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. +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)
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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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–
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
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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
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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
3.1.1Power supply section........................................................................................14
3.1.2Power output section........................................................................................16
3.1.3Description of the features of the connectors and signals............................17
3.1.4Hydraulic connection........................................................................................20
4.Operation of the control and parameters........................................................21
4.1.System power on and first window..................................................................21
4.2.EDIT Menù..........................................................................................................21
4.2.1Set the basic configuration...............................................................................21
4.2.2Input to program parameters, and first setting (Spot-weld or Seam-weld)..23
4.2.3Spot program parameters in cycles.................................................................24
4.2.4Spot program parameters in milliseconds......................................................26
4.2.5Spot cycle parameters description..................................................................28
4.2.6Forge ..................................................................................................................37
4.2.7Seam program parameters in cycles...............................................................38
4.2.8Seam program parameters in milliseconds ....................................................39
4.2.9Seam cycle parameters description ................................................................40
4.2.10System Parameters...........................................................................................45
4.2.11Auto-Step ...........................................................................................................51
4.2.12Communications ...............................................................................................53
4.2.13Error Log............................................................................................................55
4.2.14Inputs / outputs Check......................................................................................56
4.2.15Machine Calibration ..........................................................................................58
4.2.16Copy Program....................................................................................................62
4.2.17CAN 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
5.5.1Over temperature of the transformer / diode (Thermostat) .............................. 68
5.6.Control inputs....................................................................................................69
5.6.1Emergency....................................................................................................... 69
5.6.2Pressure switch................................................................................................ 69
5.6.3Current probe................................................................................................... 69
5.6.4Voltage probe................................................................................................... 69
5.6.5Reset alarms.................................................................................................... 69
5.6.6Reset steps...................................................................................................... 70
5.7.Control outputs..................................................................................................70
5.7.1Main Solenoid valves (EV 1,2,3,4) ................................................................... 70
5.7.2Forge solenoid valves and roll motor (EV 5) ................................................... 70
5.7.3Pre stroke solenoid valve (EV 6 PRE-STROKE).............................................. 70
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5.7.4Proportional valve ............................................................................................ 70
5.8.Signalling outputs .............................................................................................70
5.8.1Ready .............................................................................................................. 70
5.8.2End cycle ......................................................................................................... 71
5.8.3Anti-Concomitance........................................................................................... 71
5.8.4End current increase (END STEPS) ................................................................ 71
5.8.5Delta TS........................................................................................................... 71
5.8.6Out of range..................................................................................................... 71
5.8.7CURR 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
7.4.1Tips connections to CS-I/P .............................................................................. 74
7.4.2Tips for the voltage acquisition......................................................................... 74
7.5.Constant power, PK, introduction....................................................................75
7.5.1Constant power, PK, operative notes............................................................... 75
7.6.Constant Energy, EK, introduction..................................................................76
7.6.1Constant Energy, EK, operative notes......................................................... 76
7.7.Adaptive, AD, introduction ...............................................................................77
7.7.1Adaptive, 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
13.1.1Power supply ................................................................................................... 93
13.1.2Power output.................................................................................................... 93
13.1.3Digital signal IN – OUT .................................................................................... 93
13.1.4Analog signals IN – OUT ................................................................................. 94
13.1.5Protections....................................................................................................... 94
13.1.6Mechanical and environmental ........................................................................ 94
13.1.7Cooling............................................................................................................. 94
13.1.8Load Curve: CSI-150A..................................................................................... 95
13.1.9Load Curve: CSI-300A..................................................................................... 95
13.1.10Load Curve: CSI-450A ................................................................................. 96
13.1.11Load Curve: CSI-600A ................................................................................. 97
13.2.CS-I/T mechanical dimension...........................................................................98
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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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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.
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2.2. Main features
¾Power unit mid-frequency inverter impressed current technology using IGBT Programmable
via terminal or via remote field bus.
¾Frequency set by the user from 1000 to 7000Hz for use with DC Transformers
¾User selectable primary or secondary current measurement.
