one used during the last weld carried out, the operator uses the RIC1, RIC2 and RIC3 inputs to decide which of the four tools to use to replace the electrode as outlined in the following table:

RIC1 RIC2 RIC3 FUNCTION

OFF OFF OFF Dressing of the tool used during the last program used.

ON OFF OFF Dressing of the electrodes of tool 1

OFF ON OFF Dressing of the electrodes of tool 2

ON ON OFF Dressing of the electrodes of tool 3

OFF OFF ON Dressing of the electrodes of tool 4

The required recalls configuration must be set before the activation of the electrodes-change signal and must be kept steady for the whole duration of the electrodes-change signal activation.

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DRESSING OFFSET

Use this parameter to increase, in percentage, the starting value of the dressings welding current after the first one.

EXAMPLE:

The parameters outlined in the table below were set (with a set work program such as, for example, "WORKING MODE" IK) with an initial current value set to 10KA.

PARAMETER VALUE

DRESSING NUMBER

SPOT DRESSING

DRESSING STEPS

DRESSING ALARM

ELECTRODES ALARM

DRESSING OFFSET

The chart below shows the pattern of how the current increased during the electrodes dressing run mode.

200

30%

20 20

5 %

You may notice that the initial current of the first dressing begins at 10KA whilst a percentage is added to the starting current value of the next dressing (parameter DRESSING OFFSET).

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The graph below shows the time and modality of the signals used for this WORKING MODE (with reference to the values outlined in the foregoing table).

From the moment the control unit activates the DRESSING ALARM output it may be reset at any time by activating the DRESSING RESET input as shown in the foregoing graph for dressings 1, 3 and 4.

In the example above, the very last spot of the dressing was reached during DRESSING no. 2 without resetting the DRESSING ALARM. In this case the control unit stops and displays the relevant warning message (ERROR 116). In this case the operator must first delete the screen from the control unit either through the ERROR RESET input or the CLEAR key, and then reset the DRESSING ALARM output.

The same is applicable to clear the ELECTRODES END LIFE ALARM output.

When the ELECTRODES END LIFE CLEAR input signal is activated, the control unit resets the spots counter.

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Page 91

TECNA S.p.A. ITEM TE700 Instruction Manual

CHAPTER 3 – SEAM WELD OPERATING MODE

FEATURES TE700 START 1-2NC OFF BIC 1-2 NC OFF >SEAM WELD MODE ON

If the seam weld mode is active on setting the mode, the AUTORETAIN function will be automatically deactivated at the START inputs. If the operator does not accept the deactivation of the AUTORETAIN function it will not be possible to activate the seam weld mode. This function allows the operator to adapt the control unit to the requirements of a seam welder. Consequently, welding current is supplied either continuously or via parameter COLD 2 in pulse mode. On keeping the cycle-start command active, the control unit keeps repeating the time set in the WELD parameter to prevent the control unit from completing a long weld. time on cutting off the cycle-start command. We suggest using short weld times. The welding current is measured indifferently through pulse cycle, WELD and COLD T. 2 time combination, or through continuous cycle, WELD time only. In the seam weld mode, the EV3 output is used as a roller-start command instead of being used for the forging. On enabling the programming of the WELD 2 parameter, the operator may set not only the CURRENT parameter but also the CURRENT 2 parameter. During the welding operation it is possible to commutate between one set current value and the other using the WELD 2 input present on the INVERTER unit. If the COLD T. 2 parameter is other than zero, each time the two foregoing current values commutate, the COLD T. 2 is carried out. the COLD T. 2 parameter is equal to zero, the passage between two set current values will take place instantly. If Rogowsky was set in the FEATURES INVERTER menu as current sensor for the adjustment loop, the continuous weld cannot be carried out but only a pulsed weld with a COLD T. 2 greater than or equal to 8mS. If TA was set as current sensor for the adjustment loop, it will be possible to carry out even a continuous weld with COLD T. 2 equal to zero. According to the type of current adjustment loop, the available weld modes differ as outlined in the tables below. During the welding in the SEAM WELD mode, the value of the welding current and the conduction percentage of the power semiconductors are displayed in real time on the control unit. Said information is updated every 0.5 seconds both during the hot times and the cold

times.

