Safco CS-I 150A Installation guide

Operation and maintenance
Release: 2.8
Safco Systems S.r.l.
Via Isonzo 17/B – 20090 Cesano Boscone – Milan Italy
Tel. [phone] Fax [phone] E-mail:[e-mail]
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)

CS-I User and Maintenance, R.2.8 ENG
Safco Systems Ltd-Via Isonzo 17/b-20090 Cesano Boscone-Milan-Italy
tel. [phone] Fax [phone] E-mail:[email protected] Web site: www.safcosys.it
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Manual notes
DATE: 06-2014
Terminal CS-I/T Rel. 4.04
Power Unit CS-I/P Rel. 4.04
Manual purpose: This manual is intended as a reference book for people who have
received adequate training on methods and techniques of welding
and the specific machine where you install the unit.
Important Legal notice:
The Safco Systems S.r.l. reserves the right to make changes to unity, HW-SW, and this manual
without prior notice.
This manual contains information necessary for the proper operation of the CS-I.
The information provided is not intended to replace, supplement or modify any provision,
requirement, order, directive or law in force at the place where the installation takes place.
Safco Systems S.r.l. constantly monitors the quality of its products, in order to meet regulatory
requirements and best practice design. The device still has residual inherent risks (risk electric,
magnetic fields, weight, etc..) not eliminable and not reducible, so the user undertakes to use the
device only after reviewing the functionality of the product and verification of proper installation.
Has ruled out any use other than as described in this manual.
The device is designed and built for industrial use by trained personnel, is not intended for
other environments and should not be manipulated by someone not properly trained.
The programming of the control should be delegated to qualified personnel; improper
parameterization of the 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 of operation should be
done without having first contacted and asked for specific permission to our Service–
[email protected].
Repairs and maintenance on the devices are not allowed without permission of Safco
Systems S.r.l..
The manual can be used by customers or end users of the product described in it and with the sole
purpose of its proper installation.
Manual can not be reproduced, in whole or in part, without the prior approval in writing by Safco
Systems S.r.l..
It is also prohibited any transmission or dissemination of the manual in any form be it electronic,
mechanical or printed without prior written approval by Safco Systems S.r.l..
Safco Systems S.r.l. has overseen the publication of the manual trying to ensure a comprehensive
and complete, however, assumes no liability for errors or omissions contained within the Manual
and the possible damage that may arise.
The handbook function is solely informative. No obligation may then arise at the end of Safco
Systems S.r.l. on the comparability of product characteristics with those described in the manual of
the product that was actually bought by the customer or end user.
No statement or phrase contained in the handbook will have the effect at the end of Safco Systems
S.r.l. of additional legal obligations or restrictions or different than those contained in the individual
contracts of sale or supply of products Safco Systems S.r.l.

CS-I User and Maintenance, R.2.8 ENG
Safco Systems Ltd-Via Isonzo 17/b-20090 Cesano Boscone-Milan-Italy
tel. [phone] Fax [phone] E-mail:[email protected] Web site: www.safcosys.it
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CS-I User and Maintenance, R.2.8 ENG
Safco Systems Ltd-Via Isonzo 17/b-20090 Cesano Boscone-Milan-Italy
tel. [phone] Fax [phone] E-mail:[email protected] Web site: www.safcosys.it
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WARRANTY:
Safco Systems s.r.l. guarantees every unit produced free of defects in material and assembly for a
period of 12 months. Damaged parts must be shipped to SAFCO SYSTEMS S.r.l. with
transportation costs borne by user. If the defect is caused by misuse the repair will be charged at
customer.
For any further questions or information not given in this manual, please 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-performance track of the maintenance or miss to follow instructions
provided in this manual.
STATEMENT OF RIGHTS TO PROPERTY 'INTELLECTUAL
The information contained in this handbook are based on data that are the intellectual property of Safco Systems S.r.l.. The
publication of this information does not provide any right for reproduction or disclosure to competitors.

CS-I User and Maintenance, R.2.8 ENG
Safco Systems Ltd-Via Isonzo 17/b-20090 Cesano Boscone-Milan-Italy
tel. [phone] Fax [phone] E-mail:[email protected] Web site: www.safcosys.it
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Index
Index 5
1.CS-I system overview..........................................................................................8
2.Warnings and precautions for safe use ..........................................................10
2.1.Applicable safety rules .....................................................................................10
2.2.Main features .....................................................................................................11
2.3.CS-I/T warning lights, switches, buttons and their functionality ..................12
2.4.Notes on installation.........................................................................................14
3.Installation and connectors..............................................................................14
3.1.Connecting the CS-I / P.....................................................................................14
3.1.1Power supply section........................................................................................14
3.1.2Power output section........................................................................................16
3.1.3Description of the features of the connectors and signals............................17
3.1.4Hydraulic connection........................................................................................20
4.Operation of the control and parameters........................................................21
4.1.System power on and first window..................................................................21
4.2.EDIT Menù..........................................................................................................21
4.2.1Set the basic configuration...............................................................................21
4.2.2Input to program parameters, and first setting (Spot-weld or Seam-weld)..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 / outputs Check......................................................................................56
4.2.15Machine Calibration ..........................................................................................58
4.2.16Copy Program....................................................................................................62
4.2.17CAN bus Measures............................................................................................63
5.RUN mode..........................................................................................................66
5.1.Start cycle inputs and concomitantly..............................................................66
5.2.Selection of Running Programs.......................................................................67
5.3.Pre stroke function............................................................................................67
5.4.External input weld current enable..................................................................68
5.5.Inputs Protection...............................................................................................68
5.5.1Over temperature of the transformer / diode (Thermostat) .............................. 68
5.6.Control inputs....................................................................................................69
5.6.1Emergency....................................................................................................... 69
5.6.2Pressure switch................................................................................................ 69
5.6.3Current probe................................................................................................... 69
5.6.4Voltage probe................................................................................................... 69
5.6.5Reset alarms.................................................................................................... 69
5.6.6Reset steps...................................................................................................... 70
5.7.Control outputs..................................................................................................70
5.7.1Main Solenoid valves (EV 1,2,3,4) ................................................................... 70
5.7.2Forge solenoid valves and roll motor (EV 5) ................................................... 70
5.7.3Pre stroke solenoid valve (EV 6 PRE-STROKE).............................................. 70

