TECNA TE470 User manual

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

S.p.A. TE470/TE480 Instruction Manual
This page intentionally left blank.
The information contained in this document is subject to modification without notice.
No part of this document can be either reproduced or transferred in whatever format neither by electronic nor by mechanic
means for whatever purpose, without ’s written permission.
is a registered brand.
2/52

Instruction Manual TE470/TE480 S.p.A.
3/52
TABLE OF CONTENTS
CHAPTER 1 – THE TE470/TE480 WELD CONTROL UNIT ................................................... 5
1.1 – MAIN FEATURES.................................................................................................................................6
1.2 – COMMANDS ON THE PANEL.............................................................................................................7
1.3 – PANEL LEDs........................................................................................................................................7
1.4 – DESCRIPTION OF THE DISPLAYED INFORMATION.......................................................................8
1.5 – CONTROL UNIT SWITCH-ON...........................................................................................................10
CHAPTER 2 - CONTROL UNIT PROGRAMMING................................................................ 11
2.1 – WELDING CYCLE PARAMETERS PROGRAMMING MENU...........................................................11
2.2 – PERCENTAGE ADJUSTMENT OPERATING MODE.......................................................................12
2.3 – CONSTANT CURRENT OPERATING MODE...................................................................................14
2.4 - CONSTANT ENERGY WORKING MODE (ONLY IN TE480)............................................................16
2.5 – DESCRIPTION OF THE PARAMETERS...........................................................................................18
2.6 - SETUP MENU......................................................................................................................................22
2.7 – CURRENT STEPPER FUNCTION.....................................................................................................25
2.8 – ADJUSTING THE FIRST INSERT DELAY........................................................................................30
CHAPTER 3 – THE WORK CYCLE ...................................................................................... 31
3.1 – EXAMPLES OF WORK PROGRAMS................................................................................................32
CHAPTER 4 - WELDING CURRENT AND CONDUCTION ANGLE MEASURE.................. 34
CHAPTER 5 - STOP DUE TO SPOTS OUT OF LIMIT.......................................................... 35
5.1 - WELDING CURRENT LIMITS.............................................................................................................35
5.2 – CONDUCTION ANGLE LIMITS .........................................................................................................35
CHAPTER 6 – WELDS COUNTER FUNCTION.................................................................... 36
CHAPTER 7 - HANDLES DESCRIPTION............................................................................. 37
CHAPTER 8 – INPUTS AND OUTPUTS OPERATION......................................................... 38
8.1 – FUNCTION OF THE "PRESSURE ONLY" COMMAND ("AUX" INPUT).........................................38
8.2 - "SAFETY" CONTROL FUNCTION ("CHK" INPUT).........................................................................38

S.p.A. TE470/TE480 Instruction Manual
4/52
8.3 – FUNCTION OF THE THERMOSTAT OR FLOWSWITCH INPUT (OPTIONAL).............................. 39
8.4 - CYCLE END OUTPUT........................................................................................................................ 39
CHAPTER 9 – DOUBLE STROKE FUNCTION.....................................................................40
CHAPTER 10 – OPTIONS.....................................................................................................42
10.1 - RS-485 SERIAL INTERFACE.......................................................................................................... 42
10.2 – INTERFACE FOR PROPORTIONAL VALVE................................................................................. 43
CHAPTER 11 – DESCRIPTION OF THE SIGNALS ON THE TERMINAL STRIP ................44
CHAPTER 12 – LIST OF MESSAGES..................................................................................47
CHAPTER 13 – TECHNICAL SPECIFICATIONS..................................................................49

Instruction Manual TE470/TE480 S.p.A.
CHAPTER 1 – THE TE470/TE480 WELD CONTROL UNIT
The TE470/TE480 is a microprocessor-based weld control unit for suspended, single-phase resistance welding
guns. The task of this weld control unit is to manage the welder's components, especially the controlled diodes
that adjust the welding current. The special feature of this control unit is that it is fitted with specific functions,
when used with industrial welders, such as the double stroke control and the safeties efficiency check function
that, if installed, is present on the handle. The handle is not an integral part of the control unit since different
types of handles are used to adapt the machine to different work needs.
As many as 63 different weld programmes can be stored.
Depending on the type of handle connected to the control unit, from 2 to 4 programmes can be called from the
outside.
Each program consists of programmable parameters that describe the work cycle. In addition to the simple 4-
stroke cycle, the control unit enables the execution of welds with pre-weld, post-weld, slope and pulse current.
The TE470 can operate in conventional mode and constant current while the TE480 can work also in constant
energy mode.
Both control units display the welding current and envisage a control on the output current with settable limits.
5/52

