Safco CS-I 150A User Manual Download

Page: 1 / 109

Operation and maintenance

Release: 2.8

Safco Systems S.r.l.

Via Isonzo 17/B – 20090 Cesano Boscone – Milan Italy
Tel. +39 024504433 Fax +39 024504321 E-mail:[email protected]
Web site: www.safcosys.com

Control for resistance welding

Inverter technology

Models CS-I 150A CS-I 300A CS-I 450A CS-I 600A

(Square-wave transformers for DC)

Summary of Contents for CS-I 150A

Page 1: ...ia Isonzo 17 B 20090 Cesano Boscone Milan Italy Tel 39 024504433 Fax 39 024504321 E mail info safcosys it Web site www safcosys com Control for resistance welding Inverter technology Models CS I 150A CS I 300A CS I 450A CS I 600A Square wave transformers for DC ...

Page 2: ...welding programs could cause damages to persons or property due to spouts of incandescent material during welding During its use is compulsory to wear goggles flame retardant clothing gloves and safety shoes The connection of external equipment not provided or inconsistent with the manual should be verified by Safco Systems S r l To prevent the misuse and for the safety of personnel no other type ...

Page 3: ...aintenance R 2 8 ENG Safco Systems Ltd Via Isonzo 17 b 20090 Cesano Boscone Milan Italy tel 39 024504433 Fax 39 024504321 E mail info safcosys it Web site www safcosys it 3 of 109 THIS PAGE IS LEFT INTENTIONALLY BLANK ...

Page 4: ...ease contact our customer service providing model type serial number year of construction placed on the identification plate The manufacturer s warranty lapses 12 months after the date of delivery In case of misuse When using aftermarket parts In case of repairs adaptations of the unit by unauthorized personnel without written approval or tampering of the label identification In case of non perfor...

Page 5: ...23 4 2 3 Spot program parameters in cycles 24 4 2 4 Spot program parameters in milliseconds 26 4 2 5 Spot cycle parameters description 28 4 2 6 Forge 37 4 2 7 Seam program parameters in cycles 38 4 2 8 Seam program parameters in milliseconds 39 4 2 9 Seam cycle parameters description 40 4 2 10 System Parameters 45 4 2 11 Auto Step 51 4 2 12 Communications 53 4 2 13 Error Log 55 4 2 14 Inputs outpu...

Page 6: ... 7 6 1 Constant Energy EK operative notes 76 7 7 Adaptive AD introduction 77 7 7 1 Adaptive AD operative notes 77 8 Messaging and display 78 8 1 Main measures window 79 8 2 Sub windows measures in different modes of work 80 9 Selection mode of the program to execute 84 9 1 Control function of the welded spot 84 10 Alarms and warnings 86 11 Alarms warnings list 86 12 Expansions Interfaces Software ...

Page 7: ...Annex A 100 14 2 Expansion module interface connectors 101 14 3 Expansion module can bus for proportional valve with feedback linear position transducer and pressure sensor force Rev A 102 14 4 Serial connection cable for personal computer Annex C 103 14 5 Network cable RS 232 TO RS 485 Annex D 104 14 6 Network cable USB TO RS 485 Annex E 105 14 7 Spot cycle timing diagram Annex F 106 14 8 Seam cy...

Page 8: ...on two at is the term d control uni nce R 2 8 EN b 20090 Cesano 04321 E mail inf iew separate u minal for the ity named C NG o Boscone Mila fo safcosys it units the u e panel ins CS I P CS I T P CS I T Ha CS I n Italy Web site www unit of prog tallation or Panel andheld P safcosys it ramming a CS I T H nd visualiza for the tab 8 of 109 ation called ble use and 9 d d ...

Page 9: ...ming ed via the arameters o g Inverter block R NG o Boscone Mila fo safcosys it speed com ows the term with no wa n a single b ding without y the PLC th in the bus a nology to filt ressed curr quire a con werful proce ck of freque μs such hi managemen urrent y terminal is g and everyt RS232 or R on the PC k diagram CS n Italy Web site www munication minal to acq aiting time box with all t the need...

Page 10: ...el and equipped with the necessary means of individual protection but in any cases not before having read and understood the information contained in this manual Warning After opening the package you should check against damages or burned parts In this case do not power on the machine or its parts and contact the supplier Warning Do not expose your device to rain or agents that may compromise the ...

Page 11: ...dbus TCP Start cycle with dual push buttons dual input or pedals single input Monitoring Quality Control of the limits of the welding current in spot weld and in seam weld mode Programmable function of continuous current increment to compensate electrodes wears under variable curve up to four pairs of electrodes four transformers Welds counter with alarm and lock function Four solenoid valves flex...

Page 12: ...the t can decrea in last wind ELECTION select the d rameter up t on EXIT I upper limit WARNING you can dec n Italy Web site www and their ize three ar and EDIT centre is a ch there are t of welding the button enu in whic enable or EDIT this eters or th value of a p ys bolts and decrea various men s movemen between th s movemen pointer to t meters it ca t in first wi pointer to t ase the num ow it ...

Page 13: ...co Systems Ltd Via Isonzo 17 b 20090 Cesano Boscone Milan Italy tel 39 024504433 Fax 39 024504321 E mail info safcosys it Web site www safcosys it 13 of 109 In RUN mode it can decrease the parameter in the sub windows down to its lower limit ...

Page 14: ...ted in co tors P ion ection to th t connected ction to po efore be tre erminal is to that of p section of p rupture w an adequa ng the effic akage from NG o Boscone Mila fo safcosys it ng for oper ected from st be within ontact with CAUT he power s d ower line in eated very properly co power and power cabl ith serious ate and con ciency m the cables n Italy Web site www ration in a d dust and liq ...

