TECNA TE 500 User manual

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

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The TE500 is a microprocessor-based welding control unit for resistance welders. The task of the
welding control unit is to manage the welder components, in particular the controlled diodes that carry
out the welding current control.
It is possible to store up to 63 different welding programs, 31 of which are recalled directly from an
external device. Each program comprises 18 programmable parameters that describe the work cycle.
In addition to the plain 4-stage welding cycle, the control unit allows the running of welding processes
with pre-welding current, post-welding current, slope and pulses.
WELDING CONTROL UNIT TE 500
MAIN TECHNICAL DATA
2
3
2
1
4
MADE IN ITALY
• Simplified programming via 6 keys and a backlit alphanumeric LCD.
• Synchronous control with controlled diodes, phase control current adjustment.
• Storage of 63 welding programs, 31 recallable from the outside.
• 26 programmable parameters for each program.
• Slope, pulses, pre-weld, post-weld functions and adjustment of the welding times in half-periods.
• Display of the RMS welding current measurement in kA and relative angle of conduction.
• Dual operating mode: standard and constant current.
• Welding current or angle of conduction limits.
• Double stroke function.
• Stepper function to compensate the electrodes wear with programmable curve.
• Counter for the performed welding spots.
• Compensation function of the secondary current for welding oxidized sheets and rods.
• Single and automatic cycle. WELD and NO-WELD function.
• Adjustment of first insertion delay.
• Control of 4 solenoid valves 24 Vdc max. 5 W with self-protected output.
• Auto-regulation at mains frequency 50/60 Hz.
• Serial data transmission by means of opto-isolated RS232 or RS485 ports.
• Output for optional proportional solenoid valve.
• Key for selecting foot control or two-hand control.
• Selectable languages: Italian, English, French, German and Spanish.
• Possibility of upgrading control unit Firmware via appropriate software.

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CONTROL UNIT SWITCH-ON
It must be pressed every time the control unit is powered. When the key is pressed all the devices
connected to the VAUX are powered, such as for example, any double stroke valves.
As soon as the welding control unit is turned on, the display shows the primary mains frequency and the
software version of the program.
After a few seconds, the TE500 is set to a waiting condition until the Restart key is pressed.
This key enables the control unit’s commands and outputs.
Before starting any welding operations, first program the welding data and set some general operating
parameters of the welder.
Before pressing the key it is important to check that it will not cause
injury/damage to people or equipment.
SUPPLY FREQUENCY
50 Hz.
TECNA TE500 2.31
WELD CONTROL UNIT
PUSH KEY[//]
RESTART TO CONTINUE
009
k

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The programming parameters of the control unit are divided into different menus as shown in the
drawing above:
_ PROGRAMMING
_ CONFIGURATION
_ STEPPER
_ INSTALLATION
_ PROGRAM COPYING
_ INPUT CHECK
_ PROGRAM SEQUENCES
To begin the programming operations, turn the key in the PROG position and be aware of some of the
fundamental features of the control unit.
Arrow ">" on the left-hand side of the display indicates the cursor’s position.
Use keys dand fto move the cursor up and down whereas keys hand gare used for entering and
exiting from the menu selected by the cursor.
Use keys aand sto set the value of the parameter indicated by the cursor.
PROGRAMMING MENU
The "Programming" menu contains all the parameters associated with the welding cycle, the times and
the currents by means of which to carry out the welding process.
CONTROL UNIT PROGRAMMING
TE500 VER. 2.31
>PROGRAM DATA
SETUP MENU
STEPPER MENU
The first choice to make is the number of the program to be used. Choose among the 63 storable
programs using the aand skeys.
Then proceed with the next parameters moving with the dand fkeys, adjusting the desired value
always using the aand skeys.
As such all the parameters will be set to the desired value for carrying out the welding process. Keep in
mind that there is no need to confirm the set data item that is stored automatically after the adjustment.
Parameters can have several values, according to the type of parameter. The minimum and maximum
limits of each parameter are shown in the following table.
PROGRAM DATA
>PROGRAM NUMBER 01
WORK MODE IK
CONTROL MODE CUR

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There are few special conditions:
• If OFF TIME is set to (0), the welding control unit will work in single cycle.
• If OFF TIME is set to (99), the welding control unit will carry out the min. current compensation with a
value lower than 2.0 kA (see paragraph "COMPENSATION OF THE SECONDARY CURRENT")
• By setting the PRE-WELD parameter to zero, the pre-weld is not carried out.
• By setting the POST-WELD parameter to zero, the post-weld is not carried out.
PARAMETER DESCRIPTION VALUE RANGE
WORK MODE WORK MODE IK - PW%-FIX
CONTROL MODE CONTROL MODE NO - CURR - DEG
1 SQUEEZE 1 1s1 SQUEEZE TIME 01 - 99 cycles
2 SQUEEZE SQUEEZE TIME 00 - 99 cycles
3 PRESSURE WELDING PRESSURE 00 - 99 cycles
4 FORGE DELAY FORGING TIME 00 - 99 cycles
5 PRE-WELD PRE-WELD TIME 00.0 - 99.5 cycles
6 PRE-POWER PRE-WELD CURRENT 05 - 99%
7 COLD I COLD 1 TIME 00 - 50 cycles
8 SLOPE UP SLOPE UP TIME 00 - 25 cycles
9 WELD 1 WELDING TIME 00.5 - 99.5 cycles
10 POWER 1
CURRENT 1 WELDING CURRENT 5 - 99% 1.0 - 90.0 kA
11 COLD 2 COLD 2 TIME 01 - 50 cycles
12 N. IMPULSE NUMBER OF IMPULSES 00 - 09
13 SLOPE DOWN SLOPE DOWN TIME 00 - 25 cycles
14 COLD 3 COLD 3 TIME 00 - 50 cycles
15 POST-WELD POST-WELD TIME 00.0 - 99.5 cycles
16 POST-POWER POST-WELD CURRENT 05 - 99%
17 HOLD TIME HOLD TIME 01 - 99 cycles
18 OFF TIME DWELL TIME 00 - 99 cycles
19 CURR MIN MIN LIMIT IN CURRENT 1.0 - 90.0 kA
20 CURR MAX. MAX. LIMIT IN CURRENT 1.0 - 90.0 kA
21 ANGLE MIN MIN LIMIT IN DEGREES 001° - 180°
22 ANGLE MAX. MAX. LIMIT IN DEGREES 001° - 180°
WORK PROGRAM PARAMETERS TABLE
If CONTROL MODE is activated it will be possible to have additional parameters, namely:
if the CONTROL MODE parameter is set to CURR, otherwise
if the parameter is set to DEG.