S.p.A. TE470/TE480 Instruction Manual
6/52
1.1 – MAIN FEATURES
Simplified programming by means of 5 push-buttons and LCD alphanumeric display.
Synchronous controlled diodes command, adjustment of the phase control current.
Possibility of connecting 2 handles.
Storage of 63 weld programmes, 2 called through the switch on the handle (or 4 through the commutator).
Up to 22 programmable parameters for each program.
Current ascent, current descent, impulses, pre-weld and post-weld functions.
Welding times adjustment in half-periods.
Display of the RMS welding current measurement in kA and relative angle of conduction.
3 operating modes: conventional, constant current and constant energy (only TE480).
Either welding current or conductor angle limits.
Automatic double stroke function (to be employed only when the welder has been designed for this function).
Stepper function to balance the electrodes wear-out with adjustable curve.
Welds counter.
Single and automatic cycle. WELD/NO WELD function.
Delay of first phase shift adjustment to get the best balance of the machine absorption from mains.
Management of 2 solenoid valves 24 VDC, Max 3.5 W, with output protected against short circuits:
electrodes-closing valve and double-stroke valve.
Self-adjustment to the mains frequency 50/60 Hz.
Output for managing a proportional solenoid valve.
Cycle-end output.
Selectable languages: Italian, English, Spanish, German, French, Hungarian, Portuguese and Swedish.

Instruction Manual TE470/TE480 S.p.A.
1.2 – COMMANDS ON THE PANEL
Upward direction key used for moving the cursor inside the upper parameter.
Downward direction key used for moving the cursor inside the lower parameter.
This key is used for increasing the value of a numeric parameter or for changing the
status of a parameter.
This key is used for decreasing the value of a numeric parameter or for changing the
status of a parameter.
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.
Use the WELD/NO WELD function to carry out test cycles without welding current. Welding current is enabled or
disabled by means of the button shown above. When the lamp is on, the control unit is set to WELD and carries
out the standard welding cycles. When the lamp is off, the control unit is set to NO WELD: complete test cycles
will be carried out, without welding, while maintaining all the time parameters.
1.3 – PANEL LEDs
START
INIZIO CICLO
If on, this LED indicates that the cycle start command from the button of handle 1
(connected to XS10) is activated.
START 2
INIZIO CICLO 2 2
If on, this LED indicates that the cycle start command from the button of handle 2
(connected to XS11) is activated.
AUX
AUSILIARI
O
When this warning light turns on, it means that the stop command by means of
pressure only, through the AUX input, is activated. As a rule, it is activated by the
"PRESSURE ONLY" selector.
CURRENT
CORRENTE
If on, this LED indicates that the control unit is generating the SCR trigger impulses.
SOLENOID VALVE 1 1
It indicates that the solenoid valve executing the main cycle is activated.
SOLENOID VALVE 2 2
It indicates that the solenoid valve driving the double stroke is activated.
7/52