Page 15: ...quired s ations of co t with the p op of the inv terminals output co or RS485 unication co ry voltage c bottom of th ut terminals gs for the co ng water so Bus connec n Italy Web site www connecting ough the in figure belo sequence a onnection to ower not co verter are lo onnectors onnector to connector he inverter for driving t ooling water lenoid valve ction safcosys it the CS I nput termina w a...

Page 16: ...mended to wait at least 6 minutes after system shut down to allow the discharge of stored energy We strongly remind that during the operation these parts of the machine are under high voltages and that insulation adopted cannot be considered safe for an operator We also recommend paying attention to The section of the power cables which are subject to strong electrical stresses during operation It...

Page 17: ...232 RS485 Communication line and programming 9 pin male tank M Male footprint 2 5 Phoenix type The input signals are activated at 24VP The disposal of hardware signals is given in Annex A Pin Signal Description Type 1 GNDP Reference ground for 24VP GND 2 CANH CAN high level I O 3 SHIELD Shield connected to ground on board SHIELD 4 CANL CAN low level I O 5 24VP 24V reported to GNDP max 50 mA PWR Ta...

Page 18: ...ON OFF Signal that in spot mode enables the current flow during the hot cycles only before to enter in welding cycle in seam mode enables or disable the current flow during welding cycle before and during cycle I 10 Reset Alarms Signal silence alarms and reset the READY condition I 11 Reset Steps Signal of zero steps of current confirming the completion of the return electrodes The use of this sig...

Page 19: ...GND Table 6 OUT 1 Output terminal block for solenoid valves and alerts Pin Signal Description Type 1 GNDP Reference Ground for 24VP GND 2 END STEPS The signal is activated for the requested change electrodes as they achieved limits value apply in the stepper O 3 OUT OF RANGE alarm signal that indicates the achievement of preset limits during the hot cycle O 4 CURRENT ON Active signal provided by i...

Page 20: ...d valve e entry und itself ream or up elds or cool erter water c ction when check for p ome into co of explosio y leakage o damages in like Paraf antifreeze m ot toxic NG o Boscone Mila fo safcosys it scription 485 channel A nal data transm ceive signal dat 485 channel B ference Ground ference Ground SERVED t connected t connected ication line RS 232 to pers ns 1 4 6 7 nits with wat the cooling de...

Page 21: ...90 Cesano 04321 E mail inf and par d first wind he configura cycle input e viewing t Y setting ed below EDIT MEN Copy CAN Main ck n s or the arr PLUS to c ration Main Settings the basic se in Settin Spot cycle 50 1000 YES No Safco Via Is 20090 Milan www Mode Frequ NG o Boscone Mila fo safcosys it rameters dow ation param ts and prote the next win the key swi NU y Program bus Meas n Setting row DO ...

Page 22: ... different welding programs cycles at 50Hz 20ms cycles at 60Hz 16 6ms or milliseconds Net Frequency Range value 50Hz 60Hz Working Frequency Range value from 50 to 7000Hz step 10Hz Working frequency values of the system CS I NB After changing the working frequency in the Main Settings menu turn off and on again the CS I to give effect to the frequency change System reset The calibration values are ...

Page 23: ...et the p he modificat ing function om editing p s not go lo ease the nu SX PAG mplifies the he setting of ss the ke NG o Boscone Mila fo safcosys it and first se eters you rs depend o e first is fixe ws program nu tion made b ns is that be position to ost This fe umber of pr decrease editing f parameter ey or on an n Italy Web site www etting Spo can change on the type ed and the umber to ch by th...

Page 24: ...000J EK Res Decrem Trsh 0 1 0 1 50 0 AD Weld Current 1 100 100 999 D V Weld Current 1 1 0 1 0 ImaxKA IK EK AD POWER Weld 1 0 2 0 2 600 0KW PK Cold time 1 0 5 0 5 99 0 Impulse 1 1 1 10 Cold time 1 2 0 0 0 0 99 0 Weld Time 2 0 0 0 99 0 D V IK PK AD ENERGY 2 10 10 60000J EK Weld Current 2 100 100 999 D V Weld Current 2 1 0 1 0 ImaxKA IK EK AD POWER Weld 2 0 2 0 2 600 0KW PK Cold time 2 0 5 0 5 99 0 I...

Page 25: ... T Weld 2 Max 0 5 0 5 99 0 EK T Weld 2 Min 0 5 0 5 99 0 EK Resistance Value 0 00 0 00 650 00 IF VE YES Res Max Limit 1 1 30 IF VE YES Res Min Limit 1 1 30 IF VE YES Meas Elect Close 0 1 0 1 250 0mm Meas Elect Close Tol 0 0 0 0 9 9mm Meas Elect Close Tol 0 0 0 0 9 9mm Meas Current Cut 0 1 0 1 250 0mm End Measure Elect 0 1 0 1 250 0mm End Measure Elect Tol 0 0 0 0 9 9mm End Measure Elect Tol 0 0 0 0...

Page 26: ...0 10 60000J EK Res Decrem Trsh 0 1 0 1 50 0 AD Weld Current 1 100 100 999 D V Weld Current 1 1 0 1 0 ImaxKA IK EK AD POWER Weld 1 0 2 0 2 600 0KW PK Cold time 1 10 10 1980 Impulse 1 1 1 10 Cold time 1 2 0 0 1980 Weld Time 2 0 0 1980 D V IK PK AD ENERGY 2 10 10 60000J EK Weld Current 2 100 100 999 D V Weld Current 2 1 0 1 0 ImaxKA IK EK AD POWER Weld 2 0 2 0 2 600 0KW PK Cold time 2 10 10 1980 Impu...

