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
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The information contained in this document is subject to modification without notice.
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Instruction Manual TE470/TE480 S.p.A.
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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
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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.
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S.p.A. TE470/TE480 Instruction Manual
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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.
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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.
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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.
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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).
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