S.p.A. TE470/TE480 Instruction Manual
1.4 – DESCRIPTION OF THE DISPLAYED INFORMATION
The main screen shows a range of information after each run cycle, both for the cycles run in weld mode, with
the control unit set to WELD mode, and for the cycles run in NO WELD mode.
The values displayed in the following description are for reference only.
This is what is displayed by the screen of the TE470 control unit:
1 2 3
4 5
Pr01 12455 104°
08.0 ~ 12.3kA
1. Pr01
It indicates the program used for the last weld sequence; it may be a number between 01 and 63. It is displayed
both in WELD and in NO WELD mode.
2. 12455
This is the run welds counter; the number ranges from 00000 to 65000. It updates only in WELD mode and
resets through keys and .
3. 104°
It indicates the current conduction angle of the last weld. In WELD mode, it may have a value between 000° and
180°. In NO WELD mode, the displayed value is 000°. The conduction angle represents the current flowing time
along the half-cycle. The displayed value represents the average of the measured values for each half-cycle of
the welding time.
The showed value always refers to the main adjustment, basically to the WELD parameter one. In no instance is
the conduction angle of the current measured during the slope time. In the case of pulse weldings, the angle
value would refer to the last pulse.
Examples of currents having different conduction angles:
4. 08.0 ~
Indicates the welding time of the last weld. In WELD mode the value is between 00.5 and 99.5. In NO WELD
mode the displayed value is 00.0.
5. 12.3 kA
Indicates the value of the current with which the last weld was performed. In WELD mode the value ranges from
00.0 kA to 36.0 kA. In NO WELD mode the value is 00.00kA.
It represents the average of the RMS values measured for every weld time half-period. The displayed value
always refers to the main adjustment i.e. to that of the WELD parameter. In the case of impulse welds, the
current value will always be the average value of all the impulses.
8/52

Instruction Manual TE470/TE480 S.p.A.
This is what the screen of the TE480 control unit (Constant Energy) displays:
Where, to the above described information, is added:
6. 02500J
Indicates the value of the total energy with which the last weld was performed. In WELD mode the value ranges
from 00000 J to 99999 J. In NO WELD mode the displayed value is 00000 J.
9/52

S.p.A. TE470/TE480 Instruction Manual
1.5 – CONTROL UNIT SWITCH-ON
As soon as the welding control unit is turned on, the display shows the supply frequency and the version of the
program.
SUPPLY FREQUENCY
50 Hz
TE470 REV. 2.21
WELD CONTROL
After a few seconds, the TE470/TE480 is set in a waiting condition to carry out the welding process.
Pr01 12455 104°
08.0 ~ 12.35 kA
Before starting the programming phase, it is important to learn some fundamental features of the control unit.
The TE470/TE480 stores 63 different welding programs. If allowed by the type of handle connected to the
control unit, when working it is possible to quickly select up to four different programs called "ADJUSTMENT 1",
"ADJUSTMENT 2", "ADJUSTMENT 3" and "ADJUSTMENT 4", respectively. While working, the adjustments are
selected by means of a switch or a commutator on the handle.
For example, the choice is made through selector 4 using the following handle.
During the programming stage the user selects, for each adjustment, the weld program to be used.
The control unit dialogs with the user through a LCD. The user programs which language the control unit should
display the alarm and error messages.
The control unit is programmed by adjusting the parameters that describe the welding cycle. This is done by
selecting the parameters and setting the required values one at a time.
To better understand the meaning of each parameter, refer to the relevant paragraph (PARAMETERS
DESCRIPTION).
10/52

Instruction Manual TE470/TE480 S.p.A.
CHAPTER 2 - CONTROL UNIT PROGRAMMING
2.1 – WELDING CYCLE PARAMETERS PROGRAMMING MENU
Press buttons and simultaneously for at least one second to program the welding cycle parameters.
Once inside the menu, the control unit automatically exits from the programming procedure after 8 seconds of
inactivity and allows the process to be run.
The first choice to make is the number of the programme. Use buttons and to change this value.
ADJUSTMENT 1
PROGRAM N. 01
After having chosen the number of the programme, select the parameters that make up the program through
buttons and and set the required value each time, using buttons and .
The parameters are identified by a letter (from A to C) or a number (from 1 to 22).
The display shows the following data:
A
DJ1 PRG01 PRM07
W
ELD 1 08.0 ~
1 2 3
4 5
1. ADJ1
Indicates the ADJUSTMENT associated with the programme. According to the PRG program number selected
beforehand, the ADJ will assume the value associated inside the SETUP menu.
It can have the following values:
ADJ1 (ADJUSTMENT 1), ADJ2 (ADJUSTMENT 2), ADJ3 (ADJUSTMENT 3), ADJ4 (ADJUSTMENT 4) or ADJ–
when the selected program number is not associated with an ADJ (also see description inside the SETUP
menu).
2. PRG01
Indicates the selected program number (e.g.: PRG01 = program number 1) and its value is between 01 and 63.
3. PRM07
Identifies the selected parameter (e.g.: PRM07 = parameter number 7) with a value that includes a letter (from A
to C) or a number (from 1 to 22).
4. WELD 1
Indicates the name of the selected parameter (e.g.: WELD 1).
5. 08.0 ~
Indicates the value of the selected parameter (e.g.: 08.0 cycles).
Change the value of the parameters using buttons and to increase and decrease the displayed value.
Then set the next parameters using buttons and .
In this manner the required parameters are set to the value needed to carry out the weld. Keep in mind that no
key is to be pressed to confirm the set datum that is stored automatically after the adjustment.
When the programming operations are accomplished, wait until the control unit ends the programming phase;
this takes place automatically after 8 seconds of inactivity.
11/52