CS-I User and Maintenance, R.2.8 ENG
Safco Systems Ltd-Via Isonzo 17/b-20090 Cesano Boscone-Milan-Italy
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5.7.4Proportional valve ............................................................................................ 70
5.8.Signalling outputs .............................................................................................70
5.8.1Ready .............................................................................................................. 70
5.8.2End cycle ......................................................................................................... 71
5.8.3Anti-Concomitance........................................................................................... 71
5.8.4End current increase (END STEPS) ................................................................ 71
5.8.5Delta TS........................................................................................................... 71
5.8.6Out of range..................................................................................................... 71
5.8.7CURR ON ........................................................................................................ 71
6.Communications ...............................................................................................71
6.1.Connecting a printer .........................................................................................71
6.2.Connecting a personal computer.....................................................................71
6.3.Connecting to a network...................................................................................72
7.Control mode and features...............................................................................73
7.1.Duty rate D‰......................................................................................................73
7.2.Duty rate compensated primary voltage V‰ ..................................................73
7.3.Constant current IK...........................................................................................73
7.4.Welding mode "advanced"...............................................................................74
7.4.1Tips connections to CS-I/P .............................................................................. 74
7.4.2Tips for the voltage acquisition......................................................................... 74
7.5.Constant power, PK, introduction....................................................................75
7.5.1Constant power, PK, operative notes............................................................... 75
7.6.Constant Energy, EK, introduction..................................................................76
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 Options......................................................92
12.1.Expansion module interface connectors ........................................................92
12.2.Parallel interface module Compact Com SM300CC .......................................92
12.3.CAN Bus Interface Module for measurements managements SM300-EXP5 92
12.4.PC adapter module from RS232 to RS485.......................................................92
12.5.PC program........................................................................................................92
13.Technical data....................................................................................................93
13.1.Electrical characteristics power, inputs and outputs.....................................93
13.1.1Power supply ................................................................................................... 93
13.1.2Power output.................................................................................................... 93
13.1.3Digital signal IN – OUT .................................................................................... 93
13.1.4Analog signals IN – OUT ................................................................................. 94
13.1.5Protections....................................................................................................... 94
13.1.6Mechanical and environmental ........................................................................ 94
13.1.7Cooling............................................................................................................. 94
13.1.8Load Curve: CSI-150A..................................................................................... 95
13.1.9Load Curve: CSI-300A..................................................................................... 95
13.1.10Load Curve: CSI-450A ................................................................................. 96
13.1.11Load Curve: CSI-600A ................................................................................. 97
13.2.CS-I/T mechanical dimension...........................................................................98

CS-I User and Maintenance, R.2.8 ENG
Safco Systems Ltd-Via Isonzo 17/b-20090 Cesano Boscone-Milan-Italy
tel. [phone] Fax [phone] E-mail:[email protected] Web site: www.safcosys.it
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13.3.CS-I/P mechanical dimension...........................................................................99
14.Attachments.....................................................................................................100
14.1.Connections schematics (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 cycle timing diagram (Annex G) ..........................................................107
14.9.Product disposal at the end of its life............................................................108

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CS-I User and Maintenance, R.2.8 ENG
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2. Warnings and precautions for safe use
Warning: The power unit must be mounted with vertical
orientation and power terminals facing up and never in a
horizontal or inverted position.
The reasons are as follows:
•In water cooled models it is to avoid, in case of losses
that sensitive parts of the machine may come in
contact with the liquid.
•In air models cooled it increases the thermal
efficiency of air flow and ensures the achievement of
the performances mentioned in specification.
Warning: The drive stores high voltage (600 VDC).
Before any intervention on the machine, wait at least 6
minutes after removing the main power.
Warning: Installation should only be performed by
qualified personnel 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 integrity.
Warning: the inverter and the devices connected to it, in
their normal operation generate magnetic fields. Prevent
access nearby to pacemaker carriers and do not place
equipment sensitive to magnetic fields close to the inverter
or to the welding transformer.
2.1. Applicable safety rules
EN 50063 Safety requirements for construction and installation of equipment for resistance
welding and similar processes
EN 50240 Electromagnetic compatibility (EMC) - Product standard for resistance welding
equipment.
EN 61131 Programmable Controllers.
EN60204 Safety of machinery - Electrical equipment of machines.
UL840 Table 2 pollution degree 2. Insulation coordination for electrical equipment.