Page 27: ...lose 0 1 0 1 250 0mm Meas Elect Close Tol 0 0 0 0 9 9mm Meas Elect Close Tol 0 0 0 0 9 9mm Meas Current Cut 0 1 0 1 250 0mm End Measure Elect 0 1 0 1 250 0mm End Measure Elect Tol 0 0 0 0 9 9mm End Measure Elect Tol 0 0 0 0 9 9mm Weld Press 0 0 0 0 9 9bar Tol Press 0 0 0 0 1 0bar Weld Force 0 0 1000dN Tol Force 0 0 20dN EXIT Press where specified the parameter is only available in the indicated op...

Page 28: ...y program Working mode Range value D V IK with parameter VE set to YES PK EK AD Default Value D Sets the mode in which the CS I P will make the power supply to transformer duty fixed D duty compensated voltage Bus V constant current IK in constant power PK in constant energy EK or adaptive AD Limits Check Range value NO YES Default Value NO Enables or disables the monitoring of maximum and minimum...

Page 29: ...onds from 0 to 1980 step 10ms Cycles Default Value 0 0 Milliseconds Default Value 0 It sets the squeeze time Pressure 3 Range value from 0 to 99 Default Value 0 It sets the percentage of voltage of the analogical output for the proportional valve During the Pre squeeze time if zero the previously set value does not change Pre heating time Range value in cycles from 0 0 to 99 0 step 0 5 In millisec...

Page 30: ...ue 0 It sets the rise time of the welding current NB The parameter value is automatically limited or reset to the value of the welding time 1 if greater than welding time 1 Decr Res Thres Range value from 0 1 to 50 0 step 0 1 Default Value 0 1 It sets the percentage of decrease in the resistance of the welding core starting from the peak value detected in adaptive mode AD Weld time 1 Range value i...

Page 31: ...nds Default Value 0 It sets the cold time between weld cycle 1 and 2 Weld time 2 Range value in cycles from 0 0 to 99 0 step 0 5 in milliseconds from 0 to 1980 step 1 Cycles Default Value 0 0 not execute Milliseconds Default Value 0 It sets the Weld time 2 Weld current 2 Range value When in D e V from 50 to 999 150A 300A from 100 to 999 450A 600A When in IK or AD from 0 25 to Imax 150A 300A from 1...

Page 32: ...Value 1 It sets the number of repetitions for welding 1 and 2 Slope Dw Range value from 0 a 10 step 1 in milliseconds from 0 to 200 step 1 Cycles Default Value 0 Milliseconds Default Value 0 It sets the descent time of the last current supplied during the welding Cool time 3 Range value in cycles from 0 5 to 99 0 step 0 5 in milliseconds from 10 to 1980 step 10 Cycles Default Value 0 5 Millisecond...

Page 33: ...t Value 0 Set the off time electrodes open Pressure 5 Range value from 0 to 99 Default Value 0 It sets the percentage of the voltage for the analogical output of the proportional valve During the Forging time if zero or less the previously set value does not change Forge Range value NO YES Default Value NO If set to NO no forging pressure is applied the forging valve will not go on and will activa...

Page 34: ...in IK PK EK from 1 to 30 Default Value 1 It sets the upper limit for the monitoring of current power Curr Min P Min Limit Range value in D V from 1 0 a ImaxKA in IK PK EK from 1 to 30 Default Value 1 It sets the lower limit for the current power control during the weld Current Limit Range value only in PK from 1 to Imaxn n Electrodes number Default Value 1 Sets the maximum current at which to arri...

Page 35: ...good weld 2 Resistance Value Range value 0 00 650 00 uohm Range value 0 00 The value of resistance testing is displayed if the parameter in the VE system parameter is set to Yes and tested if it is set differently from 0 00 uohm with parameter control limits set to YES Res Max Limit Range value 1 30 Range value 1 Res Min Limit Range value 1 30 Range value 1 Meas Elect Close Range value 0 0 250 0mm...

Page 36: ...End Measure Elect Tol Range value 0 0 a 9 9mm Range value 0 0 Positive tolerance within which there is no error on the measurement End Measure Elect Tol Range value 0 0 a 9 9mm Range value 0 0 Negative tolerance within which there is no error on the measurement Weld Press Range value 0 0 9 9bar Range value 0 0 Set the welding Pressure Tol Press Range value 0 0 1 0bar Range value 0 0 Sets the toler...

Page 37: ...of forge is activated during the course of the spot program by setting the parameter Forge on YES and programming the parameter Delay Forge with a value of milliseconds or Cycles of delay from the start of a welding 1 when time has elapsed the set time from the start of welding control enables the output of the forging valve and forging pressure if set this value will be set on the proportional va...

Page 38: ...rr 0 0 50 Slope Up 0 0 10 Pressure 1 0 0 99 Weld time 1 0 5 0 5 99 0 Cold time 1 0 0 0 0 99 0 Weld Current 1 100 100 99 D V Weld Current 1 1 0 1 0 ImaxKA IK Pressure 2 0 0 99 Weld time 2 0 5 0 5 99 0 Cold time 2 0 0 0 0 99 0 Weld Current 2 100 100 999 D V Weld Current 2 1 0 1 0 ImaxKA IK Pressure 3 0 0 99 Weld Time 3 0 5 0 5 99 0 Cold time 3 0 0 0 0 99 0 Weld Current 3 100 100 999 D V Weld Current...