S.p.A. TE470/TE480 Instruction Manual
If the start of cycle device is activated before the control unit moves from the programming phase to the
working phase, it will not be considered. Release the control device and start it again.
As soon as the welding cycle is activated, the control unit checks the data of the selected program. An error
message will be displayed if the values of the parameters are not compatible.
Below the three working modes are described and the three programming screens are shown according to the
parameter selected in the WORKING MODE.
The screens contain all the programmable parameters.
2.2 – PERCENTAGE ADJUSTMENT OPERATING MODE
The welding percentage value can be set in the percentage adjustment working mode (WORKING MODE
parameter selected in PW%). In this mode, the control unit measures the real effective value (RMS) of the weld
current and shows the current value at the end of the weld.
The percentage adjustment operating mode does not foresee any secondary coil feedback during the welding
process; for this reason, it is suitable for being used especially when one operates in difficult working conditions,
beyond the welding tables, as for instance when using a very short welding time where it would be critical to use
one of the more complex working modes foreseen in this control unit.
TABLE PERCENTAGE OPERATING MODE PARAMETERS
ADJ1 PRG01 PRM A
WORKING MODE PW%
NUMBER PARAMETER DESCRIPTION VALUE RANGE
TO WORKING MODE Working mode PW%
B CONTROL MODE * Control unit mode NO - CURR - DEG
C STROKE Double stroke mode SHORT - LONG - AUTOMATIC
1 SQUEEZE 1 1st squeeze time 00 - 99 cycles
2 SQUEEZE Squeeze time 01 - 99 cycles
3 PRE-WELD Pre-weld time 00.0 - 99.0 cycles
4 POWER 1 Pre-weld current 05 - 99 %
5 COLD 1 Cold 1 time 00 - 50 cycles
6 SLOPE UP Slope up time 00 - 25 cycles
7 WELD Weld time 00.5 - 99.5 cycles
8 POWER Weld power 05 - 99 %
9 IMPULSE N. Number of impulses 01 - 09
10 COLD 2 Cold 2 time 00 - 50 cycles
11 SLOPE DOWN Slope down time 00 - 25 cycles
12 COLD 3 Cold 3 time 00 - 50 cycles
13 POST-WELD Post-weld time 00.0 - 99.0 cycles
14 POWER 2 Post-weld current 05 - 99 %
15 HOLD TIME Hold time 01 - 99 cycles
16 OFF TIME Interval time 00 - 99 cycles
12/52

Instruction Manual TE470/TE480 S.p.A.
13/52
B CONTROL MODE * Control unit mode NO
17 PRESSURE Pressure value 0.5 - 10.0 bar
B CONTROL MODE * Control unit mode CURR
17 CURR MIN Current min limit 1.0 - 36.0 kA
18 CURR MAX Current max limit 1.0 - 36.0 kA
19 PRESSURE Pressure value 0.5 - 10.0 bar
B CONTROL MODE * Control unit mode DEG
17 ANGLE MIN Min limit in degrees 005 - 180°
18 ANGLE MAX Max limit in degrees 005 - 180°
19 PRESSURE Pressure value 0.5 - 10.0 bar
There are some peculiar conditions:
If the OFF TIME (16) is set to zero, the control unit works in single cycle.
By setting the PRE-WELD parameter (3) to zero, the pre-weld is not carried out.
By setting the POST-WELD parameter (13) to zero, the post-weld is not carried out.
We recommend activating the CONTROL MODE in CUR and checking the use limit conditions before starting
the production: if use is with 2 sheets for example, limit conditions are with 1 or 3 sheets. The weld current is
adjusted by control unit TE470/TE480.
However, it is necessary to check the welding current value with one sheet so to be set as minimum limit and to
check it with 3 sheets so to be set as maximum limit.
However, it is not possible to undoubtlessly assure that the piece has been effectively welded, as all the
conditions and parameters involved in the welding process execution should be checked.