¾Six different modes of current regulation are available:
•Duty fixed percentage D‰
•Duty percentage with primary voltage compensation, V‰
•Constant Current IK
•Constant Power PK
•Constant Energy EK
•Adaptive AD
¾Possibility of setting of welding current from external voltage reference 0-10V
¾Gain adjustable current regulation loop.
¾Cycle management of spot welding machines or seam welding machines set by user.
¾Time management in Cycles or in milliseconds.
¾Electrical insulation of input and output sections.
¾Setting up and executing 64 programs, called from external input, internal, sequential or
combined in the early cycle IC1 or IC2 or recalled from the Fieldbus if any.
¾Point to point serial communication line RS232, used to connect a printer or a personal
computer or a network serial communication line RS485.
¾Availability of expansion of communication: Profibus – DeviceNet – CANopen -
Modbus/RTU - Profinet/IO - EtherNet/IP – Modbus/TCP.
¾Start cycle with dual push buttons (dual input) or pedals (single input).
¾Monitoring (Quality Control) of the limits of the welding current in spot-weld and in seam
weld mode.
¾Programmable function of continuous current increment to compensate electrodes wears
under variable curve up to four pairs of electrodes (four transformers).
¾Welds counter with alarm and lock function.
¾Four solenoid valves flexibly associated to pre-squeeze and squeeze within programs.
¾Proportional valve driving circuit galvanic insulated.
¾Proportional valve full scale setting (99%) from 5 to 10V
¾Forging solenoid-valve output.
¾Pre-stroke solenoid -valve.
¾Possible association of pressure in pre-squeeze, squeeze, preheat, welding and forging,
through the proportional valve (pressure cycle).
¾Self-calibration of 4 transformer or welding systems.
¾Four language setting, additional languages on request.
¾Dedicated signals management by PLC.
¾IGBT power unit with water cooling, through integrated water control solenoid valve.
¾Possibility of external 24V power supply in case of lack of power line.
¾Temperature monitoring of heat sink.
¾External temperature monitoring (transformer diode or coils).
¾Automatic checking and errors reports on Rogowski coil insulated
¾Check with any reporting / management start welding pliers not closed.
¾Graphs trends of weld parameter on the terminal panel.
¾Automatic duplication of the welding program in multiple programs
¾Management via can bus of linear measurements of displacement and electrode
verification, management or pressure welding force through proportional valve or load cell
with feed-back
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value of a
p
y
s "bolts",
and decre
a
v
arious me
n
s moveme
n
between t
h
s moveme
n
pointer to
t
m
eters it c
a
t
in first wi
pointer to
t
a
se the nu
m
ow, it allo
w
or CONFI
R
d
esired me
t
o its uppe
r
t is used t
o
G
MESSAG
E
c
rease the
v
.
safcosys.it
functiona
r
eas: in the
T
” mode, w
large grap
e
buttons th
g
paramete
r
also allow
s
c
h you are
,
disable th
e
button all
o
h
e retrieve
p
aramete
r
the key o
a
se button
"
n
u or in th
e
n
t in to the
h
e various
n
t in the inf
e
t
he left of t
h
a
n decrea
s
ndow, it al
t
he right of
m
ber of pro
g
s
the movi
n
R
MATION”
n
u; within t
h
r
limit. Conf
i
o
incremen
t
E
.
v
alue of th
e
a
lity
left one th
e
w
hen in pos
hic display
h
at select t
h
r
s in use.
s immedia
t
, the other
e current
o
ws the
the previ
o
o
f increase
"
-" these ar
e
menu to
t
top row.
menus or i
e
rior row.
h
e internal
s
e the nu
m
lows the r
e
internal pa
g
ram
.
n
g to the n
e
he menu al
f
irm exit fro
m
t the para
m
e
paramete
r
12 of 10
9
e
re is a ke
y
ition on th
e
to the righ
t
h
e source o
f
In edi
t
t
e exit fro
m
key allow
s
Durin
g
refresh o
f
o
us not je
t
"+", whic
h
e
describe
d
he superio
r
n the men
u
parameter
s
m
ber of th
e
e
turn to th
e
rameters t
o
e
xt window.
lows you t
o
m
the men
u
m
eter in th
e
r
down to it
s
9
y
e
t
f
t
m
s
g
f
t
h
d
r
u
s
e
e
o
o
u
e
s
CS-I User and Maintenance, R.2.8 ENG
Safco Systems Ltd-Via Isonzo 17/b-20090 Cesano Boscone-Milan-Italy
13 of 109
In RUN mode, it can decrease the parameter in the sub windows down to its lower
limit
3.