Page 39: ...V Weld Current 1 1 0 1 0 ImaxKA IK Pressure 2 0 0 99 Weld Time 2 1 1 1980 Cold time 2 0 0 1980 Weld Current 2 100 100 999 D V Weld Current 2 1 0 1 0 ImaxKA IK Pressure 3 0 0 99 Weld Time 3 1 1 1980 Cold time 3 0 0 1980 Weld Current 3 100 100 999 D V Weld Current 3 1 0 1 0 ImaxKA IK Slope Dw 0 0 200 Slope DW Final Curr 0 0 50 Hold time 10 10 1980 Off time 0 0 1980 Initial Blanking 1 1 200 Curr Max ...

Page 40: ...ing all the times set but will not provide current set to YES will provide current flow where required Working mode Range value D V IK Default value D It sets the mode in which the CS I P will supply the power to transformer duty fixed D duty compensated voltage Bus V or constant current IK Limits Check Range value NO YES Default value NO Enables or disables the monitoring of maximum and minimum c...

Page 41: ... a percentage of the welding current request Slope Up Range value in cycles from 0 to10 in milliseconds from 0 to 200 Cycles Default value 0 Default value in ms 0 It sets the rise time of the first weld current Pressure 1 Range value da 0 a 99 Default value 0 Sets the output driving the proportional valve during welding 1 Weld time 1 Range value in cycles from 0 5 to 99 0 step 0 5 in milliseconds ...

Page 42: ...1 to 1980 step 1 Cycles Default value 0 5 Default value in ms 1 It sets the weld time 2 used if cool time 2 is greater than 1 it is also used to define the test time window If limit monitoring is activated Cool time 2 Range value in cycles from 0 0 to 99 0 step 0 5 in milliseconds from 0 to 1980 step 1 Cycles Default value 0 0 Default value in ms 0 It sets pause time 1 if different from 0 enables ...

Page 43: ...o 999 150A 300A from 50 to 999 450A 600A When in IK from 0 25 to Imax 150A 300A from 1 0 to Imax 450A 600A Default value in D e V 50 100 Default value in IK 0 25 1 0 It sets the weld current 3 value Slope Dw Range value in cycles from 0 to 10 in milliseconds from 0 to 200 Cycles Default value 0 Default value in ms 0 It sets the decay time of the last current supplied during welding Slope DW Final ...

Page 44: ...illiseconds from 1 to 200 STEP 1 Cycles Default value 0 5 Default value in ms 1 Sets the time of masking fit during the welding time it has impact on display and on control Curr Max Limit Range value in D V from 1 0 to ImaxKA in IK from 1 to 30 Default value 1 Set the upper limit for the control of welding current Curr Min Limit Range value in D V from 1 0 a ImaxKA in IK from 1 to 30 Default value...

Page 45: ...10 1 99 EV Water presence YES NO YES Current source Int Int Ext Bus Open Electrodes FLT NO CHK FLT PSW Input SI NO YES S NS Input SI NO YES Password NO NO YES Electrodes YES NO YES Current YES NO YES Pre Squeeze YES NO YES Only Spot Pre Heating YES NO YES Only Spot Cool time 0 YES NO YES Only Spot Weld 2 YES NO YES Only Spot Slope Dw YES NO YES Only Spot Temper YES NO YES Only Spot Forge YES NO YE...

Page 46: ...from which to repeat the cycle B Before or A After the Pre squeeze This function is disabled in Seam mode Log spot Range value NO ALL BAD Default value NO CS I can generate a report of the welds This can be done directly on a printer connected to the serial line or through a personal computer with the appropriate software Printing of the weld values has different formats depending on the working m...

Page 47: ...0 Allows the assignment of the program to be executed with start cycle IC1 Function is active when the selection mode is set to on Function on IC1 is disabled in Seam mode Program IC2 Range value from 0 to 63 Default value 0 Allows the assignment of the program to be executed with start cycle IC2 Function is active when the selection mode is set on Function on IC2 is disabled in Seam mode Seq Star...

Page 48: ...yo tional valve E C Ope ng pre strok time n cycles req y en ocking NO n cking NO le mode age of the c of off time nning of ho of hold time time n cycles of nce R 2 8 EN b 20090 Cesano 04321 E mail inf ou to define en ke valve mo uired for lat O or unlock or unlockin cycle the CS standard ld time e f the contac NG o Boscone Mila fo safcosys it from 5 to 1 10 e the maxim NO YES NO ode at the e from ...

Page 49: ...by setting the Bus the current value is read as cyclic data type word from 100 to 999 field bus Open Electrodes Range value NO CHK FLT Default value FLT Enables management of welding electrodes open CHK and any error signal FLT or total disabling of the management NO PSW Input Range value NO YES Default value YES Allows use if YES of input Pressure Switch on the terminal board or when unused place...

Page 50: ... 999 Cool time 0 connects or disconnects in the program parameters Pressure 4 0 0 99 Cold time 0 10 10 1980 Weld 2 connects or disconnects in the program parameters Cold time 1 2 0 0 1980 Weld Time 2 0 0 1980 Weld Current 2 100 100 999 Cold time 2 10 10 1980 Impulse 2 1 1 10 Cold time Sald 1 2 10 10 1980 Impulse Weld 1 2 1 1 10 Slope DW inserisce disinserisce nei parametri di programma Slope Dw 0 ...

Page 51: ...ed at any spot roughly the ideal curve which compensates the wear of the tips When the total number of steps is reached the CS I indicates the necessity of electrodes change through the exit END STEPS and showing the message on the display After replacing the tips you need to reset the CS I via the reset input STEPS or sub window Auto Step If not reset giving a new start cycle the CS I performs th...

Page 52: ...sonzo 17 b 20090 Cesano Boscone Milan Italy tel 39 024504433 Fax 39 024504321 E mail info safcosys it Web site www safcosys it 52 of 109 Inc Range value from 0 1 t 15 9 It sets the percentage of increase of the segment to apply to the selected number of points ...