S.p.A. TE470/TE480 Instruction Manual
2.3 – CONSTANT CURRENT OPERATING MODE
When the weld control unit works in constant current operating mode (parameter WORKING MODE selected in
IK), the current value with which to perform the weld is set directly. During the weld, the control unit measures
the weld current's real effective value (RMS) in every half-period and maintains the set current according to a
mathematical correction algorithm.
In addition to simplifying the programming operations, this operating mode also permits to keep the desired
welding current even if some factors change such as: mains voltage, welding circuit dimensions and impedance,
conditions of the welding tools or surface condition of the materials being processed.
CONSTANT CURRENT OPERATING MODE SURVEY
Welding current (I) variation according to the mains
voltage (V) variation in standard working mode 80% Welding current (I) variation according to the mains voltage (V) variation in constant current 80% mode
14/52

Instruction Manual TE470/TE480 S.p.A.
TABLE CONSTANT CURRENT OPERATING MODE PARAMETERS
ADJ1 PRG01 PRM A
WORK MODE IK
NUMBER PARAMETER DESCRIPTION VALUE RANGE
TO WORKING MODE Working mode IK
B CONTROL MODE * Control unit mode NO - CURR - DEG
C STROKE Double stroke mode SHORT - LONG - AUTOMATIC
1 SQUEEZE 1 1st squeeze time 00 - 99 cycles
2 SQUEEZE Squeeze time 01 - 99 cycles
3 PRE-WELD Pre-weld time 00.0 - 99.0 cycles
4 POWER 1 Pre-weld current 05 - 99 %
5 COLD 1 Cold 1 time 00 - 50 cycles
6 SLOPE UP Slope up time 00 - 25 cycles
7 WELD Weld time 00.5 - 99.5 cycles
8 CURRENT Welding current 02.0 – 30.0KA
9 IMPULSE N. Number of impulses 01 - 09
10 COLD 2 Cold 2 time 00 - 50 cycles
11 SLOPE DOWN Slope down time 00 - 25 cycles
12 COLD 3 Cold 3 time 00 - 50 cycles
13 POST-WELD Post-weld time 00.0 - 99.0 cycles
14 POWER 2 Post-weld current 05 - 99 %
15 HOLD TIME Hold time 01 - 99 cycles
16 OFF TIME Interval time 00 - 99 cycles
B CONTROL MODE * Control unit mode NO
17 PRESSURE Pressure value 0.5-10.0 bar
B CONTROL MODE * Control unit mode CURR
17 CURR MIN Min current limit 1.0 - 36.0 kA
18 CURR MAX Max current limit 1.0 - 36.0 kA
19 PRESSURE Pressure value 0.5 - 10.0 bar
B CONTROL MODE* Control unit mode DEG
17 ANGLE MIN Min limit in degrees 005 - 180°
18 ANGLE MAX Max limit in degrees 005 - 180°
19 PRESSURE Pressure value 0.5 - 10.0 bar
We recommend activating the CONTROL MODE in DEG and checking the use limit conditions before starting
production: if use is with 2 sheets for example, limit conditions are with 1 or 3 sheets. The control unit adjusts the
constant weld current (if the conduction degrees are not near 180°). However, the conduction degrees should be
checked with 1 sheet to set the minimum limit and check the value with 3 sheets to set the maximum limit.
However, it is not possible to undoubtlessly assure that the piece has been effectively welded, as all the
conditions and parameters involved in the welding process execution should be checked.
15/52