CS
Saf
c
tel.
+
2.4. N
o
CS
Ma
Th
e
Th
e
Installa
t
3.1. C
o
3.1.1
P
o
Th
e
th
e
Th
e
it i
s
m
a
PE
gr
o
Se
l
ca
u
Ti
g
th
e
En
s
-I User an
d
c
o Systems Ltd
-
+
39 024504433
o
tes on in
s
-I is desig
n
x 80% non
-
e
operating
e
unit shoul
t
ion and
o
nnecting
o
wer su
p
e
operatio
n
e
main po
w
e
operatio
n
s
recomm
e
a
ke sure th
e
cable sec
t
o
und syst
e
l
ect the ap
u
se overh
e
g
hten the c
e
clamps c
o
s
ure no fr
a
d
Maintena
n
-
Via Isonzo 17/
b
Fax +39 0245
0
s
tallation
n
ed for pan
e
-
condensin
g
room tem
p
d not be m
o
connec
t
the CS-I /
p
ply sect
n
s of conn
e
w
er line no
t
n
of conne
c
e
nded ther
e
e
ground t
e
t
ion equal
e
m .
propriate
s
e
ating and
ables with
o
mpromisi
a
ying or le
a
n
ce, R.2.8 E
N
b
-20090 Cesan
o
0
4321 E-mail:in
f
e
l amounti
n
g
) and prot
e
p
erature mu
o
unted in c
o
t
ors
P
ion
e
ction to t
h
t
connecte
d
c
tion to p
o
e
fore be tr
e
e
rminal is
t
o that of
p
s
ection of
p
rupture, w
an adequ
a
ng the effi
c
a
kage fro
m
N
G
o
Boscone-Mila
f
n
g, for ope
r
e
cted from
st be withi
n
o
ntact with
CAU
T
h
e power
s
d
.
o
wer line i
n
e
ated very
properly c
o
p
ower, an
d
p
ower cab
l
ith seriou
s
a
te and co
n
ciency.
m
the cable
s
n-Italy
Web site: www
r
ation in a
d
d
ust and li
q
n
the range
parts subj
e
T
ION
s
upply mu
s
n
volves ris
k
carefully i
o
nnected
t
d
that the p
l
es: the in
a
s
consequ
e
n
trolled to
r
s
terminal
s
.
safcosys.it
d
ry environ
m
q
uids.
0 / 50 º C.
ct to sever
e
s
t always
b
k
s and da
n
n the cour
s
t
o the term
l
ant is equ
a
ppropriat
e
e
nces.
r
que avoid
i
s
, before p
o
m
ent (relati
e
vibration.
b
e carried
o
n
gers not
e
se of this
o
m
inal desig
n
ipped wit
h
e
use of ca
ing the d
e
owering t
h
14 of 10
9
ve humidit
y
o
ut with
e
liminable,
o
peration:
n
ated as
h
efficient
bles can
e
forming
h
e system.
9
y
CS
Saf
c
tel.
+
Th
e
ele
pla
-I User an
d
c
o Systems Ltd
-
+
39 024504433
e
electrical
ctrical net
w
ced on the
d
Maintena
n
-
Via Isonzo 17/
b
Fax +39 0245
0
power c
o
w
ork, with
superior p
a
n
ce, R.2.8 E
N
b
-20090 Cesan
o
0
4321 E-mail:in
f
o
nnection i
s
a
dequate
p
a
rt of the B
O
There is n
The oper
a
carried ou
A
t the t
o
-Power
-Input
/
RS232
-Comm
-
A
uxilia
A
t the
-Outp
u
-Fittin
g
-Cooli
n
-Field
B
N
G
o
Boscone-Mila
f
s
realized
p
ower, thr
o
O
X, see the
n
o required
s
a
tions of c
o
t with the p
o
p of the in
v
terminals:
/
output c
o
or RS485.
unication c
o
ry voltage
c
bottom of t
h
u
t terminals
g
s for the c
o
n
g water so
B
us conne
c
n-Italy
Web site: www
connecting
o
ugh the i
n
figure bel
o
s
equence
a
o
nnection t
o
ower not c
o
v
erter are l
o
o
nnectors
o
nnector to
c
onnector
+
h
e inverter
for driving
t
o
oling wate
r
lenoid valv
e
c
tion.