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All the following parameters that indicate times are expressed in periods, also called mains cycles. The
mains frequency defines the duration of a period.
Mains frequency of 50 Hz 1 period = 20 ms
Mains frequency of 60 Hz 1 period = 16.6 ms
WORK MODE
The WORK MODE parameter defines the mode for adjusting the welding current of the program: either
power percent (PW%), constant current (IK) or fixed (FIX). Welding time WELD 1 is carried out
according to the adjustment mode set in this parameter. PRE-WELD and POST-WELD times are
always run with the power percent or fixed adjustment.
CONTROL MODE
The CONTROL MODE parameter permits to select the control mode of the desired welding current.
NO No control is performed on the supplied welding current.
CUR TE500 permits to set the welding current min. and max. limits.
DEG TE500 permits to set the min. and max. limits of the welding current conduction angle.
For further information, please read the relevant paragraph.
SQUEEZE 1
The 1st SQUEEZE time or first squeeze determines the time needed by the electrode to move down.
If a pneumatic circuit is present with low-pressure squeeze, such time is that which determines the
duration of the squeeze at low pressure, i.e. the interval of time that elapses from the beginning of the
head descent to the application of the welding force. The set value must be long enough to allow the
electrodes to reach the workpiece to be welded.
In a standard pneumatic circuit, such time is the interval from the beginning of the head descent to the
beginning of the welding. The set value must be long enough to allow the electrodes to achieve the
proper clamping force, before the welding begins.
During the first squeeze time, it is possible to end the cycle if the start cycle signal is deactivated.
SQUEEZE Optional
The SQUEEZE time is a wait time like that of the 1st SQUEEZE. It is necessary for welding machines
with low-pressure squeeze functions. In this case, such time determines the interval from the
application of the welding force onto the electrodes (energizing of the SV2 valve) to the beginning of the
welding. It should be long enough to allow the electrodes to achieve the proper clamping force before
the welding begins. An inadequate adjustment of such time produces sparks among the electrodes and
the sheet when the welding begins, causing quality inconsistencies. If the welding machine does not
contemplate low-pressure squeeze, deactivate this parameter (see Installation Menu). Otherwise it will
be added to the 1st squeeze time. If the start cycle signal is deactivated, during the squeeze time, the
sequence is interrupted.
DESCRIPTION OF THE PARAMETERS

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PRESSURE Optional
This parameter, expressed in bar, expresses the welding pressure value. The set value must be such
that it guarantees a proper clamping force during the welding cycle. An inadequate adjustment of such
value produces sparks between electrodes and sheet when the welding begins.
FORGE DELAY Optional
The FORGE DELAY parameter is used exclusively with pneumatic circuits that contemplate the forging
function. Such function permits to increase the electrode force during the welding cycle.
The parameter describes the time that elapses from the beginning of the welding process to the
application of the forging force onto the electrodes by means of solenoid valve SV3. If the value is set
to zero the forging function is disabled, valve SV3 will be activated at the beginning of the squeezing
phase.
PRE-WELD
The PRE-WELD parameter indicates the duration of a current flow that can be carried out before the
welding process so as to pre-heat the workpiece to be welded. This parameter is expressed by three
digits since it can be set with half-period precision. If this parameter is set to 0, the pre-weld will not be
carried out. Pre-weld is carried out with a current adjustment equivalent to that indicated in the PRE-
POWER parameter (PRE-WELD CURRENT).
PRE-POWER (PRE-WELD CURRENT)
The value expressed in this parameter indicates the power used for carrying out the pre-weld.
COLD 1
The COLD 1 parameter indicates the time that elapses from the pre-weld (PRE-WELD) to the weld
(WELD 1).
If the pre-weld is deactivated (that is, when PRE-WELD time = 0), this cooling time is not carried out.
SLOPE UP
The SLOPE UP parameter describes the time for attaining the programmed welding current value. The
starting value of this slope always corresponds to the minimum current, whereas the final value
corresponds to the current value set at parameter CURRENT 1 (WELDING CURRENT). The slope
inclination is automatically calculated by the microprocessor according to the set values. The SLOPE
UP time is added to the welding time (WELD 1).
WELD 1 (WELDING TIME)
The WELD 1 parameter indicates the welding current flow duration. It is carried out with the same
power value set at parameter CURRENT 1 (WELDING CURRENT). When the pulse operating mode is
activated, this parameter indicates the duration of each pulse. This parameter is expressed by three
digits since it can be adjusted with half-period precision.