S.p.A. TE470/TE480 Instruction Manual
2.4 - CONSTANT ENERGY WORKING MODE (ONLY IN TE480)
WORKING MODE parameter selected in ENE, the working frame is the following one:
01 08.0~ 08.00kA
02500J 104°12345
Adjustments are performed in the constant energy control unit (TE480) as in a conventional control unit except
for the ENERGY parameter and the weld time parameter for which a precise value is not set, just the minimum
and maximum value.
During welding, the control unit reads the true efficacious welding current RMS, the non-inductive component of
the voltage at the electrodes in volts (V x cos

) and the welding duration in cycles. The product of I x V x cos

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 operating 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. adjust the minimum welding time to the same as the maximum welding time (WELD MIN = WELD
MAX) with the cycles value indicated in the traditional welding tables.
4. carry one spot weld out and verify that it is satisfactory
5. read the value of the total developed energy and set it in the ENERGY parameter of the working
program
6. adjust the minimum time (WELD MIN) to the number of periods necessary for carrying the spot out with
the new electrodes
7. adjust the maximum time (WELD MAX) to a number of periods that does not spoil the piece
ENERGY TREND READINGS DURING WELDING
0
200
400
600
800
1000
1200
1400
02468101214
E
n
e
r
g
y
Semi-cycles
16/52

Instruction Manual TE470/TE480 S.p.A.
TABLE CONSTANT ENERGY OPERATING MODE PARAMETERS
ADJ1 PRG01 PRM A
WORKING MODE ENE
NUMBER PARAMETER DESCRIPTION VALUE RANGE
TO WORKING MODE Working mode ENE
B CONTROL MODE * Control unit mode NO - CURR - DEG
C STROKE Double stroke mode SHORT - LONG -AUTOMATIC
1 SQUEEZE 1 1st squeeze time 00 - 99 cycles
2 SQUEEZE Squeeze time 01 - 99 cycles
6 SLOPE UP Slop up time 00 - 25 cycles
20 WELD MIN Weld time 00.5 - 99.5 cycles
21 WELD MAX Weld time 00.5 - 99.5 cycles
8 POWER Weld power 05 - 99 %
22 ENERGY Energy value 00060 - 60000 joule
12 COLD 3 Cold 3 time 00 - 50 cycles
13 POST-WELD Post-weld time 00.0 - 99.0 cycles
14 POWER 2 Post-weld current 05 - 99 %
15 HOLD TIME Hold time 01 - 99 cycles
16 OFF TIME Interval time 00 - 99 cycles
B CONTROL MODE * Control unit mode NO
17 PRESSURE Pressure value 0.5-10.0 bar
B CONTROL MODE * Control unit mode CURR
17 CURR MIN Min current limit 1.0 - 36.0 kA
18 CURR MAX Max current limit 1.0 - 36.0 kA
19 PRESSURE Pressure value 0.5 - 10.0 bar
B CONTROL MODE* Control unit mode DEG
17 ANGLE MIN Min limit in degrees 005 - 180°
18 ANGLE MAX Max limit in degrees 005 - 180°
19 PRESSURE Pressure value 0.5 - 10.0 bar
There are some peculiar conditions:
If the OFF TIME is set to 0, the control unit will work in single cycle.
By setting the POST-WELD parameter to zero, the post-welding process will not be carried out.
By setting the same value for both CURR. MIN and CORR MAX, the limits are disabled.
By setting the same value for both ANGLE MIN and ANGLE MAX, the limits are disabled.
We recommend activating the CONTROL MODE in CUR and checking the use limit conditions before starting
production: if use is with 2 sheets for example, limit conditions are with 1 or 3 sheets. The control unit adjusts the
constant energy.
However, it is necessary to check the welding current value with one sheet so to be set as minimum limit and to
check it with 3 sheets so to be set as maximum limit.
However, it is not possible to undoubtlessly assure that the piece has been effectively welded, as all the
conditions and parameters involved in the welding process execution should be checked.
17/52