.
safcosys.it
the CS-I/
n
put termin
a
w;
a
mong the
t
o
the pow
e
o
nnected.
o
cated:
and com
m
CS-I/T RS
4
24V
a
re located
t
he transfo
r
r
connectio
n
e
.
/
P at the
t
als, the te
t
hree phas
e
e
r line mus
t
m
unications
4
22
:
r
mer.
n
.
15 of 10
9
t
hree-phas
e
r
minals ar
e
e
s.
t
always b
e
CAN bus
9
e
e
e
,
CS-I User and Maintenance, R.2.8 ENG
Safco Systems Ltd-Via Isonzo 17/b-20090 Cesano Boscone-Milan-Italy
16 of 109
3.1.2 Power output section
For the connection to the welding system (transformer primary) use the output terminals as
shown in the picture in the previous page.
This operation must be done with inverter not-powered, due to several risks.
Furthermore it is recommended 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 also recommends a periodic inspection and, if necessary, replacement.
Absence of fraying or free threads at the terminals that could cause short-circuit, sparks or
electric arching.
The tightening the clamps must be done with an appropriate controlled torque.
CS-I User and Maintenance, R.2.8 ENG
Safco Systems Ltd-Via Isonzo 17/b-20090 Cesano Boscone-Milan-Italy
17 of 109
3.1.3 Description of the features of the connectors and signals.
The CS-I / T interfaces to the CS-I / P through the supplied 9-pin plug-socket RS422
cable. Male connector is on the CS-I / P c RS422 female on CS-I / T. The input signals and
inlets on the CS-I / P are underneath explained:
X1CANBUS (5pinM)
X2 Proportional Valve (4 pin M)
X3 Measuring inputs (6 pin M)
IN1 Control signals (12 pin M)
IN2 Signals of program selection, control and protection (12 pin M)
OUT1 Drive signals for solenoid valves and alerts (10 pin M)
OUT2 Alert signals (9 pin M)
RS422 Communication line with CS-I/T (9 pin male tank)
RS232/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
Table 1 – X1: CAN BUS terminal block
Pin Signal Description Type
1 +24V +24V reported to 0V max 250 mA PWR
2 0V 0V of reference for +24V GND
3 PROP(+) Signal 0-10V Proportional valve control O
4 PROP(-) 0V of reference for signal PRP_0-10 GND
Table 2 – X2: Proportional valve terminal block
Pin Signal Description Type
1 ROG Rogowski coil terminal I
2 ROG Rogowski coil terminal I
3 SHIELD Shield (connected to ground on board) SHIELD
4 VSEC - Voltage TIP negative I
5 VSEC + Voltage TIP positive I
6 SHIELD Shield (connected to ground on board) SHIELD
Table 3 – X3: Input terminal block for analogical measurement
CS-I User and Maintenance, R.2.8 ENG
Safco Systems Ltd-Via Isonzo 17/b-20090 Cesano Boscone-Milan-Italy
18 of 109
Pin Signal Description Type
1 +24VP +24V reported to GNDP max 250 mA PWR
2 EMERGENCY Emergency signal causes the block of power supply coming
from the welding cycle and prevent the reactivation of the
same, turn off all outputs and reset valve by removing all
power from the output drivers.
I
3 Pb Com Common signal for start concurrently with the buttons start
cycle (PUA, PUB and PU-Stroke) I
4 Pb A Signal in conjunction with Pu com in spot mode allows the
start of the welding cycle 1, in seam mode allows the cycle
start to coincide with the current 1.
I
5 Pb B Signal in conjunction with Pu Com in spot mode allows the
start of the welding cycle 2, in seam mode allows the switch
to the welding current 2.