Page 53: ... bus The ports of the CS I P RS232 and RS485 have 8 bits data anyway you can change the baud rate from 4800 to 19200 bps parity none odd even and stop bit 1 to 2 As for the RS 232C you can define three modes of operation NO is not used PRN is connected to a printer for having reports of the activity or PC is for connecting to a PC through a bi directional communication allows you to capture the co...

Page 54: ...it Range value 1 2 It selects the stop bits of the RS485 RS 485 Unit Address Range value 0 31 It selects the network node on the CS I P RS485 Active ANCC Card Range value None only for visualization Indicates the presence and type of card in the Compact Com expansion bus network communication parallel CS I P ANCC Card Unit Node Range value 1 125 Selects the network node on Compact Card Com located...

Page 55: ...o Boscone Milan Italy tel 39 024504433 Fax 39 024504321 E mail info safcosys it Web site www safcosys it 55 of 109 4 2 13 Error Log Display windows CS I Log Errors 1 2 3 4 5 Clear Errors Press EXIT Press Description Show the last 5 errors inverter unit New error overrides the oldest ...

Page 56: ...and set the outputs for solenoid valves and signals so you can check the status of machine wiring For solenoid valves from 1 to 6 The setting to 0 on inherent position switches the output off while the setting to 1 will enable the output if PB Com input is active Is possible to set the proportional valve PV output at desired value setting its parameter from 0 to 99 The associations of the inputs a...

Page 57: ...ueeze Roll motor EV2 Pre Squeeze Squeeze Roll motor EV3 Pre Squeeze Squeeze Roll motor EV4 Pre Squeeze Squeeze Roll motor EV5 Forging Rolls Motor EV6 Pre stroke AUT Latching output valves DTS Delta TS RDY Ready unit ready ENDS End Steps OOR Out Of Range ION Current enable ANC Anti parallel ENDC End Cycle PV Proportional valve WARNING P S The outlet group is feed bringing the input Pb Com or pedal ...

Page 58: ...ibration electrodes the inherent calibration parameters change as follows Calib Electrodes 2 NO NO YES Alpha 2 XXXX Beta 2 XXXX Gamma 2 XXXX Transf Ratio 2 XXX XX 1 00 200 00 Max Current 2 10 1 100KA GAIN_I 2 XXX 100 100 transducer type 2 Rog No Rog CT K_Rog 2 150 10 250 K_filt 2 2 1 2 4 Calib Electrodes 3 NO NO YES Alpha 3 XXXX Beta 3 XXXX Gamma 3 XXXX Transf Ratio 3 XXX XX 1 00 200 00 Max Curren...

Page 59: ...o it is obligatory to use the CT primary current transducer located inside the inverter K Rog 1 2 3 4 Range value from 10 to 250 Set mV rendered by Rogowski transducer for KA of current variation or flow derivative for the correct display of the current To use the CS I in the closed loop mode IK etc you must perform the calibration procedure of the plan transformer pliers etc for the determination...

Page 60: ... a calibration error and waits for another start cycle MANUAL CALIBRATION PROCEDURE 1 Enter the EDIT mode and then in the calibration menu 2 Set the parameter for the pair of electrodes to be calibrated Calib Electrodes x with the desired number 3 Set the parameters known Alpha Beta and Gamma detected by the calibration of the same plant 4 Set the maximum current of the transformer and its relatio...

Page 61: ...nce of opening times IGBT already high it is not possible to increase the dynamics of the system because it already is providing all the available voltage This situation is shown in the graph D when the value is close to 100 during the too slow In this case there is no benefit by increasing the gain The optimal behavior is achieved in the test step response characterized by slight overshoot within...

Page 62: ...Copy N Range value from 0 to 63 Sets the program number to be duplicated in one or more programs Copy Range From Prg N Range value from 0 to 63 Set the program number from which to duplicate the preset program To Prg N Range value da 0 a 63 Set the number of the program to get to duplicate the preset program Set Date for these two parameters are the same value is obtained a copy of a single progra...

Page 63: ...ment without the possibility of automatic setting for the automatic recovery of wear electrodes and the management of the measure current cut and measure the final electrodes position If set in NUT it is made and tested in the measurement of approach with the possibility of self learning of the measurement of closure electrodes with relative management of automatic compensation and the management ...

Page 64: ...anagement in the cycle spots Measure Current Cut Range Value NO SI Default Value NO Arm disarm the parameter and its management in the cycle spots End Measure Electr Range Value NO SI Default Value NO Arm disarm the parameter and its management in the cycle spots Press Force Op Mode Range Value NO Pr Fr Default Value NO Sets whether to obtain the release of pressure or force on analog output of th...

Page 65: ... output voltage 10V ES In Force Range Value 0 1000 Default Value 0 Sets the End scale output force corresponding to the maximum value of the output voltage 10V Feed Bk Range Value NO SI Default Value NO Set unset the PI cycle before welding pressure or force applied to the workpiece by means of the input and output analog pressure or force Feed Bk Delay Time Range Value 0 20 0 Default Value 0 Sets...

Page 66: ... by pedals signals for the start cycle 1 or 2 are given by the inputs PEDAL1 or PEDAL2 In spot mode the start of the cycle occurs with the assertion of the inputs as shown in the table D uring the spot cycle the entry of Pb C causes the interruption of the welding as if they were made time set Seam mode the start of the cycle occurs with the assertion of the inputs as shown in the table the weldin...