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TABLE WITH SEAM WELD OPERATING MODE PARAMETERS – SECONDARY ADJUSTMENT

PROGRAM DATA T1 >TOOLS N° 1 WORKING MODE IK CONTROL MODE NO

PARAMETER RANGE VALUE

PROGRAM N. 001 – 300 WORKING MODE IK CONTROL MODE * NO SQUEEZE 1 0.5 – 99.0 cycles SQUEEZE 00.0 – 99.0 cycles PRESSURE 00.5 – 10.0 bar MOTOR DELAY 05 - 99 cycles PRE-WELD 0000 – 1000 mS PRE CURR. 000.30 – 200.00 KA COLD 1 0000 – 1000 mS SLOPE UP 0000 – 1000 mS WELD 0001 – 2000 mS CURRENT 000.30 – 200.00 KA COLD 2 0000 – 1000 mS CURRENT 2 000.30 – 200.00 KA HOLD TIME 00.5 – 99.0 cycles

CONTROL MODE * CUR LIM I MIN 000.30 – 200.00 KA LIM I MAX 000.30 – 200.00 KA

CONTROL MODE * RO LIM RO MIN 005.0 – 100.0% LIM RO MAX 005.0 – 100.0%

CONTROL MODE * VE LIM V MIN 00.20 – 20.00 V LIM V MAX 00.20 – 20.00 V

CONTROL MODE * PW LIM P MIN 000.20 - 600.00 KW LIM P MAX 000.20 – 600.00 KW

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TABLE WITH SEAM WELD OPERATING MODE PARAMETERS – SECONDARY ADJUSTMENT

PROGRAM DATA T1 >TOOLS N° 1 WORKING MODE FIX CONTROL MODE NO

PARAMETER RANGE VALUE

PROGRAM N. 001 – 300 WORKING MODE FIX CONTROL MODE * NO SQUEEZE 1 0.5 – 99.0 cycles SQUEEZE 00.0 – 99.0 cycles PRESSURE 00.5 – 10.0 bar MOTOR DELAY 05 - 99 cycles PRE-WELD 0000 – 1000 mS PRE-RO 005.0 – 100.0 % COLD 1 0000 – 1000 mS SLOPE UP 0000 – 1000 mS WELD 0001 – 2000 mS RO 005.0 – 100.0 % COLD 2 0000 – 1000 mS RO 2 005.0 – 100.0 % HOLD TIME 00.5 – 99.0 cycles

CONTROL MODE * CUR LIM I MIN 000.30 – 200.00 KA LIM I MAX 000.30 – 200.00 KA

CONTROL MODE * RO LIM RO MIN 005.0 – 100.0% LIM RO MAX 005.0 – 100.0%

CONTROL MODE * VE LIM V MIN 00.20 – 20.00 V LIM V MAX 00.20 – 20.00 V

CONTROL MODE * PW LIM P MIN 000.20 - 600.00 KW LIM P MAX 000.20 – 600.00 KW

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TABLE WITH SEAM WELD OPERATING MODE PARAMETERS – SECONDARY ADJUSTMENT

PROGRAM DATA T1 >TOOLS N° 1 WORKING MODE VEK CONTROL MODE NO

PARAMETER RANGE VALUE

PROGRAM N. 001 – 300 WORKING MODE VEK CONTROL MODE * NO SQUEEZE 1 0.5 – 99.0 cycles SQUEEZE 00.0 – 99.0 cycles PRESSURE 00.5 – 10.0 bar MOTOR DELAY 05 - 99 cycles PRE-WELD 0000 – 1000 mS PRE-VE 00.20 – 20.00 V COLD 1 0000 – 1000 mS SLOPE UP 0000 – 1000 mS WELD. 0001 – 2000 mS VE 00.20 – 20.00 V CURR. MAX. 001.00 – 200.00 KA COLD 2 0000 – 1000 mS VE 2 00.20 – 20.00 V HOLD TIME 00.5 – 99.0 cycles

CONTROL MODE * CUR LIM I MIN 000.30 – 200.00 KA LIM I MAX 000.30 – 200.00 KA

CONTROL MODE * RO LIM RO MIN 005.0 – 100.0% LIM RO MAX 005.0 – 100.0%

CONTROL MODE * VE LIM V MIN 00.20 – 20.00 V LIM V MAX 00.20 – 20.00 V

CONTROL MODE * PW LIM P MIN 000.20 - 600.00 KW LIM P MAX 000.20 – 600.00 KW

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TABLE WITH SEAM WELD OPERATING MODE PARAMETERS – SECONDARY ADJUSTMENT