I
6 Pb C In spot mode signal that allows for the early termination of the
spot welding time to achieve thickness, in seam mode allows
the switch to the welding current 3.
I
7 Pb- PRE-STROKE
(Pb D)
Activation and deactivation signal of the pre stroke valve
output. I
8 P-SW (AUX) Auxiliary signal, in spot mode, if not present, it will freeze the
welding cycle before or after squeeze, in seam mode, if not
present, it freeze the welding cycle waiting the closure of the
roller motor relè prior to entry into welding.
I
9 Current 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 signal is compared to the
use of alternative equivalent function terminal.
I
12 +24VP +24V reported to GNDP max 250 mA PWR
Table 4 – IN-1: Input terminal block for control
Pin Signal Description Type
1 +24VP +24V reported to GNDP max 250 mA PWR
2 THERMOSTAT Thermal alarm signal, to be connected to the series of signals
"thermo-switch" or equivalent. I
3 Prog-01 Binary signal selection, weight 01 of the program code
execute in EXT mode. I
4 Prog-02 Binary signal selection, weight 02 of the program code
execute in EXT mode. I
5 Prog-04 Binary signal selection, weight 04 of the program code
execute in EXT mode.. I
6 Prog-08 Binary signal selection, weight 08 of the program code
execute in EXT mode. I
7 Prog-16 Binary signal selection, weight 16 of the program code
execute in EXT mode.. I
8 Prog-32 Binary signal selection, weight 32 of the program code
execute in EXT mode.. I
9 PEDAL-1 Signal of cycle start I
10 PEDAL-2 Signal active as cycle start in spot mode (Set mod); seam
mode, allows the exchange to the second current I
11 PED.PRE-STROKE
(PED D) Pedal signal activation of the pre stroke electro valve. I
12 +24VP +24V reported to GNDP max 250 mA PWR
Table 5 – IN-2: Inputs terminal blocks for programs selections, control and protection
CS-I User and Maintenance, R.2.8 ENG
Safco Systems Ltd-Via Isonzo 17/b-20090 Cesano Boscone-Milan-Italy
19 of 109
Pin Signal Description Type
1 GNDP Reference Ground for +24VP GND
2 EV1 Matching output signal to the electro valves of
Pre-Squeeze, Squeeze or Roller motor O
3 EV2 Matching output signal to the electro valves of
Pre-Squeeze, Squeeze or Roller motor. O
4 EV3 Matching output signal to the electro valves of
Pre-Squeeze, Squeeze or Roller motor. O
5 EV4 Matching output signal to the electro valves of
Pre-Squeeze, Squeeze or Roller motor. O
6 EV5 FORGE/ROLL-
MOTOR
Output signal, in spot mode, it drives the forging
valve; in seam mode, it drives the rolls motor
through a remote control switch or inverter.
O
7 EV6 PRE-SROKE Output signal, it drives the pre stroke electro valve. O
8 DTS Output Signal, means hot cycles under way. O
9 READY Inverter Ready signal: the output indicates that the
drive is ready to receive a command beginning of
the cycle.
O
10 GNDP Reference Ground for +24VP 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 inverter ready to
provide current during hot cycles. O
5 ANTICONCOM. N.C.1 Normally closed contact 1 of no concomitance
relay (interlock). O
6 ANTICONCOM. N.C.2 Normally closed contact 2 of no concomitance
relay (interlock). O
7 END CYCLE N.A. 1 Normally open contact 1 of end cycle relay. O
8 END CYCLE N.A. 2 Normally open contact 2 of end cycle relay O
9 +24VP +24V reported to GNDP max 250 mA PWR
Table 7 – OUT-2: Output terminal block for the reporting States or alarms
Pin Signal Description Type
1 /RXD Signal denied receive data I
2 RXD Receive signal data I
3 /TXD Denied signal data transmission O
4 TXD Signal data transmission O
5 N.C. Not connected (Spare)
6 GNDP Reference Ground for +24VP GND
7 GNDP Reference Ground for +24VP GND
8 +24VP +24V reported to GNDP max 250 mA PWR
9 +24VP +24V reported to GNDP max 250 mA PWR
Table 8 – Terminal block for RS422 communication line to CS-I/T
CS
Saf
c
tel.