Page 67: ...in windo ot the pro e pre set st menu Syste g paramete parameter 8 16 32 as held in non noid EV6 PRE STRO meters if th turned off im oid is asser ntil the begin ntil the com e NG o Boscone Mila fo safcosys it s ne by press eter SRC he source d p of inputs grams this ary code p m memory e made 50 m is shown o am is define th a program ow RUN a ogram num tart value to em Parame ers are set rs are re...

Page 68: ...nne operationa ing system transformer f air and wa or this inpu R SUGGE CHINE EQU he transfo nnected to a opening du ction area e table of al will enter in rating cond m should oc arm should NG o Boscone Mila fo safcosys it he operati energized een the wel able bling of weld on the disp h the input am selected xternal is s ected to 24 al quality r diode us ater sensors t you must ESTS USI UIPMENT ...

Page 69: ...n PK elded cable to YES in sy s input you he condition he function d and rese eared out t NG o Boscone Mila fo safcosys it emergency an immedia removing th circuit separ isplay in the tus makes im e or after sq er the detec cted to 24V or the moto by any inve ted the disp ogowski co adjusting the ng and adj e shorted o transformer of transduce ermines the is located K EK or AD e directly to ystem ...

Page 70: ...VP with load current up to 200mA protected from short circuit In spot mode this output is activated during forging phase In Seam mode this output is used to drive the roll motor 5 7 3 Pre stroke solenoid valve EV 6 PRE STROKE This active output to 24VP with load current up to 200mA protected from short circuit is activated or deactivated as described in 5 3 5 7 4 Proportional valve This output ana...

Page 71: ... to 24VP with load current up to 200mA protected from short circuit When activated signals the exit of the thresholds set in the control of the main welding It is also activated in the presence of a significant deviation from the current set at welding Measure current out of range or zero current 5 8 7 CURR ON This active output to 24VP with load current up to 200mA protected from short circuit Wh...

Page 72: ... network using the RS 485 CS I is a slave node The connection can be done via a serial cable as shown in Annex D 9 pin connector located on the present on the CS I P You can set the communications port unit in the menu of communications You must assign it a unique address on the net The setting Ser Direct should be set to none or PRN Through optional parallel expansion to the CS I P you can operat...

Page 73: ...stant voltage on the primary of the transformer in case of lowering or raising the main supply voltage With this setting is not required the connection of the Rogowski coil or of the CT With no use the system parameter current transducer must be set to NO This mode allows the use of the unit without any calibration This mode allows use of the unit without any calibration If you connect the Rogowsk...

Page 74: ...he inverter into the input side of the connector X3 The voltage measurement is strongly influenced by the electromagnetic field induced by the self sealing Although the inverter is able to remove most of the effects of these disturbances it is good to hold them up to have good results and repeatable In the selection of the site must be minimized in the area enclosed between the two conductors At t...

Page 75: ...r activating the voltage measurement it is suggested that you test welding working initially in IK mode without slope You must get good results this way the tracking power a Correct any tails or excessive overshoot by changing the gain parameter in the menu Machine Calibration b Delete from the measure the initial transient using initial mask parameter in order to have stable measurements 2 Bring ...

Page 76: ... necessary to fix the time of the initial slope up and initial masking Note that the value of energy supplied during welding depends on the current supplied the voltage measured by the presence of slope up and masking Changing any of these items may need to repeat the test working in IK 2 By analyzing the measured values on good welds define the energy values that characterize a good weld quality ...

Page 77: ...by parameter 1 Defining an optimal operating condition by working in IK mode welding only with a single pulse on a weld 1 2 Bring the program mode AD a Set the parameters T x Welding Min and Welding x T Max to the minimum and maximum time taken for welding weld 1 and 2 if used In particular as the maximum time it is suggested to set a value sufficiently greater than that found in welding IK then t...

Page 78: ...ogram Int Ext Set Seq BusRam BusPrg the state of the current YES NO the state of repetition of the cycle associated to the number program YES NO the number of pulses 1 and 2 associated to the program to be executed Status Function area In this part of the window you can find the following information On the next line marked State Function shows the status of CS I Ready or Not Ready During the weld...

Page 79: ...g program the window displays main measures readout as by the following combinations Main measures window D V and constant current IK Display window TIME 1 0ms IRMS 1 0 00KA TIME 2 0ms IRMS 2 0 00KA Main measures window in constant power PK Display window TIME 1 0ms POWER 1 0 00KW TIME 2 0ms POWER 2 0 00KW Main measures window in constant energy EK Display window TIME 1 0ms ENERGY 1 0J TIME 2 0ms ...

Page 80: ...POWER 0 00KW Sub windows only in spot present in D V IK PK EK AD Display sub window Weld 2 TIME 0ms IRMS 0 00KA ENERGY 0J POWER 0 00KW Sub windows only in spot present in D V IK PK EK AD Display sub window Pre Heating TIME 0ms IRMS 0 00KA POWER 0 00KW Sub windows only in spot present in D V IK PK EK AD Display sub window Temper TIME 0ms IRMS 0 00KA POWER 0 00KW Sub windows only in spot present in ...

Page 81: ... Reset the count of the welds highlighting the NO on the third line RESET with the down arrow key Reset with key confirmation get a YES Set the value of total points to be executed Highlight with the arrow keys up down on the first line PRESET the number Use the Key or decrease with the key until the desired value is reached Enable comparison Highlighting with the arrow keys up down the second lin...

Page 82: ... the program runs in Seam welding Display sub window Currents IRMS 1 0 00KA IRMS 2 0 00KA IRMS 3 0 00KA Sub window of Use Ro SEAM Display sub window Util Ro weld 1 0 Ro weld 2 0 Ro weld 3 0 Sub window reading inverter parameters This window displays the value of dc bus voltage V the temperature of the radiator the size of the inverter and the maximum primary supplied current Display sub window Con...