S.p.A. TE470/TE480 Instruction Manual
18/52
2.5 – DESCRIPTION OF THE PARAMETERS
All of the following parameters indicate times that are expressed in periods, also called mains cycles.
The mains frequency determines the duration of 1 period:
Mains frequency 50 Hz 1 period = 20 ms
Mains frequency 60 Hz 1 period = 16.6 ms
PRM A – WORKING MODE
The WORKING MODE parameter defines the program's weld current adjustment mode: either in power
percentage (PW%), constant current (IK) or constant energy (ENE). This parameter only affects the weld time
(WELD) that will be carried out in the adjustment mode defined in this parameter. The PRE-WELD and POST-
WELD times are always executed in power percentage adjustment mode.
PRM B – CONTROL MODE
The CONTROL MODE parameter enables to select the desired welding current control mode.
NO There is no control on the supplied welding current.
CUR The TE470/TE480 enables to set the welding current min. and max. limits.
DEG The TE470/TE480 enables to set the min. and max. limits of the welding current conduction
angle.
For further information, please read the relevant paragraph.
PRM C – STROKE
Welders with the double stroke function (or approach stroke) can work in the following modes:
SHORT Short stroke
LONG Long stroke
AUTOMATIC Automatically set stroke
Additional data on this function are given in the relevant paragraph.
This parameter can be set only if both the machine and the handle are designed for the control of the
double stroke from the control unit.
PRM01 – SQUEEZE 1
The SQUEEZE 1 time (first squeeze) is used during the double automatic stroke work mode (STROKE
parameter set to AUTOMATIC). It determines the electrode's shifting time from the long stroke position to the
short one.
The set value must be long enough to enable the mobile electrode to reach the short stroke position.
During the first squeeze time, it is possible to end the cycle if the start of cycle signal is deactivated.
This parameter can be programmed and will be displayed only if the machine and the handle
contemplate the control unit double stroke management feature.
PRM02 – SQUEEZE
The SQUEEZE time determines the closing time of the electrodes, i.e. the time interval from the moment the
electrodes begin to close to the beginning of the weld. The set value must be long enough to allow the
electrodes to reach the work piece to be welded and the correct clamping force before the welding operation
begins.
A too low adjustment of this time causes sparkles between electrodes and sheet when the welding process
starts; it can also cause an unsteadiness of the welding quality.
If the start cycle signal is deactivated during the squeeze time, the sequence is broken up.
PRM03 – PRE-WELD
The PRE-WELD parameter describes the duration of a current flow that can be carried out before the weld, to
pre-heat the workpiece.
If the parameter is set to 0, the pre-weld will not be performed. The pre-weld will be performed with a current
adjustment equivalent to that indicated in the POWER 1 parameter (pre-weld current).

Instruction Manual TE470/TE480 S.p.A.
19/52
PRM04 – POWER 1
The value expressed in the POWER 1 parameter indicates the power used to carry out the pre-weld.
PRM05 – COLD 1
The COLD 1 time parameter indicates the time that elapses between the PRE-WELD and the WELD.
When the pre-weld is off (PRE-WELD time equal to 0) this cold time is not carried out.
PRM06 – SLOPE UP
The SLOPE UP parameter describes the time during which the programmed weld current is reached. The initial
value of this slope is always equal to the minimum current whilst the final value is equal to the current value
programmed in the POWER parameter. The microprocessor calculates this slope automatically, according to the
programmed values. The SLOPE UP time is added to the WELD time.
PRM07 – WELD
The WELD time parameter represents the duration of the weld current flow. The weld will be carried out at a
power value equal to the one indicated in the POWER parameter. When the impulse mode is activated, this
parameter indicates the duration of every single impulse.
This parameter is expressed by three digits since it can be adjusted with the precision of a half period.
PRM08 – POWER / CURRENT
Depending on the adjustment mode selected via the WORKING MODE parameter, the PRM08 parameter can
assume the POWER or CURRENT values.
When the WORKING MODE parameter is adjusted to PW% (Power) or ENE (Constant Energy), the POWER
parameter appears. Its value indicates the power percentage adjustment with which the weld is carried out.
When the WORKING MODE parameter is adjusted IK (Constant Current), the CURRENT parameter appears.
Its value indicates the current adjustment with which the weld is carried out.
PRM09 – IMPULSE N.
The IMPULSE N. parameter indicates the number of impulses used to carry out the welding process. The
duration of each impulse is that set in the WELD parameter.
PRM10 – COLD 2
The COLD 2 parameter is used in the pulse operating mode; it indicates the time that elapses from a welding
impulse to the next one.
When the impulse number is set to zero, the cold time 2, even if programmed, is not carried out.
PRM11 – SLOPE DOWN
The SLOPE DOWN parameter is a weld time that is reached at the end of the welding operation and during
which the welding current decreases to minimum by the amount set in POWER or in CURRENT. The
microprocessor calculates this slope automatically, according to the programmed values.
The SLOPE DOWN time is always added to the WELD time.
PRM12 – COLD 3
The COLD 3 parameter indicates the time that elapses from the WELD time to the POST-WELD time.
PRM13 – POST-WELD
The POST-WELD time parameter describes the duration of a current flow that can be carried out after the weld
time. If the parameter is set to 0, the post-weld will not be carried out. It will be carried out with a current
adjustment equal to that indicated in the POWER 2 parameter.
PRM14 – POWER 2
The value expressed in this parameter indicates the post-welding power.