+
Pi
1
2
3
4
5
6
7
8
9
Warni
n
shown
3.1.4 Hy
NOTE
:
In case
valve is
entry o
n
NB: D
o
coolin
g
For the
located
We rec
o
−Ex
e
−Us
e
Any le
a
electro
damag
e
It is re
c
In orde
water
o
We rec
o
this pr
o
-I User an
d
c
o Systems Ltd
-
+
39 024504433
n Sign
a
TX/
R
2
TX
D
3
RX
D
4
TX/
R
5
GN
D
6
GN
D
7
RES
E
8
NC
9
NC
Table
ng
: for con
n
in annex
C
draulic c
o
This parag
r
of the abs
e
assemble
d
n
the side o
o
not conn
e
circuit of
t
connectio
n
on panel o
o
mmend:
e
cute the
w
e
extreme
c
a
kage of w
a
nics, givin
e
s.
c
ommende
r to avoid
c
o
r antifree
z
o
mmend t
o
o
duct is a
b
d
Maintena
n
-
Via Isonzo 17/
b
Fax +39 0245
0
a
l
R
X A.
D
D
R
X B
D
P
D
(+5V)
E
RVED
9 – Terminal
b
n
ection to
C
C
Never
c
o
nnection
r
aph applie
s
e
nce of sol
e
d
right on t
h
f the valve
e
ct, downst
r
t
he spot w
e
n
of the inv
e
utput.
w
ater conne
c
c
aution and
a
ter can c
o
g the risk
o
d to fix an
y
c
orrosion
d
z
e mixture
l
o
use the
a
b
solutely n
o
n
ce, R.2.8 E
N
b
-20090 Cesan
o
0
4321 E-mail:in
f
De
s
RS
4
Sig
n
Re
c
RS
4
Re
f
Re
f
RE
S
No
t
No
t
b
lock communi
C
S-I/P RS
2
c
onnect pi
n
s
only to u
n
e
noid valve
e entry (un
d
itself.
r
eam or u
p
e
lds or coo
l
e
rter water
c
c
tion when
check for
p
o
me into c
o
o
f explosi
o
y
leakage
o
d
amages i
n
l
ike “Paraf
a
ntifreeze
m
o
t toxic.
N
G
o
Boscone-Mila
f
s
cription
4
85 channel A
n
al data trans
m
c
eive signal dat
4
85 channel B
f
erence Groun
d
f
erence Groun
d
S
ERVED
t
connecte
d
t
connecte
d
i
cation line RS
2
32 to pers
n
s 1, 4, 6,
7
n
its with wa
t
the cooling
der the fan
p
stream, o
f
l
in
g
circuit
c
ircuit, it ha
s
the machi
n
p
ossible le
a
o
ntact wit
h
o
ns, electri
o
f water a
n
n
the heat
f
lu” as coo
m
ixture A
D
n-Italy
Web site: www
m
ission
a
d
for +24VP
d
for +5V DIGI
T
232/RS485 an
d
onal comp
u
7
t
er cooling.
system ha
of CS-I/P)
s
f
the powe
r
of the po
w
s
n°2 conn
e
n
e is not po
w
a
kage on h
y
h
electrical
cal arcing
n
d not turn
sink of th
e
l
ant.
D
11 based
.
safcosys.it
T
AL
d
programmin
g
u
ter or pri
n
s
no define
d
s
hould be
c
units CS-
I
w
er transfo
r
e
ctors’ fem
a
w
ered;
y
draulic jun
c
compone
n
or other m
the unit if
e
IGBT nev
e
on propyl
e
Typ
I/O
O
I
I/O
GN
D
GN
D
g
JCOM
nter, use c
a
d input; if t
h
c
onsidered
I
/P water c
r
mer.
a
le ¼ inch "
c
tions.
n
ts and po
w
m
ore seriou
they shou
e
r use de
m
e
ne glycol.
20 of 10
9
e
D
D
a
ble as
h
e electro
a
s one
i
rcuit, the
gas",
w
er
s
l
d occur.
m
ineralise
d
Moreover
9
d
This manual suits for next models
15
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