Page 83: ...s enabled VE yes The value of decimation Decim x indicates the horizontal scale time range and is equal to the number of points where the system will display the average for a single pixel The system automatically acquires a new screen with a trigger on the first warm weather of each point or in the case of Seam each time a set point After a new approach is necessary to initiate a new point to ref...

Page 84: ...afcosys it m to execu utton ection the em paramet s follows ber selected s enable on IC2 config ntial reading cted and inc and then cy from the int g the an stops flashin eters of the w dicated to th eters of the w ut dedicated spot ou can set th n Seam mod nable the co t limit value welding a bad spot es the CS et from the sured durin ration of con ming a num Y conditio n Italy Web site www ute o...

Page 85: ...ne Milan Italy tel 39 024504433 Fax 39 024504321 E mail info safcosys it Web site www safcosys it 85 of 109 In spot or Seam mode pressing the key or setting on the reset Alarm input the Ready condition is restored The alarm output is turned off and the alarm message from display is removed ...

Page 86: ...enerated the alert do not repeat It is essential pay close attention to the alerts provided by the system as in the presence of anomalies hazardous situation for the operator system failure loss of quality of the welding process etc might occur 11 Alarms warnings list N Cod Description Alarm Warning Alarm Lock GENERAL SYSTEM MESSAGES 1 ERROR Crc eeprom CS I P Data in non volatile memory CS I P cor...

Page 87: ... be carried out by qualified personnel with appropriate equipment Alarm YES 10 ERROR VBus out of static range The dc bus voltage has gone out of range while the system was not delivering power Check and if necessary to monitor power supply voltages WARNING The monitoring should be carried out by qualified personnel with appropriate equipment Alarm YES 11 POWER SUPPLY OFF CS I P off bus voltage bel...

Page 88: ...easurement machine calibration menu Alarm YES 23 ERROR Calibration required You attempted to perform a welding current control without having carried out the necessary calibration of the machine Perform the calibration Alarm YES 24 ERROR Calibration CS I in not Weld You attempted to perform a calibration with the inverter in no weld from the program select General or external input correct the set...

Page 89: ...torted and do not drop during dispensing Alarm YES 34 ERROR Calibration Low Voltage Dc bus voltage too low during the calibration phase 480V During the calibration phase is required to supply line does not drop excessively Check the quality of the supply line and the connection lead is used Alarm YES 35 ERROR Calibration Low Current Reading of current too low during the calibration phase the plant...

Page 90: ...lectrodes are not closed on the workpiece Make sure there are no abnormalities of behavior of transformer pliers and electrical connections Since this report is subject to false positives you can disable it from the system parameters Alarm YES 48 Elect Close Measure not in Tolerance After closing the control electrodes with the measure set in the running program is not in tolerance Alarm YES 49 Cu...

Page 91: ...een exceeded Limit Maximum Power set in the parameters of the program Warning No 58 WARNING Limit min power PK mode has been exceeded limit exceeded Minimum Power set in the parameters of the program Warning No 59 WARNING EK T Max reached EK mode has not been reached in the energy required set time Warning No 60 WARNING EK reached before T Min EK mode The Energy set in the program is reached befor...

Page 92: ...net IO EtherNet IP Modbus TCP 12 3 CAN Bus Interface Module for measurements managements SM300 EXP5 This module allows the conditioning of the signal from a linear potentiometer or a linear sensor 0 10V for the management of the displacement measuring electrodes and in addition is able to manage a proportional valve with feedback and make measurements of the line pressure 12 4 PC adapter module fr...

Page 93: ...ra Maximum current 210 A 360 A 530A 700A Nominal current 2 150 A 300 A 450A 600A Frequency 1000 7000 Hz Maximum voltage 600V Rogowski measurement error 3 1 Maximum cable section 90 mm 120 mm Efficiency 97 Table 3 Power output 13 1 3 Digital signal IN OUT IN MIN MAX Maximum Range 3 V 30 V Condition 0 3 V 5 V Condition 1 11 V 30 V Current consumption each input 25 mA Oscillations 24VP 23 V 26V Curre...

Page 94: ... Supply voltage out of range on the internal DC link 380 V 700 V Permitted on the heatsink over temperature Signaling values for 70 C Water machines o 75 C Air machines Overload internal power supply Hardware Protection Short circuit the digital outputs Hardware Protection with Signaling Table 5 Protections 13 1 6 Mechanical and environmental Framework Aluzinc Protection degree IP20 Overall extern...

Page 95: ...l info safcosys it Web site www safcosys it 95 of 109 13 1 8 Load Curve CSI 150A 13 1 9 Load Curve CSI 300A 10 0 10 1 10 2 70 80 90 100 110 120 130 140 150 160 ED Ton ton toff L o a d C u rre n t tra n sf p rim A Current vs ED CSI 150A 150A 400V AC Tair 45 C 1000 msl Th max 65 C freq 5000 Hz 200 ms 400 ms 600 ms 800 ms 1200 ms 1600 ms 2000 ms ...

Page 96: ...433 Fax 39 024504321 E mail info safcosys it Web site www safcosys it 96 of 109 13 1 10 Load Curve CSI 450A 10 0 10 1 10 2 100 150 200 250 300 ED Ton ton toff Load Current transf prim A Current vs ED CSI 300A 300A 400V AC Tair 45 C 1000 msl Th max 65 C freq 4000 Hz 200 ms 400 ms 600 ms 800 ms 1200 ms 1600 ms 2000 ms ...

Page 97: ...nd Maintenance R 2 8 ENG Safco Systems Ltd Via Isonzo 17 b 20090 Cesano Boscone Milan Italy tel 39 024504433 Fax 39 024504321 E mail info safcosys it Web site www safcosys it 97 of 109 13 1 11 Load Curve CSI 600A ...