PROGRAM DATA T1 >TOOLS N° 1 WORKING MODE PWK CONTROL MODE NO

PARAMETER RANGE VALUE

PROGRAM N. 001 – 300 WORKING MODE PWK CONTROL MODE * NO SQUEEZE 1 0.5 – 99.0 cycles SQUEEZE 00.0 – 99.0 cycles PRESSURE 00.5 – 10.0 bar MOTOR DELAY 05 - 99 cycles PRE-WELD 0000 – 1000 mS PRE-POWER 000.20 - 600.00 KW COLD 1 0000 – 1000 mS SLOPE UP 0000 – 1000 mS WELD 0001 – 2000 mS POWER 000.20 - 600.00 KW CURR. MAX. 001.00 – 200.00 KA COLD 2 0000 – 1000 mS POWER 2 000.20 - 600.00 KW HOLD TIME 00.5 – 99.0 cycles

CONTROL MODE * CUR LIM I MIN 000.30 – 200.00 KA LIM I MAX 000.30 – 200.00 KA

CONTROL MODE * RO LIM RO MIN 005.0 – 100.0% LIM RO MAX 005.0 – 100.0%

CONTROL MODE * VE LIM V MIN 00.20 – 20.00 V LIM V MAX 00.20 – 20.00 V

CONTROL MODE * PW LIM P MIN 000.20 - 600.00 KW LIM P MAX 000.20 – 600.00 KW

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TABLE WITH SEAM WELD OPERATING MODE PARAMETERS – PRIMARY ADJUSTMENT

PROGRAM DATA T1 >TOOLS N° 1 WORKING MODE IK CONTROL MODE NO

PARAMETER RANGE VALUE

PROGRAM N. 001 – 300 WORKING MODE IK CONTROL MODE * NO SQUEEZE 1 0.5 – 99.0 cycles SQUEEZE 00.0 – 99.0 cycles PRESSURE 00.5 – 10.0 bar MOTOR DELAY 05 - 99 cycles PRE-WELD 0000 – 1000 mS PRE-CURR. 000.30 – 200.00 KA COLD 1 0000 – 1000 mS SLOPE UP 0000 – 1000 mS WELD 0001 – 2000 mS CURRENT 000.30 – 200.00 KA COLD 2 0000 – 1000 mS CURRENT 2 000.30 – 200.00 KA HOLD TIME 00.5 – 99.0 cycles

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TECNA S.p.A. ITEM TE700 Instruction Manual

CHAPTER 4 – CASCADE OPERATING MODE

FEATURES TE700 BIC 1-2 NC OFF SEAM WELD MODE OFF >CASCADE MODE ON

This function allows the cycle-end signal to be normally closed instead of normally open. As such, multiple TE700 control units may work in electrical cascade mode.

When two or more control units are connected to one another, the signals used to synchronize control units and carry out electrical cascade welds are as follows:

- START CYCLE input

- AUX input

- CYCLE END output

All the TE700 control units receive the cycle start signal simultaneously. Connect the CYCLE END signal to the AUX input of the next control unit. It is advisable to program parameter CASCADE MODE, of the last control unit, to OFF in order to use the CYCLE END signal with the normally open contact

The cascade WORKING MODE excludes the possibility of using the control unit in SEAM WELD MODE.

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CHAPTER 5 – DESCRIPTION OF THE WORK CYCLE

The work cycle carried out by the TE700 is described by adjusting the programming parameters. These parameters describe operating times and current adjustments that make up the work cycle when run in sequence.

The following chart shows the sequence in which the programmed functions are carried out.

The numbers below refer to the following types of parameters:

01 02 03 04 05 06 07 08 09

SQUEEZE 1 (EV1) SQUEEZE (EV2) * FORGE DELAY (EV3) * PRE-WELD * PRE-POWER * COLD 1 * SLOPE UP WELD POWER / CURRENT

COLD 2

IMPULSE N.

SLOPE DOWN *

COLD 3 *

POST-WELD. *

POST-POWER *

HOLD TIME

OFF TIME

Parameters marked by symbol * may either be enabled or disabled depending on which welder is used and the job it must perform.