S.p.A. TE470/TE480 Instruction Manual
20/52
PRM15 – 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.
PRM16 – 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 machine works in single cycle, the control unit carries out only one welding cycle each time it receives
a cycle start signal.
When the machine works in automatic cycle, the welder continuously carries out welding cycles until the cycle
start signal ceases.
PRM17 – PRESSURE / CURR. MIN / ANGLE MIN
The meaning of this parameter depends on the control mode selected in the CONTROL MODE parameter.
In current control mode (CONTROL MODE = CUR), the CURR. MIN parameter fixes a minimum current limit
value. For each weld performed, the TE470/TE480 checks that the current supplied by the welder is greater than
the value set in this parameter. Otherwise an error occurs (see specific paragraph).
In degrees control mode (CONTROL MODE = DEG), the ANGLE MIN parameter fixes a minimum conduction
angle limit value. For each weld performed, the TE470/TE480 checks that the max conduction angle of the
supplied welding current is greater than the value set in this parameter. Otherwise an error occurs (see specific
paragraph).
The meaning of PRM17 turns into PRESSURE (see next description of PRM19) when instead the CONTROL
MODE is set to NO (welding current control OFF) and the PR. VALVE parameter (present in the SETUP MENU)
is set to ON (proportional valve ON).
If the CONTROL MODE parameter is set to NO and the PR. VALVE parameter is set to OFF (proportional valve
OFF), the PRM17 parameter is not displayed during the programming.
PRM18 – CURR. MAX / ANGLE MAX
The meaning of this parameter depends on the control mode selected in parameter CONTROL MODE.
When the control unit is set to current control mode (CONTROL MODE=CUR), the CURR. MAX parameter fixes
a maximum current limit value. For each weld, the TE470/TE480 checks that the current supplied by the welder
is lower than the value set in this parameter. Otherwise an error occurs (see specific paragraph).
When the control unit is set to degree control mode (CONTROL MODE=DEG), the ANGLE MAX parameter fixes
a maximum conduction angle limit value. For each weld, the TE470/TE480 checks that the maximum conduction
angle of the supplied welding current is lower than the value set in this parameter. Otherwise an error occurs
(see specific paragraph).
If the CONTROL MODE parameter is set to NO (no control on the welding current), the parameter is not
displayed during the programming.
PRM19 – PRESSURE
This parameter, expressed in bars, expresses the welding pressure and is used only when the proportional
valve is present in the pneumatic system. The set value should guarantee a suitable tightening torque during the
weld since an insufficient adjustment of this value produces sparks between electrodes and sheet when the
welding begins. This parameter may be activated through the PR. VALVE function in the SETUP MENU.
PRM20 – WELD MIN (only in TE480)
The minimum weld time parameter (WELD MIN) is expressed in periods and represents the minimum welding
duration time, which will be carried out with a power value equal to that indicated in the POWER parameter. If an
energy value higher than or equal to the corresponding programmed value is measured at the end of said time,
the welding will stop. This parameter is displayed only on selecting the ENE (Constant Energy) WORKING
MODE.