Page 98: ...ms Ltd Via Isonzo 17 b 20090 Cesano Boscone Milan Italy tel 39 024504433 Fax 39 024504321 E mail info safcosys it Web site www safcosys it 98 of 109 13 2 CS I T mechanical dimension 118mm 57mm 244mm 226mm max depth 45mm pod measure 212mm x 116mm Ø 7 ...

Page 99: ... Maintenance R 2 8 ENG Safco Systems Ltd Via Isonzo 17 b 20090 Cesano Boscone Milan Italy tel 39 024504433 Fax 39 024504321 E mail info safcosys it Web site www safcosys it 99 of 109 13 3 CS I P mechanical dimension ...

Page 100: ...ATO A nor ma di legge è vietata la riprodu zione e la trasmissione anche par ziale e per qualsiasi scopo delle informazioni ivi contenute a terzi e a Ditte concorrenti DESCRIZIONE DISTRIBUZ REV DIS DATA AUX 1 24V AC DC GND P 1 24V P 24V P GND P PS 1 TO CS I T 1 N C RXD RXD TXD TXD 6 8 9 7 5 2 3 1 4 N C GND 5V RESERVED GND P N C TX RX B 9 6 5 7 8 4 MALE RS 422 COLLEGAMENTI ESTERNI EXTERNAL CONNECTI...

Page 101: ...PROG 02 PROG 04 PROG 01 PEDAL 2 PEDAL 1 PROG 32 PROG 16 PROG 08 24V P PED PRE STROKE PED D 5 4 3 2 7 6 10 9 8 11 13 12 3 2 1 7 6 5 8 4 12 11 10 14 3 2 1 13 5 4 6 7 9 8 14 11 10 9 3 2 5 8 7 6 4 1 11 10 9 12 J IN 2 1 14 1 14 J IN 1 1 6 J PROT J ROG 1 4 J PROP 6 1 5 J CAN 1 J OUT 1 12 1 11 J OUT 2 5 N C MALE RS 422 VIS DATA DIS DIS VIS 6 7 9 8 GND P GND P 24V P 24V P 1 2 3 4 5 6 5 4 3 2 2 1 4 3 6 4 3...

Page 102: ...ata la riprodu zione e la trasmissione anche par ziale e per qualsiasi scopo delle informazioni ivi contenute a terzi e a Ditte concorrenti DESCRIZIONE DISTRIBUZ REV DIS VIS DIS DATA VIS PROP VALVE VALVE SUPPLY 24V 0V J PROP 2 1 3 GND 24V 1 4 GND segue F COLLEGAMENTI ESTERNI EXTERNAL CONNECTIONS SM300_EXP5 G M 19 11 09 300EXP5 SKD REV A CONTR DATA CE 17643 B F 1 1 2 3 4 5 GND AN 0 5V AN1 GND J AN_...

Page 103: ...fcosys it Web site www safcosys it 103 of 109 14 4 Serial connection cable for personal computer Annex C Warning for connection to CS I P RS232 to personal computer or printer use cable as shown follow Never connect pins 1 4 6 7 8 9 To CS I Front view TO CS I MALE SUB D 9 PIN TO PC FEMALE SUB D 9 PIN Back view To PC 8 8 6 7 1 2 3 6 7 1 2 3 9 4 5 9 4 5 ...

Page 104: ...504321 E mail info safcosys it Web site www safcosys it 104 of 109 14 5 Network cable RS 232 TO RS 485 Annex D to PC serial port RS 232 the interface converter is an optional accessory P S The PINS 1 AND 4 ON THE CONNECTOR ARE LINKED TOGETHER TO ENABLE SHIELD CONNECTION Interface Converter RS 232 TO RS 485 MODEL 2089 PATTON XMT G ...

Page 105: ...o 17 b 20090 Cesano Boscone Milan Italy tel 39 024504433 Fax 39 024504321 E mail info safcosys it Web site www safcosys it 105 of 109 14 6 Network cable USB TO RS 485 Annex E The interface converter is an optional accessory M 3 COD 688257 RS 485 USB RS 485 F F 1 2 ...

Page 106: ... its time is not 0 set for pressures of 0 is maintaining the pressure above In repeated cycles with the pre Squeeze first jump is set at the end of maintenance the first pressure is not between 0 to P1 2 3 4 5 this is also valid in case of non repeating cycle By setting the cycle repeated after pre jump Squeeze is set at the end of maintenance the first pressure between P2 3 4 5 is not set to 0 Th...

Page 107: ...lan Italy tel 39 024504433 Fax 39 024504321 E mail info safcosys it Web site www safcosys it 107 of 109 14 8 Seam cycle timing diagram Annex G C P Pressure switch P1 Press 1 Squeeze o entire Seam cycle P2 Press 2 Pre squeeze P3 Press 3 Pre weld P4 Press 4 weld P5 Press 5 Forge PU Spot PA Pause ...

Page 108: ...ion of electrical or electronic equipment will avoid possible negative consequences for the environment and human health resulting from improper disposal and also allows you to recover recyclable materials in which the product is made The equipment can not be disposed of as municipal waste but initiated separately the refusal can be given to the distributor for the purchase of equipment equivalent...

Page 109: ...Via Isonzo 17 b Fax 39 02450 A Rev nce R 2 8 EN b 20090 Cesano 04321 E mail inf P At the passw verse for en NG o Boscone Mila fo safcosys it Passw word promp nter in the n Italy Web site www word pt enter in s Main sett safcosys it sequence tings menù 109 of 109 9 ...

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Safco CS-I 150A, Operation And Maintenance

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