For safety reasons, the microprocessor does not start the weld cycle if the cycle start signal is activated on turning-on the welder. Therefore simply release the control and then activate it again. Micro-cutoffs or excessive voltage drops do not alter the WORKING MODE but just stop the control unit. Just turn off the machine and then turn it on again to restore operations.

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TECNA S.p.A. ITEM TE700 Instruction Manual

CHAPTER 6 - STOP BAD SPOTS

The machine may be stopped when a consecutive series of welds fall out of the regulated limits. The number of consecutive welds that cause the control unit to stop is adjusted through parameter STOP BAD SPOTS in the SETUP MENU (for the programming directions, see the relevant paragraph).

SETUP MENU >STOP BAD SPOT T1 01 STOP BAD SPOT T2 00 STOP BAD SPOT T3 00

This value may range from 0 to 15. On programming the value to 0, the function is disabled. As such, on exceeding the preset limits, this does not stop the welder. There are four STOP SPOTS parameters, one for each available welding tool, so as to be able to differentiate the max number of admissible out of limits spots for each tool used.

It must be pointed out that in order to count the out of limits welds, they must be consecutive, one after the other. This is applicable to each tool used.

In addition to activating the function in the SETUP MENU, the operator must enable the CONTROL MODE parameter relevant to the current limits in the PROGRAM DATA menu.

PROGRAM DATA T1 TOOLS N° 1 WORKING MODE IK >CONTROL MODE CUR

These parameters allow the operator to keep the consistency of the welding current under control to help achieve constant quality results. The control unit enables to select two different control modes:

Welding current limits

This mode is activated by setting parameter CONTROL MODE to CUR. Two new parameters will be displayed: LIM I MIN lower current limit LIM I MAX upper current limit These two parameters enable to set the welding current limit-values.

PROGRAM DATA T1 TOOLS N° 1 WORKING MODE IK >CONTROL MODE CUR

PROGRAM DATA T1 >PAUSE 00

LIM I MIN 010.0kA LIM I MAX 015.0kA

When the programmed condition occurs, the control unit stops and an error message is displayed. The displayed message refers to the error condition of the last run weld. In current control mode (CONTROL MODE = CUR), if the current value of the last weld is lower or higher than the values set in the foregoing parameters, one of the following messages is displayed:

STOP BAD SPOT MAX T1 WELD CURRENT [201] LIMIT LOW

STOP BAD SPOT MAX T1 WELD CURRENT [202] LIMIT HIGH

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PUSH [///] TO RESET

Inverter use percentage limits

Activate this mode by setting the CONTROL MODE parameter to RO. Two new parameters will be displayed: LIM RO MIN lower limit of the power semiconductors conduction percentage. LIM RO MAX upper limit of the power semiconductors conduction percentage. that permit setting limit values on the conduction percentage of the power semiconductors.

PROGRAM DATA T1 TOOLS N° 1 WORKING MODE IK >CONTROL MODE RO

PROGRAM DATA T1 >PAUSE 00 LIM RO MIN 006.0% LIM RO MAX 020.0%

In conduction percentage control mode (CONTROL MODE = RO), if the value of the conduction percentage of the last weld is higher or lower than the values set in the foregoing parameters, one of the following messages is displayed:

STOP BAD SPOT MAX T1 RO [203] LIMIT LOW

PUSH [///] TO RESET

TOP BAD SPOT MAX T1 RO [204] LIMIT HIGH PUSH [///] TO RESET

Limits on secondary voltage

Activate this mode by setting the CONTROL MODE parameter to VE. Two new parameters will be displayed: LIM V MIN lower limit on the secondary voltage LIM V MAX upper limit on the secondary voltage that permit setting limit values on the secondary voltage during the welding operation

PROGRAM DATA T1 TOOLS N° 1 WORKING MODE IK >CONTROL MODE VE

PROGRAM DATA T1 >PAUSE 00

LIM V MIN 00.50V

LIM V MAX 01.20V

In secondary voltage control mode (CONTROL MODE = VE), if the value of the secondary voltage is higher or lower than the values set in the foregoing parameters, one of the following messages is displayed:

STOP BAD SPOT MAX T1 SECONDARY VE [205] LIMIT LOW

PUSH [///] TO RESET

STOP BAD SPOT MAX T1 SECONDARY VE [206] LIMIT HIGH PUSH [///] TO RESET

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